KTM 450 SX ATV 505 SX ATV Full Service & Repair Manual 2010-2012

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The 450 SX ATV and 505 SX ATV are high-performance sport ATVs designed for competitive off-road riding and racing, emphasizing agility, power, and aggressive handling. Built with a strong heritage...

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Type: Atv

Vendor:

Sku: 60174

Tags: 2010 2011 2012 450 SX ATV 505 SX 505 SX ATV ATV KTM Powersports

Product variants

Description

The 450 SX ATV and 505 SX ATV are high-performance sport ATVs designed for competitive off-road riding and racing, emphasizing agility, power, and aggressive handling. Built with a strong heritage in motorsports, these models offer robust engineering and reliability, making them a formidable choice in their segment. Their focus on performance is evident in their specialized chassis, powerful engines, and responsive suspension systems, all contributing to an exhilarating riding experience. This service repair workshop manual provides comprehensive guidance for the 2010, 2011, and 2012 model years of the 450 SX ATV and 505 SX ATV. It covers all essential aspects of maintenance, repair, and troubleshooting across all major systems, including the engine, transmission, chassis, and electrical components. With detailed procedures, hundreds of diagrams, and crucial technical specifications, this manual serves as an indispensable resource for owners, mechanics, and technicians to ensure optimal performance and longevity of these sport ATVs.

🏷️ Basic Information

Identification

Make:

Model:

450 SX ATV / 505 SX ATV

Model Variant:

450 SX ATV, 505 SX ATV

Codes

Product Code:

KTM-450-505-SX-ATV-2010-2012-PDF

👋 Introduction

Market Position

Market Segment:

High-performance sport ATV for competitive off-road racing and recreational riding.

Competitive Analysis

Competitors:

Yamaha YFZ450, Honda TRX450R, Suzuki LT-R450, Can-Am DS450.

Key Features

Vehicle Focus:

Agility, power, and performance-oriented for aggressive riding.

Manual Value

Usage Rights:

Lifetime use, no expiry dates, unlimited installations on multiple devices.

📋 Manual Details

Coverage Areas

Coverage Years:

2010, 2011, 2012

Page Count

Estimated Page Count:

Hundreds

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnosis, tuning, lubrication, cooling system, fuel system (carburetor/injection), ignition system, exhaust system.

Transmission:

Clutch, gearbox, final drive, lubrication, troubleshooting, disassembly, assembly.

Chassis:

Frame, suspension (front and rear), steering, wheels, tires, brakes (hydraulic system, calipers, rotors, master cylinders), bearings.

Electrical:

Wiring diagrams, battery, starter, lighting, ignition coil, CDI unit, charging system, switches, fuses, diagnostic connectors.

Bodywork:

Body panels, seat, handlebars, footpegs, plastics, graphics, installation, removal, and repair procedures.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment, brake fluid flush, valve clearance checks.

Troubleshooting:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting, electrical fault finding, engine performance issues.

Repair:

Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major systems.

Technical Specifications:

Torque specifications, clearances, tolerances, fluid capacities, electrical resistance values, compression readings.

Engine Rebuild:

Detailed steps for engine disassembly, inspection, component replacement (pistons, rings, valves, bearings), and reassembly.

Suspension Tuning:

Guidance on adjusting suspension settings for different riding conditions and rider preferences, along with fork seal replacement and shock servicing.

Brake System Overhaul:

Procedures for bleeding brake lines, replacing brake pads, servicing calipers and master cylinders.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine rebuilds and advanced diagnostics.

Diagrams:

Hundreds of detailed photos and exploded diagrams for precise component identification and assembly.

Wiring Schematics:

Comprehensive wiring diagrams for all electrical systems, crucial for troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely searchable text within PDF (standard for professional manuals).

Print Quality

Printability:

Fully printable, single pages or entire document.

Binding Type

Binding Type:

N/A (Digital Download - no physical binding)

Paper Type

Paper Type:

N/A (Digital Download - no physical paper type)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder (SOHC for 450 SX, likely DOHC for 505 SX based on displacement, but needs verification from manual).

Engine Displacement 450:

450cc (approximate)

Engine Displacement 505:

505cc (approximate)

Performance

Horsepower Estimation:

Likely in the 40-50 HP range, dependent on specific model and tuning.

Torque Estimation:

Torque figures would be specific to engine configuration, but emphasizing low-end grunt for off-road.

Fuel System

Fuel Delivery:

Carbureted (likely Keihin FCR series) or Fuel Injection (EFI) depending on exact model variant.

Ignition:

Digital CDI with variable timing.

Lubrication

Oil Type Recommendation:

Full synthetic ATV-specific lubricant, viscosity typically 10W-40 or 20W-50 (requires manual confirmation).

Cooling System

Cooling Method:

Liquid-cooled.

🔧 Transmission

Standard

Transmission Type:

Manual, 5-speed sequential gearbox with reverse (specific features may vary).

Clutch Type:

Wet, multi-plate clutch (hydraulic actuation typical).

Features

Final Drive:

O-ring sealed chain drive.

📐 Dimensions

Weights

Dry Weight:

Likely in the range of 350-400 lbs (159-181 kg) - requires manual confirmation.

Fuel Capacity:

Approximately 2.5-3.0 gallons (9.5-11.4 liters) - requires manual confirmation.

Exterior

Wheelbase:

Specifics vary, but designed for stability in aggressive riding - requires manual confirmation.

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear, often with dual front discs for enhanced stopping power.

Throttle Control:

Standard throttle assembly with safety features. The manual will cover throttle cable adjustments and diagnostics.

Passive Features

Frame Construction:

High-strength steel or aluminum frame, designed for impact resistance. Manual details frame inspection and repair.

💡 Technology Features

Infotainment

Infotainment Features:

N/A - Performance-focused sport ATV with minimal focus on infotainment. Primarily controls and indicators.

Driver Assistance

Driver Assistance Features:

N/A - Designed for rider control, not automated assistance.

Connectivity

Connectivity Features:

N/A - No integrated connectivity features.

Diagnostics

Diagnostic Tools:

The manual provides diagnostic procedures, likely referencing specific diagnostic connectors if present on the model.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 20-40 hours of operation or annually, whichever comes first (manual will specify exact intervals and conditions).

Air Filter Cleaning:

Regular cleaning and oiling is critical, especially in dusty conditions. Manual will detail frequency based on usage.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment. Manual provides specifications.

Valve Clearance:

Periodic checks and adjustments are crucial for engine performance and longevity. Manual provides specific intervals and clearances.

Fluid Specifications

Engine Oil Capacity:

Approximately 1.7-2.0 liters (check manual for exact capacity with/without filter change).

Coolant Type:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Manual specifies type and capacity.

Brake Fluid Type:

DOT 4 hydraulic brake fluid (high temperature, low viscosity). Manual will confirm exact specification.

Known Issues

Common Wear Items:

Brake pads, chain and sprockets, tires, wheel bearings, air filter clogging are common wear items addressed in the manual.

Electrical Gremlins:

While generally reliable, manual covers troubleshooting for common electrical connections and switch issues.

📚 Vehicle History

Brand Heritage

Ktm Atv Legacy:

KTM has a strong heritage in motorsports, particularly motocross and off-road racing, which influences their ATV designs.

Model Evolution

Sx Lineage:

The SX line is KTM's flagship sport ATV series, built for performance and competition.

Production

Production Period:

Manual covers 2010-2012 model years, indicating this was a significant production run for this generation of SX ATVs.

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM ATVs have a history of success in various off-road racing disciplines, implying robust design and engineering.

Ratings

Independent Reviews:

Reviews from the era would typically praise power delivery, suspension, and handling for racing applications (manual does not contain reviews, but background info).

Certifications

Manufacturing Standards:

KTM adheres to strict manufacturing quality standards, which the manual supports through its detailed procedures.