KTM 2010 505 SX Manuals

Manuals and User Guides for KTM 2010 505 SX. We have 1 KTM 2010 505 SX manual available for free PDF download: Repair Manual

KTM 2010 505 SX Repair Manual

KTM 2010 505 SX Repair Manual (247 pages)

Brand: KTM | Category: Offroad Vehicle | Size: 13.35 MB

Table of Contents

Table of Contents
4
Means of Representation
8
Important Notes
9
View of Vehicle
10
- View of the Vehicle from the Left Front (Example)
  10
- View of the Vehicle from the Right Rear (Example)
  11
Location of Serial Numbers
12
- Chassis Number
  12
- Type Label
  12
- Key Number
  12
- Engine Number
  12
- Shock Absorber Part Number, Front
  12
- Shock Absorber Part Number, Rear
  13
Vehicle
14
- Jacking up the Vehicle
  14
- Removing the Vehicle from the Work Stand
  14
02/Handlebar, Instruments
15
03/Frame
22
- Removing the Engine Guard
  22
- Installing the Engine Guard
  22
04/Shock Absorber, Swingarm
23
05/Exhaust
61
- Removing the Main Silencer
  61
- Installing the Main Silencer
  61
- Removing the Manifold
  62
- Installing the Manifold
  62
06/Air Filter
63
07/Fuel Tank, Seat, Trim
65
- Removing the Seat
  65
- Mounting the Seat
  65
- Removing the Radiator Spoiler
  65
- Installing the Radiator Spoiler
  66
- Removing the Fuel Tank
  66
- Installing the Fuel Tank
  67
- Fuel Tap
  68
08/Mask, Fender
69
- Removing the Heel Protector
  69
- Installing the Heel Protector
  70
- Removing the Front Cover
  71
- Installing the Front Cover
  71
- Removing the Front Trim
  71
- Installing the Front Trim
  72
- Removing the Rear Fender
  72
- Installing the Rear Fender
  73
09/Front Wheel
74
- Checking the Tire Air Pressure
  74
- Checking the Tire Condition
  74
- Removing Wheel/Wheels
  74
- Installing the Wheel/Wheels
  75
- Checking Brake Discs
  76
10/Rear Wheel
77
- Checking Chain Dirt
  77
- Cleaning the Chain
  77
- Checking Chain Wear
  77
- Checking Rear Sprocket / Engine Sprocket for Wear
  78
- Checking the Chain Tension
  78
- Adjusting Chain Tension
  78
- Adjusting the Toe Width of Rear Axle
  79
- Removing the Rear Axle
  80
- Installing the Rear Axle
  81
- Changing the Rear Axle Bearing
  83
11/Wiring Harness, Battery
85
13/Brake System
90
30/Engine
101
- Removing the Engine
  101
- Installing the Engine
  102
30/Disassembling the Engine
105
- Preparations
  105
- Removing the Shift Lever
  105
- Draining the Engine Oil
  105
- Removing the Oil Filter
  105
- Removing the Spark Plug
  106
- Removing the Valve Cover
  106
- Removing the Starter Motor
  106
- Removing the Alternator Cover
  106
- Removing the Torque Limiter
  107
- Positioning the Engine at Ignition Top Dead Center (TDC)
  107
- Removing the Camshaft
  108
- Removing the Timing Chain Tensioner
  108
- Removing the Double Wheel
  109
- Removing the Cylinder Head
  109
- Removing the Water Pump Cover
  110
- Removing the Clutch Cover
  110
- Removing the Piston
  111
- Removing the Timing Chain Rails
  111
- Removing the Timing Chain
  111
- Removing the Rotor and Starter Idler Gear
  112
- Removing the Ignition Pulse Generator
  112
- Removing the Drive Wheel of the Balancer Gear
  113
- Removing the Force Pump
  113
- Removing the Spacer
  114
- Removing the Outer Clutch Hub
  114
- Removing the Primary Gear
  115
- Removing the Centrifugal Separator
  115
- Removing the Suction Pump
  116
- Removing the Shift Shaft
  116
- Removing the Shift Drum Locating Unit
  117
- Removing the Locking Lever
  117
- Removing the Left Section of the Engine Case
  117
- Removing the Shift Rails
  118
- Removing the Shift Drum
  118
- Removing the Shift Forks
  118
- Removing the Transmission Shafts
  118
- Removing the Crankshaft
  119
30/Engine - Work on Individual Parts
120
- Working on the Right Section of the Engine Case
  120
- Working on the Left Section of the Engine Case
  121
- Removing the Water Pump
  122
- Changing the Shaft Seal Ring of the Water Pump
  123
- Installing the Water Pump
  124
- Removing the Crankshaft Seal Ring in the Clutch Cover
  125
- Installing the Crankshaft Seal Ring in the Clutch Cover
  125
- Removing the Oil Pressure Regulator Valve
  125
- Checking Spring Length of Oil Pressure Regulator Valve
  125
- Installing the Oil Pressure Regulator Valve
  126
- Checking the Lubrication System
  126
- Removing the Crankshaft Bearing Inner Race
  127
- Installing the Crankshaft Bearing Inner Race
  127
- Changing Connecting Rod, Conrod Bearing and Crank Pin
  127
- Checking Crankshaft Run-Out at Bearing Pin
  128
- Measuring the Crankshaft End Play
  129
- Cylinder - Nikasil Coating
  129
- Checking/Measuring Cylinder
  129
- Checking/Measuring the Piston
  130
- Measuring Piston/Cylinder Mounting Clearance
  131
- Checking the Piston Ring End Gap
  131
- Changing the Camshaft Bearing
  131
- Checking the Autodecompressor
  132
- Checking Camshafts
  132
- Checking the Radial Clearance of the Camshaft Bearings
  132
- Checking the Camshaft Bearing Bridges
  133
- Removing the Valves
  133
- Checking the Valves
  134
- Checking the Valve Springs
  135
- Checking Valve Spring Seat
  135
- Checking the Cam Levers
  135
- Checking Cylinder Head
  135
- Installing the Valves
  136
- Removing the Freewheel
  137
- Checking the Freewheel
  137
- Installing the Free Wheel
  137
- Checking the Electric Starter Mode
  138
- Checking the Timing Assembly
  139
- Preparing the Timing Chain Tensioner for Installation
  139
- Checking Clutch
  140
- Checking Shift Mechanism
  141
- Preassembling the Shift Shaft
  142
- Disassembling the Main Shaft
  143
- Disassembling the Countershaft
  143
- Checking Transmission
  144
- Assembling the Main Shaft
  145
- Assembling the Countershaft
  146
30/Engine Assembly
147
- Installing the Crankshaft
  147
- Installing the Transmission Shafts
  147
- Installing the Shift Forks
  147
- Installing the Shift Drum
  148
- Installing the Shift Rails
  148
- Installing the Left Engine Case
  148
- Installing the Locking Lever
  149
- Installing the Shift Drum Locating Unit
  149
- Installing the Shift Shaft
  149
- Installing the Suction Pumps
  149
- Installing the Centrifugal Separator
  150
- Installing the Force Pump
  150
- Installing the Primary Gear
  151
- Installing the Outer Clutch Hub
  151
- Installing the Spacer
  152
- Installing the Drive Wheel of the Balancer Gear
  153
- Installing the Timing Chain
  153
- Installing the Free Wheel Gear
  153
- Installing the Ignition Pulse Generator
  154
- Installing the Rotor
  154
- Installing the Timing Chain Rails
  154
- Installing the Piston
  154
- Installing the Clutch Cover
  156
- Installing the Water Pump Cover
  156
- Installing the Cylinder Head
  157
- Installing the Double Wheel
  157
- Installing the Timing Chain Tensioner
  158
- Checking the Valve Timing
  158
- Adjusting the Valve Timing
  159
- Checking the Valve Clearance
  160
- Adjusting the Valve Clearance
  160
- Installing the Torque Limiter
  161
- Installing the Alternator Cover
  161
- Installing the Starter Motor
  161
- Installing the Valve Cover
  161
- Installing the Spark Plug
  162
- Installing the Oil Screen
  162
- Installing the Oil Filter
  162
- Installing the Shift Lever
  163
- Removing the Engine from the Universal Mounting Rack
  163
31/Carburetor
164
- Choke
  164
- Checking the Play in the Throttle Cable
  164
- Carburetor - Adjusting Idle
  164
- Checking the Position of the Throttle Position Sensor
  165
- Draining the Carburetor Float Chamber
  166
- Removing the Carburetor
  166
- Installing the Carburetor
  168
- Disassembling the Carburetor
  169
- Checking/Adjusting the Carburetor Components
  172
- Checking/Adjusting the Accelerator Pump
  172
- Checking the Choke Slide
  173
- Checking the Hot Start Slide
  173
- Checking the Throttle Position Sensor
  173
- Checking the Jet Needle
  174
- Checking the Throttle Slide
  174
- Checking/Adjusting the Throttle Slide Opening
  175
- Checking the Needle Jet
  175
- Checking the Float Needle Valve
  175
- Checking/Adjusting the Float Level
  176
- Adjusting the Position of the Throttle Position Sensor
  176
- Assembling the Carburetor
  177
32/Clutch
180
- Checking Fluid Level of Hydraulic Clutch
  180
- Changing the Hydraulic Clutch Fluid
  180
33/Transmission
181
- Removing the Engine Sprocket
  181
- Installing the Engine Sprocket
  181
35/Water Pump, Cooling System
182
- Checking Antifreeze and Coolant Level
  182
- Checking the Coolant Level
  182
- Draining Coolant
  183
- Filling Coolant/Bleeding the Cooling System
  183
38/Lubrication System
185
- Oil Circuit
  185
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
  185
- Draining the Engine Oil
  186
- Removing the Oil Filter
  186
- Installing the Oil Filter
  187
- Filling up with Engine Oil
  187
- Checking the Engine Oil Level
  187
- Adding Engine Oil
  188
39/Ignition System
189
- Removing the Stator
  189
- Installing the Stator
  189
- Checking the Ignition System
  189
- Checking the Ignition Coil
  190
- Checking the Spark Plug Connector
  191
- Checking the CDI Controller
  191
- Checking the Ignition Pulse Generator
  191
- Checking the Alternator
  192
61/Atv Front End
193
- Checking the Toe
  193
- Adjusting the Toe
  194
- Checking/Adjusting the Camber
  195
- Adjusting the Fork Offset
  196
- Removing the Wheel Carrier
  196
- Changing the Wheel Bearing
  198
- Installing the Wheel Carrier
  199
- Removing the A-Arms
  200
- Installing the A-Arms
  201
- A-Arm Top - Changing the Bearing
  202
- A-Arm Bottom - Changing the Bearing
  203
Technical Data - Engine
206
- Capacity - Engine Oil
  206
- Capacity - Coolant
  206
Technical Data - Engine Tolerances, Wear Limits
207
Technical Data - Engine Tightening Torques
208
Technical Data - Carburetor
210
Technical Data - Carburetor Tightening Torques
211
Technical Data - Chassis
212
- Tires
  213
- Capacity - Fuel
  213
Technical Data - Front Shock Absorber
214
Technical Data - Rear Shock Absorber
215
Technical Data - Chassis Tightening Torques
216
Cleaning
217
- Cleaning the Vehicle
  217
Storage
218
- Putting the Vehicle into Operation after Storage
  218
Service Schedule
219
Wiring Diagram
222
- 450/525 Sx Atv
  222
Substances
225
Auxiliary Substances
227
Special Tools
229
Standards
242
Index
243

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