2010 KTM 450SX 505SX Sevice Manual
User Manual: 2010 KTM 450SX 505SX Sevice Manual
Open the PDF directly: View PDF
Page Count: 247 [warning: Documents this large are best viewed by clicking the View PDF Link!]
- MEANS OF REPRESENTATION
- IMPORTANT NOTES
- VIEW OF VEHICLE
- LOCATION OF SERIAL NUMBERS
- VEHICLE
- 02/HANDLEBAR, INSTRUMENTS
- 03/FRAME
- 04/SHOCK ABSORBER, SWINGARM
- Front shock absorber - adjusting the high-speed compression damping
- Front shock absorber - adjusting the low-speed compression damping
- Front shock absorber - adjusting the rebound damping
- Front shock absorber - adjusting the spring preload
- Front shock absorber - adjusting the cross over
- Removing the front shock absorber
- Installing the front shock absorber
- Front shock absorber - changing the oil
- Service the front shock absorber
- Front shock absorber - removing the spring
- Front shock absorber - disassembling the damper
- Front shock absorber - disassembling the piston rod
- Front shock absorber - checking the damper
- Front shock absorber - removing the heim joint
- Front shock absorber - installing the heim joint
- Front shock absorber - assembling the piston rod
- Front shock absorber - assembling the damper
- Front shock absorber - bleeding and filling the damper
- Front shock absorber - filling the damper with nitrogen
- Front shock absorber - installing the spring
- Rear shock absorber - adjusting the high-speed compression damping
- Rear shock absorber - adjusting the low-speed compression damping
- Rear shock absorber - adjusting the rebound damping
- Rear shock absorber - adjusting the spring preload
- Removing the rear shock absorber
- Installing the rear shock absorber
- Rear shock absorber - changing the oil
- Servicing the rear shock absorber
- Rear shock absorber - removing the spring
- Rear shock absorber - disassembling the damper
- 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
- 06/AIR FILTER
- 07/FUEL TANK, SEAT, TRIM
- 08/MASK, FENDER
- 09/FRONT WHEEL
- 10/REAR WHEEL
- 11/WIRING HARNESS, BATTERY
- Ignition curve plug connection
- Changing the ignition curve
- Removing the battery
- Installing the battery
- Recharging the battery
- Changing the main fuse
- Changing the fuses of individual power consumers
- Checking the battery voltage
- Checking the charging voltage
- Checking the quiescent current
- Checking the starter relay
- 13/BRAKE SYSTEM
- Hand brake lever, parking brake
- Checking the free travel of the hand brake lever
- Adjusting basic position of hand brake lever
- Checking front brake fluid level
- Topping up the front brake fluid
- Changing the front brake fluid
- Checking the front brake linings
- Removing front brake linings
- Mounting front brake linings
- Changing the front brake linings
- Checking free travel of foot brake lever
- Adjusting basic position of foot brake lever
- Checking rear brake fluid level
- Adding rear brake fluid
- Changing the rear brake fluid
- Checking rear brake linings
- Removing rear brake linings
- Mounting rear brake linings
- Changing rear brake linings
- 30/ENGINE
- 30/DISASSEMBLING THE ENGINE
- Preparations
- Removing the shift lever
- Draining the engine oil
- Removing the oil filter
- Removing the spark plug
- Removing the valve cover
- Removing the starter motor
- Removing the alternator cover
- Removing the torque limiter
- Positioning the engine at ignition top dead center (TDC)
- Removing the camshaft
- Removing the timing chain tensioner
- Removing the double wheel
- Removing the cylinder head
- Removing the water pump cover
- Removing the clutch cover
- Removing the piston
- Removing the timing chain rails
- Removing the timing chain
- Removing the rotor and starter idler gear
- Removing the ignition pulse generator
- Removing the drive wheel of the balancer gear
- Removing the force pump
- Removing the spacer
- Removing the outer clutch hub
- Removing the primary gear
- Removing the centrifugal separator
- 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
- Cylinder - Nikasil® coating
- Checking/measuring cylinder
- Checking/measuring the piston
- Measuring piston/cylinder mounting clearance
- Checking the piston ring
- 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
- 33/TRANSMISSION
- 35/WATER PUMP, COOLING SYSTEM
- 38/LUBRICATION SYSTEM
- 39/IGNITION SYSTEM
- 61/ATV FRONT END
- TECHNICAL DATA - ENGINE
- TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS
- TECHNICAL DATA - ENGINE TIGHTENING TORQUES
- TECHNICAL DATA - CARBURETOR
- TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES
- TECHNICAL DATA - CHASSIS
- TECHNICAL DATA - FRONT SHOCK ABSORBER
- TECHNICAL DATA - REAR SHOCK ABSORBER
- TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
- CLEANING
- STORAGE
- SERVICE SCHEDULE
- WIRING DIAGRAM
- SUBSTANCES
- AUXILIARY SUBSTANCES
- SPECIAL TOOLS
- STANDARDS
- INDEX