The 450 MXC, produced from 2000 to 2007, is a high-performance, competition-focused off-road motorcycle renowned for its powerful LC4 engine architecture and robust construction. Featuring a liquid-cooled, 4-stroke, single-cylinder engine with a displacement around 400-450cc, this model is built for demanding motocross and enduro riding. Its design emphasizes agility and durability, incorporating a chromium-molybdenum steel trellis frame and high-quality suspension components, including USD front forks and a PDS monoshock. The braking system, utilizing calipers, provides exceptional stopping power, essential for competitive off-road use. The extensive history in off-road racing underscores the 450 MXC's pedigree as a machine engineered for victory. This comprehensive workshop service repair manual provides detailed guidance for maintaining and repairing the 450 MXC across its covered production years. It encompasses a wide range of critical systems, including complete engine overhaul, fuel and ignition systems, cooling, transmission, suspension, brakes, and electrical components. The manual includes step-by-step repair procedures, rebuild instructions, troubleshooting guides, and essential technical specifications, such as torque values and fluid recommendations. Its purpose is to empower owners, mechanics, and technicians with the knowledge required to ensure the optimal performance, reliability, and longevity of their 450 MXC. 🏷️ Basic Information Identification Make: KTM Model: 450 MXC Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Engine Code Common: LC4 (specific variations may exist per year) 👋 Introduction Market Position Category: Competition Off-Road Motorcycle (Motocross/Enduro) Purpose: High-performance off-road riding, racing, and recreational use Competitive Analysis Competitors Circa 2000S: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F Key Features Engine Architecture: Powerful single-cylinder, liquid-cooled, 4-stroke LC4 engine Suspension Type: High-quality WP suspension components (front forks, rear shock) Chassis Design: Chromium-molybdenum steel trellis frame for rigidity and light weight Braking System: Performance-oriented Brembo disc brakes front and rear 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Completeness: Complete Official Full Factory Service Manual Page Count Page Count: Hundreds of Pages (estimated 300-600 based on typical manuals of this scope) Manual Type Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, assembly, disassembly, component testing, torque specifications Fuel System: Carburetor (Mikuni, Keihin variants typical), fuel pump, fuel lines, tank maintenance Ignition System: Ignition timing, coil testing, CDI unit diagnostics, spark plug selection Cooling System: Radiator, coolant, fan operation, hose inspection and replacement Transmission: Gearbox disassembly, assembly, clutch operation, gear shift mechanism Suspension Front: Fork disassembly, oil change, seal replacement, compression/rebound adjustments Suspension Rear: Shock absorber overhaul, linkage service, bearing inspection Brakes Front: Caliper service, master cylinder overhaul, pad replacement, bleeding procedures Brakes Rear: Caliper service, master cylinder overhaul, pad replacement, bleeding procedures Electrical System: Wiring diagrams, lighting, battery maintenance, stator/regulator testing Frame And Bodywork: Chassis inspection, subframe, body panel removal and installation Wheels And Tires: Spoke tensioning, wheel bearing replacement, tire pressure recommendations Controls: Throttle, clutch lever, brake lever, footpeg adjustment and service Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, air filter cleaning Troubleshooting: Diagnostic charts, symptom-based issue resolution Repair Procedures: Step-by-step instructions for all major components and systems Rebuild Instructions: Detailed guides for engine and transmission rebuilds Torque Specifications: Comprehensive list of all critical torque values Special Tools: Identification and usage of KTM-specific or recommended tools Technical Depth Depth: Comprehensive from basic checks to full engine and chassis rebuilds 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable within the PDF Print Quality Printability: Designed to be printable for workshop use Binding Type Binding Type For Print: N/A (Digital Download) Paper Type Paper Type For Print: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, single-cylinder (LC4 architecture) Displacement Cc: Approximately 400-450cc (specific variants exist across the model years) Bore X Stroke: Typically around 95mm x 63.4mm (subject to variation) Compression Ratio: Generally around 11.0:1 to 12.0:1 Valve Train: SOHC, 4 valves Cooling Method: Liquid Cooling Performance Estimated Horsepower: Around 45-55 HP (at crank, varies by year and specific tuning) Estimated Torque: Around 40-45 Nm (at crank, varies by year and specific tuning) Fuel System Carburetor Type: Mikuni VM40SS or similar (e.g., Keihin FCR 39/41) Fuel Type Recommendation: Unleaded Gasoline (Octane rating typically 95 RON or higher) Fuel Capacity Liters: Approximately 9-11 Liters 🔧 Transmission Standard Transmission Type: 5-speed Constant Mesh Optional Optional Gearbox: N/A (standard 5-speed) Features Clutch Type: Hydraulically actuated, multi-plate wet clutch Final Drive: O-ring sealed chain, 520 pitch 📐 Dimensions Exterior Frame Material: Chromium-molybdenum steel, trellis type Front Suspension Type: WP USD (Upside-Down) telescopic forks Rear Suspension Type: WP PDS (Progressive Damping System) monoshock Front Brake Type: Hydraulic disc brake, Brembo caliper Rear Brake Type: Hydraulic disc brake, Brembo caliper Weights Dry Weight Kg: Approximately 110-120 kg (varies by year and specific equipment) Wet Weight Kg: Approximately 120-130 kg (with fluids) Wheelbase Mm: Approximately 1450-1470 mm (varies slightly by year) Seat Height Mm: Approximately 950-970...