User Manuals: KTM 505 SX ATV 2010 Orange

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

KTM 505 SX ATV 2010 Repair Manual

KTM 505 SX ATV 2010 Repair Manual (247 pages)

Brand: KTM | Category: Offroad Vehicle | Size: 13 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

Advertisement

Advertisement

Related Products

KTM Categories

Motorcycle Motorcycle Accessories Engine Offroad Vehicle Bicycle Accessories

More KTM Manuals