Model Variant:
Competition/Factory Edition
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Vehicle Type:
Off-road Motorcycle (Motocross/Enduro)
Vehicle Segment:
High-performance off-road racing motorcycle, designed for competitive motocross and supercross events.
Comparable Models:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F (though SXS is often a factory/special build).
Performance Focus:
Engineered for maximum power output, agility, and responsiveness in demanding racing conditions.
Factory Racing:
Often represents KTM's factory racing development or enhanced production models.
Manual Value:
Essential for owners and technicians to maintain and repair this specialized off-road machine.
Engine Systems:
Engine disassembly, assembly, tuning, carburetion, cooling system, lubrication, piston, cylinder, crankshaft, valve train, performance tuning.
Transmission Drivetrain:
Gearbox, clutch, chain drive, shift mechanism, internal gearbox components.
Suspension:
Front fork (WP USD), rear shock absorber (WP Monoshock), linkage systems, seals, damping adjustments, maintenance.
Brakes:
Front and rear hydraulic disc brakes, brake caliper maintenance, master cylinder, brake fluid, bleeding procedures, pad replacement.
Electrical System:
Ignition system, wiring diagrams, lighting, charging system (if applicable), troubleshooting electrical faults.
Chassis Bodywork:
Frame, subframe, handlebars, footpegs, seat, fuel tank, plastic body panels, exhaust system, wheels, tires.
Maintenance Procedures:
Routine maintenance, lubrication points, filter changes, chain adjustment, bolt torquing, pre-ride inspections.
Troubleshooting:
Diagnostic procedures for common issues, fault finding, error codes (if applicable).
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly.
Adjustment Procedures:
Carburetor adjustment, suspension settings, clutch lever adjustment, throttle cable adjustment.
Special Tool Usage:
Identification and usage of specific KTM special tools required for certain repair operations.
Diagnostic Capability:
Detailed troubleshooting guides to identify and resolve mechanical and electrical issues.
Rebuild Capability:
Comprehensive instructions for complete engine and transmission rebuilds.
Specification Data:
Precise technical specifications, tolerances, wear limits, and tightening torques for all components.
Illustrations Diagrams:
Detailed pictorial diagrams, exploded views, and photographs to guide repairs.
Engine Type:
4-stroke, single-cylinder
Engine Displacement:
Approximately 540cc (exact displacement may vary slightly based on specific SXS model year and configurations).
Bore X Stroke:
Specific values will be detailed within the manual; typically a larger bore for the 540cc designation.
Cooling System:
Liquid-cooled
Horsepower Output:
Significantly higher than standard models, likely exceeding 50-55 HP, optimized for racing.
Torque Output:
Strong mid-range and top-end torque, optimized for acceleration out of corners and jumps.
Fuel Delivery:
Carburetor (likely Keihin or similar high-performance carburetor, specific model documented in manual).
Ignition System:
Digital electronic ignition system.
Oil Change Interval:
Frequent oil changes recommended for racing use; typically every 10-15 hours of operation or as specified in manual.
Air Filter Cleaning:
Regular cleaning or replacement, especially in dusty conditions, often before every or every other ride.
Spark Plug Replacement:
Intervals depend on usage, but often checked and replaced proactively for racing performance.
Engine Oil Type:
Specific viscosity (e.g., 10W-40 or 10W-50) and API rating (e.g., SJ or higher) for 4-stroke off-road motorcycles. Manual specifies exact grade and capacity.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives. Manual specifies type and mixture ratio.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual specifies type and replacement interval.
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, chain and sprockets, fork seals are common wear items in racing applications.
Carburetor Tuning:
Carburetor jetting can be sensitive to altitude and temperature, requiring periodic adjustments.
Suspension Maintenance:
Regular fork and shock service (oil changes, seal replacement) is critical for maintaining optimal performance.
