Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Segment:
Competition Motocross / Off-Road Motorcycle
Target Audience:
Motocross racers, off-road enthusiasts, KTM owners seeking detailed maintenance and repair guidance.
Competitors:
Yamaha YZ450F, Honda CRF450X, Suzuki RM-Z450, Kawasaki KX450F.
Engine Type:
Liquid-cooled, 4-stroke, single-cylinder (LC4 engine platform).
Suspension Brand:
WP Suspension (renowned for performance in off-road).
Purpose:
Designed for competitive motocross and aggressive off-road riding.
Engine Coverage:
Complete engine overhaul, top-end and bottom-end rebuilds, carburetor tuning, ignition system diagnostics.
Transmission Coverage:
Clutch service, gearbox inspection and repair, shifting mechanism adjustments.
Chassis Coverage:
Suspension adjustments and rebuilds (forks and rear shock), steering head bearing service, wheel and tire maintenance, brake system overhaul.
Electrical Coverage:
Wiring diagrams, lighting system, ignition coil testing, battery maintenance, charging system diagnostics.
Bodywork Coverage:
Fairing removal and installation, seat service, fuel tank maintenance.
Estimated Pages:
Hundreds (Specific number not provided, but implies comprehensive coverage).
Type:
Factory Service Repair Manual
Powertrain:
Engine (LC4 4-stroke single-cylinder), transmission, final drive.
Suspension:
Front telescopic forks (WP), rear mono-shock absorber (WP).
Braking:
Front disc brake, rear disc brake.
Electrical System:
Ignition, lighting, charging system, starter (if applicable).
Fuel System:
Carburetor (likely Keihin or Mikuni), fuel tank, fuel lines.
Cooling System:
Liquid-cooled (Radiator, fan, coolant hoses).
Exhaust System:
Header pipe, muffler, heat shields.
Preventive Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for engine performance issues, electrical faults, starting problems.
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, and rebuilding.
Specifications:
Torque specifications, clearances, fluid levels, electrical resistance values.
Adjustments:
Carburetor jetting, idle speed, clutch free play, chain tension.
Depth:
Comprehensive factory-level repair and maintenance information suitable for professional mechanics and advanced DIY enthusiasts.
Type:
LC4 4-stroke, single-cylinder
Displacement:
Approximately 450cc (specific bore/stroke may vary slightly by year).
Cooling System:
Liquid-cooled
Valvetrain:
SOHC (Single Overhead Camshaft), 4 valves
Horsepower:
Estimated 40-50+ HP (varies by year and tuning).
Torque:
Not explicitly stated in product info, but strong low-to-mid range torque typical for LC4.
Carburetor Type:
Likely Keihin FCR or Mikuni VM series, specific sizes vary by year.
Fuel Type:
Unleaded Gasoline
Oil Type:
JASO MA certified motorcycle engine oil (e.g., Motorex).
Oil Capacity:
Refer to manual for specific year; typically around 1.0-1.3 liters.
Frame Type:
Chromoly steel, perimeter frame
Seat Height:
Varies by year, generally high for motocross (approx. 950-960mm).
Dry Weight:
Approximately 115-120 kg (unspecified fluid weight).
Fuel Tank Capacity:
Typically around 7-9 liters.
Oil Change:
Recommended every 10-15 hours of riding, or annually.
Air Filter Cleaning:
Recommended every 5-10 hours of riding, depending on conditions.
Spark Plug Replacement:
Recommended every 20-30 hours of riding.
Chain Maintenance:
Lubricate and adjust chain tension every 5-10 hours of riding.
Engine Oil:
SAE 10W/40 or 15W/50, JASO MA certified motorcycle oil (e.g., Motorex Power Synt 4T 10W/40).
Coolant:
Ethylene glycol-based coolant with anti-corrosion additives (e.g., Motul Motocool Expert).
Fork Oil:
Specific viscosity grade (e.g., WP Suspension Fork Oil SAE 5 or 7.5), capacity specified in manual.
Brake Fluid:
DOT 4 or DOT 5.1 (check manual for specific recommendation).
Common Wear Items:
Clutch plates, piston rings, valve seals, wheel bearings, steering head bearings.
Potential Problems:
Carburetor jetting sensitivity to altitude and temperature, occasional starter motor issues on some models, WP suspension requiring regular servicing.
Manufacturer:
KTM AG (Austria), known for its off-road racing pedigree.
Development:
The 450 MXC represents a key generation of KTM's 4-stroke motocross/off-road platform, evolving from earlier LC4 models.
Key Changes:
Throughout this generation, updates often focused on carburetor tuning, suspension refinements, and minor chassis or engine component revisions.
Manufacturing Location:
Austria
