🏷️ Basic Information

Make:

KTM

Model:

450 SX Racing

Model Years:

2000, 2001, 2002, 2003

Vehicle Type:

Motocross Motorcycle

Vin Prefix:

N/A (Motorcycle VIN structure differs)

👋 Introduction

Market Segment:

Professional Motocross Competition

Key Competitors:

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

Factory Specifications:

Provides exact factory-set specifications and procedures for optimal performance.

Diagnostic Tools:

Aids in understanding and utilizing diagnostic procedures for troubleshooting.

Owner Benefit:

Empowers owners and technicians to perform maintenance and repairs accurately and efficiently.

📋 Manual Details

Systems Covered:

Engine, Transmission, Chassis, Suspension (Front & Rear), Brakes (Front & Rear), Fuel System, Cooling System, Electrical System, Ignition System, Exhaust System, Wheels, Tires, Bodywork, Troubleshooting, Specifications

Total Pages:

Hundreds (Specific number not provided in product info, but implies comprehensive content)

Type:

Factory Service Repair Manual

Language:

English (Presumed, typical for KTM factory manuals)

Format:

PDF Download

📖 Manual Coverage

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures.

Transmission Service:

Gearbox inspection, maintenance, and repair, including clutch service.

Suspension Tuning:

Detailed procedures for front fork (WP) and rear shock absorber maintenance, adjustment, and rebuilding.

Brake Maintenance:

Hydraulic brake system service, including bleeding, pad replacement, caliper and master cylinder repair.

Electrical Diagnostics:

Wiring diagrams, troubleshooting guides for lighting, ignition, and charging systems.

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service.

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common mechanical and electrical issues.

Rebuild Procedures:

Comprehensive instructions for rebuilding major components like the engine and suspension.

Torque Specifications:

Essential torque values for all critical fasteners throughout the motorcycle.

Depth:

Comprehensive, covering everything from basic checks to full engine rebuilds and electrical diagnostics.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Searchable:

Likely searchable (standard for professionally produced PDFs)

Printability:

Printable (as stated in product description)

Binding:

N/A (Digital Download - typically printed by user)

Paper Type:

N/A (Digital Download - typically printed on standard paper)

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 4-stroke

Displacement:

Approximately 449cc (exact for specific sub-models may vary, but this is the general designation)

Bore X Stroke:

Refer to manual for exact specifications (typically around 95mm x 63.4mm for this era)

Cooling System:

Liquid-cooled

Horsepower:

Estimated 50+ HP (at crank, model dependent)

Torque:

Refer to manual for exact specifications

Fuel Delivery:

Carburetor (likely Keihin or Mikuni, specific model in manual)

Fuel Type:

Unleaded gasoline (minimum 95 RON / 91 AKI)

Ignition Type:

Digital CDI

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet multi-plate

Gear Ratios:

Specific ratios detailed in manual

Final Drive:

Chain drive

📐 Dimensions

Length:

Refer to manual for exact specifications

Width:

Refer to manual for exact specifications

Height:

Refer to manual for exact specifications

Dry Weight:

Approximately 105-110 kg (231-242 lbs) depending on model year and specific components

Wet Weight:

Refer to manual for exact specifications

Front Wheel Size:

21 inches

Rear Wheel Size:

19 inches

Front Tire Size:

Typically 80/100-21

Rear Tire Size:

Typically 110/90-19

Wheel Bolt Pattern:

N/A (Spoke wheels with axle nuts)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not subject to standard automotive crash testing)

Braking System:

Hydraulic disc brakes, front and rear

Frame Construction:

Chromoly steel trellis frame

💡 Technology Features

Infotainment System:

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

Electronic Aids:

N/A (No electronic rider aids like traction control or ABS in this era)

Connectivity Features:

N/A

🔧 Maintenance

Engine Oil Change:

Every 10-15 hours of riding (or as specified in manual)

Air Filter Cleaning:

After every ride or as needed in dusty conditions

Spark Plug Replacement:

Refer to manual, typically every 30-40 hours

Engine Oil Type:

Refer to manual (typically SAE 10W-40, JASO MA certified synthetic)

Transmission Oil Type:

Refer to manual (often shares engine oil or uses specific gear oil)

Coolant Type:

Ethylene glycol-based coolant mixture (50/50 with distilled water)

Brake Fluid Type:

DOT 4 hydraulic fluid

Common Wear Items:

Piston rings, valve guides, clutch plates, chain and sprockets, wheel bearings.

Performance Tuning:

Early 4-strokes required diligent maintenance to maintain peak performance, especially regarding valve adjustments and top-end rebuilds.

📚 Vehicle History

Brand Focus:

KTM is renowned for its off-road racing pedigree and performance-oriented motorcycles.

Early 450S:

The 450 SX Racing models from this era represented KTM's continued development in the highly competitive 4-stroke motocross class, evolving from their earlier 400 and 520/525 models.

Manufacturing Origin:

Austria

🏆 Awards & Recognition

Motocross Wins:

KTM models of this era were highly competitive and likely achieved numerous victories in regional and national motocross events, though specific awards for these model years are not readily available as general consumer ratings.