KTM 400 450 SX MXC XC 2000-2007 Service Repair Manual

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This manual covers the 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models produced between 2000 and 2007. These motorcycles represent robust off-road offerings, built...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 58128

Stichworte: 2000 2001 2002 2003 2004 2005 2006 2007 400 450 450 SX ATV KTM Motorcycle MXC Powersports SX XC

Produktvarianten

Beschreibung

This manual covers the 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models produced between 2000 and 2007. These motorcycles represent robust off-road offerings, built upon strong racing heritage and known for performance and durability. The SX, MXC, and XC variants are engineered for demanding off-road conditions, from motocross tracks to cross-country and enduro trails, reflecting a commitment to providing competitive and reliable machines. This comprehensive Service Repair Workshop Manual provides detailed guidance for owners, independent service professionals, and technicians. It encompasses all essential maintenance procedures, from routine checks and fluid changes to periodic servicing and component replacement. The manual includes in-depth repair instructions for the engine, drivetrain, chassis, and electrical systems, alongside advanced troubleshooting advice and diagnostic procedures. With clear, step-by-step instructions, diagrams, illustrations, and wiring schematics, this manual ensures accurate and efficient maintenance and repair for all covered models.

🏷️ Basic Information

Identification

Make:

Model:

400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC

Model Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Codes

Platform Code:

Specific to KTM's off-road chassis generations for these years

Generation

Generation Identifier:

Third Generation EXC/SX/MXC Platform (approximate)

👋 Introduction

Market Position

Target Audience:

KTM owners with basic mechanical skills, independent service professionals, and knowledgeable enthusiasts seeking dealership-level information.

Competitive Analysis

Manual Advantage:

Provides the exact same specifications and procedures used by authorized dealers, offering superior accuracy and completeness compared to generic or Haynes-style manuals.

Key Features

Content Highlight:

Step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications for repair and troubleshooting.

Illustration Quality:

High-quality diagrams and illustrations are a key feature, aiding in the understanding of complex procedures.

Value Proposition

Cost Savings:

Potential to save significant money on maintenance and repairs by performing tasks independently.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, repair, and troubleshooting for all listed models and years

Page Count

Page Count:

Not explicitly stated, but implied to be extensive covering all topics.

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine specifications, engine removal and installation, fuel system, intake & exhaust, cooling system, lubrication

Drivetrain:

Transmission, drive chain, sprockets

Chassis:

Steering system, shocks, body work

Electrical:

Electrical system, wiring diagram

Procedures Included

Maintenance:

Routine maintenance, periodic checks and adjustments, lubrication

Repair:

Step-by-step repair instructions for all covered systems

Troubleshooting:

Advanced troubleshooting guidance

Engine Overhaul:

Complete engine overhaul procedures, including disassembly, inspection, cleaning, repair, and reassembly of all internal engine components.

Suspension Rebuild:

Detailed procedures for rebuilding and servicing front forks and rear shock absorbers, including fluid changes and seal replacements.

Electrical Diagnostics:

Comprehensive guide to diagnosing and repairing electrical faults, utilizing wiring diagrams and component testing procedures.

Technical Depth

Depth:

Mechanic-level detail, covering everything from basic checks to complex repairs and diagnostics.

Diagnostic Tools:

Includes specifications for required tools, torque values, and clearances for accurate diagnostics and repairs.

📊 Manual Specifications

File Format

File Format Details:

PDF format, viewable on PC/Mac, phones, and ebook readers. Searchable text is typically included in professional PDFs.

Print Quality

Printability:

All pages are printable, allowing users to print specific sections for workshop use.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, liquid-cooled (typically based on LC4 architecture for these models)

Engine Displacement 400:

Approximately 400cc (specific variants exist, e.g., 380-400cc range)

Engine Displacement 450:

Approximately 450cc (specific variants exist, e.g., 440-450cc range)

Bore Stroke:

Specific values vary by exact model year and displacement, will be detailed in the manual.

Compression Ratio:

Specific values vary by exact model year and displacement, will be detailed in the manual.

Performance

Horsepower:

Estimated 40-55 HP, varies significantly with model year and tuning.

Torque:

Estimated 40-50 Nm, varies significantly with model year and tuning.

Fuel System

Fuel Delivery:

Carbureted (e.g., Keihin, Mikuni) or early fuel injection systems depending on specific model and year within the range.

Carburetor Size:

Typically 36-40mm, model dependent.

Fuel Type:

Unleaded gasoline

Engine Removal Installation

Procedure Type:

Detailed step-by-step procedures provided.

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5 or 6-speed manual

Optional

Optional Transmission:

Features

Clutch Type:

Hydraulic actuated, multi-plate wet clutch

Gear Ratios:

Specific gear ratios for each model year and variant are detailed in the manual.

📐 Dimensions

Exterior

Seat Height:

Varies by model, typically around 37-39 inches (940-990 mm)

Weights

Dry Weight:

Varies by model, typically around 230-250 lbs (105-115 kg)

Fuel Tank Capacity:

Typically 2.5-3.2 gallons (9.5-12 liters)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Off-road vehicles are not typically subjected to formal road safety crash ratings).

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Suspension:

High-performance upside-down front forks (e.g., WP) and monoshock rear suspension, offering significant adjustability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Designed for performance off-road riding, no infotainment features).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control on these models).

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Digital or analog tachometer and speedometer, basic warning lights (oil, neutral, turn signals).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of riding or annually, depending on usage. Specific recommendations in manual.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions. Daily inspection advised.

Spark Plug Replacement:

Varies, typically every 20-40 hours of riding. Specific plug type and gap in manual.

Fluid Specifications

Engine Oil Type:

High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 15W-50, meeting JASO MA standards. Specific API rating recommended in manual.

Coolant Type:

Ethylene glycol-based antifreeze coolant mixed with distilled water (typically 50/50 ratio).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, swingarm bearings, exhaust packing (for some models).

Engine Specifics:

Potential for timing chain wear, valve adjustment requirements, and carburetor tuning intricacies.

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM is an Austrian manufacturer renowned for its off-road motorcycles, with a strong racing heritage.

Model Evolution

Sx Mxc Xc Lineage:

These models represent KTM's dedicated motocross (SX), cross-country (MXC), and enduro (XC - though often closer to SX/MXC in this era) offerings. They evolved from earlier LC4 platforms and saw continuous refinement in chassis, suspension, and engine performance.

Production

Production Period:

These specific models and years reflect a key period of KTM's growth and dominance in off-road racing.

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM motorcycles of this era were highly successful in various off-road racing disciplines, including motocross, supercross, and desert racing, often winning championships with factory-supported riders.

Ratings

Industry Perception:

Highly regarded for performance, durability, and rider-centric design in the off-road community.