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KTM 450 SX MXC XC 2000-2007 Workshop Service Manual

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🏷️ Basic Information Identification Make: KTM Model: 450 SX / MXC / XC Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Vin Prefix: N/A (Motorcycle specific VIN...
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类型: Motorcycle
厂商:
Ktm
斯库: 72561
标签: 2000 2001 2002 2003 2004 2005 2006 2007 450 SX KTM Misc Motorcycle Motorcycles MXC XC
KTM 450 SX MXC XC 2000-2007 Workshop Service Manual
🏷️ Basic Information
Identification
Make:
KTM
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:
245
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:
PDF
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.
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