KTM 400 450 EXC SMR SXS Engine 2000-2007 Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 94518

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

Variantes de produits

Description

This manual provides comprehensive technical information for 400/450 EXC, SMR, and SXS models equipped with the 400/450 LC4 engine, covering production years 2000 through 2007. These versatile motorcycles, known for their Austrian engineering and performance capabilities, are designed for a range of applications from dual-sport riding to competitive motocross and supermoto. The LC4 engine platform is celebrated for its robust torque and reliability, forming the core of these capable machines. This Service and Repair Manual is designed to be an indispensable resource for owners and technicians alike. It offers detailed coverage of engine service and repair, including complete disassembly, inspection, overhaul, and reassembly procedures for the engine core, cooling system, lubrication system, fuel system, ignition system, and exhaust system. The manual also includes routine maintenance schedules, troubleshooting guides for common issues, and step-by-step instructions for component replacement and engine rebuilds, ensuring optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

EXC / SMR / SXS

Engine Family:

400 / 450 LC4

Generation

Applicable Years:

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

👋 Introduction

Market Position

Target Audience:

Owners and mechanics of KTM 400/450 EXC, SMR, and SXS models from 2000-2007 seeking detailed engine maintenance and repair information.

Competitive Analysis

Value Proposition:

Provides essential technical data and procedural guidance for maintaining the performance and longevity of the LC4 engine platform, crucial for these off-road and supermoto variants.

Key Features

Completeness:

Focuses specifically on the engine, offering in-depth information often fragmented in general workshop manuals.

📋 Manual Details

Coverage Areas

Primary Coverage:

Engine Service and Repair

Page Count

Estimated Pages:

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, overhaul, and reassembly of the engine core (cylinder, piston, crankshaft, connecting rod, valve train).

Cooling System:

Radiator, water pump, hoses, thermostat, coolant specifications, bleeding procedures.

Lubrication System:

Oil pump, oil filter, oil passages, oil type and capacity, oil change procedures.

Fuel System:

Carburetor (Mikuni VM or similar variants), fuel pump, fuel lines, fuel filter, jetting specifications.

Ignition System:

CDI unit, ignition coil, spark plug specifications, timing procedures.

Exhaust System:

Exhaust pipe, muffler, heat shields, torque specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, valve clearance adjustments, air filter cleaning/replacement, chain maintenance.

Troubleshooting:

Diagnosis of common starting issues, poor running, abnormal noises, and performance problems with detailed flowcharts and corrective actions.

Engine Rebuild:

Step-by-step instructions for complete engine overhaul, including torque sequences, specifications, and assembly tips.

Component Replacement:

Detailed guidance for replacing specific engine components like gaskets, seals, bearings, clutch components, and timing chain.

Technical Depth

Depth:

Comprehensive diagnostic procedures, detailed technical specifications, and step-by-step repair instructions for both novice and experienced mechanics.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF with searchable text for easy navigation.

Print Quality

Printability:

Designed for clear printing of individual pages or entire sections.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled (LC4 designation)

Displacement 400:

Approx. 398cc

Displacement 450:

Approx. 449cc

Bore X Stroke Typical:

Varies by specific model year and displacement (e.g., 95mm x 62.4mm for 400, 97mm x 60.8mm for 450 - *specific values detailed in manual*).

Compression Ratio Typical:

Approx. 11.5:1 to 12.5:1 - *specific values detailed in manual*.

Performance

Horsepower Estimated:

35-45 HP (Varies by model year and tuning)

Torque Estimated:

30-38 lb-ft (Varies by model year and tuning)

Fuel System

Carburetor Model Typical:

Mikuni VM40 or similar, Keihin FCR variants in later models.

Fuel Type:

Unleaded gasoline, 91-98 octane recommended.

Valvetrain

Type:

SOHC (Single Overhead Camshaft), 4 valves per cylinder.

Valve Clearance Intake:

0.05 - 0.10 mm (typical cold setting - *exact values in manual*).

Valve Clearance Exhaust:

0.10 - 0.15 mm (typical cold setting - *exact values in manual*).

🔧 Transmission

Standard

Type:

Constant mesh, sequential, 6-speed gearbox.

Optional

Features:

Hydraulically actuated clutch for smooth engagement.

Features

Clutch Type:

Wet multi-plate clutch.

Transmission Oil Type:

SAE 10W/40 or 15W/50 API SG, JASO MA certified motorcycle oil.

Transmission Oil Capacity:

Approx. 1.0 - 1.2 liters (refer to specific model year for exact capacity).

📐 Dimensions

Exterior

Bike Type:

Dual-sport (EXC), Supermoto (SMR), Competition Motocross (SXS) - *dimensions vary significantly across these models.*

Weights

Dry Weight Typical:

Approx. 115-135 kg (Varies by model configuration)

🛡️ Safety Features

Ratings

Safety Certification:

Off-road and competition use focused; road legal variants may require separate homologation.

💡 Technology Features

Infotainment

Features:

N/A (Primarily focused on performance and off-road capability, typically no infotainment systems).

Driver Assistance

Features:

N/A (Vehicle systems are mechanically driven).

Connectivity

Features:

N/A (No electronic connectivity features).

🔧 Maintenance

Service Intervals

Oil Change:

Every 15-30 operating hours or 1000-2000 km (refer to specific model recommendations and usage).

Air Filter Cleaning:

Every 5-10 operating hours or after dusty rides.

Valve Adjustment:

Every 100-150 operating hours or as needed based on inspection.

Fluid Specifications

Engine Oil:

SAE 10W/40 or 15W/50 API SG, JASO MA; Capacity: Approx. 1.2-1.4 liters (refer to manual).

Coolant:

Ethylene glycol based coolant with corrosion inhibitors, typically 50/50 mix with distilled water. Capacity: Approx. 1.0-1.2 liters.

Known Issues

Common Wear Items:

Valve guides, piston rings, clutch plates, water pump seals, starter motor components.

Carburetor Issues:

Clogged jets, float bowl issues, mixture screw sensitivity leading to starting or running problems.

Cooling System Performance:

Potential for overheating if coolant levels are low or radiator is fouled; water pump leaks.

Cam Chain Tensioner:

Early models might have less robust automatic tensioners; manual adjustment or updated parts may be beneficial.

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM Sportmotorcycle AG, Austria

Model Evolution

Lc4 Platform:

The LC4 engine platform has been a cornerstone of KTM's off-road and dual-sport lineup for decades, known for its robust torque and versatility.

Generations:

This 2000-2007 period represents a significant evolution of the LC4, incorporating advancements in chassis design, suspension, and engine tuning for improved performance across various disciplines.

Production

Manufacturing Location:

Austria

🏆 Awards & Recognition

Recognitions

Industry Reputation:

KTM's LC4 engines are renowned for their durability and performance in demanding off-road and competition environments.