🏷️ Basic Information Identification Make: KTM Model: 400 EXC, 450 EXC, SMR, SXS Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Vehicle Platform Codes: LC4 series (shared components across EXC, SXS, SMR variants) 👋 Introduction Market Position Market Segment: High-performance off-road and supermoto motorcycles. Competitive Analysis Key Competitors: Husqvarna TE/TC, Yamaha YZ-F/WR-F, Honda CRF/XR, Suzuki RM/DR, Kawasaki KX/KLX. Key Features Vehicle Key Features: Lightweight chassis, powerful single-cylinder LC4 engine, advanced WP suspension, racing pedigree, versatile for motocross, enduro, and supermoto applications. Manual Value Proposition Manual Value: Essential resource for owners and technicians to maintain, diagnose, and repair these specialized KTM models, saving time and money on professional servicing. 📋 Manual Details Coverage Areas Primary Regions Covered: Global (standardized mechanicals) Page Count Estimated Page Count: 500+ Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end rebuild, piston, rings, cylinder, crankshaft, connecting rod, valve timing, lubrication system, cooling system (liquid-cooled), oil pump, starter system, ignition system, carburetor/fuel injection (depending on specific sub-model), exhaust system. Transmission Drivetrain: Gearbox inspection, repair, clutch (hydraulic/cable), primary drive, final drive (chain), gearbox oil specifications and change intervals. Chassis Suspension: Frame inspection, fork service (WP Suspension), rear shock absorber service (WP Suspension), linkage system, swingarm, steering head bearings, wheel bearings. Braking System: Brake caliper service, master cylinder rebuild, brake fluid specifications, bleeding procedures, brake pad replacement, rotor inspection. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting system, ignition switch, starter motor, fuses, relays, fault finding and diagnostics. Fuel System: Carburetor models (Mikuni, Keihin), jetting charts, float bowl cleaning, fuel pump (if applicable), fuel filter, fuel tank maintenance. Bodywork Ergonomics: Fairing removal and installation, seat, handlebars, footpegs, plastics, graphics. Procedures Included Maintenance Procedures: Routine checks, oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug replacement, coolant flush, valve clearance adjustment, brake system maintenance. Repair Procedures: Complete engine teardown and rebuild, gearbox overhaul, suspension rebuild, clutch replacement, electrical component replacement, carburetor tuning, fork seal replacement. Troubleshooting Diagnostics: Step-by-step diagnostic guides for common issues, electrical fault finding, engine performance problems, starting issues. Technical Depth Depth Of Coverage: Comprehensive: Covers basic maintenance to full engine and chassis overhauls, including detailed torque specifications and special tool requirements. 📊 Manual Specifications File Format File Format Details: High-resolution PDF, searchable text, hyperlinked sections for easy navigation. Print Quality Print Quality Recommendation: Optimized for digital viewing and high-quality printing. Binding Type Binding Type For Print: Coil-bound or perfect-bound for lay-flat usability in a workshop environment. Paper Type Paper Type Recommendation: Durable, semi-gloss paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder (LC4) Engine Variants: 400cc, 450cc (specific displacement may vary slightly by sub-model and year) Bore X Stroke: Refer to specific model year/variant in manual (e.g., 400 EXC approx. 86x72mm, 450 EXC approx. 95x63.4mm) Compression Ratio: Refer to specific model year/variant in manual (e.g., typically 10.5:1 to 12.5:1) Performance Horsepower Range: Approx. 40-55 HP (depending on displacement and tuning) Torque Range: Approx. 35-45 Nm (depending on displacement and tuning) Fuel System Carburetor Types: Mikuni VM40/41, Keihin FCR (model dependent), or electronic fuel injection (EFI) on later models within this range (though less common on early 400/450 EXC/SXS). Lubrication System Oil Type Capacity: Refer to manual for specific grade (e.g., Motorex Power Synt 4T 10W/50 or 15W/50) and capacity (approx. 1.5-2.0 liters, with separate gearbox oil) Cooling System Coolant Type: Ethylene glycol-based antifreeze (e.g., Motorex Coolant M3.0) mixed 50/50 with distilled water. Ignition System Ignition Type: Digital CDI with variable ignition timing. 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed constant mesh gearbox Optional Optional Gearbox: N/A (standardized across variants) Features Clutch Type: Hydraulic operated multi-plate wet clutch (e.g., Magura). Gear Ratios: Refer to specific model and year in manual for detailed gear ratios. Gearbox Oil Type: KTM recommends specific gearbox oil (e.g., Motorex Gear Oil 80W/90 or SAE 85W/90). 📐 Dimensions Exterior Wheelbase: Refer to specific model and year in manual (typically around 1450-1490 mm). Weights Dry Weight: Approx. 110-125 kg (depending on model and equipment). Fuel Tank Capacity: Approx. 8-11 liters. 🛡️ Safety Features Ratings Safety Certifications: N/A (Off-road motorcycles are typically not subjected to automotive safety crash ratings) Active Features Braking System Type: Hydraulic disc brakes front and rear (e.g., Brembo components). Passive Features Frame Construction: Chromium-molybdenum steel trellis frame. 💡 Technology Features Infotainment Infotainment System: N/A (Basic analog/digital instrumentation focusing on riding essential data: speed, RPM, odometer, trip meter, engine temperature warning). Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control common on these performance-oriented models of this era). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of riding or annually. Air Filter Cleaning Interval: Every 5-10 hours of riding, or...