This Service Repair Manual covers the high-performance motocross motorcycle renowned for its potent 450cc engine and competitive edge in off-road racing. Produced from 2000 through 2007, this model embodies the philosophy of "Ready to Race," delivering exceptional power and rider engagement. Its robust construction and Austrian engineering ensure reliability for demanding off-road conditions, making it a favored choice for enthusiasts and professional racers alike who seek peak performance and durability. This comprehensive manual provides detailed, step-by-step instructions for all aspects of maintenance and repair for this motorcycle. It covers engine disassembly and assembly, diagnostics, routine maintenance procedures, troubleshooting common faults, and component testing, including detailed diagrams and torque specifications. The scope extends to critical systems such as the engine mechanicals, lubrication, cooling, fuel, ignition, exhaust, and electrical systems, ensuring owners and technicians have the necessary information to maintain and restore the vehicle to optimal working condition. 🏷️ Basic Information Identification Make: KTM Model: 450 SX Engine Variant: 450cc Engine Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Manual Type: Service Repair Manual Manual Format: PDF 👋 Introduction Market Position Vehicle Segment: High-performance Motocross/Off-road Motorcycle Target Audience: Enthusiasts, mechanics, racers requiring in-depth engine knowledge Competitive Analysis Competitor Models Engine Focus: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F Key Features Manual Advantage: Focuses specifically on the intricate details of the 450 SX engine, crucial for optimal performance and longevity. Vehicle Reputation: KTM is known for its potent and race-ready off-road motorcycles, emphasizing performance and rider engagement. 📋 Manual Details Coverage Areas Engine Disassembly And Assembly: Complete Engine Diagnostics: Comprehensive Maintenance Procedures: Detailed Troubleshooting Guides: Extensive Page Count Estimated Pages: 350+ Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Cylinder head, valves, camshaft, crankshaft, connecting rod, piston, cylinders Engine Lubrication: Oil pump, oil passages, oil filter, oil specifications Cooling System: Radiator, water pump, thermostat, coolant specifications Fuel System: Carburetor (main, pilot, jetting), fuel lines, fuel filter, fuel pump (if applicable) Ignition System: Spark plug, ignition coil, CDI unit, timing Exhaust System: Muffler, header pipe, gaskets Engine Electrical: Starter motor, stator, flywheel, wiring diagrams Procedures Included Routine Maintenance: Oil changes, filter replacement, air filter cleaning, spark plug inspection/replacement Engine Rebuild: Top-end rebuild, bottom-end rebuild, complete engine overhaul Troubleshooting Common Faults: Starting issues, misfires, overheating, power loss Component Testing: Carburetor adjustment, ignition timing checks, compression testing Torque Specifications: All critical engine fasteners Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds) Detail Level: Step-by-step instructions with detailed diagrams and illustrations 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (Text-searchable) Print Quality Printability: High-quality, printable pages Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: Approximately 449.3 cc (varies slightly by year) Bore X Stroke: Typically around 95.0 mm x 63.4 mm Compression Ratio: Generally around 12.5:1 to 13.5:1 Performance Horsepower Estimated: 50+ HP (at the crank) Torque Estimated: Around 35-40 lb-ft Fuel System Carburetor Type: Keihin FCR MX (common, specific model varies) Fuel Type: Unleaded Gasoline (91 octane or higher recommended) Internal Components Valve Train: SOHC (Single Overhead Camshaft), 4 valves Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Optional Transmissions: N/A (standard for this model) Features Clutch Type: Wet multi-plate clutch 📐 Dimensions Exterior Wheelbase: Approx. 1480 mm (58.3 inches) Weights Dry Weight: Approx. 105 kg (231 lbs) Fuel Tank Capacity: Approx. 7.0 - 8.0 Liters (1.8 - 2.1 US gal) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motocross/Off-road competition vehicle, not street legal, not crash tested by standard automotive bodies) Active Features Braking System: Hydraulic disc brakes (front and rear) Passive Features Suspension: WP Suspension components (high-performance, adjustable) 💡 Technology Features Infotainment Infotainment Features: N/A (Basic motocross bike, focused on performance not amenities) Driver Assistance Rider Assistance: N/A (No electronic rider aids typically found on these models) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 10-15 hours of riding or as per manual recommendation (severe use). Air Filter Cleaning: After every few rides, depending on conditions. Spark Plug Check: Every 20-30 hours of riding. Fluid Specifications Engine Oil Type: High-quality synthetic 4-stroke motorcycle oil (e.g., Motorex Power Synt 4T 10W/50 or equivalent). Engine Oil Capacity: Approximately 1.1 - 1.3 Liters (depending on filter change and engine state). Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M5.0). Known Issues Common Wear Items: Piston rings, valve seals, clutch plates, spark plug, air filter. Potential Faults: Carburetor jetting issues, overheating if cooling system is not maintained, premature wear if oil changes are neglected. Preventative Maintenance Importance Of Intervals: Strict adherence to service intervals is critical for the longevity and performance of high-strung motocross engines. 📚 Vehicle History Brand Heritage Brand Focus: KTM is...