This manual covers the 450 SX-F / XC-F and 505 SX-F / XC-F models from the 2008 and 2009 production years. These high-performance off-road motorcycles are engineered for Motocross and Cross-Country racing, featuring powerful 4-stroke, DOHC engines with displacements of approximately 449.3 cc and 504.7 cc, respectively. Known for their 'Ready to Race' philosophy, these motorcycles utilize premium components such as WP Suspension and Brembo hydraulic braking systems, built upon a robust chromium-molybdenum steel frame. Their design emphasizes agility, rider control, and competitive performance, reflecting a strong heritage in off-road motorsport. This comprehensive Factory Service Repair Workshop Manual provides detailed information essential for the maintenance and repair of your motorcycle. It covers all major systems, including engine mechanicals, fuel, ignition, cooling, transmission, chassis, suspension, braking, and electrical systems. The manual includes step-by-step procedures for routine maintenance, troubleshooting, component repair, and complete engine rebuilds, supplemented by hundreds of detailed photos and exploded diagrams. Technical specifications, torque values, fluid capacities, and wiring diagrams are also included, offering professional-grade guidance for owners and technicians to ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 450 SX-F / XC-F, 505 SX-F / XC-F Year: 2008, 2009 Codes Product Code: KTM450505SXF_XCF_0809_SM_DL 👋 Introduction Market Position Vehicle Class: High-performance off-road motorcycles (Motocross and Cross-Country racing) Competitive Analysis Competitors: Yamaha YZ450F, Honda CRF450R, Kawasaki KX450F, Suzuki RM-Z450, Husqvarna FC 450 (though Husqvarna brand was developing around this time). Key Features Engine Type: Single-cylinder, 4-stroke, DOHC Suspension Brand: WP Suspension (known for premium performance components) Chassis Type: Chromium-molybdenum steel frame (often referred to as 'Chromoly') Braking Components: Brembo hydraulic braking system (front and rear), known for superior stopping power and modulation. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Format: Digital Download (PDF) Language: English Accessibility: Downloadable to Computer, Tablet, or Smartphone Licensing: Unlimited Use, No Expiry Date Printing Rights: Printable (Single page or entire manual) Platform Compatibility: Windows and macOS 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, and reassembly including cylinder head, valves, piston, crankshaft, connecting rod, and lubrication system. Fuel System: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, fuel lines, and filter. Ignition System: Ignition coil, spark plug, CDI unit, stator, and wiring. Cooling System: Radiator, cooling fan, coolant hoses, water pump, and thermostat. Transmission: Gearbox disassembly, inspection, and reassembly, shift mechanism, clutch components (plates, springs, basket, hub). Chassis Frame: Frame inspection, sub-frame, steering head, and bearings. Suspension Front: Front forks (WP), damping adjustments, seals, oil levels, and spring rates. Suspension Rear: Rear shock absorber (WP), linkage system, bearings, and spring adjustments. Braking System: Front and rear brake calipers, master cylinders, brake lines, pads, discs, and bleeding procedures. Electrical System: Wiring diagrams, battery, lighting (headlight, taillight, brake light), starter motor, and fuses. Exhaust System: Exhaust pipe, muffler, and heat shields. Wheels Tires: Wheel bearing inspection, spoke tension, tire pressure, and replacement. Controls: Handlebars, grips, levers, footpegs, and shifter assembly. Bodywork: Fairings, seat, fuel tank cover, fenders, and graphics. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, air filter cleaning, spark plug inspection, and brake fluid checks. Troubleshooting: Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and suspension inconsistencies. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment across all vehicle systems. Rebuild Procedures: Detailed guidance for complete engine and transmission rebuilds. Technical Specifications: Torque specifications for all fasteners, fluid capacities, tolerances, and clearances. Wiring Diagrams: Comprehensive electrical schematics for troubleshooting and component identification. Technical Depth Depth Level: Professional Mechanic Grade - Covers basic to advanced repair and diagnostics. Visual Aids: Hundreds of detailed photos and exploded diagrams for clarity. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within PDF (standard for professional manuals) Print Quality Print Resolution: High-resolution, suitable for professional printing. Binding Type Binding Physical: N/A (Digital Download) Paper Type Paper Physical: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Family: KTM LC4 variant (though these are specific SX/XC variants) Displacement 450: Approximately 449.3 cc (specific to model variations within 450 range) Displacement 505: Approximately 504.7 cc (specific to model variations within 505 range) Bore X Stroke 450: Variable depending on specific model, but typical for the era was around 95 mm x 63.4 mm. Bore X Stroke 505: Variable depending on specific model, but typical for the era was around 97 mm x 67.7 mm. Compression Ratio: Typically high, around 12.5:1 to 13.5:1 for racing applications. Performance Horsepower 450: Estimated peak horsepower around 50-55 HP at the crank. Horsepower 505: Estimated peak horsepower around 55-60 HP at the crank. Torque: Substantial torque delivery for aggressive acceleration, specific figures vary by model. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) by Keihin (typically 40mm or 42mm throttle body) Fuel Type: Unleaded gasoline (high octane recommended for performance) Fuel...