The 450 SXS-F is a high-performance motocross motorcycle designed for competitive racing and serious off-road enthusiasts. Produced for the 2005, 2006, and 2007 model years, this Austrian-engineered machine embodies the 'Ready to Race' philosophy, often featuring factory race modifications for enhanced performance. Key attributes include a potent 450cc single-cylinder, four-stroke engine with SOHC and four valves, paired with a 5-speed transmission and a hydraulically operated wet multi-disc clutch. Its robust chassis, typically a chromoly steel trellis frame, is complemented by high-quality WP Suspension components, both front and rear, ensuring exceptional handling and control on demanding tracks. The 450 SXS-F is built for speed and agility, making it a formidable competitor in its class. This workshop repair service manual provides comprehensive guidance for the maintenance, repair, and overhaul of the 450 SXS-F models from 2005 to 2007. It covers all essential systems, including detailed procedures for the engine, transmission, chassis, brakes, fuel system, exhaust, cooling system, and electrical components. The manual includes essential information on general maintenance, engine rebuilds, suspension servicing, carburetor tuning, and troubleshooting common issues. Technicians will find detailed specifications, torque values, clearances, and exploded views with illustrations crucial for accurate diagnostics and repairs. This resource is invaluable for owners and mechanics seeking to maintain the peak performance and reliability of their 450 SXS-F. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS-F Year: 2005, 2006, 2007 Vehicle Type: Motocross Motorcycle Codes Chassis Codes 2005: Likely derived from VIN sequence, specific to model year Chassis Codes 2006: Likely derived from VIN sequence, specific to model year Chassis Codes 2007: Likely derived from VIN sequence, specific to model year 👋 Introduction Market Position Segment: High-performance motocross racing motorcycle Target Audience: Motocross racers, serious off-road enthusiasts, mechanics specializing in KTM race bikes Competitive Analysis Competitors: Honda CRF450R, Yamaha YZ450F, Kawasaki KX450F, Suzuki RM-Z450 Key Features Engine Configuration: 450cc, single-cylinder, four-stroke, SOHC Suspension Brand: High-quality WP Suspension components Racing Focus: Designed for competitive motocross racing, often with specific 'SXS' factory race modifications 📋 Manual Details Coverage Areas Primary Coverage: Repair and overhaul of KTM 450 SXS-F models 2005-2007 Technician Prerequisites: Assumes technician is fully conversant with general automobile practices Page Count Estimated Page Count: Typically 300-500 pages for a comprehensive workshop manual, exact count not specified Manual Type Type: Workshop Repair Service Manual Language Language: English (common for KTM workshop manuals of this era, but confirmation recommended) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the 450cc four-stroke engine Transmission: Clutch, gearbox, shifting mechanisms, and related components Chassis: Frame, subframe, swingarm, linkages, steering head Suspension Front: Upside-down forks (e.g., WP), internal components, seals, adjustments, service Suspension Rear: Monoshock absorber (e.g., WP), linkage system, shock servicing, adjustments Brakes: Hydraulic brake systems (front and rear calipers, master cylinders, lines, pads, discs) Fuel System: Carburetor (likely Keihin or Mikuni), fuel lines, tank, fuel filter Exhaust System: Exhaust pipe, muffler, heat shields, mounting Cooling System: Radiators, hoses, coolant, water pump Electrical System: Ignition system, stator, flywheel, CDI unit, spark plug, battery (if applicable), lighting (if any), wiring diagrams Wheel And Tire: Wheels, hubs, spokes, bearings, tires, tubes, rim locks Controls: Handlebars, grips, levers (clutch, brake), throttle assembly, footpegs, shifter, brake pedal Bodywork: Plastics (fenders, side panels, number plates), seat, fuel tank cover Procedures Included General Maintenance: Oil changes, filter replacements, chain adjustment, general inspection Engine Rebuild: Piston, rings, cylinder, valve train, crankshaft, bearings, seals Transmission Overhaul: Gearbox disassembly, inspection, replacement of worn parts Suspension Service: Fork seal replacement, oil changes, damper rebuilds, shock absorber servicing Brake System Maintenance: Pad replacement, fluid bleeding, caliper and master cylinder service Carburetor Tuning: Adjustment, cleaning, jetting, float level setting Troubleshooting: Diagnostic procedures for common problems and failures Wiring Diagrams: Electrical system diagnostics and repair Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and chassis overhauls Specifications: Includes torque values, clearances, measurements, fluid capacities Diagrams Illustrations: Detailed exploded views and step-by-step illustrations are expected 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text, crucial for efficient use Print Quality Quality: Digital PDF format allows for high-resolution printing of individual pages or sections Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, single-cylinder, liquid-cooled Displacement: Approximately 449.3 cc Bore X Stroke: Typically around 95 mm x 63.4 mm (exact may vary slightly) Compression Ratio: Likely around 11.5:1 to 12.5:1 (specific to SXS variants) Valve Train: SOHC, 4 valves Performance Horsepower: Estimated 50-55+ HP at peak (subject to specific tuning and SXS factory specs) Torque: Estimated 45-50+ Nm (subject to specific tuning and SXS factory specs) Fuel System Carburetor Type: Keihin FCR 39 MX or similar performance carburetor Fuel Type: Unleaded gasoline (min. 95 RON / 91 AKI) Engine Oil Type: High-performance 4-stroke motorcycle engine oil, SAE 10W-50 or 15W-50,...