KTM 450 SX ATV 2009-2011 Service Repair Workshop Manual

REPAIR MANUAL 2010 450 SX ATV 505 SX ATV Article no. 3206070en PartShark.com 877-999-5686

PartShark.com 877-999-5686

INTRODUCTION 1 INTRODUCTION It is important that you read this owner's manual carefully and completely before the start of work. Only use ORIGINAL KTM SPARE PARTS. This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified experts. The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in the interest of technical advancement without, at the same time, updating this repair manual. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that repair work will be performed by a fully trained mechanic. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria PartShark.com 877-999-5686

CONTENTS 2 CONTENTS MEANS OF REPRESENTATION ............................................ 6 IMPORTANT NOTES ............................................................ 7 VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example) ................. 8 View of the vehicle from the right rear (example) ................ 9 LOCATION OF SERIAL NUMBERS ...................................... 10 Chassis number ............................................................. 10 Type label ..................................................................... 10 Key number .................................................................. 10 Engine number.............................................................. 10 Shock absorber part number, front .................................. 10 Shock absorber part number, rear ................................... 11 VEHICLE .......................................................................... 12 Jacking up the vehicle ................................................... 12 Removing the vehicle from the work stand ....................... 12 02/HANDLEBAR, INSTRUMENTS....................................... 13 Hot start lever ............................................................... 13 Adjusting handlebar position .......................................... 13 Adjusting basic position of clutch lever ............................ 14 Checking the play in the throttle cable............................. 14 Adjusting play in throttle cable ....................................... 14 Removing the steering column ........................................ 14 Changing the steering column bearing ............................. 16 Installing the steering column......................................... 18 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 .......... 46 Rear shock absorber - disassembling the seal ring retainer ........................................................................ 47 Changing the pilot bushing ............................................. 47 Rear shock absorber - checking the damper ..................... 48 Rear shock absorber - removing the heim joint ................. 49 Rear shock absorber - installing the heim joint ................. 50 Rear shock absorber - assembling the seal ring retainer ..... 50 Rear shock absorber - assembling the piston rod .............. 51 Rear shock absorber - assembling the damper .................. 52 Rear shock absorber - bleeding and filling the damper ...... 54 Rear shock absorber - filling the damper with nitrogen ...... 56 Rear shock absorber - installing the spring ....................... 57 05/EXHAUST .................................................................... 59 Removing the main silencer............................................ 59 Installing the main silencer ............................................ 59 Removing the manifold .................................................. 60 Installing the manifold ................................................... 60 06/AIR FILTER.................................................................. 61 Removing the air filter ................................................... 61 Installing the air filter .................................................... 61 Cleaning air filter........................................................... 61 Removing the air filter box lid with the carburetor connection boot ............................................................ 62 Installing the air filter box lid and the carburetor connection boot ............................................................ 62 07/FUEL TANK, SEAT, TRIM.............................................. 63 Removing the seat ......................................................... 63 Mounting the seat ......................................................... 63 Removing the radiator spoiler ......................................... 63 Installing the radiator spoiler .......................................... 64 Removing the fuel tank .................................................. 64 Installing the fuel tank ................................................... 65 Fuel tap........................................................................ 66 08/MASK, FENDER ........................................................... 67 Removing the heel protector ........................................... 67 Installing the heel protector ............................................ 68 Removing the front cover................................................ 69 Installing the front cover ................................................ 69 Removing the front trim ................................................. 69 Installing the front trim .................................................. 70 Removing the rear fender ............................................... 70 Installing the rear fender ................................................ 71 09/FRONT WHEEL ............................................................ 72 Checking the tire air pressure ......................................... 72 Checking the tire condition............................................. 72 Removing wheel/wheels.................................................. 72 Installing the wheel/wheels ............................................. 73 Checking brake discs ..................................................... 74 10/REAR WHEEL .............................................................. 75 Checking chain dirt ....................................................... 75 Cleaning the chain......................................................... 75 Checking chain wear ...................................................... 75 Checking rear sprocket / engine sprocket for wear ............. 76 Checking the chain tension ............................................ 76 Adjusting chain tension.................................................. 76 Adjusting the toe width of rear axle ................................. 77 Removing the rear axle................................................... 78 Installing the rear axle ................................................... 79 Changing the rear axle bearing ........................................ 81 11/WIRING HARNESS, BATTERY ....................................... 83 Ignition curve plug connection ........................................ 83 PartShark.com 877-999-5686

CONTENTS 3 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 ......................................... 114 Removing the shift shaft .............................................. 114 Removing the shift drum locating unit ........................... 115 Removing the locking lever ........................................... 115 Removing the left section of the engine case .................. 115 Removing the shift rails ............................................... 116 Removing the shift drum .............................................. 116 Removing the shift forks .............................................. 116 Removing the transmission shafts ................................. 116 Removing the crankshaft .............................................. 117 30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 118 Working on the right section of the engine case .............. 118 Working on the left section of the engine case ................ 119 Removing the water pump ............................................ 120 Changing the shaft seal ring of the water pump .............. 121 Installing the water pump............................................. 122 Removing the crankshaft seal ring in the clutch cover ..... 123 Installing the crankshaft seal ring in the clutch cover ...... 123 Removing the oil pressure regulator valve....................... 123 Checking spring length of oil pressure regulator valve...... 123 Installing the oil pressure regulator valve ....................... 124 Checking the lubrication system.................................... 124 Removing the crankshaft bearing inner race ................... 125 Installing the crankshaft bearing inner race .................... 125 Changing connecting rod, conrod bearing and crank pin ............................................................................. 125 Checking crankshaft run-out at bearing pin .................... 126 Measuring the crankshaft end play ................................ 127 Cylinder - Nikasil ® coating ............................................ 127 Checking/measuring cylinder ........................................ 127 Checking/measuring the piston ..................................... 128 Measuring piston/cylinder mounting clearance................ 129 Checking the piston ring end gap .................................. 129 Changing the camshaft bearing ..................................... 129 Checking the autodecompressor .................................... 130 Checking camshafts ..................................................... 130 Checking the radial clearance of the camshaft bearings ..................................................................... 130 Checking the camshaft bearing bridges.......................... 131 Removing the valves .................................................... 131 Checking the valves ..................................................... 132 Checking the valve springs ........................................... 133 Checking valve spring seat............................................ 133 Checking the cam levers .............................................. 133 Checking cylinder head ................................................ 133 Installing the valves ..................................................... 134 Removing the freewheel ............................................... 135 Checking the freewheel ................................................ 135 Installing the free wheel ............................................... 135 Checking the electric starter mode ................................ 136 Checking the timing assembly ...................................... 137 Preparing the timing chain tensioner for installation ....... 137 Checking clutch .......................................................... 138 Checking shift mechanism ........................................... 139 Preassembling the shift shaft........................................ 140 Disassembling the main shaft ....................................... 141 Disassembling the countershaft .................................... 141 Checking transmission ................................................. 142 Assembling the main shaft ........................................... 143 Assembling the countershaft......................................... 144 30/ENGINE ASSEMBLY ................................................... 145 Installing the crankshaft............................................... 145 PartShark.com 877-999-5686

CONTENTS 4 Installing the transmission shafts .................................. 145 Installing the shift forks ............................................... 145 Installing the shift drum............................................... 146 Installing the shift rails ................................................ 146 Installing the left engine case ....................................... 146 Installing the locking lever............................................ 147 Installing the shift drum locating unit ............................ 147 Installing the shift shaft ............................................... 147 Installing the suction pumps ........................................ 147 Installing the centrifugal separator ................................ 148 Installing the force pump ............................................. 148 Installing the primary gear ............................................ 149 Installing the outer clutch hub ...................................... 149 Installing the spacer .................................................... 150 Installing the drive wheel of the balancer gear ................ 151 Installing the timing chain............................................ 151 Installing the free wheel gear ........................................ 151 Installing the ignition pulse generator ............................ 152 Installing the rotor ....................................................... 152 Installing the timing chain rails..................................... 152 Installing the piston ..................................................... 152 Installing the clutch cover ............................................ 154 Installing the water pump cover .................................... 154 Installing the cylinder head .......................................... 155 Installing the double wheel ........................................... 155 Installing the timing chain tensioner ............................. 156 Checking the valve timing ............................................ 156 Adjusting the valve timing ............................................ 157 Checking the valve clearance ........................................ 158 Adjusting the valve clearance........................................ 158 Installing the torque limiter .......................................... 159 Installing the alternator cover ....................................... 159 Installing the starter motor ........................................... 159 Installing the valve cover .............................................. 159 Installing the spark plug............................................... 160 Installing the oil screen ................................................ 160 Installing the oil filter .................................................. 160 Installing the shift lever ............................................... 161 Removing the engine from the universal mounting rack ........................................................................... 161 31/CARBURETOR ........................................................... 162 Choke......................................................................... 162 Checking the play in the throttle cable........................... 162 Carburetor - adjusting idle ............................................ 162 Checking the position of the throttle position sensor ....... 163 Draining the carburetor float chamber ........................... 164 Removing the carburetor .............................................. 164 Installing the carburetor ............................................... 166 Disassembling the carburetor ........................................ 167 Checking/adjusting the carburetor components ............... 170 Checking/adjusting the accelerator pump ....................... 170 Checking the choke slide.............................................. 171 Checking the hot start slide .......................................... 171 Checking the throttle position sensor ............................. 171 Checking the jet needle................................................ 172 Checking the throttle slide............................................ 172 Checking/adjusting the throttle slide opening ................. 173 Checking the needle jet................................................ 173 Checking the float needle valve ..................................... 173 Checking/adjusting the float level .................................. 174 Adjusting the position of the throttle position sensor ....... 174 Assembling the carburetor ............................................ 175 32/CLUTCH .................................................................... 178 Checking fluid level of hydraulic clutch ......................... 178 Changing the hydraulic clutch fluid ............................... 178 33/TRANSMISSION......................................................... 179 Removing the engine sprocket ...................................... 179 Installing the engine sprocket ....................................... 179 35/WATER PUMP, COOLING SYSTEM .............................. 180 Checking antifreeze and coolant level ............................ 180 Checking the coolant level ............................................ 180 Draining coolant .......................................................... 181 Filling coolant/bleeding the cooling system .................... 181 38/LUBRICATION SYSTEM .............................................. 183 Oil circuit ................................................................... 183 Changing the engine oil and oil filter, cleaning the oil screen ........................................................................ 183 Draining the engine oil ................................................. 184 Removing the oil filter.................................................. 184 Installing the oil filter .................................................. 185 Filling up with engine oil .............................................. 185 Checking the engine oil level ........................................ 185 Adding engine oil ........................................................ 186 39/IGNITION SYSTEM ..................................................... 187 Removing the stator ..................................................... 187 Installing the stator ..................................................... 187 Checking the ignition system ........................................ 187 Checking the ignition coil ............................................. 188 Checking the spark plug connector ................................ 189 Checking the CDI controller .......................................... 189 Checking the ignition pulse generator ............................ 189 Checking the alternator ................................................ 190 61/ATV FRONT END ........................................................ 191 Checking the toe ......................................................... 191 Adjusting the toe ......................................................... 192 Checking/adjusting the camber ..................................... 193 Adjusting the fork offset ............................................... 194 Removing the wheel carrier .......................................... 194 Changing the wheel bearing .......................................... 196 Installing the wheel carrier ........................................... 197 Removing the A-arms ................................................... 198 Installing the A-arms ................................................... 199 A-Arm top - changing the bearing .................................. 200 A-Arm bottom - changing the bearing ............................ 201 TECHNICAL DATA - ENGINE ............................................ 204 Capacity - engine oil .................................................... 204 Capacity - coolant ........................................................ 204 TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS ........................................................................... 205 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 206 TECHNICAL DATA - CARBURETOR ................................... 208 TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES ....................................................................... 209 TECHNICAL DATA - CHASSIS .......................................... 210 Tires .......................................................................... 211 Capacity - fuel............................................................. 211 TECHNICAL DATA - FRONT SHOCK ABSORBER ................ 212 TECHNICAL DATA - REAR SHOCK ABSORBER .................. 213 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 214 CLEANING...................................................................... 215 Cleaning the vehicle .................................................... 215 STORAGE ....................................................................... 216 Storage....................................................................... 216 Putting the vehicle into operation after storage ............... 216 PartShark.com 877-999-5686

CONTENTS 5 SERVICE SCHEDULE....................................................... 217 Important maintenance work to be carried out by an authorized KTM workshop ............................................ 217 Important maintenance work to be carried out by an authorized KTM workshop (as an additional order) .......... 218 Important checks and maintenance work to be carried out by the rider ........................................................... 218 WIRING DIAGRAM .......................................................... 220 450/525 SX ATV ......................................................... 220 SUBSTANCES ................................................................. 223 AUXILIARY SUBSTANCES................................................ 225 SPECIAL TOOLS.............................................................. 227 STANDARDS ................................................................... 240 INDEX ............................................................................ 241 PartShark.com 877-999-5686

MEANS OF REPRESENTATION 6 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained below. Proprietary name Denotes a proprietary name. Name ® Denotes a protected name. Brand™ Denotes a brand available on the open market. PartShark.com 877-999-5686

IMPORTANT NOTES 7 Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be accepted for damage resulting from manipulations and/or alterations to the vehicle. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories Use only spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com Work rules Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parenthe- ses. E.g.: valve spring mounter (59029019000) When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must be replaced with new parts. If a thread locker (e.g. Loctite ® ) is used for screw connections, follow the instructions for use from the manufacturer. Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear. Replace damaged or worn parts. After finishing the repair and maintenance work, ensure that the vehicle is roadworthy. Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss- ing, you or others may not recognize potential hazards and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. Repair instructions – It is imperative that you read this owner's manual carefully and completely before the start of work. It contains extensive information and many tips to help you repair and maintain your vehicle. – The necessary KTM special tools must be available and the workplace and workshop must be fully equipped. PartShark.com 877-999-5686

VIEW OF VEHICLE 8 3.1 View of the vehicle from the left front (example) 301769-10 1 Hand brake lever 2 Fuse box 3 Shock absorber compression adjustment 4 Front shock absorber 5 Shock absorber rebound adjustment 6 Heel protector 7 Shift lever 8 Kill switch/emergency OFF switch with rip cord 9 Clutch lever 10 Hot start lever PartShark.com 877-999-5686

KTM 450 SX ATV 2009-2011 Service Repair Workshop Manual

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