Sign In
Upload
Manuals
Brands
KTM Manuals
Offroad Vehicle
2010 505 SX
KTM 2010 505 SX Manuals
Manuals and User Guides for KTM 2010 505 SX. We have
1
KTM 2010 505 SX manual available for free PDF download: Repair Manual
KTM 2010 505 SX Repair Manual (247 pages)
Brand:
KTM
| Category:
Offroad Vehicle
| Size: 13.35 MB
Table of Contents
Table of Contents
4
Means of Representation
8
Important Notes
9
View of Vehicle
10
View of the Vehicle from the Left Front (Example)
10
View of the Vehicle from the Right Rear (Example)
11
Location of Serial Numbers
12
Chassis Number
12
Type Label
12
Key Number
12
Engine Number
12
Shock Absorber Part Number, Front
12
Shock Absorber Part Number, Rear
13
Vehicle
14
Jacking up the Vehicle
14
Removing the Vehicle from the Work Stand
14
02/Handlebar, Instruments
15
Hot Start Lever
15
Adjusting Handlebar Position
15
Adjusting Basic Position of Clutch Lever
16
Checking the Play in the Throttle Cable
16
Adjusting Play in Throttle Cable
16
Removing the Steering Column
16
Changing the Steering Column Bearing
18
Installing the Steering Column
20
03/Frame
22
Removing the Engine Guard
22
Installing the Engine Guard
22
04/Shock Absorber, Swingarm
23
Front Shock Absorber - Adjusting the High-Speed Compression Damping
23
Front Shock Absorber - Adjusting the Low-Speed Compression Damping
23
Front Shock Absorber - Adjusting the Rebound Damping
24
Front Shock Absorber - Adjusting the Spring Preload
25
Front Shock Absorber - Adjusting the Cross over
26
Removing the Front Shock Absorber
26
Installing the Front Shock Absorber
27
Front Shock Absorber - Changing the Oil
27
Service the Front Shock Absorber
29
Front Shock Absorber - Removing the Spring
30
Front Shock Absorber - Disassembling the Damper
30
Front Shock Absorber - Disassembling the Piston Rod
31
Front Shock Absorber - Checking the Damper
32
Front Shock Absorber - Removing the Heim Joint
33
Front Shock Absorber - Installing the Heim Joint
33
Front Shock Absorber - Assembling the Piston Rod
34
Front Shock Absorber - Assembling the Damper
35
Front Shock Absorber - Bleeding and Filling the Damper
36
Front Shock Absorber - Filling the Damper with Nitrogen
39
Front Shock Absorber - Installing the Spring
40
Rear Shock Absorber - Adjusting the High-Speed Compression Damping
40
Rear Shock Absorber - Adjusting the Low-Speed Compression Damping
41
Rear Shock Absorber - Adjusting the Rebound Damping
42
Rear Shock Absorber - Adjusting the Spring Preload
42
Removing the Rear Shock Absorber
43
Installing the Rear Shock Absorber
44
Rear Shock Absorber - Changing the Oil
44
Servicing the Rear Shock Absorber
46
Rear Shock Absorber - Removing the Spring
46
Rear Shock Absorber - Disassembling the Damper
47
Rear Shock Absorber - Disassembling the Piston Rod
48
Rear Shock Absorber - Disassembling the Seal Ring Retainer
49
Changing the Pilot Bushing
49
Rear Shock Absorber - Checking the Damper
50
Rear Shock Absorber - Removing the Heim Joint
51
Rear Shock Absorber - Installing the Heim Joint
52
Rear Shock Absorber - Assembling the Seal Ring Retainer
52
Rear Shock Absorber - Assembling the Piston Rod
53
Rear Shock Absorber - Assembling the Damper
54
Rear Shock Absorber - Bleeding and Filling the Damper
56
Rear Shock Absorber - Filling the Damper with Nitrogen
58
Rear Shock Absorber - Installing the Spring
59
05/Exhaust
61
Removing the Main Silencer
61
Installing the Main Silencer
61
Removing the Manifold
62
Installing the Manifold
62
06/Air Filter
63
Removing the Air Filter
63
Installing the Air Filter
63
Cleaning Air Filter
63
Removing the Air Filter Box Lid with the Carburetor Connection Boot
64
Installing the Air Filter Box Lid and the Carburetor Connection Boot
64
07/Fuel Tank, Seat, Trim
65
Removing the Seat
65
Mounting the Seat
65
Removing the Radiator Spoiler
65
Installing the Radiator Spoiler
66
Removing the Fuel Tank
66
Installing the Fuel Tank
67
Fuel Tap
68
08/Mask, Fender
69
Removing the Heel Protector
69
Installing the Heel Protector
70
Removing the Front Cover
71
Installing the Front Cover
71
Removing the Front Trim
71
Installing the Front Trim
72
Removing the Rear Fender
72
Installing the Rear Fender
73
09/Front Wheel
74
Checking the Tire Air Pressure
74
Checking the Tire Condition
74
Removing Wheel/Wheels
74
Installing the Wheel/Wheels
75
Checking Brake Discs
76
10/Rear Wheel
77
Checking Chain Dirt
77
Cleaning the Chain
77
Checking Chain Wear
77
Checking Rear Sprocket / Engine Sprocket for Wear
78
Checking the Chain Tension
78
Adjusting Chain Tension
78
Adjusting the Toe Width of Rear Axle
79
Removing the Rear Axle
80
Installing the Rear Axle
81
Changing the Rear Axle Bearing
83
11/Wiring Harness, Battery
85
Ignition Curve Plug Connection
85
Changing the Ignition Curve
85
Removing the Battery
85
Installing the Battery
85
Recharging the Battery
86
Changing the Main Fuse
87
Changing the Fuses of Individual Power Consumers
87
Checking the Battery Voltage
88
Checking the Charging Voltage
88
Checking the Quiescent Current
88
Checking the Starter Relay
89
13/Brake System
90
Hand Brake Lever, Parking Brake
90
Checking the Free Travel of the Hand Brake Lever
90
Adjusting Basic Position of Hand Brake Lever
90
Checking Front Brake Fluid Level
91
Topping up the Front Brake Fluid
91
Changing the Front Brake Fluid
92
Checking the Front Brake Linings
93
Removing Front Brake Linings
93
Mounting Front Brake Linings
94
Changing the Front Brake Linings
94
Checking Free Travel of Foot Brake Lever
95
Adjusting Basic Position of Foot Brake Lever
95
Checking Rear Brake Fluid Level
96
Adding Rear Brake Fluid
96
Changing the Rear Brake Fluid
97
Checking Rear Brake Linings
98
Removing Rear Brake Linings
98
Mounting Rear Brake Linings
99
Changing Rear Brake Linings
100
30/Engine
101
Removing the Engine
101
Installing the Engine
102
30/Disassembling the Engine
105
Preparations
105
Removing the Shift Lever
105
Draining the Engine Oil
105
Removing the Oil Filter
105
Removing the Spark Plug
106
Removing the Valve Cover
106
Removing the Starter Motor
106
Removing the Alternator Cover
106
Removing the Torque Limiter
107
Positioning the Engine at Ignition Top Dead Center (TDC)
107
Removing the Camshaft
108
Removing the Timing Chain Tensioner
108
Removing the Double Wheel
109
Removing the Cylinder Head
109
Removing the Water Pump Cover
110
Removing the Clutch Cover
110
Removing the Piston
111
Removing the Timing Chain Rails
111
Removing the Timing Chain
111
Removing the Rotor and Starter Idler Gear
112
Removing the Ignition Pulse Generator
112
Removing the Drive Wheel of the Balancer Gear
113
Removing the Force Pump
113
Removing the Spacer
114
Removing the Outer Clutch Hub
114
Removing the Primary Gear
115
Removing the Centrifugal Separator
115
Removing the Suction Pump
116
Removing the Shift Shaft
116
Removing the Shift Drum Locating Unit
117
Removing the Locking Lever
117
Removing the Left Section of the Engine Case
117
Removing the Shift Rails
118
Removing the Shift Drum
118
Removing the Shift Forks
118
Removing the Transmission Shafts
118
Removing the Crankshaft
119
30/Engine - Work on Individual Parts
120
Working on the Right Section of the Engine Case
120
Working on the Left Section of the Engine Case
121
Removing the Water Pump
122
Changing the Shaft Seal Ring of the Water Pump
123
Installing the Water Pump
124
Removing the Crankshaft Seal Ring in the Clutch Cover
125
Installing the Crankshaft Seal Ring in the Clutch Cover
125
Removing the Oil Pressure Regulator Valve
125
Checking Spring Length of Oil Pressure Regulator Valve
125
Installing the Oil Pressure Regulator Valve
126
Checking the Lubrication System
126
Removing the Crankshaft Bearing Inner Race
127
Installing the Crankshaft Bearing Inner Race
127
Changing Connecting Rod, Conrod Bearing and Crank Pin
127
Checking Crankshaft Run-Out at Bearing Pin
128
Measuring the Crankshaft End Play
129
Cylinder - Nikasil Coating
129
Checking/Measuring Cylinder
129
Checking/Measuring the Piston
130
Measuring Piston/Cylinder Mounting Clearance
131
Checking the Piston Ring End Gap
131
Changing the Camshaft Bearing
131
Checking the Autodecompressor
132
Checking Camshafts
132
Checking the Radial Clearance of the Camshaft Bearings
132
Checking the Camshaft Bearing Bridges
133
Removing the Valves
133
Checking the Valves
134
Checking the Valve Springs
135
Checking Valve Spring Seat
135
Checking the Cam Levers
135
Checking Cylinder Head
135
Installing the Valves
136
Removing the Freewheel
137
Checking the Freewheel
137
Installing the Free Wheel
137
Checking the Electric Starter Mode
138
Checking the Timing Assembly
139
Preparing the Timing Chain Tensioner for Installation
139
Checking Clutch
140
Checking Shift Mechanism
141
Preassembling the Shift Shaft
142
Disassembling the Main Shaft
143
Disassembling the Countershaft
143
Checking Transmission
144
Assembling the Main Shaft
145
Assembling the Countershaft
146
30/Engine Assembly
147
Installing the Crankshaft
147
Installing the Transmission Shafts
147
Installing the Shift Forks
147
Installing the Shift Drum
148
Installing the Shift Rails
148
Installing the Left Engine Case
148
Installing the Locking Lever
149
Installing the Shift Drum Locating Unit
149
Installing the Shift Shaft
149
Installing the Suction Pumps
149
Installing the Centrifugal Separator
150
Installing the Force Pump
150
Installing the Primary Gear
151
Installing the Outer Clutch Hub
151
Installing the Spacer
152
Installing the Drive Wheel of the Balancer Gear
153
Installing the Timing Chain
153
Installing the Free Wheel Gear
153
Installing the Ignition Pulse Generator
154
Installing the Rotor
154
Installing the Timing Chain Rails
154
Installing the Piston
154
Installing the Clutch Cover
156
Installing the Water Pump Cover
156
Installing the Cylinder Head
157
Installing the Double Wheel
157
Installing the Timing Chain Tensioner
158
Checking the Valve Timing
158
Adjusting the Valve Timing
159
Checking the Valve Clearance
160
Adjusting the Valve Clearance
160
Installing the Torque Limiter
161
Installing the Alternator Cover
161
Installing the Starter Motor
161
Installing the Valve Cover
161
Installing the Spark Plug
162
Installing the Oil Screen
162
Installing the Oil Filter
162
Installing the Shift Lever
163
Removing the Engine from the Universal Mounting Rack
163
31/Carburetor
164
Choke
164
Checking the Play in the Throttle Cable
164
Carburetor - Adjusting Idle
164
Checking the Position of the Throttle Position Sensor
165
Draining the Carburetor Float Chamber
166
Removing the Carburetor
166
Installing the Carburetor
168
Disassembling the Carburetor
169
Checking/Adjusting the Carburetor Components
172
Checking/Adjusting the Accelerator Pump
172
Checking the Choke Slide
173
Checking the Hot Start Slide
173
Checking the Throttle Position Sensor
173
Checking the Jet Needle
174
Checking the Throttle Slide
174
Checking/Adjusting the Throttle Slide Opening
175
Checking the Needle Jet
175
Checking the Float Needle Valve
175
Checking/Adjusting the Float Level
176
Adjusting the Position of the Throttle Position Sensor
176
Assembling the Carburetor
177
32/Clutch
180
Checking Fluid Level of Hydraulic Clutch
180
Changing the Hydraulic Clutch Fluid
180
33/Transmission
181
Removing the Engine Sprocket
181
Installing the Engine Sprocket
181
35/Water Pump, Cooling System
182
Checking Antifreeze and Coolant Level
182
Checking the Coolant Level
182
Draining Coolant
183
Filling Coolant/Bleeding the Cooling System
183
38/Lubrication System
185
Oil Circuit
185
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
185
Draining the Engine Oil
186
Removing the Oil Filter
186
Installing the Oil Filter
187
Filling up with Engine Oil
187
Checking the Engine Oil Level
187
Adding Engine Oil
188
39/Ignition System
189
Removing the Stator
189
Installing the Stator
189
Checking the Ignition System
189
Checking the Ignition Coil
190
Checking the Spark Plug Connector
191
Checking the CDI Controller
191
Checking the Ignition Pulse Generator
191
Checking the Alternator
192
61/Atv Front End
193
Checking the Toe
193
Adjusting the Toe
194
Checking/Adjusting the Camber
195
Adjusting the Fork Offset
196
Removing the Wheel Carrier
196
Changing the Wheel Bearing
198
Installing the Wheel Carrier
199
Removing the A-Arms
200
Installing the A-Arms
201
A-Arm Top - Changing the Bearing
202
A-Arm Bottom - Changing the Bearing
203
Technical Data - Engine
206
Capacity - Engine Oil
206
Capacity - Coolant
206
Technical Data - Engine Tolerances, Wear Limits
207
Technical Data - Engine Tightening Torques
208
Technical Data - Carburetor
210
Technical Data - Carburetor Tightening Torques
211
Technical Data - Chassis
212
Tires
213
Capacity - Fuel
213
Technical Data - Front Shock Absorber
214
Technical Data - Rear Shock Absorber
215
Technical Data - Chassis Tightening Torques
216
Cleaning
217
Cleaning the Vehicle
217
Storage
218
Putting the Vehicle into Operation after Storage
218
Service Schedule
219
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
219
Important Maintenance Work to be Carried out by an Authorized KTM Workshop (as an Additional Order)
220
Important Checks and Maintenance Work to be Carried out by the Rider
220
Wiring Diagram
222
450/525 Sx Atv
222
Substances
225
Auxiliary Substances
227
Special Tools
229
Standards
242
Index
243
Advertisement
Advertisement
Related Products
KTM 2010 450 SX
KTM 2012 525 XC ATV
KTM 2008 525 XC ATV
KTM 2008 450 XC ATV
KTM 2012 505 SX
KTM 2010 50 SX MINI
KTM 2010 530 EXC EU
KTM 2010 530 XC-W SIX DAYS USA
KTM 2010 450 SX-F USA
KTM 2010 300 EXC SixDays
KTM Categories
Motorcycle
Motorcycle Accessories
Offroad Vehicle
Engine
Bicycle Accessories
More KTM Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL