KTM 450/505 SX ATV Workshop Service Repair Manual

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This workshop service repair manual PDF download for the KTM 450/505 SX ATV has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

KTM 450 SX ATV
KTM 505 SX ATV

TABLE OF CONTENTS :

IMPORTANT NOTES
VIEW OF VEHICLE
LOCATION OF SERIAL NUMBERS
VEHICLE
02/HANDLEBAR, INSTRUMENTS
03/FRAME
04/SHOCK ABSORBER, SWINGARM
05/EXHAUST
06/AIR FILTER
07/FUEL TANK, SEAT, TRIM
08/MASK, FENDER
09/FRONT WHEEL
10/REAR WHEEL
11/WIRING HARNESS, BATTERY
13/BRAKE SYSTEM
30/ENGINE
30/DISASSEMBLING THE ENGINE
30/ENGINE – WORK ON INDIVIDUAL PARTS
30/ENGINE ASSEMBLY
31/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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 3206070en
Total Pages : 247

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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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
Removing the engine guard
Installing the engine guard
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
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
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
Removing the engine
Installing the 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
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
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
A
B
C
D
E
F
H
I
K
M
O
P
Q
R
S
T
V
W

 

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KTM 450/505 SX ATV Workshop Service Repair Manual.pdf

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