Model:
400/450 SX, MXC, XC, EXC, SMR, SXS RACING
Applicable Years:
2000-2007
Engine Type Covered:
400cc and 450cc Four-Stroke Engines
Manual Code:
Not specified in product information
Target Audience:
KTM owners and technicians working on 400/450cc off-road and supermoto models from 2000-2007.
Value Proposition:
Provides in-depth technical information to enable owners to perform their own maintenance and repairs, saving time and money compared to dealership services.
Manual Comparison:
Essential resource for enthusiasts and mechanics, offering a level of detail often exceeding basic owner's manuals.
Detail Level:
High level of detail suitable for complex engine repairs and diagnostics.
Accessibility:
Digital format offers portability and instant access for troubleshooting or reference.
Primary Coverage:
Engine Mechanical, Electrical, Diagnostics, Troubleshooting, Repair, Rebuild, Maintenance
Model Variant Coverage:
SX (Motocross), MXC (Cross-Country), XC (Cross-Country), EXC (Enduro), SMR (Supermoto), SXS (Racing Special)
Estimated Page Count:
Likely extensive, typically 300-600+ pages for detailed workshop manuals
Type:
Digital Workshop Manual / Repair Manual
Language:
English (presumed, standard for technical manuals)
Engine Mechanical:
Top End (Cylinder Head, Valves, Camshafts), Bottom End (Crankshaft, Connecting Rod, Piston), Cylinder Block, Lubrication System, Cooling System (Radiators, Hoses, Water Pump)
Engine Management:
Fuel Injection System (TPS, Injector, Fuel Pump, Regulator), Ignition System (CDI, Spark Plug), Sensors (MAP, Temperature, Crank Position)
Electrical System:
Wiring Diagrams, Battery, Charging System (Stator, Rectifier/Regulator), Lighting, Starter System
Routine Maintenance:
Oil Change Intervals and Specifications, Air Filter Cleaning/Replacement, Spark Plug Replacement, Valve Clearance Checks and Adjustment, Coolant Flush and Replacement
Disassembly Reassembly:
Complete engine teardown and reassembly procedures, including torque specifications for all fasteners.
Troubleshooting:
Diagnostic flowcharts for common starting, running, and performance issues. Fault code interpretation (if applicable).
Performance Tuning:
Information on carburetor/fuel injection adjustments, ignition timing (if adjustable), and basic engine performance tuning principles.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Depth:
Comprehensive from basic owner maintenance to full engine rebuilds. Includes detailed specifications, diagrams, and step-by-step instructions.
Engine Displacement Options:
Approximately 398cc (400) and 449cc (450) (specific bore/stroke may vary by sub-model)
Engine Configuration:
Single Cylinder, Four-Stroke
Engine Cooling:
Liquid-Cooled
Horsepower Range:
Typically 50-60+ HP (specific output varies by model and year)
Torque Range:
Typically 40-45+ lb-ft (specific output varies by model and year)
Fuel Delivery:
Fuel Injection (EFI) for most models in this range, some earlier may have had Carburetion (check specific model year/variant).
Ignition Type:
Digital CDI
Valve Actuation:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific engine variant within the 400/450 range.
Crash Test Data:
N/A for off-road motorcycles
Braking System:
Hydraulic Disc Brakes (Front and Rear). Specific caliper and rotor sizes will be detailed.
Suspension System:
High-performance, adjustable Upside-Down (USD) front forks (e.g., WP Suspension) and Monoshock rear suspension. Detailed adjustment and maintenance procedures covered.
Frame Construction:
Chromium-Molybdenum Steel Trellis Frame (characteristic of KTM).
Oil Change Interval:
Typically every 10-15 hours of riding, or as specified in the manual for different riding conditions. Manual will detail exact intervals.
Air Filter Service:
Frequent cleaning/replacement recommended, especially in dusty conditions. Manual will provide guidance.
Valve Clearance Check:
Typically every 20-30 hours of riding. Specific intervals and procedures are critical and found in the manual.
Engine Oil Type:
High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-50 or 15W-50 (JASO MA/MA2 certified). Specific recommendations in manual.
Coolant Type:
Ethylene Glycol based motorcycle coolant, usually a 50/50 mix with distilled water. Manual will specify grade and capacity.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Clutch Fluid Type:
Mineral Oil (e.g., Magura Blood or equivalent) for hydraulic clutch systems. Manual will specify exact type.
Common Wear Items:
Piston rings, valve guides, cam chain, clutch plates, wheel bearings, steering head bearings are common wear items on high-performance off-road motorcycles.
Fuel Injection Maintenance:
Regular cleaning of fuel injectors and checking of fuel filter are important for maintaining optimal performance.
Cooling System Efficiency:
Ensuring radiator fins are clean and coolant is fresh is vital for preventing overheating, especially under racing conditions.
Ktm Legacy:
KTM is renowned for its off-road racing pedigree, particularly in motocross, enduro, and rally raid events. This heritage influences the design and performance of their street-legal and competition models.
400 450 Series Development:
The 400/450cc engine platform has been a core component of KTM's off-road lineup, evolving through various chassis generations and incorporating advancements in engine management and suspension technology during the 2000-2007 period.
Manufacturing Location:
Austria (primary manufacturing for KTM)
Brand Reputation:
KTM models from this era consistently received praise for their power, handling, and race-bred performance in their respective categories.
Motorcycle Press Reviews:
Reviews from period motorcycle publications (e.g., Dirt Bike Magazine, Motocross Action) often highlighted the competitive edge of these KTM models.
