2009 ktm 450 sx-f 505 xc-f Workshop Repair Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 64336

Mots clés: 2009 450 SX-F 505 SX 505 XC-F ATV KTM Motorcycle Powersports

Variantes de produits

Description

The 450 SX-F and 505 XC-F, produced in 2009, represent a pinnacle of high-performance off-road motorcycle engineering, designed for motocross and cross-country competition. Building on a renowned 'Ready to Race' heritage, these models emphasize lightweight construction, powerful four-stroke engines (449.3 cc for the 450 SX-F and 505.6 cc for the 505 XC-F), and agile handling. Features like a liquid-cooled engine, DOHC 4-valve configuration, and a chromoly steel trellis frame contribute to their exceptional performance and rider control. These machines are engineered for the demanding environments of professional racing, where reliability and precision are paramount. This comprehensive Workshop Repair Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of the 2009 450 SX-F and 505 XC-F. It covers all essential systems, including the engine mechanicals, fuel injection, ignition, transmission, suspension, brakes, and electrical systems. The manual offers step-by-step instructions for scheduled maintenance, component overhauls, and diagnostic procedures, making it an indispensable resource for both DIY enthusiasts and professional mechanics. Adherence to the procedures outlined within this manual is critical for ensuring the longevity, optimal performance, and reliability of these specialized competition motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

450 SX-F / 505 XC-F

Year:

Codes

Platform Code:

XC/SX Series (Generation 2)

👋 Introduction

Market Position

Motorcycle Segment:

High-performance Motocross and Cross-Country Competition

Competitive Analysis

Key Competitors:

Yamaha YZ450F, Honda CRF450R, Kawasaki KX450F, Suzuki RM-Z450

Key Features

Vehicle Design Philosophy:

Lightweight, powerful, and agile for competitive off-road racing, emphasizing performance and rider control.

Manual Value Proposition:

Provides the definitive guide for maintaining and repairing these specialized performance machines, enabling cost savings and optimal performance.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Hundreds (Exact count not specified, but typical for factory service manuals of this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, piston, crankshaft, connecting rod, valve train, timing, lubrication system, cooling system.

Fuel System:

Fuel injection system, fuel pump, injectors, throttle body, fuel tank, lines, diagnostics.

Ignition System:

Ignition coil, spark plug, ECU, wiring diagrams, timing adjustments.

Transmission:

Clutch operation, gear shifting mechanisms, internal transmission components, lubrication.

Suspension:

Front fork (WP), rear shock absorber (WP), linkage system, adjustments, rebuild procedures.

Brakes:

Hydraulic brake system (front and rear), master cylinders, calipers, brake lines, pads, rotor specifications, bleeding procedures.

Electrical System:

Wiring diagrams, battery, starter, lighting, sensors, ECU, troubleshooting.

Chassis And Frame:

Frame inspection, subframe, steering head bearings, swingarm, wheel bearings.

Bodywork And Plastics:

Fairings, seat, fuel tank cover, removal, installation, and general care.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning.

Troubleshooting:

Diagnostic charts, common problems, symptom-based troubleshooting for engine, electrical, and chassis issues.

Repair:

Step-by-step repair instructions for all major components, including complete engine disassembly and reassembly.

Installation:

Installation procedures for replacement parts and accessories.

Diagnostics:

On-board diagnostics (OBD) information where applicable, sensor data interpretation, fault code analysis.

Technical Depth

Depth Level:

Comprehensive Factory Level

Target Audience:

DIY enthusiasts and experienced professional mechanics

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Compatibility:

Windows and Mac operating systems

Print Quality

Printability:

All pages are printable

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, Single Cylinder

450 Sx-F Displacement:

449.3 cc

505 Xc-F Displacement:

505.6 cc

Bore X Stroke 450:

97 mm x 60.8 mm

Bore X Stroke 505:

97 mm x 67.7 mm

Compression Ratio:

11.0:1 (typical for this generation)

Valve Train:

DOHC, 4 Valves

Cooling System:

Liquid-cooled

Lubrication System:

Semi-dry sump, dual oil pumps

Performance

450 Sx-F Horsepower:

~53 HP (at crankshaft, estimated)

505 Xc-F Horsepower:

~56 HP (at crankshaft, estimated)

450 Sx-F Torque:

~47 Nm (at crankshaft, estimated)

505 Xc-F Torque:

~50 Nm (at crankshaft, estimated)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Keihin 41mm throttle body

Fuel Type:

Unleaded Premium (95-98 RON / 91-93 AKI)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-disc clutch (Hydraulically operated)

Gear Ratios:

Specific ratios available in manual, typical for motocross application (e.g., 1st: ~2.57, 2nd: ~1.84, 3rd: ~1.40, 4th: ~1.13, 5th: ~0.96)

Final Drive:

Chain

📐 Dimensions

Exterior

Wheelbase:

Approx. 1480 mm (58.3 inches)

Seat Height:

Approx. 960 mm (37.8 inches)

Weights

Dry Weight:

Approx. 107 kg (235.9 lbs) (varies slightly between models)

Fuel Tank Capacity:

7.5 Liters (1.98 US gallons)

🛡️ Safety Features

Ratings

Safety Certification:

N/A (Competition Off-Road Motorcycle - not subject to road safety regulations)

Active Features

Braking System:

Hydraulic disc brakes, front and rear.

Passive Features

Frame Design:

Chromoly steel trellis frame for high strength-to-weight ratio and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

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

Driver Assistance

Electronic Aids:

No electronic rider aids such as ABS or traction control are present on this competition model.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of riding (or as per manual recommendation, typically after major race events).

Air Filter Cleaning:

Every 5-8 hours of riding, or more frequently in dusty conditions.

Spark Plug Replacement:

Every 20-30 hours of riding, depending on plug type and usage.

Valve Clearance Check:

Every 20-30 hours of riding for precision motocross engines.

Fluid Specifications

Engine Oil Type:

SAE 10W-50, API SJ or higher, JASO MA/MA2 (e.g., Motorex Power Synt 4T 10W/50).

Engine Oil Capacity:

Approx. 1.1 Liters (1.16 US quarts) with filter change.

Cooling System Coolant:

Mixture of distilled water and antifreeze (ethylene glycol based), typically 50/50 ratio. Coolant spec: JASO M325 / KG-001.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, swingarm bearings, chain and sprockets.

Maintenance Criticality:

Due to the high-stress nature of competition, adherence to strict maintenance schedules is paramount for longevity and performance.

📚 Vehicle History

Brand Heritage

Ktm Motorsport Focus:

KTM has a long and successful history in off-road motorcycle racing, particularly in motocross and rally raid, earning the nickname 'Ready to Race'.

Model Evolution

2009 Generation:

This generation represented a significant update for KTM's motocross and cross-country platforms, featuring advanced chassis and engine technology.

Sx-F Vs Xc-F:

The SX-F is primarily designed for motocross, while the XC-F is geared towards cross-country racing, often with minor differences in suspension, gearing, or emissions controls for broader usability.

Production

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Motocross Championships:

KTM models of this era have achieved numerous national and international motocross and supercross victories, validating their engineering and performance.

Ratings

Magazine Reviews:

Praised by motorcycle publications for their potent engines, agile handling, and premium componentry (e.g., WP suspension).

Certifications

Racing Homologation:

Designed and built to meet the demands of professional racing series.