The KTM 450 EXC, produced between 2000 and 2007, is a high-performance enduro motorcycle renowned for its powerful liquid-cooled, four-stroke, single-cylinder engine and exceptional off-road capability. Featuring a robust chromium-molybdenum steel frame and advanced suspension components, this model is engineered for demanding terrain and competitive riding. Its design prioritizes agility, power delivery, and durability, making it a favored choice for enthusiasts and competitors in enduro and trail riding disciplines. The 450 EXC embodies a philosophy of being "Ready to Race," consistently delivering a superior riding experience in challenging environments. This workshop repair service manual provides comprehensive guidance for the maintenance, servicing, and repair of the KTM 450 EXC (2000-2007). It covers all essential systems, including detailed procedures for engine disassembly and assembly, transmission, suspension, brakes, electrical systems, and fuel systems. The manual includes routine maintenance schedules, troubleshooting guides for common issues, rebuild procedures, and essential technical specifications such as torque values and fluid recommendations. Its thorough coverage aims to assist owners, mechanics, and technicians in effectively maintaining and repairing their vehicle, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC Year: 2000-2007 Product Type: Workshop Repair Service Manual Format: PDF Download 👋 Introduction Market Position Category: Enduro/Off-road motorcycle Target Audience: Enthusiast riders, mechanics, and owners of the KTM 450 EXC for the specified years. Competitive Analysis Segment: Highly competitive 450cc four-stroke enduro segment. Competitors: Husaberg FE450, Husqvarna TE450, Honda CRF450X, Yamaha WR450F, Suzuki RM-Z450 (converted to enduro use), Kawasaki KX450F (converted to enduro use). Key Features Engine Type: Liquid-cooled, four-stroke, single-cylinder (typically SOHC or DOHC depending on specific year/variant). Suspension: High-quality WP Suspension components, known for performance in off-road conditions. Chassis: Chromium-molybdenum steel frame, emphasizing rigidity and light weight. Off Road Capability: Designed for competitive off-road riding, including enduro, trail riding, and motocross (with modifications). 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, maintenance, and troubleshooting Page Count Estimated Page Count: Detailed page count not specified, but expected to be extensive for a workshop manual. Manual Type Type: Workshop Repair Service Manual Language Language: English (Assumed, standard for professional manuals) Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and repair for various configurations. Transmission: Gearbox, clutch, and driveline inspection, maintenance, and repair. Suspension: Front fork (WP Suspension), rear shock absorber, linkage, and swingarm service. Brakes: Hydraulic brake systems (front and rear calipers, master cylinders, lines), bleeding procedures. Electrical System: Ignition system, lighting, charging system, wiring diagrams, starter motor, battery. Fuel System: Carburetor (Mikuni or Keihin), fuel lines, fuel tank, and petcock maintenance. Cooling System: Radiator, coolant hoses, thermostat, and coolant fluid specifications. Exhaust System: Exhaust pipe, muffler, and mounting hardware service. Chassis And Frame: Frame inspection, steering head bearing service, footpeg mounting. Wheels And Tires: Spoke tensioning, wheel bearing replacement, tire mounting and balancing. Procedures Included Maintenance: Regular service intervals, oil changes, filter replacements, chain adjustment, spark plug replacement. Troubleshooting: Diagnostic guides for common and uncommon problems, symptom-based troubleshooting. Repair: Detailed step-by-step instructions for component disassembly, cleaning, inspection, and reassembly. Rebuilds: Complete engine rebuild procedures, including piston, ring, valve, and crankshaft replacement. Adjustments: Carburetor jetting and adjustment, valve clearance adjustment, suspension sag adjustment. Wiring Diagrams: Color-coded wiring schematics for all electrical components. Torque Specifications: Essential torque values for all critical fasteners. Technical Depth Depth: Comprehensive, covering from basic user maintenance to advanced mechanical and electrical diagnostics and repairs. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text, enabling quick access to information. Print Quality Quality: Assumed high resolution for clear diagrams and text, suitable for printing. Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, four-stroke Displacement: Approximately 449cc (may vary slightly by specific model year). Cooling: Liquid-cooled Valve Train: SOHC or DOHC (depending on specific year/variant) Performance Horsepower: Estimated 45-55 HP (at crankshaft, subject to tuning and specific year). Torque: Estimated 40-45 Nm (at crankshaft, subject to tuning and specific year). Fuel System Carburetor: Mikuni TM40 or Keihin FCR (depending on specific year/market, e.g., 39mm or 41mm). Fuel Type: Unleaded gasoline, minimum 91 octane recommended. Ignition System: Digital CDI (Capacitor Discharge Ignition) Lubrication System: Wet sump (or combined engine/transmission oil system, requiring specific oil). 🔧 Transmission Standard Type: 5-speed manual transmission Optional Options: N/A (Standard configuration for this model) Features Clutch: Hydraulically operated multi-plate wet clutch. Gear Ratios: Specific gear ratios would be detailed within the manual, crucial for off-road performance tuning. Final Drive: Chain drive (e.g., 520 pitch chain). 📐 Dimensions Exterior Wheelbase: Approx. 1470-1485 mm (subject to year and suspension setup). Seat Height: Approx. 960-970 mm (subject to year and suspension setup). Weights Dry Weight: Approx. 110-115 kg (subject to year and components). Fuel Tank Capacity: Approx. 8-10 liters (subject to year and specific tank). 🛡️ Safety Features...