KTM 450 SMR Engine 2000-2007 Service Repair Manual

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This manual covers the motorcycle, produced between the years 2000 and 2007. The 450 SMR is a high-performance Supermoto machine, built upon a renowned motorsports heritage. It features a potent...

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Type: Motorcycle

Vendor:

Sku: 94523

Tags: 2000 2001 2002 2003 2004 2005 2006 2007 450 SMR Engine KTM Misc Motorcycle Motorcycles

Product variants

Description

This manual covers the motorcycle, produced between the years 2000 and 2007. The 450 SMR is a high-performance Supermoto machine, built upon a renowned motorsports heritage. It features a potent single-cylinder, 4-stroke, liquid-cooled engine with a displacement of approximately 449cc, delivering an impressive horsepower range of 50-60 HP. This model is characterized by its robust chromium-molybdenum steel trellis frame, advanced suspension components for both front and rear, and powerful hydraulic disc braking systems. The 450 SMR is engineered for demanding track use and spirited riding, embodying a commitment to performance and a racing DNA. This comprehensive Service Repair Manual is designed for owners and independent motorcycle technicians. It provides detailed guidance for maintaining and repairing the vehicle, covering a wide array of systems including engine mechanicals, fuel, ignition, cooling, lubrication, exhaust, and electrical systems. The manual details routine maintenance procedures, such as oil changes and valve clearance checks, alongside in-depth engine rebuild instructions and troubleshooting diagnostics. With approximately 300-400 pages of information presented in English, this text-searchable and printable manual offers essential technical data to ensure optimal performance and longevity of your 450 SMR.

🏷️ Basic Information

Identification

Make:

Model:

450 SMR

Engine Variant:

450 SMR Engine

Codes

Product Code:

Engine Code Range:

2000-2007

👋 Introduction

Market Position

Target Audience:

KTM 450 SMR owners and independent motorcycle technicians

Primary Use:

Performance motorcycle maintenance and repair

Competitive Analysis

Value Proposition:

Provides essential technical data for DIY repairs and professional servicing, saving costs compared to dealership service

Key Features

Manual Format:

Digital PDF for easy access and search

Content Scope:

Focuses specifically on the engine for enhanced detail

📋 Manual Details

Coverage Areas

Vehicle Years Covered:

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

Page Count

Estimated Page Count:

300-400

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, and overhaul

Fuel System:

Carburetor (Mikuni/Keihin variants) tuning, inspection, and overhaul

Ignition System:

CDI, ignition timing, coil testing, spark plug specifications

Cooling System:

Radiator, fan, thermostat, coolant flow, and bleeding procedures

Lubrication System:

Oil pump, oil filter, oil passages, lubrication schedules

Exhaust System:

Muffler, header pipe inspection and maintenance

Electrical System:

Wiring diagrams, starter motor, charging system (stator/rotor)

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, valve clearance checks, spark plug replacement

Troubleshooting:

Diagnostic charts, common fault identification, and solutions

Engine Rebuild:

Piston, rings, cylinder, crankshaft, connecting rod, and bearing replacement

Component Replacement:

Detailed steps for replacing specific engine components

Calibration Adjustment:

Carburetor jetting, ignition timing adjustments

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine rebuilds and diagnostics

📊 Manual Specifications

File Format

File Type:

Digital PDF

Searchability:

Text-searchable for quick information retrieval

Printability:

Printable pages for workshop use

Print Quality

Image Resolution:

High-resolution diagrams and images

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper Quality:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, Liquid-cooled

Displacement:

Approximately 449cc (specific to model year variations)

Bore X Stroke:

Typically around 95mm x 63.4mm (check specific model year)

Compression Ratio:

Varies by year, often in the range of 11.0:1 to 12.5:1

Performance

Horsepower Approximate:

50-60 HP (crankshaft, depending on tuning and year)

Torque Approximate:

40-45 Nm (crankshaft, depending on tuning and year)

Fuel System

Carburetor Type:

Mikuni VM/TM or Keihin FCR series (specific model varies)

Fuel Grade Recommendation:

Unleaded gasoline with an octane rating of 91 or higher (RON+MON/2)

Fuel Delivery:

Carburetor with accelerator pump (common on SMR models)

Internal Components

Valve Train:

DOHC, 4 valves per cylinder

Camshaft Timing:

Detailed specifications provided in the manual

Piston Ring Gap:

Specific clearances for new and worn rings detailed

🔧 Transmission

Standard

Transmission Type:

5-speed or 6-speed constant mesh sequential gearbox

Clutch Type:

Hydraulically operated multi-plate wet clutch

Features

Gear Ratios:

Specific ratios for each gear provided in the manual

Final Drive:

O-ring sealed chain drive (specific sprocket sizes and chain pitch provided)

Transmission Oil Type:

API GL-4, SAE 10W/40 or 15W/50 motorcycle-specific transmission oil

Transmission Oil Capacity:

Approximately 0.7 - 0.9 liters (check specific model year and engine configuration)

📐 Dimensions

Exterior

Wheelbase:

Typically around 1470-1480 mm

Seat Height:

Typically around 900-930 mm

Weights

Dry Weight:

Approximately 110-115 kg (without fuel)

Curb Weight:

Approximately 118-125 kg (with all fluids)

🛡️ Safety Features

Ratings

Crash Safety:

N/A (Motorcycle - individual component safety focus)

Active Features

Braking System Front:

Hydraulic disc brake, typically 320mm disc with 4-piston radial caliper

Braking System Rear:

Hydraulic disc brake, typically 220mm disc with 1-piston caliper

Passive Features

Frame Type:

Chromium-molybdenum steel trellis frame

Suspension Front:

Upside-down telescopic fork (WP Suspension), adjustable compression and rebound damping

Suspension Rear:

Monoshock (WP Suspension), adjustable preload, compression, and rebound damping

💡 Technology Features

Infotainment

Infotainment System:

N/A (Race-focused motorcycle, no infotainment system)

Driver Assistance

Traction Control:

Typically not equipped on models from this era

Connectivity

Connectivity Features:

N/A (Race-focused motorcycle)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 10-15 riding hours or annually

Air Filter Cleaning:

Every 5-10 riding hours, or as needed based on conditions

Valve Clearance Check:

Every 20-30 riding hours or annually

Spark Plug Replacement:

Every 15-25 riding hours or as required

Fluid Specifications

Engine Oil Specification:

SAE 10W/40 or 15W/50, API SG or higher, JASO MA certified motorcycle oil

Coolant Type:

Ethylene glycol based coolant, 50% mixture with distilled water

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, fork seals, wheel bearings

Carburetor Tuning Sensitivity:

Can be sensitive to altitude and temperature changes, requiring periodic re-jetting or adjustment

Valve Seat Wear:

Can occur with high mileage and aggressive use, requiring valve seat grinding or replacement

📚 Vehicle History

Brand Heritage

Ktm Motorsport Focus:

KTM is renowned for its off-road and motorsports heritage, with a strong emphasis on performance and racing DNA.

Model Evolution

Smr Development:

The SMR line represents KTM's dedication to Supermoto racing, translating performance-oriented off-road technology to the tarmac.

Production

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM 450 SMR models have a strong history of success in Supermoto racing championships globally, testament to their performance and reliability.