The KTM 450 EXC Racing, produced between 2000 and 2003, is a performance-oriented competition enduro motorcycle renowned for its off-road capabilities. As an evolution of KTM's dedicated enduro platform, this model is engineered for challenging terrains and demanding racing conditions. Its robust construction, featuring a chromium-molybdenum steel frame, and a liquid-cooled, 4-stroke, single-cylinder engine with approximately 449cc displacement, make it a formidable machine. The motorcycle is equipped with a 5-speed manual transmission, a wet multi-plate clutch, and chain drive, delivering power efficiently to the rear wheel. Designed for off-road riders, enduro racers, and adventure enthusiasts, the 450 EXC Racing offers a powerful and agile experience. This comprehensive Service Repair Workshop Manual in English provides in-depth technical guidance essential for maintaining and repairing the KTM 450 EXC Racing. It covers all critical systems, including engine mechanicals, fuel, ignition, cooling, exhaust, transmission, suspension (front and rear), brakes, wheels, tires, electrical systems, and frame/chassis. The manual details routine maintenance procedures, troubleshooting diagnostics, component overhauls, and adjustments, making it suitable for professional mechanics and experienced DIY enthusiasts. Its high-resolution, searchable format ensures clear access to information, enabling owners and technicians to effectively service and preserve the performance and longevity of this specialized off-road motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC Racing Model Variant: 450 EXC Racing Years Covered: 2000, 2001, 2002, 2003 Codes Vin Code Digit 4 5: Varies by model year and specific variant, consult manual for detailed breakdown 👋 Introduction Market Position Category: Competition Enduro Motorcycle Target Audience: Off-road riders, enduro racers, adventure riders seeking robust maintenance capabilities. Competitive Analysis Competitors: Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Suzuki DR-Z400E Key Features Vehicle Focus: Performance-oriented off-road machine with a focus on racing and challenging terrain. Manual Utility: Provides in-depth technical guidance essential for maintaining and repairing this specialized motorcycle. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Page Count Page Count: Comprehensive (Specific page count not provided in product info, but typical for a full workshop manual is 300-500+ pages) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, tuning, and overhaul of all internal components. Fuel System: Carburetor service, cleaning, adjustment, fuel pump, fuel lines, fuel tank maintenance. Ignition System: Ignition coil, CDI unit, spark plug diagnosis and replacement, timing adjustments. Cooling System: Radiator, coolant hoses, water pump, fan operation, bleeding procedure. Exhaust System: Muffler, header pipe, gasket replacement, emissions control (if applicable). Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, gear selection mechanisms, chain and sprockets maintenance. Suspension Front: Fork disassembly, seal replacement, oil level and type, damping adjustments, steering head bearing service. Suspension Rear: Shock absorber service, linkage system maintenance, swingarm bearings, rear wheel bearings. Brakes Front: Brake caliper service, master cylinder overhaul, brake pad replacement, disc inspection, hydraulic fluid specifications. Brakes Rear: Brake caliper service, master cylinder overhaul, brake pad replacement, disc inspection, hydraulic fluid specifications. Wheels Tires: Wheel bearing replacement, spoke tensioning, tire pressure recommendations, wheel balancing. Electrical System: Wiring diagrams, lighting systems, battery maintenance, charging system diagnosis (stator, regulator/rectifier), starter motor. Frame Chassis: Frame inspection, subframe, footpegs, controls, and mounting hardware. Bodywork Plastics: Fairing removal, seat, tank shrouds, fender replacement, decal application. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning, spark plug checks. Troubleshooting: Diagnostic procedures for common starting issues, performance problems, and system failures. Component Overhaul: Detailed step-by-step instructions for rebuilding major components like the engine and suspension. Adjustments: Carburetor jetting, valve clearance, chain slack, clutch lever free play. Inspections: Regular visual and functional checks of all critical systems. Technical Depth Depth: Comprehensive from basic maintenance to full engine and chassis rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Typically, PDF workshop manuals offer searchable text for quick information retrieval. Print Quality Print Quality: High-resolution, designed for clear printing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single Cylinder Displacement: Approx. 449cc Bore X Stroke: Specifications vary slightly by year, consult specific manual pages for exact figures. Cooling System: Liquid-cooled Performance Horsepower Approx: Estimated 45-55 HP (depending on model year and tuning, peak figures often not published by manufacturer for off-road competition models). Torque Approx: Specifications vary, refer to detailed engine data within the manual. Fuel System Carburetor: Keihin FCR (Flat CR) type carburetor, specific jetting and settings detailed in the manual. Fuel Type: Unleaded gasoline Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Clutch Type: Wet multi-plate clutch Drive Type: Chain drive Features Gear Ratios: Specific gear ratios are detailed within the manual for each model year. 📐 Dimensions Exterior Wheelbase: Varies by model year, typically around...