How-To: KTM 450 505 SX-F Top & Bottom Engine Rebuild 2007-2012
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
Dial indicator with magnetic base
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 is 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.
All OEM bearings, seals, gaskets were purchased from Rocky MTN ATV.
My bike is a 2008 KTM 450 xcr-w. Does your instructional video work for my bike?
No. Your bike is different.
Hey , I got a buddy getting rid of a 2011 sxf 450 and I have a 09 sxf 450 that needs a bottom end will the parts off the 2011 match up , he want to sell his for 1000 and it done need much
Not sure on parts interchangeability, sorry.
Hey I purchased this video a couple of years ago ! Just unsure how to get back to the link to watch it again
Resent email link. Check your inbox.
-Matt
My bike is a 2010 ktm exc 400. Does this vidoe work?
No this video won’t work for your model. Sorry.
I have a 2008 450 XCF. While I suspect it may be different for the transmission, would the rest be the same?
Yes, this video applies for your model.
Matthew,
I am on an “extended” work trip to West Africa. As I may not get home till July, I would like to buy the video – but get access form myself and also my 15yr old son to each watch it from where we are. It’s our summer cofinement plan to start the rebuild when i get back home some time.
I bought a blown ’08 450SXf. I also bought a bottom end from someone who had trued the crank and had all the parts zip locked and wrapped packed perfect. He rebuilds as a hobby. He had the bottom end left over from a 500 upgrade. He also sent me a 5 speed tranny from a 450 exc he noted will fit my bike.
William,
Yes you can view it with your son, just have to share credentials in order to log in.
Sounds like a cool father/son project! Awesome!
Matt,
I have a question on my 2019 KTM SX-F 450. I bought a Hi-Flow water pump for it and while i was going to change the prop, I went a head and changed the seal as well. I also have a “2019 Service Manual”. Here is my issue. When i took the clutch cover off (1st time)with the water pump gear, I didn’t realize there is balance gear on the water pump shaft. This gear has 2 dots. One of them is on one side and the other is on the other 180 degrees on the back side. The manual which i check several times, does “NOT” mention ANYTHING about these 2 dots,or the dot on the crankshaft gear where it turns the water pump gear. I’m assuming one of these 2 dots from the water-pump balancer gear has to lineup with the dot on the crank gear. Its so strange that service manual does NOT mention ANYTHING about ANY dots on any of these gears.
(((((((FYI, my main concern is that the water pump gear has a “weigh piece of metal” on it, I’m assuming its for engine vibration to keep the engine vibration down, not 100% sure. Not really sure why water pump gear is shaped like that with weight balance on it,))))))
Anyway, would you happen to know the proper installation of this water pump gear and the lining up the dots?
I appreciate any help or advice. Thank you
Yes the service manual covers correct alignment of that shaft. This rebuild video also covers the procedure.
Matt
Looking for the full video to rebuild 2008 KTM 450 SX-F
Kenny, looks like you bought the video. Thanks!
Hi i nead cylinder head for ktm 2008 505 sxf
Sorry I don’t stock parts.
Matthew,
Just three questions for you. All in, how much are all the parts for the motor rebuild? Then with sending parts out, how much was the rebuild? Second, will this also work for a 2010 KTM 450 XCF?
Thanks,
Impossible to know what parts cost or are needed w/o opening it up. I don’t see the 450 XCF listed in that year. I do see XCW and that is a different engine.
Yes, it is an XCW, what would the difference be between those two motors? Just the transmission or are they completely different?
Transmissions are pretty much the same. Cam/timing drive and lubrication systems are different.
Will this video work for this bike or is it best I look for another?
Thanks Matthew
I can’t point you for a better option. The video should be 60-70% applicable. I feel it should still help. If you decide to buy, and it does not provide value, just ask for a refund.
I have a 2009 Polaris outlaw mxr 450. Is this video compatible with my Atv?
No, looks different.
How-To: KTM 450 505 SX-F Top & Bottom Engine Rebuild 2007-2012
Hello ! Is this video still available and will work after purchase?
Yes:
https://matthewmcrepair.gumroad.com/l/ktm450
Hey I’m new to the KTM world! Just about myself a bike 2008 450 SXF. Needs a rebuild. I’m not sure which parts to order though. I found your video for sale online and I was curious if you had a parts list with that video purchase So I know which parts to purchase?
I don’t recommend buying anything until you fully disassemble it. Then assess what you need.