Segment:
High-performance Motocross/Supercross competition engine.
Target Audience:
Professional and semi-professional motocross racers, dedicated mechanics, and advanced DIY enthusiasts working on competition motorcycles.
Competitors:
Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F of the same era.
Sxs F Designation:
SXS-F (Supercross/Supermoto Factory) indicates a higher-spec, often factory-developed or race-prepped engine variant compared to standard SX models.
Manual Value:
Crucial for maintaining peak performance and longevity of a high-strung competition engine.
Primary Focus:
Engine Service and Repair
Additional Systems Covered:
Cooling, Lubrication, Fuel Delivery (Engine-Specific), Ignition (Engine-Specific), Exhaust (Engine-Specific)
Estimated Pages:
Varies by specific PDF compilation, typically 100-200 pages for detailed engine work
Type:
Service Repair Manual
Language:
English (likely, based on common industry practice for KTM)
Engine Mechanical:
Complete disassembly, inspection, and reassembly of all internal engine components.
Cylinder Head Assembly:
Valve train (camshafts, valves, springs, retainers), cylinder head gasket replacement, valve clearance adjustment.
Piston And Crankshaft:
Piston, piston rings, connecting rod, crankshaft, bearings inspection and replacement.
Clutch Assembly:
Clutch pack inspection, replacement, and adjustment procedures.
Cooling System:
Radiator, hoses, water pump, coolant specifications, bleeding procedures.
Lubrication System:
Oil pump, oil filter, oil passages, oil specifications and change intervals.
Fuel System Engine Intake:
Carburetor (likely Keihin FCR MX) tuning, jetting, float bowl maintenance, intake manifold inspection.
Ignition System Engine Output:
Spark plug specifications, ignition timing checks (if applicable/adjustable), CDI unit troubleshooting (basic).
Exhaust System Engine Performance:
Exhaust header and silencer inspection, gasket replacement.
Disassembly And Reassembly:
Step-by-step instructions for complete engine teardown and rebuild.
Troubleshooting:
Diagnostic charts for common engine issues like hard starting, misfires, loss of power.
Maintenance:
Oil changes, filter replacements, spark plug replacement, valve adjustments, cooling system flushes.
Component Inspection:
Detailed wear limits and specifications for critical engine parts.
Torque Specifications:
Precise torque values for all fasteners during assembly.
Valve Clearance Adjustment:
Step-by-step guide for setting valve clearances.
Clutch Adjustment And Replacement:
Procedures for clutch lever free play and clutch pack replacement.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete engine rebuilds.
Diagnostic Capability:
Includes troubleshooting guides and common issue diagnosis.
Specificity:
Highly specific to the 2007 KTM 450 SXS-F engine, including model-specific nuances.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
Approximately 450cc (exact figure might vary slightly by specific internal components, but nominal is 450cc).
Bore X Stroke:
Typically around 97 mm x 60.8 mm (standard for this generation of KTM 450s).
Compression Ratio:
Likely a high compression ratio for performance, e.g., 12.5:1 or higher.
Valve Train:
DOHC (Dual Overhead Camshafts), 4 valves per cylinder.
Horsepower Estimate:
Likely in the range of 50-55 HP at the crankshaft for a factory-spec SXS-F model.
Torque Estimate:
Estimated around 35-40 lb-ft at the crankshaft.
Fuel Delivery:
Carbureted (typically Keihin FCR 41mm MX).
Recommended Fuel:
Premium unleaded gasoline (91+ octane). May specify higher for competition use.
Oil Type:
High-performance motorcycle-specific 4-stroke engine oil, often synthetic. Specific viscosity (e.g., 10W-50 or 15W-50) and JASO MA/MA2 specification.
Oil Capacity:
Approximately 1.1 - 1.3 liters (check manual for exact figure).
Transmission Type:
Constant mesh, sequential 5-speed gearbox.
Gear Ratios:
Specific gear ratios would be detailed in the manual, crucial for performance tuning.
Clutch Type:
Hydraulically operated, multi-plate wet clutch.
Fluid Type:
Often shared with engine oil, but check manual. If separate, specific gearbox oil (e.g., 80W or 75W-90).
Oil Change Interval:
Typically every 10-15 hours of riding for competitive use, or based on specific race conditions.
Air Filter Cleaning:
Frequent cleaning/replacement, often after every few hours of riding, especially in dusty conditions.
Valve Clearance Check:
Typically every 20-40 hours of riding, or as recommended by the manual.
Spark Plug Replacement:
Check and replace as needed, often every 20-30 hours or based on inspection.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for specific recommendation).
Common Wear Items:
Piston rings, valve guides, clutch plates, timing chain, wheel bearings, steering head bearings due to high-stress operation.
Potential Failure Points:
Can include issues related to overheating if cooling system maintenance is neglected, premature wear on the cam chain tensioner, or clutch basket wear.
Oil Filter Part Number:
Requires consultation of the specific manual or KTM parts catalog (e.g., KTM often uses HI-FLO filters, part number would be model-specific).
Air Filter Part Number:
Requires consultation of the specific manual or KTM parts catalog (e.g., Twin Air or UNI Filter part numbers are common).
Heritage:
KTM has a strong heritage in off-road racing, particularly motocross and rally raid, known for performance-oriented machines.
450 Sxf Evolution:
The 450 SXS-F represents a lineage of KTM's flagship 450cc motocross bikes, continually refined for racing dominance. The 2007 model would reflect advancements from previous years and internal factory developments.
Manufacturing Location:
KTM motorcycles are primarily manufactured in Austria.
Motocross Championships:
KTM 450 SX-F platforms, including variations like the SXS-F, have historically been successful in various national and international motocross and supercross championships.
Performance Reviews:
Professional motorcycle media reviews from 2007 would typically highlight the engine's power, delivery, and reliability for racing, as well as chassis performance.
Note:
Competition vehicles are built to FIM/AMA racing homologation standards rather than street-legal certifications.
