Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Category:
High-performance Motocross/Off-Road Competition
Competitors:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F
Vehicle Focus:
Competition-oriented, lightweight, powerful, agile handling
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
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
Depth:
Comprehensive, covering from basic maintenance to full engine rebuilds and diagnostics
Engine Type:
4-Stroke, Single Cylinder
Displacement:
Approx. 449cc (specific variants may exist)
Horsepower:
Estimated 50-55 HP (at crank, depending on year/tuning)
Torque:
Estimated 40-45 Nm (at crank, depending on year/tuning)
Carburetor Type:
Keihin FCR (Flat CR-type), specific sizes vary by year (e.g., 39mm, 41mm)
Fuel Type:
Unleaded Gasoline (95-98 RON)
System:
Semi-Dry Sump (often with separate oil reservoirs for engine and gearbox)
Features:
N/A (Performance motocross bike, no infotainment system)
Features:
N/A (Performance motocross bike, no driver assistance systems)
Features:
N/A (Performance motocross bike, no connectivity features)
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.
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).
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.
Heritage:
KTM is renowned for its off-road racing pedigree, particularly in motocross and enduro.
Evolution:
The 450 SXS (Supercross/Supermotard) represents KTM's dedicated effort in the 450cc class, evolving with chassis updates, engine refinements, and suspension improvements throughout its production run.
Manufacturing Location:
Austria (KTM AG)
