This manual covers the 450 SX, a high-performance motocross motorcycle produced between 2000 and 2007. Renowned for its 'Ready to Race' philosophy, the 450 SX models are characterized by a potent single-cylinder, four-stroke engine delivering strong torque and power, typically around 50-55 horsepower. These machines are engineered with agile chassis and responsive handling, often featuring advanced suspension components for superior adjustability and performance on the track. The 450 SX is a direct competitor in the premier open-class motocross category, building on an extensive off-road racing heritage. This comprehensive workshop service repair manual provides detailed guidance for owners, mechanics, and technicians to maintain and repair the 450 SX. It covers a wide range of critical systems, including complete engine overhaul, fuel and ignition systems, cooling, transmission, clutch, front and rear suspension, braking systems, wheels and tires, electrical components, frame, and bodywork. The manual includes procedures for routine maintenance, troubleshooting and diagnostics, engine and suspension rebuilds, brake system service, and clutch adjustments. It also details technical specifications, special tool requirements, and recommended fluid types, ensuring the vehicle remains in optimal condition for peak performance. 🏷️ Basic Information Identification Make: KTM Model: 450 SX Year: 2000-2007 Product Type: Workshop Service Repair Manual Format: PDF Download 👋 Introduction Market Position Vehicle Segment: High-performance Motocross Brand Reputation: KTM is renowned for its 'Ready to Race' philosophy and competitive off-road motorcycles. Competitive Analysis Key Competitors Era: Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F. Key Features Engine Configuration: Single-cylinder, four-stroke engine, known for strong torque and power delivery. Suspension Technology: Typically equipped with high-quality WP (White Power) suspension components, offering advanced adjustability. Handling Characteristics: Agile chassis and responsive steering optimized for motocross tracks. 📋 Manual Details Coverage Areas Primary Coverage: KTM 450 SX Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: Hundreds of pages (specific count not provided in product description but implied to be comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (assumed for official factory manuals targeting global markets) Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly procedures for the 450cc engine. Fuel System: Carburetor (likely Keihin or Mikuni) tuning, cleaning, repair, and component replacement. Ignition System: Ignition coil, CDI unit, spark plug specifications, and troubleshooting. Cooling System: Radiator, coolant hoses, water pump, and thermostat maintenance and repair. Transmission Gearbox: Gearbox disassembly, inspection, gear and shift drum service, and clutch operation. Clutch Assembly: Clutch plate replacement, spring inspection, and hydraulic or cable actuation service. Suspension Front: Fork disassembly, seal replacement, oil level and viscosity specifications, damping adjustments (WP USD forks common). Suspension Rear: Monoshock absorber service, linkage lubrication, spring preload adjustment, and damper rebuild procedures (WP likely). Braking System Front: Caliper service, pad replacement, rotor inspection, and hydraulic system bleeding (Brembo often used). Braking System Rear: Caliper service, pad replacement, rotor inspection, and hydraulic system bleeding (Brembo often used). Wheel And Tire: Wheel bearing inspection, spoke tensioning, tire changes, and rim maintenance. Electrical System: Wiring diagrams, component testing (lights, horn, kill switch), and battery maintenance. Frame And Bodywork: Frame inspection, plastic component removal/installation, seat, fuel tank, and handlebar service. Exhaust System: Exhaust pipe and muffler inspection, gasket replacement, and de-carbonization procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks, and air filter cleaning. Troubleshooting Diagnostics: Step-by-step guides for identifying and resolving common mechanical and electrical issues. Engine Rebuilds: Detailed instructions for top-end and bottom-end engine rebuilds, including piston, ring, and valve service. Suspension Rebuilds: Instructions for servicing fork seals, bushings, and shock absorber components. Brake System Service: Bleeding procedures, component replacement (pads, rotors, lines), and caliper maintenance. Clutch Adjustment And Repair: Guidance on clutch lever adjustment, cable/hydraulic system service, and clutch pack replacement. Electrical Troubleshooting: Using wiring diagrams to diagnose electrical faults. Cleaning And Lubrication: Recommended procedures and lubricant types for various components. Technical Depth Depth Level: Comprehensive (covers routine maintenance to full engine and component rebuilds) Diagnostic Capabilities: Detailed diagnostic charts and troubleshooting flowcharts. Component Specifications: Includes critical torque values, clearances, and tolerances. Special Tools: Lists required special tools for specific procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Print Readability: Designed for clarity, suitable for printing specific sections or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Displacement: 450cc (approximately) Bore X Stroke: Specifics vary by sub-model year, consult manual for exact figures. Compression Ratio: Specifics vary by sub-model year, consult manual for exact figures. Performance Horsepower: Estimated 50-55 HP (peak, varies by year and tuning). Torque: Strong low-to-mid range torque delivery. Fuel System Fuel Delivery: Carburetor (e.g., Keihin FCR series or similar performance carburetors) Recommended...