KTM 450 SMR 2000-2007 Factory Service Repair Manual

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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...

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Taper: Motorcycle

Distributeur:

UGS: 78444

Mots clés: 2000 2001 2002 2003 2004 2005 2006 2007 450 SMR Engines KTM Motorcycle

Variantes de produits

Description

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:

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 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

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 MA).

Coolant Type:

Ethylene Glycol based coolant (e.g., Motorex Coolant M3.0 or equivalent).

Brake Fluid Type:

DOT 4 or DOT 5.1 (Refer to manual for precise specification).

Known Issues

Carburetor Tuning:

Requires periodic adjustment and cleaning for optimal performance, especially if fuel quality varies.

Valve Clearance:

Regular checking and adjustment of valve clearances are critical for engine health.

Electrical Connections:

Vibration can lead to loose electrical connections; periodic inspection recommended.

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM AG (Austria)

Specialty:

Known for off-road and performance motorcycles (Off-road competition success)

Model Evolution

Lc4 Platform:

The 450 SMR is part of KTM's robust LC4 engine platform, known for its torque and durability.

Production

Production Period:

2000-2007

🏆 Awards & Recognition

Recognitions

Brand Reputation:

KTM is widely recognized for its off-road racing pedigree and performance-oriented motorcycles.

Ratings

Review Consensus:

Highly regarded for its power, handling, and capability in supermoto applications during its production years.