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KTM 450 505 SX F 450 SXS F Engine 2007-2011 Service Repair Workshop Manual Pdf

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This manual covers the 450 SX-F, 505 SX-F, and 450 SXS-F models produced between 2007 and 2011. These high-performance off-road motorcycles are designed for Motocross and Supercross racing, embodying a renowned off-road heritage. They feature powerful LC4 engines, advanced WP suspension, and robust chassis designs, making them a competitive choice for racers and enthusiasts. The models are characterized by their strong performance, durability, and focus on competition-grade engineering, reflecting a commitment to excellence in the off-road segment. This comprehensive service repair workshop manual provides detailed information for the maintenance and repair of your motorcycle. It covers all essential systems, including the engine, transmission, clutch, fuel system, ignition system, chassis, suspension, brakes, and electrical components. The manual includes scheduled maintenance procedures, detailed repair instructions for major overhauls, troubleshooting guides, and information on special tools. With hundreds of pages of detailed photos, diagrams, and explanations, this resource is invaluable for owners, mechanics, and technicians seeking to ensure optimal performance and longevity of their 450 SX-F, 505 SX-F, or 450 SXS-F. 🏷️ Basic Information Identification Make: KTM Model: 450 SX-F / 505 SX-F / 450 SXS-F Model Designation Sx F: Sport Cross-Country Factory Model Designation Sxs F: Sport Cross-Country Supercross Factory Codes Year Coverage: 2007, 2008, 2009, 2010, 2011 Engine Codes Covered: LC4 450 (SX-F, SXS-F), LC4 505 (SX-F) 👋 Introduction Market Position Segment: High-performance Motocross/Supercross Off-Road Motorcycles Target Audience: Motocross Racers, Enthusiasts, Professional Mechanics, DIY Technicians Competitive Analysis Competitors: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F Key Features Manual Value: Comprehensive, detailed, professional-grade information for maintenance and repair Visual Aid Quality: Hundreds of pages with detailed photos and diagrams, including exploded views Accessibility: Instant download, cross-platform compatibility, lifetime access 📋 Manual Details Coverage Areas Scope: Complete Factory Service Repair Workshop Manual Primary Market: North America, Europe Page Count Estimated Pages: Hundreds Manual Type Type: Service Repair Workshop Manual Language Language: English Format Digital Format: PDF Availability: Instant Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Clutch, Fuel System, Ignition System Chassis: Frame, Suspension (Front & Rear), Steering, Brakes, Wheels, Tires Electrical: Wiring Diagrams, Lighting, Battery, Ignition Control, Sensors Bodywork: Fairings, Seat, Fuel Tank, Handlebars Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication Repair: Engine Rebuilds, Transmission Overhaul, Suspension Servicing, Brake Bleeding, Electrical Component Replacement Troubleshooting: Diagnostic Flowcharts, Fault Finding Procedures, Component Testing Special Tools: Identification and Usage of KTM Specific Tools Technical Depth Depth: Comprehensive, from basic checks to complete engine and chassis overhauls Diagnostic Capability: Advanced diagnostic procedures and component testing 📊 Manual Specifications File Format Compatibility: Windows & MAC Computers Searchability: Likely searchable PDF text content Print Quality Print Ability: Print single page or entire manual Print Resolution: High-resolution for clear diagrams and photos Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Licensing Usage Rights: Unlimited use on multiple devices, lifetime access ⚙️ Engine Specifications Primary Engine Engine Type 450: Single-cylinder, 4-stroke, LC4 engine Engine Type 505: Single-cylinder, 4-stroke, LC4 engine Bore X Stroke 450: Approx. 97 mm x 60.8 mm (Specifics vary slightly by year, consult manual) Bore X Stroke 505: Approx. 102 mm x 60.8 mm (Specifics vary slightly by year, consult manual) Displacement 450: Approx. 449.3 cc (Specifics vary slightly by year, consult manual) Displacement 505: Approx. 503.6 cc (Specifics vary slightly by year, consult manual) Cooling System: Liquid-cooled Performance Horsepower 450: Approx. 50-55 HP (Varies by year and tuning, consult manual for exact figures) Horsepower 505: Approx. 55-60 HP (Varies by year and tuning, consult manual for exact figures) Torque: Significant torque figures appropriate for its class, consult manual for specific Nm values. Fuel System Fuel Delivery: Carbureted (Keihin FCR MX) for most models in this range, potential EFI on later models Carburetor Model: Keihin FCR 41 MX (typical) Recommended Fuel: Unleaded gasoline with Octane rating of 95 RON (or equivalent 91 AKI) Oil Capacity With Filter: Approx. 1.1 Liters (0.75 L for engine, 0.35 L for gearbox/clutch - consult manual for exact quantity and procedure) Lubrication Oil Type: High-performance 4-stroke motorcycle oil, JASO MA/MA2 certified, SAE 10W-40 or 15W-50 (consult manual for specific viscosity and OEM recommendations) 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed Optional Optional Gear Ratios: Not applicable, standard gear ratios for motocross applications Features Clutch Type: Hydraulically operated, multi-disc wet clutch (APT-C System on some models) Gearbox Oil Capacity: Separate oil for gearbox/clutch, typically 0.35 Liters (integrated with engine oil in some wet-sump designs, verify with manual) Gearbox Oil Type Oil Specification: Same as engine oil (high-performance 4-stroke motorcycle oil, JASO MA/MA2 certified, SAE 10W-40 or 15W-50 - consult manual) 📐 Dimensions Exterior Seat Height: Approx. 970-985 mm (Varies by year and suspension setup, consult manual) Ground Clearance: Approx. 350-370 mm (Varies by year and suspension setup, consult manual) Weights Dry Weight 450: Approx. 108-110 kg (Varies by year and specifications, consult manual)...
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KTM 450 505 SX F 450 SXS F Engine 2007-2011 Service Repair Workshop Manual PdfKTM 450 505 SX F 450 SXS F Engine 2007-2011 Service Repair Workshop Manual PdfKTM 450 505 SX F 450 SXS F Engine 2007-2011 Service Repair Workshop Manual PdfKTM 450 505 SX F 450 SXS F Engine 2007-2011 Service Repair Workshop Manual Pdf
This manual covers the 450 SX-F, 505 SX-F, and 450 SXS-F models produced between 2007 and 2011. These high-performance off-road motorcycles are designed for Motocross and Supercross racing, embodying a renowned off-road heritage. They feature powerful LC4 engines, advanced WP suspension, and robust chassis designs, making them a competitive choice for racers and enthusiasts. The models are characterized by their strong performance, durability, and focus on competition-grade engineering, reflecting a commitment to excellence in the off-road segment. This comprehensive service repair workshop manual provides detailed information for the maintenance and repair of your motorcycle. It covers all essential systems, including the engine, transmission, clutch, fuel system, ignition system, chassis, suspension, brakes, and electrical components. The manual includes scheduled maintenance procedures, detailed repair instructions for major overhauls, troubleshooting guides, and information on special tools. With hundreds of pages of detailed photos, diagrams, and explanations, this resource is invaluable for owners, mechanics, and technicians seeking to ensure optimal performance and longevity of their 450 SX-F, 505 SX-F, or 450 SXS-F.
🏷️ Basic Information
Identification
Make:
KTM
Model:
450 SX-F / 505 SX-F / 450 SXS-F
Model Designation Sx F:
Sport Cross-Country Factory
Model Designation Sxs F:
Sport Cross-Country Supercross Factory
Codes
Year Coverage:
2007, 2008, 2009, 2010, 2011
Engine Codes Covered:
LC4 450 (SX-F, SXS-F), LC4 505 (SX-F)
👋 Introduction
Market Position
Segment:
High-performance Motocross/Supercross Off-Road Motorcycles
Target Audience:
Motocross Racers, Enthusiasts, Professional Mechanics, DIY Technicians
Competitive Analysis
Competitors:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F
Key Features
Manual Value:
Comprehensive, detailed, professional-grade information for maintenance and repair
Visual Aid Quality:
Hundreds of pages with detailed photos and diagrams, including exploded views
Accessibility:
Instant download, cross-platform compatibility, lifetime access
📋 Manual Details
Coverage Areas
Scope:
Complete Factory Service Repair Workshop Manual
Primary Market:
North America, Europe
Page Count
Estimated Pages:
Hundreds
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF
Availability:
Instant Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Clutch, Fuel System, Ignition System
Chassis:
Frame, Suspension (Front & Rear), Steering, Brakes, Wheels, Tires
Electrical:
Wiring Diagrams, Lighting, Battery, Ignition Control, Sensors
Bodywork:
Fairings, Seat, Fuel Tank, Handlebars
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication
Repair:
Engine Rebuilds, Transmission Overhaul, Suspension Servicing, Brake Bleeding, Electrical Component Replacement
Troubleshooting:
Diagnostic Flowcharts, Fault Finding Procedures, Component Testing
Special Tools:
Identification and Usage of KTM Specific Tools
Technical Depth
Depth:
Comprehensive, from basic checks to complete engine and chassis overhauls
Diagnostic Capability:
Advanced diagnostic procedures and component testing
📊 Manual Specifications
File Format
Compatibility:
Windows & MAC Computers
Searchability:
Likely searchable PDF text content
Print Quality
Print Ability:
Print single page or entire manual
Print Resolution:
High-resolution for clear diagrams and photos
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
Licensing
Usage Rights:
Unlimited use on multiple devices, lifetime access
⚙️ Engine Specifications
Primary Engine
Engine Type 450:
Single-cylinder, 4-stroke, LC4 engine
Engine Type 505:
Single-cylinder, 4-stroke, LC4 engine
Bore X Stroke 450:
Approx. 97 mm x 60.8 mm (Specifics vary slightly by year, consult manual)
Bore X Stroke 505:
Approx. 102 mm x 60.8 mm (Specifics vary slightly by year, consult manual)
Displacement 450:
Approx. 449.3 cc (Specifics vary slightly by year, consult manual)
Displacement 505:
Approx. 503.6 cc (Specifics vary slightly by year, consult manual)
Cooling System:
Liquid-cooled
Performance
Horsepower 450:
Approx. 50-55 HP (Varies by year and tuning, consult manual for exact figures)
Horsepower 505:
Approx. 55-60 HP (Varies by year and tuning, consult manual for exact figures)
Torque:
Significant torque figures appropriate for its class, consult manual for specific Nm values.
Fuel System
Fuel Delivery:
Carbureted (Keihin FCR MX) for most models in this range, potential EFI on later models
Carburetor Model:
Keihin FCR 41 MX (typical)
Recommended Fuel:
Unleaded gasoline with Octane rating of 95 RON (or equivalent 91 AKI)
Oil Capacity With Filter:
Approx. 1.1 Liters (0.75 L for engine, 0.35 L for gearbox/clutch - consult manual for exact quantity and procedure)
Lubrication
Oil Type:
High-performance 4-stroke motorcycle oil, JASO MA/MA2 certified, SAE 10W-40 or 15W-50 (consult manual for specific viscosity and OEM recommendations)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 5-speed
Optional
Optional Gear Ratios:
Not applicable, standard gear ratios for motocross applications
Features
Clutch Type:
Hydraulically operated, multi-disc wet clutch (APT-C System on some models)
Gearbox Oil Capacity:
Separate oil for gearbox/clutch, typically 0.35 Liters (integrated with engine oil in some wet-sump designs, verify with manual)
Gearbox Oil Type
Oil Specification:
Same as engine oil (high-performance 4-stroke motorcycle oil, JASO MA/MA2 certified, SAE 10W-40 or 15W-50 - consult manual)
📐 Dimensions
Exterior
Seat Height:
Approx. 970-985 mm (Varies by year and suspension setup, consult manual)
Ground Clearance:
Approx. 350-370 mm (Varies by year and suspension setup, consult manual)
Weights
Dry Weight 450:
Approx. 108-110 kg (Varies by year and specifications, consult manual)
Dry Weight 505:
Approx. 110-112 kg (Varies by year and specifications, consult manual)
Wet Weight:
Approx. 117-120 kg (with fluids, consult manual)
Fuel Tank Capacity:
Approx. 7.0 - 8.0 Liters (Varies by year, consult manual)
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet off-road competition safety standards and regulations; not street legal
Active Features
Braking System:
Hydraulic disc brakes front and rear (Brembo calipers typical)
Brake Rotor Diameter Front:
Approx. 260 mm
Brake Rotor Diameter Rear:
Approx. 220 mm
Passive Features
Frame Construction:
Chromium-molybdenum steel trellis frame for rigidity and impact absorption
💡 Technology Features
Infotainment
Infotainment System:
N/A (Performance motocross bike, no infotainment system)
Driver Assistance
Driver Assistance Features:
N/A (Performance motocross bike, no electronic driver assistance systems like ABS or traction control)
Connectivity
Connectivity Features:
N/A (Performance motocross bike, no connectivity features)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15-20 operating hours or annually (consult manual for detailed recommendations based on usage)
Air Filter Cleaning:
After every few rides or more frequently in dusty conditions
Spark Plug Replacement:
Refer to manual, typically every 40-50 operating hours or as inspection dictates
Fluid Specifications
Brake Fluid:
DOT 4 synthetic brake fluid (for Brembo systems)
Coolant:
Proprietary KTM coolant or equivalent high-quality ethylene glycol based coolant with anti-corrosion additives
Fork Oil Type:
Specific WP fork oil (e.g., WP Suspension Fluid 0W or 5W), consult manual for exact type and quantity
Known Issues
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, linkage bearings
Potential Trouble Spots:
Carburetor jetting (requires tuning for altitude/temperature), chain and sprockets wear, suspension seals
Maintenance Importance:
Regular and meticulous maintenance is crucial for optimal performance and longevity of these high-strung racing machines.
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM is renowned for its off-road racing heritage, particularly in Motocross, Enduro, and Rally Raid
Model Evolution
Generation Characteristics:
These models represent a significant evolution in KTM's motocross lineup, featuring strong engines, advanced chassis designs, and competitive performance for their era.
Technical Advancements:
Key advancements include powerful LC4 engines, WP suspension components, and strong braking systems, making them a dominant force in racing.
Production
Manufacturing Location:
Austria (KTM AG)
🏆 Awards & Recognition
Recognitions
Racing Success:
KTM models of this era have a strong track record in professional motocross and supercross championships, earning numerous victories and accolades.
Industry Reputation:
KTM is highly regarded for producing powerful, durable, and competitive off-road motorcycles
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