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

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Alright boys and girls, it took me a good 2 months to put this 4 hour 30 minute long video together. It covers disassembly and reassembly, step by step, on every component except the cylinder head.
 

Full Length Video

The full length video can be purchased here. It streams instantly on any device with unlimited views.
 


 

Service Manual

Visit kristofsx for free service manual downloads. Make sure to leave a donation, after all he is saving you at least $30.
 

Tools

Here is a list of tools used in this video. I bought most of this stuff on Amazon. Using these links support me at no cost to you.

Motion pro 08-0008 clutch holder tool

Motion Pro Gear Jammer 08-0427

Motion Pro 08-0535 Flywheel Puller – M26 x 1.0 RH

Pen magnet

Titan scraper

Super scraper

Exacto knife

IR thermometer

Seal puller

Proto horseshoe pliers

Dial indicator with magnetic base

Loctite 243

Red loctite 271

Permatex assembly lube

Boa strap wrench

Torque wrench adapter

Angle torque wrench

Tapered feeler gauges

Crocus cloth

Tusk bearing puller

The last tool I used is a homemade DIY cam bridge holder. This is needed IF you need to time your cams. The KTM PN isĀ 77329050000 and cost about $100, so it’s worth trying to make this part yourself.


 

Parts

The crank was rebuild by Crank Works.

The cylinder was replated by Millenium Technologies.

Vertex 23342A piston.

All OEM bearings, seals, gaskets were purchased from Rocky MTN ATV.

 

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