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: KTM 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: PDF 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...