KTM 400 450 EXC SMR SXS 2000-2007 Workshop Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 78578

Mots clés: 2000 2001 2002 2003 2004 2005 2006 2007 400 450 EXC KTM Misc Motorcycle Motorcycles SMR SXS

Variantes de produits

Description

This manual covers 400 EXC, 450 EXC, SMR, and SXS models manufactured between 2000 and 2007. These high-performance motorcycles, built around the robust LC4 engine architecture, are renowned for their powerful, torquey performance and exceptional off-road capability. Featuring premium WP suspension for superior damping and adjustability, along with agile chassis designs, these bikes are engineered for demanding terrain and competitive use. Whether for Enduro, Motocross, or Supermoto applications, motorcycles of this era are recognized for their racing heritage and handling prowess, with a strong emphasis on rider control and durability. This comprehensive Workshop Service Manual provides detailed information essential for the maintenance, repair, and troubleshooting of your motorcycle. It covers a wide array of systems, including engine mechanicals, fuel and ignition systems, transmission, drivetrain, suspension, brakes, and the electrical system. Within its pages, you will find procedures for routine maintenance, in-depth engine rebuilds, suspension and brake servicing, and electrical diagnostics. The manual also includes technical specifications, torque values, and troubleshooting charts, enabling owners and technicians to effectively maintain and restore these high-performance machines to optimal working condition.

🏷️ Basic Information

Identification

Make:

Model:

400 EXC, 450 EXC, SMR, SXS

Year:

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

Codes

Common Chassis Codes:

LC4 (general family), specific variations for EXC/SMR/SXS models

👋 Introduction

Market Position

Vehicle Segment:

High-performance off-road motorcycles (Enduro, Motocross, Supermoto variants).

Competitive Analysis

Competitors:

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

Key Features

Engine Philosophy:

Powerful, torquey LC4 single-cylinder engines known for their robustness and off-road capability.

Suspension Performance:

Premium WP suspension components providing exceptional damping and adjustability for demanding terrain.

Handling:

Agile and responsive chassis design optimized for competitive off-road riding.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Varies by specific model variant and year; typically 300-600 pages for comprehensive coverage.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, assembly, inspection, repair of cylinder head, valves, piston, crankshaft, connecting rod, oil pump, and cooling system.

Fuel System:

Carburetor (Keihin, Mikuni variants), fuel pump, fuel tank, lines, and filtration.

Ignition System:

CDI unit, ignition coil, spark plug, stator, and wiring.

Transmission Drivetrain:

Gearbox disassembly, inspection, repair, clutch operation, chain and sprocket maintenance.

Suspension Front:

Fork disassembly, seal replacement, oil levels, spring rates, damping adjustments (WP USD forks common).

Suspension Rear:

Monoshock (WP PDS or linkage systems), shock absorber service, linkage bearing maintenance.

Brakes Front:

Brake caliper service, master cylinder overhaul, pad replacement, disc inspection, hydraulic lines.

Brakes Rear:

Brake caliper service, master cylinder overhaul, pad replacement, disc inspection, hydraulic lines.

Electrical System:

Wiring diagrams, lighting, starter motor, battery maintenance, charging system, fuse box, switchgear.

Frame Chassis:

Frame inspection, steering head bearing service, swingarm maintenance, subframe.

Bodywork:

Fairing removal and installation, seat, fuel tank mounting, fenders.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, valve clearance checks.

Troubleshooting:

Diagnostic tables for common starting, running, and electrical issues.

Engine Rebuild:

Complete engine disassembly, component inspection, torque specifications for critical fasteners, reassembly procedures.

Suspension Service:

Front fork seal replacement, rear shock absorber service (where applicable), linkage lubrication.

Brake Service:

Brake bleeding, caliper piston cleaning and lubrication, pad and disc replacement.

Electrical Diagnostics:

Using multimeters to test circuits, identifying faulty components based on symptoms.

Carburetor Tuning:

Adjustment of idle speed, mixture screws, jetting recommendations for altitude and conditions.

Technical Depth

Diagnostics Level:

Advanced diagnostics including troubleshooting charts and component testing procedures.

Repair Scope:

Comprehensive repair procedures for major mechanical and electrical components.

Rebuild Procedures:

Detailed instructions for engine and transmission rebuilds.

Technical Drawings:

Includes exploded diagrams and illustrations of components and assemblies.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Typically yes, allowing for easy keyword searches.

Print Quality

Print Quality:

High-resolution scans suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled (LC4 architecture).

Displacement 400:

Approximately 398cc.

Displacement 450:

Approximately 449cc (exact figures may vary slightly by year and sub-model).

Bore X Stroke 400:

Typical around 95mm x 70.5mm (check specific model year).

Bore X Stroke 450:

Typical around 97mm x 60.8mm (check specific model year).

Performance

Horsepower 400:

Estimated 45-55 HP (may vary with tuning and exhaust).

Horsepower 450:

Estimated 50-60 HP (may vary with tuning and exhaust).

Torque:

Strong mid-range torque characteristic of LC4 engines.

Fuel System

Carburetor Type:

Keihin FCR flat-slide or Mikuni VM (depending on year and model variant).

Fuel Type:

Unleaded Gasoline, 91 octane or higher recommended.

Engine Features

Valve Train:

SOHC, 4 valves per cylinder.

Starting System:

Electric Starter (standard on most variants).

Cooling System:

Liquid-cooled.

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh manual gearbox.

Clutch Type:

Wet multi-plate clutch, hydraulically operated.

Features

Gear Ratios:

Specific gear ratios vary by model and intended use (EXC, SXS, SMR); refer to manual for detailed charts.

Final Drive:

Chain drive (e.g., 520 pitch).

Fluid Specifications

Transmission Oil:

SAE 10W-40 or 15W-50 motorcycle-specific engine oil (check manual for exact API rating and specifications, e.g., JASO MA).

📐 Dimensions

Exterior

Wheelbase:

Varies by model, typically around 1450-1500 mm.

Seat Height:

High, typical for off-road bikes, around 930-970 mm (unladen).

Weights

Dry Weight:

Typically in the range of 115-130 kg, depending on model and equipment.

Fuel Tank Capacity:

Around 7-9 liters, with some EXC models having larger optional tanks.

Wheels Tires

Front Wheel Size:

1.60 x 21 inches (EXC/SXS), 3.50 x 17 inches (SMR).

Rear Wheel Size:

2.15 x 18 inches (EXC/SXS), 5.00 x 17 inches (SMR).

Front Tire Size:

80/100-21 (EXC/SXS), 120/70-17 (SMR).

Rear Tire Size:

100/100-18 or 110/100-18 (EXC/SXS), 160/60-17 (SMR).

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles not typically subject to automotive crash ratings in the same way; focus is on rider protection and active safety through handling).

Active Features

Braking Performance:

High-performance Brembo braking systems providing excellent stopping power and modulation.

Suspension Stability:

WP suspension contributes to rider control and stability over varied terrain.

Passive Features

Frame Integrity:

Chromoly steel trellis frame designed for strength and impact resistance.

💡 Technology Features

Infotainment

Display Type:

Basic LCD display (speedometer, odometer, trip meter, clock). No advanced infotainment systems on these models.

Driver Assistance

ABS was generally not standard or available on these performance-oriented off-road models during this period.

Connectivity

Connectivity Features:

N/A (No Bluetooth or smartphone connectivity).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 1,000-1,500 km or 6 months, whichever comes first (refer to manual for exact recommendation based on usage).

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides or 500 km).

Valve Clearance Check:

Initial check at 1,000 km, then every 3,000-5,000 km or annually. Critical for performance and engine longevity.

Chain Tension Adjustment:

Check and adjust as needed, typically every 500-1,000 km.

Fluid Specifications

Coolant:

Ethylene glycol based coolant, mixture of 50% coolant and 50% distilled water.

Brake Fluid:

DOT 4 brake fluid.

Fork Oil:

Specific WP fork oil (e.g., SAE 5 or 7.5), with specific level and volume requirements.

Known Issues

Starter Clutch Wear:

Can be susceptible to wear over time, especially with hard starting or frequent use.

Piston Ring Wear:

As with any high-performance engine, piston ring wear can occur and affect compression and oil consumption.

Water Pump Seal:

The water pump seal is a common maintenance item that may require replacement due to leaks.

Carburetor Jetting Sensitivity:

Carburetors can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments for optimal performance.

📚 Vehicle History

Brand Heritage

Ktm Legacy:

KTM has a strong heritage in off-road racing, particularly Enduro and Motocross, dating back to the 1950s.

Model Evolution

Lc4 Development:

The LC4 engine platform has been a cornerstone of KTM's lineup for decades, evolving through various displacements and configurations.

Exc Series:

The EXC line represents KTM's dedicated off-road/enduro models, built for tackling demanding trails and competitions.

Sx Series Legacy:

The SXS models are often race-prepped versions derived from the motocross (SX) line, emphasizing performance for closed-course competition.

Smr Series:

The SMR models are KTM's Supermoto offerings, featuring smaller wheels, street tires, and suspension modifications for asphalt-based racing and high-performance street use.

Production

Manufacturing Location:

Primarily Austria.

🏆 Awards & Recognition

Recognitions

Off Road Dominance:

KTM EXC models have a long history of success in professional Enduro championships and off-road racing events.

Supermoto Contender:

SMR models are recognized for their competitive edge in the Supermoto racing scene.