Description
This 2009 KTM 450 525 XC ATV Repair Manual is an authorized reproduction of the original, out of print manual. It is a printed and bound book providing service and repair information for KTM 450 525 ATVs. This manual features 252 pages of repair information.
Table of Contents
MEANS OF REPRESENTATION
IMPORTANT NOTES
Overview of labels
SERIAL NUMBERS
Chassis number
Type label
Key number
Engine number
Setting number, front shock absorber
Setting number, rear shock absorber
VEHICLE
Raising the vehicle with the lifting gear
Removing the vehicle from the lifting gear
Starting
Starting the vehicle for checking
02/HANDLEBAR, INSTRUMENTS
Adjusting the handlebar position
Adjusting basic position of clutch lever
Checking the throttle cable routing
Checking the play in the throttle cable
Adjusting play in throttle cable
Checking the play in the cable using the reverse gear release lever
Adjusting the cable play on the reverse gear release lever
Detaching the reverse gear cable
Attaching the reverse gear cable
Removing the steering column
Changing the steering column bearing
Installing the steering column
03/FRAME
Removing the engine guard
Installing the engine guard
04/SHOCK ABSORBER, SWINGARM
Front shock absorber – adjusting the compression damping
Front shock absorber – adjusting the rebound damping
Front shock absorber – adjusting the spring preload
Front shock absorber – adjusting the cross over
Removing the front shock absorber
Installing the front shock absorber
Servicing the front shock absorber
Front shock absorber – removing the spring
Front shock absorber – disassembling the damper
Front shock absorber – disassembling the piston rod
Front shock absorber – removing the heim joint
Front shock absorber – installing the heim joint
Front shock absorber – assembling the piston rod
Front shock absorber – assembling the damper
Front shock absorber – bleeding and filling the damper
Front shock absorber – installing the spring
Rear shock absorber – adjusting the compression damping
Rear shock absorber – adjusting the rebound damping
Rear shock absorber – adjusting the spring preload
Removing the rear shock absorber
Installing the rear shock absorber
Servicing the rear shock absorber
Rear shock absorber – removing the spring
Rear shock absorber – disassembling the damper
Rear shock absorber – disassembling the piston rod
Rear shock absorber – removing the heim joint
Rear shock absorber – installing the heim joint
Rear shock absorber – assembling the piston rod
Rear shock absorber – assembling the damper
Rear shock absorber – bleeding and filling the damper
Rear shock absorber – installing the spring
05/EXHAUST
Removing the main silencer
Installing the main silencer
Removing the manifold
Installing the manifold
06/AIR FILTER
Removing the air filter
Installing the air filter
Cleaning the air filter and air filter box
Removing the air filter box lid with the carburetor connection boot
Installing the air filter box lid and the carburetor connection boot
07/FUEL TANK, SEAT, TRIM
Removing the seat
Mounting the seat
Removing the radiator spoiler
Installing the radiator spoiler
Removing the fuel tank
Installing the fuel tank
Fuel tap
08/MASK, FENDER
Removing the front cover
Installing the front cover
Removing the front trim
Installing the front trim
Removing the rear fender
Installing the rear fender
09/FRONT WHEEL
Checking the tire air pressure
Checking the tire condition
Removing wheel/wheels
Mounting wheel/wheels
Checking brake discs
10/REAR WHEEL
Checking chain dirt
Cleaning the chain
Checking the chain, rear sprocket, engine sprocket, and chain guide
Checking the chain tension
Adjusting chain tension
Adjusting the toe width of rear axle
Removing the rear axle
Installing the rear axle
Changing the rear axle bearing
Greasing the rear wheel eccentric element
11/WIRING HARNESS, BATTERY
Ignition curve plug connection
Changing the ignition curve
Removing the battery
Installing the battery
Recharging the battery
Changing the main fuse
Changing the fuses of individual power consumers
Checking the charging voltage
Checking the quiescent current
Checking the starter relay
13/BRAKE SYSTEM
Hand brake lever, parking brake
Checking the free travel of the hand brake lever
Adjusting basic position of hand brake lever
Checking front brake fluid level
Topping up the front brake fluid
Changing the front brake fluid
Checking the front brake linings
Removing front brake linings
Mounting front brake linings
Changing the front brake linings
Checking free travel of foot brake lever
Adjusting basic position of foot brake lever
Checking rear brake fluid level
Topping up brake fluid of rear brake
Changing the rear brake fluid
Checking rear brake linings
Removing rear brake linings
Mounting rear brake linings
Changing rear brake linings
14/LIGHTING SYSTEM, INSTRUMENTS
Checking the headlight setting
Adjusting the headlight range of the headlight
30/ENGINE
Removing the engine
Installing the engine
30/DISASSEMBLING THE ENGINE
Preparations
Removing the shift lever
Draining the engine oil
Removing the oil filter
Removing the starter motor
Removing the clutch cover
Removing the clutch discs
Removing the outer clutch hub
Removing the starter idler gear/torque limiter
Removing the shift shaft
Removing the shift drum locating
Removing the locking lever
Removing the oil pump gear
Removing the primary gear with the free-wheel-gear
Removing the spark plug
Removing the alternator cover
Installing the crankshaft locking bolt
Removing the ignition pulse generator
Removing the rotor
Removing the oil pump gears
Removing the oil line
Removing the timing chain tensioner
Removing the water pump cover
Removing the cylinder head top section
Removing the camshaft
Removing the cylinder head
Removing the cylinder
Removing the piston
Removing the timing chain
Removing the timing chain sprocket
Removing the locking shaft lever
Removing the gear sensor
Taking off the left section of the engine case
Removing the shifting rails and forks
Removing the shift drum
Removing the transmission shaft
Removing the balancer shaft
Removing the crankshaft
30/ENGINE – WORK ON INDIVIDUAL PARTS
Work on the right section of the engine case
Removing the oil pressure regulator valve
Checking the spring length of the oil pressure regulator valve
Installing the oil pressure regulator valve
Work on the left section of the engine case
Changing the crankshaft seal ring in the clutch cover
Checking the camshaft
Disassembling the autodecompressor
Assembling the autodecompressor
Changing the camshaft bearing
Checking the rocker arms and rocker arm shafts
Removing the valves
Checking the valves
Checking the valve springs
Checking the valve spring seat
Checking the cylinder head
Installing the valves
Checking the timing assembly
Preparing the timing chain tensioner for installation
Changing the connecting rod, conrod bearing, and crank pin
Checking the crankshaft run-out on the bearing pin
Measuring the crankshaft end play
Correcting the axial clearance of the crankshaft
Cylinder – Nikasil coating
Checking/measuring the cylinder
Checking/measuring the piston
Checking the piston ring end gap
Piston/cylinder – determining the mounting clearance
Checking the oil pumps for wear
Checking the shift mechanism
Disassembling the shift shaft
Preassembling the shift shaft
Disassembling the main shaft
Checking the main shaft
Assembling the main shaft
Disassembling the countershaft
Checking the countershaft
Assembling the countershaft
Checking/premounting the reverse gear shaft
Checking electric starter operation
Removing the free-wheel
Checking the free-wheel
Installing the free-wheel
30/ENGINE ASSEMBLY
Installing the crankshaft
Installing the balancer shaft
Installing the transmission shaft
Installing the shift forks
Installing the shift drum
Installing the shift rails
Installing the left engine case
Installing the timing chain sprocket
Installing the timing chain rails
Installing the piston
Installing the cylinder
Installing the cylinder head
Installing the timing chain
Installing the camshaft
Installing the cylinder head top section
Installing the timing chain tensioner
Installing the rotor
Checking the valve clearance
Adjusting the valve clearance
Installing the valve cover
Installing the water pump cover
Installing the oil line
Installing the spark plug
Installing the primary gear with the free-wheel-gear
Installing the oil pumps
Installing the ignition pulse generator
Installing the alternator cover
Installing the gear sensor
Installing the locking shaft lever
Installing the locking lever
Installing the shift drum locating
Installing the shift shaft
Installing the starter idler gear/torque limiter
Removing the crankshaft locking bolt
Installing the outer clutch hub and clutch discs
Installing the clutch cover
Installing the starter motor
Installing the oil drain plug
Installing the oil screens
Installing the oil filter
Filling up with engine oil
Installing the shift lever
Installing the clutch push rod
Removing the engine from the universal mounting rack
31/CARBURETOR
Choke
Hot start button
Carburetor – adjusting idle
Checking the position of the throttle position sensor
Emptying the carburetor float chamber
Removing the carburetor
Installing the carburetor
Checking/adjusting the carburetor components
Checking the throttle position sensor
Disassembling the carburetor
Checking the choke slide
Checking the hot start slide
Checking the jet needle
Checking the throttle slide
Checking the needle jet
Checking the float needle valve
Assembling the carburetor
Checking/adjusting the float level
Checking/adjusting the throttle slide opening
Checking/adjusting the accelerator pump
Adjusting the position of the throttle position sensor
32/CLUTCH
Checking fluid level of hydraulic clutch
Changing the hydraulic clutch fluid
33/TRANSMISSION
Removing the engine sprocket
Installing the engine sprocket
35/WATER PUMP, COOLING SYSTEM
Checking the antifreeze and coolant level
Checking the coolant level
Draining coolant
Filling coolant / bleeding cooling system
38/LUBRICATION SYSTEM
Changing engine oil and oil filter, cleaning oil screens
Draining engine oil, cleaning oil screens
Removing the oil filter
Mounting the oil filter
Filling up with engine oil
Checking the engine oil level
Adding engine oil
39/IGNITION SYSTEM
Checking the ignition system
Ignition coil – checking the primary winding
Ignition coil – checking the secondary winding
Checking the spark plug connector
Alternator – checking the stator winding
Checking the ignition pulse generator
40/ELECTRIC STARTER
Checking the starter motor
61/ATV FRONT END
Checking the toe
Adjusting the toe
Checking/adjusting the camber
Adjusting the fork offset
Removing the wheel carrier
Changing the wheel bearing
Installing the wheel carrier
Removing the A-arms
Installing the A-arms
A-arm top – changing the bearing
A-arm bottom – changing the bearing
TECHNICAL DATA-ENGINE
Capacity – engine oil
Capacity – coolant
TECHNICAL DATA – ENGINE TOLERANCES, WEAR LIMITS
TECHNICAL DATA – ENGINE TIGHTENING TORQUES
TECHNICAL DATA – CARBURETOR
450/525 XC ATV
TECHNICAL DATA – CARBURETOR TIGHTENING
TORQUES
TECHNICAL DATA – CHASSIS
Lighting equipment
Tires
Capacity-fuel
TECHNICAL DATA – FRONT SHOCK ABSORBER
TECHNICAL DATA – REAR SHOCK ABSORBER
TECHNICAL DATA – TIGHTENING TORQUES FOR CHASSIS
CLEANING
Cleaning the vehicle
STORAGE
Storage
Preparing the vehicle for use after storage
SERVICE SCHEDULE
Service schedule
Maintenance work (as an additional order)
WIRING DIAGRAM
Wiring diagram
SUBSTANCES
AUXILIARY SUBSTANCES
SPECIAL TOOLS
STANDARDS
INDEX
