The KTM 450 SMR is a high-performance Supermoto motorcycle renowned for its potent 449cc single-cylinder engine, lightweight construction, and agile handling, making it ideal for both track use and aggressive street riding. Produced from 2000 to 2007, this model exemplifies KTM's dedication to motorsport, leveraging its extensive off-road racing heritage to create a machine focused on raw power and exceptional suspension performance, typically featuring premium WP components. Its design emphasizes a direct connection between rider and machine, offering a thrilling and responsive experience for enthusiasts seeking the pinnacle of Supermoto engineering. This comprehensive service repair workshop manual provides in-depth guidance for the KTM 450 SMR models spanning the years 2000 through 2007. It covers all essential aspects of maintenance, repair, and troubleshooting, including detailed procedures for the engine, transmission, fuel, ignition, cooling, and exhaust systems. Additionally, the manual offers extensive information on chassis components, front and rear suspension, braking systems, wheels, tires, and the electrical system, along with routine maintenance schedules, engine overhaul instructions, and torque specifications, empowering owners and technicians to maintain this high-performance machine effectively. 🏷️ Basic Information Identification Make: KTM Model: 450 SMR Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Manual Identifier: Likely KTM Part Number: 3205900EN or similar for the 450 SMR generation 👋 Introduction Market Position Motorcycle Segment: High-performance Supermoto motorcycle, designed for track use and aggressive street riding. Competitive Analysis Key Competitors: Competed against other factory Supermoto machines and heavily modified dirt bikes from brands like Yamaha (YZ450F conversion), Honda (CRF450R conversion), and Husqvarna. Key Features Performance Focus: Emphasis on lightweight construction, potent engine power, and agile handling for Supermoto racing dynamics. Suspension Quality: Utilized premium WP suspension components, providing excellent adjustability and performance. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, repair, and workshop procedures for the KTM 450 SMR models from 2000 to 2007. Page Count Estimated Page Count: Approximately 400-600 pages (typical for a full workshop manual covering this range). Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (implied by product description, common for KTM manuals of this era) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Detailed coverage of the 450cc engine, including disassembly, assembly, inspection, troubleshooting, and component specifications. Transmission System: Information on the gearbox, clutch, shift mechanism, lubrication, and associated components. Fuel System: Carburetor (likely Keihin FCR) tuning, servicing, jetting, and troubleshooting. Fuel tank, lines, and petcock maintenance. Ignition System: CDI ignition, spark plug specifications, troubleshooting ignition faults, and component testing. Cooling System: Radiator, coolant hoses, fan (if applicable), and coolant specifications and bleeding procedures. Exhaust System: Exhaust pipe, muffler inspection, and gasket replacement. Chassis And Frame: Frame inspection, headstock bearing maintenance, and general chassis component checks. Suspension System Front: Detailed procedures for WP USD (Upside Down) forks, including oil change, seal replacement, spring inspection, and adjustment. Suspension System Rear: Servicing of the rear monoshock (likely WP), including damping adjustments, spring preload, linkage maintenance, and seal replacement. Braking System Front: Front brake caliper, master cylinder, brake line, and rotor service and bleeding procedures. Braking System Rear: Rear brake caliper, master cylinder, brake line, and rotor service and bleeding procedures. Wheels And Tires: Spoke tensioning, wheel bearing replacement, tire mounting/demounting, and recommended tire pressures. Electrical System: Wiring diagrams, battery maintenance, lighting system, and troubleshooting electrical faults. Controls: Throttle, clutch lever, and brake lever adjustments and servicing. Bodywork And Plastics: Fairing removal and installation, seat servicing, and plastic component care. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning, spark plug checks. Engine Overhaul: Piston, rings, cylinder head, valve clearance adjustment, camshaft removal/installation, and complete engine reassembly. Suspension Rebuild: Complete fork and shock absorber disassembly, seal replacement, and fluid changes. Troubleshooting Guides: Diagnostic flowcharts and common problem identification for various systems. Torque Specifications: Precise torque values for critical fasteners throughout the motorcycle. Wiring Diagrams: Detailed electrical schematics for all systems. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures for identifying and resolving complex mechanical and electrical issues. Rebuild Instructions: Complete step-by-step instructions for engine and major component rebuilds. Special Tool Requirements: Identification and usage of specific KTM tools required for certain procedures. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Digital Printability: High-resolution, printable quality suitable for home or professional printing. Binding Type Digital Binding: N/A (Digital download, no physical binding) Paper Type Digital Paper Emulation: N/A (Digital download, no physical paper) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, Liquid-cooled Engine Displacement: 449cc (approximately) Bore X Stroke: Likely around 95 mm x 63.4 mm (typical for KTM 450s of this era) Compression Ratio: Typically around 11.5:1 to 12.5:1 Valve Train: SOHC (Single Overhead Camshaft) with 4 valves Performance Horsepower Estimate: Around 50-55 HP (at the crankshaft, depending on specific tuning and year) Torque Estimate: Around 45-50 Nm...