Positioning:
High-performance motocross racing machines, targeted at competitive riders and enthusiasts.
Competitors 2007:
Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F.
Engine Architecture:
Powerful single-cylinder 4-stroke engine known for its strong mid-range and top-end power delivery.
Chassis Design:
Lightweight and agile chromoly steel frame, premium WP suspension components, performance-oriented ergonomics.
Manual Value Proposition:
Provides dealership-level repair and maintenance information, enabling cost savings for owners and independent workshops.
Primary Coverage:
Full Service, Repair, and Troubleshooting
Specific Models Covered:
KTM 450 SX-F, KTM 450 SXS-F, KTM 505 SX-F, KTM 505 SXS-F
Estimated Page Count:
Detailed, full coverage (specific page count not provided but implied to be comprehensive)
Type:
Service Repair Workshop Manual
File Format:
PDF Download
Compatibility:
Compatible with all versions of Windows and Mac.
Reader Requirement:
Requires Adobe PDF Reader or compatible software.
Download Speed:
Speed Download
Engine Mechanical:
Engine specifications, engine removal and installation, internal component repair (pistons, valves, crankshaft), cylinder head service.
Fuel System:
Fuel system diagnosis, carburetor (or injection if applicable for the year) adjustment and repair, fuel pump, fuel tank, lines.
Cooling System:
Cooling system diagnosis, radiator, coolant, water pump, hoses, thermostat (if equipped).
Transmission Drivetrain:
Transmission service, gear inspection, clutch operation, drive chain and sprocket maintenance, lubrication.
Suspension:
Front fork (shocks) service and adjustment, rear shock absorber service, linkage maintenance.
Electrical System:
Wiring schematic, ignition system, lighting, charging system (stator, regulator/rectifier), battery, troubleshooting electrical faults.
Bodywork Chassis:
Body panel removal and installation, frame inspection, steering system service, seat, handlebars.
Brakes:
Brake system inspection, pad replacement, fluid service, caliper and master cylinder maintenance.
Intake Exhaust:
Air filter service, exhaust system inspection and maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, general inspections, lubrication points.
Troubleshooting:
Advanced troubleshooting for common and uncommon issues, diagnostic procedures.
Rebuilds:
Complete engine rebuild procedures, transmission overhaul, suspension component overhauls.
Adjustments:
Periodic checks and adjustments for various systems (e.g., clutch, throttle, brakes, suspension sag).
Diagnostics:
Step-by-step diagnostic guides for identifying malfunctions.
Specification Tables:
Detailed specification tables for all components and systems are included.
Depth:
Comprehensive. Covers everything from basic maintenance to complete engine and chassis overhauls. Includes detailed diagrams and schematics.
Diagrams Illustrations:
Includes detailed diagrams, step-by-step illustrations, and exploded views for component identification and assembly.
Wiring Schematic Detail:
Comprehensive wiring diagrams provided for troubleshooting and understanding the electrical system.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled
Displacement 450:
Approximately 449.3 cc
Displacement 505:
Approximately 504.7 cc
Bore X Stroke 450:
Typically around 97.0 mm x 60.8 mm (refer to manual for exact figures)
Bore X Stroke 505:
Typically around 97.0 mm x 67.3 mm (refer to manual for exact figures)
Compression Ratio:
High compression ratio, typically above 11.0:1 (refer to manual for exact figures)
Valvetrain:
SOHC (Single Overhead Camshaft), 4 valves
Carburetor Model:
Keihin FCR 39 MX (standard for 450, 505 may differ, consult manual)
Horsepower Estimate:
Estimated 50+ HP at peak (specific figures vary, consult manual)
Torque Estimate:
Strong mid-range torque delivery (specific figures vary, consult manual)
Fuel Delivery:
Carburetor (Keihin FCR 39 MX for most 450 models, check manual for specifics)
Fuel Type:
Unleaded gasoline, octane rating specified in manual (typically 95 RON or higher)
Oil Change Interval:
Refer to manual for specific hours or mileage, typically every 10-15 hours of hard use for race bikes.
Air Filter Cleaning:
Frequent cleaning/replacement recommended, often after every few riding sessions depending on conditions.
Valve Clearance Check:
Refer to manual for interval, typically in the range of 20-40 hours of use.
Engine Oil Type:
High-quality synthetic motorcycle oil, viscosity grade specified in manual (e.g., 10W-50 or 15W-50).
Coolant Type:
Specific coolant mixture, usually a 50/50 mix of ethylene glycol and distilled water, or a pre-mixed coolant. Consult manual for KTM-specific recommendations.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Clutch Fluid Type:
Mineral oil (e.g., Magura Blood) for hydraulically actuated clutch. Specific type is critical.
Engine Oil Capacity:
Refer to manual for exact capacity, typically around 0.7 - 0.8 liters for engine oil.
Common Wear Items:
Clutch plates, chain and sprockets, tires, fork seals, wheel bearings, piston rings, valve guides due to high-stress operation.
Engine Care:
Regular oil and filter changes are critical for engine longevity. Overheating can lead to premature wear.
