KTM 450 505 SX - Service Repair Manual - Wiring Diagrams - Owners

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KTM 450 SX ATV, 505 SX ATV - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual, Owners Manual and Wiring Diagrams, to quad KTM 450 505 SX.

 
CONTENTS:

SERVICE MANUAL

Means Of Representation
Important Notes
View Of Vehicle
- View of the vehicle from the left front (example)
- View of the vehicle from the right rear (example)
Location Of Serial Numbers
- Chassis number
- Type label
- Key number
- Engine number
- Shock absorber part number, front
- Shock absorber part number, rear
Vehicle
- Jacking up the vehicle
- Removing the vehicle from the work stand
02/Handlebar, Instruments
- Hot start lever
- Adjusting handlebar position
- Adjusting basic position of clutch lever
- Checking the play in the throttle cable
- Adjusting play in throttle cable
- Removing the steering column
- Changing the steering column bearing
- Installing the steering column
03/Frame
- Removing the engine guard
- Installing the engine guard
04/Shock Absorber, Swingarm
- Front shock absorber - adjusting the high-speed compression damping
- Front shock absorber - adjusting the low-speed compression damping
- Front shock absorber - adjusting the rebound damping
- Front shock absorber - adjusting the spring preload
- Front shock absorber - adjusting the cross over
- Removing the front shock absorber
- Installing the front shock absorber
- Front shock absorber - changing the oil
- Service the front shock absorber
- Front shock absorber - removing the spring
- Front shock absorber - disassembling the damper
- Front shock absorber - disassembling the piston rod
- Front shock absorber - checking the damper
- Front shock absorber - removing the heim joint
- Front shock absorber - installing the heim joint
- Front shock absorber - assembling the piston rod
- Front shock absorber - assembling the damper
- Front shock absorber - bleeding and filling the damper
- Front shock absorber - filling the damper with nitrogen
- Front shock absorber - installing the spring
- Rear shock absorber - adjusting the high-speed compression damping
- Rear shock absorber - adjusting the low-speed compression damping
- Rear shock absorber - adjusting the rebound damping
- Rear shock absorber - adjusting the spring preload
- Removing the rear shock absorber
- Installing the rear shock absorber
- Rear shock absorber - changing the oil
- Servicing the rear shock absorber
- Rear shock absorber - removing the spring
- Rear shock absorber - disassembling the damper
- Rear shock absorber - disassembling the piston rod
- Rear shock absorber - disassembling the seal ring retainer
- Changing the pilot bushing
- Rear shock absorber - checking the damper
- Rear shock absorber - removing the heim joint
- Rear shock absorber - installing the heim joint
- Rear shock absorber - assembling the seal ring retainer
- Rear shock absorber - assembling the piston rod
- Rear shock absorber - assembling the damper
- Rear shock absorber - bleeding and filling the damper
- Rear shock absorber - filling the damper with nitrogen
- Rear shock absorber - installing the spring
05/Exhaust
- Removing the main silencer
- Installing the main silencer
- Removing the manifold
- Installing the manifold
06/Air Filter
- Removing the air filter
- Installing the air filter
- Cleaning air filter
- Removing the air filter box lid with the carburetor connection boot
- Installing the air filter box lid and the carburetor connection boot
07/Fuel Tank, Seat, Trim
- Removing the seat
- Mounting the seat
- Removing the radiator spoiler
- Installing the radiator spoiler
- Removing the fuel tank
- Installing the fuel tank
- Fuel tap
08/Mask, Fender
- Removing the heel protector
- Installing the heel protector
- Removing the front cover
- Installing the front cover
- Removing the front trim
- Installing the front trim
- Removing the rear fender
- Installing the rear fender
09/Front Wheel
- Checking the tire air pressure
- Checking the tire condition
- Removing wheel/wheels
- Installing the wheel/wheels
- Checking brake discs
10/Rear Wheel
- Checking chain dirt
- Cleaning the chain
- Checking chain wear
- Checking rear sprocket / engine sprocket for wear
- Checking the chain tension
- Adjusting chain tension
- Adjusting the toe width of rear axle
- Removing the rear axle
- Installing the rear axle
- Changing the rear axle bearing
11/Wiring Harness, Battery
- Ignition curve plug connection
- Changing the ignition curve
- Removing the battery
- Installing the battery
- Recharging the battery
- Changing the main fuse
- Changing the fuses of individual power consumers
- Checking the battery voltage
- Checking the charging voltage
- Checking the quiescent current
- Checking the starter relay
13/Brake System
- Hand brake lever, parking brake
- Checking the free travel of the hand brake lever
- Adjusting basic position of hand brake lever
- Checking front brake fluid level
- Topping up the front brake fluid
- Changing the front brake fluid
- Checking the front brake linings
- Removing front brake linings
- Mounting front brake linings
- Changing the front brake linings
- Checking free travel of foot brake lever
- Adjusting basic position of foot brake lever
- Checking rear brake fluid level
- Adding rear brake fluid
- Changing the rear brake fluid
- Checking rear brake linings
- Removing rear brake linings
- Mounting rear brake linings
- Changing rear brake linings
30/Engine
- Removing the engine
- Installing the engine
30/Disassembling The Engine
- Preparations
- Removing the shift lever
- Draining the engine oil
- Removing the oil filter
- Removing the spark plug
- Removing the valve cover
- Removing the starter motor
- Removing the alternator cover
- Removing the torque limiter
- Positioning the engine at ignition top dead center (TDC)
- Removing the camshaft
- Removing the timing chain tensioner
- Removing the double wheel
- Removing the cylinder head
- Removing the water pump cover
- Removing the clutch cover
- Removing the piston
- Removing the timing chain rails
- Removing the timing chain
- Removing the rotor and starter idler gear
- Removing the ignition pulse generator
- Removing the drive wheel of the balancer gear
- Removing the force pump
- Removing the spacer
- Removing the outer clutch hub
- Removing the primary gear
- Removing the centrifugal separator
- Removing the suction pump
- Removing the shift shaft
- Removing the shift drum locating unit
- Removing the locking lever
- Removing the left section of the engine case
- Removing the shift rails
- Removing the shift drum
- Removing the shift forks
- Removing the transmission shafts
- Removing the crankshaft
30/Engine - Work On Individual Parts
- Working on the right section of the engine case
- Working on the left section of the engine case
- Removing the water pump
- Changing the shaft seal ring of the water pump
- Installing the water pump
- Removing the crankshaft seal ring in the clutch cover
- Installing the crankshaft seal ring in the clutch cover
- Removing the oil pressure regulator valve
- Checking spring length of oil pressure regulator valve
- Installing the oil pressure regulator valve
- Checking the lubrication system
- Removing the crankshaft bearing inner race
- Installing the crankshaft bearing inner race
- Changing connecting rod, conrod bearing and crank pin
- Checking crankshaft run-out at bearing pin
- Measuring the crankshaft
- Cylinder - Nikasil® coating
- Checking/measuring cylinder
- Checking/measuring the piston
- Measuring piston/cylinder mounting clearance
- Checking the piston ring
- Changing the camshaft bearing
- Checking the autodecompressor
- Checking camshafts
- Checking the radial clearance of the camshaft bearings
- Checking the camshaft bearing bridges
- Removing the valves
- Checking the valves
- Checking the valve springs
- Checking valve spring seat
- Checking the cam levers
- Checking cylinder head
- Installing the valves
- Removing the freewheel
- Checking the freewheel
- Installing the free wheel
- Checking the electric starter mode
- Checking the timing assembly
- Preparing the timing chain tensioner for installation
- Checking clutch
- Checking shift mechanism
- Preassembling the shift shaft
- Disassembling the main shaft
- Disassembling the countershaft
- Checking transmission
- Assembling the main shaft
- Assembling the countershaft
30/Engine Assembly
- Installing the crankshaft
- Installing the transmission shafts
- Installing the shift forks
- Installing the shift drum
- Installing the shift rails
- Installing the left engine case
- Installing the locking lever
- Installing the shift drum locating unit
- Installing the shift shaft
- Installing the suction pumps
- Installing the centrifugal separator
- Installing the force pump
- Installing the primary gear
- Installing the outer clutch hub
- Installing the spacer
- Installing the drive wheel of the balancer gear
- Installing the timing chain
- Installing the free wheel gear
- Installing the ignition pulse generator
- Installing the rotor
- Installing the timing chain rails
- Installing the piston
- Installing the clutch cover
- Installing the water pump cover
- Installing the cylinder head
- Installing the double wheel
- Installing the timing chain tensioner
- Checking the valve timing
- Adjusting the valve timing
- Checking the valve clearance
- Adjusting the valve clearance
- Installing the torque limiter
- Installing the alternator cover
- Installing the starter motor
- Installing the valve cover
- Installing the spark plug
- Installing the oil screen
- Installing the oil filter
- Installing the shift lever
- Removing the engine from the universal mounting rack
31/Carburetor
- Choke
- Checking the play in the throttle cable
- Carburetor - adjusting idle
- Checking the position of the throttle position sensor
- Draining the carburetor float chamber
- Removing the carburetor
- Installing the carburetor
- Disassembling the carburetor
- Checking/adjusting the carburetor components
- Checking/adjusting the accelerator pump
- Checking the choke slide
- Checking the hot start slide
- Checking the throttle position sensor
- Checking the jet needle
- Checking the throttle slide
- Checking/adjusting the throttle slide opening
- Checking the needle jet
- Checking the float needle valve
- Checking/adjusting the float level
- Adjusting the position of the throttle position sensor
- Assembling the carburetor
32/Clutch
- Checking fluid level of hydraulic clutch
- Changing the hydraulic clutch fluid
33/Transmission
- Removing the engine sprocket
- Installing the engine sprocket
35/Water Pump, Cooling System
- Checking antifreeze and coolant level
- Checking the coolant level
- Draining coolant
- Filling coolant/bleeding the cooling system
38/Lubrication System
- Oil circuit
- Changing the engine oil and oil filter, cleaning the oil screen
- Draining the engine oil
- Removing the oil filter
- Installing the oil filter
- Filling up with engine oil
- Checking the engine oil level
- Adding engine oil
39/Ignition System
- Removing the stator
- Installing the stator
- Checking the ignition system
- Checking the ignition coil
- Checking the spark plug connector
- Checking the CDI controller
- Checking the ignition pulse generator
- Checking the alternator
61/Atv Front End
- Checking the toe
- Adjusting the toe
- Checking/adjusting the camber
- Adjusting the fork offset
- Removing the wheel carrier
- Changing the wheel bearing
- Installing the wheel carrier
- Removing the A-arms
- Installing the A-arms
- A-Arm top - changing the bearing
- A-Arm bottom - changing the bearing
Technical Data - Engine
- Capacity - engine oil
- Capacity - coolant
Technical Data - Engine Tolerances, Wear Limits
Technical Data - Engine Tightening Torques
Technical Data - Carburetor
Technical Data - Carburetor Tightening Torques
Technical Data - Chassis
- Tires
- Capacity - fuel
Technical Data - Front Shock Absorber
Technical Data - Rear Shock Absorber
Technical Data - Chassis Tightening Torques
Cleaning
- Cleaning the vehicle
Storage
- Storage
- Putting the vehicle into operation after storage
Service Schedule
- Important maintenance work to be carried out by an authorized KTM workshop
- Important maintenance work to be carried out by an authorized KTM workshop (as an additional order)
- Important checks and maintenance work to be carried out by the rider
Wiring Diagram
- 450/525 SX ATV
Substances
Auxiliary Substances
Special Tools
Standards
Index


ENGINE REPAIR MANUAL
 
General Information
- Changing The Cooling Liquid
- Checking The Cooling Liquid Level
- Engine Oil
- Changing The Engine Oil
- Changing The Oil Filter
- Checking The Engine Oil Level
- Engine Oil Circuit
- Checking The Oil Pressure
- Checking The Oil Level Of The Hydraulic Clutch
- Bleeding Of The Hydraulic Clutch
- Adjusting The Throttle Cables
- Changing The Front Brake Fluid
- Changing The Rear Brake Fluid
- Special Tools - Engine
Dismounting And Mounting The Engine
- Dismounting The Engine
- Mounting The Engine
Disassembling The Engine
- Preparation
- Draining The Engine Oil
- Removing The Oil Filter
- Removing The Starter
- Removing The Sprocket
- Removing The Ignition Cover
- Removing The Starter Drive
- Removing The Pulse Generator
- Moving The Engine To Ignition Tdc
- Removing The Clutch Cover
- Removing The Clutch
- Removing The Timing Chain Tensioner
- Removing The Camshafts
- Removing The Cylinder Head
- Removing The Cylinder / Piston
- Removing The Timing Chain
- Removing The Rotor
- Removing The Freewheel Hub
- Removing The Primary Gear
- Removing The Oil Pumps
- Removing The Shift Mechanism
- Separating The Engine Case Halves
Servicing Individual Components
- Left Engine Case Half
- Right Engine Case Half
- Water Pump
- Balancer Gear
- Clutch Cover
- Lubrication System
- Crankshaft
- Axial Clearance Of The Crankshaft
- Piston / Cylinder
- Camshafts
- Automatic Decompression
- Radial Clearance Of The Camshaft Bearings
- Camshaft Bearing Bridges
- Cylinder Head
- Timing Chain Tensioner
- Timing Train
- Clutch
- Shift Mechanism
- General Information On Servicing The Transmission
- Main Shaft
- Countershaft
- Starter Drive
- Freewheel Hub
- Ignition Cover / Stator
Assembling The Engine
- Assembling The Engine Case Halves
- Mounting The Shift Mechanism
- Mounting The Oil Pump
- Mounting The Primary Gear
- Mounting The Freewheel Hub
- Mounting The Timing Chain
- Mounting The Piston / Cylinder
- Mounting The Cylinder Head
- Mounting The Timing Chain Tensioner
- Mounting The Camshafts
- Checking The Valve Clearance
- Mounting The Clutch
- Mounting The Clutch Cover
- Mounting The Rotor
- Mounting The Pulse Generator
- Mounting The Starter Drive
- Mounting The Ignition Cover
- Mounting The Sprocket
- Mounting The Starter
- Mounting The Shift Lever
- Filling The Engine With Engine Oil
Electrical
- Ignition System Troubleshooting
- Cdi Unit
- Checking The Ignition Coil
- Checking The Pickup And Stator
- Checking The Throttle Sensor
- Main Fuse
- Checking The Starter
- Checking The Start Relay
- Dismounting And Mounting The Battery
- Charging The Battery
- Checking The Charging Voltage
- Checking For Loss Of Current
- Engine Characteristic
- Static Ignition Values
- Static Generator Values
Fuel System
- Dismounting And Mounting The Carburetor
- Disassembling The Carburetor
- Checking The Choke Slide
- Checking The Accelerator Pump
- Checking The Jet Needle
- Checking The Needle Jet
- Checking The Float Needle Valve
- Checking The Throttle Slide
- Assembling The Carburetor
- Checking/Adjusting The Float Height
- Checking/Adjusting The Throttle Slide Opening
- Checking/Adjusting The Operation Of The Accelerator Pump
- Adjusting The Position Of The Throttle Sensor
- Checking The Throttle Sensor
- Removing And Mounting The Throttle Sensor
- Adjusting The Idle Speed
Trouble Shooting
- Trouble Shooting
Technical Specifications
- Engine
- Chassis
- Mounting Clearances, Wear Limits
- Tightening Torques
Periodic Maintenance Schedule
- 450/505 Sx-F / 450 Sxs-F
Wiring Diagrams
- Wiring Diagram
- Terms/Translations, Cable Colors


OWNERS MANUAL

Means Of Representation
Important Information
View Of Vehicle
- View of the vehicle from the left front (example)
- View of the vehicle from the right rear (example)
Location Of Serial Numbers
- Chassis number
- Type label
- Engine number
- Shock absorber part number, front
- Shock absorber part number, rear
Controls
- Clutch lever
- Hot start lever
- Hand brake lever, parking brake
- Throttle lever
- Electric starter button
- Kill switch/emergency OFF switch with rip cord
- Opening filler cap
- Closing filler cap
- Fuel tap
- Choke
- Shift lever
- Foot brake pedal
General Tips And Hints On Putting Into Operation
- advice on first use
- Running in the engine
Riding Instructions
- Checks before putting into operation
- Starting
- Starting up
- Shifting
- Braking
- Riding
- Riding in bends
- Riding downhill
- Riding uphill
- Riding perpendicular to the slope
- Turning on slopes
- Riding through water
- Switching off the engine
- Stopping, parking
- Refueling
Service Schedule
- Important maintenance work to be carried out by an authorized KTM workshop
- Important maintenance work to be carried out by an authorized KTM workshop (as an additional order)
- Important checks and maintenance work to be carried out by the rider
Maintenance On Chassis And Engine
- Jacking up the vehicle
- Removing the vehicle from the work stand
- Basic information on changing the chassis settings
- Compression damping of the shock absorber
- Front shock absorber - Adjusting the high-speed compression damping
- Front shock absorber - Adjusting the low-speed compression damping
- Front shock absorber - adjusting the rebound damping
- Front shock absorber - adjusting the cross over
- Front shock absorber - adjusting the spring preload
- Rear shock absorber - adjusting the high speed compression damping
- Rear shock absorber - adjusting the low-speed compression damping
- Rear shock absorber - adjusting the rebound damping
- Rear shock absorber - adjusting the spring preload x
- Removing the rear shock absorber x
- Installing the rear shock absorber x
- Checking the toe x
- Adjusting the toe x
- Checking/adjusting the camber x
- Fork offset
- Adjusting the fork offset x
- Toe width of rear axle
- Adjusting the toe width of rear axle x
- Handlebar position
- Adjusting handlebar position x
- Checking the play in the throttle cable
- Adjusting play in throttle cable
- Checking chain dirt
- Cleaning the chain
- Checking the chain tension
- Checking rear sprocket / engine sprocket for wear
- Checking chain wear
- Adjusting chain tension
- Greasing the rear wheel eccentric element
- Checking brake discs
- Checking the free travel of the hand brake lever
- Adjusting basic position of hand brake lever
- Checking front brake fluid level
- Topping up the front brake fluid x
- Checking the front brake linings
- Removing front brake linings x
- Installing the front brake linings x
- Changing the front brake linings x
- Checking free travel of foot brake lever
- Adjusting basic position of foot brake lever x
- Checking rear brake fluid level
- Adding rear brake fluid x
- Checking rear brake linings
- Removing rear brake linings x
- Installing the rear brake linings x
- Changing rear brake linings x
- Removing wheel/wheels
- Installing the wheel/wheels
- Checking the tire condition
- Checking the tire air pressure
- Removing the battery
- Installing the battery
- Recharging the battery x
- Changing the main fuse
- Changing the fuses of individual power consumers
- Ignition curve plug connection
- Changing the ignition curve
- Removing the seat
- Mounting the seat
- Removing the radiator spoiler
- Installing the radiator spoiler
- Removing the front cover
- Installing the front cover
- Removing the front trim
- Installing the front trim
- Removing the rear fender
- Installing the rear fender
- Removing the engine guard
- Installing the engine guard
- Removing the air filter x
- Installing the air filter x
- Cleaning air filter x
- Adjusting basic position of clutch lever
- Checking fluid level of hydraulic clutch
- Cooling system
- Radiator fan
- Checking antifreeze and coolant level
- Checking the coolant level
- Draining coolant x
- Filling coolant/bleeding the cooling system x
- Carburetor - idle
- Carburetor - adjusting idle x
- Draining the carburetor float chamber x
- Checking the engine oil level
- Changing the engine oil and oil filter, cleaning the oil screen x
- Draining the engine oil x
- Cleaning the oil screen x
- Removing the oil filter x
- Installing the oil filter x
- Filling up with engine oil x
- Adding engine oil
Troubleshooting
Cleaning
- Cleaning the vehicle
Storage
- Storage
- Putting the vehicle into operation after storage
Technical Data - Engine
- Capacity - engine oil
- Capacity - coolant
Technical Data - Engine Tightening Torques
Technical Data - Carburetor
Technical Data - Chassis
- Tires
- Capacity - fuel
Technical Data - Front Shock Absorber
Technical Data - Rear Shock Absorber
Technical Data - Tightening Torques For Chassis
Operating Substances
Auxiliary Substances
Standards
Index