The 450 SXS is a high-performance four-stroke, single-cylinder, liquid-cooled competition motocross machine, produced from 2000 to 2007. Engineered with a strong emphasis on lightweight design, agile handling, and potent engine performance, this model embodies the 'Ready to Race' philosophy. Its development reflects extensive heritage and success in off-road racing, offering features optimized for demanding motocross and supercross environments. The 450 SXS is recognized for its robust construction and the inherent performance capabilities that have contributed to a strong standing in professional racing circuits. This comprehensive Factory Service Repair Manual in English provides essential information for the maintenance and repair of the 450 SXS models from 2000 through 2007. It covers a wide array of systems, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission, cooling, suspension, brakes, and the electrical and chassis components. The manual includes guidance on routine maintenance, troubleshooting, component rebuilds, adjustments, and critical torque specifications, offering factory-level detail. This resource is invaluable for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their 450 SXS. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Segment: High-performance Motocross/Off-Road Competition Machine Target Audience: Motocross racers, off-road enthusiasts, and mechanics specializing in KTM off-road motorcycles. Competitive Analysis Competitors: Competed against similar displacement models from Yamaha (YZ450F), Honda (CRF450R), Suzuki (RM-Z450), Kawasaki (KX450F), and Husqvarna during its production run. Key Features Design Philosophy: Lightweight, powerful, and agile chassis optimized for competitive off-road racing. Performance Focus: Emphasis on engine power delivery, suspension performance, and chassis handling characteristics crucial for motocross and supercross tracks. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download Completeness: Comprehensive Official Factory Documentation Page Count Page Count Estimate: Hundreds of Pages (Specific count not provided, but implies extensive content) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, tuning, and specifications for the 450cc engine platform. Fuel System: Carburetor systems (Mikuni/Keihin likely), fuel tank, fuel lines, and related components. Ignition System: CDI, ignition coils, stator, rotor, spark plug specifications, and troubleshooting. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and assembly, shift mechanism, chain drive maintenance, and gear ratios. Cooling System: Radiator, cooling fan, coolant types, flow, and maintenance for liquid-cooled models. Suspension Front: Upside-down telescopic forks (e.g., WP Suspension), seal replacement, oil levels, damping adjustments, and fork leg service. Suspension Rear: Monoshock rear suspension (e.g., WP), shock absorber service, linkage maintenance, spring preload, and damping adjustments. Brakes Front: Hydraulic disc brake system, caliper service, master cylinder, brake pads, fluid type (DOT 4), bleeding procedures, and rotor specifications. Brakes Rear: Hydraulic disc brake system, caliper service, master cylinder, brake pads, fluid type (DOT 4), bleeding procedures, and rotor specifications. Electrical System: Wiring diagrams, battery specifications, lighting (if applicable for SXS models), fuses, and basic electrical troubleshooting. Frame Chassis: Frame inspection, steering head bearing maintenance, swingarm service, and general chassis component checks. Bodywork Plastics: Seat removal, fender installation/removal, fuel tank cover, and general plastic component maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), chain lubrication and adjustment, spark plug checks, and pre-ride inspections. Troubleshooting: Detailed diagnostic procedures for common issues related to starting, running, and component failures. Repair Rebuild: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly. Adjustments: Carburetor tuning, suspension adjustments, clutch lever free play, and throttle cable slack. Torque Specifications: Precise torque values for all critical fasteners and components. Technical Depth Depth: Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic checks to complete engine rebuilds. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF allowing for quick information retrieval. Print Quality Printability: Designed for printing individual sections or the entire manual for workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: Approximately 450cc (specific bore x stroke may vary slightly by year/model revision, but typically around 95mm bore x 63.4mm stroke). Valvetrain: SOHC (Single Overhead Camshaft) with 4 valves (common for this era). Performance Horsepower Estimate: Estimated 50+ HP at the crankshaft (highly dependent on tuning and specific year). Torque Estimate: Estimated 35-40 lb-ft at the crankshaft (highly dependent on tuning and specific year). Fuel System Carburetor Type: Typically a high-performance flat-slide carburetor, such as Mikuni TM40 or Keihin FCR (specific model varies). Fuel Type: Unleaded gasoline (91-98 octane recommended). Engine Oil Oil Type Specification: KTM recommends specific high-quality motorcycle engine oil, often SAE 10W/40 or 15W/50 with JASO MA rating. Consult manual for exact specification. Oil Capacity: Approximately 1.0 - 1.2 liters (check manual for exact specification and filter change amount). 🔧 Transmission Standard Transmission Type: 5-speed constant mesh manual transmission Optional Optional...