Vehicle Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Estimated Page Count:
Comprehensive (Exact number not specified in product info, but typical for a full service manual is 300-600 pages)
Manual Type:
Service Repair Manual
Language:
English (Assumed, standard for most international manuals)
Engine Mechanical:
Complete engine disassembly, assembly, inspection, repair, and overhaul of all internal components including cylinder, piston, crankshaft, connecting rod, camshaft, valve train, etc.
Engine Lubrication System:
Oil pump, oil filter, oil passages, oil pressure testing, oil capacity specifications.
Engine Cooling System:
Radiator, coolant hoses, thermostat, water pump, coolant specifications, bleeding procedures.
Fuel System:
Carburetor (likely Keihin specific to the era) adjustment, cleaning, overhaul, fuel filter replacement, fuel line maintenance.
Ignition System:
Spark plug specifications, ignition coil, CDI unit, timing adjustment (if applicable).
Exhaust System:
Muffler, header pipe inspection and maintenance.
Electrical System Engine Related:
CDI unit, ignition coil, stator, wiring harness relevant to engine operation. Basic troubleshooting for engine-related electrical faults.
Routine Maintenance:
Oil change intervals, oil filter replacement, air filter cleaning/replacement, spark plug replacement, valve clearance adjustment.
Troubleshooting:
Diagnosing common engine problems, fault finding charts, electrical diagnostics (related to engine management).
Repair Overhaul:
Detailed step-by-step instructions for engine rebuilds, component replacement, and critical torque specifications.
Special Tool Requirements:
Identification and use of specialized tools for engine service and repair.
Torque Specifications:
All critical torque values for engine fasteners, head bolts, crankcase bolts, etc.
Clearances And Tolerances:
Specifications for piston-to-cylinder wall clearance, ring gap, bearing clearances, valve clearances, etc.
Depth:
Comprehensive: Covers everything from basic maintenance and fluid changes to complete engine disassembly, rebuild, and advanced diagnostics.
Diagnostic Charts:
Fault finding charts and diagnostic procedures for identifying and resolving engine issues.
Searchability:
Searchable text content for efficient information retrieval.
Compatibility:
Compatible with all PDF readers on PC, Mac, tablets, and smartphones.
Graphic Resolution:
High-resolution for clear diagrams, illustrations, and photographs.
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Type:
4-stroke, Single-cylinder, Liquid-cooled
Displacement:
Approximately 450cc (exact displacement may vary slightly by sub-model within the 450 EXC range for these years, e.g., 449.7cc)
Bore X Stroke:
Typical for this era: ~95mm x 63.4mm (specific values would be in the manual)
Valve Train:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) with 4 valves (typically DOHC for this era KTM).
Compression Ratio:
Typically around 11.0:1 to 12.0:1 (specific to model year and tuning)
Starter System:
Electric Starter
Horsepower Estimated:
Around 50-60 HP (at crankshaft), dependent on specific model year and tuning.
Torque Estimated:
Around 45-50 Nm (at crankshaft), dependent on specific model year and tuning.
Fuel Delivery:
Carburetor (Likely Keihin FCR series - Flat Slide Carburetor, e.g., FCR MX series)
Carburetor Size:
Typically 39mm or 41mm
Fuel Type:
Unleaded gasoline, minimum Octane rating of 91 (RON+MON)/2 (or 87 AKI)
Overall Length:
Varies by model year, refer to specific bike specs; manual covers engine dimensions relevant to chassis fitment.
Overall Width:
Varies by model year, refer to specific bike specs; manual covers engine dimensions relevant to chassis fitment.
Seat Height:
Varies by model year, refer to specific bike specs; manual covers engine dimensions relevant to chassis fitment.
Dry Weight Estimated:
Approximately 105-115 kg (for the complete motorcycle, engine weight is a component of this).
Infotainment Features:
N/A (This is an engine service manual for an off-road motorcycle, not a road bike with infotainment).
Driver Assistance Systems:
N/A (Off-road motorcycle, no electronic driver assistance systems).
Connectivity Features:
N/A (Off-road motorcycle, no standard connectivity features).
Oil Change Interval:
Typically every 10-15 hours of riding or annually (specifics vary based on riding conditions and manual recommendation).
Air Filter Cleaning:
Regularly, depending on dust conditions (e.g., every few rides).
Valve Clearance Check:
Typically every 20-30 hours of riding or annually.
Spark Plug Replacement:
As per manual recommendations, often around 20-30 hours or annually.
Engine Oil Type:
Full synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG, SH, SJ, SL or JASO MA/MA2 specification). Specific viscosity and API/JASO rating to be confirmed in the manual.
Engine Oil Capacity:
Approximately 1.2 - 1.5 liters (including filter, dependent on model year; precise capacity will be in the manual).
Coolant Type:
Ethylene glycol based coolant, pre-mixed or concentrated with distilled water (50/50 ratio). Specific color/brand not specified here, but manual will detail.
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to specific model's requirements).
Transmission Oil Type:
Dedicated transmission oil (or shared with engine oil for some designs, manual will specify). SAE 75W/80 or 80W/90 gear oil might be specified depending on design.
Transmission Oil Capacity:
Approx. 0.7 - 1.0 liters (manual will confirm exact amount).
Common Wear Items:
Piston rings, valve seats, clutch plates, timing chain, fork seals (though not engine-specific, common off-road wear).
Carburetor Troubles:
Clogged jets, float bowl issues, worn needle and seat, requiring regular cleaning and adjustment.
Cooling System Prone To:
Leaking hoses, faulty thermostat, potential for overheating if coolant levels are not maintained.
Ktm Offroad Heritage:
KTM has a long and successful history in off-road motorcycle racing and manufacturing, known for its 'Ready to Race' philosophy and durable, high-performance machines.
450 Exc Evolution:
The 450 EXC model line has evolved significantly over the years, with this generation representing a period of refinement in engine performance and chassis design for enduro competition.
Manufacturing Location:
Primarily Austria (Mattighofen) for KTM motorcycles.
Model Awards:
The KTM 450 EXC has historically been well-regarded in the off-road and enduro community, often winning awards for performance, handling, and reliability in its class. Specific awards for these model years would need further research.
Owner Satisfaction:
Generally high for KTM motorcycles within the off-road segment, reflecting the brand's reputation for quality and performance.
Certifications:
N/A for manual; relates to vehicle emissions or road legality if applicable.
