🏷️ Basic Information Identification Make: KTM Model: 400 EXC, 450 EXC, SMR, SXS Year: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Common Chassis Codes: LC4 (general family), specific variations for EXC/SMR/SXS models 👋 Introduction Market Position Vehicle Segment: High-performance off-road motorcycles (Enduro, Motocross, Supermoto variants). Competitive Analysis Competitors: Yamaha YZ/WR, Honda CRF/XR, Suzuki RM/DR, Kawasaki KX/KLX, Husqvarna, GasGas. Key Features Engine Philosophy: Powerful, torquey LC4 single-cylinder engines known for their robustness and off-road capability. Suspension Performance: Premium WP suspension components providing exceptional damping and adjustability for demanding terrain. Handling: Agile and responsive chassis design optimized for competitive off-road riding. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: Varies by specific model variant and year; typically 300-600 pages for comprehensive coverage. 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, assembly, inspection, repair of cylinder head, valves, piston, crankshaft, connecting rod, oil pump, and cooling system. Fuel System: Carburetor (Keihin, Mikuni variants), fuel pump, fuel tank, lines, and filtration. Ignition System: CDI unit, ignition coil, spark plug, stator, and wiring. Transmission Drivetrain: Gearbox disassembly, inspection, repair, clutch operation, chain and sprocket maintenance. Suspension Front: Fork disassembly, seal replacement, oil levels, spring rates, damping adjustments (WP USD forks common). Suspension Rear: Monoshock (WP PDS or linkage systems), shock absorber service, linkage bearing maintenance. Brakes Front: Brake caliper service, master cylinder overhaul, pad replacement, disc inspection, hydraulic lines. Brakes Rear: Brake caliper service, master cylinder overhaul, pad replacement, disc inspection, hydraulic lines. Electrical System: Wiring diagrams, lighting, starter motor, battery maintenance, charging system, fuse box, switchgear. Frame Chassis: Frame inspection, steering head bearing service, swingarm maintenance, subframe. Bodywork: Fairing removal and installation, seat, fuel tank mounting, fenders. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, valve clearance checks. Troubleshooting: Diagnostic tables for common starting, running, and electrical issues. Engine Rebuild: Complete engine disassembly, component inspection, torque specifications for critical fasteners, reassembly procedures. Suspension Service: Front fork seal replacement, rear shock absorber service (where applicable), linkage lubrication. Brake Service: Brake bleeding, caliper piston cleaning and lubrication, pad and disc replacement. Electrical Diagnostics: Using multimeters to test circuits, identifying faulty components based on symptoms. Carburetor Tuning: Adjustment of idle speed, mixture screws, jetting recommendations for altitude and conditions. Technical Depth Diagnostics Level: Advanced diagnostics including troubleshooting charts and component testing procedures. Repair Scope: Comprehensive repair procedures for major mechanical and electrical components. Rebuild Procedures: Detailed instructions for engine and transmission rebuilds. Technical Drawings: Includes exploded diagrams and illustrations of components and assemblies. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Typically yes, allowing for easy keyword searches. Print Quality Print Quality: High-resolution scans suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled (LC4 architecture). Displacement 400: Approximately 398cc. Displacement 450: Approximately 449cc (exact figures may vary slightly by year and sub-model). Bore X Stroke 400: Typical around 95mm x 70.5mm (check specific model year). Bore X Stroke 450: Typical around 97mm x 60.8mm (check specific model year). Performance Horsepower 400: Estimated 45-55 HP (may vary with tuning and exhaust). Horsepower 450: Estimated 50-60 HP (may vary with tuning and exhaust). Torque: Strong mid-range torque characteristic of LC4 engines. Fuel System Carburetor Type: Keihin FCR flat-slide or Mikuni VM (depending on year and model variant). Fuel Type: Unleaded Gasoline, 91 octane or higher recommended. Engine Features Valve Train: SOHC, 4 valves per cylinder. Starting System: Electric Starter (standard on most variants). Cooling System: Liquid-cooled. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh manual gearbox. Clutch Type: Wet multi-plate clutch, hydraulically operated. Features Gear Ratios: Specific gear ratios vary by model and intended use (EXC, SXS, SMR); refer to manual for detailed charts. Final Drive: Chain drive (e.g., 520 pitch). Fluid Specifications Transmission Oil: SAE 10W-40 or 15W-50 motorcycle-specific engine oil (check manual for exact API rating and specifications, e.g., JASO MA). 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1450-1500 mm. Seat Height: High, typical for off-road bikes, around 930-970 mm (unladen). Weights Dry Weight: Typically in the range of 115-130 kg, depending on model and equipment. Fuel Tank Capacity: Around 7-9 liters, with some EXC models having larger optional tanks. Wheels Tires Front Wheel Size: 1.60 x 21 inches (EXC/SXS), 3.50 x 17 inches (SMR). Rear Wheel Size: 2.15 x 18 inches (EXC/SXS), 5.00 x 17 inches (SMR). Front Tire Size: 80/100-21 (EXC/SXS), 120/70-17 (SMR). Rear Tire Size: 100/100-18 or 110/100-18 (EXC/SXS), 160/60-17 (SMR). 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles not typically subject to automotive crash ratings in the same way; focus is on rider protection and active safety through handling). Active Features Braking Performance: High-performance...