This manual covers the 450 SXS, a high-performance competition motocross and Supermoto motorcycle produced between 2000 and 2007. Renowned for its race-bred engineering and potent 450cc single-cylinder engine, the 450 SXS embodies the 'Ready to Race' philosophy. Its design prioritizes lightweight construction, agile handling, and powerful engine performance, making it a formidable machine for motocross racers, Supermoto enthusiasts, and track day participants. The vehicle's robust chromoly steel trellis frame and adjustable suspension components are engineered for demanding competitive use, reflecting a strong heritage in motorsports. This comprehensive Service and Repair Manual provides detailed guidance for the maintenance, diagnosis, and repair of the 450 SXS. It covers all essential systems, including engine mechanicals, fuel and lubrication systems, cooling, ignition, transmission, clutch, chassis, suspension, and brakes. Included are procedures for routine maintenance, major engine repairs, troubleshooting common issues, and detailed technical specifications. This manual is an indispensable resource for owners and technicians, enabling them to efficiently maintain the performance and reliability of their 450 SXS. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS Engine Variant: 450cc Single-Cylinder Codes Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Vehicle Type: Competition Motocross/Supermoto Target Audience: Motocross racers, Supermoto enthusiasts, track day participants, and dedicated KTM owners seeking comprehensive service information. Competitive Analysis Key Competitors Era: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F, Husqvarna FC450 Key Features Vehicle Design Philosophy: Lightweight, high-performance, race-bred engineering focused on power delivery and handling. Manual Value Proposition: Empowers owners and technicians with the knowledge to maintain, diagnose, and repair the KTM 450 SXS engine and related systems efficiently and effectively, reducing reliance on expensive dealer service. 📋 Manual Details Coverage Areas Systems Covered: Engine Mechanical, Engine Fuel System, Engine Lubrication, Engine Cooling, Ignition System, Engine Electrical Components, Clutch, Transmission, Chassis, Suspension (Front & Rear), Brakes (Front & Rear), Wheels & Tires, Frame, Exhaust System, Electrical Wiring Diagrams Page Count Estimated Page Count: 300-400 (estimated based on typical comprehensive service manuals for this era/type of vehicle) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical Rebuild: Complete disassembly, inspection, repair, and reassembly of the 450cc engine, including cylinder head, piston, crankshaft, connecting rod, camshaft, valve train, and timing components. Fuel System Diagnostics: Carburetor (likely Keihin or Mikuni) tuning, cleaning, overhaul, jetting specifications, float bowl adjustment, and troubleshooting of fuel delivery issues. Lubrication System Maintenance: Oil change procedures, oil filter replacement (part numbers), oil type and viscosity recommendations (e.g., Motul 5100 10W-50 or similar high-performance motorcycle oil), oil pump inspection and testing. Cooling System Service: Coolant type (e.g., Motul Motocool Expert), coolant capacity, bleeding procedures, radiator inspection, water pump inspection and seal replacement. Ignition System Troubleshooting: CDI unit testing, spark plug specifications (e.g., NGK CR9EKB or equivalent), ignition timing checks, stator and rotor inspection. Electrical System Diagnostics: Wiring diagrams for lighting, ignition, charging system, and auxiliary components. Troubleshooting starter motor, battery, and charging system issues. Clutch And Transmission Overhaul: Clutch plate replacement, clutch spring tension specifications, transmission gear inspection, shift drum and fork alignment, gearbox oil type and capacity (e.g., SAE 75W/90 or specific motorcycle gearbox oil). Chassis And Suspension Setup: Fork seal replacement, fork oil type and level specifications, rear shock absorber servicing, linkage maintenance, wheel bearing inspection and replacement, steering head bearing adjustment. Brake System Maintenance: Brake pad replacement procedures, brake fluid type (DOT 4), bleeding procedures for hydraulic brakes, caliper and master cylinder overhaul, brake disc inspection. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug checks, general inspection procedures. Major Engine Repairs: Top-end rebuilds (piston, rings, valves), bottom-end rebuilds (crankshaft, bearings), complete engine disassembly and assembly. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon issues across all covered systems, including flowcharts and symptom-based problem solving. Suspension Tuning And Rebuild: Detailed steps for fork and shock absorber disassembly, cleaning, seal replacement, oil changes, and adjustments for optimal performance. Electrical System Repair: Wiring harness repair, component testing (e.g., stator, CDI, regulator/rectifier), battery charging system diagnostics. Torque Specifications: Critical torque values for all fasteners, including engine components, suspension, and chassis. Technical Depth Diagnostics Level: Advanced diagnostics, including electrical system testing, fuel system analysis, and internal engine component evaluation. Repair Scope: Comprehensive repair procedures covering routine maintenance to complete engine and chassis rebuilds. Special Tool Requirements: Identification and usage instructions for specialized tools required for specific repair or diagnostic procedures. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text content for quick information retrieval. Printable: Printable pages for on-site workshop use. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, SOHC (Single Overhead Camshaft)...