This manual covers the motorcycle, produced between the years 2000 and 2007. The 450 SMR is a high-performance Supermoto machine, built upon a renowned motorsports heritage. It features a potent single-cylinder, 4-stroke, liquid-cooled engine with a displacement of approximately 449cc, delivering an impressive horsepower range of 50-60 HP. This model is characterized by its robust chromium-molybdenum steel trellis frame, advanced suspension components for both front and rear, and powerful hydraulic disc braking systems. The 450 SMR is engineered for demanding track use and spirited riding, embodying a commitment to performance and a racing DNA. This comprehensive Service Repair Manual is designed for owners and independent motorcycle technicians. It provides detailed guidance for maintaining and repairing the vehicle, covering a wide array of systems including engine mechanicals, fuel, ignition, cooling, lubrication, exhaust, and electrical systems. The manual details routine maintenance procedures, such as oil changes and valve clearance checks, alongside in-depth engine rebuild instructions and troubleshooting diagnostics. With approximately 300-400 pages of information presented in English, this text-searchable and printable manual offers essential technical data to ensure optimal performance and longevity of your 450 SMR. 🏷️ Basic Information Identification Make: KTM Model: 450 SMR Engine Variant: 450 SMR Engine Codes Product Code: N/A Engine Code Range: 2000-2007 👋 Introduction Market Position Target Audience: KTM 450 SMR owners and independent motorcycle technicians Primary Use: Performance motorcycle maintenance and repair Competitive Analysis Value Proposition: Provides essential technical data for DIY repairs and professional servicing, saving costs compared to dealership service Key Features Manual Format: Digital PDF for easy access and search Content Scope: Focuses specifically on the engine for enhanced detail 📋 Manual Details Coverage Areas Vehicle Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: 300-400 Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, and overhaul Fuel System: Carburetor (Mikuni/Keihin variants) tuning, inspection, and overhaul Ignition System: CDI, ignition timing, coil testing, spark plug specifications Cooling System: Radiator, fan, thermostat, coolant flow, and bleeding procedures Lubrication System: Oil pump, oil filter, oil passages, lubrication schedules Exhaust System: Muffler, header pipe inspection and maintenance Electrical System: Wiring diagrams, starter motor, charging system (stator/rotor) Procedures Included Routine Maintenance: Oil changes, filter replacements, valve clearance checks, spark plug replacement Troubleshooting: Diagnostic charts, common fault identification, and solutions Engine Rebuild: Piston, rings, cylinder, crankshaft, connecting rod, and bearing replacement Component Replacement: Detailed steps for replacing specific engine components Calibration Adjustment: Carburetor jetting, ignition timing adjustments Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine rebuilds and diagnostics 📊 Manual Specifications File Format File Type: Digital PDF Searchability: Text-searchable for quick information retrieval Printability: Printable pages for workshop use Print Quality Image Resolution: High-resolution diagrams and images Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Quality: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, Liquid-cooled Displacement: Approximately 449cc (specific to model year variations) Bore X Stroke: Typically around 95mm x 63.4mm (check specific model year) Compression Ratio: Varies by year, often in the range of 11.0:1 to 12.5:1 Performance Horsepower Approximate: 50-60 HP (crankshaft, depending on tuning and year) Torque Approximate: 40-45 Nm (crankshaft, depending on tuning and year) Fuel System Carburetor Type: Mikuni VM/TM or Keihin FCR series (specific model varies) Fuel Grade Recommendation: Unleaded gasoline with an octane rating of 91 or higher (RON+MON/2) Fuel Delivery: Carburetor with accelerator pump (common on SMR models) Internal Components Valve Train: DOHC, 4 valves per cylinder Camshaft Timing: Detailed specifications provided in the manual Piston Ring Gap: Specific clearances for new and worn rings detailed 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed constant mesh sequential gearbox Clutch Type: Hydraulically operated multi-plate wet clutch Features Gear Ratios: Specific ratios for each gear provided in the manual Final Drive: O-ring sealed chain drive (specific sprocket sizes and chain pitch provided) Transmission Oil Type: API GL-4, SAE 10W/40 or 15W/50 motorcycle-specific transmission oil Transmission Oil Capacity: Approximately 0.7 - 0.9 liters (check specific model year and engine configuration) 📐 Dimensions Exterior Wheelbase: Typically around 1470-1480 mm Seat Height: Typically around 900-930 mm Weights Dry Weight: Approximately 110-115 kg (without fuel) Curb Weight: Approximately 118-125 kg (with all fluids) 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle - individual component safety focus) Active Features Braking System Front: Hydraulic disc brake, typically 320mm disc with 4-piston radial caliper Braking System Rear: Hydraulic disc brake, typically 220mm disc with 1-piston caliper Passive Features Frame Type: Chromium-molybdenum steel trellis frame Suspension Front: Upside-down telescopic fork (WP Suspension), adjustable compression and rebound damping Suspension Rear: Monoshock (WP Suspension), adjustable preload, compression, and rebound damping 💡 Technology Features Infotainment Infotainment System: N/A (Race-focused motorcycle, no infotainment system) Driver Assistance Traction Control: Typically not equipped...