This manual covers the 450 SXS-F, a high-performance 450cc four-stroke competition motorcycle produced in 2007. The SXS-F designation signifies a special factory or works-spec model, built for peak performance in motocross and supercross racing. Known for its powerful engine and competitive chassis, the 450 SXS-F represents dedication to engineering excellence in the off-road racing arena, offering riders a machine honed for demanding track conditions and championship aspirations. This comprehensive service repair manual is primarily focused on engine service and repair, detailing procedures for complete engine disassembly, inspection, and reassembly. It covers critical systems including the cylinder head assembly, piston and crankshaft components, clutch assembly, cooling system, lubrication system, fuel delivery, ignition, and exhaust systems. The manual provides step-by-step instructions, troubleshooting guides, maintenance schedules, and precise torque specifications, making it an essential resource for mechanics and enthusiasts aiming to maintain and optimize the performance and longevity of their 2007 450 SXS-F. 🏷️ Basic Information Identification Make: KTM Model: 450 SXS-F Year: 2007 Engine Variant: 450cc Four-Stroke Codes Chassis Code Indicator: SXS-F designates a special factory/works-spec model 👋 Introduction Market Position Segment: High-performance Motocross/Supercross competition engine. Target Audience: Professional and semi-professional motocross racers, dedicated mechanics, and advanced DIY enthusiasts working on competition motorcycles. Competitive Analysis Competitors: Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F of the same era. Key Features Sxs F Designation: SXS-F (Supercross/Supermoto Factory) indicates a higher-spec, often factory-developed or race-prepped engine variant compared to standard SX models. Manual Value: Crucial for maintaining peak performance and longevity of a high-strung competition engine. 📋 Manual Details Coverage Areas Primary Focus: Engine Service and Repair Additional Systems Covered: Cooling, Lubrication, Fuel Delivery (Engine-Specific), Ignition (Engine-Specific), Exhaust (Engine-Specific) Page Count Estimated Pages: Varies by specific PDF compilation, typically 100-200 pages for detailed engine work Manual Type Type: Service Repair Manual Language Language: English (likely, based on common industry practice for KTM) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, and reassembly of all internal engine components. Cylinder Head Assembly: Valve train (camshafts, valves, springs, retainers), cylinder head gasket replacement, valve clearance adjustment. Piston And Crankshaft: Piston, piston rings, connecting rod, crankshaft, bearings inspection and replacement. Clutch Assembly: Clutch pack inspection, replacement, and adjustment procedures. Cooling System: Radiator, hoses, water pump, coolant specifications, bleeding procedures. Lubrication System: Oil pump, oil filter, oil passages, oil specifications and change intervals. Fuel System Engine Intake: Carburetor (likely Keihin FCR MX) tuning, jetting, float bowl maintenance, intake manifold inspection. Ignition System Engine Output: Spark plug specifications, ignition timing checks (if applicable/adjustable), CDI unit troubleshooting (basic). Exhaust System Engine Performance: Exhaust header and silencer inspection, gasket replacement. Procedures Included Disassembly And Reassembly: Step-by-step instructions for complete engine teardown and rebuild. Troubleshooting: Diagnostic charts for common engine issues like hard starting, misfires, loss of power. Maintenance: Oil changes, filter replacements, spark plug replacement, valve adjustments, cooling system flushes. Component Inspection: Detailed wear limits and specifications for critical engine parts. Torque Specifications: Precise torque values for all fasteners during assembly. Valve Clearance Adjustment: Step-by-step guide for setting valve clearances. Clutch Adjustment And Replacement: Procedures for clutch lever free play and clutch pack replacement. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete engine rebuilds. Diagnostic Capability: Includes troubleshooting guides and common issue diagnosis. Specificity: Highly specific to the 2007 KTM 450 SXS-F engine, including model-specific nuances. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if the PDF is well-produced. Print Quality Quality: Dependent on source, but a good PDF should be clear for printing diagrams and text. Binding Type Binding: Not applicable (PDF format) Paper Type Paper: Not applicable (PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: Approximately 450cc (exact figure might vary slightly by specific internal components, but nominal is 450cc). Bore X Stroke: Typically around 97 mm x 60.8 mm (standard for this generation of KTM 450s). Compression Ratio: Likely a high compression ratio for performance, e.g., 12.5:1 or higher. Valve Train: DOHC (Dual Overhead Camshafts), 4 valves per cylinder. Performance Horsepower Estimate: Likely in the range of 50-55 HP at the crankshaft for a factory-spec SXS-F model. Torque Estimate: Estimated around 35-40 lb-ft at the crankshaft. Fuel System Fuel Delivery: Carbureted (typically Keihin FCR 41mm MX). Recommended Fuel: Premium unleaded gasoline (91+ octane). May specify higher for competition use. Engine Oil Oil Type: High-performance motorcycle-specific 4-stroke engine oil, often synthetic. Specific viscosity (e.g., 10W-50 or 15W-50) and JASO MA/MA2 specification. Oil Capacity: Approximately 1.1 - 1.3 liters (check manual for exact figure). 🔧 Transmission Standard Transmission Type: Constant mesh, sequential 5-speed gearbox. Optional Gear Ratios: Specific gear ratios would be detailed in the manual, crucial for performance tuning. Features Clutch Type: Hydraulically operated, multi-plate wet clutch. Transmission Fluid Fluid Type: Often shared with engine oil, but check manual. If separate, specific gearbox...