How-To: KTM 450 505 SX-F Top & Bottom Engine Rebuild 2007-2012

www.howtomotorcyclerepair.com...
Blog post with full video, tool list, service manual links, and more.
Direct link to purchase video:
gumroad.com/l/ktm450
Tools used in this engine rebuild. I get a little affiliate commission if you use these links, which further support me. Every little bit helps me out to make more videos.
Motion pro 08-0008 clutch holder tool
amzn.to/2v23reG
Motion Pro Gear Jammer 08-0427
amzn.to/2hqgGTh
Motion Pro 08-0535 Flywheel Puller - M26 x 1.0 RH
amzn.to/2v1J4hP
Pen magnet
amzn.to/2w1H9vA
Titan scraper
amzn.to/2vsZAWz
Super scraper
amzn.to/2w1p29c
Exacto knife
amzn.to/2xfJcel
IR thermometer
amzn.to/2w7sA8l
Seal puller
amzn.to/2wrGzZn
Proto horseshoe pliers
amzn.to/2wBpIDL
Dial indicator with magnetic base
amzn.to/2xgbuFF
Loctite 243
amzn.to/2wrvuHq
Red loctite 271
amzn.to/2w1pdBe
Permatex assembly lube
amzn.to/2g8MLyX
Boa strap wrench
amzn.to/2wrGZPr
Torque wrench adapter
amzn.to/2w1KjQ7
Angle torque wrench
amzn.to/2w1IDWG
Tapered feeler gauges
amzn.to/2w7tQIB
Crocus cloth
amzn.to/2w12JQT
Tusk bearing puller
amzn.to/2vsY2vE
Support me on Patreon.
/ matthewmcrepair
Buy me a beer
www.howtomotorcyclerepair.com...
Now on Facebook. Give me a Like.
/ howtomotorcyclerepair
Sign up for my newsletter! Get emailed when new videos come out.
www.howtomotorcyclerepair.com...
Cool Rock - Take the Lead by Kevin MacLeod is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Source: incompetech.com/music/royalty-...
Artist: incompetech.com/

[@themotochannelu.k5098]

Jeez brother, seems ages since you gave us anymore of this top quality content !!! We need more bro 👍

[@HTMR]

Trying...super busy with family. I'll keep them coming though.

[@dnrg62]

Excellent video ,worth every cent cheersd

[@HTMR]

Thanks!

[@awfab3517]

I have bad vibration in my handle bars and my feet, been that way since I bought it used, could it be bottom end bearings, rode my buddies 2008 450 ktm and its so smooth.

[@ricardogrifon]

Good morning! could i imformed where could buy the slave cylinder clutch rekluse for KTM 450 XCF 2008?

[@eddiegajdosik7349]

Man, I wish you had a video for a 525 RFS! I might just buy this one to help myself out.

[@HTMR]

Maybe someday.

[@teddybeer1757]

@@HTMR Does this engine use plain bearings for the crankshaft?

[@HTMR]

@@teddybeer1757 Babbitt bearings? No.

[@-arielnaspi1894]

hello is the second time I break the admission valve always breaks the same one on the opposite side of the decompressor. I change everything new that I would like to know if you can guide me from where the problem may come

[@HTMR]

Sure, email me here: www.howtomotorcyclerepair.com/contact/

[@codyheil3933]

To do crank seals and crank seals only. Do i have to pull the crank like you did to get to the gear hiding the crank seal on the right side (clutch side) ??? 2008 sxf 450 stock

[@HTMR]

You can swap seals w/o splitting the cases.

[@FabioSilva-vs6ry]

o problema da outra vez estava na bobina de ignição . sabe me informar qual a folga normal que tem entre o volante magnetico e o motor o meu tem uma folga para dentro e para fora mas não encontro informação se é normal ou se é um problema . no teu video é o minuto 20:50 ?

[@domenjeram9180]

Do you happen to know which colour original sealant between main blocks is on ktms? Im trying to figure whether my blocks have been split before

[@HTMR]

Light grey

[@allenaldrich6227]

Hi I am searching for a bottom end rebuild for the ktm 450/525 xc ATV was wondering if you had a video or could point me in the direction of one?

[@HTMR]

What year?

[@tommyc6r1]

Hi, Matt. I got 10 KTM 250 SX-F need to rebuild the Crankshaft. Do you have a video for that to purchase. Thanks

[@HTMR]

Not yet sorry.

[@TrisdenMcneille]

Where can I find a rebuild kit ?

[@savannahrondeau6988]

hi is it that for my ktm 450 xc atv 2009?

[@scania161616]

Can I check the piston ,but not replace gasket ? Old gasket should good ?

[@HTMR]

In order to fully inspect the piston, you need to remove the cylinder. Yes, I'd replace all gaskets with new ones.

[@dannybrooking6886]

I notice you just use a rubber hammer to break open the case?Can I do the same with my ktm400?

[@HTMR]

Not sure. Check with the service manual if a puller is needed.

[@lanevemma]

I’ve got a 2010 ktm 450 XC-w six days will this video be the same for my bike?

[@HTMR]

No your model is different.

[@antoniomotos6457]

Jefe👨‍🔧 🤝 🙋gracias .

[@-arielnaspi1894]

hello consultation maybe you can help me I have a ktm sxf 450 2007 and I drop the intake valve is the second time. I can not use it. I changed the guide to the rocker valve insurance kit full of springs and saucers

[@HTMR]

What do you need help with exactly?

[@-arielnaspi1894]

hello is the second time I broke the intake valve always breaks the same on the side of the decompressor. I change everything new I would like to know if you can guide me where the problem may come from

[@-arielnaspi1894]

hola es la segunda ves que se me rompe la valvula de admision se rompe siempre la misma la contraria al lado del descompresor. le cambie todo nuevo. Quisiera saber si me podes orientar por donde puede venir el problema

[@ronchappel4812]

This kind of thing is the best part of the internet.Well, this and pirated free workshop manuals ;-)

[@teddybeer1757]

Does this engine use plain bearings for the crankshaft?

[@denniskpesie3420]

Please my ktm is not starting when I try starting is backfiring what must i do to start the bike

[@Venneman417]

Could I use this as a reference for a 250 sxf 2016?

[@HTMR]

As a reference yes. However your engine is different. If you choose to buy, and the video does not help, then just ask me for your money back.

[@Venneman417]

MatthewMCRepair alright thanks!

[@LillSotarn]

hi i have the same enigen on my bike ! and i think my auto decompressing is failing ! can u repair it or do i have to get a new cam??

[@HTMR]

Start taking it apart and see whats the problem.

[@LillSotarn]

@@HTMR my problem is even white a new battery and a new starter i cant start the bike on the e-start unless i jump start white a car battery! i have checked the starting system, valve timing,cam chain timing by the workshop manual and i find nothing wrong!

[@FOCUSPRODUCTIONSUS]

I had a question if the 2007 450 SXF cylinder head would be the same as a 2008 505 sxf ? Ill be a Detect replacement !

[@HTMR]

I don't know sorry.

[@brentsterner2468]

Would this be the same as the 08 ktm 505 XC-F? I’m just doing the top end

[@HTMR]

Yes.

[@steadfastjack277]

How many hours can the average joe blow rider put on a newer ktm before he needs to get the bottom end serviced? Thanks in advance 🙏🙂

[@teddybeer1757]

Does this engine use plain bearings for the crankshaft?

[@alexandr0804458]

hey man i got 2009 xc-w that has a seized engine is this engine the same ? were are you located ?

[@HTMR]

No your engine is different. I'm in Chicago.

[@thahoova6818]

Minus the d extra gear will this video work for my 2009 450 xcf?

[@HTMR]

Yes sir.

[@thahoova6818]

awesome thanks for the quick reply ill be purchasing the video soon!

[@HTMR]

No problem. Let me know if you have any other Q's.

[@thahoova6818]

will do is there a direct contact link for you after purchasing the video or would i just post the question here

[@HTMR]

Yes, you reply to email after purchase and it goes directly to me. Or post it here. Either way works.

[@miguelemolina1442]

Will this video apply to a 505 xcf 09

[@HTMR]

Yes.

[@rubencampa6999]

Where can i get the cylinder head ktm 450 sxf 2008.. help me please

[@HTMR]

Can it be rebuilt?

[@mortirius1]

Hey there Matthewcrepair I'm watching this whole video to see how to remove the cylinder and you just magically take it off. Mine is giving me a hard time. Do you have any advice?

[@HTMR]

There are 2 orings that make it a tight fit. Try a soft rubber mallet. Go easy.

[@mortirius1]

@@HTMR Should they be replaced after ?

[@HTMR]

@@mortirius1 Orings? Yes.

[@michaelritzau7492]

Hi Mathew, I have a 2009 KTM 450 EXC would this video suit me

[@HTMR]

Your model is different, sorry.

[@michaelritzau7492]

Ok thank you

[@tgnidebnu]

Is this the motor with engine oil and seperate gearbox oil? Ever heard of the issue with that?

[@martykath4427]

A 2007 Sx 450 doesn't have separate g-box oil. Both are combined. A 2007 530 exc r has separate engine and gearbox oils though quite often they get modified to run the same oil through both. There was an oil pump modification on this model too, to stop oil draining from one area to flood the other.

[@FabioSilva-vs6ry]

boa tarde eu tenho uma sx-f 450 2008 e ultimamente sempre que paro no fim de uma trilha o motor desliga sabe me indicar de onde possa estar o problema ? motor trabalha bem e levou filtro de ar novo e vela nova e continua igual sou dos açores e não temos oficinas nesta ilha para motos , se poder dar uma dica agradecia muito obrigado .

[@HTMR]

Tune the fuel screw: kzbin.info/www/bejne/oYbaZWSpiraViructtps://kzbin.info/www/bejne/oYbaZWSpiraVirs

[@FabioSilva-vs6ry]

@@HTMR vou tentar isso muito obrigado por responder .

[@FabioSilva-vs6ry]

BOA noite meu ktm sxf450 quando está mais quente fica a afogar tem alguma ideia da solução ?

[@FabioSilva-vs6ry]

o problema da outra vez estava na bobina de ignição . sabe me informar qual a folga normal que tem entre o volante magnetico e o motor o meu tem uma folga para dentro e para fora mas não encontro informação se é normal ou se é um problema . no teu video é o minuto 20:50 ?

[@jaapiekrekelgsxr]

Is this the same for an KTM SMR 450 2010?

[@HTMR]

Yes the video will be applicable.

[@steadfastjack277]

How many hours do YOU go before replacing the bottom end of a 450 Thanks in advance 🙏🙂

[@HTMR]

That is a really hard question to answer since it depends on how well you maintain it and how you ride it.

[@steadfastjack277]

MatthewMCRepair I’m asking you about your schedule 🙂

[@rosapercs4524]

Is your link still active? Just bought the full video and have not received an email to watch full video. Anyways great video and thanks a lot!

[@HTMR]

You should have received an email instantly. Contact me here and I'll look into it: howtomotorcyclerepair.com/contact/

[@BRWfilms]

Hey you have helped me before, i have a yz125 just bought it. Its a 2000 model has a 144 big bore in it I was ridding yesterday about 2 hours and it sounded like it ran out of gas but had half a tank. I cleaned the carb with carb cleaner. I checked for spark and it has spark. Did compression test 4 hours after it quit and it was 120 I mixed gas 40-1 Spark plug had black on it when i took it out so i cleaned it an put it back in Also i sprayed starter fluid in the engine and it still didnt start Any idea what might be wrong One guy told told me power valves but that dont make sense to me i would think if power valves were messed up it would still run Another guy said crank but if crank was messed up would it even kick over?

[@HTMR]

Did you try to install a brand new spark plug? Send me an email here so you can share some pics: www.howtomotorcyclerepair.com/contact/

[@BRWfilms]

MatthewMCRepair i am going to go get a new spark plug in a few hours and try it And i will send pics when i get home as well

[@BRWfilms]

MatthewMCRepair Got it running!! Just needed new spark plug

[@HTMR]

Sounds like you fouled a plug. Either it is jetted too rich or running rich due to other issues.

[@BRWfilms]

MatthewMCRepair i buy and sell bikes so only had this one 2 weeks so I'm not sure how its jetted But it actually had the wrong plug in it, it had a br9es and its supposed to have a br9eg

[@calebknight4558]

It looks like the same top end as an 2008 ktm 450 excr, is it?

[@HTMR]

Top end is a little different.

[@calebknight4558]

@@HTMR would timing be the same?

[@HTMR]

@@calebknight4558 Not sure, I don't have the service manual for your model.

[@FOCUSPRODUCTIONSUS]

What would cause a cam bridge to brake on my 2007 KTM 450

[@HTMR]

Did the cams seize?

[@FOCUSPRODUCTIONSUS]

@@HTMR yeah I just bought the bike and pulled the valve cover off by the looks the head has to be changed. Do u Kobe ware I can find a good hed ?

[@HTMR]

@@FOCUSPRODUCTIONSUS Where do you live I can recommend someone who fixes them.

[@FOCUSPRODUCTIONSUS]

That would be great if u hook me up. I live in Springfield Missouri.

[@HTMR]

@@FOCUSPRODUCTIONSUS Contact these people, they fixed the cam area on motor in video: www.pointviewcycle.com/ktmmotorcrossoffroadservic

[@ronik1974]

is it fit to kTM530 2008?

[@HTMR]

Your model is different.

[@danedixon9942]

What size is the black socket

[@HTMR]

Forgot, it was 2 years ago.

[@mkejlore6425]

Hi, can I use this for KTM sxf 350 (2012) ?

[@HTMR]

It may help. Not really the same though. If you decide to buy and does not help, ask for a refund.

[@harrypopss1357]

What is your email? I have a ktm 520 sx and im stuck! Thanks

[@HTMR]

www.howtomotorcyclerepair.com/contact/

[@RomainGOMES]

hi what are your carburetor settings?

[@HTMR]

It has a JD jet kit.

[@RomainGOMES]

@@HTMR what are the jet values ​​to put?

[@HTMR]

I can't remember sorry.

[@RomainGOMES]

MatthewMCRepair the manual write slide 15 what it is ?

[@HTMR]

@@RomainGOMES Sure it's not 1.5?

[@ToniBikic]

How much it cost to rebuild the engine

[@HTMR]

Really depends on what needs to be replaced. Do you know what went south?

[@JAYZRIDEZ]

Why did you skip the part where yoy take the timing chain sprocket off?😅

[@michaelhornshaw4697]

2009 XC-W 400?

[@HTMR]

Yours if different than the 450 in this video. Sorry.

[@michaelhornshaw4697]

MatthewMCRepair thanks for quick response. This thing just stopped. Any ideas as to common causes?

[@HTMR]

Email me here and I will try and help: www.howtomotorcyclerepair.com/contact/

[@scotsman9490]

HEY BRO were have you been

[@HTMR]

Haha....tending to a teething baby.

[@scotsman9490]

that's must be fun mate

[@rafifrasyiqul5542]

You not show counter balance

[@scoremxcom]

May I send you my engine?

[@HTMR]

I'm not accepting service work at this time.

[@vistkri]

Fucking hate that ktm engine

[@peteh8077]

Bahaha another garbage hot rods crank