Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Model Variant:
SXS Racing (Specific motocross/supercross variant)
Target Audience:
Motocross and Supercross racers, performance tuners, KTM dealerships, and skilled motorcycle mechanics specializing in off-road competition bikes.
Manual Value Proposition:
Provides critical technical data for maintaining and optimizing a high-performance competition machine, directly impacting race readiness and longevity.
Content Focus:
Detailed procedural steps, precise specifications, and diagnostic information specific to the 450 SXS RACING model, crucial for competitive advantage.
Primary Focus:
Workshop Repair and Overhaul
Additional Coverage:
Maintenance, Troubleshooting, Diagnostics, Component Replacement, Assembly
Estimated Pages:
Likely 200-400 pages (typical for comprehensive workshop manuals of this era)
Type:
Workshop Repair Service Manual
Language:
English (assumed, based on product description)
Powertrain:
Engine (including top-end, bottom-end, lubrication, cooling), Transmission (gearbox, clutch, shifting mechanism)
Chassis And Suspension:
Frame, Swingarm, Front Forks (upside-down telescopic), Rear Shock Absorber (monoshock), Linkages
Brakes:
Front and Rear Hydraulic Disc Brakes (caliper, master cylinder, lines, pads)
Controls:
Throttle, Clutch Lever, Brake Lever, Gear Shift Lever, Handlebars
Electrical System:
Ignition System, CDI Unit, Spark Plug, Wiring Diagrams, Lighting (if applicable, though typically minimal on race bikes), Battery (if applicable)
Fuel And Exhaust:
Carburetor (likely Keihin FCR), Fuel Tank, Fuel Lines, Exhaust System
Wheels And Tires:
Spoked Wheels, Tire Mounting/Dismounting, Tube Replacement
Routine Maintenance:
Oil Changes, Air Filter Cleaning/Replacement, Chain Adjustment, Spark Plug Checks, Tire Pressure
Component Overhaul:
Engine Rebuild (piston, rings, valves, crankshaft), Fork Seal Replacement, Shock Absorber Service, Clutch Rebuild, Transmission Disassembly/Reassembly
Troubleshooting:
Diagnostic flowcharts, common problem identification and solutions (e.g., starting issues, performance problems)
Assembly And Disassembly:
Step-by-step instructions for complete disassembly and reassembly of major components and the entire motorcycle
Depth:
Comprehensive, suitable for experienced mechanics and dedicated enthusiasts. Includes detailed torque specifications, clearances, and special tool requirements.
Type:
Single-cylinder, 4-stroke, Liquid-cooled
Displacement:
Approximately 450cc (specific bore x stroke would be detailed in the manual)
Configuration:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) - likely DOHC for performance in this era, to be confirmed in manual.
Power Output:
Estimated 50-60+ HP (stock, varies by specific model year and tuning)
Torque:
Specific figures detailed in manual, but characteristic of strong mid-range power delivery for motocross.
Carburetor Model:
Likely Keihin FCR (Flat CR, High Performance) - e.g., FCR MX
Carburetor Size:
Typically 39mm or 41mm for this class of bike
Oil Type Specification:
Manual will specify API SG or higher, SAE 10W-40 or 15W-50 motorcycle-specific oil. Separate gearbox oil may be specified.
Type:
Liquid-cooled with radiator and fan (electric or engine-driven, depending on year)
Type:
5-speed or 6-speed constant mesh sequential gearbox
Features:
Close-ratio gear sets are common for racing applications, enhancing acceleration.
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Gearbox Oil:
Manual will specify type and quantity (often a dedicated gearbox oil or motorcycle engine oil meeting specific JASO standards).
Wheelbase:
Approx. 1470-1490 mm (specific value in manual)
Seat Height:
Approx. 970-985 mm (specific value in manual)
Dry Weight:
Approx. 100-105 kg (specific value in manual)
Fuel Tank Capacity:
Approx. 7-9 Liters (specific value in manual)
Front Forks:
Approx. 300-320 mm (e.g., WP USD forks)
Rear Shock:
Approx. 320-340 mm (e.g., WP PDS or linkage-based system)
Vehicle Classification:
Competition Off-Road Motorcycle (Not street legal, safety features are performance-oriented).
Braking System:
High-performance hydraulic disc brakes front and rear for superior stopping power.
Suspension And Handling:
Advanced WP suspension systems designed for maximum control and feedback in demanding race conditions.
Frame Construction:
Robust chromoly steel perimeter frame for optimal rigidity and rider feel.
Features:
N/A (Focus is on pure performance, no infotainment systems like navigation or audio).
Features:
N/A (No electronic rider aids like traction control or ABS, as this is a race-prepped machine).
Ignition System:
Digital CDI (Capacitor Discharge Ignition) for precise spark timing.
Engine Oil Change:
Every 10-15 hours of riding or after major race events. Specific interval in manual.
Air Filter Cleaning:
After every few rides or as conditions dictate (dusty environments require more frequent cleaning).
Valve Adjustment:
Typically every 30-50 hours of riding. Critical for performance and engine longevity.
Chain And Sprockets:
Regular inspection for wear and adjustment; replacement based on mileage/hours.
Coolant Type:
Manual will specify a high-quality coolant with anti-corrosion properties, typically a 50/50 mix of distilled water and ethylene glycol coolant.
Brake Fluid:
DOT 4 High-Temperature Brake Fluid
Common Wear Items:
Piston rings, valve guides, clutch plates, wheel bearings, fork seals, shock linkages are typical wear items on competition bikes due to high stress.
Carburetor Tuning:
Requires precise tuning for optimal performance across different altitudes and temperatures; manual provides baseline settings and jetting recommendations.
Ktm Legacy:
KTM has a long-standing reputation in off-road and motorsport, with a strong focus on performance and 'Ready to Race' philosophy.
Sxs Development:
The SXS line represents factory-spec or near-factory-spec racing machines, often incorporating race-developed components and engine tuning beyond standard SX models.
Manufacturing Location:
Primarily Austria (KTM AG Headquarters)
