Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Vehicle Type:
Motocross Motorcycle
Chassis Codes:
Likely to vary by year, but common for this era's SX models would include references like 'EXC' or specific model year identifiers within VIN
Engine Codes:
Varied based on specific engine updates throughout the model run, but generally a 450cc single-cylinder design.
Market Position:
The KTM 450 SX of this era was a prominent contender in the professional motocross and supercross racing scene, known for its powerful engine and competitive chassis. This manual targets owners and independent repair shops seeking to maintain and repair these performance-oriented machines.
Competitive Analysis:
Competed against models from Yamaha (YZ450F), Honda (CRF450R), Suzuki (RM-Z450), and Kawasaki (KX450F) during this period. The KTM 450 SX was often recognized for its strong engine performance and agile handling.
Key Features:
Comprehensive repair and maintenance coverage, vehicle-specific information (not generic), detailed diagrams and illustrations, troubleshooting guides, torque specifications, electrical schematics, printable format for workshop use, accessible for DIY enthusiasts and professional mechanics.
Coverage Areas:
Engine Identification, General Precautions, Maintenance Check List, Check and Maintenance, Special Tools, Engine Body, Fuel System, Troubleshooting, Servicing Specifications, Tightening Torques, Disassembling and Servicing, Cooling System, Fuel Filter, Electrical System, Alternator, Regulator. (Implies comprehensive coverage of all mechanical and electrical systems)
Page Count:
Not explicitly stated, but described as 'full service and repair instruction' and 'all major topics are covered complete,' suggesting a substantial document.
Manual Type:
Service Repair Workshop Manual
Systems Covered:
Engine Mechanical (including disassembly, reassembly, internal components), Fuel System (carburetor, fuel delivery, filters), Cooling System (radiators, coolant flow), Electrical System (alternator, regulator, ignition, wiring schematics), Chassis Components, Frame, Suspension (likely front forks and rear shock absorber adjustments/rebuilds), Braking System (hydraulic components), Drivetrain (clutch, gearbox, chain drive), Wheels and Tires, Bodywork, Controls and Cables.
Procedures Included:
Routine Maintenance (oil changes, filter replacements, chain adjustment), Troubleshooting Fault Diagnosis, Component Disassembly and Reassembly, Engine Rebuilds (top-end and bottom-end), Carburetor Tuning and Overhaul, Electrical System Diagnostics and Repair, Suspension Adjustments and Servicing, Brake Bleeding and Pad Replacement, Clutch Operation and Adjustment, Cooling System Maintenance, Torque Specifications for critical fasteners, Use of Special Tools.
Technical Depth:
Comprehensive. Covers everything from basic owner maintenance to in-depth mechanical repairs and diagnostics, suitable for both novice owners and professional mechanics. Includes detailed specifications, diagrams, illustrations, and wiring schematics.
Primary Engine:
4-stroke, single-cylinder
Engine Displacement:
Approximately 449.3 cc (exact may vary slightly by year)
Horsepower Range:
Estimated 50-55 HP (stock, peak, will vary by year and tuning)
Torque Range:
Estimated 30-35 lb-ft (stock, peak, will vary by year)
Fuel System:
Carbureted (typically Keihin FCR series, size may vary by year)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Type:
High-performance 4-stroke motorcycle oil, API SG or higher, JASO MA certified. Specific viscosity (e.g., 10W-40, 10W-50) to be confirmed in manual.
Cooling System:
Liquid-cooled, dual radiators
Ignition System:
Digital CDI (Capacitive Discharge Ignition)
Length:
Varies by year, generally around 2100-2200 mm
Width:
Varies by year, generally around 800-850 mm
Height:
Varies by year, generally around 1200-1250 mm
Dry Weight:
Typically in the range of 100-110 kg (220-240 lbs), without fluids.
Wet Weight:
Significantly higher when filled with oil, coolant, and fuel. Manual will provide exact figures.
Safety Ratings:
N/A (Motorcycles are not typically rated by agencies like NHTSA in the same way as cars).
Active Features:
Powerful hydraulic disc brakes (front and rear), performance-oriented suspension for stability.
Passive Features:
Durable frame construction, rider footpegs for stability, controlled rider ergonomics.
Service Intervals:
Highly dependent on usage (hours of operation, severity of use). Typical intervals include: Oil changes (every 5-15 operating hours), Air filter cleaning/replacement (every 2-5 operating hours), Spark plug inspection/replacement (every 10-20 operating hours), Valve clearance check (every 10-20 operating hours), Chain and sprockets inspection/lubrication (after every ride). Manual will provide detailed schedules.
Engine Oil Capacity:
Approx. 1.1 - 1.3 liters (check manual for exact capacity and fill level)
Coolant Type:
Ethylene glycol based antifreeze, mixed with distilled water (typically 50/50). Manual will specify approved brands/types.
Brake Fluid Type:
DOT 4 or DOT 5.1 high-temperature hydraulic brake fluid (refer to manual for specific recommendation).
Known Issues:
Common issues for this era can include carburetor performance tuning, clutch wear, and occasional electrical gremlins if not maintained. Overheating can occur if cooling system is not properly maintained. Piston and ring wear are typical wear items on high-performance 4-stroke engines that are ridden hard.
Common Replacement Parts:
Piston and rings, clutch plates, spark plugs, air filters, oil filters, brake pads, wheel bearings, steering head bearings, linkage bearings, tires.
Brand Heritage:
KTM, founded in 1934 in Austria, has a strong heritage in off-road motorcycling, particularly motocross and enduro racing. Known for its 'Ready to Race' philosophy.
Model Evolution:
The 450 SX was a significant model in KTM's motocross lineup, evolving through various engine updates, suspension improvements, and chassis refinements during the 2000-2007 period, including the transition from earlier LC4-based engines to more modern designs.
Production Location:
Austria
