This manual covers the 450 SXS Motocross Competition Motorcycle models produced between 2000 and 2007. Renowned for its high-performance, lightweight design, the 450 SXS is a competition-tuned machine built for professional racing. The heritage in off-road competition is evident in this model, which offers advanced engineering and a focus on delivering peak performance on the track. The SXS designation signifies factory or special edition competition models, often featuring upgraded specifications beyond standard SX variants. This comprehensive Professional Workshop Manual is designed to guide owners and technicians through all aspects of maintenance, repair, and troubleshooting for the 450 SXS. It provides detailed coverage of the engine, transmission, chassis, suspension, braking, fuel, and electrical systems, including complete overhaul and rebuild procedures. Essential information such as technical specifications, torque values, fluid types, and diagnostic guides are included to ensure optimal performance and longevity. The manual's scope is extensive, catering to those requiring in-depth knowledge for maintaining and servicing this high-performance motocross motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS Model Variant: SXS (Factory Racing/Competition) Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Vehicle Type: Motocross Competition Motorcycle 👋 Introduction Market Position Market Segment: Professional Motocross Competition (Pro-Level) Intended User: Factory race teams, professional mechanics, highly skilled privateer racers Competitive Analysis Key Competitors: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F Key Features Vehicle Focus: High-performance, lightweight, competition-tuned motocross machine Manual Purpose: Enable detailed maintenance, repair, and tuning for peak performance 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Page Count: High (typically 300+ pages for this level of detail) Manual Type Manual Type: Professional Workshop Manual / Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Complete overhaul, tuning, carburation, ignition, cooling, lubrication Transmission System: Clutch, gearbox, shift mechanism, lubrication Chassis System: Frame, subframe, swingarm, linkages, bearings Suspension System: Front fork (WP USD), rear shock absorber (WP Monoshock), seals, oil levels, adjustments, rebuild procedures Braking System: Hydraulic front and rear brakes (Brembo components common), master cylinders, calipers, pads, fluid specifications, bleeding Fuel System: Carburetor (e.g., Keihin FCR), fuel tank, fuel lines, filter Electrical System: Ignition system, CDI unit, stator, wiring diagrams, battery (if applicable), kill switch Cooling System: Radiators, hoses, coolant type, fluid capacity Exhaust System: Header pipe, muffler, repack procedures (if applicable) Wheel And Tire System: Spoke tension, rim types, tire pressures, wheel bearing maintenance Procedures Included Maintenance Procedures: Regular servicing, oil changes, filter replacements, chain adjustment, valve clearance checks Repair Procedures: Engine rebuild, gearbox overhaul, suspension fork and shock rebuild, brake caliper service, wheel bearing replacement Troubleshooting Guides: Diagnostic charts for common performance issues, starting problems, electrical faults Technical Data Tables: Torque specifications, clearances, fluid capacities, specifications for critical components Technical Depth Depth Of Coverage: Comprehensive (suitable for experienced mechanics and dedicated enthusiasts) Diagnostic Capabilities: Detailed fault finding procedures, likely without electronic diagnostic tools due to era and type Rebuild Instructions: Full disassembly, inspection, repair, and reassembly guidance for major components 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High resolution, suitable for printing on standard office/home printers Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchability: Likely text-searchable PDF for quick information retrieval Navigation Navigation: Hyperlinked table of contents and index for easy navigation ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder Engine Displacement: 449.3 cc (approximate, may vary slightly by year) Bore X Stroke: Approx. 95 mm x 63.4 mm (check specific year for precise figures) Valvetrain: SOHC, 4 valves Cooling System: Liquid-cooled Performance Horsepower: Estimated 50+ HP (at crankshaft, stock tune) Torque: Significant mid-range and top-end power delivery (specific figures vary) Fuel System Fuel Delivery: Carbureted (typically Keihin FCR 39mm or similar) Ignition: Digital CDI Oil Capacity Engine Oil Capacity: Approx. 1.1 - 1.3 liters (check specific manual for exact amount and procedure) Oil Type Recommended Engine Oil: High-quality, motorcycle-specific 4-stroke engine oil (e.g., Motorex, Bel-Ray) with appropriate viscosity (e.g., 10W-40, 15W-50) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Hydraulically operated multi-disc wet clutch Features Gear Ratios: Specific gear ratios will be detailed in the manual, optimized for motocross racing Oil Type Transmission Oil Type: Dedicated transmission oil or compatible engine oil depending on design (check manual) 📐 Dimensions Exterior Frame Type: Chromoly steel trellis frame Weights Dry Weight: Approx. 105 kg / 231 lbs (varies by year and specific configuration) Wet Weight: Significantly higher than dry weight due to fluids Fuel Tank Capacity: Approx. 8-9 liters (1.9-2.4 US gallons) 🛡️ Safety Features Ratings Safety Ratings: N/A (Competition Motorcycle - not subject to standard road safety ratings) Active Features Active Safety Features: High-performance braking system, responsive chassis and suspension for rider control Passive Features Passive Safety...