Table Of Contents - KTM 450 SX ATV 2010 Repair Manual

CONTENTS
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
2