KTM 450 SX ATV 2010 Repair Manual page 6

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