KTM 450 SX ATV, 505 SX ATV Repair Service Manual (2010)
Complete service repair manual with Electrical Wiring Diagrams for KTM 450 SX ATV, 505 SX ATV, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
KTM 450 SX ATV, 505 SX ATV 2010 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KTM 450 SX ATV, 505 SX ATV REPAIR MANUAL 2010.pdf
PRODUCT DETAILS:
Total Pages: 247 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
MEANS OF REPRESENTATION....8
IMPORTANT NOTES....9
VIEW OF VEHICLE....10
View of the vehicle from the left front (example)....10
View of the vehicle from the right rear (example)....11
LOCATION OF SERIAL NUMBERS....12
Chassis number....12
Type label....12
Key number....12
Engine number....12
Shock absorber part number, front....12
Shock absorber part number, rear....13
VEHICLE....14
Jacking up the vehicle....14
Removing the vehicle from the work stand....14
02/HANDLEBAR, INSTRUMENTS....15
Hot start lever....15
Adjusting handlebar position....15
Adjusting basic position of clutch lever....16
Checking the play in the throttle cable....16
Adjusting play in throttle cable....16
Removing the steering column....16
Changing the steering column bearing....18
Installing the steering column....20
03/FRAME....22
Removing the engine guard....22
Installing the engine guard....22
04/SHOCK ABSORBER, SWINGARM....23
Front shock absorber - adjusting the high-speed compression damping....23
Front shock absorber - adjusting the low-speed compression damping....23
Front shock absorber - adjusting the rebound damping....24
Front shock absorber - adjusting the spring preload....25
Front shock absorber - adjusting the cross over....26
Removing the front shock absorber....26
Installing the front shock absorber....27
Front shock absorber - changing the oil....27
Service the front shock absorber....29
Front shock absorber - removing the spring....30
Front shock absorber - disassembling the damper....30
Front shock absorber - disassembling the piston rod....31
Front shock absorber - checking the damper....32
Front shock absorber - removing the heim joint....33
Front shock absorber - installing the heim joint....33
Front shock absorber - assembling the piston rod....34
Front shock absorber - assembling the damper....35
Front shock absorber - bleeding and filling the damper....36
Front shock absorber - filling the damper with nitrogen....39
Front shock absorber - installing the spring....40
Rear shock absorber - adjusting the high-speed compression damping....40
Rear shock absorber - adjusting the low-speed compression damping....41
Rear shock absorber - adjusting the rebound damping....42
Rear shock absorber - adjusting the spring preload....42
Removing the rear shock absorber....43
Installing the rear shock absorber....44
Rear shock absorber - changing the oil....44
Servicing the rear shock absorber....46
Rear shock absorber - removing the spring....46
Rear shock absorber - disassembling the damper....47
Rear shock absorber - disassembling the piston rod....48
Rear shock absorber - disassembling the seal ring retainer....49
Changing the pilot bushing....49
Rear shock absorber - checking the damper....50
Rear shock absorber - removing the heim joint....51
Rear shock absorber - installing the heim joint....52
Rear shock absorber - assembling the seal ring retainer....52
Rear shock absorber - assembling the piston rod....53
Rear shock absorber - assembling the damper....54
Rear shock absorber - bleeding and filling the damper....56
Rear shock absorber - filling the damper with nitrogen....58
Rear shock absorber - installing the spring....59
05/EXHAUST....61
Removing the main silencer....61
Installing the main silencer....61
Removing the manifold....62
Installing the manifold....62
06/AIR FILTER....63
Removing the air filter....63
Installing the air filter....63
Cleaning air filter....63
Removing the air filter box lid with the carburetor connection boot....64
Installing the air filter box lid and the carburetor connection boot....64
07/FUEL TANK, SEAT, TRIM....65
Removing the seat....65
Mounting the seat....65
Removing the radiator spoiler....65
Installing the radiator spoiler....66
Removing the fuel tank....66
Installing the fuel tank....67
Fuel tap....68
08/MASK, FENDER....69
Removing the heel protector....69
Installing the heel protector....70
Removing the front cover....71
Installing the front cover....71
Removing the front trim....71
Installing the front trim....72
Removing the rear fender....72
Installing the rear fender....73
09/FRONT WHEEL....74
Checking the tire air pressure....74
Checking the tire condition....74
Removing wheel/wheels....74
Installing the wheel/wheels....75
Checking brake discs....76
10/REAR WHEEL....77
Checking chain dirt....77
Cleaning the chain....77
Checking chain wear....77
Checking rear sprocket / engine sprocket for wear....78
Checking the chain tension....78
Adjusting chain tension....78
Adjusting the toe width of rear axle....79
Removing the rear axle....80
Installing the rear axle....81
Changing the rear axle bearing....83
11/WIRING HARNESS, BATTERY....85
Ignition curve plug connection....85
Changing the ignition curve....85
Removing the battery....85
Installing the battery....85
Recharging the battery....86
Changing the main fuse....87
Changing the fuses of individual power consumers....87
Checking the battery voltage....88
Checking the charging voltage....88
Checking the quiescent current....88
Checking the starter relay....89
13/BRAKE SYSTEM....90
Hand brake lever, parking brake....90
Checking the free travel of the hand brake lever....90
Adjusting basic position of hand brake lever....90
Checking front brake fluid level....91
Topping up the front brake fluid....91
Changing the front brake fluid....92
Checking the front brake linings....93
Removing front brake linings....93
Mounting front brake linings....94
Changing the front brake linings....94
Checking free travel of foot brake lever....95
Adjusting basic position of foot brake lever....95
Checking rear brake fluid level....96
Adding rear brake fluid....96
Changing the rear brake fluid....97
Checking rear brake linings....98
Removing rear brake linings....98
Mounting rear brake linings....99
Changing rear brake linings....100
30/ENGINE....101
Removing the engine....101
Installing the engine....102
30/DISASSEMBLING THE ENGINE....105
Preparations....105
Removing the shift lever....105
Draining the engine oil....105
Removing the oil filter....105
Removing the spark plug....106
Removing the valve cover....106
Removing the starter motor....106
Removing the alternator cover....106
Removing the torque limiter....107
Positioning the engine at ignition top dead center (TDC)....107
Removing the camshaft....108
Removing the timing chain tensioner....108
Removing the double wheel....109
Removing the cylinder head....109
Removing the water pump cover....110
Removing the clutch cover....110
Removing the piston....111
Removing the timing chain rails....111
Removing the timing chain....111
Removing the rotor and starter idler gear....112
Removing the ignition pulse generator....112
Removing the drive wheel of the balancer gear....113
Removing the force pump....113
Removing the spacer....114
Removing the outer clutch hub....114
Removing the primary gear....115
Removing the centrifugal separator....115
Removing the suction pump....116
Removing the shift shaft....116
Removing the shift drum locating unit....117
Removing the locking lever....117
Removing the left section of the engine case....117
Removing the shift rails....118
Removing the shift drum....118
Removing the shift forks....118
Removing the transmission shafts....118
Removing the crankshaft....119
30/ENGINE - WORK ON INDIVIDUAL PARTS....120
Working on the right section of the engine case....120
Working on the left section of the engine case....121
Removing the water pump....122
Changing the shaft seal ring of the water pump....123
Installing the water pump....124
Removing the crankshaft seal ring in the clutch cover....125
Installing the crankshaft seal ring in the clutch cover....125
Removing the oil pressure regulator valve....125
Checking spring length of oil pressure regulator valve....125
Installing the oil pressure regulator valve....126
Checking the lubrication system....126
Removing the crankshaft bearing inner race....127
Installing the crankshaft bearing inner race....127
Changing connecting rod, conrod bearing and crank pin....127
Checking crankshaft run-out at bearing pin....128
Measuring the crankshaft....129
Cylinder - Nikasil® coating....129
Checking/measuring cylinder....129
Checking/measuring the piston....130
Measuring piston/cylinder mounting clearance....131
Checking the piston ring....131
Changing the camshaft bearing....131
Checking the autodecompressor....132
Checking camshafts....132
Checking the radial clearance of the camshaft bearings....132
Checking the camshaft bearing bridges....133
Removing the valves....133
Checking the valves....134
Checking the valve springs....135
Checking valve spring seat....135
Checking the cam levers....135
Checking cylinder head....135
Installing the valves....136
Removing the freewheel....137
Checking the freewheel....137
Installing the free wheel....137
Checking the electric starter mode....138
Checking the timing assembly....139
Preparing the timing chain tensioner for installation....139
Checking clutch....140
Checking shift mechanism....141
Preassembling the shift shaft....142
Disassembling the main shaft....143
Disassembling the countershaft....143
Checking transmission....144
Assembling the main shaft....145
Assembling the countershaft....146
30/ENGINE ASSEMBLY....147
Installing the crankshaft....147
Installing the transmission shafts....147
Installing the shift forks....147
Installing the shift drum....148
Installing the shift rails....148
Installing the left engine case....148
Installing the locking lever....149
Installing the shift drum locating unit....149
Installing the shift shaft....149
Installing the suction pumps....149
Installing the centrifugal separator....150
Installing the force pump....150
Installing the primary gear....151
Installing the outer clutch hub....151
Installing the spacer....152
Installing the drive wheel of the balancer gear....153
Installing the timing chain....153
Installing the free wheel gear....153
Installing the ignition pulse generator....154
Installing the rotor....154
Installing the timing chain rails....154
Installing the piston....154
Installing the clutch cover....156
Installing the water pump cover....156
Installing the cylinder head....157
Installing the double wheel....157
Installing the timing chain tensioner....158
Checking the valve timing....158
Adjusting the valve timing....159
Checking the valve clearance....160
Adjusting the valve clearance....160
Installing the torque limiter....161
Installing the alternator cover....161
Installing the starter motor....161
Installing the valve cover....161
Installing the spark plug....162
Installing the oil screen....162
Installing the oil filter....162
Installing the shift lever....163
Removing the engine from the universal mounting rack....163
31/CARBURETOR....164
Choke....164
Checking the play in the throttle cable....164
Carburetor - adjusting idle....164
Checking the position of the throttle position sensor....165
Draining the carburetor float chamber....166
Removing the carburetor....166
Installing the carburetor....168
Disassembling the carburetor....169
Checking/adjusting the carburetor components....172
Checking/adjusting the accelerator pump....172
Checking the choke slide....173
Checking the hot start slide....173
Checking the throttle position sensor....173
Checking the jet needle....174
Checking the throttle slide....174
Checking/adjusting the throttle slide opening....175
Checking the needle jet....175
Checking the float needle valve....175
Checking/adjusting the float level....176
Adjusting the position of the throttle position sensor....176
Assembling the carburetor....177
32/CLUTCH....180
Checking fluid level of hydraulic clutch....180
Changing the hydraulic clutch fluid....180
33/TRANSMISSION....181
Removing the engine sprocket....181
Installing the engine sprocket....181
35/WATER PUMP, COOLING SYSTEM....182
Checking antifreeze and coolant level....182
Checking the coolant level....182
Draining coolant....183
Filling coolant/bleeding the cooling system....183
38/LUBRICATION SYSTEM....185
Oil circuit....185
Changing the engine oil and oil filter, cleaning the oil screen....185
Draining the engine oil....186
Removing the oil filter....186
Installing the oil filter....187
Filling up with engine oil....187
Checking the engine oil level....187
Adding engine oil....188
39/IGNITION SYSTEM....189
Removing the stator....189
Installing the stator....189
Checking the ignition system....189
Checking the ignition coil....190
Checking the spark plug connector....191
Checking the CDI controller....191
Checking the ignition pulse generator....191
Checking the alternator....192
61/ATV FRONT END....193
Checking the toe....193
Adjusting the toe....194
Checking/adjusting the camber....195
Adjusting the fork offset....196
Removing the wheel carrier....196
Changing the wheel bearing....198
Installing the wheel carrier....199
Removing the A-arms....200
Installing the A-arms....201
A-Arm top - changing the bearing....202
A-Arm bottom - changing the bearing....203
TECHNICAL DATA - ENGINE....206
Capacity - engine oil....206
Capacity - coolant....206
TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS....207
TECHNICAL DATA - ENGINE TIGHTENING TORQUES....208
TECHNICAL DATA - CARBURETOR....210
TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES....211
TECHNICAL DATA - CHASSIS....212
Tires....213
Capacity - fuel....213
TECHNICAL DATA - FRONT SHOCK ABSORBER....214
TECHNICAL DATA - REAR SHOCK ABSORBER....215
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES....216
CLEANING....217
Cleaning the vehicle....217
STORAGE....218
Storage....218
Putting the vehicle into operation after storage....218
SERVICE SCHEDULE....219
Important maintenance work to be carried out by an authorized KTM workshop....219
Important maintenance work to be carried out by an authorized KTM workshop (as an additional order)....220
Important checks and maintenance work to be carried out by the rider....220
WIRING DIAGRAM....222
450/525 SX ATV....222
SUBSTANCES....225
AUXILIARY SUBSTANCES....227
SPECIAL TOOLS....229
STANDARDS....242
INDEX....243
KTM 450 SX ATV, 505 SX ATV Repair Service Manual (2010)
