Model Variant:
SXS (Factory Racing/Competition)
Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Vehicle Type:
Motocross Competition Motorcycle
Market Segment:
Professional Motocross Competition (Pro-Level)
Intended User:
Factory race teams, professional mechanics, highly skilled privateer racers
Key Competitors:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F
Vehicle Focus:
High-performance, lightweight, competition-tuned motocross machine
Manual Purpose:
Enable detailed maintenance, repair, and tuning for peak performance
Engine System:
Complete overhaul, tuning, carburation, ignition, cooling, lubrication
Transmission System:
Clutch, gearbox, shift mechanism, lubrication
Chassis System:
Frame, subframe, swingarm, linkages, bearings
Suspension System:
Front fork (WP USD), rear shock absorber (WP Monoshock), seals, oil levels, adjustments, rebuild procedures
Braking System:
Hydraulic front and rear brakes (Brembo components common), master cylinders, calipers, pads, fluid specifications, bleeding
Fuel System:
Carburetor (e.g., Keihin FCR), fuel tank, fuel lines, filter
Electrical System:
Ignition system, CDI unit, stator, wiring diagrams, battery (if applicable), kill switch
Cooling System:
Radiators, hoses, coolant type, fluid capacity
Exhaust System:
Header pipe, muffler, repack procedures (if applicable)
Wheel And Tire System:
Spoke tension, rim types, tire pressures, wheel bearing maintenance
Maintenance Procedures:
Regular servicing, oil changes, filter replacements, chain adjustment, valve clearance checks
Repair Procedures:
Engine rebuild, gearbox overhaul, suspension fork and shock rebuild, brake caliper service, wheel bearing replacement
Troubleshooting Guides:
Diagnostic charts for common performance issues, starting problems, electrical faults
Technical Data Tables:
Torque specifications, clearances, fluid capacities, specifications for critical components
Depth Of Coverage:
Comprehensive (suitable for experienced mechanics and dedicated enthusiasts)
Diagnostic Capabilities:
Detailed fault finding procedures, likely without electronic diagnostic tools due to era and type
Rebuild Instructions:
Full disassembly, inspection, repair, and reassembly guidance for major components
Engine Type:
Four-stroke, single-cylinder
Engine Displacement:
449.3 cc (approximate, may vary slightly by year)
Bore X Stroke:
Approx. 95 mm x 63.4 mm (check specific year for precise figures)
Valvetrain:
SOHC, 4 valves
Cooling System:
Liquid-cooled
Horsepower:
Estimated 50+ HP (at crankshaft, stock tune)
Torque:
Significant mid-range and top-end power delivery (specific figures vary)
Fuel Delivery:
Carbureted (typically Keihin FCR 39mm or similar)
Engine Oil Capacity:
Approx. 1.1 - 1.3 liters (check specific manual for exact amount and procedure)
Recommended Engine Oil:
High-quality, motorcycle-specific 4-stroke engine oil (e.g., Motorex, Bel-Ray) with appropriate viscosity (e.g., 10W-40, 15W-50)
Infotainment System:
N/A (Pure Competition Motorcycle)
Driver Assistance Features:
N/A (Pure Competition Motorcycle)
Connectivity Features:
N/A (Pure Competition Motorcycle)
Suspension Technology:
High-quality WP suspension components, featuring advanced damping and adjustability
Engine Management:
Carburetor tuning and ignition mapping are critical for performance optimization.
Oil Change Interval:
Every 10-15 hours of riding (competition use) or annually, whichever comes first (refer to manual for specific recommendations)
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions
Spark Plug Check:
Every 20-30 hours of riding
Valve Clearance Check:
Every 30-40 hours of riding, or as per manual recommendation
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for specific recommendation)
Coolant Type:
Ethylene glycol-based coolant (e.g., Motorex Coolant M3.0) mixed with distilled water
Common Wear Items:
Clutch plates, piston rings, valve seats, suspension seals, wheel bearings, chain and sprockets
Typical Race Maintenance:
Regular piston/ring replacement, valve jobs, suspension service are common for high-hour competition use.
Brand Specialty:
KTM is renowned for its off-road racing heritage and performance-oriented motorcycles
Sxs Designation:
SXS typically denotes factory 'works' or 'special edition' competition models, offering higher specifications than standard SX models.
Engine Development:
This era saw significant advancements in 4-stroke motocross engine technology, with KTM being at the forefront.
Manufacturing Location:
Austria (KTM Sportmotorcycle AG)
