🏷️ Basic Information Identification Make: KTM Model: 450 SX Codes Engine Family Code: LC4 (Single Cylinder, Four-Stroke) Model Designation: SX (Motocross) 👋 Introduction Market Position Segment: High-performance Motocross (MX) competition motorcycle. Competitive Analysis Rivals Era: Competed against models like Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F during its production run. Key Features Engine Platform: Robust LC4 engine known for its torque and reliability in demanding off-road conditions. Suspension Components: Typically equipped with high-quality WP Suspension components, a hallmark of KTM's performance focus. Target Audience User Base: Motocross racers, off-road enthusiasts, and mechanics requiring in-depth service information. 📋 Manual Details Coverage Areas Vehicle Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Pages: 350-500 (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, internal components (piston, rings, valves, camshaft, crankshaft), cylinder head, lubrication system, cooling system, torque specifications. Fuel System: Carburetor (Keihin, Mikuni likely), fuel pump, fuel lines, fuel tank inspection and maintenance. Ignition System: CDI unit, ignition coil, spark plug, stator, wiring diagrams. Transmission Drivetrain: Gearbox operation, clutch assembly (hydraulic or cable), gear shift mechanism, chain and sprocket maintenance, gearbox oil specifications. Suspension: Front forks (WP Suspension likely), rear shock absorber (WP Suspension likely), service procedures, oil levels, seal replacement, adjustments. Brakes: Front and rear brake systems (Brembo likely), hydraulic lines, master cylinders, calipers, brake pads, fluid specifications, bleeding procedures. Electrical System: Wiring diagrams, battery maintenance, lighting, starter motor, fuses, troubleshooting electrical faults. Chassis Frame: Frame inspection, steering head bearings, footpegs, handlebars, controls. Wheels Tires: Wheel bearing service, spoke tensioning, tire pressure recommendations, wheel removal and installation. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug checks, valve clearance checks. Troubleshooting: Diagnostic procedures for common engine, electrical, and chassis issues, symptom-based troubleshooting guides. Component Rebuilds: Detailed instructions for rebuilding engine components (cylinder, piston, crankshaft), carburetor, clutch, and suspension components. Wiring Diagrams: Comprehensive electrical schematics for all model years covered, facilitating diagnosis and repair. Technical Depth Depth Level: Comprehensive factory-level repair and service procedures, suitable for professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Print Quality Resolution: High-resolution, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) File Characteristics Searchable: Likely searchable text content for easy navigation. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC (Dual Overhead Camshafts) Displacement: Approximately 450cc (exact figures may vary slightly across model years) Bore X Stroke: Refer to manual for precise dimensions (e.g., ~95mm x 63.4mm for early models). Performance Horsepower Approx: Around 50-55 HP (peak, varies by year and tuning). Torque Approx: Around 45-50 Nm (peak, varies by year). Fuel System Carburetor Type: Likely Keihin FCR (Flat CR-series) or Mikuni TM flat slide carburetors (e.g., 39mm or 41mm). Fuel Type: Unleaded gasoline, octane rating appropriate for performance engines (e.g., 91+ RON). Lubrication Oil Capacity: Refer to manual for specific capacity (often shared sump or separate gearbox oil). Cooling System Coolant Type: Ethylene glycol based coolant with corrosion inhibitors. 🔧 Transmission Standard Type: 5-speed or 6-speed constant mesh sequential gearbox (confirm specific year). Optional Optional Gearing: N/A for factory models, but aftermarket options exist. Features Clutch Type: Hydraulic clutch actuation (Magura or Brembo slave/master cylinders common). Gear Ratios Gear Ratios: Refer to manual for specific ratios for each gear. Typically optimized for motocross use. Fluid Type Gearbox Oil: Dedicated gearbox oil or specialized engine oil (refer to manual for exact specification, e.g., Motorex). 📐 Dimensions Exterior Wheelbase: Refer to manual for specific measurements (typically around 1470-1480mm). Seat Height: Refer to manual for specific measurement (high for motocross, ~950-960mm). Weights Dry Weight: Approximately 110-115 kg (dry, without fluids). Fuel Tank Capacity: Around 7-9 liters. Wheels Tires Front Wheel Size: 21 inches Rear Wheel Size: 19 inches Tire Pressure Front: Refer to manual for competition settings (e.g., 14-18 PSI). Tire Pressure Rear: Refer to manual for competition settings (e.g., 14-18 PSI). 🛡️ Safety Features Ratings Safety Certification: Not applicable for competition-off-road vehicles in the same way as street-legal vehicles. Focus on component integrity. Active Features Braking System: Powerful hydraulic disc brakes (Brembo). Front: Dual piston caliper. Rear: Single piston caliper. Passive Features Frame Construction: High-strength Chromoly steel trellis frame for rigidity and impact resistance. 💡 Technology Features Infotainment Infotainment System: Not applicable. This is a purebred motocross machine focused on performance, not comfort or entertainment features. Driver Assistance Traction Control: Not equipped. Designed for direct rider input. Connectivity Bluetooth Usb: Not equipped. 🔧 Maintenance Service Intervals Oil Change Interval: Every 10-20 hours of riding (competition schedule), or as specified in the manual. Air Filter Cleaning: After every few rides or more frequently in dusty conditions....