KTM 450 SX ATV 2010 Repair Manual page 5

CONTENTS
Changing the ignition curve ............................................ 83
Removing the battery ..................................................... 83
Installing the battery...................................................... 83
Recharging the battery ................................................... 84
Changing the main fuse ................................................. 85
Changing the fuses of individual power consumers............ 85
Checking the battery voltage........................................... 86
Checking the charging voltage ........................................ 86
Checking the quiescent current....................................... 86
Checking the starter relay ............................................... 87
13/BRAKE SYSTEM........................................................... 88
Hand brake lever, parking brake...................................... 88
Checking the free travel of the hand brake lever ............... 88
Adjusting basic position of hand brake lever..................... 88
Checking front brake fluid level....................................... 89
Topping up the front brake fluid...................................... 89
Changing the front brake fluid ........................................ 90
Checking the front brake linings...................................... 91
Removing front brake linings .......................................... 91
Mounting front brake linings........................................... 92
Changing the front brake linings ..................................... 92
Checking free travel of foot brake lever ............................ 93
Adjusting basic position of foot brake lever ...................... 93
Checking rear brake fluid level........................................ 94
Adding rear brake fluid .................................................. 94
Changing the rear brake fluid.......................................... 95
Checking rear brake linings ............................................ 96
Removing rear brake linings............................................ 96
Mounting rear brake linings ............................................ 97
Changing rear brake linings ............................................ 98
30/ENGINE....................................................................... 99
Removing the engine ..................................................... 99
Installing the engine .................................................... 100
30/DISASSEMBLING THE ENGINE................................... 103
Preparations................................................................ 103
Removing the shift lever............................................... 103
Draining the engine oil ................................................. 103
Removing the oil filter.................................................. 103
Removing the spark plug .............................................. 104
Removing the valve cover ............................................. 104
Removing the starter motor .......................................... 104
Removing the alternator cover....................................... 104
Removing the torque limiter ......................................... 105
Positioning the engine at ignition top dead center
(TDC) ......................................................................... 105
Removing the camshaft................................................ 106
Removing the timing chain tensioner............................. 106
Removing the double wheel .......................................... 107
Removing the cylinder head.......................................... 107
Removing the water pump cover ................................... 108
Removing the clutch cover ........................................... 108
Removing the piston .................................................... 109
Removing the timing chain rails.................................... 109
Removing the timing chain........................................... 109
Removing the rotor and starter idler gear ....................... 110
Removing the ignition pulse generator ........................... 110
Removing the drive wheel of the balancer gear ............... 111
Removing the force pump ............................................ 111
Removing the spacer ................................................... 112
Removing the outer clutch hub ..................................... 112
Removing the primary gear ........................................... 113
Removing the centrifugal separator ............................... 113
Removing the suction pump ......................................... 114
Removing the shift shaft .............................................. 114
Removing the shift drum locating unit ........................... 115
Removing the locking lever........................................... 115
Removing the left section of the engine case.................. 115
Removing the shift rails ............................................... 116
Removing the shift drum .............................................. 116
Removing the shift forks .............................................. 116
Removing the transmission shafts ................................. 116
Removing the crankshaft .............................................. 117
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 118
Working on the right section of the engine case .............. 118
Working on the left section of the engine case................ 119
Removing the water pump ............................................ 120
Changing the shaft seal ring of the water pump .............. 121
Installing the water pump............................................. 122
Removing the crankshaft seal ring in the clutch cover ..... 123
Installing the crankshaft seal ring in the clutch cover...... 123
Removing the oil pressure regulator valve....................... 123
Checking spring length of oil pressure regulator valve...... 123
Installing the oil pressure regulator valve ....................... 124
Checking the lubrication system.................................... 124
Removing the crankshaft bearing inner race ................... 125
Installing the crankshaft bearing inner race.................... 125
Changing connecting rod, conrod bearing and crank
pin............................................................................. 125
Checking crankshaft run-out at bearing pin .................... 126
Measuring the crankshaft end play ................................ 127
Cylinder - Nikasil ® coating ............................................ 127
Checking/measuring cylinder ........................................ 127
Checking/measuring the piston ..................................... 128
Measuring piston/cylinder mounting clearance................ 129
Checking the piston ring end gap .................................. 129
Changing the camshaft bearing..................................... 129
Checking the autodecompressor.................................... 130
Checking camshafts..................................................... 130
Checking the radial clearance of the camshaft
bearings ..................................................................... 130
Checking the camshaft bearing bridges.......................... 131
Removing the valves .................................................... 131
Checking the valves ..................................................... 132
Checking the valve springs ........................................... 133
Checking valve spring seat............................................ 133
Checking the cam levers .............................................. 133
Checking cylinder head ................................................ 133
Installing the valves ..................................................... 134
Removing the freewheel ............................................... 135
Checking the freewheel ................................................ 135
Installing the free wheel ............................................... 135
Checking the electric starter mode ................................ 136
Checking the timing assembly ...................................... 137
Preparing the timing chain tensioner for installation ....... 137
Checking clutch .......................................................... 138
Checking shift mechanism ........................................... 139
Preassembling the shift shaft........................................ 140
Disassembling the main shaft ....................................... 141
Disassembling the countershaft .................................... 141
Checking transmission ................................................. 142
Assembling the main shaft ........................................... 143
Assembling the countershaft......................................... 144
30/ENGINE ASSEMBLY ................................................... 145
Installing the crankshaft............................................... 145
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