Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Vehicle Segment:
Off-Road / Motocross / Enduro (XC designation implies Cross Country/Enduro)
Category:
Performance Off-Road Motorcycle
Target User:
Competitive motocross and cross-country racers, off-road enthusiasts, and mechanics maintaining these vehicles.
Competitors:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F (contemporary models).
Vehicle Focus:
High-performance off-road capability, potent engine, advanced suspension, and lightweight chassis.
Manual Purpose:
To provide comprehensive guidance for the maintenance, repair, and troubleshooting of the KTM 450 XC.
Engine:
Complete engine overhaul, disassembly, inspection, assembly, tuning, and troubleshooting for the 450cc four-stroke engine.
Transmission:
Gearbox service, clutch operation, maintenance, and repair procedures.
Fuel System:
Carburetor (likely Keihin FCR) tuning, cleaning, jetting, and rebuild; fuel tank and petcock maintenance.
Electrical System:
Ignition system, lighting, charging system (stator, CDI), starter system (if applicable), wiring diagrams, and troubleshooting.
Suspension:
Front fork (WP USD forks) and rear shock absorber (WP) service, rebuild, oil changes, and adjustments.
Brakes:
Hydraulic brake system service, caliper maintenance, master cylinder rebuild, brake fluid flush, and pad replacement.
Cooling System:
Radiator service, coolant flush, fan operation (if equipped), and hose replacement.
Chassis And Frame:
Frame inspection, swingarm maintenance, linkage service, and bearing replacement.
Bodywork And Plastics:
Fairing, seat, fuel tank cover, and fender removal, installation, and maintenance.
Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, and spark plug service.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault finding.
Repair:
Detailed instructions for disassembly, component replacement, and reassembly of all major vehicle systems.
Rebuilds:
Comprehensive guides for engine, transmission, and suspension component rebuilds.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, and performance data.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to full engine rebuilds.
Type:
Four-stroke, liquid-cooled, single-cylinder (LC4 architecture variation).
Displacement:
Approximately 450cc (exact may vary slightly by year/specific variant, e.g., 449.7cc).
Bore X Stroke:
Typically around 95 mm x 63.4 mm (subject to verification for specific model years within the range).
Valvetrain:
SOHC (Single Overhead Camshaft) with 4 valves, or DOHC (Dual Overhead Camshaft) depending on the specific evolution within the 2000-2007 period. DOHC is more common for performance models in later years.
Compression Ratio:
Typically in the range of 11.5:1 to 12.5:1.
Horsepower:
Estimated 45-55 HP at peak, depending on tuning and specific model year.
Torque:
Estimated 40-45 Nm (Newton-meters) at peak.
Carburetor Type:
Keihin FCR (Flat CR) 39mm or 41mm carburetor is highly probable for this era.
Fuel Type:
Unleaded gasoline, premium octane (91 RON or higher recommended).
Type:
5-speed constant mesh manual transmission.
Clutch:
Hydraulically operated multi-plate wet clutch.
Availability:
N/A (standard configuration for this model)
Gear Ratios:
Specific gear ratios vary by year and model variant; typically optimized for off-road performance. Manual will detail exact ratios.
Transmission Fluid:
Manual will specify SAE viscosity grade (e.g., SAE 10W-40 or SAE 15W-50) and required capacity. Often shared with engine oil or separate.
Length:
Approximate: 2170-2200 mm (varies by year).
Width:
Approximate: 810-830 mm (excluding handlebars).
Height:
Approximate: 1200-1250 mm (to top of handlebars).
Wheelbase:
Approximate: 1470-1485 mm.
Ground Clearance:
Approximate: 350-380 mm.
Dry Weight:
Approximate: 105-115 kg (unladen).
Wet Weight:
Approximate: 115-125 kg (with fluids).
Fuel Capacity:
Approximately 7.5 - 9.0 liters (depending on model year and tank size).
Not Applicable:
Motorcycles of this era are not typically subjected to standardized crash ratings like passenger vehicles.
Braking System:
Powerful hydraulic disc brakes front and rear, typically with Brembo components.
Suspension Design:
Performance-oriented, adjustable WP suspension for optimal control and stability in off-road conditions.
Frame Construction:
Lightweight, robust chromoly steel or aluminum frame designed for rigidity and impact absorption.
Ergonomics:
Designed for rider control and comfort during aggressive off-road riding.
Not Applicable:
This is a dedicated off-road performance motorcycle, lacking typical automotive infotainment systems.
Not Applicable:
No electronic driver assistance systems are featured on this model.
Not Applicable:
No connectivity features are present.
Ignition System:
Digital CDI (Capacitor Discharge Ignition) unit, providing precise spark timing.
Oil Change:
Typically every 10-15 engine hours or annually. Manual will provide exact intervals based on usage.
Air Filter Cleaning:
Regular cleaning (after every few rides or as per manual recommendations, especially in dusty conditions).
Spark Plug Replacement:
Intervals vary, but typically around 30-50 engine hours. Manual will specify.
Valve Clearance Check:
Crucial for engine longevity; typically every 20-30 engine hours. Manual will detail the procedure and specifications.
Chain And Sprocket Maintenance:
Regular cleaning, lubrication, and adjustment every 5-10 hours of riding.
Engine Oil Type:
Refer to manual for exact SAE grade (e.g., SAE 10W-40 or 15W-50) and API classification. High-quality synthetic motorcycle oil recommended.
Engine Oil Capacity:
Approximately 1.0 - 1.2 liters. Manual will provide exact capacity.
Coolant Type:
Ethylene glycol-based antifreeze coolant with corrosion inhibitors. Manual will specify mix ratio (e.g., 50/50 water/coolant).
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual will confirm.
Carburetor Tuning:
Sensitivity to altitude and temperature changes, requiring occasional re-jetting or adjustment for optimal performance.
Clutch Wear:
Standard wear item for performance off-road bikes, requiring periodic inspection and replacement of plates/springs based on usage.
Suspension Seals:
Fork and shock seals can wear over time, requiring replacement to prevent leaks and maintain damping performance.
Valve Adjustment Frequency:
Regular valve clearance checks are essential; neglecting this can lead to performance degradation or valve damage.
Manufacturer:
KTM Sportmotorcycle AG, an Austrian manufacturer renowned for its off-road racing pedigree.
Lineage:
The 450 XC is part of KTM's established lineage of high-performance off-road motorcycles, building on the LC4 engine platform. The 'XC' designation specifically points to the Cross Country or Enduro racing variants, distinct from motocross 'SX' models, often featuring wider gear ratios and lighting.
Manufacturing Origin:
Austria
Key Developments:
This period saw KTM refine its four-stroke engine technology and chassis design, often incorporating advancements from their racing efforts.
Brand Performance:
KTM has a strong history of success in off-road racing disciplines, including Enduro and Motocross, often winning championships with models like the 450 XC.
Performance Reviews:
Contemporary reviews from motorcycle publications of the era praised the KTM 450 XC for its potent engine, agile handling, and capable suspension, solidifying its reputation as a top-tier off-road machine.
