Introducing the 450 SXS, a high-performance motocross competition motorcycle produced between 2000 and 2007. This powerful machine, powered by a 450cc single-cylinder, four-stroke engine, is engineered for peak racing performance and is a staple in the world of professional off-road racing. Known for its engineering, the 450 SXS embodies the 'Ready to Race' philosophy, offering riders exceptional power, responsive handling, and the durability required for demanding motocross circuits. Its design focuses on delivering a competitive edge, making it a favored choice for serious racers and enthusiasts. This comprehensive workshop service repair manual in English provides detailed guidance for the maintenance, repair, and troubleshooting of the 450 SXS models from 2000-2007. It covers all essential systems, including the engine, transmission, suspension, brakes, and electrical components, with in-depth procedures for routine maintenance, component overhauls, and diagnostics. The manual includes crucial technical specifications, torque values, assembly sequences, and wiring diagrams, making it an invaluable resource for owners, mechanics, and technicians aiming to keep this competition machine in optimal racing condition. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS Model Variant: Motocross Competition Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Codes: SX-F (specific year variations likely exist, consult manual for precise identification) 👋 Introduction Market Position Segment: High-performance motocross competition bike. Target Audience: Professional motocross racers, serious amateur riders, and mechanics specializing in off-road motorcycles. Competitive Analysis Competitors: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F of similar model years. Key Features Engine Layout: Single-cylinder, four-stroke, liquid-cooled. Suspension Brand: Typically equipped with WP Suspension components. Competition Focus: Designed and tuned for racing performance, not street legality. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download Completeness: Complete Factory Official Full Service Manual Page Count Estimated Page Count: Hundreds of pages (specific number not provided, but indicative of comprehensive coverage) 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, diagnostics, tuning, and repair of the 450cc four-stroke engine. Transmission: Clutch assembly, gearbox operation, maintenance, and repair procedures. Suspension: Front fork (WP or similar) and rear shock absorber maintenance, adjustments, and rebuilds. Brakes: Hydraulic brake system (front and rear calipers, master cylinders, lines) maintenance and repair. Electrical: Ignition system, charging system, lighting (if applicable to competition models), wiring diagrams, and component testing. Cooling System: Radiator, hoses, thermostat, and coolant maintenance. Fuel System: Carburetor (likely Keihin FCR) tuning, cleaning, and overhaul; fuel tank and lines. Exhaust System: Exhaust pipe and muffler maintenance and inspection. Chassis And Frame: Frame inspection, linkage systems, bearings, and general chassis maintenance. Wheels And Tires: Hubs, spokes, rim maintenance, and tire replacement procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning. Troubleshooting: Diagnostic guides for common performance issues, starting problems, and component failures. Engine Rebuild: Step-by-step instructions for cylinder head service, piston and connecting rod replacement, crankshaft service. Suspension Rebuild: Fork seal replacement, damper rod service, shock absorber seal head replacement. Brake System Repair: Bleeding procedures, pad replacement, caliper and master cylinder overhaul. Electrical Diagnostics: Component testing, fault finding using wiring diagrams. Carburetor Tuning: Jetting recommendations, idle speed adjustment, throttle response optimization. Wheel Bearing Service: Inspection and replacement of wheel hub bearings. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Detail Level: Includes torque specifications, clearances, assembly sequences, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text-based PDF for efficient information retrieval. Printability: Printable pages for on-site workshop use. Print Quality Image Resolution: Expected to be high enough for clear diagrams and illustrations. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, SOHC, liquid-cooled. Displacement: Approximately 450cc (specific bore and stroke vary slightly by year). Bore X Stroke: Example: 95 mm x 63.4 mm (verify specific year in manual). Compression Ratio: Typically around 12.0:1 or higher (verify specific year in manual). Performance Horsepower: Estimated 50+ HP (at crankshaft, varies by year and tuning). Torque: Estimated 45+ Nm (at crankshaft, varies by year). Fuel System Fuel Delivery: Carbureted (likely Keihin FCR41 or similar). Fuel Type: Unleaded gasoline, premium octane recommended. Carburetor Size: Typically 41mm throttle bore diameter. Lubrication Oil Type: High-performance motorcycle-specific 4-stroke engine oil, SAE 10W-40 or 10W-50 (API SG, SH, SJ or higher). Oil Capacity: Approx. 1.0 - 1.2 liters (refer to manual for precise capacity and filter change level). 🔧 Transmission Standard Type: 5-speed manual transmission. Optional Options: N/A (Competition models typically have a single fixed transmission configuration). Features Clutch Type: Wet, multi-plate clutch (hydraulic actuation). Gear Ratios: Specific ratios are detailed within the manual, crucial for performance tuning. Transmission Oil: Dedicated transmission oil or shared engine oil (verify manual specification). 📐 Dimensions Exterior Wheelbase: Approx. 1450-1480 mm (verify specific year). Seat Height: Approx. 960-970 mm...