KTM 400 450 SX MXC XC 2000-2007 Service & Repair Workshop Manual Download PDF

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This manual covers the 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models manufactured between 2000 and 2007. These high-performance off-road motorcycles, powered by the...

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UGS: 77745

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

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Description

This manual covers the 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models manufactured between 2000 and 2007. These high-performance off-road motorcycles, powered by the robust LC4 engine family, are renowned for their potent performance, capable suspension, and aggressive design, making them suitable for motocross, cross-country, and enduro racing. The legacy in off-road competition is reflected in the engineering quality and durability of these machines, which have earned numerous accolades. This comprehensive factory service and repair workshop manual provides in-depth guidance for owners and technicians. It details essential maintenance procedures, from routine checks and fluid changes to critical component adjustments and rebuilds. The manual covers all major systems, including the engine, transmission, chassis, suspension, brakes, and electrical systems, offering step-by-step instructions, troubleshooting tips, and essential technical specifications. The scope of this manual ensures that users can effectively maintain, diagnose, and repair their motorcycles, maximizing performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

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

Model Variants:

SX (Motocross), MXC (Cross Country), XC (Cross Country/Enduro)

Generation

Generation Identifier:

2000-2007 Models

Codes

Chassis Codes:

Likely varied by specific year and model variant, common codes can be found within the manual.

Engine Codes:

LC4 engine family (various displacements within 400-450cc range)

👋 Introduction

Market Position

Market Segment:

High-performance off-road motorcycles (Motocross, Cross Country, Enduro).

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CR/XR series, Suzuki RM/DR series, Kawasaki KX/KDX series, Husqvarna, Beta.

Key Features

Vehicle Strengths:

Powerful LC4 engines, robust chassis, excellent suspension performance, aggressive styling, capable for demanding off-road competition.

Manual Value Proposition

Target Audience:

KTM owners, aspiring mechanics, off-road enthusiasts looking for in-depth knowledge to maintain and repair their motorcycles.

📋 Manual Details

Coverage Areas

Countries Of Operation:

Global (with potential regional variations noted for emissions/specific components)

Page Count

Estimated Page Count:

Estimated 400-700+ pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Factory Service & Repair Workshop Manual

Language

Language:

English (primary language expected for download versions of this era)

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Complete engine assembly, disassembly, overhaul, tuning, lubrication, cooling system, exhaust system, fuel system, ignition system, starting system.

Transmission:

Gearbox disassembly, assembly, inspection, lubrication, clutch operation and maintenance, shifting mechanisms.

Chassis And Suspension:

Frame inspection, fork disassembly and rebuild, rear shock absorber servicing, swingarm, linkage, wheel bearings, steering head bearings.

Brakes:

Hydraulic brake system diagnosis, caliper servicing, master cylinder overhaul, bleeding procedures, brake pad replacement, rotor inspection.

Electrical System:

Wiring diagrams, lighting system, ignition coils, battery maintenance, stator and rotor testing, starter motor, fuses, switches, sensors.

Fuel System:

Carburetor (likely Mikuni or Keihin) disassembly, cleaning, tuning, jetting, fuel pump (if applicable), fuel tank, fuel lines.

Bodywork And Ergonomics:

Fairings, seat, handlebars, controls, footpegs, fender replacement, graphics/plastics.

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment, brake fluid changes, coolant checks.

Troubleshooting:

Diagnostic charts for common problems, symptoms, and solutions for engine, electrical, and chassis issues.

Repair And Rebuild:

Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly of all major vehicle systems.

Technical Specifications:

Torque values, tolerances, fluid capacities, electrical specifications, diagnostic data.

Technical Depth

Depth:

Comprehensive, covering everything from basic pre-ride checks to full engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format:

Print Quality

Image Resolution:

High-resolution scans, clear diagrams, and readable text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchable Text:

Likely includes searchable text for quick information retrieval.

Licensing

Expiry Dates:

No expiry dates

Additional Fees:

No extra fees

⚙️ Engine Specifications

Primary Engine

Engine Family:

KTM LC4 Single-cylinder, four-stroke

Displacement Options:

Approximately 400cc and 450cc (specific bore/stroke variations within the model range)

Cooling System:

Liquid-cooled

Valve Train:

SOHC (Single Overhead Camshaft), 4 valves

Performance

Horsepower Range:

Estimated 45-55+ hp (depending on specific model and tuning, precise figures in manual)

Torque Range:

Estimated 35-45+ lb-ft (depending on specific model and tuning, precise figures in manual)

Fuel System

Carburetor Type:

Mikuni (e.g., TM40, TM42) or Keihin FCR (specific model dependent, detailed in manual)

Fuel Type:

Unleaded gasoline (91-98 octane RON recommended)

Ignition System

Ignition Type:

Electronic ignition (CDI/Digital)

🔧 Transmission

Standard

Transmission Type:

6-speed manual gearbox

Optional

Optional Gearbox:

N/A (standard 6-speed)

Features

Clutch Type:

Wet multi-plate clutch (hydraulic actuation typical)

Gear Ratios:

Specific ratios provided within the manual for each model variant.

Final Drive:

Chain drive

📐 Dimensions

Exterior

Wheelbase:

Varies by model variant and year, typically around 1470-1490 mm (57.9-58.7 inches). Precise figures in manual.

Weights

Dry Weight:

Typically around 110-120 kg (242-265 lbs) without fluids. Specific figures in manual.

Fuel Tank Capacity:

Approximately 8-10 liters (2.1-2.6 US gallons). Specific figures in manual.

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Off-road motorcycles are not subjected to typical automotive safety crash testing regimes).

Active Features

Active Safety:

Powerful hydraulic disc brakes (front and rear), responsive steering geometry.

Passive Features

Passive Safety:

Durable frame construction, rider-controlled handling.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Dedicated off-road competition machines, no infotainment features).

Driver Assistance

Driver Assistance Features:

N/A (Focus is on rider control and mechanical systems).

Connectivity

Connectivity Options:

Engine Management

Engine Management System:

Basic CDI ignition system and carburetor for fuel delivery.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-20 hours of riding or annually, whichever comes first (specific recommendations in manual).

Air Filter Cleaning:

After every few rides or as needed based on riding conditions (detailed in manual).

Valve Clearance Check:

Typically every 40-60 hours of riding (critical maintenance item, detailed in manual).

Chain And Sprockets:

Regular cleaning, lubrication, and tension adjustment; replacement based on wear.

Fluid Specifications

Engine Oil Type:

High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 15W-50, meeting JASO MA standards (check manual for exact specification).

Coolant Type:

Mixture of distilled water and ethylene glycol-based antifreeze (specific ratio and type in manual).

Brake Fluid Type:

DOT 4 hydraulic brake fluid (check manual for confirmation).

Known Issues

Common Wear Items:

Clutch wear, valve seat wear, fork seal leaks, swingarm/linkage bearings, wheel bearings, cam chain tensioner (depending on year).

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments.

Cooling System Maintenance:

Regular coolant flushes and inspection of hoses for leaks are important to prevent overheating.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road racing heritage and 'Ready to Race' philosophy, specializing in dirt bikes, ATVs, and adventure motorcycles.

Model Evolution

Lc4 Lineage:

The LC4 engine platform has a long and storied history within KTM, evolving from earlier models to become a dominant force in various off-road disciplines.

Sx Mxc Xc Differentiation:

SX models are pure motocross race bikes, MXC and XC models are tailored for cross-country and endurance racing with features like larger fuel tanks, lighting, and often slightly different suspension/engine tuning.

Production

Production Period:

2000-2007

🏆 Awards & Recognition

Recognitions

Off Road Accolades:

KTM motorcycles of this era consistently received praise and accolades in off-road racing magazines and competitive events for their performance and durability.

Ratings

Reliability Reputation:

Generally good, but requires diligent maintenance, especially valve adjustments and oil changes, to ensure longevity.