🏷️ Basic Information Identification Make: KTM Model: 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Platform Code: Specific to KTM's off-road chassis generations for these years Generation Generation Identifier: Third Generation EXC/SX/MXC Platform (approximate) 👋 Introduction Market Position Target Audience: KTM owners with basic mechanical skills, independent service professionals, and knowledgeable enthusiasts seeking dealership-level information. Competitive Analysis Manual Advantage: Provides the exact same specifications and procedures used by authorized dealers, offering superior accuracy and completeness compared to generic or Haynes-style manuals. Key Features Content Highlight: Step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications for repair and troubleshooting. Illustration Quality: High-quality diagrams and illustrations are a key feature, aiding in the understanding of complex procedures. Value Proposition Cost Savings: Potential to save significant money on maintenance and repairs by performing tasks independently. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, repair, and troubleshooting for all listed models and years Page Count Page Count: Not explicitly stated, but implied to be extensive covering all topics. Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine specifications, engine removal and installation, fuel system, intake & exhaust, cooling system, lubrication Drivetrain: Transmission, drive chain, sprockets Chassis: Steering system, shocks, body work Electrical: Electrical system, wiring diagram Procedures Included Maintenance: Routine maintenance, periodic checks and adjustments, lubrication Repair: Step-by-step repair instructions for all covered systems Troubleshooting: Advanced troubleshooting guidance Engine Overhaul: Complete engine overhaul procedures, including disassembly, inspection, cleaning, repair, and reassembly of all internal engine components. Suspension Rebuild: Detailed procedures for rebuilding and servicing front forks and rear shock absorbers, including fluid changes and seal replacements. Electrical Diagnostics: Comprehensive guide to diagnosing and repairing electrical faults, utilizing wiring diagrams and component testing procedures. Technical Depth Depth: Mechanic-level detail, covering everything from basic checks to complex repairs and diagnostics. Diagnostic Tools: Includes specifications for required tools, torque values, and clearances for accurate diagnostics and repairs. 📊 Manual Specifications File Format File Format Details: PDF format, viewable on PC/Mac, phones, and ebook readers. Searchable text is typically included in professional PDFs. Print Quality Printability: All pages are printable, allowing users to print specific sections for workshop use. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled (typically based on LC4 architecture for these models) Engine Displacement 400: Approximately 400cc (specific variants exist, e.g., 380-400cc range) Engine Displacement 450: Approximately 450cc (specific variants exist, e.g., 440-450cc range) Bore Stroke: Specific values vary by exact model year and displacement, will be detailed in the manual. Compression Ratio: Specific values vary by exact model year and displacement, will be detailed in the manual. Performance Horsepower: Estimated 40-55 HP, varies significantly with model year and tuning. Torque: Estimated 40-50 Nm, varies significantly with model year and tuning. Fuel System Fuel Delivery: Carbureted (e.g., Keihin, Mikuni) or early fuel injection systems depending on specific model and year within the range. Carburetor Size: Typically 36-40mm, model dependent. Fuel Type: Unleaded gasoline Engine Removal Installation Procedure Type: Detailed step-by-step procedures provided. 🔧 Transmission Standard Transmission Type: Constant mesh, 5 or 6-speed manual Optional Optional Transmission: N/A Features Clutch Type: Hydraulic actuated, multi-plate wet clutch Gear Ratios: Specific gear ratios for each model year and variant are detailed in the manual. 📐 Dimensions Exterior Seat Height: Varies by model, typically around 37-39 inches (940-990 mm) Weights Dry Weight: Varies by model, typically around 230-250 lbs (105-115 kg) Fuel Tank Capacity: Typically 2.5-3.2 gallons (9.5-12 liters) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road vehicles are not typically subjected to formal road safety crash ratings). Active Features Braking System: Hydraulic disc brakes front and rear. Suspension: High-performance upside-down front forks (e.g., WP) and monoshock rear suspension, offering significant adjustability. 💡 Technology Features Infotainment Infotainment System: N/A (Designed for performance off-road riding, no infotainment features). Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control on these models). Connectivity Connectivity Features: N/A Instrumentation Instrument Cluster: Digital or analog tachometer and speedometer, basic warning lights (oil, neutral, turn signals). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of riding or annually, depending on usage. Specific recommendations in manual. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions. Daily inspection advised. Spark Plug Replacement: Varies, typically every 20-40 hours of riding. Specific plug type and gap in manual. Fluid Specifications Engine Oil Type: High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 15W-50, meeting JASO MA standards. Specific API rating recommended in manual. Coolant Type: Ethylene glycol-based antifreeze coolant mixed with distilled water (typically 50/50 ratio). Brake Fluid Type: DOT 4 hydraulic brake fluid. Known...