The 450 SX / MXC / XC series represents a lineage of high-performance, single-cylinder, 4-stroke, liquid-cooled off-road competition motorcycles produced from 2000 to 2007. Renowned for their powerful engines, estimated at over 50 horsepower, and capable chassis, these Austrian-engineered machines are built for the demanding world of motocross and cross-country racing. They have consistently been praised for their competitive edge, offering a potent combination of speed, agility, and durability that has secured numerous victories in professional racing circuits. This comprehensive workshop service and repair manual provides essential information for owners, mechanics, and technicians to maintain and repair the 450 SX / MXC / XC models. The manual covers all major systems, including the engine, transmission, clutch, fuel system, chassis, suspension, and electrical components. Detailed procedures for routine maintenance, troubleshooting, and complex repairs are explained with clarity, supported by technical specifications, torque values, and exploded views. This resource is designed to ensure optimal performance and longevity of your competition motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 450 SX / MXC / XC Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Vin Prefix: N/A (Motorcycle specific VIN structure) 👋 Introduction Market Position Category: Performance Motocross/Off-Road Competition Motorcycles Competitive Analysis Key Competitors: Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F Key Features Target Audience: Motocross racers, off-road enthusiasts, mechanics performing service and repair 📋 Manual Details Coverage Areas Scope: Comprehensive workshop service and repair manual Page Count Total Pages: 245 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, clutch, fuel system, exhaust system Chassis: Frame, suspension (forks, shock absorber), wheels, tires, steering, braking system Electrical: Ignition system, lighting, charging system, battery, wiring diagrams Bodywork: Plastics, seat, handlebars, controls Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, spark plug service Troubleshooting: Diagnostic procedures for common performance issues, starting problems, electrical faults Repair: Engine rebuilds, transmission overhauls, suspension service, brake caliper rebuilds, carburetor tuning Technical Specifications: Torque values, clearances, fluid capacities, electrical specifications Technical Depth Depth: Detailed overhaul instructions, diagnostic flowcharts, exploded views for component identification and assembly/disassembly 📊 Manual Specifications File Format File Type: PDF Print Quality Readability: High-resolution scans suitable for printing or on-screen viewing Binding Type Binding: N/A (Digital download) Paper Type Paper Quality: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, 4-stroke, liquid-cooled Displacement: Approximately 449cc (specific bore/stroke may vary slightly by year) Bore X Stroke: e.g., 95 mm x 63.4 mm (Check manual for exact year-specific values) Compression Ratio: e.g., 12.5:1 (Check manual for exact year-specific values) Valve Train: DOHC, 4 valves Performance Horsepower: Estimated 50+ HP (specific figures vary by year and tuning) Torque: Estimated 45+ Nm (specific figures vary by year and tuning) Fuel System Carburetor: Keihin FCR MX series (e.g., FCR41 or FCR40, specific model varies by year) Fuel Type: Unleaded gasoline, minimum 91 octane Lubrication Oil Capacity: Approximately 1.0-1.2 Liters (Check manual for exact specification) Oil Type: SAE 10W-40, JASO MA (or MA2) certified motorcycle specific 4-stroke engine oil 🔧 Transmission Standard Type: 5-speed constant mesh Optional Optional Types: N/A (Single transmission configuration typical for competition models) Features Clutch: Hydraulic actuated, multi-plate wet clutch Final Drive: O-ring sealed chain, 520 pitch (specific gearing ratio varies) 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel, single-beam, perimetric frame Wheelbase: Approximately 1475-1490 mm (Check manual for exact year-specific values) Seat Height: Approximately 950-960 mm (Check manual for exact year-specific values) Ground Clearance: Approximately 350-370 mm (Check manual for exact year-specific values) Weights Dry Weight: Approximately 105-110 kg (Check manual for exact year-specific values) Fuel Tank Capacity: Approximately 7.5 - 8.5 Liters (Check manual for exact year-specific values) 🛡️ Safety Features Ratings Safety Standards: Off-road competition standards, not road-legal without modification Active Features Braking System: Hydraulic disc brakes, front and rear Front Brake Rotor Size: e.g., 260mm (Check manual for exact year-specific values) Rear Brake Rotor Size: e.g., 220mm (Check manual for exact year-specific values) Passive Features Lighting: Minimal lighting for off-road use (headlight, taillight/brake light) 💡 Technology Features Infotainment Infotainment System: N/A (Pure competition off-road motorcycle, no infotainment features) Driver Assistance Assistance Features: N/A (No electronic rider aids like traction control or ABS) Connectivity Connectivity Features: N/A (No connectivity features) Engine Management Ignition System: Digital CDI (Capacitor Discharge Ignition) Engine Control: Carburetor-based fuel and ignition timing control 🔧 Maintenance Service Intervals Oil Change Interval: Every 10-15 hours of operation or annually (competition use) Air Filter Cleaning: After every few rides, or as needed based on conditions Spark Plug Replacement: Refer to manual, typically based on hours or performance degradation Valve Clearance Check: Refer to manual, typically every 20-30 hours of operation Fluid Specifications Brake Fluid: DOT 4 (Check manual for specific caliper type recommendations) Coolant: Mixture of distilled water and antifreeze (e.g., 50/50 ethylene glycol based) Known Issues...