KTM 450 SXS-F 2007 Factory Service Repair Manual

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Stichworte: 2007 450 SXS-F KTM Misc Motorcycle Motorcycles

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Beschreibung

The 2007 KTM 450 SXS-F is a high-performance, competition-focused motocross motorcycle, representing a pinnacle of off-road engineering. This Factory Edition model was designed for serious racers, embodying a 'Ready to Race' philosophy with factory-spec tuning and upgraded components for maximum performance on the track. Known for its potent 4-stroke, single-cylinder engine, robust chromium-molybdenum steel frame, and advanced WP suspension, the 450 SXS-F was built to deliver a competitive edge in the demanding world of motocross. This service repair manual provides comprehensive coverage for the 2007 KTM 450 SXS-F, serving as an essential resource for owners, technicians, and mechanics. It details all aspects of the motorcycle, including complete engine, fuel, ignition, cooling, exhaust, and transmission systems, as well as clutch, suspension, braking, and electrical components. The manual offers in-depth troubleshooting guidance, periodic maintenance schedules, technical data, and step-by-step repair procedures, ensuring the motorcycle remains in peak condition for optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

450 SXS-F

Year:

Model Variant:

Factory Edition (SXS-F)

Segment:

Motocross Competition Off-Road Motorcycle

Generation

Generation Designation:

First Generation (2007-2008)

Codes

Chassis Code Identifier:

WP 4860 MXMA (Front Fork), WP DME (Rear Shock)

👋 Introduction

Market Position

Market Positioning:

The 2007 KTM 450 SXS-F was positioned as a premium, factory-level motocross machine designed for serious competition, offering enhanced performance and exclusivity over standard SX models.

Competitive Analysis

Key Competitors:

Competed against top-tier motocross bikes from Yamaha (YZ450F), Honda (CRF450R), Suzuki (RM-Z450), and Kawasaki (KX450F).

Key Features

Factory Enhancements:

Often included factory-spec engine tuning, upgraded suspension components, and other performance-oriented modifications straight from KTM's racing division.

Target Audience:

Professional and amateur motocross racers seeking a competitive edge and a machine built for peak performance.

📋 Manual Details

Coverage Areas

Engine Mechanics:

Complete

Fuel System:

Complete

Ignition System:

Complete

Cooling System:

Complete

Exhaust System:

Complete

Transmission And Drivetrain:

Complete

Clutch System:

Complete

Suspension Front:

Complete

Suspension Rear:

Complete

Braking System Front:

Complete

Braking System Rear:

Complete

Wheel And Tire Service:

Complete

Electrical System Wiring Harness:

Complete

Bodywork Chassis Frame:

Complete

Troubleshooting Diagnostics:

Comprehensive

Periodic Maintenance:

Comprehensive

Technical Data Specifications:

Comprehensive

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Assembly Disassembly:

Complete disassembly, inspection, repair, and reassembly procedures for the 4-stroke, single-cylinder engine.

Carburetor Tuning And Rebuild:

Detailed instructions for the Keihin FCR 41 carburetor, including jetting, float adjustment, and rebuild.

Valve Clearance Adjustment:

Precise specifications and procedures for checking and adjusting valve clearances.

Timing Chain Inspection And Replacement:

Procedures for timing chain inspection and replacement, including camshaft timing.

Cooling System Flushing And Antifreeze Specifications:

Guidelines for coolant maintenance and specific antifreeze recommendations.

Transmission Gear Ratios And Inspection:

Detailed information on the 5-speed transmission, including gear inspection and replacement.

Clutch Friction Plate And Disassembly:

Procedures for clutch service, including clutch plate inspection and replacement.

Wp 4860 Mxma Fork Rebuild And Service:

Comprehensive instructions for servicing the front suspension, including seal replacement, oil changes, and internal adjustments.

Wp Dme Rear Shock Servicing:

Detailed procedures for maintenance and repair of the rear shock absorber.

Brembo Brake System Overhaul:

Complete instructions for servicing front and rear Brembo brakes, including caliper rebuild and pad replacement.

Electrical Schematics And Troubleshooting:

Detailed wiring diagrams and guidance for diagnosing electrical issues.

Procedures Included

Engine Rebuild:

Full step-by-step engine overhaul procedures for performance and longevity.

Suspension Tuning And Adjustment:

Guidance on setting up suspension for various track conditions and rider preferences.

Carburetor Jetting Guide:

Specific jetting recommendations for different altitudes and temperatures.

Brake Bleeding And Fluid Replacement:

Proper procedures for bleeding the hydraulic brake system and specifying fluid types.

Wheel Bearing Replacement:

Instructions for maintaining and replacing wheel bearings.

Chain And Sprocket Maintenance:

Guidance on chain adjustment, lubrication, and sprocket replacement.

Torque Specifications Chart:

Comprehensive list of all critical torque values for fasteners.

Troubleshooting Flowcharts:

Systematic diagnostic flowcharts for common problems.

Technical Depth

Depth Of Information:

Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Capabilities:

In-depth diagnostic procedures for identifying and resolving mechanical and electrical faults.

Repair Procedures:

Detailed, step-by-step repair instructions with accompanying diagrams and illustrations.

Special Tool Requirements:

Identification of necessary special tools for specific procedures.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download - printable)

Paper Type

Paper Type:

N/A (Digital Download - user dependent)

Searchability

Searchability:

Searchable text within the PDF document for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder, Liquid-cooled

Displacement:

449.3 cc

Bore X Stroke:

97 mm x 60.8 mm

Compression Ratio:

12.5:1 (approx.)

Valve Train:

SOHC, 4-valve

Camshaft Type:

Single overhead camshaft (SOHC) with 4 titanium valves

Performance

Horsepower Est:

50+ hp (at crankshaft, est.)

Torque Est:

35+ lb-ft (at crankshaft, est.)

Fuel System

Carburetor:

Keihin FCR 41 MX

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2

Oil Specifications

Engine Oil Type:

SAE 10W/40, JASO MA certified motorcycle oil

Engine Oil Capacity:

Approx. 1.1 Liters (1.16 US qt)

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh

Clutch Type:

Wet multi-disc clutch (Hydraulic actuation)

Features

Gear Ratios:

Specific gear ratios detailed within the manual.

Final Drive:

Chain drive, 520 pitch

📐 Dimensions

Exterior

Frame Type:

Chromium-molybdenum steel central-tube frame

Weights

Dry Weight:

Approx. 104 kg (229 lbs)

Fuel Tank Capacity:

7.5 Liters (1.98 US gal)

🛡️ Safety Features

Ratings

Safety Features Notes:

As a competition-only off-road motorcycle, traditional automotive safety ratings (e.g., NHTSA, Euro NCAP) do not apply. Safety is inherent in design for intended use.

Active Features

Braking System:

Hydraulic disc brakes front and rear (Brembo components).

Passive Features

Frame Construction:

Robust chromium-molybdenum steel frame designed for rigidity and impact resistance.

💡 Technology Features

Infotainment

Infotainment Systems:

N/A (Competition off-road motorcycle, no infotainment features).

Driver Assistance

Driver Assistance Systems:

N/A (Competition off-road motorcycle, no driver assistance systems).

Connectivity

Connectivity Features:

N/A (Competition off-road motorcycle, no connectivity features).

Ignition System

Ignition Type:

Digital CDI ignition.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15 hours of riding (or monthly if not ridden).

Air Filter Cleaning:

After every riding session or as needed based on conditions.

Valve Clearance Check:

Every 30 hours of riding.

Spark Plug Inspection:

Every 30 hours of riding.

Suspension Service:

Recommended fork oil change every 20-30 hours, rear shock service as needed or annually.

Fluid Specifications

Brake Fluid Type:

DOT 4 hydraulic fluid.

Cooling System Coolant:

Premixed coolant with a minimum of 30% antifreeze (e.g., ethylene glycol) and distilled water. KTM recommends specific coolant for optimal performance.

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, fork seals, wheel bearings due to high-performance nature and competition use.

Potential Issues:

Overheating if cooling system is not meticulously maintained, carburetor jetting sensitivity to altitude and temperature changes.

📚 Vehicle History

Brand Heritage

Ktm Brand Focus:

KTM has a long-standing heritage in off-road motorcycle racing, particularly in motocross and rally raid, known for its 'Ready to Race' philosophy.

Model Evolution

Sxf Lineage:

The 450 SXS-F represents a significant iteration in KTM's 450cc 4-stroke motocross development, preceding the widespread adoption of fuel injection in this class.

Production

Production Origin:

Austria

🏆 Awards & Recognition

Recognitions

Motocross Championships:

KTM models of this era were highly competitive in professional motocross championships worldwide, often winning races and contributing to brand prestige.

Ratings

Performance Reviews:

Consistently praised in motorcycle media for its potent engine, advanced suspension, and sharp handling, making it a top choice for racers.

Certifications

Certification Type:

Not applicable for competition vehicles in the traditional sense. Built to FIM/AMA racing homologation standards where applicable.