This manual covers the 450 SXS RACING models produced between 2000 and 2007. The 450 SXS RACING is a specialized competition off-road motorcycle, engineered for the demanding environments of motocross and supercross racing. It represents dedication to performance and its "Ready to Race" philosophy, incorporating robust construction and advanced components, such as WP suspension and a high-performance liquid-cooled engine, to provide riders with a competitive edge. This model is designed for optimal handling, power delivery, and durability under extreme racing conditions. This comprehensive workshop repair service manual provides detailed instructions for the maintenance, troubleshooting, diagnostics, and repair of the 450 SXS RACING. It covers all essential systems including the engine, transmission, chassis, suspension, brakes, and electrical components, offering step-by-step procedures for routine maintenance, component overhaul, and assembly. The manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of this high-performance competition machine, offering precise specifications and diagnostic guidance critical for race readiness. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS RACING Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Model Variant: SXS Racing (Specific motocross/supercross variant) 👋 Introduction Market Position Target Audience: Motocross and Supercross racers, performance tuners, KTM dealerships, and skilled motorcycle mechanics specializing in off-road competition bikes. Competitive Analysis Manual Value Proposition: Provides critical technical data for maintaining and optimizing a high-performance competition machine, directly impacting race readiness and longevity. Key Features Content Focus: Detailed procedural steps, precise specifications, and diagnostic information specific to the 450 SXS RACING model, crucial for competitive advantage. 📋 Manual Details Coverage Areas Primary Focus: Workshop Repair and Overhaul Additional Coverage: Maintenance, Troubleshooting, Diagnostics, Component Replacement, Assembly Page Count Estimated Pages: Likely 200-400 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair Service Manual Language Language: English (assumed, based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (including top-end, bottom-end, lubrication, cooling), Transmission (gearbox, clutch, shifting mechanism) Chassis And Suspension: Frame, Swingarm, Front Forks (upside-down telescopic), Rear Shock Absorber (monoshock), Linkages Brakes: Front and Rear Hydraulic Disc Brakes (caliper, master cylinder, lines, pads) Controls: Throttle, Clutch Lever, Brake Lever, Gear Shift Lever, Handlebars Electrical System: Ignition System, CDI Unit, Spark Plug, Wiring Diagrams, Lighting (if applicable, though typically minimal on race bikes), Battery (if applicable) Fuel And Exhaust: Carburetor (likely Keihin FCR), Fuel Tank, Fuel Lines, Exhaust System Wheels And Tires: Spoked Wheels, Tire Mounting/Dismounting, Tube Replacement Procedures Included Routine Maintenance: Oil Changes, Air Filter Cleaning/Replacement, Chain Adjustment, Spark Plug Checks, Tire Pressure Component Overhaul: Engine Rebuild (piston, rings, valves, crankshaft), Fork Seal Replacement, Shock Absorber Service, Clutch Rebuild, Transmission Disassembly/Reassembly Troubleshooting: Diagnostic flowcharts, common problem identification and solutions (e.g., starting issues, performance problems) Assembly And Disassembly: Step-by-step instructions for complete disassembly and reassembly of major components and the entire motorcycle Technical Depth Depth: Comprehensive, suitable for experienced mechanics and dedicated enthusiasts. Includes detailed torque specifications, clearances, and special tool requirements. 📊 Manual Specifications File Format Quality: High-resolution PDF, ensuring clear text and diagrams. Searchable text is highly probable for efficiency. Print Quality Reproducibility: Designed for printing of individual pages or sections as needed for workshop use. Binding Type Digital Format: N/A (Digital Download) Paper Type Digital Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, 4-stroke, Liquid-cooled Displacement: Approximately 450cc (specific bore x stroke would be detailed in the manual) Configuration: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) - likely DOHC for performance in this era, to be confirmed in manual. Performance Power Output: Estimated 50-60+ HP (stock, varies by specific model year and tuning) Torque: Specific figures detailed in manual, but characteristic of strong mid-range power delivery for motocross. Fuel System Carburetor Model: Likely Keihin FCR (Flat CR, High Performance) - e.g., FCR MX Carburetor Size: Typically 39mm or 41mm for this class of bike Lubrication System Oil Type Specification: Manual will specify API SG or higher, SAE 10W-40 or 15W-50 motorcycle-specific oil. Separate gearbox oil may be specified. Cooling System Type: Liquid-cooled with radiator and fan (electric or engine-driven, depending on year) 🔧 Transmission Standard Type: 5-speed or 6-speed constant mesh sequential gearbox Optional Features: Close-ratio gear sets are common for racing applications, enhancing acceleration. Features Clutch Type: Hydraulically operated, multi-plate wet clutch Fluid Specification Gearbox Oil: Manual will specify type and quantity (often a dedicated gearbox oil or motorcycle engine oil meeting specific JASO standards). 📐 Dimensions Exterior Wheelbase: Approx. 1470-1490 mm (specific value in manual) Seat Height: Approx. 970-985 mm (specific value in manual) Weights Dry Weight: Approx. 100-105 kg (specific value in manual) Fuel Tank Capacity: Approx. 7-9 Liters (specific value in manual) Suspension Travel Front Forks: Approx. 300-320 mm (e.g., WP USD forks) Rear Shock: Approx. 320-340 mm (e.g., WP PDS or linkage-based system) 🛡️ Safety Features Ratings...