KTM 450 SX MXC XC 2000-2007 Workshop Service Manual

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Type: Motorcycle

Vendor:

Sku: 72561

Tags: 2000 2001 2002 2003 2004 2005 2006 2007 450 SX KTM Misc Motorcycle Motorcycles MXC XC

Product variants

Description

The 450 SX / MXC / XC series represents a lineage of high-performance, single-cylinder, 4-stroke, liquid-cooled off-road competition motorcycles produced from 2000 to 2007. Renowned for their powerful engines, estimated at over 50 horsepower, and capable chassis, these Austrian-engineered machines are built for the demanding world of motocross and cross-country racing. They have consistently been praised for their competitive edge, offering a potent combination of speed, agility, and durability that has secured numerous victories in professional racing circuits. This comprehensive workshop service and repair manual provides essential information for owners, mechanics, and technicians to maintain and repair the 450 SX / MXC / XC models. The manual covers all major systems, including the engine, transmission, clutch, fuel system, chassis, suspension, and electrical components. Detailed procedures for routine maintenance, troubleshooting, and complex repairs are explained with clarity, supported by technical specifications, torque values, and exploded views. This resource is designed to ensure optimal performance and longevity of your competition motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

450 SX / MXC / XC

Covered Years:

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

Codes

Vin Prefix:

N/A (Motorcycle specific VIN structure)

👋 Introduction

Market Position

Category:

Performance Motocross/Off-Road Competition Motorcycles

Competitive Analysis

Key Competitors:

Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F

Key Features

Target Audience:

Motocross racers, off-road enthusiasts, mechanics performing service and repair

📋 Manual Details

Coverage Areas

Scope:

Comprehensive workshop service and repair manual

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, clutch, fuel system, exhaust system

Chassis:

Frame, suspension (forks, shock absorber), wheels, tires, steering, braking system

Electrical:

Ignition system, lighting, charging system, battery, wiring diagrams

Bodywork:

Plastics, seat, handlebars, controls

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, chain adjustment, spark plug service

Troubleshooting:

Diagnostic procedures for common performance issues, starting problems, electrical faults

Repair:

Engine rebuilds, transmission overhauls, suspension service, brake caliper rebuilds, carburetor tuning

Technical Specifications:

Torque values, clearances, fluid capacities, electrical specifications

Technical Depth

Depth:

Detailed overhaul instructions, diagnostic flowcharts, exploded views for component identification and assembly/disassembly

📊 Manual Specifications

File Format

File Type:

Print Quality

Readability:

High-resolution scans suitable for printing or on-screen viewing

Binding Type

Binding:

N/A (Digital download)

Paper Type

Paper Quality:

N/A (Digital download)

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, 4-stroke, liquid-cooled

Displacement:

Approximately 449cc (specific bore/stroke may vary slightly by year)

Bore X Stroke:

e.g., 95 mm x 63.4 mm (Check manual for exact year-specific values)

Compression Ratio:

e.g., 12.5:1 (Check manual for exact year-specific values)

Valve Train:

DOHC, 4 valves

Performance

Horsepower:

Estimated 50+ HP (specific figures vary by year and tuning)

Torque:

Estimated 45+ Nm (specific figures vary by year and tuning)

Fuel System

Carburetor:

Keihin FCR MX series (e.g., FCR41 or FCR40, specific model varies by year)

Fuel Type:

Unleaded gasoline, minimum 91 octane

Lubrication

Oil Capacity:

Approximately 1.0-1.2 Liters (Check manual for exact specification)

Oil Type:

SAE 10W-40, JASO MA (or MA2) certified motorcycle specific 4-stroke engine oil

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Optional Types:

N/A (Single transmission configuration typical for competition models)

Features

Clutch:

Hydraulic actuated, multi-plate wet clutch

Final Drive:

O-ring sealed chain, 520 pitch (specific gearing ratio varies)

📐 Dimensions

Exterior

Frame Type:

Chromium-molybdenum steel, single-beam, perimetric frame

Wheelbase:

Approximately 1475-1490 mm (Check manual for exact year-specific values)

Seat Height:

Approximately 950-960 mm (Check manual for exact year-specific values)

Ground Clearance:

Approximately 350-370 mm (Check manual for exact year-specific values)

Weights

Dry Weight:

Approximately 105-110 kg (Check manual for exact year-specific values)

Fuel Tank Capacity:

Approximately 7.5 - 8.5 Liters (Check manual for exact year-specific values)

🛡️ Safety Features

Ratings

Safety Standards:

Off-road competition standards, not road-legal without modification

Active Features

Braking System:

Hydraulic disc brakes, front and rear

Front Brake Rotor Size:

e.g., 260mm (Check manual for exact year-specific values)

Rear Brake Rotor Size:

e.g., 220mm (Check manual for exact year-specific values)

Passive Features

Lighting:

Minimal lighting for off-road use (headlight, taillight/brake light)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure competition off-road motorcycle, no infotainment features)

Driver Assistance

Assistance Features:

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

Connectivity

Connectivity Features:

N/A (No connectivity features)

Engine Management

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

Engine Control:

Carburetor-based fuel and ignition timing control

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of operation or annually (competition use)

Air Filter Cleaning:

After every few rides, or as needed based on conditions

Spark Plug Replacement:

Refer to manual, typically based on hours or performance degradation

Valve Clearance Check:

Refer to manual, typically every 20-30 hours of operation

Fluid Specifications

Brake Fluid:

DOT 4 (Check manual for specific caliper type recommendations)

Coolant:

Mixture of distilled water and antifreeze (e.g., 50/50 ethylene glycol based)

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, suspension seals, chain and sprockets

Potential Engine Concerns:

Valve guide wear at high mileage, carburetor jetting sensitivity to altitude/temperature changes

Suspension Maintenance:

Regular fork seal and oil changes are critical for performance and longevity

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM Sportmotorcycle AG (Austria)

Specialization:

Renowned for off-road and racing motorcycles (Motocross, Enduro, Rally Raid)

Model Evolution

Lineage:

Continuation of KTM's powerful 4-stroke motocross and cross-country platforms.

Key Changes During Era:

Minor updates in suspension settings, graphics, and carburetor tuning across the model years. Transition towards more refined chassis and engine performance.

Production

Manufacturing Location:

Austria

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM's 450cc platform has a strong history of success in professional motocross and off-road racing championships globally.

Ratings

Magazine Reviews:

Consistently praised for powerful engines and capable chassis by major motorcycle publications during its production run.

Certifications

Certification:

Meets applicable off-road competition standards for performance and safety within its class.