This manual covers the 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC motocross and off-road motorcycles produced between the 2000 and 2007 model years. These machines are renowned for their performance-oriented design and are built for competitive off-road use. The heritage in motorsport is evident in the engineering quality and reliability of these models, which were developed to excel in demanding racing environments. The robust construction and potent single-cylinder, 4-stroke engines provide riders with the power and agility needed for motocross and enduro disciplines. This comprehensive workshop service repair manual provides detailed information essential for the maintenance, repair, and troubleshooting of your motorcycle. It covers all major systems, including the engine, transmission, chassis, suspension, brakes, and electrical system, with specific attention to components like the top end, crankshaft, clutch, and final drive. The manual includes step-by-step disassembly and assembly instructions, torque specifications, diagnostic procedures, and wiring diagrams, all presented in clear English. This resource is designed to empower owners and technicians to perform professional-level service, ensuring the optimal performance and longevity of these capable off-road machines. 🏷️ Basic Information Identification Make: KTM Model: 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Vehicle Type: Motocross/Off-Road Motorcycle Generation Code Name: Not explicitly stated, but refers to a specific platform evolution for these model years 👋 Introduction Market Position Target Audience: Owners and technicians of KTM 400/450 SX, MXC, and XC models from 2000-2007. Competitive Analysis Value Proposition: Provides the same comprehensive information as factory service manuals used by professional shops, enabling DIY repairs and maintenance, saving significant costs. Key Features Features: Authoritative factory information, detailed diagrams, step-by-step procedures, troubleshooting guides, and electrical schematics. Format Advantage: Digital PDF format allows for easy searching, printing of specific sections, and protection from workshop dirt. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Chassis: Yes Suspension: Yes Brakes: Yes Electrical System: Yes Fuel System: Yes Cooling System: Yes Clutch: Yes Lubrication System: Yes Final Drive: Yes Steering: Yes Frame: Yes Bodywork: Yes Wiring Diagrams: Yes Troubleshooting: Yes Maintenance: Yes General Information: Yes Appendix: Yes Page Count Estimated Pages: Hundreds (Exact count not specified but implied to be comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Top End: Detailed coverage of cylinder head, valves, camshaft, piston, rings, and cylinder. Crankshaft Transmission: In-depth information on crankshaft assembly, connecting rod, transmission gears, shift mechanism, and bearings. Wheels Tires Final Drive: Covers wheel hub maintenance, spoke tensioning, tire selection and mounting, chain adjustment and lubrication, and sprocket replacement. Brakes Suspension Steering: Comprehensive data on brake caliper service, pad replacement, hydraulic systems, fork disassembly and assembly, shock absorber service, steering head bearing maintenance, and handlebar setup. Procedures Included Disassembly Assembly: Step-by-step instructions for component disassembly and reassembly, including torque specifications. Cleaning Reinstalling: Detailed guidance on cleaning parts and proper reinstallation techniques. Diagnostics: Includes diagnostic procedures for identifying common problems and fault finding. Repair: Covers repair procedures for all major components and systems. Technical Depth Depth: Professional-level repair and maintenance, suitable for both experienced mechanics and dedicated enthusiasts. Detail Level: Hundreds of pages with detailed diagrams, illustrations, photos, and numbered instructions. 📊 Manual Specifications File Format Format: PDF Requirements: Adobe PDF Reader, WinZip Compatibility: All Versions of Windows & Mac Print Quality Printability: Full Printable Zoom Functionality: YES (Zoom IN/OUT) Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Delivery Delivery Method: Instant Download Shipping Cost: None ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke (specific engine variants may differ, but manual covers both 400 and 450 displacements) Bore Stroke 400: Specific values detailed in the manual (e.g., typical 400cc class would be around 95mm x 57.5mm, but requires manual confirmation) Bore Stroke 450: Specific values detailed in the manual (e.g., typical 450cc class would be around 95mm x 63.4mm, but requires manual confirmation) Cooling: Liquid-cooled Performance Horsepower Range: Information on power output for both 400 and 450cc models available in the manual. Torque Range: Information on torque output for both 400 and 450cc models available in the manual. Fuel System Carburetor Type: Likely Keihin MX carburetor (specific model numbers, jetting, and settings detailed in manual). Fuel Delivery: Carbureted (manual covers fuel tank, petcock, and carburetor service). 🔧 Transmission Standard Type: 5-speed manual transmission Optional Optional Transmissions: Not applicable for these models; all feature a 5-speed manual. Features Gear Ratios: Detailed gear ratios for all 5 speeds are provided in the manual. Clutch Type: Hydraulically actuated multi-plate wet clutch. Transmission Oil: Specifications for transmission oil type and capacity are included. 📐 Dimensions Exterior General Dimensions: Wheelbase, seat height, ground clearance, and overall dimensions specific to SX, MXC, and XC variants are...