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KTM 2010 450 SX, Repair Manual

The KTM 2010 450 SX Repair Manual is a comprehensive user manual that provides step-by-step instructions for maintaining and repairing your KTM 450 SX. Easily accessible for free download on manualshive.com, this manual ensures smooth operation and optimal performance of your bike. Get your copy now!

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13/BRAKE SYSTEM

97

301830-10

–

Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.

100064-10

–

Loosen the screw

while holding the hexagonal head

of the bearing bolt.

Unscrew the screw by approx. 10 turns and use the screw to press the bearing bolt
out of the brake caliper. Remove screw.

100066-10

Note

Danger of damage

 

Kinking of brake line.

–

Position and handle the brake line without straining it. The brake line must be
replaced if it is kinked.

–

Swing the brake caliper up, unhook it from the brake caliper support

and set it

down.

–

Remove the brake linings

.

–

Clean brake caliper and brake caliper support.

16.18

Mounting rear brake linings

Warning

Danger of accidents

 

Reduced braking efficiency due to oil or grease on the brake discs.

–

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidents

 

Reduced braking efficiency due to use of non-approved brake linings.

–

Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

–

Check the brake discs. (

p. 74)

300265-10

–

Check that the sliding plate

is seated correctly in the brake caliper support and

insert the brake linings.

Info

Make sure that the decoupling plate

is mounted on the piston side of the

brake lining.

PartShark.com 

877-999-5686

Summary of Contents for 2010 450 SX

Page 1: ...REPAIR MANUAL 2010 450 SX ATV 505 SX ATV Article no 3206070en P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 2: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 3: ...y reserves the right to modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprint...

Page 4: ... preload 40 Removing the rear shock absorber 41 Installing the rear shock absorber 42 Rear shock absorber changing the oil 42 Servicing the rear shock absorber 44 Rear shock absorber removing the spring 44 Rear shock absorber disassembling the damper 45 Rear shock absorber disassembling the piston rod 46 Rear shock absorber disassembling the seal ring retainer 47 Changing the pilot bushing 47 Rear...

Page 5: ...suction pump 114 Removing the shift shaft 114 Removing the shift drum locating unit 115 Removing the locking lever 115 Removing the left section of the engine case 115 Removing the shift rails 116 Removing the shift drum 116 Removing the shift forks 116 Removing the transmission shafts 116 Removing the crankshaft 117 30 ENGINE WORK ON INDIVIDUAL PARTS 118 Working on the right section of the engine...

Page 6: ...e 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 ...

Page 7: ...ntenance work to be carried out by an authorized KTM workshop as an additional order 218 Important checks and maintenance work to be carried out by the rider 218 WIRING DIAGRAM 220 450 525 SX ATV 220 SUBSTANCES 223 AUXILIARY SUBSTANCES 225 SPECIAL TOOLS 227 STANDARDS 240 INDEX 241 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 8: ...pected reaction e g of a work step or a function Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained below Proprietary name Denotes a proprietary name Name Denotes a protected name Brand Denotes a brand available on the open market P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 9: ...e manufacturer Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear Replace damaged or worn parts After finishing the repair and maintenance work ensure that the vehicle is roadworthy Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labe...

Page 10: ...Hand brake lever 2 Fuse box 3 Shock absorber compression adjustment 4 Front shock absorber 5 Shock absorber rebound adjustment 6 Heel protector 7 Shift lever 8 Kill switch emergency OFF switch with rip cord 9 Clutch lever 10 Hot start lever P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 11: ...0 10 1 Filler cap 2 Main silencer 3 Seat release 4 Shock absorber rebound adjustment 5 Rear sprocket with chain 6 Rear wheel eccentric element 7 Rear brake 8 Foot brake pedal 9 Handlebar bridge 10 Throttle lever 11 Handlebar cushion P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 12: ...the radia tor 4 3 Key number 100089 10 The key number is indicated on the KEYCODECARD Info You need the key number to order a replacement key Keep the KEYCODECARD in a safe place 4 4 Engine number 301772 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 5 Shock absorber part number front 301832 10 The shock absorber part number is stamped on the upper part ...

Page 13: ...LOCATION OF SERIAL NUMBERS 11 4 6 Shock absorber part number rear 301831 10 The shock absorber part number is stamped on the upper part of the shock absorber P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 14: ...ee work stand Jack up the vehicle on the frame underneath the engine The wheels must no longer touch the ground Secure the vehicle 5 2 Removing the vehicle from the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Lower the vehicle Remove the work stand P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 15: ...s Remove the handlebar clamps swing the handlebar forward and set it down Remove the nuts and remove the handlebar support with the screws Remove screws and Remove screws Remove the handlebar bridge Place the handlebar bridge onto the steering column in the desired position Mount and tighten screw Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount and tighten screw Guideline Screw steering...

Page 16: ...e throttle cable play does not meet specifications Adjust the play in the throttle cable p 14 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the eng...

Page 17: ...ke off the handlebar with the handlebar bridge and screw swing it forward and set it down Info Protect the vehicle and its attachments from damage by covering them 301519 10 Remove screw 301520 10 Loosen screws Pull the steering arm down 301863 10 Remove screws Swing the cable guide forward P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 18: ...pport off from above 6 7 Changing the steering column bearing Remove the steering column p 14 301528 10 Remove spacer 301524 10 Remove shaft seal ring 301529 10 Remove lock ring 301525 10 Mount special tool Extractor 83019020000 p 235 Press out the steering column bearing by turning in the screw P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 19: ... in the screw 301529 10 Mount lock ring 301527 10 Position the shaft seal ring Mount special tool Extractor 83019020000 p 235 Press in the shaft seal ring by turning in the screw 301528 10 Mount spacer 301530 10 Remove shaft seal rings from the bearing support 301531 10 Press out the sleeve bearing Extractor 83019020000 p 235 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 20: ...olumn Long life grease p 225 301864 11 Mount the steering column with bearing support from above Position the bearing support Mount and tighten screws Guideline Screw bearing support steering M8 25 Nm 18 4 lbf ft 301863 11 Position the cable guide Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 301520 11 Position the steering arm Tighten screw Guideline Screw steeri...

Page 21: ...dge and screw Mount and tighten screw Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 301861 11 Tighten screws Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft 301860 11 Tighten screw Guideline Screw steering column top M20x1 5 25 Nm 18 4 lbf ft 301859 11 Mount handlebar cushion on the handlebar Install the front cover p 69 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 22: ...the engine guard 7 2 Installing the engine guard 301823 10 Position the engine guard on the frame bearer Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 23: ...osen nut Turn back counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 1 5 turns Standard 1 turn Sport 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 8 2 Front shock absorber adjusting the low speed compression damping Danger Danger of accidents Disassembly of pressurized parts ca...

Page 24: ...e suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling charac teristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Info The rebound damping setting ...

Page 25: ...ake a note of the present setting e g by measuring the length of the spring Jack up the vehicle p 12 Clean the shock absorber thoroughly 301790 11 Release counter ring Hook wrench 83019001000 p 234 Turn adjusting ring until the spring pack is no longer under tension Measure the overall spring pack when not under tension 800064 10 Tighten the spring pack by turning adjusting ring to measurement Gui...

Page 26: ...action at the front harder and the front of the vehicle lies higher Adjust the spring preload for the front shock absorbers p 23 Jack up the vehicle p 12 Clean the shock absorber thoroughly 301789 10 Loosen adjusting rings and Hook wrench 83019001000 p 234 301790 10 Measure the cross over setting between sliding bushing and the collar of adjusting ring Guideline Cross over 19 1 5 mm 0 75 0 059 in ...

Page 27: ... the shock absorber in the lower A arm Mount and tighten screw Guideline Screw front shock absorber M10 45 Nm 33 2 lbf ft Remove the tension belt Remove the vehicle from the work stand p 12 8 8 Front shock absorber changing the oil Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provide...

Page 28: ...th nitrogen p 37 201150 11 Mount rubber cap of the reservoir 201133 10 Alternative 1 Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 12 clicks Turn adjusting screw clockwise with a screwdriver up to the last perceptible cli...

Page 29: ... screw and to the position determined when the part was removed Install the spring of the front shock absorber p 38 8 9 Service the front shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Condition The shock absorber has been removed 201217 01 Remove the spring fro...

Page 30: ...ve the spring Remove sleeve Remove spring Remove adjusting ring and retaining ring 8 11 Front shock absorber disassembling the damper Remove the spring from the front shock absorber p 28 201133 10 Note down the present state of rebound damping and compression damping Completely open the adjusters of the rebound and compression damping 201134 10 Remove rubber cap of the reservoir Slowly open screw ...

Page 31: ...the piston rod with the heim joint in a bench vise Remove nut Remove supporting plate 201140 10 Remove rebound shim stack Info Thread the rebound shim stack onto a screwdriver and set them down together Remove piston 201141 10 Remove compression shim stack with bushing Info Thread the compression shim stack onto a screwdriver and set them down together 200924 10 Remove seal ring retainer Remove lo...

Page 32: ...wear If there is damage or wear Change the damper cartridge 200946 10 Measure the diameter of the piston rod Piston rod Diameter 13 95 mm 0 5492 in If the specified value is not reached Replace the piston rod Measure the run out of the piston rod Piston rod Run out 0 06 mm 0 0024 in If the measured value is greater than the specified value Replace the piston rod Check the piston for damage and wea...

Page 33: ...the heim joint Pin T120 p 237 200907 10 Remove seal rings on both sides 200908 10 Press heim joint to the side Pressing tool T1207S p 238 The heim joint is lined up with a lock ring Remove the other lock ring 200909 10 Place special tool underneath and press out the heim joint using special tool Pressing tool T1207S p 238 8 15 Front shock absorber installing the heim joint Info The operations are ...

Page 34: ... piston rod with the heim joint in a bench vise Mount bump rubber and locking cap Position special tool on the piston rod Mounting sleeve T313 p 239 Grease the seal ring and slide seal ring retainer onto the piston rod Lubricant T625 p 225 Remove the special tool 201145 10 Mount bushing Info Mount the larger inside diameter of the supporting plate facing downward Mount compression damping shim sta...

Page 35: ...mpression damping adjuster M31x1 50 Nm 36 9 lbf ft 201136 10 Fill the damper cartridge about half full Shock absorber oil SAE 2 5 50180342S1 p 224 Grease the O ring of the seal ring retainer Lubricant T158 p 225 Carefully mount the piston rod 201149 10 Mount seal ring retainer and slide it below the ring groove Mount lock ring Info Do not scratch the inner surface Pull out the piston rod until the...

Page 36: ... Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the f...

Page 37: ... specified value measure distance between the floating piston and reservoir hole using the special tool Depth micrometer T107S p 237 The floating piston is positioned in the lowermost position 200267 10 Turn control lever Oil reservoir to Equalize pressure Guideline 4 mbar The pressure gauge increases to the required value 0 bar 200268 10 When the pressure gauge reaches the required value turn con...

Page 38: ...re gauge reaches the required value turn control lever Damper to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar When the pressure gauge reaches the required value activate the On Off switch Guideline 0 bar The vacuum pump is switched off 201154 10 Stand the damper in a vertical position Info Do not close off the adapter yet Slide O ring to the end of the special tool b...

Page 39: ...e special tool to the pressure regulator of the filling cylinder Filling gas nitrogen Adjust the pressure regulator Guideline Gas pressure 10 bar 145 psi Position the damper in the special tool The hexagonal part of turning handle engages in the female hexagonal sec tion of the filling port screw Open spigot Fill the damper for at least 15 seconds Guideline Gas pressure 10 bar 145 psi Info Watch t...

Page 40: ... ride behavior Tighten the spring by turning the adjusting ring to the position determined when it was removed Hold the adjusting ring in place Tighten retaining ring 302076 10 Loosen adjusting rings and Hook wrench 83019001000 p 234 Measure the cross over setting between sliding bushing and the collar of adjusting ring Guideline Cross over 19 1 5 mm 0 75 0 059 in Adjust the sleeve by turning adju...

Page 41: ...nger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling charac teristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behav...

Page 42: ...t 20 clicks Standard 15 clicks Sport 15 clicks Info Turning to the right increases damping while turning to the left lessens damping 8 24 Rear shock absorber adjusting the spring preload Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Warning Danger of accidents Modifications t...

Page 43: ...ing preload you should also slightly increase the rebound damping Install the rear shock absorber p 42 8 25 Removing the rear shock absorber Jack up the vehicle p 12 Remove the rear fender p 70 301835 10 Note Danger of damage The chain sliding piece and frame can be damaged from incor rect handling When removing the rear shock absorber secure the swingarm with a tension belt to prevent it from swi...

Page 44: ...oil Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Condition The shock absorber has been removed Remove the spring from the rear shock absorber p 44 201050 11 Note down the present state of rebound damping and compression damping Completely open the adjusters of the rebound an...

Page 45: ... all the way clockwise with a socket wrench Turn back counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 1 5 turns Standard 1 turn Sport 1 turn Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of th...

Page 46: ...ber p 47 Checking the damper of the rear shock absorber p 48 Assemble the seal ring retainer of the rear shock absorber p 50 Assemble the piston rod of the rear shock absorber p 51 Assemble the damper of the rear shock absorber p 52 Install the spring of the rear shock absorber p 57 8 29 Rear shock absorber removing the spring Condition The shock absorber has been removed Clamp the shock absorber ...

Page 47: ... the adjusters of the rebound and compression damping 201051 10 Remove rubber cap of the reservoir Slowly open screw The pressurized nitrogen is bled off 201052 10 Remove screw Let the oil drain out 201053 10 Remove locking cap Press in seal ring retainer Remove lock ring Info Do not scratch the inner surface 201054 10 Remove the piston rod Drain the remaining oil Remove adjusting ring with the in...

Page 48: ...10 Remove piston Remove compression shim stack Info Thread the compression shim stack onto a screwdriver and set them down together 201065 10 Remove sleeve Remove rebound shim stack Info Thread the rebound shim stack onto a screwdriver and set them down together 201066 10 Remove piston Remove compression shim stack Info Thread the compression shim stack onto a screwdriver and set them down togethe...

Page 49: ...5 10 Remove rebound rubber Remove centering disk 200786 10 Remove seal ring Remove washer from seal ring 200787 10 Remove washer Remove O ring Remove dust boot 8 33 Changing the pilot bushing Disassemble the seal ring retainer of the rear shock absorber p 47 200796 10 Press pilot bushing out of seal ring retainer using the special tool Press drift T1504 p 238 P a r t S h a r k c o m 8 7 7 9 9 9 5 ...

Page 50: ...king the damper Condition The damper has been disassembled 201070 10 Measure the inside diameter on both ends and in the middle of the damper car tridge Damper cartridge Minimum diameter 46 10 mm 1 815 in If the measured value is greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge Check t...

Page 51: ...on The shock absorber has been removed 201084 10 Clamp the shock absorber in a vise using soft jaws Remove both collar bushings of the heim joint using a pin 201085 10 Remove seal rings on both sides 201086 10 Press the heim joint against a lock ring using the special tool Pressing tool T1207S p 238 Remove the second lock ring 201087 10 Place special tool underneath and press out heim joint using ...

Page 52: ...n 201086 11 Press the heim joint against the lock ring using the special tool Pressing tool T1207S p 238 Mount the second lock ring 201085 11 Mount seal rings on both sides 201089 10 Position and press in both collar bushings 8 37 Rear shock absorber assembling the seal ring retainer 200792 10 Mount dust boot with the special tool Mounting sleeve T1204 p 237 Lubricate the sealing lip of the dust b...

Page 53: ... p 50 201071 10 Clamp the piston rod into a vise Mount bump rubber and locking cap Position the special tool on the piston rod Mounting sleeve T1554 p 239 Grease the dust boot and slide seal ring retainer onto the piston rod Lubricant T625 p 225 Remove the special tool 201072 10 Mount rebound damping washer Mount compression damping shim stack with the smaller shims facing down ward 201073 10 Grin...

Page 54: ...he lower rebound washer and washer Info The washer centers the lower rebound washer Mount the upper rebound washer Mount and tighten nut Guideline Nut piston rod M10x1 30 Nm 22 1 lbf ft 8 39 Rear shock absorber assembling the damper Assemble the piston rod of the rear shock absorber p 51 201078 10 Slide the spring and piston onto compression damping adjuster Lubricate the O rings Lubricant T158 p ...

Page 55: ... with the lock ring 201081 10 Mount locking cap of the damper cartridge Bleed and fill the damper of the rear shock absorber p 54 Fill the damper of the rear shock absorber with nitrogen p 56 201082 10 Mount rubber cap of the reservoir Turn adjusting ring with the intermediate washer and retaining ring all the way down 201083 10 Alternative 1 Turn adjusting screw clockwise up to the last perceptib...

Page 56: ...ition determined when the part was removed 8 40 Rear shock absorber bleeding and filling the damper Info Before working with the vacuum pump carefully read the vacuum pump operating manual Completely open the adjusters of the rebound and compression damping 201090 10 Remove the screw from the filling port Mount adapter on the damper Info Hand tighten only without using a tool Connect adapter to co...

Page 57: ...Damper to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge increases to the required value 3 bar 200269 10 When the pressure gauge reaches the required value turn control lever Damper to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar 200270 10 When the pressure gauge reaches the required value turn control lever Oil reser voir to Vacuum Guideli...

Page 58: ...distance minus specified value Guideline 10 mm Depth micrometer T107S p 237 Push the floating piston into the reservoir to the distance described above using the special tool Info When the piston rod is fully extended the floating piston must be at pre cisely this position otherwise damage will occur when the shock absorber compresses and rebounds Remove the special tool 201093 10 Remove adapter f...

Page 59: ... filling port shut with turning handle Close spigot and remove the damper from the special tool Tighten the filling port screw Guideline Screw filling port for reservoir M5 3 Nm 2 2 lbf ft 8 42 Rear shock absorber installing the spring 201049 11 Ensure that adjusting ring is screwed on with the washer and retaining ring Screw the adjusting ring and retaining ring all the way down 201048 11 Measure...

Page 60: ...y alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Tighten the spring by turning adjusting ring to the position determi...

Page 61: ...0 Remove screws and and remove the main silencer 9 2 Installing the main silencer Info In order to present them more clearly the following steps are shown with a removed fender 301857 11 Attach the main silencer and position and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 301856 11 Reconnect spring Spring hooks 50305017000 p 227 P a r t S h a r k c o m 8 7 7 9 9 9 5 6...

Page 62: ...00 p 227 301865 10 Remove screws Slip out the manifold 9 4 Installing the manifold Info In order to present them more clearly the following steps are shown with a removed fender 301580 11 Position manifold and mount springs Spring hooks 50305017000 p 227 301865 11 Mount and tighten screw Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Install the main silencer p 59 P a r t S h a r k c o m ...

Page 63: ...r from the air filter support 10 2 Installing the air filter 301262 10 Mount the clean air filter onto the air filter support Grease the air filter in area Long life grease p 225 301825 10 Put in both parts together position them and fix them with the air filter support Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Mount the air fi...

Page 64: ...g the air filter box lid with the carburetor connection boot Remove the seat p 63 301854 10 Remove hose clip Raise the air filter box lid and remove with carburetor connection boot 10 5 Installing the air filter box lid and the carburetor connection boot 301854 10 Attach the air filter box lid with carburetor connection boot and hose clip to the carburetor Position the air filter box lid Position ...

Page 65: ... the rear of the seat and slide tab under fuel tank 301809 11 Push down the rear of the seat until release hook engages Make sure that the seat is correctly locked in 11 3 Removing the radiator spoiler Info The operations are the same on the left and right Remove the seat p 63 301817 10 Remove the screws on the fuel tank 301816 10 Remove the screws on the radiator Detach the radiator spoiler and r...

Page 66: ...e components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin are...

Page 67: ...health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and kee...

Page 68: ...ap handle on the fuel tap you can open or close the supply of fuel to the car buretor Possible states Fuel supply closed OFF No fuel can flow from the tank to the carburetor Fuel supply open ON Fuel can flow from the tank to the carburetor The fuel tank empties completely P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 69: ...ve screw 301848 11 Remove screw Pull the heel protector off of the cross member 301851 11 Remove screws Remove screw 301850 11 Remove screw Pull the heel protector off of the cross member 301847 11 Remove screw Take off brace and washer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 70: ...s M6 15 Nm 11 1 lbf ft Mount screws but do not tighten yet Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft 301850 10 Slide the heel protector onto the cross member and position it Mount screw but do not tighten yet Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft 301851 10 Position the retaining bracket Mount screws but do not tighten yet Guideline Remaining nuts chassis M6 15 Nm 11 1 l...

Page 71: ... 10 Position the front cover in slots on both sides of the front trim Mount and tighten the screw 12 5 Removing the front trim Remove the front cover p 69 301820 10 Remove screws Raise the front trim and disconnect the plug in connector from the emergency OFF switch with the rip cord Remove the front trim P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 72: ...ine Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the front cover p 69 12 7 Removing the rear fender Remove the seat p 63 301822 10 Remove screws 301821 10 Raise the rear of the air filter box lid At the same time use your other hand to press on the carburetor connection boot to kink it at that location This prevents the carburetor connection boot from disconnecting from the carburetor Rais...

Page 73: ...revents the car buretor connection boot from disconnecting from the carburetor Position front fender Fix the air filter box lid in the fender Info If the air filter box lid is not correctly mounted dust and dirt can penetrate into the engine and cause damage 301822 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 63 P a r t S h a r k c o m 8 7 7 9...

Page 74: ...l have an important impact on the handling characteristics of the vehicle The tires mounted on the front and rear wheels must have similar profiles Worn tires have a negative effect on vehicle handling especially on wet surfaces 400602 10 Examine the tire for cuts foreign bodies and other damage Check the tire age Info The tire s date of manufacture is usually part of the tire markings and is indi...

Page 75: ...tside when the wheels are positioned and mounted Info Proceed in the same way on the other wheels if necessary 300278 10 Position the wheel on the hub Info Note the direction of travel of the front wheels Carefully position the wheel on the hub being careful not to damage the threads of the screws Mount wheel nuts but do not tighten Remove the vehicle from the work stand p 12 Pull the hand brake l...

Page 76: ... if it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 3 5 mm 0 138 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deformati...

Page 77: ...ray p 226 14 3 Checking chain wear Park the vehicle on a horizontal surface and shift gears to neutral 301796 10 Pull on the lower part of the chain with the specified weight Guideline Chain wear measuring weight 10 15 kg 22 33 lb Measure the distance of 18 chain links in the upper chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions M...

Page 78: ...sh the upper chain section at the end of the chain sliding component upwards to measure the chain tension Info The lower chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 140 145 mm 5 51 5 71 in If the chain tension does not meet specifications Adjust the chain tension p 76 14 6 Adjusting chain tension Warning ...

Page 79: ... that the grease nipple is visible This ensures that the vehicle has the greatest ground clearance Fully tighten screws Guideline Screw rear wheel eccentric element M8 20 Nm 14 8 lbf ft Remove the tool 14 7 Adjusting the toe width of rear axle Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at ...

Page 80: ...le p 12 Remove nuts on both sides and take all parts off of the rear axle 600409 10 Remove chain joint Remove the chain from the rear sprocket 600410 10 Loosen screw Turn clamping nut counterclockwise using the special tool until lock rings are freely accessible Remove the lock rings Open end wrench attachment 46 mm 83019010461 p 234 Turn clamping nut clockwise using the special tool and remove 60...

Page 81: ...iscs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 600422 10 Slide on the rear axle from the left to the right all the way Info The machined surfaces must be to the right of bearing seat 600423 10 Position O ring Attach chain sprocket carrier with the nuts facing outward Carefully insert sealing area on the chain sprocket carrier into the shaft...

Page 82: ...ings 600428 10 Tighten the clamping nut in the direction of the arrow using the special tool Guideline Clamping nut rear axle 2 10UNS 2B LH 25 Nm 18 4 lbf ft Only applies when using Open end wrench attachment 46 mm 83019010461 p 234 Open end wrench attachment 46 mm 83019010461 p 234 Tighten screw Guideline Screw clamping nut rear axle M6 10 Nm 7 4 lbf ft 600429 10 Position the brake caliper Mount ...

Page 83: ...04 11 Setting a wide toe width Mount spacing sleeve with the cone facing inward Mount conical ring with the cone facing outward Mount wheel hub Mount the washer and the new self locking nut 301538 11 Remove the vehicle from the work stand p 12 Tighten nuts on both sides Guideline Nut rear wheel hub M18x1 5 130 Nm 95 9 lbf ft Check the chain tension p 76 14 10 Changing the rear axle bearing Remove ...

Page 84: ...race in rear wheel eccentric on the right side Mount shaft seal ring with the green marking on the right side Use the spe cial tool Press mandrel 83019012000 p 234 Info Do not swap the shaft seal rings as otherwise grease may get onto the brake disc from the rear wheel eccentric Lightly grease the sealing lips of the shaft seal rings Long life grease p 224 600416 11 Insert the rear wheel eccentric...

Page 85: ...ery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at l...

Page 86: ...h charging current has a negative impact on the service life If the charging current charging voltage and charging time are exceeded electrolyte escapes via the safety valves This reduces the battery capacity If the vehicle is started repeatedly until the battery is depleted the battery must be charged immediately If the battery is left in a discharged state for an extended period it will drain co...

Page 87: ...uses of individual power consumers Remove the front cover p 69 Switch off all power consumers and switch off the engine 301815 10 Open the cover of the fuse box Info The designation of the fuses is located on the inside cover of the fuse box Remove the faulty fuse Guideline Fuse 1 10A CDI controller Fuse 2 10A radiator fan Fuse 3 not used Fuse 4 not used Fuse 5 power supply for auxiliary equipment...

Page 88: ...ct the red measuring lead to the positive terminal Measurement while loaded light switched on brakes activated Charging voltage under load at 5 000 rpm 13 5 15 V If the value displayed does not meet specifications Check the alternator p 190 If the alternator is working properly Change the voltage regulator 15 10 Checking the quiescent current Switch off all power consumers and switch off the engin...

Page 89: ...he starter relay Disconnect cables and from the starter relay 700089 01 Connect the starter relay to a 12 V power supply as shown in the figure Use a mul timeter to check the route between the terminals Info When the starter relay is switched a clicking sound can also be heard Resistance with the starter relay pulled 0 Ω When the display does not equal the setpoint Change the starter relay P a r t...

Page 90: ... fail due to overheating Adjust free travel on hand brake lever according to specifications 301799 10 Push the hand brake lever forward and check free travel Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specifications Adjust the basic position of hand brake lever p 88 16 3 Adjusting basic position of hand brake lever 301800 10 Check the free travel of the hand brak...

Page 91: ...ake system or worn out brake linings Check the brake system and not continue riding Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Re...

Page 92: ...ke fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container Remove the wheel wheels p 72 302054 10 Move the brake flui...

Page 93: ...anger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Remove the wheel wheels p 72 100074 10 Check the brake linings of both front brake calipers for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings p 92 Check the brake linings for damage and cracking If damage ...

Page 94: ... the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Info The operations are the same on the left and right Check the brake discs p 74 100072 10 Insert the inside brake lining into the brake caliper and fix with bolt Insert the external brake lining into the brake caliper and slide the bolts in all the way 100073 10 Mount the loc...

Page 95: ...ake fluid DOT 4 DOT 5 1 p 223 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 16 11 Checking free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adju...

Page 96: ...ystem or worn out brake linings Check the brake system and not continue riding Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule 301805 10 Park the vehicle on a horizontal surface Check the brake fluid level in the viewer When the brake fluid level has dropped to the bottom of the viewe...

Page 97: ...vel Brake fluid DOT 4 DOT 5 1 p 223 Refit screw with membrane Info Clean up overflowed or spilt brake fluid immediately with water 16 15 Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse th...

Page 98: ... 1 p 223 Mount the screw cap with the membrane Info Clean up overflowed or spilt brake fluid immediately with water Repeatedly activate the foot brake lever until a firm pressure point is reached 16 16 Checking rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately 100038 10 Check the brake linings for minimum th...

Page 99: ...discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power ca...

Page 100: ...hange the brake fluid of the front and rear brakes according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designe...

Page 101: ... slave cylinder Info Do not activate the clutch lever if the clutch slave cylinder has been removed 301584 10 Remove cable binder 301585 10 Disconnect plug of the alternator Disconnect plug of the ignition pulse generator Detach spark plug connector 301586 10 Remove screw Hang the ground wire to the side Slide back the cover Remove nut from the electrical connection on the starter motor and detach...

Page 102: ...ngarm with a suitable pin 301590 10 Remove screw Remove screws and take off both engine bearers 301591 10 Remove screw 301852 10 Lift the engine out of the frame Info It is recommended to have assistance for performing this step 17 2 Installing the engine 301852 10 Position the engine in the frame Info It is recommended to have assistance for performing this step P a r t S h a r k c o m 8 7 7 9 9 ...

Page 103: ...t M10 60 Nm 44 3 lbf ft 301853 11 Remove pin Mount the swingarm pivot Mount and tighten nut Guideline Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Tighten screw Guideline Engine mounting bolt M10 60 Nm 44 3 lbf ft Tighten screw Guideline Engine bracket screw M10 60 Nm 44 3 lbf ft Tighten screw Guideline Engine mounting bolt M10 60 Nm 44 3 lbf ft 301588 11 Reconnect spring Spring hooks 50305017000...

Page 104: ...inder M6 10 Nm 7 4 lbf ft Connect the negative cable of the battery Install the engine sprocket p 179 Install the carburetor p 166 Install the manifold p 60 Install the rear fender p 71 302071 10 Remove the filler cap on the clutch cover and fill up with engine oil Engine oil 2 00 l 2 11 qt External tem perature 0 C 32 F Engine oil SAE 10W 50 p 223 External tem perature 0 C 32 F Engine oil SAE 5W ...

Page 105: ...st 18 2 Removing the shift lever 301597 10 Remove screw Take off the shift lever 18 3 Draining the engine oil 301598 10 Remove oil drain plug with magnet 301599 10 Loosen screw plug by striking it lightly with a hammer a few times Remove screw plug with the oil screen and the O rings Completely drain the engine oil 18 4 Removing the oil filter 301600 10 Remove screws Remove oil filter cover with t...

Page 106: ... spark plug using special tool Spark plug wrench 77329072000 p 232 18 6 Removing the valve cover 301603 10 Remove screws Remove the valve cover with the valve cover seal 18 7 Removing the starter motor 301604 10 Remove screws and the starter motor 18 8 Removing the alternator cover 301605 10 Remove screws Take off the alternator cover P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 107: ...8 10 Positioning the engine at ignition top dead center TDC 301608 10 Remove screw 301609 10 Turn the crankshaft counterclockwise until holes of the camshafts are flush above sealing area 301610 10 Mark the double wheel and the cylinder head in one line Info The markings will be of assistant when the camshafts are assembled P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 108: ...Remove screws Take off the camshaft bearing bridge Info Ensure that the needle rollers and the O ring remain in place 301613 10 Remove camshafts 18 12 Removing the timing chain tensioner 301614 10 Loosen screw Remove screw with the seal ring 301615 10 Pull out timing chain tensioner Remove O ring P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 109: ... double wheel and remove spindle 301618 10 Take the timing chain off the double wheel Remove the double wheel with both needle bearings Remove the screw from the spindle 18 14 Removing the cylinder head 301619 10 Remove nut 301620 10 Unscrew nuts in a crisscross pattern and remove them with the washers Take off the cylinder head P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 110: ...Remove the gasket 18 16 Removing the clutch cover 301623 10 Remove screw Info If work is to be performed on the water pump unscrew the nut of the water pump impeller 301624 10 Mount special tool Assembly pin 77329012100 p 231 Remove screws and take off the clutch cover 301625 10 Remove the locating pins Remove quad ring Take off O ring P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 111: ...rformed on the cylinder and piston the piston can remain in the cylinder 301627 10 Take off locating pins and cylinder base gasket Remove O rings 18 18 Removing the timing chain rails 301628 10 Remove spindle Remove the timing chain guide rail from above Remove spindle Remove the timing chain tensioning rail from above 18 19 Removing the timing chain 301629 10 Remove screws Take off the retaining ...

Page 112: ...0 p 230 Attach special tool to the rotor Counteracting with the special tool pull off the rotor by screwing in the screw Extractor 58012009000 p 228 Info Ensure that the spring washer remains in place 301634 10 Remove starter idler gear 18 21 Removing the ignition pulse generator 301635 10 Remove screws Take off the retaining bracket Pull the cable support sleeve from the engine case Remove screws...

Page 113: ...special tool Special socket 36 mm drive 77329021000 p 231 Take off drive wheel of the balancer gear 18 23 Removing the force pump 301649 10 Remove screws Take off oil pump housing Info Ensure that the dowel pins remain in place 301650 10 Take off force pump 301651 10 Remove needle roller Remove oil pump housing with the gasket P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 114: ... Completely remove clutch discs 301685 10 Remove the special tool Engine blocking screw 77329010000 p 231 Bend open lock washer Hold the inner clutch hub with special tool and remove nut with the lock washer Clutch holder 77329003000 p 231 Take off the inner clutch hub 301686 10 Lock the outer clutch hub and primary gear using the special tool Gear quadrant 80029004000 p 233 Loosen nut with the sp...

Page 115: ... 10 Remove needle bearing and collar sleeve 18 26 Removing the primary gear 301653 10 Remove nut Take off primary gear 301654 10 Remove the drive wheel of balancer shaft 18 27 Removing the centrifugal separator 301655 10 Take off centrifugal separator P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 116: ...with the bearing 301657 10 Remove pin Remove screws Take off the oil pump cover 301658 10 Remove suction pump Remove pin 301659 10 Remove suction pump with the needle roller and oil pump shaft 18 29 Removing the shift shaft 301660 10 Push sliding plate away from the shift drum locating unit Remove shift shaft with the washer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 117: ...ove screws Remove screws Tilt the left section of the engine case upward and remove the threaded fasteners of the engine fixing arm 301690 10 Insert the special tool into the crankshaft Protection cover 75029090000 p 230 Mount special tool with the appropriate screws Extractor 83529048000 p 237 Info Use the drill hole marked with 835 Take off the section of the engine case Info Do not subject the ...

Page 118: ... Info Do not misplace the shift rollers Remove shift drum 18 35 Removing the shift forks 301693 10 Remove shift forks Info Do not misplace shift rollers 18 36 Removing the transmission shafts 301695 10 Secure the engine in an upright position Remove lock ring 301696 10 Pull out both transmission shafts together from the bearing seats Info Do not misplace the washers P a r t S h a r k c o m 8 7 7 9...

Page 119: ...30 DISASSEMBLING THE ENGINE 117 18 37 Removing the crankshaft 301697 10 Take out crankshaft Take off the right section of the engine case P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 120: ...fo When pressing in ensure that the section of the engine case lies flat in order to prevent damage Only press in the bearings by way of the outer ring as otherwise the bear ings will be damaged when they are pressed in After the section of the engine case has cooled down check to ensure that the bearings are firmly seated Info If the bearings are not firmly seated once cooled down it can be assum...

Page 121: ...earings still remaining in the section of the engine case must be removed with a suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing in ensure that the section of the engine case lies flat in order prevent damage Only press in the bearings ...

Page 122: ...4 Nm 3 lbf ft Loctite 243 Position all bearing retainers Mount and tighten screws Guideline Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 Mount and tighten oil suction pipe Guideline Oil suction pipe M14x1 15 Nm 11 1 lbf ft Loctite 243 301756 10 Blow out the oil channel with compressed air and check that it is clear 19 3 Removing the water pump 301673 10 Remove nut Take off the water pu...

Page 123: ...ft seal ring of the water pump 301675 10 Remove shaft seal ring 301676 10 Remove shaft seal ring 301676 11 Press in shaft seal ring all the way with the open side facing inward Distance pieces face outward 301675 10 Press shaft seal ring with the open side facing inward all the way in toward dis tance pieces P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 124: ...ount special tool Mounting sleeve 58529005000 p 228 301674 11 Press balancer gear into the clutch cover Position the retaining bracket Mount and tighten screws Guideline Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 301681 10 Align marking with special tool Assembly pin 77329012100 p 231 301677 10 Mount and tighten nut Guideline Nut water pump wheel M6 6 Nm 4 4 lbf ft Loctite 243 P a r ...

Page 125: ...ut the oil channel with compressed air and check that it is clear 19 8 Removing the oil pressure regulator valve 301672 10 Remove screw plug with sealing washer Remove pressure spring and ball 19 9 Checking spring length of oil pressure regulator valve Remove the oil pressure regulator valve p 123 200155 10 Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve ...

Page 126: ...Check the internal rotor and external rotor of oil pumps for damage and wear If there is damage or wear Change the oil pumps Check oil pump shaft for damage and wear If there is damage or wear Change the oil pump shaft Check oil pump housing and oil pressure regulator valve for damage and wear If there is damage or wear Change the oil pump housing oil pressure regulator valve and if necessary the ...

Page 127: ...aring inner race in special tool and mount together Guideline 120 C 248 F Repeat these steps on the opposite side Ensure that the new crankshaft bearing inner race is flush Info After replacing the crankshaft bearings the crankshaft end play must be measured 19 14 Changing connecting rod conrod bearing and crank pin 301286 10 Position the crankshaft in the press with the special tool Extrude plate...

Page 128: ...web as far as possible Info The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely 301704 10 Measure the end play between the connecting rod and the crank webs with the spe cial tool Feeler gauge 59029041100 p 229 Connecting rod end play of lower con rod bearing 0 40 0 60 mm 0 0157 0 0236 in If the measu...

Page 129: ...t be added Install the crankshaft bearing inner race p 125 19 17 Cylinder Nikasil coating 301248 10 Nikasil is a surface protection layer for a coating procedure developed by Mahle The name is derived from the two materials used in this procedure a layer of nickel into which is embedded the particularly hard silicone carbide The most important advantages of the Nikasil coating are very good heat c...

Page 130: ...piston ring can be used to clean the piston ring groove Check the piston rings for damage If the piston ring is damaged Replace the piston ring Info Mount the piston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Replace the piston pin Place the piston pin in the connecting rod and check the se...

Page 131: ...ign with the piston Guideline Below the upper edge of the cylinder 10 mm 0 39 in Measure the end gap with feeler gauge Guideline Piston ring end gap Compression ring 0 80 mm 0 0315 in Oil scraper ring 1 00 mm 0 0394 in If the end gap is greater than the specified measurement Check measure the cylinder p 127 If cylinder wear lies within the specified tolerance Replace the piston ring Mount the pist...

Page 132: ...301250 10 Check the camshaft for damage and wear If there is damage or wear Change the camshaft If the surface of the cams is damaged check the oil supply to the camshaft and cam lever Measure the cams of the camshaft Camshaft cam height Exhaust 33 10 33 30 mm 1 3031 1 311 in Camshaft cam height 450 SX ATV Intake 33 90 34 10 mm 1 3346 1 3425 in Camshaft cam height 505 SX ATV Intake 34 20 34 40 mm ...

Page 133: ...ce gauge is a measure of the bearing play Remove camshaft bearing bridge Take off the camshafts and clean the parts 19 26 Checking the camshaft bearing bridges 301225 10 Check the camshaft bearing bridges for damage If there is damage or wear Change the cylinder head with the camshaft bearing bridge 19 27 Removing the valves 301228 10 Fold up the cam levers Take shims out of the valve spring retai...

Page 134: ...rresponding to their installation position Info Place the valves in a carton corresponding to their installation position and label them 19 28 Checking the valves 200193 10 Check the valve plate for run out Valve run out At the valve plate 0 05 mm 0 002 in If the measured value does not meet specifications Change the valve 0 0 A A 400373 10 Check sealing seat on the valve Valve sealing seat width ...

Page 135: ...ons Change the valve spring seat 19 31 Checking the cam levers 301227 10 Check the cam levers and cam lever shafts for damage and wear If there is damage or wear Change the cam levers and or cam lever shafts 19 32 Checking cylinder head 301252 10 Check the valve guides with the special tool Limit plug gauge 59029026006 p 229 If the special tool is easy to insert into the valve guide Change the val...

Page 136: ...ng retainers 301230 10 Pre tension the valve springs using the special tool Valve spring compressor 59029019000 p 229 Insert for valve spring lever 77329060000 p 232 301233 10 Mount valve keys Info When mounting the valve keys ensure that they are seated properly it is recommended to adhere the valve keys to the valves with a small amount of grease 301229 11 Position cam levers in the positions th...

Page 137: ... If the freewheel gear does not turn clockwise or if it does not lock counterclock wise Remove the freewheel p 135 Turn the freewheel 180 Install the free wheel p 135 19 36 Installing the free wheel 301234 10 Thoroughly oil all parts Pull the ends of expansion ring together Slide freewheel into the freewheel hub Info Note the direction of rotation 301235 10 Ensure that all of the tabs of the expan...

Page 138: ...r If there is damage or wear Change the freewheel gear or bearing Check free wheel for damage and wear when it is disassembled If there is damage or wear Change the free wheel Checking the gear mesh of starter motor for damage and wear If there is damage or wear Change the starter motor Change O ring of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the st...

Page 139: ... wear Replace the timing chain guide rail Check camshaft gears for damage and wear If there is damage or wear Change the camshaft gears Check timing chain for damage and wear If there is damage or wear Replace the timing chain Check the timing chain links for smooth operation Let the timing chain hang down freely The chain links no longer align in a straight line Replace the timing chain 19 39 Pre...

Page 140: ...ficient timing chain tension even at low oil pressures 19 40 Checking clutch 0 0 4 4 0 0 5 5 0 0 2 2 0 0 1 1 0 0 3 3 0 0 bl bl 0 0 6 6 0 0 8 8 0 0 7 7 0 0 bm bm 0 0 bk bk 0 0 9 9 301246 01 Check the pressure piece for damage and wear If there is damage or wear Change the pressure piece Check axial bearing for damage and wear If there is damage or wear Change the axial bearing Place push rod on a l...

Page 141: ...h lining discs Check the disc for damage and wear If there is damage or wear Change the disc Check the inner clutch hub for damage and wear If there is damage or wear Change the inner clutch hub 19 41 Checking shift mechanism 0 0 D D 0 0 C C 0 0 E E 0 0 5 5 0 0 3 3 0 0 B B 0 0 3 3 0 0 A A 0 0 1 1 0 0 2 2 0 0 A A 0 0 1 1 0 0 4 4 0 0 1 1 0 0 A A 0 0 4 4 301263 01 Check the shift forks on disc for da...

Page 142: ...ng Change the sliding plate Check guide bolts for firm seating and wear If the guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft p 140 0 0 0 0 0 F F 300122 01 Preassemble the shift shaft p 140 Check clearance between the sliding plate and the shift quadrant Shift shaft sliding plate shift quad rant clearance 0 40 0 80 mm 0 0157 0 0315 in If the measured value does ...

Page 143: ...ve 5th gear idler gear and needle bearing Remove stop disk Remove lock ring Remove 4th gear sliding gear Remove lock ring Remove stop disk Remove 3rd gear idler gear Remove needle bearing 19 44 Disassembling the countershaft 0 0 bp bp 0 0 5 5 0 0 3 3 0 0 1 1 0 0 6 6 0 0 8 8 0 0 bk bk 0 0 bm bm 0 0 bq bq 0 0 bo bo 0 0 bn bn 0 0 2 2 0 0 4 4 0 0 7 7 0 0 9 9 0 0 bl bl 301261 01 Secure the countershaft...

Page 144: ...r If there is damage or wear Change the needle bearing Check the pivot points of main shaft and countershaft for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profile of main shaft and countershaft for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the pivot points of idler gears for damage and wear ...

Page 145: ...disks Use new lock rings with every repair 19 46 Assembling the main shaft Info Use new lock rings with every repair Carefully lubricate all parts before assembling Check the transmission p 142 0 0 bl bl 0 0 9 9 0 0 7 7 0 0 5 5 0 0 3 3 0 0 1 1 0 0 4 4 0 0 bk bk 0 0 8 8 0 0 6 6 0 0 2 2 301260 01 Mount needle bearing Mount 3rd gear idler gear Mount stop disk and lock ring Mount 4th gear sliding gear...

Page 146: ...e Guideline Use soft jaws Mount needle bearing and 2nd gear idler gear onto the countershaft with the protruding collar facing downward Mount stop disk and lock ring Mount the 5th gear sliding gear with the shift groove facing up Mount lock ring and stop disk Mount needle bearing and 4th gear idler gear with the shift dogs facing upward Mount stop disk and lock ring Mount the 3rd gear sliding gear...

Page 147: ... Do not misplace the washers 301695 10 Mount lock ring 20 3 Installing the shift forks 301694 10 Shift fork has a smaller inside diameter mount this in the shift groove of the main shaft Mount shift fork in the lower shift groove of the countershaft Mount shift fork in the upper shift groove of the countershaft Slide on shift rollers Tip Fix the shift rollers to the shift forks with grease Marking...

Page 148: ...ing compound to the left section of the engine case Loctite 5910 301663 10 Mount the left section of the engine case If necessary strike it lightly with a rub ber mallet and turn the transmission shafts Info Do not use the screws to pull the two sections of the engine case together Mount screws and once all screws of the left section of the engine case have been mounted tighten them Guideline Scre...

Page 149: ... ft Loctite 243 20 9 Installing the shift shaft 301660 11 Slide shift shaft with the washer into the bearing seat Push sliding plate away from the shift drum locating unit Insert the shift shaft all the way Let sliding plate engage in the shift drum locating unit Shift through the transmission 20 10 Installing the suction pumps 301664 10 Oil the oil pump shaft internal rotor and external rotor bef...

Page 150: ... 11 Mount the needle roller Insert suction pump 20 11 Installing the centrifugal separator 301655 10 Mount centrifugal separator 20 12 Installing the force pump 301651 11 Mount oil pump housing with the gasket Info Ensure that the dowel pins are seated properly Insert needle roller 301659 12 Position force pump Info Ensure that the dowel pins are seated properly P a r t S h a r k c o m 8 7 7 9 9 9...

Page 151: ...4 11 Position the drive wheel of balancer shaft 301653 11 Position primary gear Mount nut but do not tighten yet Guideline Nut primary gear M27x1 80 Nm 59 lbf ft Loctite 243 20 14 Installing the outer clutch hub 301689 11 Mount collar sleeve and needle bearing 301688 11 Mount the outer clutch hub Info Turn the outer clutch hub and oil pump gears back and forth slightly to help them engage Mount wa...

Page 152: ...01684 11 Thoroughly oil the clutch facing discs Engine oil SAE 10W 50 p 223 Beginning with an intermediate disc alternately insert all other clutch facing discs and intermediate discs into the outer clutch hub Insert pressure piece with the push rod into the gearbox main shaft 301683 11 Position the crankshaft at TDC and lock it with the special tool Engine blocking screw 77329010000 p 231 Positio...

Page 153: ...cer gear Info If the timing chain was used before ensure it is running in the correct direction Mount the stop disks with the collar facing the balancer gear Insert the timing chain balancer gear with stop disk and needle bearings into the chain shaft Align markings and to each other Mount spindle with the O ring 301666 10 Position the retaining bracket Mount and tighten screws Guideline Screw tim...

Page 154: ... engine oil 20 21 Installing the timing chain rails 301628 11 Slip in the timing chain guide rail from above Mount and tighten spindle Guideline Axle guide rail for timing chain M14x1 15 Nm 11 1 lbf ft Slip in the timing chain tensioning rail from above Mount and tighten spin dle Guideline Axle tension rail for timing chain M14x1 15 Nm 11 1 lbf ft 20 22 Installing the piston 301155 10 Move the joi...

Page 155: ...them more clearly the following steps will be shown with a removed piston Position the piston pin retainer 200084 10 Insert the special tool and press it forcefully to the piston Turn the special tool counterclockwise thereby pushing the piston pin retainer into the groove 450 SX ATV Insert for piston pin retainer 77329030100 p 232 505 SX ATV Insertion for piston ring lock 77629030000 p 233 Ensure...

Page 156: ...Screw clutch cover M7x1 14 Nm 10 3 lbf ft Mount screws and tighten all screws in a crisscross pattern Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 301623 11 Remove the special tool Assembly pin 77329012100 p 231 Mount and tighten screw with the O ring Guideline Screw plug clutch cover M10x1 10 Nm 7 4 lbf ft 20 24 Installing the water pump cover 301622 11 Position the gasket Put the water pump ...

Page 157: ...lubricated with engine oil 301619 11 Mount and tighten nut Guideline Nut cylinder head M6 10 Nm 7 4 lbf ft lubricated with engine oil 20 26 Installing the double wheel 301646 10 Oil the needle bearings and insert them in the double wheel lubricated with engine oil Place the timing chain on the double wheel Align markings and to each other Mount spindle with the O ring 301616 11 Align the spindle f...

Page 158: ...ideline Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft 20 28 Checking the valve timing Condition The camshaft has not been disassembled 301642 10 Oil the camshafts and bearing positions lubricated with engine oil Position the camshafts and turn them so the flat surfaces face upward 301640 10 Position special tool Adjustment bush bridge 77329050000 p 232 Check the valve timing Th...

Page 159: ...ine Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft lubricated with engine oil 301643 10 Position camshaft bearing bridge Info Ensure that the locating pins are seated properly Mount and tighten the screws Guideline Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft lubricated with engine oil Tighten screw Guideline Screw camshaft gear M10x1 50 Nm 36 9 lbf ft lubricated with engine oil 3016...

Page 160: ...lve clearance p 158 301638 10 Remove special tool Mount and tighten screw Guideline Plug crankshaft location M8 20 Nm 14 8 lbf ft 20 31 Adjusting the valve clearance Remove the camshaft p 106 301639 10 Raise cam levers Remove shims and set down in the position in which they were installed Correct the shims according to the findings from checking the valve play Insert the fitting shims 301612 12 Po...

Page 161: ...a crisscross pattern Guideline Screw alternator cover M6 10 Nm 7 4 lbf ft 20 34 Installing the starter motor 301604 10 Grease the O ring Position the starter motor Long life grease p 225 Mount and tighten screws Guideline Screw starter motor M6 10 Nm 7 4 lbf ft 20 35 Installing the valve cover 301603 10 Position the valve cover with the gasket Mount and tighten screws Guideline Screw valve cover M...

Page 162: ... M12x1 5 20 Nm 14 8 lbf ft 301599 10 Mount and tighten screw plug with the oil screen and the O rings Guideline Plug oil screen M32x1 5 30 Nm 22 1 lbf ft 20 38 Installing the oil filter 301601 11 Tilt the engine on one side and fill the oil filter housing to about full with engine oil Fill the oil filter with engine oil and place it in the oil filter container 301600 11 Oil the O ring of the oil f...

Page 163: ...deline Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 20 40 Removing the engine from the universal mounting rack 301596 10 Remove the screw connection from the special tool Engine fixing arm 83529002000 p 237 Remove the engine from the universal mounting rack Engine work stand 61229001000 p 230 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 164: ...ways make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 14 21 3 Carburetor adjusting idle 301826 10 Screw in t...

Page 165: ...cessary rich mixture use a larger idling jet After changing the idling jet start from the beginning with the adjusting steps Adjust the idle speed with the adjusting screw Guideline Choke function deactivated The choke lever is pushed in to the stop p 162 Idle speed 1 500 1 600 rpm Info Following extreme air temperature or altitude changes adjust the idle speed again 21 4 Checking the position of ...

Page 166: ...and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warning Environmental...

Page 167: ...engine breather hose from the carburetor 301546 10 Loosen hose clip 301547 10 Take carburetor out of the frame from the rear and set it down on the frame 301548 10 Remove screws Remove carburetor cover 301549 10 Loosen nut Detach the throttle cable and hang it to the side P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 168: ...that the throttle cable is routed correctly Adjust the play in the throttle cable and tighten nut Guideline Play in throttle cable 3 5 mm 0 12 0 2 in 301548 11 Position carburetor cover Mount and tighten screws Guideline Other screws carburetor M5 5 Nm 3 7 lbf ft 301547 11 Insert carburetor into the rubber sleeve Info Ensure that the carburetor hoses are routed correctly 301546 11 Position and tig...

Page 169: ...carburetor connection boot p 62 Install the fuel tank p 65 Check the play in the throttle cable p 162 21 8 Disassembling the carburetor Condition The carburetor has been removed 301561 10 Remove screws and detach all vent hoses from the carburetor 301560 10 Remove screws Take off the throttle slide cover and seal 301562 10 Remove screw with the spring and washer Pull the jet needle out of the thro...

Page 170: ...pring and membrane Remove screws and take off the float chamber body 301554 10 Remove fulcrum pin Take off the float and float needle valve Remove main jet 301555 10 Remove idling jet cold start jet needle jet and buffer plate Screw in mixture control screw all the way counting and noting down the num ber of rotations Remove the mixture control screw with the spring washer and O ring 301556 10 Scr...

Page 171: ... ened the throttle position sensor must be readjusted Unscrew choke slide 301559 10 Remove idle air jet Clean all jets and other parts thoroughly and blow out with compressed air Carburetor cleaner p 225 Clean the carburetor housing and blow out all channels in the carburetor with com pressed air Carburetor cleaner p 225 Info Do not use nitro thinner to clean the carburetor P a r t S h a r k c o m...

Page 172: ... the float level p 174 Check adjust the throttle slide opening p 173 Check the throttle position sensor p 171 Assemble the carburetor p 175 21 10 Checking adjusting the accelerator pump Condition The carburetor and accelerator pump have been removed 700051 10 Check the membrane of damage or brittleness If the membrane is damaged or brittle Change the membrane Check holes to ensure that they are fr...

Page 173: ...nger of the choke slide is damaged or worn Change the choke slide Check the rubber sleeve and lock If the rubber sleeve is damaged or brittle or if the lock does not function Change the choke slide 21 12 Checking the hot start slide Condition The hot start slide has been removed 302065 10 Check the hot start slide for smooth operation If the hot start slide cannot be moved easily or is soiled Clea...

Page 174: ...dle for bending and wear of the coating If the jet needle is bent or the coating is damaged or worn Change the jet needle Check that the needle clip is firmly seated If the needle clip is not firmly seated Change the needle clip or jet needle 21 15 Checking the throttle slide Condition The throttle slide has been removed 700055 10 Check the throttle slide rollers for damage and wear If the throttl...

Page 175: ... jet needle make a mark above the level at a distance Guideline Distance 3 mm 0 12 in Info The marking must be completely removable 700054 10 Insert the marked jet needle into the needle jet to be tested Push the two parts together carefully Check the needle jet If marking is not visible on the jet needle at the upper edge of the needle jet Change the needle jet 21 18 Checking the float needle val...

Page 176: ...ack bl cable of the throttle position sensor connector Measure the total throttle position sensor resistance Rtot Guideline Throttle position sensor total resis tance Rtot 4 6 kΩ 700064 10 Multiply the total throttle position sensor resistance Rtot by 0 17 The product is the variable throttle position sensor resistance Rvar for the setting Rtot x 0 17 Rvar tolerance 0 05 kΩ 700066 10 Connect the p...

Page 177: ...ctite 243 Info The hose connection must be easy to turn when it is mounted 301555 11 Screw in the mixture control screw with the spring washer and O ring all the way Guideline Mixture control screw M6x0 5 1 Nm 0 7 lbf ft Screw in the mixture control screw by the number of turns that were required to disassemble it or adjust it to the specified basic setting Guideline Idle mixture adjusting screw O...

Page 178: ...ide roller and the throttle slide plate into throttle slide arm and position it in the carburetor Position the needle clip on the jet needle Guideline Needle position 3rd position from top Insert the jet needle 301562 11 Mount and tighten screw with the spring and washer Guideline Needle screw M8 3 5 Nm 2 58 lbf ft Mount and tighten screw Guideline Screw throttle slide arm M4 2 Nm 1 5 lbf ft Locti...

Page 179: ...with the rounded side facing out 301551 11 Position the accelerator pump cover Mount and tighten screws Guideline Other screws carburetor M4 2 Nm 1 5 lbf ft 301561 01 Position and mount the bleeder hoses Position the hose holder Mount screws and tighten all screws in a crisscross pattern Guideline Other screws carburetor M4 2 Nm 1 5 lbf ft Adjust the position of the throttle position sensor p 174 ...

Page 180: ...e disposed of as stipulated in applicable regulations 302061 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane 302062 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 p 227 Hydraulic oil 15 p 224 Remove the bleeder screw on the clutch slave cylinder and mount the bleeding syringe 3020...

Page 181: ...he engine sprocket 301542 11 Insert engine sprocket into chain with the collar facing the engine and slide onto the countershaft together Activate the rear brake Mount and tighten screw with spring washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 243 301543 11 Position the engine sprocket cover Mount and tighten screws Guideline Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft R...

Page 182: ... in If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 223 Alternative 2 Coolant mixed ready to use p 223 Mount the radiator cap 24 2 Checking the coolant level Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated Do not remove the radiator cap or remove radiator hoses or other cooling system c...

Page 183: ...ont trim p 69 301837 10 Place a suitable container under the vehicle Remove screw Remove screw 301838 10 Remove the radiator cap Completely drain the coolant Mount screw with a new seal and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft Mount screw with a new seal and tighten it Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 24 4 Filling coolant bleeding the cooling system...

Page 184: ... emerges from the opening Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 301839 10 Add coolant to level above the radiator fins Guideline 10 mm 0 39 in Mount the radiator cap Install the front trim p 70 Make a short test ride Check the coolant level p 180 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 185: ...r 6 Oil jet piston cooling 7 Oil jet conrod lubrication 8 Oil jet for oil supply clutch 9 Oil channel cam lever bearing 10 Oil jet for cam lever lubrication 11 Oil channel camshaft bearing Oil circuit suction pump 12 Suction pump for evacuating the crank chamber 13 Oil channel transmission lubrication 25 2 Changing the engine oil and oil filter cleaning the oil screen 301702 10 Drain the engine oi...

Page 186: ...ith the magnet Clean the sealing area on the engine Fit oil drain plug with seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Clean the oil screen 25 4 Removing the oil filter Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under...

Page 187: ... Engine oil SAE 5W 40 p 223 Mount and tighten filler cap Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Ch...

Page 188: ...of engine oil or poor quality engine oil results in premature wear to the engine 301845 10 Check the engine for leakage Remove the filler cap on the clutch cover and fill up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 223 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 223 Info To ensure optimal engine oil performance it is advisable to not use di...

Page 189: ...nger of an electric shock do not touch metal parts and the ends of the connection cable during and imme diately after measuring Condition The battery must be charged The fuse in the starter relay must be functional Shift gear to neutral 301568 10 Pull off the spark plug connector and remove the spark plug connector from the ignition wire Hold the free end of the ignition wire a distance from groun...

Page 190: ...gnition coil primary winding Ground ignition coil input at 20 C 68 F 0 25 0 35 Ω If the measured value differs from the set value Change the ignition coil 301573 10 Measure the secondary winding with a multimeter Ignition coil secondary winding Ignition wire ignition coil input at 20 C 68 F 5 7 5 kΩ If the measured value differs from the set value Change the ignition coil 301574 10 Connect the spe...

Page 191: ...ust be charged Remove the fuel tank p 64 301577 10 Disconnect the electrical plug in connector connecting the ignition pulse generator to the CDI controller Measure the resistance of the ignition pulse generator using a multimeter Ignition pulse generator resistance Red green at 20 C 68 F 80 120 Ω Red ground at 20 C 68 F If the measured value differs from the set value Change the ignition pulse ge...

Page 192: ...nnector of the stator coil Measure the stator coil with a multimeter Stator coil resistance Alternator outputs against each other 1 Ω Alternator outputs against ground If the value displayed does not meet specifications Change the stator 301575 10 Check the alternator output for voltage between the individual wires Connect the special tool to the multimeter Peak voltage adapter 58429042000 p 228 I...

Page 193: ...on and fix it Handlebar fixation for straight ahead position 83019015100 p 235 400333 10 Measure distances and If distances and are not equal Adjust the toe p 192 Measure distances and Guideline Toe Front 0 mm 0 in Info The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when driving straight ahead The distance is measured at the height of ...

Page 194: ... 400333 11 Loosen nuts and Adjust the distances and to the same value by rotating the tie rods Adjust the distances and to the specified value by evenly rotating the tie rods Guideline Toe Front 0 mm 0 in Info The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when driving straight ahead The distance is measured at the height of the wheel ...

Page 195: ...oints If marking is not aligned with the top edge of the A arm Turn tool with the heim joint in steps of 180 until the marking is in line with the top edge of the A arm Remove tool 300274 10 Position the A arm with bushings Mount and tighten screws Guideline Screw A arm top M10x52 45 Nm 33 2 lbf ft 300273 10 Align the heim joint at right angles to screws and tighten nut Guideline Nut A arm top M12...

Page 196: ... stand p 12 27 5 Removing the wheel carrier Info The operations are the same on the left and right Remove the wheel wheels p 72 301500 10 Remove brake disc guard Remove cable clamp and take off brake line guide 301501 10 Pull the hand brake lever and release it again Locking pawl moves into its basic position parking brake is deactivated Remove screws Press the brake caliper onto the brake disc by...

Page 197: ...nd take the tie rod out of the wheel carrier 301503 10 Remove nuts 301504 10 Position special tool Press the lower ball head out of the wheel carrier Push out tool 83019021000 p 236 301505 10 Turn and position special tool Press the upper ball head out of the wheel car rier Remove the wheel carrier P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 198: ... carrier in the vise Info Use soft jaws Remove nut Remove the wheel hub 301510 10 Remove spacers 301511 10 Pry out shaft seal rings 301512 10 Secure the wheel bearing with a suitable tool Remove the bearing spacer 301514 10 Press the wheel bearing all the way in Press mandrel 83019013000 p 235 Mount the bearing spacer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 199: ...Mount and tighten nut Guideline Nut front wheel hub M12 70 Nm 51 6 lbf ft Install the wheel carrier p 197 27 7 Installing the wheel carrier Info The operations are the same on the left and right sides 301503 11 Insert the wheel carrier between the A arms Mount and tighten nuts Guideline Nut ball head A arm bottom M12x1 5 40 Nm 29 5 lbf ft Nut ball head A arm top M10x1 25 35 Nm 25 8 lbf ft P a r t ...

Page 200: ...Brake calipers have been mounted activate the hand brake lever several times until the brake linings are in contact with brake disc and there is a pressure point 301500 11 Position brake line guide and secure it with cable clamp Info Note the holding lug of the brake line guide Mount brake disc guard Install the wheel wheels p 73 Check the toe p 191 27 8 Removing the A arms Info The operations are...

Page 201: ...rber in the lower A arm Mount and tighten screw Guideline Screw front shock absorber M10 45 Nm 33 2 lbf ft 300277 10 Insert tool in the heim joint and clip onto the A arm Camber gauge 83019014000 p 235 Check the camber on both heim joints If the marking is not flush with the top edge of the A arm Remove the nuts on the heim joint Turn tool with the heim joint in steps of 180 until the marking is i...

Page 202: ...the left and right sides Remove the A arms p 198 600467 10 Remove lock ring Circlip pliers reverse 51012011000 p 228 600468 10 Press out ball head using special tool Disassembly assembly holder 83019020150 p 236 600469 01 Press in the ball head using the special tool Press mandrel 83019020130 p 236 Mounting sleeve 83019020100 p 235 600467 10 Mount lock ring Circlip pliers reverse 51012011000 p 228...

Page 203: ...l in the heim joint and clip onto the A arm Camber gauge 83019014000 p 235 Align marking with the upper edge of the A arm by rotating the heim joint Info Nuts are tightened when the A arm is installed Install the A arms p 199 27 11 A Arm bottom changing the bearing Info The operations are the same on the left and right sides Remove the A arms p 198 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 204: ...019020170 p 236 Press mandrel 83019020130 p 236 Clean the pivot point 600459 01 Press in a new needle bearing on all pivot points using the thick end of the special tool Press mandrel 83019020170 p 236 Info The needle bearing cannot be pushed through from one side Grease the needle bearing On the front pivot point insert the two spacing washers Install the new shaft seal rings Lightly grease the s...

Page 205: ...bly holder 83019020150 p 236 600466 01 Press in the ball head using the special tool Press mandrel 83019020130 p 236 Disassembly assembly holder 83019020150 p 236 600464 10 Mount lock ring Circlip pliers reverse 51012011000 p 228 Info When mounting the lock ring do not damage the rubber boot Install the A arms p 199 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 206: ...ush DLC plated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmission 29 74 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 16 34 2nd gear 19 31 3rd gear 20 26 4th gear 23 25 5th gear 26 24 Alternator 12 V 42 W Ignition Contactless c...

Page 207: ... 99 971 99 980 mm 3 93586 3 93621 in Cylinder drill hole diameter 450 SX ATV Size I 97 000 97 012 mm 3 81889 3 81936 in Size II 97 013 97 025 mm 3 8194 3 81987 in Cylinder drill hole diameter 505 SX ATV Size I 100 000 100 012 mm 3 937 3 93747 in Size II 100 013 100 025 mm 3 93751 3 93798 in Piston cylinder mounting clearance Size I 0 030 0 052 mm 0 00118 0 00205 in Size II 0 032 0 054 mm 0 00126 0...

Page 208: ...10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw ignition pulse generator cable holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil pump casing M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm ...

Page 209: ... ft Axle guide rail for timing chain M14x1 15 Nm 11 1 lbf ft Axle tension rail for timing chain M14x1 15 Nm 11 1 lbf ft Nut compensating sprocket M14x1 20 Nm 14 8 lbf ft Loctite 243 Oil suction pipe M14x1 15 Nm 11 1 lbf ft Loctite 243 Oil pressure regulator valve plug M14x1 5 18 Nm 13 3 lbf ft Nut inner clutch hub M18x1 5 80 Nm 59 lbf ft Loctite 243 Plug timing chain tensioner M24x1 5 25 Nm 18 4 l...

Page 210: ...le position 3 th position from top Idle mixture adjusting screw Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Hot start button Diameter of bore in carburetor body 2 5 mm 0 098 in Main jet 175 Jet needle OBEKR Idling jet 42 Idle air jet 100 Cold start jet 85 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 211: ... Nm 1 5 lbf ft Screw carburetor cover M5 2 5 Nm 1 84 lbf ft Screw throttle position sensor M5 3 5 Nm 2 58 lbf ft Cold start jet M5x0 75 2 Nm 1 5 lbf ft Main jet M5x0 75 2 Nm 1 5 lbf ft Mixture control screw M6x0 5 1 Nm 0 7 lbf ft Idling jet M6x0 75 2 Nm 1 5 lbf ft Needle jet M7x0 75 3 5 Nm 2 58 lbf ft Needle screw M8 3 5 Nm 2 58 lbf ft Choke slide M12 2 5 Nm 1 84 lbf ft Hot start activation M12 2 ...

Page 212: ...y 165 kg 364 lb Fuel tank full 173 kg 381 lb Maximum allowable axle load Front 144 kg 317 lb Rear 149 kg 328 lb Maximum permissible overall weight 293 kg 646 lb Vehicle length 1 810 mm 71 26 in Vehicle width 1 265 mm 49 8 in Vehicle height 1 100 mm 43 31 in Brake system Front Disc brakes brake calipers fixed 4 brake pistons per brake caliper Rear Disc brake brake caliper floating 1 brake piston Br...

Page 213: ...x 11 00 9 MAXXIS Razr M 932 Additional information is available in the Service section under http www ktm com 33 2 Capacity fuel Total fuel tank capacity approx 10 3 l 2 72 US gal Super unleaded ROZ 95 RON 95 PON 91 p 224 Fuel reserve approx 3 l 3 qt P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 214: ... 0 75 0 059 in Spring preload Comfort 3 mm Standard 5 mm Sport 8 mm Spring rate main spring Weight of rider 64 75 kg 141 165 lb 21 26 N mm 120 148 lb in Weight of rider 75 85 kg 165 187 lb 24 29 N mm 137 166 lb in Weight of rider 85 95 kg 187 209 lb 27 32 N mm 154 183 lb in Spring rate auxiliary spring 40 N mm 228 lb in Spring length main spring 275 mm 10 83 in Spring length auxiliary spring 60 mm...

Page 215: ...r 19 1 5 mm 0 75 0 059 in Spring preload Comfort 3 mm Standard 5 mm Sport 5 mm Spring rate main spring Weight of rider 65 75 kg 143 165 lb 78 N mm 445 lb in Weight of rider 75 85 kg 165 187 lb 82 N mm 468 lb in Weight of rider 85 95 kg 187 209 lb 85 N mm 485 lb in Spring rate auxiliary spring 100 N mm 571 lb in Spring length main spring 200 mm 7 87 in Spring length auxiliary spring 55 mm 2 17 in F...

Page 216: ...uts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw A arm bottom M10x70 45 Nm 33 2 lbf ft Screw A arm top M10x52 45 Nm 33 2 lbf ft Screw footrest M10 45 Nm 33 2 lbf ft Screw front shock absorber M10 45 Nm 33 2 lbf ft Screw steering column at bottom of steering lever M10 25 Nm 18 4 lbf ft Nut ball head A arm top M10x1 25 35 Nm 25 8 lbf ft Nut rear sprocket screw M...

Page 217: ...torcycle cleaner p 226 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the vehicle with a gentle spray of water allow it to dry thoroughly Clean and dry the air filter box Drain the carburetor float chamber p 164 Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Af...

Page 218: ...he vehicle p 215 Change the engine oil and oil filter clean the oil screen p 183 Check the antifreeze and coolant level p 180 Drain the fuel from the tank into a suitable container Drain the carburetor float chamber p 164 Check the tire air pressure p 72 Remove the battery p 83 Recharge the battery p 84 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Store the vehic...

Page 219: ...s Check the free travel of the hand brake lever p 88 Check the free travel of the foot brake lever p 93 Check the brake system Check screws and guide pins of the brake system for tightness Chassis Check shock absorbers for cracks and proper functioning Check the steering column bearing for wear and smooth operation Clean and grease bearing and sealing elements of steering column Check the handleba...

Page 220: ...he transmission p 142 Check the shift mechanism p 139 Check the spring length of the oil pressure regulator valve p 123 Change glass fiber yarn filling of main silencer Replace foot brake cylinder seals Check adjust the carburetor components p 170 S10A Every 10 service hours corresponds to about 70 liters of fuel 18 5 US gal S20A Every 20 service hours corresponds to about 140 liters of fuel 37 US...

Page 221: ...olant level p 180 Check that all controls for smooth operation Check braking force incl parking brake Check all screws nuts and hose clamps regularly for tightness NB1A Depending on conditions of use according to requirements P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 222: ... 2 X 1 1 2 3 2 1 4 5 6 9 8 7 0 1 1 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 8 1 U B 1 A t 2 V A 4 S 2 1 3 M A 3 R A 1 B 1 2 3 1 1 L 4 B E 2 K 2 1 3 4 4 K B 4 R B 2 S 3 2 1 4 2 X A 5 1 4 F A 1 K 4 1 2 3 1 G M 1 M 3 X U 1 N FA 4 FB 4 1 2 3 4 2 K A 3 S 2 1 2 H A 1 A B 5 X 1 1 X 4 X 3 3 4 3 5 1 4 1 1 3 4 5 6 7 8 9 10 11 12 13 14 14 13 12 10 11 39 31 32 31 42 43 5 6 3 8 9 17 29 2 37 41 7 38 40 38 16 18 23 35 20 2...

Page 223: ...3 Emergency OFF switch with rip cord S4 Temperature switch for radiator fan S5 Clutch switch Cable colors 1 White blue 2 brown 3 white 4 Blue red 5 Grey 6 white red 7 White black 8 Yellow green 9 Black yellow 10 Red 11 Green 12 Blue 13 Yellow 14 Black 15 White brown 16 Brown 17 Black yellow 18 Black red 19 Yellow 20 White red 21 White red 22 White red 23 Green 24 Green 25 Green 26 Green 27 Red 28 ...

Page 224: ...WIRING DIAGRAM 222 35 White black 36 Brown 37 Brown 38 Black 39 White red 40 White black 41 White red 42 Brown 43 Black yellow P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 225: ...inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 240 SAE p 240 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Synthetic engine oil ...

Page 226: ...ydraulic oil that complies with the specified standards see specifications on the container and that possesses the cor responding properties HUSABERG recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Long life grease According to NLGI Guideline Use only grease that complies with the specified standards see specifications on the container and that possesses the corre sponding properti...

Page 227: ... preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact Long life grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 Lubricant T158 Guideline KTM recommends Lubcon products Supplier Lubcon Turmogrease PP 300 Lubricant...

Page 228: ...products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean...

Page 229: ...g puller 400038 01 Art no 15112018000 Feature 12 16 mm 0 47 0 63 in Insert for bearing puller 400125 01 Art no 15112018100 Feature 18 23 mm 0 71 0 91 in Spring hooks 400363 01 Art no 50305017000 Bleed syringe 400058 01 Art no 50329050000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 230: ...Art no 51012011000 Extractor 400073 01 Art no 58012009000 Tool for inner bearing race 400082 01 Art no 58429037037 Peak voltage adapter 400083 01 Art no 58429042000 Mounting sleeve 400095 01 Art no 58529005000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 231: ...000 Limit plug gauge 400104 01 Art no 59029026006 Extractor 400105 01 Art no 59029033000 Adjustment tool for mixture control screw 400106 01 Art no 59029034000 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 232: ...29012000 Piston ring mounting tool 400123 01 Art no 60029015000 Engine work stand 200306 01 Art no 61229001000 Pressing device for crankshaft complete 400185 01 Art no 75029047000 Protection cover 400167 01 Art no 75029090000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 233: ... blocking screw 400177 01 Art no 77329010000 Assembly pin 400178 01 Art no 77329012100 Internal bearing puller 400038 01 Art no 77329020000 Feature 8 12 mm 0 31 0 47 in Special socket 36 mm drive 301703 01 Art no 77329021000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 234: ...100 Adjustment bush bridge 301381 10 Art no 77329050000 Release device for timing chain tensioner 400181 01 Art no 77329051000 Insert for valve spring lever 400129 01 Art no 77329060000 Spark plug wrench 400170 01 Art no 77329072000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 235: ... no 77629008000 Extrude plate base 400187 01 Art no 77629009001 Extrude plate top 400186 01 Art no 77629009002 Insertion for piston ring lock 400160 01 Art no 77629030000 Gear quadrant 500164 01 Art no 80029004000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 236: ...no 83019001000 Hook wrench 200225 10 Art no 83019002000 Open end wrench attachment 46 mm 500172 01 Art no 83019010461 Hook wrench 600430 01 Art no 83019011000 Press mandrel 600421 01 Art no 83019012000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 237: ...19013000 Camber gauge 500229 01 Art no 83019014000 Handlebar fixation for straight ahead position 200424 10 Art no 83019015100 Extractor 600477 01 Art no 83019020000 Mounting sleeve 600461 01 Art no 83019020100 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 238: ...t no 83019020130 Disassembly assembly holder 600463 01 Art no 83019020150 Press mandrel 600460 01 Art no 83019020170 Push out tool 600452 01 Art no 83019021000 Adapter cable 600402 01 Art no 83029043000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 239: ...fixing arm 301487 10 Art no 83529002000 Extractor 301700 10 Art no 83529048000 Depth micrometer 300577 10 Art no T107S Pin 201235 10 Art no T120 Mounting sleeve 200788 10 Art no T1204 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 240: ...ration pin 200790 10 Art no T1205 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Press drift 200789 10 Art no T1504 Assembly tool 200791 10 Art no T150S P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 241: ...OOLS 239 Mounting sleeve 300578 10 Art no T1554 Hook wrench 200899 10 Art no T157S Nitrogen filling tool 300574 10 Art no T170S1 Mounting sleeve 300578 10 Art no T313 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 242: ...nded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vi...

Page 243: ...n pump installing 147 timing chain guide rail installing 152 timing chain tensioner installing 156 timing chain installing 151 torque limiter installing 159 transmission shafts installing 145 valve clearance adjusting 158 valve clearance checking 158 valve cover installing 159 valve timing adjusting 157 valve timing checking 156 water pump cover installing 154 B Battery installing 83 recharging 84...

Page 244: ...ork on individual parts autodecompressor checking 130 cam levers checking 133 camshaft bearing bridges checking 131 camshaft changing 129 camshafts checking 130 clutch checking 138 connecting rod conrod bearing and crank pin changing 125 countershaft assembling 144 countershaft disassembling 141 crankshaft bearing inner race installing 125 crankshaft bearing inner race removing 125 crankshaft end ...

Page 245: ...28 Front trim installing 70 removing 69 Fuel tank installing 65 removing 64 Fuel tap 66 Fuel oils etc 7 Fuse changing fuses of individual power consumers 85 changing the main fuse 85 H Hand brake lever 88 basic position adjusting 88 free travel checking 88 Handlebar position adjusting 13 Heel protector installing 68 removing 67 Hot start lever 13 I Ignition coil checking 188 Ignition curve changin...

Page 246: ...hing changing 47 shock absorber part number front 10 shock absorber part number rear 11 Spare parts 7 Spark plug connector checking 189 Starter relay checking 87 Stator installing 187 removing 187 Steering column installing 18 removing 14 Steering column bearing changing 16 Storage 216 T Technical data carburetor 208 carburetor tightening torques 209 chassis 210 211 chassis tightening torques 214 ...

Page 247: ... 3206070en 3206070en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 08 2009 Photo Mitterbauer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

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