Issuu on Google+

2010 KTM 450 SX, 505 SX ATV Workshop Repair Service Manual

Please DOWNLOAD this PDF file then click the

DIRECT DOWNLOAD LINK HERE 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速 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 --------------------------------INSTANT DOWNLOAD MEANS THERE WILL BE NO SHIPPING COSTS OR WAITING FOR A PAPER OR CD MANUAL TO ARRIVE IN THE MAIL. YOU WILL RECEIVE THIS MANUAL TODAY VIA INSTANT DOWNLOAD. BUY WITH CONFIDENCE !!


2010 ktm 450 sx, 505 sx atv workshop repair service manual