Name: KTM 505 SX ATV 2010
Brand: KTM
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REPAIR MANUAL 2010

450 SX ATV

505 SX ATV

Article no. 3206070en

PartShark.com

877-999-5686

Table of Contents4
Means of Representation8
Important Notes9
View of Vehicle10
- View of the Vehicle from the Left Front (Example)10
- View of the Vehicle from the Right Rear (Example)11
Location of Serial Numbers12
- Chassis Number12
- Type Label12
- Key Number12
- Engine Number12
- Shock Absorber Part Number, Front12
- Shock Absorber Part Number, Rear13
Vehicle14
- Jacking up the Vehicle14
- Removing the Vehicle from the Work Stand14
02/Handlebar, Instruments15
- Hot Start Lever15
- Adjusting Handlebar Position15
- Adjusting Basic Position of Clutch Lever16
- Checking the Play in the Throttle Cable16
- Adjusting Play in Throttle Cable16
- Removing the Steering Column16
- Changing the Steering Column Bearing18
- Installing the Steering Column20
03/Frame22
- Removing the Engine Guard22
- Installing the Engine Guard22
04/Shock Absorber, Swingarm23
- Front Shock Absorber - Adjusting the High-Speed Compression Damping23
- Front Shock Absorber - Adjusting the Low-Speed Compression Damping23
- Front Shock Absorber - Adjusting the Rebound Damping24
- Front Shock Absorber - Adjusting the Spring Preload25
- Front Shock Absorber - Adjusting the Cross over26
- Removing the Front Shock Absorber26
- Installing the Front Shock Absorber27
- Front Shock Absorber - Changing the Oil27
- Service the Front Shock Absorber29
- Front Shock Absorber - Removing the Spring30
- Front Shock Absorber - Disassembling the Damper30
- Front Shock Absorber - Disassembling the Piston Rod31
- Front Shock Absorber - Checking the Damper32
- Front Shock Absorber - Removing the Heim Joint33
- Front Shock Absorber - Installing the Heim Joint33
- Front Shock Absorber - Assembling the Piston Rod34
- Front Shock Absorber - Assembling the Damper35
- Front Shock Absorber - Bleeding and Filling the Damper36
- Front Shock Absorber - Filling the Damper with Nitrogen39
- Front Shock Absorber - Installing the Spring40
- Rear Shock Absorber - Adjusting the High-Speed Compression Damping40
- Rear Shock Absorber - Adjusting the Low-Speed Compression Damping41
- Rear Shock Absorber - Adjusting the Rebound Damping42
- Rear Shock Absorber - Adjusting the Spring Preload42
- Removing the Rear Shock Absorber43
- Installing the Rear Shock Absorber44
- Rear Shock Absorber - Changing the Oil44
- Servicing the Rear Shock Absorber46
- Rear Shock Absorber - Removing the Spring46
- Rear Shock Absorber - Disassembling the Damper47
- Rear Shock Absorber - Disassembling the Piston Rod48
- Rear Shock Absorber - Disassembling the Seal Ring Retainer49
- Changing the Pilot Bushing49
- Rear Shock Absorber - Checking the Damper50
- Rear Shock Absorber - Removing the Heim Joint51
- Rear Shock Absorber - Installing the Heim Joint52
- Rear Shock Absorber - Assembling the Seal Ring Retainer52
- Rear Shock Absorber - Assembling the Piston Rod53
- Rear Shock Absorber - Assembling the Damper54
- Rear Shock Absorber - Bleeding and Filling the Damper56
- Rear Shock Absorber - Filling the Damper with Nitrogen58
- Rear Shock Absorber - Installing the Spring59
05/Exhaust61
- Removing the Main Silencer61
- Installing the Main Silencer61
- Removing the Manifold62
- Installing the Manifold62
06/Air Filter63
- Removing the Air Filter63
- Installing the Air Filter63
- Cleaning Air Filter63
- Removing the Air Filter Box Lid with the Carburetor Connection Boot64
- Installing the Air Filter Box Lid and the Carburetor Connection Boot64
07/Fuel Tank, Seat, Trim65
- Removing the Seat65
- Mounting the Seat65
- Removing the Radiator Spoiler65
- Installing the Radiator Spoiler66
- Removing the Fuel Tank66
- Installing the Fuel Tank67
- Fuel Tap68
08/Mask, Fender69
- Removing the Heel Protector69
- Installing the Heel Protector70
- Removing the Front Cover71
- Installing the Front Cover71
- Removing the Front Trim71
- Installing the Front Trim72
- Removing the Rear Fender72
- Installing the Rear Fender73
09/Front Wheel74
- Checking the Tire Air Pressure74
- Checking the Tire Condition74
- Removing Wheel/Wheels74
- Installing the Wheel/Wheels75
- Checking Brake Discs76
10/Rear Wheel77
- Checking Chain Dirt77
- Cleaning the Chain77
- Checking Chain Wear77
- Checking Rear Sprocket / Engine Sprocket for Wear78
- Checking the Chain Tension78
- Adjusting Chain Tension78
- Adjusting the Toe Width of Rear Axle79
- Removing the Rear Axle80
- Installing the Rear Axle81
- Changing the Rear Axle Bearing83
11/Wiring Harness, Battery85
- Ignition Curve Plug Connection85
- Changing the Ignition Curve85
- Removing the Battery85
- Installing the Battery85
- Recharging the Battery86
- Changing the Main Fuse87
- Changing the Fuses of Individual Power Consumers87
- Checking the Battery Voltage88
- Checking the Charging Voltage88
- Checking the Quiescent Current88
- Checking the Starter Relay89
13/Brake System90
- Hand Brake Lever, Parking Brake90
- Checking the Free Travel of the Hand Brake Lever90
- Adjusting Basic Position of Hand Brake Lever90
- Checking Front Brake Fluid Level91
- Topping up the Front Brake Fluid91
- Changing the Front Brake Fluid92
- Checking the Front Brake Linings93
- Removing Front Brake Linings93
- Mounting Front Brake Linings94
- Changing the Front Brake Linings94
- Checking Free Travel of Foot Brake Lever95
- Adjusting Basic Position of Foot Brake Lever95
- Checking Rear Brake Fluid Level96
- Adding Rear Brake Fluid96
- Changing the Rear Brake Fluid97
- Checking Rear Brake Linings98
- Removing Rear Brake Linings98
- Mounting Rear Brake Linings99
- Changing Rear Brake Linings100
30/Engine101
- Removing the Engine101
- Installing the Engine102
30/Disassembling the Engine105
- Preparations105
- Removing the Shift Lever105
- Draining the Engine Oil105
- Removing the Oil Filter105
- Removing the Spark Plug106
- Removing the Valve Cover106
- Removing the Starter Motor106
- Removing the Alternator Cover106
- Removing the Torque Limiter107
- Positioning the Engine at Ignition Top Dead Center (TDC)107
- Removing the Camshaft108
- Removing the Timing Chain Tensioner108
- Removing the Double Wheel109
- Removing the Cylinder Head109
- Removing the Water Pump Cover110
- Removing the Clutch Cover110
- Removing the Piston111
- Removing the Timing Chain Rails111
- Removing the Timing Chain111
- Removing the Rotor and Starter Idler Gear112
- Removing the Ignition Pulse Generator112
- Removing the Drive Wheel of the Balancer Gear113
- Removing the Force Pump113
- Removing the Spacer114
- Removing the Outer Clutch Hub114
- Removing the Primary Gear115
- Removing the Centrifugal Separator115
- Removing the Suction Pump116
- Removing the Shift Shaft116
- Removing the Shift Drum Locating Unit117
- Removing the Locking Lever117
- Removing the Left Section of the Engine Case117
- Removing the Shift Rails118
- Removing the Shift Drum118
- Removing the Shift Forks118
- Removing the Transmission Shafts118
- Removing the Crankshaft119
30/Engine - Work on Individual Parts120
- Working on the Right Section of the Engine Case120
- Working on the Left Section of the Engine Case121
- Removing the Water Pump122
- Changing the Shaft Seal Ring of the Water Pump123
- Installing the Water Pump124
- Removing the Crankshaft Seal Ring in the Clutch Cover125
- Installing the Crankshaft Seal Ring in the Clutch Cover125
- Removing the Oil Pressure Regulator Valve125
- Checking Spring Length of Oil Pressure Regulator Valve125
- Installing the Oil Pressure Regulator Valve126
- Checking the Lubrication System126
- Removing the Crankshaft Bearing Inner Race127
- Installing the Crankshaft Bearing Inner Race127
- Changing Connecting Rod, Conrod Bearing and Crank Pin127
- Checking Crankshaft Run-Out at Bearing Pin128
- Measuring the Crankshaft End Play129
- Cylinder - Nikasil Coating129
- Checking/Measuring Cylinder129
- Checking/Measuring the Piston130
- Measuring Piston/Cylinder Mounting Clearance131
- Checking the Piston Ring End Gap131
- Changing the Camshaft Bearing131
- Checking the Autodecompressor132
- Checking Camshafts132
- Checking the Radial Clearance of the Camshaft Bearings132
- Checking the Camshaft Bearing Bridges133
- Removing the Valves133
- Checking the Valves134
- Checking the Valve Springs135
- Checking Valve Spring Seat135
- Checking the Cam Levers135
- Checking Cylinder Head135
- Installing the Valves136
- Removing the Freewheel137
- Checking the Freewheel137
- Installing the Free Wheel137
- Checking the Electric Starter Mode138
- Checking the Timing Assembly139
- Preparing the Timing Chain Tensioner for Installation139
- Checking Clutch140
- Checking Shift Mechanism141
- Preassembling the Shift Shaft142
- Disassembling the Main Shaft143
- Disassembling the Countershaft143
- Checking Transmission144
- Assembling the Main Shaft145
- Assembling the Countershaft146
30/Engine Assembly147
- Installing the Crankshaft147
- Installing the Transmission Shafts147
- Installing the Shift Forks147
- Installing the Shift Drum148
- Installing the Shift Rails148
- Installing the Left Engine Case148
- Installing the Locking Lever149
- Installing the Shift Drum Locating Unit149
- Installing the Shift Shaft149
- Installing the Suction Pumps149
- Installing the Centrifugal Separator150
- Installing the Force Pump150
- Installing the Primary Gear151
- Installing the Outer Clutch Hub151
- Installing the Spacer152
- Installing the Drive Wheel of the Balancer Gear153
- Installing the Timing Chain153
- Installing the Free Wheel Gear153
- Installing the Ignition Pulse Generator154
- Installing the Rotor154
- Installing the Timing Chain Rails154
- Installing the Piston154
- Installing the Clutch Cover156
- Installing the Water Pump Cover156
- Installing the Cylinder Head157
- Installing the Double Wheel157
- Installing the Timing Chain Tensioner158
- Checking the Valve Timing158
- Adjusting the Valve Timing159
- Checking the Valve Clearance160
- Adjusting the Valve Clearance160
- Installing the Torque Limiter161
- Installing the Alternator Cover161
- Installing the Starter Motor161
- Installing the Valve Cover161
- Installing the Spark Plug162
- Installing the Oil Screen162
- Installing the Oil Filter162
- Installing the Shift Lever163
- Removing the Engine from the Universal Mounting Rack163
31/Carburetor164
- Choke164
- Checking the Play in the Throttle Cable164
- Carburetor - Adjusting Idle164
- Checking the Position of the Throttle Position Sensor165
- Draining the Carburetor Float Chamber166
- Removing the Carburetor166
- Installing the Carburetor168
- Disassembling the Carburetor169
- Checking/Adjusting the Carburetor Components172
- Checking/Adjusting the Accelerator Pump172
- Checking the Choke Slide173
- Checking the Hot Start Slide173
- Checking the Throttle Position Sensor173
- Checking the Jet Needle174
- Checking the Throttle Slide174
- Checking/Adjusting the Throttle Slide Opening175
- Checking the Needle Jet175
- Checking the Float Needle Valve175
- Checking/Adjusting the Float Level176
- Adjusting the Position of the Throttle Position Sensor176
- Assembling the Carburetor177
32/Clutch180
- Checking Fluid Level of Hydraulic Clutch180
- Changing the Hydraulic Clutch Fluid180
33/Transmission181
- Removing the Engine Sprocket181
- Installing the Engine Sprocket181
35/Water Pump, Cooling System182
- Checking Antifreeze and Coolant Level182
- Checking the Coolant Level182
- Draining Coolant183
- Filling Coolant/Bleeding the Cooling System183
38/Lubrication System185
- Oil Circuit185
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen185
- Draining the Engine Oil186
- Removing the Oil Filter186
- Installing the Oil Filter187
- Filling up with Engine Oil187
- Checking the Engine Oil Level187
- Adding Engine Oil188
39/Ignition System189
- Removing the Stator189
- Installing the Stator189
- Checking the Ignition System189
- Checking the Ignition Coil190
- Checking the Spark Plug Connector191
- Checking the CDI Controller191
- Checking the Ignition Pulse Generator191
- Checking the Alternator192
61/Atv Front End193
- Checking the Toe193
- Adjusting the Toe194
- Checking/Adjusting the Camber195
- Adjusting the Fork Offset196
- Removing the Wheel Carrier196
- Changing the Wheel Bearing198
- Installing the Wheel Carrier199
- Removing the A-Arms200
- Installing the A-Arms201
- A-Arm Top - Changing the Bearing202
- A-Arm Bottom - Changing the Bearing203
Technical Data - Engine206
- Capacity - Engine Oil206
- Capacity - Coolant206
Technical Data - Engine Tolerances, Wear Limits207
Technical Data - Engine Tightening Torques208
Technical Data - Carburetor210
Technical Data - Carburetor Tightening Torques211
Technical Data - Chassis212
- Tires213
- Capacity - Fuel213
Technical Data - Front Shock Absorber214
Technical Data - Rear Shock Absorber215
Technical Data - Chassis Tightening Torques216
Cleaning217
- Cleaning the Vehicle217
Storage218
- Putting the Vehicle into Operation after Storage218
Service Schedule219
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop219
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop (as an Additional Order)220
- Important Checks and Maintenance Work to be Carried out by the Rider220
Wiring Diagram222
- 450/525 Sx Atv222
Substances225
Auxiliary Substances227
Special Tools229
Standards242
Index243

Brand	KTM
Model	505 SX ATV 2010
Category	Offroad Vehicle
Language	English

KTM 505 SX ATV 2010 User Manual

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KTM 505 SX ATV 2010 Specifications

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