This manual covers the 450 XC, a performance-oriented off-road motorcycle renowned for its potent engine, agile handling, and competitive prowess. Produced between 2000 and 2007, the 450 XC is a staple in the lineup, built with a focus on demanding cross-country racing and recreational off-road use. Its single-cylinder, four-stroke, liquid-cooled engine, typically around 450cc, delivers strong mid-range torque and is supported by a robust chromium-Molybdenum steel trellis frame and advanced suspension systems, including upside-down telescopic forks and a monoshock rear. The Austrian manufacturing heritage is evident in the model's consistent accolades for off-road performance and durability. This comprehensive Service Repair Manual provides essential information for the maintenance and repair of the 450 XC engine. It details complete engine overhaul procedures, including disassembly, inspection, and assembly, along with specific guidance for the fuel, ignition, cooling, lubrication, and exhaust systems. The manual also covers routine maintenance tasks such as oil changes, filter replacements, and valve adjustments, alongside troubleshooting common issues and identifying necessary special tools. With clear instructions and critical torque specifications, this English-language manual is an indispensable resource for owners, mechanics, and technicians aiming to preserve the performance and longevity of their 450 XC. 🏷️ Basic Information Identification Make: KTM Model: 450 XC Engine Type: XC (Cross Country) Product Name: KTM 450 XC Engine 2000-2007 Service Repair Manual Generation Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Vehicle Segment: Performance Off-Road/Competition Motorcycle (Enduro/Cross Country) Target Audience: KTM 450 XC owners, mechanics, and enthusiasts performing maintenance and repairs. Competitive Analysis Competitors: Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (off-road variants), Husqvarna TE450. Key Features Manual Value: Essential for maintaining the performance and longevity of the 450 XC engine. Vehicle Appeal: Renowned for its potent engine, agile handling, and off-road prowess. 📋 Manual Details Coverage Areas Primary Focus: Engine Service and Repair Page Count Estimated Pages: Likely 300-500 pages (typical for comprehensive engine service manuals) Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including disassembly, inspection, assembly, and troubleshooting. Fuel System: Carburetor (likely Keihin or Mikuni) tuning, maintenance, and repair; fuel pump and lines. Ignition System: CDI unit, ignition coil, spark plug maintenance and testing. Cooling System: Radiator, water pump, thermostat, coolant specifications, and bleeding procedures. Lubrication System: Oil pump, oil filter, oil passages, and oil change procedures. Exhaust System: Exhaust pipe and muffler maintenance, gasket replacement. Engine Internal Components: Piston, rings, cylinder bore, connecting rod, crankshaft, valves, camshaft, timing chain/belt. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, valve adjustments, spark plug checks. Troubleshooting: Diagnostic charts, common problems, causes, and solutions. Repair: Step-by-step instructions for component repair and replacement. Disassembly Assembly: Detailed instructions for complete engine teardown and reassembly. Torque Specifications: Critical torque values for all engine fasteners. Special Tools: Identification and usage of specialized tools required for specific procedures. Technical Depth Depth: Comprehensive, covering routine maintenance to full engine rebuilds. Diagnostic Capability: Advanced diagnostics for engine performance issues. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Quality: High-resolution, clear text and diagrams. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Displacement: Approximately 450cc (specific bore/stroke for each year may vary slightly). Engine Configuration: Single-cylinder, four-stroke, liquid-cooled. Engine Code: Specific engine codes vary by year (e.g., LC4 variant for some models in this era). Performance Horsepower Estimate: Typically in the range of 50-60 HP at peak, depending on specific model year and tuning. Torque Estimate: Strong mid-range torque characteristic of KTM off-road engines. Fuel System Fuel Delivery: Carbureted (likely Keihin FCR or similar). Fuel Type: Unleaded Gasoline (91+ octane recommended). Engine Internal Components Bore X Stroke: Varies by year, consult manual for precise dimensions. Valve Train: SOHC (Single Overhead Camshaft) with 4 valves. Lubrication System Oil Capacity: Typically around 1.0 - 1.5 liters (refer to manual for exact capacity and oil type). Oil Type Specification: High-quality synthetic motorcycle engine oil, e.g., SAE 10W-50 or 10W-40 (API SG or higher). 🔧 Transmission Standard Transmission Type: 6-speed manual constant mesh. Optional Optional Transmission: N/A (standard configuration for XC model). Features Clutch Type: Hydraulically operated multi-plate wet clutch. Gear Ratios: Specific gear ratios vary by model year; consult manual for exact data. Transmission Fluid: Engine oil acts as transmission fluid; refer to manual for oil type and change interval. 📐 Dimensions Exterior Wheelbase: Approximately 1470-1485 mm (consult manual for specific year). Weights Dry Weight: Around 105-115 kg (unladen, without fuel; consult manual for exact figure). Wet Weight: Approximately 115-125 kg (with all fluids). 🛡️ Safety Features Ratings Safety Standards: Designed for off-road competition and recreational use; not street legal in most jurisdictions without modification. Active Features Braking System: Hydraulic disc brakes (front and rear) with Brembo calipers. Suspension Front: Upside-down telescopic forks...