Segment:
High-performance motocross/off-road competition motorcycles.
Target Audience:
Motocross racers, experienced off-road riders, mechanics specializing in performance motorcycles.
Competitors:
Honda CRF450R, Yamaha YZ450F, Kawasaki KX450F, Suzuki RM-Z450.
Engine Architecture:
Single-cylinder, 4-valve, DOHC (Double Overhead Camshaft) design.
Performance Focus:
Designed for peak power output and aggressive riding conditions.
Advanced Technology:
Often featured advanced suspension (WP), lightweight chassis, and potent engine tuning for its era.
Engine Disassembly Assembly:
Complete overhaul procedures for the 450cc and 505cc engines.
Cylinder Head:
Valve adjustment, camshaft removal/installation, cylinder head gasket replacement.
Piston Cylinder:
Piston ring replacement, cylinder inspection and honing.
Crankshaft Connecting Rod:
Bearing inspection, con-rod replacement.
Fuel System:
Carburetor (likely Keihin FCR MX) tuning, cleaning, and overhaul; fuel pump and filter replacement (if applicable).
Cooling System:
Radiator and coolant management, water pump inspection and repair.
Ignition System:
Spark plug specifications, CDI unit troubleshooting, stator and rotor inspection.
Lubrication System:
Oil pump inspection, oil filter replacement, oil change procedures and specifications.
Exhaust System:
Muffler and header pipe maintenance.
Routine Maintenance:
Oil changes, filter replacements, valve clearance checks.
Troubleshooting:
Diagnostic charts for common engine issues and symptoms.
Engine Rebuild:
Step-by-step instructions for complete engine disassembly and reassembly.
Component Replacement:
Detailed procedures for replacing specific engine parts.
Torque Specifications:
Essential torque values for all critical fasteners.
Depth:
Comprehensive, covering everything from basic maintenance to full engine rebuilds.
Diagnostic Level:
Detailed diagnostic procedures for identifying and resolving engine problems.
Special Tools:
Identification and usage of any specialized tools required for engine service.
Engine Type:
Four-stroke, single-cylinder
Displacement 505:
477cc (often marketed as 505cc due to stroke/bore characteristics or marketing)
Bore X Stroke 450:
97.0 mm x 60.8 mm (typical for 450cc class)
Bore X Stroke 505:
97.0 mm x 66.5 mm (typical for 505cc class)
Compression Ratio:
Typically around 12.5:1 or higher (specific value to be found in manual)
Valve Train:
DOHC, 4 valves
Horsepower Estimate:
Estimated 50-55 HP (at crankshaft, typical for 2009 450cc motocross bikes)
Torque Estimate:
Estimated 35-40 lb-ft (at crankshaft, typical for 2009 450cc motocross bikes)
Carburetor Type:
Keihin FCR MX41 (typical for 2009 models)
Fuel Type:
Unleaded gasoline, high octane (91+ RON)
Oil Capacity:
Approximately 1.0-1.1 Liters (specific value in manual)
Oil Type:
High-quality, motorcycle-specific 4-stroke engine oil (e.g., Motorex, Bel-Ray, Castrol) with JASO MA rating. Viscosity typically 10W-40 or 10W-50 depending on climate.
Cooling Type:
Liquid-cooled, dual radiators
Coolant Type:
Ethylene glycol-based antifreeze coolant mixed with distilled water (typically 50/50 ratio)
Transmission Type:
Constant mesh, 5-speed
Clutch Type:
Wet, multi-plate clutch (hydraulic actuation common)
Final Drive:
Chain drive (520 pitch typically)
Optional Gearing:
N/A (Gearing is usually fixed for specific models, but aftermarket sprockets vary)
Gear Ratios:
Specific gear ratios would be detailed in the manual.
Transmission Fluid:
Engine oil serves as transmission lubricant.
Safety Rating:
N/A (Off-road competition motorcycles are not subject to DOT safety ratings or crash testing in the same way as street vehicles.)
Brakes Front:
Hydraulic disc brake, 260mm (typical)
Brakes Rear:
Hydraulic disc brake, 220mm (typical)
Frame Construction:
Chromium-molybdenum steel central tube frame (typical for KTM of this era)
Infotainment System:
N/A (No infotainment features on this competition model)
Driver Assistance Features:
N/A (No electronic driver assistance systems)
Connectivity Features:
N/A (No connectivity features)
Ignition System Type:
Digital electronic ignition (CDI)
Efi Availability:
Not equipped with Electronic Fuel Injection (EFI) for this model year; utilizes carburetor.
Oil Change Interval:
Every 5-10 hours of aggressive riding, or as specified in the manual based on usage conditions.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Valve Adjustment Interval:
Every 20-30 hours of riding, or when noticeable performance changes occur.
Spark Plug Replacement:
As needed based on inspection, typically every 20-40 hours.
Engine Oil Spec:
KTM recommends specific motorcycle oils, consult manual for exact viscosity (e.g., Motorex Power Synt 4T 10W-50).
Coolant Spec:
Ethylene glycol-based coolant, 50% distilled water.
Brake Fluid Spec:
DOT 4 hydraulic brake fluid.
Engine Wear Points:
Piston and ring wear, valve seat wear, and cam chain tensioner issues can occur with high mileage or improper maintenance.
Clutch Slippage:
Can occur due to worn clutch plates or improper adjustment.
Cooling System Leaks:
Potential for leaks at hose connections or radiator damage.
Carburetor Tuning:
Sensitivity to jetting changes based on altitude, temperature, and modifications.
Brand Origin:
Austrian manufacturer renowned for off-road and sports motorcycles.
Sx F Lineage:
The SX-F line represents KTM's flagship motocross machines, evolving significantly with engine size and chassis technology year by year.
2009 Updates:
The 2009 models saw updates including revised chassis, suspension tuning, and often engine refinements for improved power delivery and reliability. This manual specifically targets these revisions.
Manufacturing Location:
Austria
