🏷️ Basic Information

Make:

KTM

Model:

450 MXC

Model Variant:

MXC

Production Years Covered:

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

👋 Introduction

Segment:

Competition Motocross / Off-Road Motorcycle

Target Audience:

Motocross racers, off-road enthusiasts, KTM owners seeking detailed maintenance and repair guidance.

Competitors:

Yamaha YZ450F, Honda CRF450X, Suzuki RM-Z450, Kawasaki KX450F.

Engine Type:

Liquid-cooled, 4-stroke, single-cylinder (LC4 engine platform).

Suspension Brand:

WP Suspension (renowned for performance in off-road).

Purpose:

Designed for competitive motocross and aggressive off-road riding.

📋 Manual Details

Engine Coverage:

Complete engine overhaul, top-end and bottom-end rebuilds, carburetor tuning, ignition system diagnostics.

Transmission Coverage:

Clutch service, gearbox inspection and repair, shifting mechanism adjustments.

Chassis Coverage:

Suspension adjustments and rebuilds (forks and rear shock), steering head bearing service, wheel and tire maintenance, brake system overhaul.

Electrical Coverage:

Wiring diagrams, lighting system, ignition coil testing, battery maintenance, charging system diagnostics.

Bodywork Coverage:

Fairing removal and installation, seat service, fuel tank maintenance.

Estimated Pages:

Hundreds (Specific number not provided, but implies comprehensive coverage).

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine (LC4 4-stroke single-cylinder), transmission, final drive.

Suspension:

Front telescopic forks (WP), rear mono-shock absorber (WP).

Braking:

Front disc brake, rear disc brake.

Electrical System:

Ignition, lighting, charging system, starter (if applicable).

Fuel System:

Carburetor (likely Keihin or Mikuni), fuel tank, fuel lines.

Cooling System:

Liquid-cooled (Radiator, fan, coolant hoses).

Exhaust System:

Header pipe, muffler, heat shields.

Preventive Maintenance:

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

Troubleshooting:

Diagnostic procedures for engine performance issues, electrical faults, starting problems.

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, and rebuilding.

Specifications:

Torque specifications, clearances, fluid levels, electrical resistance values.

Adjustments:

Carburetor jetting, idle speed, clutch free play, chain tension.

Depth:

Comprehensive factory-level repair and maintenance information suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

Format:

PDF

Searchable:

Likely searchable text within the PDF for quick access to information.

Quality:

High-resolution images and diagrams, clear text for easy reading and printing.

Type:

N/A (Digital Download)

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Type:

LC4 4-stroke, single-cylinder

Displacement:

Approximately 450cc (specific bore/stroke may vary slightly by year).

Cooling System:

Liquid-cooled

Valvetrain:

SOHC (Single Overhead Camshaft), 4 valves

Horsepower:

Estimated 40-50+ HP (varies by year and tuning).

Torque:

Not explicitly stated in product info, but strong low-to-mid range torque typical for LC4.

Carburetor Type:

Likely Keihin FCR or Mikuni VM series, specific sizes vary by year.

Fuel Type:

Unleaded Gasoline

Oil Type:

JASO MA certified motorcycle engine oil (e.g., Motorex).

Oil Capacity:

Refer to manual for specific year; typically around 1.0-1.3 liters.

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Hydraulically actuated, multi-plate wet clutch

Options:

N/A (Standardized for racing models)

Gear Ratios:

Specific ratios detailed in the manual.

Final Drive:

Chain drive

📐 Dimensions

Frame Type:

Chromoly steel, perimeter frame

Seat Height:

Varies by year, generally high for motocross (approx. 950-960mm).

Dry Weight:

Approximately 115-120 kg (unspecified fluid weight).

Fuel Tank Capacity:

Typically around 7-9 liters.

🛡️ Safety Features

Crash Test Results:

N/A (Off-road vehicles are not subjected to standard road vehicle crash testing).

Braking System:

Hydraulic disc brakes front and rear, capable of strong stopping power.

Ergonomics:

Designed for rider control and maneuverability in off-road conditions.

💡 Technology Features

System:

N/A (Focus is on performance and utility, not infotainment).

Features:

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

Features:

N/A

🔧 Maintenance

Oil Change:

Recommended every 10-15 hours of riding, or annually.

Air Filter Cleaning:

Recommended every 5-10 hours of riding, depending on conditions.

Spark Plug Replacement:

Recommended every 20-30 hours of riding.

Chain Maintenance:

Lubricate and adjust chain tension every 5-10 hours of riding.

Engine Oil:

SAE 10W/40 or 15W/50, JASO MA certified motorcycle oil (e.g., Motorex Power Synt 4T 10W/40).

Coolant:

Ethylene glycol-based coolant with anti-corrosion additives (e.g., Motul Motocool Expert).

Fork Oil:

Specific viscosity grade (e.g., WP Suspension Fork Oil SAE 5 or 7.5), capacity specified in manual.

Brake Fluid:

DOT 4 or DOT 5.1 (check manual for specific recommendation).

Common Wear Items:

Clutch plates, piston rings, valve seals, wheel bearings, steering head bearings.

Potential Problems:

Carburetor jetting sensitivity to altitude and temperature, occasional starter motor issues on some models, WP suspension requiring regular servicing.

📚 Vehicle History

Manufacturer:

KTM AG (Austria), known for its off-road racing pedigree.

Development:

The 450 MXC represents a key generation of KTM's 4-stroke motocross/off-road platform, evolving from earlier LC4 models.

Key Changes:

Throughout this generation, updates often focused on carburetor tuning, suspension refinements, and minor chassis or engine component revisions.

Manufacturing Location:

Austria

🏆 Awards & Recognition

Category:

Motocross/Off-Road Motorcycle

Performance Recognition:

KTM models of this era are generally well-regarded for their performance and handling in off-road disciplines. Specific awards for the 450 MXC model year are not detailed in product info but the platform itself is competitive.