The KTM 450 SXS is a high-performance motocross and off-road competition motorcycle, renowned for its powerful 4-stroke, single-cylinder engine, agile handling, and lightweight construction. Produced between 2000 and 2007, this Austrian-engineered machine is designed for demanding racing environments, offering an estimated 50-55 horsepower and exceptional performance on challenging tracks. Its competition-oriented focus is evident in its robust chassis, advanced suspension systems, and race-proven drivetrain, making it a formidable contender against other leading models in its class. This comprehensive English-language service repair workshop manual provides detailed instructions for the maintenance, repair, and overhaul of the KTM 450 SXS models from 2000 to 2007. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with step-by-step guides for disassembly, assembly, and troubleshooting. Essential technical specifications, preventative maintenance schedules, and crucial torque values are also included, empowering owners and technicians to keep this competition machine in optimal condition and ensure its peak performance. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Category: High-performance Motocross/Off-Road Competition Competitive Analysis Competitors: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F Key Features Vehicle Focus: Competition-oriented, lightweight, powerful, agile handling 📋 Manual Details Coverage Areas General Coverage: Comprehensive service, repair, and workshop instructions Page Count Estimated Pages: High (typically 300+ pages for this scope) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, carburetor/fuel injection, cooling system, lubrication Transmission: Clutch, gearbox, shifting mechanisms, maintenance, repair Chassis: Frame, suspension (front forks, rear shock), steering, wheels, bearings Brakes: Hydraulic system, caliper service, pad replacement, fluid bleeding, master cylinder Electrical: Wiring diagrams, ignition system, lighting, battery, starter, ECU troubleshooting Fuel System: Fuel tank, lines, pump, carburetor/injection system service Exhaust System: Muffler, header pipe maintenance and inspection Procedures Included Preventative Maintenance: Regular servicing, inspection points, lubrication schedules Troubleshooting: Diagnostic procedures for common and uncommon issues Repair Instructions: Step-by-step guides for component replacement and repair Disassembly Assembly: Detailed instructions for component removal and installation Torque Specifications: Crucial fastener torque values for critical components Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine rebuilds and diagnostics 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Quality: High-resolution, clear diagrams and text Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Single Cylinder Displacement: Approx. 449cc (specific variants may exist) Performance Horsepower: Estimated 50-55 HP (at crank, depending on year/tuning) Torque: Estimated 40-45 Nm (at crank, depending on year/tuning) Fuel System Carburetor Type: Keihin FCR (Flat CR-type), specific sizes vary by year (e.g., 39mm, 41mm) Fuel Type: Unleaded Gasoline (95-98 RON) Cooling System Type: Liquid-Cooled Lubrication System: Semi-Dry Sump (often with separate oil reservoirs for engine and gearbox) 🔧 Transmission Standard Type: 5-Speed Manual Features Clutch: Hydraulically actuated, multi-plate wet clutch Gear Ratios: Specific ratios detailed within the manual for each model year. 📐 Dimensions Exterior Wheelbase: Approx. 1475 mm (58.1 in) - varies slightly by year Weights Dry Weight: Approx. 104 kg (229 lbs) - varies slightly by year 🛡️ Safety Features Ratings Certification: Off-road competition use only, not street legal 💡 Technology Features Infotainment Features: N/A (Performance motocross bike, no infotainment system) Driver Assistance Features: N/A (Performance motocross bike, no driver assistance systems) Connectivity Features: N/A (Performance motocross bike, no connectivity features) 🔧 Maintenance Service Intervals Oil Change: Every 10-15 hours of riding, or as specified in the manual for specific conditions. Air Filter: Clean/replace as needed, typically after every few riding sessions. Spark Plug: Inspect and gap every 20-30 hours, replace as needed. Valve Clearance: Inspect every 20-30 hours of riding. Fluid Specifications Engine Oil: KTM recommends specific high-quality motorcycle-specific 4-stroke oils (e.g., Motorex Power Synt 4T SAE 10W/40 or equivalent). Check manual for precise viscosity and API ratings. Coolant: Mixture of distilled water and suitable antifreeze (e.g., ethylene glycol-based) with corrosion inhibitors. Refer to manual for specific ratio and type. Brake Fluid: DOT 4 hydraulic brake fluid (ensure compatibility with seals). Gearbox Oil: Often shares oil with the engine, or uses a specific shared oil. Check manual for capacity and type (e.g., Motorex Gear Oil SAE 75W/80). Known Issues Common Wear Items: Clutch plates, wheel bearings, steering head bearings, fork seals, piston rings due to high-performance usage. Carburetor Tuning: Can be sensitive to altitude and temperature changes, requiring periodic re-jetting or adjustment. Cooling System Maintenance: Regular flushing and inspection of hoses and radiator are crucial to prevent overheating. 📚 Vehicle History Brand Heritage Heritage: KTM is renowned for its off-road racing pedigree, particularly in motocross and enduro. Model Evolution Evolution: The 450 SXS (Supercross/Supermotard) represents KTM's dedicated effort in the 450cc class, evolving with chassis updates, engine refinements, and suspension...