This manual covers the 400 and 450 SX, MXC, XC, EXC, SMR, and SXS RACING models produced between 2000 and 2007, featuring 400cc and 450cc four-stroke engines. The brand is recognized for its strong off-road racing heritage, and these models embody that legacy with their focus on performance, handling, and competitive capabilities. The engineering quality and reliability inherent in the Austrian manufacturing are reflected in the robust design of these versatile machines, suitable for motocross, cross-country, enduro, and supermoto applications. This comprehensive digital workshop manual provides essential technical information for maintaining and repairing these motorcycles. It details engine mechanical and electrical systems, diagnostics, troubleshooting, and repair procedures for various model variants. The manual covers routine maintenance, complete engine teardown and reassembly, electrical system diagrams, and specific fluid requirements. It is an indispensable resource for owners and technicians seeking to ensure optimal performance and longevity of their 400/450cc models. 🏷️ Basic Information Identification Make: KTM Model: 400/450 SX, MXC, XC, EXC, SMR, SXS RACING Applicable Years: 2000-2007 Engine Type Covered: 400cc and 450cc Four-Stroke Engines Codes Manual Code: Not specified in product information 👋 Introduction Market Position Target Audience: KTM owners and technicians working on 400/450cc off-road and supermoto models from 2000-2007. Value Proposition: Provides in-depth technical information to enable owners to perform their own maintenance and repairs, saving time and money compared to dealership services. Competitive Analysis Manual Comparison: Essential resource for enthusiasts and mechanics, offering a level of detail often exceeding basic owner's manuals. Key Features Detail Level: High level of detail suitable for complex engine repairs and diagnostics. Accessibility: Digital format offers portability and instant access for troubleshooting or reference. 📋 Manual Details Coverage Areas Primary Coverage: Engine Mechanical, Electrical, Diagnostics, Troubleshooting, Repair, Rebuild, Maintenance Model Variant Coverage: SX (Motocross), MXC (Cross-Country), XC (Cross-Country), EXC (Enduro), SMR (Supermoto), SXS (Racing Special) Page Count Estimated Page Count: Likely extensive, typically 300-600+ pages for detailed workshop manuals Manual Type Type: Digital Workshop Manual / Repair Manual Language Language: English (presumed, standard for technical manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Top End (Cylinder Head, Valves, Camshafts), Bottom End (Crankshaft, Connecting Rod, Piston), Cylinder Block, Lubrication System, Cooling System (Radiators, Hoses, Water Pump) Engine Management: Fuel Injection System (TPS, Injector, Fuel Pump, Regulator), Ignition System (CDI, Spark Plug), Sensors (MAP, Temperature, Crank Position) Electrical System: Wiring Diagrams, Battery, Charging System (Stator, Rectifier/Regulator), Lighting, Starter System Procedures Included Routine Maintenance: Oil Change Intervals and Specifications, Air Filter Cleaning/Replacement, Spark Plug Replacement, Valve Clearance Checks and Adjustment, Coolant Flush and Replacement Disassembly Reassembly: Complete engine teardown and reassembly procedures, including torque specifications for all fasteners. Troubleshooting: Diagnostic flowcharts for common starting, running, and performance issues. Fault code interpretation (if applicable). Performance Tuning: Information on carburetor/fuel injection adjustments, ignition timing (if adjustable), and basic engine performance tuning principles. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive from basic owner maintenance to full engine rebuilds. Includes detailed specifications, diagrams, and step-by-step instructions. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable PDF, allowing for quick information retrieval. Print Quality Resolution: Dependent on original source scan quality, typically clear for digital distribution. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement Options: Approximately 398cc (400) and 449cc (450) (specific bore/stroke may vary by sub-model) Engine Configuration: Single Cylinder, Four-Stroke Engine Cooling: Liquid-Cooled Performance Horsepower Range: Typically 50-60+ HP (specific output varies by model and year) Torque Range: Typically 40-45+ lb-ft (specific output varies by model and year) Fuel System Fuel Delivery: Fuel Injection (EFI) for most models in this range, some earlier may have had Carburetion (check specific model year/variant). Ignition Type: Digital CDI Valve Train Valve Actuation: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific engine variant within the 400/450 range. 🔧 Transmission Standard Type: Constant Mesh, Sequential, Dog-Shifted Manual Transmission Gear Count: Typically 5 or 6 Speed Features Clutch Type: Hydraulically Actuated Wet Multi-Plate Clutch Gear Ratio Information: Detailed gear ratios and final drive ratios will be provided within the manual. 📐 Dimensions Exterior Body Style: Dirt Bike / Motocross / Enduro / Supermoto Styling Weights Dry Weight: Varies significantly by model, typically between 105-120 kg (230-265 lbs) un-fueled. 🛡️ Safety Features Ratings Crash Test Data: N/A for off-road motorcycles Active Features Braking System: Hydraulic Disc Brakes (Front and Rear). Specific caliper and rotor sizes will be detailed. Suspension System: High-performance, adjustable Upside-Down (USD) front forks (e.g., WP Suspension) and Monoshock rear suspension. Detailed adjustment and maintenance procedures covered. Passive Features Frame Construction: Chromium-Molybdenum Steel Trellis Frame (characteristic of KTM). 💡 Technology Features Infotainment Features: Minimal to none; focus is on performance and off-road capability. Typically a basic digital...