KTM 400 450 SX MXC XC EXC SMR SXS Racing Complete Workshop Service Repair Manual 2000 2001 2002 2003 2004 2005 2006 2007

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Basic Information Identification Make: KTM Model: SX, MXC, XC, EXC, SMR, SXS Racing Model Variant: 400, 450 Codes Product Code: KTM400450SR0007PDF Introduction Market Position Segment: High-performance off-road and motocross motorcycles....

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Type: Motorcycle

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Sku: 87209

Tags: 2000 2001 2002 2003 2004 2005 2006 2007 400 EXC 400 MXC 400 SMR 400 SX 400 SXS Racing 400 XC 450 EXC 450 MXC 450 SMR 450 SX 450 SXS Racing 450 XC KTM Misc Motorcycle Motorcycles

Product variants

Description

Basic Information
Identification
Make:	KTM
Model:	SX, MXC, XC, EXC, SMR, SXS Racing
Model Variant:	400, 450
Codes
Product Code:	KTM400450SR0007PDF

Introduction
Market Position
Segment:	High-performance off-road and motocross motorcycles.
Competitive Analysis
Competitors:	Yamaha YZ/WR, Honda CR/CRF, Suzuki RM/RM-Z, Kawasaki KX/KLX.
Key Features
Brand Focus:	KTM's reputation for powerful engines, advanced suspension, and race-bred chassis design.
Manual Purpose:	Essential resource for owners and technicians to maintain, repair, and optimize these performance motorcycles.

Manual Details
Coverage Areas
Years Covered:	2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Page Count
Estimated Page Count:	Likely 500+ pages (typical for comprehensive workshop manuals of this era/scope)
Manual Type
Type:	Complete Workshop Service Repair Manual
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine:	Complete engine overhaul, assembly, disassembly, tuning, lubrication, cooling system, exhaust system.
Transmission:	Gearbox disassembly, assembly, inspection, repair, clutch operation and service.
Chassis:	Frame inspection and repair, suspension (forks, rear shock), steering system, swingarm.
Electrical:	Wiring diagrams, ignition system, lighting, starting system, charging system, sensors, ECU diagnostics.
Fuel System:	Carburetor/fuel injection system diagnosis and repair, fuel pump, fuel lines, fuel tank.
Brakes:	Hydraulic brake system diagnosis and repair, caliper overhaul, master cylinder, brake lines, bleeding procedures.
Cooling System:	Radiator, coolant hoses, water pump, thermostat.
Bodywork:	Fairings, seat, fuel tank cover, fenders, graphics.
Procedures Included
Maintenance:	Routine maintenance, oil changes, filter replacements, chain adjustment, valve clearance checks.
Troubleshooting:	Diagnostic procedures for common problems, electrical troubleshooting charts, engine performance issues.
Repair:	Step-by-step repair instructions for all major components and systems.
Rebuilds:	Detailed procedures for complete engine and gearbox rebuilds.
Specifications:	Torque specifications, clearances, fluid capacities, wear limits.
Technical Depth
Depth:	Comprehensive - Covers everything from basic maintenance to complete engine and chassis rebuilds, including advanced diagnostics.

Manual Specifications
File Format
Quality:	High-resolution PDF, typically searchable text and clear, legible diagrams.
Print Quality
Printability:	Designed for printing, with clear page breaks and organized sections.
Binding Type
Binding:	N/A (Digital Download)
Paper Type
Paper Type:	N/A (Digital Download)

Engine Specifications
Primary Engine
Type:	Four-stroke, single-cylinder (typically LC4 engine architecture for EXC/SX/MXC models).
Bore X Stroke:	Varies by specific 400/450 displacement (e.g., approx. 95mm x 63.4mm for 450 EXC/SX).
Displacement:	400cc, 450cc (specific models vary).
Valve Train:	SOHC (Single Overhead Camshaft) with 4 valves.
Cooling:	Liquid-cooled.
Performance
Horsepower:	Approx. 50-60 HP (depending on model and tuning).
Torque:	Approx. 40-45 lb-ft (depending on model and tuning).
Fuel System
Carburetion:	Keihin FCR flatside carburetors (e.g., FCR 41).
Fuel Type:	Unleaded gasoline, minimum 95 RON (Octane rating).
Lubrication System
Oil Type:	JASO MA certified 4-stroke motorcycle oil, SAE 10W/40 or 15W/50 (refer to manual for specific recommendations).
Oil Capacity:	Approx. 1.5 - 1.7 liters (including clutch operation).

Transmission
Standard
Type:	6-speed constant mesh gearbox.
Optional
Clutch:	Hydraulically operated, multi-plate wet clutch.
Features
Gear Ratios:	Specific ratios vary by model (e.g., SX, EXC, MXC will have different gearing).
Transmission Oil:	SAE 75W/90 or 80W/90 GL-4 gear oil.

Dimensions
Exterior
Wheelbase:	Approx. 1470-1485 mm (depending on model).
Seat Height:	Approx. 960-980 mm (unladen).
Weights
Dry Weight:	Approx. 115-125 kg (depending on model).
Fuel Tank Capacity:	Approx. 8-10 liters (depending on model).

Safety Features
Ratings
Crash Safety:	N/A (Off-road competition motorcycles are not subject to road vehicle safety ratings).
Active Features
Brakes:	Hydraulic disc brakes (front and rear) with high-performance calipers and rotors.
Suspension:	High-quality WP suspension components with adjustable damping and rebound.
Passive Features
Frame:	Chromoly steel trellis frame for strength and rigidity.

Technology Features
Infotainment
Features:	N/A (Minimalistic, race-focused design, typically no infotainment features).
Driver Assistance
Features:	N/A (No electronic driver assistance systems common in this era of off-road bikes).
Connectivity
Features:	N/A.

Maintenance
Service Intervals
Oil Change:	Every 10-15 engine hours or annually, whichever comes first.
Air Filter Cleaning:	After every few rides, or more frequently in dusty conditions.
Valve Clearance Check:	Every 20-30 engine hours.
Spark Plug Replacement:	Recommended every 30-40 engine hours.
Fluid Specifications
Coolant:	Ethylene glycol-based coolant, 50% mixture with distilled water.
Brake Fluid:	DOT 4 hydraulic brake fluid.
Known Issues
Common Problems:	Potential for starter motor issues (early models), wear on valve seats, clutch slave cylinder leaks, carburetor jetting sensitivity to altitude/temperature.
Preventative Maintenance:	Regular oil changes, air filter cleaning, thorough pre-ride inspections are crucial for longevity.

Vehicle History
Brand Heritage
Origin:	KTM is an Austrian manufacturer known for its off-road motorcycles.
Model Evolution
Development:	These models represent KTM's focus on racing and high-performance off-road capabilities during the early 2000s.
Production
Manufacturing Location:	Austria.

Awards & Recognition
Recognitions
Racing Success:	KTM models from this era consistently achieved podium finishes and wins in various off-road racing disciplines (motocross, enduro, desert racing).