KTM 400 450 SX MXC XC Complete Workshop Service Repair Manual 2000 2001 2002 2003 2004 2005 2006 2007

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The 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models represent high-performance off-road competition motorcycles from an Austrian manufacturer renowned for its racing heritage. These...

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Tipo: Motorcycle

Proveedor:

SKU: 75131

Etiquetas: 2000 2001 2002 2003 2004 2005 2006 2007 400 450 KTM Misc Motorcycle Motorcycles MXC SX XC

Variantes de producto

Descripción

The 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models represent high-performance off-road competition motorcycles from an Austrian manufacturer renowned for its racing heritage. These models, produced between 2000 and 2007, are powered by the robust LC4 4-stroke, single-cylinder engine, available in 400cc (approximately 373cc-398cc) and 450cc (approximately 435cc-449cc) displacements. They are engineered for demanding motocross, marathon cross country, and cross country racing, featuring powerful engines, strong steel trellis frames, and advanced suspension systems. These machines are built for performance and reliability in competitive environments. This comprehensive workshop service repair manual, provided in English, is designed to assist owners, mechanics, and technicians in maintaining and repairing the specified models. It covers a wide range of critical areas, including complete engine overhauls, transmission servicing, chassis components, and the electrical system. Detailed procedures for regular maintenance, such as oil changes, filter replacements, and valve clearance checks, are included alongside in-depth repair instructions for engine, gearbox, suspension, and electrical systems. The manual also offers troubleshooting guidance for common issues, ensuring the optimal performance and longevity of these competition motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

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

Codes

Engine Codes:

LC4 (various iterations for 400cc and 450cc variants)

👋 Introduction

Market Position

Category:

Competition Motorcycles (Motocross, Enduro, Cross Country)

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CRF/XR series, Suzuki RM/DR series, Kawasaki KX/KLX series.

Key Features

Vehicle Focus:

High-performance off-road machines known for their powerful engines and robust construction, designed for demanding competitive use.

📋 Manual Details

Coverage Areas

Years Covered:

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

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, fuel system (carburetor), ignition system, cooling system, lubrication system, engine internals (pistons, rings, valves, camshafts, crankshaft).

Transmission:

Clutch, gearbox (gear selection, internal components), final drive (chain and sprockets).

Chassis:

Frame, subframe, swingarm, steering system, suspension (forks and rear shock absorber), wheels, tires, brakes (front and rear caliper, master cylinder, lines, pads), electrical system (wiring harness, lighting, ignition switch, starter motor, battery).

Procedures Included

Maintenance:

Regular service intervals, oil changes, filter replacements, chain adjustment, brake fluid flush, coolant replacement, spark plug inspection/replacement, valve clearance checks.

Repair:

Complete engine rebuild, gearbox repair, suspension overhaul, brake system repair, electrical diagnostics and repair, carburetor tuning and rebuilding, bodywork repair and replacement.

Troubleshooting:

Diagnostic flowcharts, common fault identification, solutions for starting problems, running issues, electrical faults, suspension performance.

Technical Depth

Depth:

Comprehensive, covering from basic rider maintenance to full workshop-level mechanical and electrical repairs, including detailed diagrams and specifications for complete disassembly and reassembly.

📊 Manual Specifications

File Format

Quality:

High-resolution scans, searchable text content within PDF, clear diagrams and illustrations.

Binding Type

Type:

Digital Download (PDF)

Paper Type

Type:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, Single Cylinder, LC4 engine (Liquid-cooled)

Bore X Stroke 400:

Approx. 89 mm x 63.5 mm (varies slightly by specific year/variant)

Bore X Stroke 450:

Approx. 95 mm x 63.4 mm (varies slightly by specific year/variant)

Displacement 400:

373cc - 398cc (approx.)

Displacement 450:

435cc - 449cc (approx.)

Performance

Horsepower 400:

Approx. 30-35 HP (subject to variant and tuning)

Horsepower 450:

Approx. 35-45 HP (subject to variant and tuning)

Fuel System

Carburetor:

Mikuni VM Series (e.g., VM33, VM34) or Keihin FCR Series (often 39mm or 41mm) depending on model and year.

Fuel Type:

Unleaded Gasoline (Octane rating specified by KTM, typically 91+)

🔧 Transmission

Standard

Type:

5-speed constant mesh sequential gearbox.

Optional

Type:

Not Applicable (standardized for competition models)

Features

Clutch:

Wet multi-plate clutch, hydraulically actuated.

📐 Dimensions

Exterior

Wheelbase:

Approx. 1450-1480 mm (varies by model and year)

Seat Height:

Approx. 950-990 mm (varies by model and year)

Weights

Dry Weight:

Approx. 110-120 kg (varies by model and year)

🛡️ Safety Features

Ratings

Type:

Not Applicable (Competition Off-Road Motorcycle, not subject to road vehicle safety ratings like NHTSA or Euro NCAP).

Active Features

Brakes:

Hydraulic disc brakes (front and rear) with floating calipers. Brembo components often utilized.

Passive Features

Frame:

High-strength steel trellis frame providing rigidity and impact absorption.

💡 Technology Features

Infotainment

Type:

Not Applicable (Purely focused on performance and racing, no infotainment systems).

Driver Assistance

Features:

None. These are analog, rider-controlled machines.

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Oil Change:

Every 15-20 hours of riding or as per manual recommendations (depending on severity of use).

Air Filter Cleaning:

After every riding session or as needed in dusty conditions.

Spark Plug Inspection:

Every 20-30 hours of riding.

Valve Clearance Check:

Every 30-50 hours of riding (critical for performance).

Fluid Specifications

Engine Oil:

KTM recommends specific semi-synthetic or fully synthetic motorcycle engine oils (e.g., Motorex Power Synt 4T 10W/40 or 15W/50). Consult manual for precise API/JASO specifications.

Coolant:

Mixture of distilled water and a quality motorcycle coolant/antifreeze (ethylene glycol based), typically a 50/50 mix. Refer to manual for specific type and capacity.

Brake Fluid:

DOT 4 hydraulic brake fluid (for Brembo systems).

Fork Oil:

Specific suspension fork oil grade (e.g., WP Suspension recommends 5W or 7.5W, but consult manual for exact type and level).

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, fork seals, rear shock absorber seals, chain and sprockets.

Carburetor Tuning:

Sensitivity to altitude and temperature changes, requiring occasional jetting adjustments.

Electrical System:

Wiring harness integrity in high-vibration environments, stator and regulator/rectifier reliability (though generally robust).

📚 Vehicle History

Brand Heritage

Focus:

KTM AG, an Austrian manufacturer renowned for its off-road racing motorcycles, consistently dominating motocross and enduro championships.

Model Evolution

Lc4 Development:

The LC4 engine platform has a long history within KTM, evolving from earlier models to incorporate liquid cooling, electric start (on some variants later), and higher performance tuning for racing applications. The SX, MXC, and XC designations represent specific off-road racing disciplines (Motocross, Marathon Cross Country, Cross Country).

Production

Manufacturing Location:

Austria (Primary)

🏆 Awards & Recognition

Recognitions

Model Legacy:

KTM's SX, MXC, and XC platforms are synonymous with off-road racing success and have garnered numerous championships and accolades across various disciplines and continents.