Segment:
High-performance Motocross (MX) competition motorcycle.
Rivals Era:
Competed against models like Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F during its production run.
Engine Platform:
Robust LC4 engine known for its torque and reliability in demanding off-road conditions.
Suspension Components:
Typically equipped with high-quality WP Suspension components, a hallmark of KTM's performance focus.
User Base:
Motocross racers, off-road enthusiasts, and mechanics requiring in-depth service information.
Vehicle Years:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Estimated Pages:
350-500 (typical for comprehensive workshop manuals of this era)
Type:
Workshop Repair Service Manual
Engine Mechanical:
Engine assembly, disassembly, internal components (piston, rings, valves, camshaft, crankshaft), cylinder head, lubrication system, cooling system, torque specifications.
Fuel System:
Carburetor (Keihin, Mikuni likely), fuel pump, fuel lines, fuel tank inspection and maintenance.
Ignition System:
CDI unit, ignition coil, spark plug, stator, wiring diagrams.
Transmission Drivetrain:
Gearbox operation, clutch assembly (hydraulic or cable), gear shift mechanism, chain and sprocket maintenance, gearbox oil specifications.
Suspension:
Front forks (WP Suspension likely), rear shock absorber (WP Suspension likely), service procedures, oil levels, seal replacement, adjustments.
Brakes:
Front and rear brake systems (Brembo likely), hydraulic lines, master cylinders, calipers, brake pads, fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, lighting, starter motor, fuses, troubleshooting electrical faults.
Chassis Frame:
Frame inspection, steering head bearings, footpegs, handlebars, controls.
Wheels Tires:
Wheel bearing service, spoke tensioning, tire pressure recommendations, wheel removal and installation.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug checks, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common engine, electrical, and chassis issues, symptom-based troubleshooting guides.
Component Rebuilds:
Detailed instructions for rebuilding engine components (cylinder, piston, crankshaft), carburetor, clutch, and suspension components.
Wiring Diagrams:
Comprehensive electrical schematics for all model years covered, facilitating diagnosis and repair.
Depth Level:
Comprehensive factory-level repair and service procedures, suitable for professional mechanics and advanced DIY enthusiasts.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC (Dual Overhead Camshafts)
Displacement:
Approximately 450cc (exact figures may vary slightly across model years)
Bore X Stroke:
Refer to manual for precise dimensions (e.g., ~95mm x 63.4mm for early models).
Horsepower Approx:
Around 50-55 HP (peak, varies by year and tuning).
Torque Approx:
Around 45-50 Nm (peak, varies by year).
Carburetor Type:
Likely Keihin FCR (Flat CR-series) or Mikuni TM flat slide carburetors (e.g., 39mm or 41mm).
Fuel Type:
Unleaded gasoline, octane rating appropriate for performance engines (e.g., 91+ RON).
Oil Capacity:
Refer to manual for specific capacity (often shared sump or separate gearbox oil).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors.
Type:
5-speed or 6-speed constant mesh sequential gearbox (confirm specific year).
Optional Gearing:
N/A for factory models, but aftermarket options exist.
Clutch Type:
Hydraulic clutch actuation (Magura or Brembo slave/master cylinders common).
Gear Ratios:
Refer to manual for specific ratios for each gear. Typically optimized for motocross use.
Gearbox Oil:
Dedicated gearbox oil or specialized engine oil (refer to manual for exact specification, e.g., Motorex).
Wheelbase:
Refer to manual for specific measurements (typically around 1470-1480mm).
Seat Height:
Refer to manual for specific measurement (high for motocross, ~950-960mm).
Dry Weight:
Approximately 110-115 kg (dry, without fluids).
Fuel Tank Capacity:
Around 7-9 liters.
Front Wheel Size:
21 inches
Rear Wheel Size:
19 inches
Tire Pressure Front:
Refer to manual for competition settings (e.g., 14-18 PSI).
Tire Pressure Rear:
Refer to manual for competition settings (e.g., 14-18 PSI).
Oil Change Interval:
Every 10-20 hours of riding (competition schedule), or as specified in the manual.
Air Filter Cleaning:
After every few rides or more frequently in dusty conditions.
Valve Clearance Check:
Typically every 30-50 hours of riding.
Engine Oil Type:
High-performance motorcycle-specific 4-stroke engine oil (e.g., Motorex Power Synt 4T 10W-50 or equivalent).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Type:
KTM recommends specific coolant or a 50/50 mix of distilled water and high-quality antifreeze/coolant.
Clutch Wear:
Hydraulic clutch systems can require periodic fluid changes and seal checks. Clutch pack wear is normal with use.
Carburetor Tuning:
Carburetors may require re-jetting based on altitude, temperature, and exhaust modifications.
Suspension Seals:
Fork and shock seals can degrade over time, requiring periodic replacement to prevent oil leaks.
