The 450 SX-F and 505 XC-F, produced in 2009, represent a pinnacle of high-performance off-road motorcycle engineering, designed for motocross and cross-country competition. Building on a renowned 'Ready to Race' heritage, these models emphasize lightweight construction, powerful four-stroke engines (449.3 cc for the 450 SX-F and 505.6 cc for the 505 XC-F), and agile handling. Features like a liquid-cooled engine, DOHC 4-valve configuration, and a chromoly steel trellis frame contribute to their exceptional performance and rider control. These machines are engineered for the demanding environments of professional racing, where reliability and precision are paramount. This comprehensive Workshop Repair Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of the 2009 450 SX-F and 505 XC-F. It covers all essential systems, including the engine mechanicals, fuel injection, ignition, transmission, suspension, brakes, and electrical systems. The manual offers step-by-step instructions for scheduled maintenance, component overhauls, and diagnostic procedures, making it an indispensable resource for both DIY enthusiasts and professional mechanics. Adherence to the procedures outlined within this manual is critical for ensuring the longevity, optimal performance, and reliability of these specialized competition motorcycles. 🏷️ Basic Information Identification Make: KTM Model: 450 SX-F / 505 XC-F Year: 2009 Codes Platform Code: XC/SX Series (Generation 2) 👋 Introduction Market Position Motorcycle Segment: High-performance Motocross and Cross-Country Competition Competitive Analysis Key Competitors: Yamaha YZ450F, Honda CRF450R, Kawasaki KX450F, Suzuki RM-Z450 Key Features Vehicle Design Philosophy: Lightweight, powerful, and agile for competitive off-road racing, emphasizing performance and rider control. Manual Value Proposition: Provides the definitive guide for maintaining and repairing these specialized performance machines, enabling cost savings and optimal performance. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Page Count Estimated Page Count: Hundreds (Exact count not specified, but typical for factory service manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, piston, crankshaft, connecting rod, valve train, timing, lubrication system, cooling system. Fuel System: Fuel injection system, fuel pump, injectors, throttle body, fuel tank, lines, diagnostics. Ignition System: Ignition coil, spark plug, ECU, wiring diagrams, timing adjustments. Transmission: Clutch operation, gear shifting mechanisms, internal transmission components, lubrication. Suspension: Front fork (WP), rear shock absorber (WP), linkage system, adjustments, rebuild procedures. Brakes: Hydraulic brake system (front and rear), master cylinders, calipers, brake lines, pads, rotor specifications, bleeding procedures. Electrical System: Wiring diagrams, battery, starter, lighting, sensors, ECU, troubleshooting. Chassis And Frame: Frame inspection, subframe, steering head bearings, swingarm, wheel bearings. Bodywork And Plastics: Fairings, seat, fuel tank cover, removal, installation, and general care. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning. Troubleshooting: Diagnostic charts, common problems, symptom-based troubleshooting for engine, electrical, and chassis issues. Repair: Step-by-step repair instructions for all major components, including complete engine disassembly and reassembly. Installation: Installation procedures for replacement parts and accessories. Diagnostics: On-board diagnostics (OBD) information where applicable, sensor data interpretation, fault code analysis. Technical Depth Depth Level: Comprehensive Factory Level Target Audience: DIY enthusiasts and experienced professional mechanics 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Compatibility: Windows and Mac operating systems Print Quality Printability: All pages are printable Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Single Cylinder 450 Sx-F Displacement: 449.3 cc 505 Xc-F Displacement: 505.6 cc Bore X Stroke 450: 97 mm x 60.8 mm Bore X Stroke 505: 97 mm x 67.7 mm Compression Ratio: 11.0:1 (typical for this generation) Valve Train: DOHC, 4 Valves Cooling System: Liquid-cooled Lubrication System: Semi-dry sump, dual oil pumps Performance 450 Sx-F Horsepower: ~53 HP (at crankshaft, estimated) 505 Xc-F Horsepower: ~56 HP (at crankshaft, estimated) 450 Sx-F Torque: ~47 Nm (at crankshaft, estimated) 505 Xc-F Torque: ~50 Nm (at crankshaft, estimated) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Keihin 41mm throttle body Fuel Type: Unleaded Premium (95-98 RON / 91-93 AKI) 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-disc clutch (Hydraulically operated) Gear Ratios: Specific ratios available in manual, typical for motocross application (e.g., 1st: ~2.57, 2nd: ~1.84, 3rd: ~1.40, 4th: ~1.13, 5th: ~0.96) Final Drive: Chain 📐 Dimensions Exterior Wheelbase: Approx. 1480 mm (58.3 inches) Seat Height: Approx. 960 mm (37.8 inches) Weights Dry Weight: Approx. 107 kg (235.9 lbs) (varies slightly between models) Fuel Tank Capacity: 7.5 Liters (1.98 US gallons) 🛡️ Safety Features Ratings Safety Certification: N/A (Competition Off-Road Motorcycle - not subject to road safety regulations) Active Features Braking System: Hydraulic disc brakes, front and rear. Passive Features Frame Design: Chromoly steel trellis frame for high strength-to-weight ratio and rigidity. 💡 Technology Features Infotainment Infotainment System: N/A (Pure performance off-road motorcycle, no infotainment features). Driver Assistance Electronic Aids: No electronic rider aids such as...