This manual provides comprehensive service and repair information for 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models manufactured between 2000 and 2007. These liquid-cooled, four-stroke motorcycles, featuring 398cc and 449cc engines respectively, are renowned for their high-performance off-road capabilities, stemming from a strong heritage in motocross and cross-country racing. Engineered for demanding conditions, these bikes offer robust construction and are designed to deliver exceptional performance and reliability. The scope of this factory service repair manual is extensive, covering all aspects of engine service and repair, including complete disassembly, assembly, and component servicing. It details procedures for engine removal and refitting, as well as maintenance of the electrical and fuel systems. With hundreds of illustrations and step-by-step instructions, this English-language manual is an invaluable resource for owners and mechanics alike, facilitating routine maintenance, troubleshooting common issues, and executing all necessary repair procedures to keep these performance machines in optimal condition. 🏷️ Basic Information Identification Make: KTM Model: 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC Engine Variant: 400cc and 450cc Engines Codes Product Name: KTM 400 450 SX MXC XC Engine 2000-2007 Service Repair Manual PDF 👋 Introduction Market Position Target Audience: Owners of KTM 400/450 SX, MXC, and XC models seeking comprehensive service and repair information, DIY enthusiasts, and professional mechanics. Competitive Analysis Advantage Digital Format: Offers a cost-effective and convenient alternative to traditional printed manuals, with instant access and enhanced portability. Key Features Completeness: Complete official full factory service repair manual covering all styles. Usability: Easy to use, designed for DIYers and experienced mechanics alike. Cost Savings: Enables significant cost savings by empowering owners to perform their own maintenance and repairs. 📋 Manual Details Coverage Areas Primary Coverage: Engine Service and Repair Specific Models Covered: KTM 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Pages: Hundreds (exact count not specified, but described as comprehensive) Manual Type Type: Factory Service Repair Manual / Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, and servicing of individual components Engine Removal Refitting: Procedures for removing and refitting the engine Electrical System: Wiring diagrams and electrical system servicing Fuel System: Fuel system diagnostics and servicing Procedures Included Routine Maintenance: Periodic maintenance schedule, fluid checks, and component servicing Troubleshooting: Comprehensive troubleshooting guides for common issues Repair Procedures: Step-by-step instructions for all repair and service procedures, based on complete disassembly Technical Depth Depth: Full factory level detail, suitable for both DIY enthusiasts and experienced mechanics Illustrations: Hundreds of photos and illustrations to guide procedures 📊 Manual Specifications File Format Compatibility: All versions of Windows and macOS Accessibility: Accessible via web browser on any computer or mobile device Print Quality Printability: Printable in its entirety or selected pages Binding Type Binding: Digital (PDF) - No physical binding Paper Type Paper: Not Applicable (Digital Format) Software Requirements Reader: Adobe PDF Reader Extraction: Winzip (or similar extraction software) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Single Cylinder (typical for KTM motocross/off-road models of this era, though manual covers both 400 and 450 variants) Performance Engine Displacement Range: Approximately 398cc (400 models) and 449cc (450 models) Fuel System Fuel Delivery: Carbureted (specific carburetor models like Keihin FCR expected, though manual will detail exact specifications) Cooling System Cooling: Liquid-cooled 🔧 Transmission Standard Transmission Type: Constant-mesh, sequential 6-speed gearbox (common for this model line) Features Clutch: Hydraulically operated, multi-plate wet clutch (specifics detailed in manual) 📐 Dimensions Weights Dry Weight Approximate: Varies by model, but typically in the range of 100-115 kg (220-255 lbs) depending on specific SX, MXC, or XC configuration. Manual will provide exact figures. 🛡️ Safety Features Ratings Safety Compliance: Manual will cover safety guidelines relevant to motorcycle operation and maintenance. 💡 Technology Features Infotainment Infotainment System: Not applicable. These are performance-oriented off-road motorcycles focused on rider control and feedback. Driver Assistance Assistance Features: No electronic driver assistance systems (e.g., ABS, traction control) are typically found on these models from this era. The focus is on mechanical systems and rider input. 🔧 Maintenance Service Intervals Oil Change Interval: Typically recommended every 10-15 operating hours or annually, depending on usage severity. Manual will specify exact intervals. Fluid Specifications Engine Oil Type: High-quality 4-stroke motorcycle engine oil, typically SAE 10W/40 or 15W/50, meeting JASO MA standards. Manual will provide precise specification. Coolant Type: Ethylene glycol-based coolant, mixed with distilled water. Manual will specify ratio and type. Known Issues Common Wear Items: Piston rings, valve guides, clutch plates, wheel bearings, and fork seals are common wear items on high-performance off-road motorcycles of this era. The manual will provide guidance on inspection and replacement. Engine Tuning: Proper carburetor jetting and ignition timing...