This manual covers the 450 MXC, a competition motocross and off-road motorcycle produced from 2000 to 2007. Known for its robust LC4 4-stroke, single-cylinder engine and high-performance WP Suspension, the 450 MXC is engineered for aggressive riding and racing. Its design emphasizes rider control and power delivery, making it a formidable machine in its segment, competing with other leading off-road motorcycles. The brand's heritage in off-road racing underpins the development and capabilities of this model. This factory service repair manual provides comprehensive information for the maintenance and repair of the 450 MXC across its production years. It details procedures for engine overhaul, transmission service, chassis and suspension adjustments, and electrical system diagnostics. The manual includes essential technical specifications, troubleshooting guides for common issues, and recommended service intervals for optimal performance and longevity. This resource is designed to assist owners, mechanics, and technicians in performing all necessary upkeep and repairs, ensuring the 450 MXC remains in peak condition for off-road adventures. 🏷️ Basic Information Identification Make: KTM Model: 450 MXC Model Variant: MXC Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Segment: Competition Motocross / Off-Road Motorcycle Target Audience: Motocross racers, off-road enthusiasts, KTM owners seeking detailed maintenance and repair guidance. Competitive Analysis Competitors: Yamaha YZ450F, Honda CRF450X, Suzuki RM-Z450, Kawasaki KX450F. Key Features Engine Type: Liquid-cooled, 4-stroke, single-cylinder (LC4 engine platform). Suspension Brand: WP Suspension (renowned for performance in off-road). Purpose: Designed for competitive motocross and aggressive off-road riding. 📋 Manual Details Coverage Areas Engine Coverage: Complete engine overhaul, top-end and bottom-end rebuilds, carburetor tuning, ignition system diagnostics. Transmission Coverage: Clutch service, gearbox inspection and repair, shifting mechanism adjustments. Chassis Coverage: Suspension adjustments and rebuilds (forks and rear shock), steering head bearing service, wheel and tire maintenance, brake system overhaul. Electrical Coverage: Wiring diagrams, lighting system, ignition coil testing, battery maintenance, charging system diagnostics. Bodywork Coverage: Fairing removal and installation, seat service, fuel tank maintenance. Page Count Estimated Pages: Hundreds (Specific number not provided, but implies comprehensive coverage). Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (LC4 4-stroke single-cylinder), transmission, final drive. Suspension: Front telescopic forks (WP), rear mono-shock absorber (WP). Braking: Front disc brake, rear disc brake. Electrical System: Ignition, lighting, charging system, starter (if applicable). Fuel System: Carburetor (likely Keihin or Mikuni), fuel tank, fuel lines. Cooling System: Liquid-cooled (Radiator, fan, coolant hoses). Exhaust System: Header pipe, muffler, heat shields. Procedures Included Preventive Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for engine performance issues, electrical faults, starting problems. Repair Procedures: Detailed step-by-step instructions for component removal, installation, and rebuilding. Specifications: Torque specifications, clearances, fluid levels, electrical resistance values. Adjustments: Carburetor jetting, idle speed, clutch free play, chain tension. Technical Depth Depth: Comprehensive factory-level repair and maintenance information suitable for professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text within the PDF for quick access to information. Print Quality Quality: High-resolution images and diagrams, clear text for easy reading and printing. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: LC4 4-stroke, single-cylinder Displacement: Approximately 450cc (specific bore/stroke may vary slightly by year). Cooling System: Liquid-cooled Valvetrain: SOHC (Single Overhead Camshaft), 4 valves Performance Horsepower: Estimated 40-50+ HP (varies by year and tuning). Torque: Not explicitly stated in product info, but strong low-to-mid range torque typical for LC4. Fuel System Carburetor Type: Likely Keihin FCR or Mikuni VM series, specific sizes vary by year. Fuel Type: Unleaded Gasoline Lubrication System Oil Type: JASO MA certified motorcycle engine oil (e.g., Motorex). Oil Capacity: Refer to manual for specific year; typically around 1.0-1.3 liters. 🔧 Transmission Standard Type: 5-speed constant mesh Clutch: Hydraulically actuated, multi-plate wet clutch Optional Options: N/A (Standardized for racing models) Features Gear Ratios: Specific ratios detailed in the manual. Final Drive: Chain drive 📐 Dimensions Exterior Frame Type: Chromoly steel, perimeter frame Seat Height: Varies by year, generally high for motocross (approx. 950-960mm). Weights Dry Weight: Approximately 115-120 kg (unspecified fluid weight). Fuel Tank Capacity: Typically around 7-9 liters. 🛡️ Safety Features Ratings Crash Test Results: N/A (Off-road vehicles are not subjected to standard road vehicle crash testing). Active Features Braking System: Hydraulic disc brakes front and rear, capable of strong stopping power. Passive Features Ergonomics: Designed for rider control and maneuverability in off-road conditions. 💡 Technology Features Infotainment System: N/A (Focus is on performance and utility, not infotainment). Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Recommended every 10-15 hours of riding, or annually. Air Filter Cleaning: Recommended every 5-10 hours of riding, depending...