🏷️ Basic Information Identification Make: KTM Model: 450 SXS RACING Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Model Variant: SXS Racing (Specific motocross/supercross variant) 👋 Introduction Market Position Target Audience: Motocross and Supercross racers, performance tuners, KTM dealerships, and skilled motorcycle mechanics specializing in off-road competition bikes. Competitive Analysis Manual Value Proposition: Provides critical technical data for maintaining and optimizing a high-performance competition machine, directly impacting race readiness and longevity. Key Features Content Focus: Detailed procedural steps, precise specifications, and diagnostic information specific to the 450 SXS RACING model, crucial for competitive advantage. 📋 Manual Details Coverage Areas Primary Focus: Workshop Repair and Overhaul Additional Coverage: Maintenance, Troubleshooting, Diagnostics, Component Replacement, Assembly Page Count Estimated Pages: Likely 200-400 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair Service Manual Language Language: English (assumed, based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (including top-end, bottom-end, lubrication, cooling), Transmission (gearbox, clutch, shifting mechanism) Chassis And Suspension: Frame, Swingarm, Front Forks (upside-down telescopic), Rear Shock Absorber (monoshock), Linkages Brakes: Front and Rear Hydraulic Disc Brakes (caliper, master cylinder, lines, pads) Controls: Throttle, Clutch Lever, Brake Lever, Gear Shift Lever, Handlebars Electrical System: Ignition System, CDI Unit, Spark Plug, Wiring Diagrams, Lighting (if applicable, though typically minimal on race bikes), Battery (if applicable) Fuel And Exhaust: Carburetor (likely Keihin FCR), Fuel Tank, Fuel Lines, Exhaust System Wheels And Tires: Spoked Wheels, Tire Mounting/Dismounting, Tube Replacement Procedures Included Routine Maintenance: Oil Changes, Air Filter Cleaning/Replacement, Chain Adjustment, Spark Plug Checks, Tire Pressure Component Overhaul: Engine Rebuild (piston, rings, valves, crankshaft), Fork Seal Replacement, Shock Absorber Service, Clutch Rebuild, Transmission Disassembly/Reassembly Troubleshooting: Diagnostic flowcharts, common problem identification and solutions (e.g., starting issues, performance problems) Assembly And Disassembly: Step-by-step instructions for complete disassembly and reassembly of major components and the entire motorcycle Technical Depth Depth: Comprehensive, suitable for experienced mechanics and dedicated enthusiasts. Includes detailed torque specifications, clearances, and special tool requirements. 📊 Manual Specifications File Format Quality: High-resolution PDF, ensuring clear text and diagrams. Searchable text is highly probable for efficiency. Print Quality Reproducibility: Designed for printing of individual pages or sections as needed for workshop use. Binding Type Digital Format: N/A (Digital Download) Paper Type Digital Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, 4-stroke, Liquid-cooled Displacement: Approximately 450cc (specific bore x stroke would be detailed in the manual) Configuration: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) - likely DOHC for performance in this era, to be confirmed in manual. Performance Power Output: Estimated 50-60+ HP (stock, varies by specific model year and tuning) Torque: Specific figures detailed in manual, but characteristic of strong mid-range power delivery for motocross. Fuel System Carburetor Model: Likely Keihin FCR (Flat CR, High Performance) - e.g., FCR MX Carburetor Size: Typically 39mm or 41mm for this class of bike Lubrication System Oil Type Specification: Manual will specify API SG or higher, SAE 10W-40 or 15W-50 motorcycle-specific oil. Separate gearbox oil may be specified. Cooling System Type: Liquid-cooled with radiator and fan (electric or engine-driven, depending on year) 🔧 Transmission Standard Type: 5-speed or 6-speed constant mesh sequential gearbox Optional Features: Close-ratio gear sets are common for racing applications, enhancing acceleration. Features Clutch Type: Hydraulically operated, multi-plate wet clutch Fluid Specification Gearbox Oil: Manual will specify type and quantity (often a dedicated gearbox oil or motorcycle engine oil meeting specific JASO standards). 📐 Dimensions Exterior Wheelbase: Approx. 1470-1490 mm (specific value in manual) Seat Height: Approx. 970-985 mm (specific value in manual) Weights Dry Weight: Approx. 100-105 kg (specific value in manual) Fuel Tank Capacity: Approx. 7-9 Liters (specific value in manual) Suspension Travel Front Forks: Approx. 300-320 mm (e.g., WP USD forks) Rear Shock: Approx. 320-340 mm (e.g., WP PDS or linkage-based system) 🛡️ Safety Features Ratings Vehicle Classification: Competition Off-Road Motorcycle (Not street legal, safety features are performance-oriented). Active Features Braking System: High-performance hydraulic disc brakes front and rear for superior stopping power. Suspension And Handling: Advanced WP suspension systems designed for maximum control and feedback in demanding race conditions. Passive Features Frame Construction: Robust chromoly steel perimeter frame for optimal rigidity and rider feel. 💡 Technology Features Infotainment Features: N/A (Focus is on pure performance, no infotainment systems like navigation or audio). Driver Assistance Features: N/A (No electronic rider aids like traction control or ABS, as this is a race-prepped machine). Connectivity Features: N/A Engine Management Ignition System: Digital CDI (Capacitor Discharge Ignition) for precise spark timing. 🔧 Maintenance Service Intervals Engine Oil Change: Every 10-15 hours of riding or after major race events. Specific interval in manual. Air Filter Cleaning: After every few rides or as conditions dictate (dusty environments require more frequent cleaning). Valve Adjustment: Typically every 30-50 hours of riding. Critical for performance...