KTM 450 SX ATV 2010 Repair Manual
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KTM 450 SX ATV 2010 Repair Manual

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REPAIR MANUAL
2010
450 SX ATV
505 SX ATV
Article no. 3206070en

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Summary of Contents for KTM 450 SX ATV 2010

  • Page 1 REPAIR MANUAL 2010 450 SX ATV 505 SX ATV Article no. 3206070en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    CONTENTS Rear shock absorber - disassembling the piston rod ..46 CONTENTS MEANS OF REPRESENTATION ..........6 Rear shock absorber - disassembling the seal ring IMPORTANT NOTES ............7 retainer ................ 47 VIEW OF VEHICLE............... 8 Changing the pilot bushing..........47 View of the vehicle from the left front (example) ....
  • Page 5 CONTENTS Changing the ignition curve ..........83 Removing the suction pump ......... 114 Removing the battery ............. 83 Removing the shift shaft ..........114 Installing the battery............83 Removing the shift drum locating unit ......115 Recharging the battery ........... 84 Removing the locking lever...........
  • Page 6 CONTENTS Installing the transmission shafts ........145 32/CLUTCH ..............178 Installing the shift forks ..........145 Checking fluid level of hydraulic clutch ......178 Installing the shift drum..........146 Changing the hydraulic clutch fluid ....... 178 Installing the shift rails ..........146 33/TRANSMISSION............
  • Page 7 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 ............

  • Page 8: Means Of Representation

    MEANS OF REPRESENTATION 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.

  • Page 9: Important Notes

    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.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 301769-10 Hand brake lever Fuse box Shock absorber compression adjustment Front shock absorber Shock absorber rebound adjustment Heel protector Shift lever Kill switch/emergency OFF switch with rip cord Clutch lever Hot start lever...

  • Page 11: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 301770-10 Filler cap Main silencer Seat release Shock absorber rebound adjustment Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Handlebar bridge Throttle lever Handlebar cushion...

  • Page 12: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the  upper control arm. 301771-10 Type label The type label is located on the frame tube on the right and left in front of the radia- ...

  • Page 13: Shock Absorber Part Number, Rear

    LOCATION OF SERIAL NUMBERS Shock absorber part number, rear The shock absorber part number is stamped on the upper part of the shock  absorber. 301831-10...

  • Page 14: Vehicle

    VEHICLE Jacking up the vehicle Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. – Jack up the vehicle on the frame underneath the engine. The wheels must no longer touch the ground.

  • Page 15: 02/Handlebar, Instruments

    02/HANDLEBAR, INSTRUMENTS Hot start lever Hot start lever is fitted on the left side of the handlebar.  If you pull the hot start lever to the handlebar when starting the engine, an opening is exposed in the carburetor through which the engine can draw additional air. This gives a leaner fuel-air mixture, which is needed for a hot start.

  • Page 16: Adjusting Basic Position Of Clutch Lever

    02/HANDLEBAR, INSTRUMENTS Adjusting basic position of clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar.
  • Page 17 02/HANDLEBAR, INSTRUMENTS – Loosen screw  Info The screw cannot be removed. 301860-10 – Loosen screws  301861-10 – Remove screw  – Take off the handlebar with the handlebar bridge and screw , swing it forward  and set it down. Info Protect the vehicle and its attachments from damage by covering them.

  • Page 18: Changing The Steering Column Bearing

    02/HANDLEBAR, INSTRUMENTS – Remove screws  – Pull out the steering column with bearing support from above.  301864-10 – Pull bearing support off from above.  301523-10 Changing the steering column bearing – Remove the steering column. ( p. 14) –...
  • Page 19 02/HANDLEBAR, INSTRUMENTS – Position the steering column bearing. – Mount special tool  Extractor (83019020000) ( p. 235) – Press in the steering column bearing by turning in the screw. 301526-10 – Mount lock ring  301529-10 – Position the shaft seal ring. –...

  • Page 20: Installing The Steering Column

    02/HANDLEBAR, INSTRUMENTS – Press in the sleeve bearing. Extractor (83019020000) ( p. 235) 301532-10 – Press in shaft seal rings from the outside to the inside with the open side facing  inward. 301530-10 Installing the steering column – Lightly grease bearing support and slide it onto the steering column.
  • Page 21 02/HANDLEBAR, INSTRUMENTS – Mount and tighten screw  Guideline Screw, steering column, bottom M20x1.5 40 Nm (29.5 lbf ft) 301519-10 – Mount the handlebar with the handlebar bridge and screw  – Mount and tighten screw  Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) 301862-11...

  • Page 22: 03/Frame

    03/FRAME Removing the engine guard – Remove screws . Remove the engine guard.   301823-10 Installing the engine guard – Position the engine guard on the frame bearer. Mount and tighten screws   Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft)

  • Page 23: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - adjusting the high-speed compression damping Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. –...

  • Page 24: Front Shock Absorber - Adjusting The Rebound Damping

    04/SHOCK ABSORBER, SWINGARM – Turn adjusting screw clockwise with a screwdriver up to the last perceptible  click. Info Do not loosen nut  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed 301787-10 Comfort...

  • Page 25: Front Shock Absorber - Adjusting The Spring Preload

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - adjusting the spring preload Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. –...

  • Page 26: Front Shock Absorber - Adjusting The Cross Over

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - adjusting the cross over Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The cross over setting is used to adjust the suspension travel of the short (soft) spring. Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower.

  • Page 27: Installing The Front Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Remove screw  301535-10 – Remove screw . Remove the shock absorber.  301536-10 Installing the front shock absorber Info The operations are the same on the left and right. – Position the front shock absorber. Mount and tighten screw ...
  • Page 28 04/SHOCK ABSORBER, SWINGARM – Note down the present state of rebound damping and compression damping   – Completely open the adjusters of the rebound and compression damping. 201133-10 – Remove rubber cap of the reservoir.  – Slowly open screw ...

  • Page 29: Service The Front Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Turn adjusting screw all the way clockwise with a socket wrench.  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Alternative 2...

  • Page 30: Front Shock Absorber - Removing The Spring

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - removing the spring 8.10 Condition The shock absorber has been removed. – Clamp the shock absorber in a vise using soft jaws. – Measure and note down the spring length in the preloaded state. –...

  • Page 31: Front Shock Absorber - Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Remove the piston rod. Drain the oil. 201136-10 – Remove compression damping . Remove the spring and piston.  201137-10 Front shock absorber - disassembling the piston rod 8.12 – Disassemble the damper of the front shock absorber. ( p.

  • Page 32: Front Shock Absorber - Checking The Damper

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - checking the damper 8.13 Condition The damper has been disassembled. – Measure the inside diameter on both ends and in the middle of the damper car- tridge. Damper cartridge Minimum diameter 36.04 mm (1.4189 in) »...

  • Page 33: Front Shock Absorber - Removing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - removing the heim joint 8.14 Info The operations are the same on the top and bottom heim joint. Condition The shock absorber has been removed. – Clamp the shock absorber in a vise using soft jaws. –...

  • Page 34: Front Shock Absorber - Assembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Place special tool underneath and press in the heim joint to the lock ring using  special tool  Pressing tool (T1207S) ( p. 238) Pressing tool (T1206) ( p. 238) 200911-10 – Mount the second lock ring ...

  • Page 35: Front Shock Absorber - Assembling The Damper

    04/SHOCK ABSORBER, SWINGARM – Mount rebound damping shim stack with the smaller shims at the top.  – Mount supporting plate  – Mount and tighten nut with the collar facing upward.  Guideline Nut, piston rod M10x1 30 Nm (22.1 lbf ft) 201147-10 Front shock absorber - assembling the damper...

  • Page 36: Front Shock Absorber - Bleeding And Filling The Damper

    04/SHOCK ABSORBER, SWINGARM Alternative 1 – Turn adjusting screw clockwise up to the last perceptible click.  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks 201151-10 Sport 12 clicks...
  • Page 37 04/SHOCK ABSORBER, SWINGARM Info The filling port must be located at the highest point. The piston rod moves in and out during filling; do not immobilize it by hold- ing it with your hand. – Position the control lever as shown in the photo. Control lever External tank is set to Closed;...
  • Page 38 04/SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the required value, turn control lever Oil reser- voir to Vacuum.  Guideline 0 bar The vacuum gauge drops to the required value. 8 mbar 200270-10 – When the vacuum gauge reaches the required value, turn control lever Oil reser- voir to Equalize Pressure.

  • Page 39: Front Shock Absorber - Filling The Damper With Nitrogen

    04/SHOCK ABSORBER, SWINGARM – Remove the special tool. – Remove adapter from connector of the vacuum pump.   Info Hold the damper so that the filling port is at the highest location. – Remove the adapter. – Mount and tighten screw ...

  • Page 40: Front Shock Absorber - Installing The Spring

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - installing the spring 8.20 – Clamp the damper in a vise using soft jaws. – Mount retaining ring and adjusting ring   – Measure the overall spring length in an unloaded state. –...

  • Page 41: Rear Shock Absorber - Adjusting The Low-Speed Compression Damping

    04/SHOCK ABSORBER, SWINGARM Info The high-speed setting has an impact on the fast compression of the shock absorber. – Turn adjusting screw all the way clockwise with a socket wrench.  Info Do not loosen nut  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type.

  • Page 42: Rear Shock Absorber - Adjusting The Rebound Damping

    04/SHOCK ABSORBER, SWINGARM Rear shock absorber - adjusting the rebound damping 8.23 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. –...

  • Page 43: Removing The Rear Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Release counter ring . Hold adjusting ring while doing so.   Hook wrench (83019002000) ( p. 234) – Turn the adjusting ring until the spring pack is no longer under tension. 200601-01 – Measure the overall spring pack when not under tension. Info The spring preload is the difference in length between the spring pack...

  • Page 44: Installing The Rear Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Installing the rear shock absorber 8.26 – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw  Guideline Screw, rear top shock absorber 60 Nm (44.3 lbf ft) –...
  • Page 45 04/SHOCK ABSORBER, SWINGARM – Mount rubber cap of the reservoir.  201082-11 Alternative 1 – Turn adjusting screw clockwise up to the last perceptible click.  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort...

  • Page 46: Servicing The Rear Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Servicing the rear shock absorber 8.28 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. –...

  • Page 47: Rear Shock Absorber - Disassembling The Damper

    04/SHOCK ABSORBER, SWINGARM – Remove sleeve  – Remove spring with washer   201048-10 Rear shock absorber - disassembling the damper 8.30 – Remove the spring from the rear shock absorber. ( p. 44) – Note down the present state of rebound damping and compression damping ...

  • Page 48: Rear Shock Absorber - Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Remove compression damping adjuster . Remove the spring and piston.  201055-10 Rear shock absorber - disassembling the piston rod 8.31 – Disassemble the damper of the rear shock absorber. ( p. 45) – Clamp the piston rod into a vise. –...

  • Page 49: Rear Shock Absorber - Disassembling The Seal Ring Retainer

    04/SHOCK ABSORBER, SWINGARM – Remove locking cap and rubber buffer   201068-10 Rear shock absorber - disassembling the seal ring retainer 8.32 – Disassemble the piston rod of the rear shock absorber. ( p. 46) – Remove rebound rubber ...

  • Page 50: Rear Shock Absorber - Checking The Damper

    04/SHOCK ABSORBER, SWINGARM – Slide the new pilot bushing onto the special tool.  Press drift (T1504) ( p. 238) – Position the pilot bushing in the seal ring retainer using the special tool. Press drift (T1504) ( p. 238) –...

  • Page 51: Rear Shock Absorber - Removing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM – Check the piston rings for damage and wear. » If damaged or if a bronze-colored surface is visible: – Change the piston rings. 200813-10 Rear shock absorber - removing the heim joint 8.35 Info The operations are the same on the top and bottom heim joint. Condition The shock absorber has been removed.

  • Page 52: Rear Shock Absorber - Installing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM Rear shock absorber - installing the heim joint 8.36 Info The operations are the same on the top and bottom heim joint. – Position the new heim joint and the special tool.  Pressing tool (T1206) ( p.

  • Page 53: Rear Shock Absorber - Assembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Lubricate the groove of the O-ring. Lubricant (T158) ( p. 225) – Mount O-ring  – Mount washer  200793-10 – Position washer on seal ring   – Grease the seal ring and mount with the washer facing downward. Lubricant (T511) ( p.

  • Page 54: Rear Shock Absorber - Assembling The Damper

    04/SHOCK ABSORBER, SWINGARM – Mount rebound damping shim stack with the smaller shims at the top.  – Mount sleeve  201074-10 – Mount compression damping shim stack with the smaller shims at the bottom.  201075-10 – Grind piston on both sides on a surface plate using 1200 grit sandpaper.
  • Page 55 04/SHOCK ABSORBER, SWINGARM – Mount adjusting ring with the intermediate washer and retaining ring   Info It is not possible to mount the rings after the piston rod has been mounted. – Mount screw but do not tighten yet. ...

  • Page 56: Rear Shock Absorber - Bleeding And Filling The Damper

    04/SHOCK ABSORBER, SWINGARM Guideline Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks – Turn adjusting screw all the way clockwise with a socket wrench.  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type.
  • Page 57 04/SHOCK ABSORBER, SWINGARM – Determine distance between the floating piston and reservoir hole with the spe-  cial tool. Depth micrometer (T107S) ( p. 237) The floating piston is positioned in the lowermost position. 201091-10 – When the vacuum gauge reaches the required value, turn control lever Oil reser- voir to Equalize pressure.

  • Page 58: Rear Shock Absorber - Filling The Damper With Nitrogen

    04/SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the required value, turn control lever Damper  to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – When the pressure gauge reaches the required value, turn control lever Damper ...

  • Page 59: Rear Shock Absorber - Installing The Spring

    04/SHOCK ABSORBER, SWINGARM – Fix the special tool in the vise. Nitrogen filling tool (T170S1) ( p. 239) – Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen – Adjust the pressure regulator. Guideline Gas pressure 10 bar (145 psi)
  • Page 60 04/SHOCK ABSORBER, SWINGARM – Mount washer and spring retainer   – Mount ring  Alternative 1 – Tighten the spring by turning adjusting ring to the specified measurement.  Guideline Spring preload Comfort 3 mm Standard 5 mm Sport 5 mm Hook wrench (T157S) ( p.

  • Page 61: 05/Exhaust

    05/EXHAUST Removing the main silencer Info In order to present them more clearly, the following steps are shown with a removed fender. – Remove spring  Spring hooks (50305017000) ( p. 227) 301856-10 – Remove screws and remove the main silencer. ...

  • Page 62: Removing The Manifold

    05/EXHAUST Removing the manifold Info In order to present them more clearly, the following steps are shown with a removed fender. – Remove the main silencer. ( p. 59) – Remove both springs  Spring hooks (50305017000) ( p. 227) 301580-10 –...

  • Page 63: 06/Air Filter

    06/AIR FILTER Removing the air filter 10.1 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 64: Removing The Air Filter Box Lid With The Carburetor Connection Boot

    06/AIR FILTER Info Only press the air filter to dry it, never wring it out. – Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( p. 226) – Clean the air filter box. –...

  • Page 65: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM Removing the seat 11.1 – Pull the release hook back. Lift up the seat at the rear, pull it back and then  remove from above. 301809-10 Mounting the seat 11.2 – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the ...

  • Page 66: Installing The Radiator Spoiler

    07/FUEL TANK, SEAT, TRIM Installing the radiator spoiler 11.4 Info The operations are the same on the left and right. – Hook catch of the radiator spoiler into holder of the fuel tank and position it   on the radiator. 301819-10 –...

  • Page 67: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM – Remove screw and take off the fuel tank.  301855-11 Installing the fuel tank 11.6 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 68: Fuel Tap

    07/FUEL TANK, SEAT, TRIM Fuel tap 11.7 The fuel tap is located on the right side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the car-  buretor.

  • Page 69: 08/Mask, Fender

    08/MASK, FENDER Removing the heel protector 12.1 – Remove screws  – Remove screw  301849-11 – Remove screw  – Pull the heel protector off of the cross member. 301848-11 – Remove screws  – Remove screw  301851-11 –...

  • Page 70: Installing The Heel Protector

    08/MASK, FENDER Installing the heel protector 12.2 – Position washer and cross member   – Mount screw but do not tighten yet.  Guideline Remaining nuts, chassis 30 Nm (22.1 lbf ft) 301847-10 – Slide the heel protector onto the cross member and position it. –...

  • Page 71: Removing The Front Cover

    08/MASK, FENDER Removing the front cover 12.3 – Remove screw  – Slide the front cover up and remove it. 301811-10 Installing the front cover 12.4 – Position the front cover in slots on both sides of the front trim. ...

  • Page 72: Installing The Front Trim

    08/MASK, FENDER Installing the front trim 12.6 – Connect the plug-in connector of the emergency OFF switch with the rip cord and position the front trim. – Mount all screws. – Fully tighten screws  Guideline Screw on fuel tank 6 Nm (4.4 lbf ft) –...

  • Page 73: Installing The Rear Fender

    08/MASK, FENDER Installing the rear fender 12.8 – Raise the rear of air filter box lid . At the same time, use your other hand to press  on the carburetor connection boot to kink it at that location. This prevents the car- buretor connection boot from disconnecting from the carburetor.

  • Page 74: 09/Front Wheel

    DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. 400602-10 »...

  • Page 75: Installing The Wheel/Wheels

    09/FRONT WHEEL – Loosen the wheel nuts  – Jack up the vehicle. ( p. 12) – Remove the wheel nuts. Remove the wheel. Info Carefully remove the wheel, making sure it does not become jammed with the threads of the screws. 300278-10 Installing the wheel/wheels 13.4...

  • Page 76: Checking Brake Discs

    09/FRONT WHEEL Checking brake discs 13.5 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 77: 10/Rear Wheel

    10/REAR WHEEL Checking chain dirt 14.1 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 75) 400678-01 Cleaning the chain 14.2 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

  • Page 78: Checking Rear Sprocket / Engine Sprocket For Wear

    10/REAR WHEEL Checking rear sprocket / engine sprocket for wear 14.4 – Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Replace the rear sprocket / engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).

  • Page 79: Adjusting The Toe Width Of Rear Axle

    10/REAR WHEEL – Loosen the screws by four turns.  Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric   element. Alternative 2 – Position the special tool at the rear wheel eccentric element. Hook wrench (83019011000) ( p.

  • Page 80: Removing The Rear Axle

    10/REAR WHEEL Setting a wide toe width: – Mount the spacer with the cone facing inward.  0 0 2 0 0 3 – Mount the conical ring with the cone facing outward.  – Mount the wheel hub  –...

  • Page 81: Installing The Rear Axle

    10/REAR WHEEL – Take brake disc off the rear axle with the holder.  – Remove the O-ring. 600412-10 – Push the rear axle slightly to the left. Using a plastic hammer, lightly strike against the chain sprocket carrier to release the chain sprocket carrier from the lock ...
  • Page 82 10/REAR WHEEL – Position O-ring . Attach brake disc holder with the thread facing outward.   – Carefully insert sealing area on the brake disc carrier into the shaft seal ring of  the rear wheel eccentric by lightly turning and tilting the rear axle. Info Do not damage the sealing lip of the shaft seal ring.

  • Page 83: Changing The Rear Axle Bearing

    10/REAR WHEEL – Place the chain on the sprocket. Mount chain joint  Info When installing the chain joint, always make sure that the closed side of the joint is facing forward (direction of travel). 600409-11 Setting a narrow toe width: –...
  • Page 84 10/REAR WHEEL – Take out shaft seal rings on both sides and remove inner bearing races   600417-10 – Remove old grease and clean the rear wheel eccentric. – Heat the rear wheel eccentric. Guideline 100 °C (212 °F) –...

  • Page 85: 11/Wiring Harness, Battery

    11/WIRING HARNESS, BATTERY Ignition curve plug connection 15.1 Plug-in connector is located under the trim at the front on the frame tube.  Possible states Performance – The plug-in connector is connected to achieve better performance. • Soft – The plug-in connector is disconnected for better driveability. •...

  • Page 86: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 87: Changing The Main Fuse

    11/WIRING HARNESS, BATTERY Changing the main fuse 15.6 – Switch off all power consumers and switch off the engine. – The main fuse is located in the starter relay in front of the battery.   – Remove protection covers ...

  • Page 88: Checking The Battery Voltage

    11/WIRING HARNESS, BATTERY – Close the cover of the fuse box. – Install the front cover. ( p. 69) Checking the battery voltage 15.8 – Turn the key in the ignition switch to the position – Remove the rear fender. ( p.

  • Page 89: Checking The Starter Relay

    11/WIRING HARNESS, BATTERY Checking the starter relay 15.11 – Remove the rear fender. ( p. 70) – Disconnect the negative (minus) cable of the battery. – Remove the starter relay from holder next to the battery.  – Disconnect connector from the starter relay.

  • Page 90: 13/Brake System

    13/BRAKE SYSTEM Hand brake lever, parking brake 16.1 The hand brake lever is located on the right side of the handlebar and operates the  front brakes. The hand brake lever is combined with the parking brake, which blocks the front wheels to prevent the vehicle from rolling away.

  • Page 91: Checking Front Brake Fluid Level

    13/BRAKE SYSTEM Checking front brake fluid level 16.4 Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and not continue riding. Warning Danger of accidents Reduced braking effect caused by old brake fluid.

  • Page 92: Changing The Front Brake Fluid

    13/BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Add brake fluid to level  Guideline Dimension (brake fluid level below 5 mm (0.2 in) ...

  • Page 93: Checking The Front Brake Linings

    13/BRAKE SYSTEM – Pull off dust cap and connect a commercially available suction device (workshop  equipment). – Remove the bleeder screw and suck out the old brake fluid. Info During suction, ensure that the brake fluid reservoir is always sufficiently filled with fresh brake fluid.

  • Page 94: Mounting Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 95: Checking Free Travel Of Foot Brake Lever

    13/BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 96: Checking Rear Brake Fluid Level

    13/BRAKE SYSTEM – Disconnect spring  – Loosen nut and with push rod , turn it back until you have maximum free   travel. – To adjust the basic position of the foot brake lever individually, loosen nut  turn screw accordingly.

  • Page 97: Changing The Rear Brake Fluid

    13/BRAKE SYSTEM Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple.

  • Page 98: Checking Rear Brake Linings

    13/BRAKE SYSTEM – Remove screw cap with membrane   – Extract the old brake fluid from the brake fluid reservoir with a syringe and add fresh brake fluid. Bleed syringe (50329050000) ( p. 227) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 99: Mounting Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 100: Changing Rear Brake Linings

    13/BRAKE SYSTEM – Grease the bearing bolt and insert the brake caliper with the bearing bolt into  the brake caliper support  Lubricant (T625) ( p. 225) 100068-10 – Swing the brake caliper downward. Mount and tighten the screw. Guideline Screw, rear brake caliper 10 Nm...

  • Page 101: 30/Engine

    30/ENGINE Removing the engine 17.1 – Remove the engine guard. ( p. 20) – Remove the heel protector. ( p. 67) – Drain the coolant. ( p. 181) – Remove the rear fender. ( p. 70) – Remove the manifold. ( p.

  • Page 102: Installing The Engine

    30/ENGINE – Disconnect spring  Spring hooks (50305017000) ( p. 227) 301588-10 – Remove nut  – Pull out the swingarm pivot. Info Pull the swingarm pivot to the point where it is still being held. – Secure the swingarm with a suitable pin ...
  • Page 103 30/ENGINE – Mount screw but do not tighten yet.  Guideline Engine mounting bolt 60 Nm (44.3 lbf ft) 301591-11 – Position both engine bearers on the frame. Mount screws but do not tighten yet.  Guideline Engine bracket screw 60 Nm (44.3 lbf ft) –...
  • Page 104 30/ENGINE – Position the electrical connection on the starter motor. Mount and tighten nut  Slide on the cover. Guideline Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Position the ground wire. Mount and tighten screw  Guideline Screw, starter motor 10 Nm (7.4 lbf ft) 301586-11 –...

  • Page 105: 30/Disassembling The Engine

    30/DISASSEMBLING THE ENGINE Preparations 18.1 – Mount the special tool on the engine work stand. Engine fixing arm (83529002000) ( p. 237) Engine work stand (61229001000) ( p. 230) – Mount the engine on the special tool. Info Use a helper or motorized hoist. 301596-10 Removing the shift lever 18.2...

  • Page 106: Removing The Spark Plug

    30/DISASSEMBLING THE ENGINE – Pull oil filter out of the oil filter housing.  Circlip pliers reverse (51012011000) ( p. 228) 301601-10 Removing the spark plug 18.5 – Remove the spark plug using special tool  Spark plug wrench (77329072000) ( p.

  • Page 107: Removing The Torque Limiter

    30/DISASSEMBLING THE ENGINE – Remove centering pins . Take off the alternator cover gasket   301606-10 Removing the torque limiter 18.9 – Remove torque limiter  301607-10 Positioning the engine at ignition top dead center (TDC) 18.10 – Remove screw ...

  • Page 108: Removing The Camshaft

    30/DISASSEMBLING THE ENGINE – Mount special tool  Engine blocking screw (77329010000) ( p. 231) 301611-10 Removing the camshaft 18.11 – Remove screws  – Take off the camshaft bearing bridge. Info Ensure that the needle rollers and the O-ring remain in place. 301612-10 –...

  • Page 109: Removing The Double Wheel

    30/DISASSEMBLING THE ENGINE Removing the double wheel 18.13 – Remove screws  – Take off the retaining bracket. 301616-10 – Screw a fitting screw into spindle  – Hold the double wheel and remove spindle  301617-10 – Take the timing chain off the double wheel. –...

  • Page 110: Removing The Water Pump Cover

    30/DISASSEMBLING THE ENGINE – Remove centering pins and cylinder head gasket   301621-10 Removing the water pump cover 18.15 – Remove screws . Take off the water pump cover.  – Remove the gasket. 301622-10 Removing the clutch cover 18.16 –...

  • Page 111: Removing The Piston

    30/DISASSEMBLING THE ENGINE Removing the piston 18.17 – Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out. – Remove the piston pin retainer  – Remove the piston pin. –...

  • Page 112: Removing The Rotor And Starter Idler Gear

    30/DISASSEMBLING THE ENGINE – Take off the timing chain and balancer gear with the needle bearings. Info Identify the direction of travel. 301631-10 Removing the rotor and starter idler gear 18.20 – Remove screw  301632-10 – Insert special tool into the crankshaft.

  • Page 113: Removing The Drive Wheel Of The Balancer Gear

    30/DISASSEMBLING THE ENGINE Removing the drive wheel of the balancer gear 18.22 – Remove freewheel gear with the needle bearing.  301636-10 – Remove nut with the special tool.  Special socket, 36 mm; ½" drive (77329021000) ( p. 231) –...

  • Page 114: Removing The Spacer

    30/DISASSEMBLING THE ENGINE Removing the spacer 18.24 – Remove spacer from the countershaft.  – Remove the O-ring. 301652-10 Removing the outer clutch hub 18.25 – Unscrew screws and remove them with the washers and springs.  – Remove pressure cap ...

  • Page 115: Removing The Primary Gear

    30/DISASSEMBLING THE ENGINE – Take off washer  – Take off the outer clutch hub. 301688-10 – Remove needle bearing and collar sleeve   301689-10 Removing the primary gear 18.26 – Remove nut  – Take off primary gear ...

  • Page 116: Removing The Suction Pump

    30/DISASSEMBLING THE ENGINE Removing the suction pump 18.28 – Remove the shaft locking device  – Take off washers  – Remove oil pump gear and oil pump idler gear with the bearing.   301656-10 – Remove pin  –...

  • Page 117: Removing The Shift Drum Locating Unit

    30/DISASSEMBLING THE ENGINE Removing the shift drum locating unit 18.30 – Remove screw  – Push away locking lever from shift drum locating unit and remove the shift   drum locating unit. – Relieve tension from the locking lever. 301661-10 Removing the locking lever 18.31...

  • Page 118: Removing The Shift Rails

    30/DISASSEMBLING THE ENGINE Removing the shift rails 18.33 – Remove shift rails together with upper springs and the lower springs.   301691-10 Removing the shift drum 18.34 – Tilt shift forks to the side.  Info Do not misplace the shift rollers. –...

  • Page 119: Removing The Crankshaft

    30/DISASSEMBLING THE ENGINE Removing the crankshaft 18.37 – Take out crankshaft  – Take off the right section of the engine case. 301697-10...

  • Page 120: 30/Engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS Working on the right section of the engine case 19.1 – Remove all dowels. – Remove shaft seal ring of the crankshaft.  – Remove the screws of bearing bolt  – Take off bearing bolt with the lock washer.

  • Page 121: Working On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Position all bearing retainers. – Mount and tighten screws  Guideline Locking screw for bearing 6 Nm Loctite ® 243™ (4.4 lbf ft) – Blow out the oil channel with compressed air and check that it is clear. 301757-10 Working on the left section of the engine case 19.2...

  • Page 122: Removing The Water Pump

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Press in shaft seal ring of the countershaft so it is flush with the open side fac-  ing in. – Mount and tighten oil jet in the oil channel.  Guideline Oil jet, clutch oil supply M5x1 6 Nm Loctite...

  • Page 123: Changing The Shaft Seal Ring Of The Water Pump

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove nut  – Pull off bearing  Extractor (59029033000) ( p. 229) – Remove retaining bracket  301209-10 Changing the shaft seal ring of the water pump 19.4 – Remove shaft seal ring ...

  • Page 124: Installing The Water Pump

    30/ENGINE - WORK ON INDIVIDUAL PARTS Installing the water pump 19.5 – Position retaining bracket  – Press bearing in place.  – Mount and tighten nut  Guideline Nut, compensating M14x1 20 Nm Loctite ® 243™ sprocket (14.8 lbf ft) 301209-11 –...

  • Page 125: Removing The Crankshaft Seal Ring In The Clutch Cover

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the crankshaft seal ring in the clutch cover 19.6 – Remove shaft seal ring of the crankshaft.  301678-10 Installing the crankshaft seal ring in the clutch cover 19.7 – Press in shaft seal ring all the way, with the open side facing inward.

  • Page 126: Installing The Oil Pressure Regulator Valve

    30/ENGINE - WORK ON INDIVIDUAL PARTS Installing the oil pressure regulator valve 19.10 – Install ball and pressure spring   – Mount and tighten screw plug with sealing washer   Guideline Oil pressure regulator valve plug M14x1.5 18 Nm (13.3 lbf ft) 301672-11 Checking the lubrication system...

  • Page 127: Removing The Crankshaft Bearing Inner Race

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the crankshaft bearing inner race 19.12 – Fix the crankshaft in the vise. Info Use soft jaws. – Warm up special tool  Guideline 150 °C (302 °F) Tool for inner bearing race (58429037037) ( p.

  • Page 128: Checking Crankshaft Run-Out At Bearing Pin

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Press in the new crank pin as far as possible.  Oil hole is aligned with oil hole   If the oil holes are not correctly aligned, the conrod bearing will not be sup- plied with oil.

  • Page 129: Measuring The Crankshaft End Play

    30/ENGINE - WORK ON INDIVIDUAL PARTS Measuring the crankshaft end play 19.16 – Insert the crankshaft in the right section of the engine case. Info Do not forget the fitted bushings. – Mount the left section of the engine case. –...

  • Page 130: Checking/Measuring The Piston

    30/ENGINE - WORK ON INDIVIDUAL PARTS – The cylinder size is marked on the cylinder collar.  301249-10 – Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. Feeler gauge (59029041100) ( p.

  • Page 131: Measuring Piston/Cylinder Mounting Clearance

    30/ENGINE - WORK ON INDIVIDUAL PARTS Measuring piston/cylinder mounting clearance 19.20 – Check/measure the cylinder. ( p. 127) – Check/measure the piston. ( p. 128) – The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mounting clearance equals the largest cylinder bore diameter minus the smallest piston diameter.

  • Page 132: Checking The Autodecompressor

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Mount screw but do not tighten yet.  Guideline Screw, camshaft gear M10x1 50 Nm lubricated with (36.9 lbf ft) engine oil – Repeat these steps for the second camshaft. 301219-11 Checking the autodecompressor 19.23 –...

  • Page 133: Checking The Camshaft Bearing Bridges

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Position camshaft bearing bridge . Mount and tighten the screws.   Guideline Screw, camshaft bearing M7x1 14 Nm lubricated with bridge (10.3 lbf ft) engine oil Info Do not forget the O-ring and needle rollers. Do not turn the camshaft.

  • Page 134: Checking The Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Pre-tension the valve springs using the special tool. Valve spring compressor (59029019000) ( p. 229) Insert for valve spring lever (77329060000) ( p. 232) – Remove the valve keys and unload the valve springs. 301230-10 –...

  • Page 135: Checking The Valve Springs

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the valve springs 19.29 – Check the valve springs for breakage and wear (visual check). » If the valve spring is broken or worn: – Change the valve spring. – Measure the length of the valve springs. Valve spring Minimum length 42.8 mm (1.685 in)

  • Page 136: Installing The Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check sealing seat of the valves.  Valve - sealing seat width Intake 1.50 mm (0.0591 in) 0 0 A Valve - sealing seat width Exhaust 1.50 mm (0.0591 in) » If the measured value does not meet specifications: –...

  • Page 137: Removing The Freewheel

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the freewheel 19.34 – Press expansion ring together using suitable pliers.  – Take freewheel out of the freewheel hub.  301234-10 Checking the freewheel 19.35 – Insert freewheel gear into the freewheel hub, turning the freewheel gear clock- ...

  • Page 138: Checking The Electric Starter Mode

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the electric starter mode 19.37 301211-01 – Check the gear mesh and bearing of starter idler gear for damage and wear.  » If there is damage or wear: – Change the starter idler gear. –...

  • Page 139: Checking The Timing Assembly

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the timing assembly 19.38 0 0 4 0 0 1 0 0 5 0 0 4 0 0 3 0 0 2 0 0 1 301245-01 – Clean all parts well. – Check the balancer gear/double wheel for damage and wear.

  • Page 140: Checking Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Place two spacing washers or similar aids next to the timing chain tensioner piston. This ensures that, when pressed in, the piston cannot go in all the way. Guideline Thickness of the spacing washers 2…...

  • Page 141: Checking Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS » If the contact surface exhibits significant wear: – Change the clutch lining discs and the outer clutch hub. – Check needle bearing and collar sleeve for damage and wear.   » If there is damage or wear: –...

  • Page 142: Preassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Change the grooved ball bearing. – Check the shift rollers for damage and wear. » If there is damage or wear: – Change the shift rollers. – Check the springs of the shift rails for damage and wear.

  • Page 143: Disassembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Disassembling the main shaft 19.43 0 0 b k 0 0 8 0 0 b l 0 0 6 0 0 9 0 0 4 0 0 7 0 0 2 0 0 5 0 0 3 0 0 1 301259-01...

  • Page 144: Checking Transmission

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove stop disk and 1st-gear idler gear   – Remove needle bearing and stop disk   – Remove 3rd-gear sliding gear  – Remove lock ring  – Remove stop disk ...

  • Page 145: Assembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check solid gears for smooth operation in the profile of main shaft   » If the solid gear does not move freely: – Change the solid gear or the main shaft. – Check solid gears for smooth operation in the profile of countershaft ...

  • Page 146: Assembling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Assembling the countershaft 19.47 Info Use new lock rings with every repair. – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 142) 0 0 b p 0 0 b n 0 0 b q 0 0 b k 0 0 b o...

  • Page 147: 30/Engine Assembly

    30/ENGINE ASSEMBLY Installing the crankshaft 20.1 – Position the right section of the engine case in the engine work stand. – Push crankshaft into the bearing seat.  301697-10 Installing the transmission shafts 20.2 – Slide both transmission shafts into the bearing seats. Info Do not misplace the washers.

  • Page 148: Installing The Shift Drum

    30/ENGINE ASSEMBLY Installing the shift drum 20.4 – Push shift drum into the bearing seat.  – Put shift forks in the shift drum.  Info Do not misplace the shift rollers. 301692-11 Installing the shift rails 20.5 – Install shift rails together with upper springs and lower springs.

  • Page 149: Installing The Locking Lever

    30/ENGINE ASSEMBLY Installing the locking lever 20.7 – Mount locking lever with the sleeve and spring.  – Mount and tighten screw with the washer.  Guideline Screw, locking lever 6 Nm Loctite ® 243™ (4.4 lbf ft) 301662-11 Installing the shift drum locating unit 20.8 –...

  • Page 150: Installing The Centrifugal Separator

    30/ENGINE ASSEMBLY – Position oil pump gear and oil pump idler gear with the bearing.   – Position washers  – Mount shaft locking devices  – Crank the oil pump gear and ensure that it can move easily. 301656-11 –...

  • Page 151: Installing The Primary Gear

    30/ENGINE ASSEMBLY – Position oil pump housing  – Mount and tighten screws  Guideline Screw, oil pump casing 10 Nm Loctite ® 243™ (7.4 lbf ft) – Crank the oil pump gear and ensure that it can move easily. 301649-11 Installing the primary gear 20.13...

  • Page 152: Installing The Spacer

    30/ENGINE ASSEMBLY – Lock the outer clutch hub and primary gear with the special tool and tighten  Guideline Loctite ® 243™ Nut, primary gear M27x1 80 Nm (59 lbf ft) Gear quadrant (80029004000) ( p. 233) Info 301687-10 Ensure that the crankshaft is not locked. –...

  • Page 153: Installing The Drive Wheel Of The Balancer Gear

    30/ENGINE ASSEMBLY Installing the drive wheel of the balancer gear 20.16 – Position drive wheel of the balancer gear.  – Mount and tighten nut with the special tool.  Guideline Nut, freewheel hub M27x1 80 Nm Loctite ® 243™ (59 lbf ft) Special socket, 36 mm;...

  • Page 154: Installing The Ignition Pulse Generator

    30/ENGINE ASSEMBLY Installing the ignition pulse generator 20.19 – Position the ignition pulse generator. – Mount screws but do not tighten yet.  Guideline Screw, ignition pulse gen- 6 Nm Loctite ® 243™ erator adapter (4.4 lbf ft) – Position the cable and insert the cable support sleeve into the engine case. –...
  • Page 155 30/ENGINE ASSEMBLY – Mount O-rings  – Mount locating pins and position cylinder base gasket   301627-11 – Ensure that piston mark faces the exhaust side.  301156-10 – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft.

  • Page 156: Installing The Clutch Cover

    30/ENGINE ASSEMBLY – Remove the cloth. Keep the timing chain taut. – Carefully push the cylinder downward, letting the locating pins engage. 301647-10 Installing the clutch cover 20.23 – Insert quad ring  – Mount O-ring  – Position the dowel pins. 301625-11 –...

  • Page 157: Installing The Cylinder Head

    30/ENGINE ASSEMBLY Installing the cylinder head 20.25 – Mount centering pins  – Position cylinder head gasket  – Put the cylinder head in place. 301621-11 – Mount nut with the washers and tighten in a crisscross pattern.  Guideline Nut, cylinder head M10x1.25 Tightening...

  • Page 158: Installing The Timing Chain Tensioner

    30/ENGINE ASSEMBLY Installing the timing chain tensioner 20.27 – Position timing chain tensioner and insert it with new O-ring   301615-11 – Mount and tighten screw plug with the seal ring.  Guideline Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –...

  • Page 159: Adjusting The Valve Timing

    30/ENGINE ASSEMBLY – Position the camshaft bearing bridges. Info Ensure that the needle rollers and the O-ring are correctly seated. – Mount screws and tighten from the inside to the outside.  Guideline Screw, camshaft bearing M7x1 14 Nm lubricated with bridge (10.3 lbf ft) engine oil...

  • Page 160: Checking The Valve Clearance

    30/ENGINE ASSEMBLY Checking the valve clearance 20.30 – Remove special tool  Engine blocking screw (77329010000) ( p. 231) – Crank over the engine repeatedly. – Position the engine at ignition top dead center (TDC). ( p. 105) 301611-11 – Check the valve clearance at all valves between the camshaft and cam levers.

  • Page 161: Installing The Torque Limiter

    30/ENGINE ASSEMBLY Installing the torque limiter 20.32 – Mount torque limiter  301607-10 Installing the alternator cover 20.33 – Mount centering pins . Position alternator cover gasket   301606-11 – Position the alternator cover. Mount screws and tighten in a crisscross pattern. ...

  • Page 162: Installing The Spark Plug

    30/ENGINE ASSEMBLY Installing the spark plug 20.36 – Mount and tighten the spark plug with special tool  Guideline Spark plug 10… 12 Nm (7.4… 8.9 lbf ft) Spark plug wrench (77329072000) ( p. 232) 301602-10 Installing the oil screen 20.37 –...

  • Page 163: Installing The Shift Lever

    30/ENGINE ASSEMBLY Installing the shift lever 20.39 – Position the shift lever. Mount and tighten screw with the collar sleeve.  Guideline Screw, shift lever 10 Nm Loctite ® 243™ (7.4 lbf ft) 301597-10 Removing the engine from the universal mounting rack 20.40 –...

  • Page 164: 31/Carburetor

    31/CARBURETOR Choke 21.1 The choke is fitted on the left side of the carburetor.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 165: Checking The Position Of The Throttle Position Sensor

    31/CARBURETOR – Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls. – Adjust to the point between these two positions with the highest idle speed. Info If there is a large increase in the engine speed, reduce the idle speed to a normal level and repeat the above steps.

  • Page 166: Draining The Carburetor Float Chamber

    31/CARBURETOR » If the specified value is not reached: – Carburetor - adjust the idle speed. ( p. 162) – Adjust the position of the throttle position sensor. ( p. 174) » If the specified value is reached: – Remove the cable jumper. –...
  • Page 167 31/CARBURETOR – Unplug connector of the throttle position sensor.  – Remove cable binder  301544-10 – Detach engine breather hose from the carburetor.  301545-10 – Loosen hose clip  301546-10 – Take carburetor out of the frame from the rear and set it down on the frame. ...

  • Page 168: Installing The Carburetor

    31/CARBURETOR – Unscrew the hot start activation  – Remove the carburetor. 301550-10 Installing the carburetor 21.7 – Mount the hot start activation  Guideline Hot start activation 2.5 Nm (1.84 lbf ft) 301550-11 – Attach the throttle cable. Info Ensure that the throttle cable is routed correctly.

  • Page 169: Disassembling The Carburetor

    31/CARBURETOR – Attach engine breather hose to the carburetor.  Info Ensure that the engine breather hose is routed properly. 301545-11 – Connect plug of the throttle position sensor.  – Secure the cables with cable binders  – Install the air filter box lid and the carburetor connection boot. ( p.
  • Page 170 31/CARBURETOR – Pull up throttle slide arm . Take throttle slide out of the carburetor along with   throttle slide roller and the throttle slide plate.  301563-10 – Remove screws . Take off the accelerator pump cover with the seal ring. ...
  • Page 171 31/CARBURETOR – Remove screw . Pull the hose connector out of the carburetor.  301557-10 – Remove screw . Take off throttle position sensor   Info Only remove the throttle position sensor if necessary. If screw is loos-  ened, the throttle position sensor must be readjusted.

  • Page 172: Checking/Adjusting The Carburetor Components

    31/CARBURETOR Checking/adjusting the carburetor components 21.9 301703-01 – Disassemble the carburetor. ( p. 167) – Check/adjust the accelerator pump. ( p. 170) – Check the choke slide. ( p. 171) – Check the jet needle. ( p. 172) – Check the throttle slide. ( p.

  • Page 173: Checking The Choke Slide

    31/CARBURETOR – Check/adjust the throttle slide opening. ( p. 173) Info Adjustment of the play of the accelerator pump affects the starting point of injection and has no influence on the injection rate or the intensity of the accelerator pump. –...

  • Page 174: Checking The Jet Needle

    31/CARBURETOR – Connect the plus cable of the multimeter to the blue (bu) cable and the ground cable to the black (bl) cable of the throttle position sensor connector. Measure the total throttle position sensor resistance R Guideline Throttle position sensor, total resis- 4…...

  • Page 175: Checking/Adjusting The Throttle Slide Opening

    31/CARBURETOR Checking/adjusting the throttle slide opening 21.16 Info The basic setting of the throttle slide is used to check the beginning of injection of the accelerator pump and the basic setting of the throttle position sensor. Condition The carburetor has been removed. –...

  • Page 176: Checking/Adjusting The Float Level

    31/CARBURETOR Checking/adjusting the float level 21.19 Condition The carburetor and float chamber have been removed. – Tilt the carburetor to one side, preventing the pin of the float from falling out. – Tilt the carburetor until the float rests against the float needle valve but the float needle valve is not pushed together.

  • Page 177: Assembling The Carburetor

    31/CARBURETOR Assembling the carburetor 21.21 – Mount and tighten idle air jet  Guideline Idle air jet M4.5x0.75 2 Nm (1.5 lbf ft) 301559-11 – Mount and tighten choke slide  Guideline Choke slide 2.5 Nm (1.84 lbf ft) – Position throttle position sensor .
  • Page 178 31/CARBURETOR – Mount and tighten main jet  Guideline Main jet M5x0.75 2 Nm (1.5 lbf ft) – Position the float together with the float needle valve, and mount fulcrum pin  – Check/adjust the float level. ( p. 174) 301554-11 –...
  • Page 179 31/CARBURETOR – Check/adjust the accelerator pump. ( p. 170) – Position seal ring , membrane and spring    Info The label on the membrane must be visible when the membrane is mounted. 301566-10 – Position seal ring in the accelerator pump cover with the rounded side facing ...

  • Page 180: 32/Clutch

    32/CLUTCH Checking fluid level of hydraulic clutch 22.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 181: 33/Transmission

    33/TRANSMISSION Removing the engine sprocket 23.1 – Disconnect plug of the brake light switch.  – Remove screws . Take off the engine sprocket cover.   301543-10 – Activate the rear brake and remove screw with spring washer  ...

  • Page 182: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM Checking antifreeze and coolant level 24.1 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 183: Draining Coolant

    35/WATER PUMP, COOLING SYSTEM – Mount the radiator cap. Draining coolant 24.3 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
  • Page 184 35/WATER PUMP, COOLING SYSTEM – Open screw to bleed the radiator. Tighten the screw when coolant emerges from  the opening. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 301840-10 – Add coolant to level above the radiator fins. ...

  • Page 185: 38/Lubrication System

    38/LUBRICATION SYSTEM Oil circuit 25.1 0 0 0 b k 0 0 b k 0 0 b l 0 0 b l 0 0 9 0 0 9 0 0 6 0 0 6 0 0 5 0 0 7 0 0 8 0 0 b n 0 0 b m...

  • Page 186: Draining The Engine Oil

    38/LUBRICATION SYSTEM Draining the engine oil 25.3 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under lukewarm water immedi- ately.

  • Page 187: Installing The Oil Filter

    38/LUBRICATION SYSTEM Installing the oil filter 25.5 – Fill oil filter with engine oil and place it in the oil filter housing.  301844-10 – Oil the O-ring of the oil filter cover and install it with the oil filter cover. –...

  • Page 188: Adding Engine Oil

    38/LUBRICATION SYSTEM » When the engine oil does not reach the middle of the viewer  – Add engine oil. ( p. 186) Condition The engine is cold. – Check the engine oil level. The engine oil reaches the bottom of the viewer ...

  • Page 189: 39/Ignition System

    39/IGNITION SYSTEM Removing the stator 26.1 Condition The alternator cover has been removed. – Remove screw and the retaining bracket.  – Remove cable support sleeve from the alternator case.  – Remove screws  – Take the stator out of the alternator cover. 301682-10 Installing the stator 26.2...

  • Page 190: Checking The Ignition Coil

    39/IGNITION SYSTEM – Check the alternator. ( p. 190) – Check the spark plug connector. ( p. 189) – Change the spark plug. – Connect the spark plug connector with the ignition wire again. Unscrew the spark plug and insert it into the spark plug connector. Touch the spark plug to ground. –...

  • Page 191: Checking The Spark Plug Connector

    39/IGNITION SYSTEM Checking the spark plug connector 26.5 – Measure the dismantled spark plug connector with a multimeter. Spark plug connector Resistance at: 20 °C (68 °F) 3.75… 6.25 kΩ » If the value displayed does not meet specifications: – Change the spark plug connector.

  • Page 192: Checking The Alternator

    39/IGNITION SYSTEM – Connect the CDI controller. Connect the red measuring lead of the special tool to the green wire. Connect the black measuring lead to the red wire. – Remove the spark plug connector. – Press the electric starter button. Ignition pulse generator - output voltage - connector connected Red - green at: 20 °C (68 °F) 1…...

  • Page 193: 61/Atv Front End

    61/ATV FRONT END Checking the toe 27.1 – Park the vehicle on a horizontal surface. – Check the tire condition. ( p. 72) – Check the tire air pressure. ( p. 72) – Check the chassis parts for damage, play and wear. –...

  • Page 194: Adjusting The Toe

    61/ATV FRONT END Adjusting the toe 27.2 – Park the vehicle on a horizontal surface. – Check the tire condition. ( p. 72) – Check the tire air pressure. ( p. 72) – Check the chassis parts for damage, play and wear. Replace damaged or worn parts.

  • Page 195: Checking/Adjusting The Camber

    61/ATV FRONT END Checking/adjusting the camber 27.3 Info The left and right camber should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( p. 12) – Loosen nuts  300273-10 –...

  • Page 196: Adjusting The Fork Offset

    61/ATV FRONT END Adjusting the fork offset 27.4 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( p. 12) – Remove screws with bushings ...
  • Page 197 61/ATV FRONT END – Unthread the brake caliper. – Hang the brake caliper and the brake line loosely to one side. 400691-10 – Remove nut and take the tie rod out of the wheel carrier.  301502-10 – Remove nuts ...

  • Page 198: Changing The Wheel Bearing

    61/ATV FRONT END Changing the wheel bearing 27.6 Info The operations are the same on the left and right. – Remove the wheel carrier. ( p. 194) – Fix the wheel carrier in the vise. Info Use soft jaws. – Remove nut ...

  • Page 199: Installing The Wheel Carrier

    61/ATV FRONT END – Press the wheel bearing all the way in. Press mandrel (83019013000) ( p. 235) 301513-10 – Press in shaft seal rings so they are flush.  301511-10 – Mount spacers  301510-10 – Slide the wheel hub onto the wheel carrier. –...

  • Page 200: Removing The A-Arms

    61/ATV FRONT END – Insert the tie rod in the wheel carrier. Mount and tighten nut  Guideline Nut, tie rod end M10x1.25 45 Nm (33.2 lbf ft) 301502-11 – Thread the brake caliper and position it. 400691-11 – Mount and tighten screws ...

  • Page 201: Installing The A-Arms

    61/ATV FRONT END – Remove screws and take off upper A-arm   Info When removing screws , make sure that bushings remain in place.   301506-10 – Remove screw and the shock absorber out of the guide.  –...

  • Page 202: A-Arm Top - Changing The Bearing

    61/ATV FRONT END – When the nuts on the heim joint have been released, align the heim joint at right angles to the screws and tighten nut  Guideline Nut, A-arm top M12x1.25 30 Nm (22.1 lbf ft) – Install the wheel carrier. ( p.

  • Page 203: A-Arm Bottom - Changing The Bearing

    61/ATV FRONT END – Loosen nuts . Remove heim joint . Screw the nuts off of the heim joints.   600470-10 – Screw the nuts on the new heim joints. Mount the heim joints  600471-10 – Insert the tool in the heim joint and clip onto the A-arm.
  • Page 204 61/ATV FRONT END 600457-01 – Remove flange adapters and bearing sleeves   – Remove shaft seal rings  – Remove spacing washers  Info The spacing washers are only installed at the front pivot point. – Press out needle bearing using the thin long side of the special tool.
  • Page 205 61/ATV FRONT END – Remove lock ring  Circlip pliers reverse (51012011000) ( p. 228) 600464-10 – Press out ball head using the special tool.  Disassembly/assembly holder (83019020150) ( p. 236) 600465-10 – Press in the ball head using the special tool. Press mandrel (83019020130) ( p.

  • Page 206: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement (450 SX ATV) 449.3 cm³ (27.418 cu in) Displacement (505 SX ATV) 477.5 cm³ (29.139 cu in) Stroke 60.8 mm (2.394 in) Bore (450 SX ATV) 97 mm (3.82 in) Bore (505 SX ATV) 100 mm (3.94 in) Compression ratio...

  • Page 207: Technical Data - Engine Tolerances, Wear Limits

    TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS Camshaft - cam height Exhaust 33.10… 33.30 mm (1.3031… 1.311 in) Camshaft - cam height (450 SX ATV) Intake 33.90… 34.10 mm (1.3346… 1.3425 in) Camshaft - cam height (505 SX ATV) Intake 34.20…...

  • Page 208: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Jet, engine case breather On block Loctite 243™ ® Oil jet for conrod lubrication 4 Nm (3 lbf ft) Loctite 243™ ® Oil jet, cam lever lubrication 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 209 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Nut, cylinder head M10x1.25 Tightening sequence: lubricated with engine oil Tighten in diagonal sequence. Tightening stage 1 10 Nm (7.4 lbf ft) Tightening stage 2 30 Nm (22.1 lbf ft) Tightening stage 3 50° –...

  • Page 210: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4125L Needle position 3 th position from top Idle mixture adjusting screw Open 1.5 turns Pump membrane stop 2.15 mm (0.0846 in) Hot start button Diameter of bore in carburetor body 2.5 mm (0.098 in) Main jet Jet needle...

  • Page 211: Technical Data - Carburetor Tightening Torques

    TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES – Other screws, carburetor 2 Nm (1.5 lbf ft) ® Screw, hose connection 2 Nm (1.5 lbf ft) Loctite 243™ ® Screw, throttle slide arm 2 Nm (1.5 lbf ft) Loctite 243™ – Spill jet M4x0.7 2 Nm (1.5 lbf ft) –...

  • Page 212: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Double cradle of chromium molybdenum steel tubes, powder- coated Wheel suspension Front Single wheel suspension with double transverse control arm Rear Rigid axle Suspension travel Front 244 mm (9.61 in) Rear 258 mm (10.16 in) Fork offset Front 50 mm (1.97 in)

  • Page 213: Tires

    21 x 7.00 - 10 20 x 11.00 - 9 MAXXIS Razr M‑931 MAXXIS Razr M‑932 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 33.2 Total fuel tank capacity 10.3 l (2.72 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 214: Technical Data - Front Shock Absorber

    TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber part number 03.18.7J.16 Shock absorber WP Suspension 3612 BAVP DCC Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort...

  • Page 215: Technical Data - Rear Shock Absorber

    TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber part number 15.18.7J.16 Shock absorber WP Suspension PDS 4618 BAVP DCC Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks Rebound damping...

  • Page 216: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw on fuel tank 6 Nm (4.4 lbf ft) – Screw, clamping nut, rear axle 10 Nm (7.4 lbf ft) ®...

  • Page 217: Cleaning

    CLEANING Cleaning the vehicle 37.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 218: Storage

    STORAGE Storage 38.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 219: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop 39.1 S10A S30A Engine Change the engine oil and oil filter, clean the oil screen. ( p. 183) • • • • Replace spark plug. •...

  • Page 220: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As An Additional Order)

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop (as an additional order) 39.2 S10A S20A S40A S80A Change the oil in the front shock absorber. ( p. 25) • • Service the front shock absorber. ( p.
  • Page 221 SERVICE SCHEDULE NB1A Check the tire condition. ( p. 72) • Check the coolant level. ( p. 180) • Check that all controls for smooth operation. • Check braking force (incl. parking brake). • Check all screws, nuts and hose clamps regularly for tightness. •...

  • Page 222: Wiring Diagram

    WIRING DIAGRAM 450/525 SX ATV 40.1 302012-01...
  • Page 223 WIRING DIAGRAM Components CDI controller Throttle position sensor Battery Alternator Starter relay with fuse Power relay Ignition coil Ignition pulse generator Starter motor Radiator fan Voltage regulator/rectifier Switch for throttle lever Electric starter button Emergency OFF switch with rip cord Temperature switch for radiator fan Clutch switch Cable colors...
  • Page 224 WIRING DIAGRAM White-black Brown Brown Black White-red White-black White-red Brown Black-yellow...

  • Page 225: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 226 According to – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the ® corresponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...

  • Page 227: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Carburetor cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Carburetor Chain cleaner Guideline – ®...
  • Page 228 AUXILIARY SUBSTANCES Lubricant (T159) Guideline – ® KTM recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® MC‑11 Lubricant (T511) Guideline – ® KTM recommends Lubcon products. Supplier ® Lubcon – ® Turmsilon GTI 300 P Motorcycle cleaner Guideline – ®...

  • Page 229: Special Tools

    SPECIAL TOOLS Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018000 Feature 12… 16 mm (0.47… 0.63 in) 400038-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400125-01 Spring hooks Art.
  • Page 230 SPECIAL TOOLS Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58012009000 400073-01 Tool for inner bearing race Art. no.: 58429037037 400082-01 Peak voltage adapter Art. no.: 58429042000 400083-01 Mounting sleeve Art. no.: 58529005000 400095-01...
  • Page 231 SPECIAL TOOLS Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01 Adjustment tool for mixture control screw Art. no.: 59029034000 400106-01 Feeler gauge Art. no.: 59029041100 400110-01...
  • Page 232 SPECIAL TOOLS Plastigauge measuring strips Art. no.: 60029012000 400122-01 Piston ring mounting tool Art. no.: 60029015000 400123-01 Engine work stand Art. no.: 61229001000 200306-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01 Protection cover Art. no.: 75029090000 400167-01...
  • Page 233 SPECIAL TOOLS Clutch holder Art. no.: 77329003000 301488-10 Engine blocking screw Art. no.: 77329010000 400177-01 Assembly pin Art. no.: 77329012100 400178-01 Internal bearing puller Art. no.: 77329020000 Feature 8… 12 mm (0.31… 0.47 in) 400038-01 Special socket, 36 mm; ½" drive Art.
  • Page 234 SPECIAL TOOLS Insert for piston pin retainer Art. no.: 77329030100 400160-01 Adjustment bush bridge Art. no.: 77329050000 301381-10 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Insert for valve spring lever Art. no.: 77329060000 400129-01 Spark plug wrench Art.
  • Page 235 SPECIAL TOOLS Pressing tool, crankshaft Art. no.: 77629008000 400185-01 Extrude plate, base Art. no.: 77629009001 400187-01 Extrude plate, top Art. no.: 77629009002 400186-01 Insertion for piston ring lock Art. no.: 77629030000 400160-01 Gear quadrant Art. no.: 80029004000 500164-01...
  • Page 236 SPECIAL TOOLS Hook wrench Art. no.: 83019001000 200224-10 Hook wrench Art. no.: 83019002000 200225-10 Open-end wrench attachment, 46 mm Art. no.: 83019010461 500172-01 Hook wrench Art. no.: 83019011000 600430-01 Press mandrel Art. no.: 83019012000 600421-01...
  • Page 237 SPECIAL TOOLS Press mandrel Art. no.: 83019013000 600476-01 Camber gauge Art. no.: 83019014000 500229-01 Handlebar fixation for straight-ahead position Art. no.: 83019015100 200424-10 Extractor Art. no.: 83019020000 600477-01 Mounting sleeve Art. no.: 83019020100 600461-01...
  • Page 238 SPECIAL TOOLS Press mandrel Art. no.: 83019020130 600462-01 Disassembly/assembly holder Art. no.: 83019020150 600463-01 Press mandrel Art. no.: 83019020170 600460-01 Push-out tool Art. no.: 83019021000 600452-01 Adapter cable Art. no.: 83029043000 600402-01...
  • Page 239 SPECIAL TOOLS Engine fixing arm Art. no.: 83529002000 301487-10 Extractor Art. no.: 83529048000 301700-10 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10 Mounting sleeve Art. no.: T1204 200788-10...
  • Page 240 SPECIAL TOOLS Calibration pin Art. no.: T1205 200790-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Press drift Art. no.: T1504 200789-10 Assembly tool Art. no.: T150S 200791-10...
  • Page 241 SPECIAL TOOLS Mounting sleeve Art. no.: T1554 300578-10 Hook wrench Art. no.: T157S 200899-10 Nitrogen filling tool Art. no.: T170S1 300574-10 Mounting sleeve Art. no.: T313 300578-10...

  • Page 242: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 243: Index

    INDEX valve timing, checking ..... . . 156 INDEX water pump cover, installing ....154 A-Arm bottom changing the bearing .
  • Page 244 INDEX Chain tension valve cover, removing ..... . . 104 adjusting ....... . . 76 water pump cover, removing .
  • Page 245 INDEX changing ....... . 183 Handlebar position draining ....... . 184 adjusting .
  • Page 246 INDEX Rear axle carburetor tightening torques ....209 installing ....... . . 79 chassis .
  • Page 247 *3206070en* 3206070en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

505 sx atv 20102010 450 sx2010 505 sx

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