2008 KTM 450 505 SXF Engine Service Repair Manual

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🏷️ Basic Information Identification Make: KTM Model: 450 SX-F Model Variant: SX-F Year: 2008 Codes Engine Code: LC4 Chassis Code: KTM EXC/SX Chassis Designations Vary 👋 Introduction Market Position Segment:...

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Type: Motorcycle

Vendor:

Sku: 603772

Tags: 2008 450 SXF 505 505 SXF KTM Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

450 SX-F

Model Variant:

Year:

Codes

Engine Code:

Chassis Code:

KTM EXC/SX Chassis Designations Vary

👋 Introduction

Market Position

Segment:

High-performance Motocross/Off-Road Competition

Target User:

Motocross racers, experienced off-road riders, mechanics

Competitive Analysis

Competitors:

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

Key Features

Vehicle Focus:

Power, agility, track performance

Manual Value:

Essential for maintaining peak performance and reliability of a high-strung racing engine

📋 Manual Details

Coverage Areas

Primary Coverage:

Engine Service and Repair

Secondary Coverage:

General Maintenance and Troubleshooting

Page Count

Estimated Pages:

300-500 (typical for this type of manual)

Manual Type

Type:

Service/Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of all engine components

Engine Electrical:

Ignition system, starting system, charging system diagnostics

Fuel System:

Carburetor overhaul and tuning (likely Keihin FCR), fuel pump (if applicable)

Cooling System:

Radiator, hoses, water pump maintenance and repair

Lubrication System:

Oil pump, oil passages, oil filter maintenance

Procedures Included

Disassembly Reassembly:

Complete engine teardown and rebuild procedures

Troubleshooting:

Diagnostic flowcharts and common issue resolution for engine performance problems

Maintenance:

Scheduled maintenance tasks, filter changes, fluid checks

Torque Specifications:

Torque values for all critical fasteners and components

Valve Adjustment:

Detailed instructions for valve clearance adjustment

Clutch Service:

Clutch plate replacement, spring inspection, hydraulic clutch system bleeding

Technical Depth

Depth:

Comprehensive, covering internal engine components, timing, and tuning

Detail Level:

Detailed diagrams, step-by-step instructions, and specifications for expert-level repairs

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text content for quick information retrieval

Print Quality

Resolution:

High resolution for clear diagrams and text

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, LC4

Displacement:

449.0 cc

Bore X Stroke:

97.0 mm x 60.8 mm

Valvetrain:

SOHC, 4 Valves

Compression Ratio:

11.5:1 (typical for this generation)

Performance

Horsepower:

Approx. 50-55 HP (at crankshaft, estimated)

Torque:

Approx. 45-48 Nm (at crankshaft, estimated)

Fuel System

Carburetor:

Keihin FCR 41 MX (specific variant may apply)

Fuel Type:

Unleaded Gasoline (91-98 RON recommended)

Ignition

Ignition System:

Digital CDI (Capacitive Discharge Ignition)

Lubrication

Oil Type:

SAE 10W-50 Synthetic Motorcycle Oil (API SG or higher, JASO MA)

Oil Capacity:

Approx. 1.1 Liters (without filter change), 1.2 Liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Clutch Type:

Wet multi-plate, hydraulic actuation

Gear Ratios:

Specific ratios documented in the manual

Features

Transmission Oil:

SAE 80W-90 Gear Oil (API GL-4)

Transmission Oil Capacity:

Approx. 0.8 Liters

📐 Dimensions

Exterior

Wheelbase:

Approx. 1465 mm (57.7 in)

Seat Height:

Approx. 960 mm (37.8 in)

Weights

Dry Weight:

Approx. 106 kg (233.7 lbs)

Fuel Tank Capacity:

Approx. 8.0 Liters (1.76 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

Not Applicable (Competition Off-Road Vehicle)

Active Features

Braking System Front:

Hydraulic disc brake, Brembo caliper (specific size)

Braking System Rear:

Hydraulic disc brake, Brembo caliper (specific size)

Passive Features

Frame:

Chromium-molybdenum steel trellis frame

💡 Technology Features

Infotainment

Infotainment System:

Not Applicable (Competition Motocross Bike)

Driver Assistance

Driver Assistance Features:

None (Competition Motocross Bike)

Connectivity

Connectivity Features:

None (Competition Motocross Bike)

Engine Management

Engine Management System:

Basic ignition timing, no advanced electronic fuel injection or rider modes

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15-20 hours of operation or 6 months, whichever comes first (competition use)

Air Filter Cleaning:

After every ride or as needed based on dust conditions

Valve Check Interval:

Every 20-30 hours of operation

Spark Plug Replacement:

Every 40-50 hours of operation or as needed

Fluid Specifications

Engine Oil Spec:

SAE 10W-50 Synthetic (API SG/SH/SJ/SL, JASO MA)

Transmission Oil Spec:

SAE 80W-90 Gear Oil (API GL-4)

Coolant Type:

Ethylene Glycol based antifreeze coolant (50/50 mix with distilled water)

Known Issues

Engine Wear:

Piston and ring wear at higher hours, potential cam chain tensioner issues

Clutch Slippage:

Can occur with aggressive riding and prolonged use, requires timely plate replacement

Carburetor Tuning:

Sensitivity to altitude and temperature changes, requiring proper jetting adjustments

📚 Vehicle History

Brand Heritage

Heritage:

KTM is renowned for its off-road racing prowess and 'Ready to Race' philosophy.

Model Evolution

Evolution 2008:

The 2008 model year represented a significant step in KTM's 4-stroke motocross development, focusing on power delivery and chassis refinement.

Production

Manufacturing Location:

Austria

🏆 Awards & Recognition

Recognitions

Motocross Magazine Reviews:

KTM SX-F models consistently received high praise in motocross publications for performance and handling during this era.