2010 Ktm 450 Sx, 505 Sx Atv Workshop Repair Service Manual (MT034824)

2010 Ktm 450 Sx, 505 Sx Atv Workshop Repair Service Manual (MT034824)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• 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.

  == Format: PDF
  
  System: All Versions of Windows, Mac, iOS, BB, Android, etc
  
  Requirements: PDF Reader.
  
  Printable: Yes

  2010 KTM 450 SX, 505 SX ATV
  
  == 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 .
  
  ———————————
  
  And A LOT MORE
  
  ———————————
  
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