KTM 450 SX Engine 2000-2007 Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 94524

Mots clés: 2000 2001 2002 2003 2004 2005 2006 2007 450 SX KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

This Service Repair Manual covers the high-performance motocross motorcycle renowned for its potent 450cc engine and competitive edge in off-road racing. Produced from 2000 through 2007, this model embodies the philosophy of "Ready to Race," delivering exceptional power and rider engagement. Its robust construction and Austrian engineering ensure reliability for demanding off-road conditions, making it a favored choice for enthusiasts and professional racers alike who seek peak performance and durability. This comprehensive manual provides detailed, step-by-step instructions for all aspects of maintenance and repair for this motorcycle. It covers engine disassembly and assembly, diagnostics, routine maintenance procedures, troubleshooting common faults, and component testing, including detailed diagrams and torque specifications. The scope extends to critical systems such as the engine mechanicals, lubrication, cooling, fuel, ignition, exhaust, and electrical systems, ensuring owners and technicians have the necessary information to maintain and restore the vehicle to optimal working condition.

🏷️ Basic Information

Identification

Make:

Model:

450 SX

Engine Variant:

450cc Engine

Model Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Codes

Manual Type:

Service Repair Manual

Manual Format:

👋 Introduction

Market Position

Vehicle Segment:

High-performance Motocross/Off-road Motorcycle

Target Audience:

Enthusiasts, mechanics, racers requiring in-depth engine knowledge

Competitive Analysis

Competitor Models Engine Focus:

Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F

Key Features

Manual Advantage:

Focuses specifically on the intricate details of the 450 SX engine, crucial for optimal performance and longevity.

Vehicle Reputation:

KTM is known for its potent and race-ready off-road motorcycles, emphasizing performance and rider engagement.

📋 Manual Details

Coverage Areas

Engine Disassembly And Assembly:

Complete

Engine Diagnostics:

Comprehensive

Maintenance Procedures:

Detailed

Troubleshooting Guides:

Extensive

Page Count

Estimated Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Cylinder head, valves, camshaft, crankshaft, connecting rod, piston, cylinders

Engine Lubrication:

Oil pump, oil passages, oil filter, oil specifications

Cooling System:

Radiator, water pump, thermostat, coolant specifications

Fuel System:

Carburetor (main, pilot, jetting), fuel lines, fuel filter, fuel pump (if applicable)

Ignition System:

Spark plug, ignition coil, CDI unit, timing

Exhaust System:

Muffler, header pipe, gaskets

Engine Electrical:

Starter motor, stator, flywheel, wiring diagrams

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, air filter cleaning, spark plug inspection/replacement

Engine Rebuild:

Top-end rebuild, bottom-end rebuild, complete engine overhaul

Troubleshooting Common Faults:

Starting issues, misfires, overheating, power loss

Component Testing:

Carburetor adjustment, ignition timing checks, compression testing

Torque Specifications:

All critical engine fasteners

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine rebuilds)

Detail Level:

Step-by-step instructions with detailed diagrams and illustrations

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (Text-searchable)

Print Quality

Printability:

High-quality, printable pages

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke

Displacement:

Approximately 449.3 cc (varies slightly by year)

Bore X Stroke:

Typically around 95.0 mm x 63.4 mm

Compression Ratio:

Generally around 12.5:1 to 13.5:1

Performance

Horsepower Estimated:

50+ HP (at the crank)

Torque Estimated:

Around 35-40 lb-ft

Fuel System

Carburetor Type:

Keihin FCR MX (common, specific model varies)

Fuel Type:

Unleaded Gasoline (91 octane or higher recommended)

Internal Components

Valve Train:

SOHC (Single Overhead Camshaft), 4 valves

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Optional

Optional Transmissions:

N/A (standard for this model)

Features

Clutch Type:

Wet multi-plate clutch

📐 Dimensions

Exterior

Wheelbase:

Approx. 1480 mm (58.3 inches)

Weights

Dry Weight:

Approx. 105 kg (231 lbs)

Fuel Tank Capacity:

Approx. 7.0 - 8.0 Liters (1.8 - 2.1 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motocross/Off-road competition vehicle, not street legal, not crash tested by standard automotive bodies)

Active Features

Braking System:

Hydraulic disc brakes (front and rear)

Passive Features

Suspension:

WP Suspension components (high-performance, adjustable)

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Basic motocross bike, focused on performance not amenities)

Driver Assistance

Rider Assistance:

N/A (No electronic rider aids typically found on these models)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of riding or as per manual recommendation (severe use).

Air Filter Cleaning:

After every few rides, depending on conditions.

Spark Plug Check:

Every 20-30 hours of riding.

Fluid Specifications

Engine Oil Type:

High-quality synthetic 4-stroke motorcycle oil (e.g., Motorex Power Synt 4T 10W/50 or equivalent).

Engine Oil Capacity:

Approximately 1.1 - 1.3 Liters (depending on filter change and engine state).

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M5.0).

Known Issues

Common Wear Items:

Piston rings, valve seals, clutch plates, spark plug, air filter.

Potential Faults:

Carburetor jetting issues, overheating if cooling system is not maintained, premature wear if oil changes are neglected.

Preventative Maintenance

Importance Of Intervals:

Strict adherence to service intervals is critical for the longevity and performance of high-strung motocross engines.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is a leading manufacturer of off-road motorcycles, known for its 'Ready to Race' philosophy.

Model Evolution

Generation Context:

This generation of the 450 SX represents KTM's commitment to powerful, competitive motocross machines.

Production

Manufacturing Origin:

Austria

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM 450 SX models have consistently been competitive in professional motocross and supercross racing throughout their production years.