The 2012 KTM 450 SX-F Factory Replica is a high-performance motocross motorcycle engineered for competitive racing. Building on KTM's strong motorsports heritage, this model represents a pinnacle of off-road engineering, featuring a potent 449.3 cc LC4 engine with electronic fuel injection and a robust chromium-molybdenum steel trellis frame. Known for its exceptional power-to-weight ratio and agile handling, the Factory Replica trim highlights performance upgrades and components often found on factory race bikes, making it a formidable machine for demanding motocross circuits. This comprehensive workshop service repair manual, written in English, provides in-depth technical information for the 2012 KTM 450 SX-F Factory Replica. It covers all major systems, including the engine, transmission, fuel, electrical, suspension, and braking systems, offering detailed procedures for maintenance, troubleshooting, repair, and component rebuilds. With step-by-step instructions, detailed diagrams, and essential specifications, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair this specialized motocross machine to peak performance. 🏷️ Basic Information Identification Make: KTM Model: 450 SX-F Factory Replica Year: 2012 Vehicle Type: Motorcycle Motorcycle Segment: Motocross Codes Engine Code Prefix: LC4 Chassis Code: SX-F 👋 Introduction Market Position Segment Focus: High-performance motocross racing Target Audience: Motocross racers, performance enthusiasts, mechanics Competitive Analysis Competitors: Yamaha YZ450F, Honda CRF450R, Kawasaki KX450F, Suzuki RM-Z450 Key Features Factory Replica Distinction: Highlights performance upgrades and specific components found on factory race bikes Diagnostic Emphasis: Focus on identifying and rectifying performance-related issues 📋 Manual Details Coverage Areas Geographic Coverage: Global (primarily Europe and North America) Vehicle Variant Coverage: Factory Replica trim Page Count Estimated Page Count: 300+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, and overhaul Transmission: Gearbox, clutch, shifting mechanisms Fuel System: Fuel injection system (EFI), throttle body, fuel pump, injectors Electrical System: Ignition system, charging system, lighting, ECU, wiring diagrams Suspension: Front forks (WP), rear shock absorber (WP), linkages Brakes: Front and rear brake systems, master cylinders, calipers, discs, fluid bleeding Chassis And Frame: Frame, subframe, swingarm, steering head bearings Cooling System: Radiator, hoses, water pump Exhaust System: Muffler, header pipe Bodywork And Plastics: Fairings, seat, fuel tank, fenders Procedures Included Maintenance: Regular service, oil changes, filter replacements, chain adjustment, spark plug replacement Troubleshooting: Diagnostic procedures for common and uncommon issues Repair: Component-level repair and replacement for all major systems Rebuilds: Engine and suspension component rebuild procedures Specifications: Torque specifications, clearances, fluid capacities, electrical values Technical Depth Depth: Comprehensive; suitable for professional mechanics and experienced DIY enthusiasts Detail Level: Step-by-step instructions with detailed diagrams and illustrations 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text Print Quality Resolution: High-resolution scans suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, SOHC, LC4 engine Displacement: 449.3 cc Bore X Stroke: 97 mm x 60.8 mm Compression Ratio: 12.5:1 Cooling System: Liquid-cooled Performance Estimated Horsepower: Approx. 54-56 HP (stock) Estimated Torque: Approx. 32-34 lb-ft (stock) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Keihin 44mm throttle body Fuel Type: Unleaded gasoline, minimum 95 octane Oil Specifications Engine Oil Type: High-performance synthetic motorcycle oil (e.g., Motorex Power Synth 4T 10W/50) Oil Capacity W Filter: 1.1 Liters (1.2 US qt) 🔧 Transmission Standard Type: 5-speed constant mesh gearbox Clutch Type: Wet multi-disc clutch (hydraulically operated) Features Shift Pattern: 1-N-2-3-4-5 Transmission Oil Type: High-performance synthetic motorcycle gear oil (e.g., Motorex Gear Oil 75W/90) Transmission Oil Capacity: 0.8 Liters (0.85 US qt) 📐 Dimensions Exterior Length: Approx. 2170 mm (85.4 in) Width Handlebar: Approx. 815 mm (32.1 in) Height Seat: Approx. 970 mm (38.2 in) Ground Clearance: Approx. 357 mm (14.05 in) Weights Dry Weight: Approx. 104.5 kg (230.4 lbs) Fuel Tank Capacity: 7.0 Liters (1.85 US gal) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle segment does not have standardized crash test ratings like automobiles) Active Features Braking System: Hydraulic disc brakes (Brembo calipers front and rear) Front Brake Disc Size: 260 mm Rear Brake Disc Size: 220 mm Passive Features Frame Construction: Chromium-molybdenum steel trellis frame Handlebars: Renthal tapered aluminum handlebar 💡 Technology Features Infotainment Display: Basic LCD display (speed, trip meter, clock) Driver Assistance Traction Control: N/A (Race-focused machine) Launch Control: N/A (Race-focused machine) Connectivity Bluetooth: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 15-20 hours of operation (racing conditions) or annually Air Filter Cleaning: After every few rides, especially in dusty conditions Spark Plug Replacement: Every 30-50 hours of operation Valve Clearance Check: Every 20-30 hours of operation Chain Lubrication And Adjustment: Regularly (before or after every ride) Fluid Specifications Coolant Type: Ethylene glycol based coolant (e.g., Motorex Coolant M3.0) Brake Fluid Type: DOT 4 brake fluid Known Issues Common Wear Items: Clutch plates, piston rings,...