Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Chassis Codes:
Likely corresponds to specific KTM chassis designations for this period, though not explicitly stated in product info.
Engine Codes:
Likely corresponds to specific KTM LC4 engine designations for this period, though not explicitly stated in product info.
Category:
Competition Motorcycle / Off-Road Enduro
Target Audience:
Enduro riders, motocross enthusiasts, off-road racing participants
Competitors:
Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450, Kawasaki KX450F (for similar era competition models)
Performance Focus:
Designed for off-road performance, durability, and reliability in demanding conditions
Brand Reputation:
KTM is renowned for its 'Ready to Race' philosophy and high-performance off-road machines.
Primary Focus:
Workshop Repair and Service
Scope:
Comprehensive maintenance, troubleshooting, and repair procedures
Estimated Page Count:
While not specified, professional workshop manuals for this era typically range from 300-600 pages, depending on the scope.
Type:
Workshop Service Manual
Language:
English (assumed, based on typical market)
Engine:
Complete engine overhaul, disassembly, assembly, component specifications, diagnostics
Fuel System:
Carburetor tuning, cleaning, rebuilding; fuel pump, filter, lines
Ignition System:
CDI unit, ignition coil, spark plug specifications, troubleshooting
Cooling System:
Radiator, coolant, water pump, fan operation (if applicable)
Transmission:
Gearbox disassembly, assembly, clutch operation, gear ratio details
Suspension:
Front forks (WP), rear shock absorber, seal replacement, damping adjustment, oil levels
Brakes:
Hydraulic brake systems (front and rear), caliper servicing, master cylinder, bleeding procedures, pad replacement
Electrical System:
Wiring diagrams, lighting, battery, charging system, starter motor, troubleshooting
Chassis Frame:
Frame inspection, component mounting, steering head bearing service
Bodywork Trim:
Fairing removal and installation, seat, plastics
Wheels Tires:
Wheel bearing maintenance, tire fitment, spoke tension
Maintenance:
Scheduled maintenance intervals, fluid changes, filter replacements, lubrication points
Troubleshooting:
Diagnostic charts, common problems and solutions, symptom-based repair guidance
Repair:
Step-by-step disassembly and reassembly of all major components
Adjustments:
Carburetor adjustment, suspension adjustments, chain tension, clutch and throttle cables
Overhaul:
Complete engine and transmission overhaul procedures
Depth:
Comprehensive, covering basic maintenance to full engine rebuilds and advanced diagnostics
User Level:
Suitable for professional mechanics and experienced DIY enthusiasts
Searchability:
Likely text-searchable, enabling quick navigation to specific topics
Quality:
High-resolution, ensuring clarity of diagrams and text
Binding:
Not applicable (digital PDF download)
Paper Type:
Not applicable (digital PDF download)
Type:
4-stroke, Liquid-Cooled, Single Cylinder (LC4 engine architecture)
Displacement:
450cc (approximate, specific variants may exist)
Bore X Stroke:
Specifications would be detailed within the manual, typically around 95mm x 63.4mm for this engine family.
Valve Train:
SOHC (Single Overhead Camshaft), typically 4 valves
Compression Ratio:
Specifications would be detailed within the manual, often around 11.5:1 to 12.5:1.
Horsepower Est:
Typically in the range of 45-55 HP at the crank, depending on tuning and regulations.
Torque Est:
Torque figures would be detailed within the manual, generally providing strong low-end and mid-range grunt.
Carburetor Type:
Likely a Keihin FCR (Flat CR) carburetor, with specific sizes (e.g., 39mm or 41mm) detailed in the manual.
Fuel Type:
Unleaded gasoline, Octane rating as specified in manual (likely 91 or higher).
Oil Type:
High-quality motorcycle-specific 4-stroke engine oil, viscosity grade (e.g., 10W-40 or 10W-50) to be confirmed in manual.
Oil Capacity:
Capacity for engine oil and clutch operation (often a shared or separate system) specified in manual.
Type:
5-speed constant mesh manual transmission
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Optional Features:
No optional transmission types expected for this model.
Gear Ratios:
Specific gear ratios for each of the 5 speeds and final drive ratio will be detailed in the manual.
Transmission Oil:
Type and capacity of transmission fluid (often the same as engine oil for this era KTM) will be specified.
Wheelbase:
Specific wheelbase dimensions will be listed in the manual, typical for an MXC model around 1470-1500 mm.
Seat Height:
Approximate seat height will be available in the manual; typically high for off-road capability.
Dry Weight:
Dry weight figures are typically around 110-115 kg for this class of motorcycle.
Fuel Tank Capacity:
Fuel tank capacity will be specified in the manual, generally around 8-12 liters for an enduro model.
Front Wheel Size:
Typically 21-inch
Rear Wheel Size:
Typically 18-inch
Front Tire Size:
Common sizes like 80/100-21 or 90/90-21.
Rear Tire Size:
Common sizes like 110/100-18 or 120/90-18.
Wheel Bolt Pattern:
Not applicable; spoke wheels with hub mounting.
Safety Ratings:
Motorcycles typically do not receive formal crash test ratings like passenger cars.
Braking System:
Hydraulic disc brakes front and rear, likely Brembo calipers, providing effective stopping power.
Suspension Performance:
High-quality WP suspension components designed for off-road stability and control.
Frame Construction:
Robust steel trellis frame for strength and rigidity.
Ergonomics:
Designed for rider control and comfort during demanding off-road riding.
Infotainment System:
No integrated infotainment system; focused on raw off-road performance.
Assistance Features:
No electronic rider aids like traction control or ABS on this model.
Connectivity Options:
No electronic connectivity features.
Dashboard:
Basic digital or analog instrumentation, typically including speedometer, odometer, and indicator lights.
Oil Change Interval:
Typically every 10-15 hours of riding or annually, with specific recommendations in the manual.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions, as per manual instructions.
Spark Plug Replacement:
Intervals will be specified in the manual, often tied to engine hours or mileage.
Valve Clearance Check:
Periodic checks are critical for performance and longevity, with specific intervals in the manual.
Chain And Sprockets:
Regular cleaning, lubrication, and tension adjustment are essential.
Engine Oil Grade:
Refer to manual for exact viscosity (e.g., Motorex Power Synt 10W-40 is a common KTM recommendation).
Coolant Type:
Proprietary or specific ethylene glycol-based coolant for optimal heat transfer and corrosion protection.
Brake Fluid:
DOT 4 hydraulic brake fluid is standard.
Carburetor Jetting:
Can require careful tuning for optimal performance across different altitudes and conditions.
Clutch Slave Cylinder:
Some models may have had issues with clutch slave cylinder seals, leading to fluid leaks or poor clutch operation.
Suspension Seals:
Like all off-road bikes, fork and shock seals require regular inspection and maintenance to prevent leaks.
Electrical Connections:
Ensure all electrical connectors are clean and tight, especially in an off-road environment prone to moisture and dirt.
K T M History:
KTM has a long and successful history in off-road racing and motorcycle manufacturing, dating back to the 1950s.
Mxc Series:
The MXC (Motocross Competition) designation signifies KTM's pure off-road competition lineage, often a homologated version for enduro or cross-country events.
Lc4 Engine:
The LC4 engine platform has been a cornerstone of KTM's larger displacement off-road and dual-sport bikes for decades, known for its torque and durability.
Manufacturing Location:
KTM motorcycles are primarily manufactured in Austria.
