This manual covers the 450 SMR Supermoto motorcycle, produced between 2000 and 2007. As a performance-oriented machine built on a robust LC4 engine platform, the 450 SMR is renowned for its power, handling, and track-focused capabilities, appealing to motocross and supermoto enthusiasts. Known for its Austrian engineering heritage, the brand has established a strong reputation in off-road racing, and this model reflects that commitment to performance and durability, offering an exhilarating riding experience for discerning riders. This comprehensive Factory Service Repair Manual provides in-depth, factory-level information essential for the maintenance and repair of your 450 SMR. It includes detailed procedures for engine overhaul, fuel system service, cooling system maintenance, electrical system diagnostics with wiring diagrams, and chassis component repairs. The manual covers scheduled maintenance, troubleshooting common issues with diagnostic flowcharts, and step-by-step disassembly and reassembly instructions for all major components. With hundreds of illustrations and precise specifications, this English-language resource is designed to empower owners and technicians to maintain optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: KTM Model: 450 SMR Model Variant: Supermoto Applicable Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Vehicle Category: Performance Supermoto Motorcycle Target Audience: Motocross and Supermoto Enthusiasts, Performance Riders Competitive Analysis Positioning: High-performance, track-focused motorcycle with road-legal capabilities Key Features Manual Advantage: Provides factory-level diagnostic and repair information, enabling owners to perform complex tasks and reduce labor costs. Manual Value: Authoritative resource for maintaining optimal performance and longevity of the KTM 450 SMR. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download Printability: Fully Printable Digital Features: Searchable Text, Bookmark Navigation 📖 Manual Coverage Systems Covered Engine: Complete Overhaul, Diagnosis, Troubleshooting Fuel System: Carburetor Service, Fuel Filter Replacement Cooling System: Radiator, Hoses, Coolant Specifications Electrical System: Wiring Diagrams, Alternator, Regulator, Ignition System Chassis: Frame, Suspension, Wheels, Brakes Engine Identification: Identification of engine components and serial numbers. General Precautions: Safety guidelines and general workshop practices. Maintenance Checklist: Routine checks and scheduled maintenance tasks. Check And Maintenance: Detailed procedures for inspection and upkeep. Special Tools: Listing and usage of specialized tools required for repairs. Engine Body: Engine casing, cylinders, pistons, connecting rods. Troubleshooting: Problem diagnosis and solutions for common issues. Servicing Specifications: Key measurements, tolerances, and performance parameters. Tightening Torques: Precise torque values for all fasteners. Disassembling And Servicing: Detailed procedures for taking apart and reassembling components. Fuel Filter: Maintenance and replacement of the fuel filter. Alternator: Service and testing of the charging system alternator. Regulator: Service and testing of the voltage regulator. Wiring Diagrams: Comprehensive electrical schematics. Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements Troubleshooting: Diagnostic Flowcharts, Common Faults and Solutions Repair: Step-by-Step Disassembly and Reassembly of all Major Components Tuning: Carburetor Adjustment, Ignition Timing (if applicable) Technical Depth Depth: Comprehensive Factory-Level Detail, Suitable for Professional Technicians and Advanced DIYers Illustrations: Hundreds of detailed illustrations, diagrams, and photos. Instruction Style: Step-by-step, numbered instructions with notes, cautions, and warnings. Diagnostic Guide: Advanced troubleshooting guide for efficient problem diagnosis. Completeness: Covers everything needed to repair, maintain, rebuild, refurbish, or restore the vehicle. 📊 Manual Specifications File Format File Format: PDF PDF Quality: High Resolution Delivery Method: Instant Download Post-Payment Software Requirement: Adobe PDF Reader Portability: Can be burned to CD-ROM ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: Approximately 450cc (Specific displacement may vary slightly by year, e.g., LC4 engine variants) Cooling System: Liquid-cooled Valve Train: SOHC or DOHC (depending on specific LC4 variant, SOHC more common for this era) Performance Horsepower Range: Estimated 50-60+ HP (Stock, may vary with modifications) Fuel System Fuel Delivery: Carburetor (e.g., Keihin FCR, Mikuni VM series depending on year/market) Fuel Type: Unleaded Gasoline (Octane rating specified in manual) 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Clutch Type: Wet Multi-plate Clutch Features Final Drive: Chain Drive 📐 Dimensions Exterior Wheelbase: Refer to manual for specific year; typically around 1480-1500 mm Weights Dry Weight: Refer to manual for specific year; typically around 110-120 kg Fuel Tank Capacity: Refer to manual for specific year; typically around 9-10 Liters 🛡️ Safety Features Ratings Certification: Road-legal (typically Euro 2/3 compliant for later years, depending on market) Active Features Brakes Front: Hydraulic Disc Brake (e.g., Brembo caliper) Brakes Rear: Hydraulic Disc Brake Passive Features Lighting: Headlight, Taillight, Turn Signals (for road-legal variants) 💡 Technology Features Infotainment Instrumentation: Digital or Analog Tachometer, Speedometer, Odometer, Basic Indicator Lights. Driver Assistance ABS: Not typically equipped on this model/era. Connectivity Features: Minimal; focus is on mechanical and performance aspects. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual; typically every 10-15 operating hours or annually for frequent use. Air Filter Cleaning: Frequent cleaning recommended based on operating conditions, particularly dusty environments. Fluid Specifications Engine Oil Type: Specific viscosity and API rating as per manual (e.g., SAE 10W/40, JASO...