This manual covers the 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, and 450 XC models produced between 2000 and 2007. These off-road motorcycles are renowned for their performance and success in motocross and cross-country racing, representing significant advancements in chassis design, engine tuning, and suspension technology during their production years. Dedication to off-road excellence is evident in these robust machines, designed for competitive riding and demanding terrain. This comprehensive Factory Service Repair Manual provides detailed instructions for all maintenance, troubleshooting, and repair procedures. It covers all major systems including the engine, fuel system, cooling system, clutch, transmission, wheels, brakes, suspension, steering, and electrical system. With step-by-step guidance, detailed illustrations, diagrams, and factory specifications, this manual is an essential resource for owners and technicians seeking to maintain, repair, and optimize the performance of their off-road motorcycles, offering potential labor cost savings. 🏷️ Basic Information Identification Make: KTM Model: 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC Year Range: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Product Type: Factory Service Repair Manual Codes Model Designations: SX (Motocross), MXC (Cross-Country), XC (Cross-Country variants, often similar to MXC but may have slight differences). 👋 Introduction Market Position Positioning: Official Factory Service Repair Manual, providing the same information as professional KTM technicians. Competitive Analysis Comparison: Distinguished from 3rd party manuals by being an 'Actual Genuine Repair Service Factory Manual'. Key Features Features: Downloadable PDF, printable, comprehensive coverage, detailed illustrations/diagrams, advanced troubleshooting, direct access to factory-level information, significant potential labor cost savings. Cost Savings: Enables owners to perform maintenance and repairs themselves, potentially saving $50-$60 per hour in shop labor costs. 📋 Manual Details Coverage Areas Coverage: Complete repair and maintenance for all specified models and years. Page Count Estimated Page Count: Hundreds of pages (specific count not provided but implied to be extensive). Manual Type Type: Factory Service Repair Manual Source Authenticity: Actual Genuine Factory Manuals, not third-party reproductions. Language Language: English Format Format: PDF Download Delivery Method: Instant download link provided on checkout page after payment. Software Requirements: Adobe PDF Reader required. 📖 Manual Coverage Systems Covered Systems: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix. Electrical System Detail: Detailed wiring diagrams, troubleshooting for lighting, ignition, and charging systems (if applicable to specific trims). Suspension Service: Detailed procedures for front fork (USD) and rear shock absorber maintenance, including seal replacement, oil changes, and adjustments. Brake System Service: Procedures for hydraulic brake caliper service, master cylinder overhaul, brake pad replacement, and bleeding the brake system. Frame And Bodywork: Information on frame inspection, mounting points for body panels, subframe, and related components. Fuel System Detail: Comprehensive coverage of fuel tank, petcock, fuel lines, carburetor disassembly, cleaning, and adjustment. Procedures Included Procedures: Maintenance, troubleshooting, repair, diagnostics, rebuild, refurbishment, restoration, engine fault symptom diagnosis, part evaluation, part testing, wiring diagram tracing, engine management system analysis, common fixes, pre-emptive maintenance tips. Rebuild Procedures: Comprehensive step-by-step instructions for engine rebuilds, including piston replacement, cylinder inspection, crankshaft and connecting rod service. Wheel And Tire Service: Instructions for wheel bearing replacement, tire mounting and balancing, spoke tension checks, and rim repairs. Suspension Tuning: Guidance on adjusting suspension sag, compression, and rebound damping for different riding conditions and rider preferences. Technical Depth Depth: Comprehensive, step-by-step instructions, advanced troubleshooting, detailed illustrations, diagrams, photos, and specifications, covering everything professional technicians know. Diagnostic Capabilities: Includes an advanced troubleshooting guide to diagnose and correct virtually any problem the vehicle might encounter. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable without restriction (individual pages or entire manual). Binding Type Binding: N/A (Digital Download - printable) Paper Type Paper Type: N/A (Digital Download - user printable) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke single-cylinder (specific engine codes/displacements would be detailed within the manual, typically 400cc and 450cc variants for these models). Bore Stroke: Specific bore and stroke dimensions for 400cc and 450cc engines will be provided in the manual, crucial for component identification and rebuilds. Engine Cooling: Liquid-cooled, with detailed procedures for radiator, water pump, and coolant system maintenance. Performance Performance Details: Manual provides all specifications for engine performance, including power, torque, and tuning procedures. Actual figures vary by specific model year and variant. Compression Ratio: Manual will list the correct compression ratios for various engine configurations. Fuel System Fuel System Type: Carburetor (likely Keihin or similar) for the specified model years, with detailed information on fuel delivery, jets, and tuning. Carburetor Model: Likely Keihin PWK series or similar, with detailed tuning and jetting information specific to each model variant. 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed constant mesh gearbox (specific to model variant). Optional Optional Transmissions: N/A (Standard manual transmission for motocross/enduro bikes). Features Transmission Features:...