KTM 450 SXS-F 2007 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: KTM Model: 450 SXS-F Year: 2007 Model Variant: Factory Edition (SXS-F) Segment: Motocross Competition Off-Road Motorcycle Generation Generation Designation: First Generation (2007-2008) Codes Chassis Code...

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类型: Motorcycle

斯库: 60346

标签: 2007 450 SXS-F KTM Misc Motorcycle Motorcycles

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Description

🏷️ 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.