Category:
High-performance motocross off-road motorcycle.
Target Audience:
Motocross racers, off-road enthusiasts, and mechanics who maintain KTM SX-F 450 motorcycles.
Competitors:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, Kawasaki KX450F of the same era.
Performance Focus:
Designed for competitive motocross racing, emphasizing power, handling, and agility.
Technological Advancements:
For its time, featured advanced suspension (WP), strong engine performance, and lightweight chassis design.
Engine:
Detailed information on engine disassembly, assembly, tuning, diagnostics, and component specifications for the 450cc single-cylinder engine.
Transmission:
Coverage of gearbox operation, maintenance, clutch service, and lubrication requirements.
Suspension:
In-depth procedures for front fork (WP USD) and rear shock absorber maintenance, servicing, and adjustments, including seal replacement and oil changes.
Brakes:
Service information for front and rear hydraulic braking systems, including caliper maintenance, fluid bleeding, and pad replacement.
Electrical System:
Wiring diagrams, troubleshooting guides for ignition, lighting, and charging systems.
Cooling System:
Radiator and water pump maintenance, coolant specifications, and troubleshooting of overheating issues.
Fuel System:
Carburetor servicing, jetting information, fuel pump and filter maintenance.
Chassis:
Frame inspection, steering head bearing service, swingarm and linkage maintenance.
Maintenance:
Routine maintenance tasks such as oil changes, air filter cleaning/replacement, spark plug inspection, and chain adjustment.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components.
Troubleshooting:
Diagnostic tables and procedures for identifying and resolving common mechanical and electrical faults.
Disassembly Assembly:
Complete guides for stripping down and reassembling engine, transmission, and chassis components.
Torquing:
Specific torque values for critical fasteners to ensure proper assembly and prevent damage.
Depth:
Comprehensive, suitable for both amateur mechanics and professional technicians. Covers everything from basic adjustments to complete engine rebuilds.
Type:
4-stroke, single-cylinder
Displacement:
Approximately 449.3 cc (exact figure may vary slightly by sub-model year, confirm with manual)
Bore X Stroke:
Typical for this era and displacement, expect figures around 95mm x 63.4mm (confirm with manual).
Cooling System:
Liquid-cooled
Valvetrain:
SOHC, 4 valves
Horsepower:
Estimated 50-55 HP (at crankshaft, unconfirmed without manual specifics)
Torque:
Estimated 45-50 Nm (at crankshaft, unconfirmed without manual specifics)
Carburetor:
Keihin FCR MX series (e.g., FCR 39 or 41mm, confirm with manual)
Fuel Type:
Unleaded Gasoline (Octane rating as specified in manual)
Oil Type:
High-performance 4-stroke motorcycle oil, specific viscosity and API rating to be detailed in the manual (e.g., 10W-40, JASO MA).
Oil Capacity:
Engine oil capacity and clutch/transmission oil capacity (separate or shared, confirm with manual).
Clutch:
Hydraulically operated multi-plate wet clutch.
Gear Ratios:
Specific gear ratios for each of the 5 speeds will be provided in the manual, crucial for performance tuning.
Final Drive:
Chain drive (specific sprocket sizes to be found in manual).
Transmission Oil:
Specific type and quantity of transmission oil will be detailed in the manual.
Wheelbase:
Approximately 1485-1510 mm (confirm with manual for specific year).
Seat Height:
Approximately 950-965 mm (confirm with manual).
Dry Weight:
Approximately 105-108 kg (confirm with manual).
Fuel Tank Capacity:
Approximately 7.5 - 8.5 liters (confirm with manual).
Front Travel:
Typically 300-310 mm for WP USD forks of this era.
Rear Travel:
Typically 330-340 mm for WP PDS or linkage rear suspension (confirm type with manual).
Engine Oil Change:
Refer to manual; typically every 15-25 hours of riding for motocross use.
Air Filter Cleaning:
Frequently, especially in dusty conditions; often every few hours of riding.
Spark Plug Inspection:
Refer to manual; typically every 20-30 hours of riding.
Suspension Service:
Fork seal replacement and oil change typically every 40-60 hours. Shock service varies.
Engine Oil:
Specific viscosity and API rating (e.g., 10W-40, JASO MA) and capacity detailed in manual.
Coolant:
Proprietary or standard 50/50 ethylene glycol mixture; manual will specify.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic fluid (confirm with manual).
Common Wear Items:
Clutch plates, piston rings, valve guides, swingarm/linkage bearings, wheel bearings, fork seals.
Engine Longevity:
Proper and timely maintenance is critical for engine longevity, especially for competition use. Piston and ring replacement intervals are important.
Manufacturer:
KTM is an Austrian manufacturer renowned for its off-road motorcycles, with a strong racing pedigree.
Development:
The SX-F 450 models from this period represented KTM's continued push for dominance in the open-class motocross segment, evolving from earlier 400cc and 450cc models.
Production Years Covered:
2005, 2006, 2007
