KTM 450 SX ATV User manual

OWNER'S MANUAL 2010
450 SX ATV
505 SX ATV
Art. no. 3211488en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous
pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design can however not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
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 misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 3
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
VIEW OF VEHICLE................................................................ 12
View of the vehicle from the left front (example).................. 12
View of the vehicle from the right rear (example) ................. 14
LOCATION OF SERIAL NUMBERS ......................................... 16
Chassis number................................................................ 16
Type label........................................................................ 16
Engine number................................................................. 17
Shock absorber part number, front ..................................... 17
Shock absorber part number, rear ...................................... 18
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hot start lever .................................................................. 19
Hand brake lever, parking brake......................................... 20
Throttle lever.................................................................... 21
Electric starter button ....................................................... 21
Kill switch/emergency OFF switch with rip cord ................... 22
Opening filler cap............................................................. 22
Closing filler cap .............................................................. 23
Fuel tap........................................................................... 24
Choke.............................................................................. 25
Shift lever........................................................................ 25
Foot brake pedal .............................................................. 26
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................... 27
advice on first use ............................................................ 27
Running in the engine....................................................... 29
RIDING INSTRUCTIONS ....................................................... 31
Checks before putting into operation .................................. 31
Starting ........................................................................... 32
Starting up ...................................................................... 33
Shifting ........................................................................... 34
Braking ........................................................................... 34
Riding ............................................................................. 35
Riding in bends................................................................ 36
Riding downhill ................................................................ 37
Riding uphill.................................................................... 38
Riding perpendicular to the slope....................................... 39
Turning on slopes ............................................................. 39
Riding through water ........................................................ 41
Switching off the engine ................................................... 41
Stopping, parking ............................................................. 42
Refueling......................................................................... 43
SERVICE SCHEDULE............................................................ 45
Important maintenance work to be carried out by an
authorized KTM workshop ................................................. 45
Important maintenance work to be carried out by an
authorized KTM workshop (as an additional order) ............... 47
Important checks and maintenance work to be carried out
by the rider...................................................................... 48
MAINTENANCE ON CHASSIS AND ENGINE ........................... 50
Jacking up the vehicle ...................................................... 50
Removing the vehicle from the work stand .......................... 50
Basic information on changing the chassis settings.............. 50
Compression damping of the shock absorber ....................... 51
Front shock absorber - Adjusting the high-speed
compression damping ....................................................... 51

TABLE OF CONTENTS 4
Front shock absorber - Adjusting the low-speed
compression damping ....................................................... 52
Front shock absorber - adjusting the rebound damping......... 54
Front shock absorber - adjusting the cross over.................... 55
Front shock absorber - adjusting the spring preload ............. 56
Rear shock absorber - adjusting the high speed
compression damping ....................................................... 58
Rear shock absorber - adjusting the low-speed compression
damping .......................................................................... 60
Rear shock absorber - adjusting the rebound damping.......... 61
Rear shock absorber - adjusting the spring preload x......... 62
Removing the rear shock absorber x................................. 64
Installing the rear shock absorber x.................................. 66
Checking the toe x......................................................... 66
Adjusting the toe x......................................................... 69
Checking/adjusting the camber x..................................... 71
Fork offset ....................................................................... 73
Adjusting the fork offset x............................................... 74
Toe width of rear axle........................................................ 74
Adjusting the toe width of rear axle x............................... 75
Handlebar position ........................................................... 77
Adjusting handlebar position x........................................ 78
Checking the play in the throttle cable................................ 80
Adjusting play in throttle cable .......................................... 81
Checking chain dirt .......................................................... 81
Cleaning the chain............................................................ 82
Checking the chain tension ............................................... 82
Checking rear sprocket / engine sprocket for wear ................ 83
Checking chain wear......................................................... 84
Adjusting chain tension..................................................... 85
Greasing the rear wheel eccentric element .......................... 87
Checking brake discs ........................................................ 87
Checking the free travel of the hand brake lever .................. 88
Adjusting basic position of hand brake lever........................ 89
Checking front brake fluid level.......................................... 89
Topping up the front brake fluid x.................................... 90
Checking the front brake linings......................................... 92
Removing front brake linings x........................................ 93
Installing the front brake linings x................................... 94
Changing the front brake linings x................................... 95
Checking free travel of foot brake lever ............................... 97
Adjusting basic position of foot brake lever x.................... 98
Checking rear brake fluid level........................................... 99
Adding rear brake fluid x.............................................. 100
Checking rear brake linings ............................................. 102
Removing rear brake linings x........................................ 103
Installing the rear brake linings x................................... 104
Changing rear brake linings x........................................ 106
Removing wheel/wheels................................................... 107
Installing the wheel/wheels.............................................. 108
Checking the tire condition.............................................. 110
Checking the tire air pressure .......................................... 110
Removing the battery...................................................... 111
Installing the battery....................................................... 112
Recharging the battery x............................................... 113
Changing the main fuse .................................................. 115
Changing the fuses of individual power consumers............. 116
Ignition curve plug connection......................................... 118

TABLE OF CONTENTS 5
Changing the ignition curve ............................................. 118
Removing the seat.......................................................... 119
Mounting the seat .......................................................... 119
Removing the radiator spoiler .......................................... 120
Installing the radiator spoiler ........................................... 121
Removing the front cover................................................. 122
Installing the front cover ................................................. 123
Removing the front trim .................................................. 123
Installing the front trim................................................... 125
Removing the rear fender ................................................ 125
Installing the rear fender................................................. 127
Removing the engine guard ............................................. 129
Installing the engine guard .............................................. 129
Removing the air filter x............................................... 130
Installing the air filter x................................................ 131
Cleaning air filter x....................................................... 132
Adjusting basic position of clutch lever............................. 133
Checking fluid level of hydraulic clutch ............................ 133
Cooling system ............................................................... 134
Radiator fan................................................................... 134
Checking antifreeze and coolant level............................... 135
Checking the coolant level............................................... 136
Draining coolant x........................................................ 137
Filling coolant/bleeding the cooling system x.................. 138
Carburetor - idle ............................................................. 140
Carburetor - adjusting idle x.......................................... 140
Draining the carburetor float chamber x......................... 142
Checking the engine oil level ........................................... 143
Changing the engine oil and oil filter, cleaning the oil
screen x...................................................................... 145
Draining the engine oil x............................................... 145
Cleaning the oil screen x............................................... 146
Removing the oil filter x................................................ 147
Installing the oil filter x................................................ 149
Filling up with engine oil x............................................ 149
Adding engine oil ........................................................... 150
TROUBLESHOOTING.......................................................... 152
CLEANING......................................................................... 156
Cleaning the vehicle ....................................................... 156
STORAGE .......................................................................... 158
Storage.......................................................................... 158
Putting the vehicle into operation after storage.................. 159
TECHNICAL DATA - ENGINE............................................... 160
Capacity - engine oil ....................................................... 161
Capacity - coolant........................................................... 161
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 162
TECHNICAL DATA - CARBURETOR...................................... 165
TECHNICAL DATA - CHASSIS ............................................. 166
Tires ............................................................................. 168
Capacity - fuel................................................................ 168
TECHNICAL DATA - FRONT SHOCK ABSORBER................... 169
TECHNICAL DATA - REAR SHOCK ABSORBER..................... 171
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................... 173
OPERATING SUBSTANCES................................................. 175
AUXILIARY SUBSTANCES................................................... 179
STANDARDS...................................................................... 182

TABLE OF CONTENTS 6
INDEX ............................................................................... 183

MEANS OF REPRESENTATION 7
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed at an authorized KTM workshop! There, your vehicle will be serviced optimally
by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT INFORMATION 8
Use definition
KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid
regulations and categories of the top international motorsport organizations.
Warning
Danger of accidents Incorrect assessment of riding situations.
–The vehicle may only be ridden by persons over the age of 16.
Info
The ATV must be used only on secluded property remote from public road traffic.
The ATV is designed for off-road sport endurance competition (Enduro) and not predominantly for motocross use.
Maintenance
A prerequisite for trouble-free operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such
as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the ser-
vice schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT INFORMATION 9
Spare parts, accessories
For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Transport
Note
Danger of damage Danger of damage from accidental rolling of vehicle.
–Park the vehicle on a surface that is as horizontal as possible and activate the parking brake.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
–Switch off the engine.
–Turn handle of the fuel tap to the OFF position. (Figure 301779-10 p. 24)
–Use straps or other suitable devices to secure the vehicle against accidents or falling over.
–Pull the hand brake lever, push the locking pawl down and release the hand brake lever. (Figure 301776-10 p. 20)
Work rules
Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses.
E.g.: valve spring mounter (59029019000)
When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must
be replaced with new parts.

IMPORTANT INFORMATION 10
If a thread locker (e.g. Loctite®) is used for screw connections, follow the instructions for use from the 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.
Environment
Off-road riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem
for the environment and can lead to conflicts with other persons. But if you use your vehicle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of off-road sport, make sure that you use your ATV legally, display environ-
mental consciousness, and respect the rights of others.
Rider training
If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the
first time.
A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain.
Your KTM dealer will be glad to advise you.
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 labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.

IMPORTANT INFORMATION 11
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains a lot of information
and tips to help you operate and handle your vehicle. Only then will you find out how to customize the vehicle ideally for your own use
and how you can protect yourself from injury. The owner's manual also contains important information on servicing the vehicle.
–The owner's manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE 12
3.1View of the vehicle from the left front (example)
301769-10

VIEW OF VEHICLE 13
1 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

VIEW OF VEHICLE 14
3.2View of the vehicle from the right rear (example)
301770-10

VIEW OF VEHICLE 15
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

LOCATION OF SERIAL NUMBERS 16
4.1Chassis number
301771-10
The chassis number is stamped on the right side of the frame in the vicinity of the upper
control arm.
4.2Type label
301858-10
The type label is located on the frame tube on the right and left in front of the radiator.

LOCATION OF SERIAL NUMBERS 17
4.3Engine number
301772-10
The engine number is stamped on the left side of the engine under the engine sprocket.
4.4Shock absorber part number, front
301832-10
The shock absorber part number is stamped on the upper part of the shock absorber.

LOCATION OF SERIAL NUMBERS 18
4.5Shock absorber part number, rear
301831-10
The shock absorber part number is stamped on the upper part of the shock absorber.