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2010 KTM 450 SX, 505 SX ATV Workshop Repair Service Manual
This is a COMPLETE Service and Repair Manual for your 2010 KTM 450 SX, 505 SX ATV. It covers every single detail. All models, and all engines are included.
This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. This manual for 2010 KTM 450 SX, 505 SX ATV can be viewed on any computer, as well as zoomed and printed. All repair procedures are covered A-Z. This manual makes any repair job easy to do with very easy to follow step-by-step instructions & pictures on all areas of repair.
Fixing problems in your vehicle is a do-it-approach with the this Repair Manual for 2010 KTM 450 SX, 505 SX ATV as they contain comprehensive instructions and procedures on how to fix the problems in your ride. Repair Manuals can come in handy especially when you have to do immediate repair. The durability of your vehicle/bike is unquestionable but you also know that no matter how tough they are, constant use can cause them to deteriorate. When this happens, and ultimately it will, you will have to replace them. Some car/bike parts are very simple to mount and do not require professional help. By having a trusty repair manual you not only save money but you also get to experience the fun of do-it-yourself projects. A repair manual comes with comprehensive details regarding technical data, diagrams, a complete list of car parts and pictures. Even the most novice can easily follow the step-by-step guides which are made simple by the illustrations and drawings. You can find a complete list of accessories that can further enhance the performance of your engine. This Repair Manual for 2010 KTM 450 SX, 505 SX ATV can save you a lot of time. These packages are complete with all the information needs. You will surely enjoy browsing through the pages and learning how to repair the different parts. It makes you up-to-date and more knowledge. Now, you dont have to rely on your mechanic for the simplest repair. You can do it at the comfort of your garage. All pages are printable, so print off what you need and take it with you into the garage or workshop. This manual will never get dirty and rip as you can keep it safely on your PC and print the pages you need in matter of seconds.
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Format: PDF
System: All Versions of Windows, Mac, iOS, BB, Android, etc
Requirements: PDF Reader.
Printable: Yes
2010 KTM 450 SX, 505 SX ATV
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SERVICE REPAIR MANUAL COVERS:
CONTENTS
CONTENTS
MEANS OF REPRESENTATION
IMPORTANT NOTES
VIEW OF VEHICLE
View of the vehicle from the left front (example)
View of the vehicle from the right rear (example)
LOCATION OF SERIAL NUMBERS
Chassis number
Type label
Key number
Engine number
Shock absorber part number, front
Shock absorber part number, rear
VEHICLE
Jacking up the vehicle
Removing the vehicle from the work stand
02/HANDLEBAR, INSTRUMENTS
Hot start lever
Adjusting handlebar position
Adjusting basic position of clutch lever
Checking the play in the throttle cable
Adjusting play in throttle cable
Removing the steering column
Changing the steering column bearing
Installing the steering column
03/FRAME 20
Removing the engine guard 20
Installing the engine guard 20
04/SHOCK ABSORBER, SWINGARM 21
Front shock absorber - adjusting the high-speed
compression damping . 21
Front shock absorber - adjusting the low-speed
compression damping . 21
Front shock absorber - adjusting the rebound damping 22
Front shock absorber - adjusting the spring preload . 23
Front shock absorber - adjusting the cross over 24
Removing the front shock absorber. 24
Installing the front shock absorber . 25
Front shock absorber - changing the oil 25
Service the front shock absorber . 27
Front shock absorber - removing the spring . 28
Front shock absorber - disassembling the damper . 28
Front shock absorber - disassembling the piston rod 29
Front shock absorber - checking the damper 30
Front shock absorber - removing the heim joint . 31
Front shock absorber - installing the heim joint . 31
Front shock absorber - assembling the piston rod 32
Front shock absorber - assembling the damper 33
Front shock absorber - bleeding and filling the damper 34
Front shock absorber - filling the damper with nitrogen 37
Front shock absorber - installing the spring . 38
Rear shock absorber - adjusting the high-speed
compression damping . 38
Rear shock absorber - adjusting the low-speed
compression damping . 39
Rear shock absorber - adjusting the rebound damping. 40
Rear shock absorber - adjusting the spring preload 40
Removing the rear shock absorber 41
Installing the rear shock absorber 42
Rear shock absorber - changing the oil . 42
Servicing the rear shock absorber 44
Rear shock absorber - removing the spring 44
Rear shock absorber - disassembling the damper 45
Rear shock absorber - disassembling the piston rod .
Rear shock absorber - disassembling the seal ring
retainer
Changing the pilot bushing
Rear shock absorber - checking the damper
Rear shock absorber - removing the heim joint
Rear shock absorber - installing the heim joint
Rear shock absorber - assembling the seal ring retainer
Rear shock absorber - assembling the piston rod
Rear shock absorber - assembling the damper
Rear shock absorber - bleeding and filling the damper
Rear shock absorber - filling the damper with nitrogen
Rear shock absorber - installing the spring
05/EXHAUST
Removing the main silencer
Installing the main silencer
Removing the manifold
Installing the manifold
06/AIR FILTER
Removing the air filter
Installing the air filter .
Cleaning air filter
Removing the air filter box lid with the carburetor
connection boot
Installing the air filter box lid and the carburetor
connection boot
07/FUEL TANK, SEAT, TRIM.
Removing the seat
Mounting the seat
Removing the radiator spoiler
Installing the radiator spoiler
Removing the fuel tank
Installing the fuel tank
Fuel tap
08/MASK, FENDER
Removing the heel protector .
Installing the heel protector
Removing the front cover
Installing the front cover
Removing the front trim .
Installing the front trim
Removing the rear fender
Installing the rear fender
09/FRONT WHEEL
Checking the tire air pressure
Checking the tire condition
Removing wheel/wheels
Installing the wheel/wheels
Checking brake discs
10/REAR WHEEL
Checking chain dirt .
Cleaning the chain
Checking chain wear
Checking rear sprocket / engine sprocket for wear .
Checking the chain tension
Adjusting chain tension
Adjusting the toe width of rear axle
Removing the rear axle
Installing the rear axle
Changing the rear axle bearing.
11/WIRING HARNESS, BATTERY
Ignition curve plug connection .
Changing the ignition curve 83
Removing the battery 83
Installing the battery 83
Recharging the battery 84
Changing the main fuse . 85
Changing the fuses of individual power consumers 85
Checking the battery voltage. 86
Checking the charging voltage . 86
Checking the quiescent current 86
Checking the starter relay 87
13/BRAKE SYSTEM 88
Hand brake lever, parking brake 88
Checking the free travel of the hand brake lever 88
Adjusting basic position of hand brake lever 88
Checking front brake fluid level 89
Topping up the front brake fluid 89
Changing the front brake fluid . 90
Checking the front brake linings 91
Removing front brake linings 91
Mounting front brake linings. 92
Changing the front brake linings . 92
Checking free travel of foot brake lever . 93
Adjusting basic position of foot brake lever . 93
Checking rear brake fluid level. 94
Adding rear brake fluid 94
Changing the rear brake fluid 95
Checking rear brake linings 96
Removing rear brake linings 96
Mounting rear brake linings 97
Changing rear brake linings 98
30/ENGINE 99
Removing the engine 99
Installing the engine . 100
30/DISASSEMBLING THE ENGINE 103
Preparations. 103
Removing the shift lever 103
Draining the engine oil . 103
Removing the oil filter 103
Removing the spark plug . 104
Removing the valve cover 104
Removing the starter motor 104
Removing the alternator cover 104
Removing the torque limiter 105
Positioning the engine at ignition top dead center
(TDC) . 105
Removing the camshaft 106
Removing the timing chain tensioner 106
Removing the double wheel 107
Removing the cylinder head 107
Removing the water pump cover 108
Removing the clutch cover . 108
Removing the piston . 109
Removing the timing chain rails 109
Removing the timing chain. 109
Removing the rotor and starter idler gear 110
Removing the ignition pulse generator 110
Removing the drive wheel of the balancer gear 111
Removing the force pump 111
Removing the spacer 112
Removing the outer clutch hub . 112
Removing the primary gear . 113
Removing the centrifugal separator . 113
Removing the suction pump
Removing the shift shaft .
Removing the shift drum locating unit
Removing the locking lever.
Removing the left section of the engine case
Removing the shift rails
Removing the shift drum .
Removing the shift forks .
Removing the transmission shafts
Removing the crankshaft .
30/ENGINE - WORK ON INDIVIDUAL PARTS
Working on the right section of the engine case
Working on the left section of the engine case.
Removing the water pump
Changing the shaft seal ring of the water pump
Installing the water pump
Removing the crankshaft seal ring in the clutch cover
Installing the crankshaft seal ring in the clutch cover
Removing the oil pressure regulator valve
Checking spring length of oil pressure regulator valve
Installing the oil pressure regulator valve
Checking the lubrication system
Removing the crankshaft bearing inner race .
Installing the crankshaft bearing inner race
Changing connecting rod, conrod bearing and crank
pin
Checking crankshaft run-out at bearing pin
Measuring the crankshaft end play
Cylinder - Nikasil® coating
Checking/measuring cylinder .
Checking/measuring the piston .
Measuring piston/cylinder mounting clearance.
Checking the piston ring end gap .
Changing the camshaft bearing.
Checking the autodecompressor
Checking camshafts
Checking the radial clearance of the camshaft
bearings
Checking the camshaft bearing bridges
Removing the valves .
Checking the valves
Checking the valve springs .
Checking valve spring seat
Checking the cam levers .
Checking cylinder head
Installing the valves
Removing the freewheel
Checking the freewheel
Installing the free wheel
Checking the electric starter mode
Checking the timing assembly
Preparing the timing chain tensioner for installation .
Checking clutch .
Checking shift mechanism .
Preassembling the shift shaft.
Disassembling the main shaft
Disassembling the countershaft
Checking transmission .
Assembling the main shaft .
Assembling the countershaft
30/ENGINE ASSEMBLY
Installing the crankshaft
Installing the transmission shafts .
Installing the shift forks
Installing the shift drum
Installing the shift rails
Installing the left engine case
Installing the locking lever
Installing the shift drum locating unit.
Installing the shift shaft
Installing the suction pumps .
Installing the centrifugal separator
Installing the force pump
Installing the primary gear
Installing the outer clutch hub
Installing the spacer .
Installing the drive wheel of the balancer gear .
Installing the timing chain
Installing the free wheel gear.
Installing the ignition pulse generator.
Installing the rotor .
Installing the timing chain rails.
Installing the piston
Installing the clutch cover
Installing the water pump cover
Installing the cylinder head
Installing the double wheel.
Installing the timing chain tensioner
Checking the valve timing
Adjusting the valve timing
Checking the valve clearance .
Adjusting the valve clearance.
Installing the torque limiter
Installing the alternator cover
Installing the starter motor .
Installing the valve cover .
Installing the spark plug
Installing the oil screen
Installing the oil filter
Installing the shift lever
Removing the engine from the universal mounting
rack
31/CARBURETOR
Choke.
Checking the play in the throttle cable
Carburetor - adjusting idle
Checking the position of the throttle position sensor .
Draining the carburetor float chamber
Removing the carburetor .
Installing the carburetor
Disassembling the carburetor.
Checking/adjusting the carburetor components
Checking/adjusting the accelerator pump
Checking the choke slide.
Checking the hot start slide
Checking the throttle position sensor
Checking the jet needle
Checking the throttle slide
Checking/adjusting the throttle slide opening
Checking the needle jet
Checking the float needle valve.
Checking/adjusting the float level.
Adjusting the position of the throttle position sensor .
Assembling the carburetor
32/CLUTCH
Checking fluid level of hydraulic clutch .
Changing the hydraulic clutch fluid .
33/TRANSMISSION
Removing the engine sprocket
Installing the engine sprocket
35/WATER PUMP, COOLING SYSTEM
Checking antifreeze and coolant level .
Checking the coolant level
Draining coolant .
Filling coolant/bleeding the cooling system
38/LUBRICATION SYSTEM .
Oil circuit .
Changing the engine oil and oil filter, cleaning the oil
screen
Draining the engine oil .
Removing the oil filter
Installing the oil filter
Filling up with engine oil.
Checking the engine oil level .
Adding engine oil
39/IGNITION SYSTEM
Removing the stator
Installing the stator
Checking the ignition system .
Checking the ignition coil
Checking the spark plug connector
Checking the CDI controller
Checking the ignition pulse generator .
Checking the alternator
61/ATV FRONT END
Checking the toe
Adjusting the toe
Checking/adjusting the camber .
Adjusting the fork offset
Removing the wheel carrier
Changing the wheel bearing
Installing the wheel carrier .
Removing the A-arms
Installing the A-arms
A-Arm top - changing the bearing.
A-Arm bottom - changing the bearing .
TECHNICAL DATA - ENGINE
Capacity - engine oil .
Capacity - coolant
TECHNICAL DATA - ENGINE TOLERANCES, WEAR
LIMITS
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
TECHNICAL DATA - CARBURETOR
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES
TECHNICAL DATA - CHASSIS
Tires
Capacity - fuel.
TECHNICAL DATA - FRONT SHOCK ABSORBER.
TECHNICAL DATA - REAR SHOCK ABSORBER
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
CLEANING.
Cleaning the vehicle .
STORAGE
Storage
Putting the vehicle into operation after storage
216CONTENTS
SERVICE SCHEDULE.
Important maintenance work to be carried out by an
authorized KTM workshop
Important maintenance work to be carried out by an
authorized KTM workshop (as an additional order) .
Important checks and maintenance work to be carried
out by the rider
WIRING DIAGRAM .
450/525 SX ATV
SUBSTANCES
AUXILIARY SUBSTANCES
SPECIAL TOOLS
STANDARDS.
INDEX .
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And A LOT MORE
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