SPAREPARTSCATALOG: // CHASSIS 450 SMR 2014 ART.-NR.: 3CFF8403N0EN

Transcription

1 SPAREPARTSCATALOG: // CHASSIS ART.-NR.: 3CFF8403N0EN

2 CONTENT FRONT FORK, TRIPLE CLAMP FRONT FORK DISASSEMBLED 4 SHOCK ABSORBER HANDLEBAR, CONTROLS 5 SHOCK ABSORBER DISASSEMBLED 9 EXHAUST SYSTEM 7 PRO LEVER LINKING 10 AIR FILTER 13 FRAME SWING ARM 11 TANK, SEAT, COVER FUEL PUMP CHASSIS // 1

3 CONTENT MASK, FENDERS DECAL 17 WIRING HARNESS FRONT WHEEL 18 HAND BRAKE CYLINDER 21 BRAKE CALIPER REAR 19 REAR BRAKE CONTROL 22 ACCESSORIES KIT 25 REAR WHEEL 20 BRAKE CALIPER FRONT WP SHIMS FOR SETTING CHASSIS // 2

4 CONTENT All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTMSPORTMOTORCYCLE AG, Mattighofen only. CHASSIS // 3

5 FRONT FORK, TRIPLE CLAMP 1* 14187M0801 FORK WP 450 SMR HH COLLAR SCREW M8X50 TX HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X35 TX S HH COLLAR SCREW M8X25 TX S AH-COLLAR SCREW M10X35 ISA STE.HEAD SCR. M20X1,5 WS=27 SL SELF-LOCKING O-RING 25X3,55 NBR * SCREW F. PLASTIC K60X20AL SW6 2 32* BOTTOM TRIPLE CLAMP CPL FORK TUBE L=244MM 1 34* TOP TRIPLE CLAMP SMR X=16MM STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP 28MM XC HANDLEB.SUPP. D=28MM H=32MM 05 x HANDLEB.SUPP. D=28MM H=37MM HANDLEB.SUPP. D=28MM H=42MM 05 x TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F.SPEED.CABLE D=6MM STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS= FORK PROTECT. L/S+R/S WHITE HANDLEBAR SUPPORT KIT D28/H37 x STEARING HEAD REP. KIT x C CHASSIS // 4

6 FRONT FORK DISASSEMBLED S ADJUSTING KNOB + SCREW GUIDING RING D=58MM OUTER TUBE L577 D54/60MM FORK PROTECTION RING GUIDING BUSH 48X52X12 R SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING D48 SKF LOCK WASHER SB DUST SEAL DL D48 SKF GUIDING BUSH 47X49X20 R MEMBRANE O-RING NBR 9,5X1, O-RING NBR 17X2 PA S SCREW BUSH M20X1 L=33 CPL COPPER WASHER 20,5X26X ADJUSTING TUBE L PISTON ROD D=12 M9X1 L= COUNTERNUT M12X1 WS ADJUSTER NEEDLE O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM S SPRING 4,8 N/MM SET D=5,25MM x S SPRING D43.2 L465 5N/MM SET x SPACER 43X35X2,5 x SPACER 43X35X5 x SPACER 43X35X1,5 x GUIDING BUSH REBOUND SPRING SPRING SUPPORT O-RING 6X1,2 NBR SPRING REB. L=32 C=37 DI=13, PISTON ROD REBOUND SHUTTLE VALVE SPRING C=0, SPRING CHECK VALVE D=0, S3 MEMBRANE HOLDER INKL. PIN SET LOCK WASHER D=25, AH SCREW M4X O-RING NBR 21X PISTON COMPRESSION D=27, C CHASSIS // 5

7 FRONT FORK DISASSEMBLED O-RING NBR 4X1, S PIN KIT NUT M6X0,5 REBOUND GUIDE RING 44 X RING SPRING-SUPPORT O-RING NBR 46 X S2 AXLE CLAMP S1 FORK AX.PASS + TUBE CPL HH COLLAR SCREW M8X25 TX CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0, PISTON ROD COMPRESSION PISTON REBOUND SX PISTON RING 5X1X RING 23,45X8, PISTON ROD SEALING S SCREW SLEEVE M24,5X1 CPL DU BUSH FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D= SILICON CAP RUBBER CAP D=26, S1 FORK OIL SAE4 5L O-RING NBR 43X S1 SCREW CAP CPL. L= SCREW M4X MEMBRANE SLEEVE 2 98 T511 SILICONE GREASE F. DUST STRI 1 99 R14020 SXS SERVICE KIT C CHASSIS // 6

8 HANDLEBAR, CONTROLS HANDLEBAR RENTHAL BLACK * BAR PAD RENTHAL SHORT CIRCUIT BUTTON STARTER BUTTON GREY HOLDER INDICATOR LIGHT SX SPECIAL SCREW M6X12,5 WS= INDICATOR LIGHT LED YELLOW FI THROTTLE GRIP CPL GRIP SET CABLE TIE 140/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x * HANDGUARDS CLOSED 1 30* MASTER CYLINDER CPL CLUTCH LEVER CPL. BREMBO REP. KIT PISTON * COVER HYD. CLUTCH CPL VALVE BOLT KPL BRAKE FLUID DOT5.1 0,25L PROTECTION CAP LEVER SCREW CPL PUSH ROD CPL CLAMP CPL CLUTCH PIPE THROTTLE CABLE 4T C CHASSIS // 7

9 FRAME BE FRAME ANTRAZIT "789M3" SUB FRAME SX 1 3* SUB FRAME APPLICATION LEFT 1 4* SUB FRAME APPLICATION RIGHT REINFORCING RUBBER CABLE TIE 75MM TANK REST RUBBER S HH COLLAR SCREW M8X16 TX WIRING HOLDER 16MM ENGINEBRAC.SCREW M10X123 WS= S FLAT HEAD SCREW M. ISA45 M8X HH COLLAR SCREW M 8X44 WS BLIND PLUG-IN NUT M5 WN 22A CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X BUSH F. FRAME PROTECTION CABLE TIE 140/2,5MM BLACK x SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X30 TX * FOOTREST L/S 1 40* FOOTREST R/S BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN X25 NIRO 2 45* FOOTREST CPL ANGLE PIECE ' PVC-HOSE 7X10 PER METER CHAIN GUARD 450/500 EXC CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX x PLASTIC FRAME PROTECTION SET CHAIN SLIDING KIT BELOW CPL SPROCKET COVER KIT x C CHASSIS // 8

10 SHOCK ABSORBER M0801 MONOSHOCK LINK 450 SMR HH COLLAR SCREW M10X52 SW C CHASSIS // 9

11 SHOCK ABSORBER DISASSEMBLED SA1 MONOSHOCK BOTTOM PART CPL ADAPTOR-BUSH M10x1,50, D= BUMP RUBBER RESERVOIR CAP D=50 H= CIRCLIP 53X1, S3 ADAPTER D50 H28 CPL REBOUND SPRING REBOUND RUBBER SPRING RING SA ADAPTER D50 H28 CPL SHIM D29,75 X D19 X T0, DU-BUSH 18X20X O-RING 41X DUST SEAL PISTON ROD NUT M16X S PISTON D REBOUND DISC D43 H CIRCLIP 58,2X VALVE SPRING D80 CLOSED SPACER RING ADJUSTING NUT S SPRING N/MM D11,5 OR. x S SPRING N/MM D11,75 OR S SPRING N/MM ORANGE x SPACER RING SPRING 61,3X78X ADJUSTING NUT PLASTIC TENSIONING RING D64 H %ALLENHEAD SCREW M5 L=20 STAIN RUBBER CAP "DO NOT OPEN" SCREW PLUG M5X O-RING NBR 5,28X1, S15 DCC COMPR.DAMP.CON. SX 12 LINK BLEED PLUG R 1/ S1 MONOSHOCK UPPER PART CPL R12012 REP. KIT BEAR./SEAL UP BUSH KGW 10X STICKER WP MONOSHOCK S1 SHOCK ABSORBER FLUID 5 LT 1 99 R12018 REPAIR-KIT C CHASSIS // 10

12 PRO LEVER LINKING TRIANGLE LEVER CPL. SX PULL ROD CPL PULL ROD ANCHOR BOLT NEEDLE BUSH HK SHIM 20X32X SHAFT SEAL RING 25X32X BUCKET SHAFT SEAL RING 25X BUSHING SLEEVE 15 X 20 X SHIM D29,75 X D19 X T0, SHAFT SEAL RING 24X30X BUCKET FOR SHAFT SEAL RING BOLT FOR CANTILEVER M HEX NUT M14X1.5 SW BEARING SLEEVE 10X18X25, NEEDLE BUSH HN1816 RS 18/24/ BEARING SLEEVE NEEDLE BEARING HK X28X SHAFT SEAL RING G22x28x STEEL WASHER 15,2X19X0,1 x STEEL WASHER 15,2X19X0,2 x STEEL WASHER 15,2X19X0,3 x TRIANGLE LEVER REP. KIT REAR x TRIANGLE LEVER REP. KIT FRONT x PULL ROD REP. KIT SX/SX-F x C CHASSIS // 11

13 SWING ARM 2* SWING ARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR EJOT SPIRAL SCREW SF M5X10-K BRAKE LINE GUIDE SPECIAL SCREW M6X13 WS= BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X BEARING SLEEVE 17X22X38, NEEDLEBEAR HK2212V 22/28/12 MB STOP DISK 22,2X31,7X1 2 14* CHAIN GUIDE REAR CPL. SX SPECIAL SCREW M6X19 WS= HH COLLAR SCREW M6X45 TX BUSH. F. CHAIN FAIL. PROT SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC CHAIN STOP GUARD SMR SCREW FOR PLASTIC K60X20 SW6 1 98* CHAIN GUIDE KIT REAR SX-F SWINGARM REP. KIT x C CHASSIS // 12

14 EXHAUST SYSTEM 1* SILENCER THERMAL PROTECTION FOIL THERMAL PROTECTION FOIL 1 4* SILENCER HOUSING 1 8* CONNECTING CAP CPL BUSHING 7.5x12x28x SPRING WASHER DIN0137-B BUSHING 7.5x12x20x DAMP. COMPON. BLACK O-RING 74,00X1,50 FKM 75SH HH COLLAR SCREW M6X30 TX EXHAUST BRACKET RUBBER BLACK TEN.SPRING L=62MM EY.MOVEABLE TEN.SPRING L=75MM EY.MOVEABLE SCREW TORX M5X * ENDCAP CPL ROCKWOOL PREFORMED EXHAUST SX-F HH COLLAR SCREW M8X25 TX BUSHING FOR EXHAUST SUPPORT EXHAUST PARTS KIT x C CHASSIS // 13

15 AIR FILTER 1* C AIR BOX COVER R/S SX COLLAR BUSH. F.REAR FENDER * C AIR BOX COVER L/S SX FILTER BOX CPL. WHITE HH COLLAR SCREW M6X20 TX QUICK RELEASE-NIPPLE BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX 1 11* AIR BOX CLIP AIR FILTER FILTER CARRIER FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX INTAKEBOOT HOSE CLAMP 45-65MM 1 51* SCREW F. PLASTIC K60X20AL SW BUSHING F. CHAIN SLIDING PR SPLASH PROTECTOR KIT SX/EXC x C CHASSIS // 14

16 TANK, SEAT, COVER SCREW SEAT FASTENING D=6X23/ PVC-HOSE 5,6X10X270MM 1 8* TANK PLUG CPL * FUEL TANK CPL. 7,5L EFI SX TANK ROLLER 12X26X12 ' * SCREW F. PLASTIC K60X20AL SW ANGLE PIECE 90 DEGREE M10X1 1 35* SEAT SEAT COVER 1 50* C SPOILER KIT SX 2014 WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X12 TX C CHASSIS // 15

17 FUEL PUMP GASKET KIT FILTER KIT FUEL PUMP CPL. EXC NUT F. FUEL PUMP M FUEL CONNECTOR M VARIABLE ONE-EAR CLAMP 15,7MM FUEL HOSE DKK O-RING VITON F. PLUG CPC CLUTCH CPC BLACK CONNECTOR FUEL PUMP FUEL FILTER EJOT PT SCREW K60X25-Z SW= C CHASSIS // 16

18 MASK, FENDERS START NUMBER PLATE CPL. WHITE BRAKE HOSE GUIDE BLACK * SCREW F. PLASTIC K60X20AL SW HH COLLAR SCREW M6X10 TX30 1 6* HH COLLAR SCREW M6X16 TX FENDER FRONT SMR SPACER BUSHING HH COLLAR SCREW M6X20 TX COLLAR BUSH. F.REAR FENDER REARPART ORANGE SX COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M6X25 TX C CHASSIS // 17

19 DECAL 1* DECAL NUMBER PLATE SX/XC * DECAL REARPART C CHASSIS // 18

20 FRONT WHEEL FRONT WHEEL 3,5X16,5 SMR FRONT WHEEL HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL * SPACER BUSHING F. FR. WHEEL SPOKE M4,5X164-16,5" SPOKE NIPPLE M4,5X0,75 8X FRONT RIM 3,5X16,5" RIM BAND 17" 1 19* BRAKE DISC SUPPORT SM WAVE BRAKE DISC FRONT * SPECIAL SCREW M6X26 SW= * WHEEL SPIN.FR. D=26MM SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= AUXILIARY SCREW FRONT C CHASSIS // 19

21 REAR WHEEL REAR WHEEL CPL. 5X17" SMR REAR WHEEL HUB CPL BEARING DISTANCE TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL DISTANCE BUSHING REAR WHEEL SPOKE M5X174-13,5G 17" SPOKE NIPPLE M5-TA 8X21MM REAR RIM 5,0X17" BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 17" DISTANCE RING REAR WHEEL REP. KIT x REAR SPROCKET 38-T x REAR SPROCKET 40-T x REAR SPROCKET 42-T x REAR SPROCKET 45-T x REAR SPROCKET 48-T x REAR SPROCKET 49-T x REAR SPROCKET 50-T x REAR SPROCKET 51-T x REAR SPROCKET 52-T x S COUNTER-SUNK SCREW ISA45 M8X HEXAGON NUT DIN EN1661 M8 SW CHAIN 5/8X1/4" MX CONNECTING LINK F WHEEL SPINDLE CPL. ' CHAIN TENSIONER R/S SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= COLLAR NUT M25X1,5 WS= C CHASSIS // 20

22 WIRING HARNESS 1* WIRING HARNESS SX-F VOLTAGE REGULATOR CABLE TIE 140/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x CABLE GUIDE WIRING HOLDER 16MM x RETAINING PLATE CONDENSATOR CONDENSATOR HH COLLAR SCREW M5X30 TX HH COLLAR SCREW M6X20 TX * ELECTRIC BOX INDICATOR LIGHT LED YELLOW FI HOLDER INDICATOR LIGHT SX SPECIAL SCREW M6X12,5 WS= GROUND CABLE D=6MM L=140MM ' CONTACT WASHER M6 VSV-K EJOT SPIRAL SCREW SF M5X10-K SELF LOCK. NUT DIN0985-M PROTECTION CAP F. STARTER ENG STARTERCABLE 700 MM ' STARTER RELAY 12V ' FUSE 10 A RELAY CM1A-R-12V-H WIRING HARNESS BATTERY DUKE' BATTERY 12V 3AH YTX4L-BS RUBBER L=145MM BATTERY BOX 1 29* SCREW FOR PLASTIC K60X20 SW AH OVAL SCREW ISO 7380 M 6X DUMMY PLUG MAPSELECTSWITCH END PLUG CAN-BUS HH COLLAR SCREW M5X12 TX BUSHING CONENSATOR BRACKET 2 35* ECU SPLASH PROTECT. 1 36* SCREW FOR PLASTIC K50X18 T C CHASSIS // 21

23 HAND BRAKE CYLINDER 1* HAND BRAKE CYLINDER 1 2* BRAKE FLUID RESERVOIR CPL. 1 3* SCREW + NUT F. RESERVOIR 2 4* SCREW RET.PANEL-RESERVOIR 1 5* RUBBER BUSH * RET.PANEL FLUID RES. FRONT * SCREW RET.PANEL-BRAKE CYLINDER 1 8* NUT FOR RESERVOIR 1 9* HOSE FOR RESERVOIR 6X1,5 x 10* YDNAC CLAMP (10,4MM) 2 11* HAND BRAKE LEVER CPL * RUBBER CUP * LEVER SCREW CPL * BLEEDER SCREW WITH CAP 1 16* ANGLE PIECE 1 17* CLAMP CPL. BLACK BRAKE FLUID DOT5.1 0,25L C CHASSIS // 22

24 REAR BRAKE CONTROL REAR BRAKE CYLINDER CPL.SX REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX HOLLOW SCREW BLACK M10X1X BRAKE HOSE REAR XXXMM COPPER GASKET DIN X14X FOOT BRAKE LEVER CPL STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX RETURN SPRING FOR BRAKE LEVER S HH COLLAR SCREW M6X20 TX PUSH ROD L=28MM SELF LOCK. NUT DIN0985-M SWIVEL HEAD KA S AH-COLLAR SCREW M10X40 ISA SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= BALL BEARING SKF RS COLLAR NUT M10 WS= HH COLLAR SCREW M6X12 TX BRAKE FLUID DOT5.1 0,25L C CHASSIS // 23

25 BRAKE CALIPER FRONT 1* BRAKE CALIPER FRONT - W/O PADS WASHER 10,2X20X2,5 MM AH-COLLAR SCREW M10X1,25X55 2 4* HOLLOW SCREW BLACK M10X1X19 1 5* BRAKE PADS TT2910HH 1 7* SEAL RINGS CPL. 1 8* SPRING PLATE 1 9* BRAKE PISTON CPL. 1 10* BLEEDER SCREW WITH CAP 1 11* COPPER GASKET DIN X14X1 2 12* BRAKE PIPE FRONT C CHASSIS // 24

26 BRAKE CALIPER REAR BRAKE CAL. REAR - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM RETAINING SPRING SET BRAKE CALIPER BRACKET REAR CUP SET SHORT BRAKE HOSE REAR XXXMM BLEEDER SCREW CPL COPPER GASKET DIN X14X C CHASSIS // 25

27 ACCESSORIES KIT KTM BALLPOINT PEN ORANGE * CUSTOMER WELCOME LETTER DOCUMENTS BAG FOOTREST CPL PLASTIC FRAME PROTECTION SET AIR FILTER OIL 100ML BAR PAD RENTHAL BATTERY 12V 3AH YTX4L-BS HH COLLAR SCREW M5X12 TX CONTACT WASHER M6 VSV-K PRINT LABEL 60X51 MM WASH CAP SET GB POWER WEAR FOLDER * HANDGUARDS CLOSED SPARK PLUG SOCKET EN OWN. MANUAL 450 SMR TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F T-WRENCH WS=6/8/10/TX45/SK4X SPOKE-SPANNER WS 7/ C CHASSIS // 26

28 WP SHIMS FOR SETTING WASHER 5X15X2 x SHIM 6X12X0,1 x SHIM 6X14X0,1 x SHIM 6X16X0,1 x SHIM 6X18X0,1 x SHIM 6X12X0,15 x SHIM 6X14X0,15 x SHIM 6X16X0,15 x SHIM 6X18X0,15 x SHIM 6X12X0,2 x SHIM 6X14X0,2 x SHIM 6X16X0,2 x SHIM 6X18X0,2 x * SHIM 6X20X0,20 x SHIM 6X12X0,25 x SHIM 6X14X0,25 x SHIM 6X16X0,25 x SHIM 6X18X0,25 x SHIM 6X8,5X0,10 x SHIM 6X9X0,10 x SHIM 6X9,5X0,10 x SHIM 6X9,5X0,15 x SHIM 6X8,5X0,20 x SHIM 6X9X0,20 x SHIM 6X9,5X0,20 x SHIM 6X10X0,3 x SHIM 6X9X0,3 x SHIM 6X9,5X0,3 x SHIM 6X18X0,4 x SHIM 6X18X0,1 DELTA x SHIM 6X11X0,1 x SHIM 6X11X0,3 x SHIM 6X11X0,2 x SHIM 6X10X0,20 x SHIM 6X10X0,1 x SHIM 6X10X0,15 x SHIM 6X11X0,15 x SHIM 6X8,0X0,30 x C CHASSIS // 27

29 WP SHIMS FOR SETTING SHIM 6X8,0X0,10 x SHIM 6X8X0,3 x SHIM 6X11X0,25 x * SHIM 6X24X0,25 x SHIM 6X24X0,1 x SHIM 6X22X0,1 x SHIM 6X20X0,1 x SHIM 6X20X0,15 x SHIM 6X24X0,15 x SHIM 6X24X0,1 DELTA x SHIM 6X22X0,1 DELTA x BACKPLATE 6X10X0,25 x SHIM 6X13X0,1 x SHIM 6X15X0,1 x SHIM 6X17X0,1 x SHIM 6X19X0,1 x * SHIM 6X20X0,25 x SHIM 6X22X0,15 x * SHIM 6X22X0,25 x BACKPLATE 6X8,5X0,30 x SHIM 6X20X0,1 T/3H x SHIM 6X21X0,1 x SHIM 6X23X0,1 x * SHIM 6X12X0,3 x SHIM 6X17X0,15 x SHIM 6X28X0,10 x SHIM 6X26X0,10 x SHIM 6X28X0,15 x SHIM 6X26X0,15 x SHIM 8X18X0,4 x SHIM 8X18X0,10 x WASHER 8,4X16X0,8 x WASHER 8,2X15X1 x WASHER 8,2X11X1 x SHIM 8X16X0,1 x SHIM 8X11X0,2 x CHECK VALVE 8X20X0,1 x CHECK VALVE 8X24X0,4 x C CHASSIS // 28

30 WP SHIMS FOR SETTING CHECK VALVE 8X24X0,1 x CHECK VALVE 8X22X0,1 x SHIM 8X10X0,20 x SHIM 8X16X0,20 x SHIM 8X14X0,10 x CHECK VALVE 8X11X0,1 x CHECK VALVE 8X12X0,1 x SHUTTLE VALVE 8X20X0,4 x SHIM 8X17X0,10 x SHIM 10X16X0,10 x SHIM 10X16X0,2 x SHIM 10X16X0,30 x SHIM 10X18X0,30 x SHIM 10X19X0,15 x SHIM 10X23X0,15 x SHIM 10X25X0,15 x SHIM 10X27X0,15 x SHIM 10X29X0,15 x SHIM 10X31X0,15 x SHIM 10X33X0,15 x SHIM 10X21X0,20 x SHIM 10X23X0,20 x SHIM 10X25X0,20 x SHIM 10X27X0,20 x SHIM 10X29X0,20 x SHIM 10X31X0,20 x SHIM 10X33X0,20 x SHIM 10X21X0,25 x SHIM 10X23X0,25 x SHIM 10X25X0,25 x SHIM 10X27X0,25 x SHIM 10X19X0,30 x SHIM 10X21X0,30 x WASHER 10X35X0,15 x * SHIM 10X29X0,25 x * SHIM 16X24X0,10 x SHIM D10XD22X2,5 x SHIM 12X24X0,20 x C CHASSIS // 29

31 WP SHIMS FOR SETTING SHIM 12X26X0,20 x SHIM 12X28X0,20 x SHIM 12X30X0,20 x SHIM 12X32X0,20 x SHIM 12X34X0,20 x SHIM 12X36X0,20 x SHIM 12X38X0,20 x SHIM 12X40X0,20 x SHIM 12X24X0,25 x SHIM 12X26X0,25 x SHIM 12X28X0,25 x SHIM 12X30X0,25 x SHIM 12X34X0,25 x SHIM 12X36X0,25 x SHIM 12X40X0,25 x SHIM 12X24X0,30 x SHIM 12X26X0,30 x SHIM 12X28X0,30 x SHIM 12X32X0,30 x SHIM 12X34X0,30 x SHIM 12X26X0,15 x SHIM 12X28X0,15 x SHIM 12X30X0,15 x SHIM 12X32X0,15 x SHIM 12X34X0,15 x SHIM 12X36X0,15 x SHIM 12X38X0,15 x SHIM 12X40X0,15 x SHIM 12X20X0,10 x SHIM 12X22X0,10 x SHIM 12X23X0,10 x SHIM 12X24X0,10 x SHIM 12X27X0,15 x SHIM 12X18X0,15 x SHIM 12X19X0,15 x SHIM 12X22X0,15 x BACKPLATE 12X16X0,30 x BACKPLATE 12X17X0,30 x C CHASSIS // 30

32 WP SHIMS FOR SETTING BACKPLATE 12X18X0,30 x SHIM 12X19X0,30 x BACKPLATE 12X21X0,30 x BACKPLATE 12X30X0,10 x SHIM 12X20X0,25 x SHIM 12X22X0,25 x SHIM 12X32X0,10 x SHIM 12X32X0,25 x * SHIM 12X24X0,15 x SHIM 12X20X0,30 x SHIM 14,5X35,4X1,25 x * SHIM 16X23X0,20 x SHIM x BACKPLATE 16X20X0,10 x SHIM 16X21X0,10 x SHIM 16X21X0,25 x WASHER 16X21X1 x SHIM 16X22X0,10 x SHIM 16X22X0,20 x SHIM 16X23X0,30 x SHIM 16X24X0,30 x SHIM 15X25X0,25 x SHIM 16X25X0,30 x SHIM 16X26X0,10 x SHIM 16X26X0,15 x SHIM 16X26X0,20 x SHIM 16X26X0,30 x SHIM 16X28X0,10 x SHIM 16X28X0,15 x SHIM 16X28X0,20 x SHIM 16X28X0,25 x SHIM 16X28X0,30 x SHIM 16X30X0,15 x SHIM 16X30X0,20 x SHIM 16X30X0,25 x SHIM 16X30X0,30 x SHIM 16X32X0,15 x SHIM 16X32X0,20 x C CHASSIS // 31

33 WP SHIMS FOR SETTING SHIM 16X32X0,25 x SHIM 16X32X0,30 x SHIM 16X34X0,10 x SHIM 16X34X0,15 x SHIM 16X34X0,20 x SHIM 16X34X0,25 x SHIM 16X34X0,30 x SHIM 16X36X0,15 x SHIM 16X36X0,20 x SHIM 16X36X0,25 x SHIM 16X36X0,30 x SHIM 16X38X0,15 x SHIM 16X38X0,20 x SHIM 16X38X0,25 x SHIM 16X38X0,30 x SHIM 16X40X0,15 x SHIM 16X40X0,20 x SHIM 16X40X0,25 x SHIM 16X40X0,30 x SHIM 16X42X0,15 x SHIM 16X42X0,20 x SHIM 16X42X0,25 x SHIM 16X42X0,30 x SHIM 16X44X0,15 x SHIM 16X44X0,20 x SHIM 16X44X0,25 x SHIM 16X44X0,30 x WASHER 16X8,2X0,6 x SHIM 16X26X0.25 x BACKPLATE 16X20X0,30 x BACKPLATE 16X21X0,30 x BACKPLATE 16X22X0,30 x SHIM x * SHIM 16X24X0,20 x * SHIM 16X20X0,25 x SHIM x PRESSURE-RING 20X16,25X0,20 x SHIM 20X24X0,30 x C CHASSIS // 32

34 WP SHIMS FOR SETTING SHIM 20X36X0,20 x SHIM 20X38X0,20 x SHIM 20X40X0,20 x SHIM 20X40X0,25 x SHIM 20X34X0,25 x SHIM 20X24X0,25 x SHIM 20X34X0,20 x RING 20X22,9X1 x SHIM 20,2X28X0,20 x SHIM 20X36X0,25 x SHIM 20X38X0,25 x SHIM 20,2X28X0,25 x WASHER 21X36X0,25 x * PRESS. RING 22X18X0,30 x SHUTTLE VALVE 23X38X0,25 x SHIM D23XD16X2 x WASHER 24,5X34X2 x SHIM 28,5X14X2 x SHIM 28,5X14X5 x WASHER 32X42X2,5 x SHIM 32X45X2 x PRESSURE RING 36X32,25 x SHIM 52X59X2,2 x C CHASSIS // 33

35 SPAREPARTSCATALOG: // ENGINE ART.-NR.: 3CM089580NEN

36 CONTENT ENGINE CASE CLUTCH COVER 3 CRANKSHAFT, PISTON BALANCER SHAFT 4 CLUTCH 7 SHIFTING MECHANISM 5 TRANSMISSION I - MAIN SHAFT 8 WATER PUMP 11 CYLINDER TRANSMISSION II - COUNTERSHAFT 9 COOLING SYSTEM VALVE DRIVE ENGINE // 1

37 CONTENT TIMING DRIVE CYLINDER HEAD 16 ELECTRIC STARTER LUBRICATING SYSTEM 17 IGNITION SYSTEM THROTTLE BODY All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTMSPORTMOTORCYCLE AG, Mattighofen only. ENGINE // 2

38 ENGINE CASE 1* ENGINE CASE CPL MAIN JET OIL JET 70 M CASE BUSH DOWEL 21X DOWEL 6X8X11, DOWEL 17 X 13 X O-RING 3,5X2,00 NBR OIL JET ANGLED AH.SCREW DIN0912-M 4X CU-SEAL RING DIN X18X1, OILDRAIN PLUG W.MAG. M 12X1, INT. TORX OVAL HEAD M 5X TAB WASHER BEARING MAIN SHAFT TAB WASHER BEARING COUNT.SHAFT S INT. TORX FLAT HEAD M5X12 T HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X60 TX HH COLLAR SCREW M6X75 TX HH COLLAR SCREW M6X80 TX HH COLLAR SCREW M6X85 TX GASKET SET 450/500 EXC C ENGINE // 3

39 CLUTCH COVER 1* CLUTCH COVER CPL CLUTCH COVER OUTSIDE GASKET - CLUTCH OUTER COVER 1 4* CLUTCH COVER GASKET OIL LEVEL GLASS VITON CIRCLIP OIL LEVEL GLASS DOWEL 9,8 X 7 X O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R SHAFT SEAL RING 14X24X6 B SHAFT SEAL RING 12X30X7 PTFE NEEDLE BUSH NK LOCATING SCREW HH COLLAR SCREW M6X25 TX CU-SEAL RING 8 X 14 X HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M6X60 TX C ENGINE // 4

40 BALANCER SHAFT BALANCE SHAFT BALANCE SHAFT GEAR BALANCE SHAFT WOODRUFF KEY DIN6888-3X3, NEEDLE BUSH NK C ENGINE // 5

41 CYLINDER 1* CYLINDER + PISTON CPL DOWEL 6X8X11, CYLINDER BASE GASKET DOWEL BUSHING 10,2X12,5X C ENGINE // 6

42 CRANKSHAFT, PISTON CRANKSHAFT CPL CON. ROD. REP. KIT 1 3* I PISTON D=95MM 1 3* II PISTON D=95MM COMPRESSION RING OIL SCRAPER RING PISTON PIN CIRCLIP BALL BEARING 6207 TM-SX07E NUT PRIMARY WHEEL M20X1, PRIMARY GEAR TIMING GEAR 18T WOODRUFF KEY DIN6888-3X3, SHAFT SEAL RING 35X47X7 VITON WOODRUFF KEY DIN6888-3X5X PISTON KIT GR.I 450 SX-F x PISTON KIT GR.II 450 SX-F13-14 x CRANKSHAFT REP. KIT 450 SX-F13 x C ENGINE // 7

43 CLUTCH PUSH ROD COLLARSLEEVE NEEDLE BEAR K 25X29X CLUTCH CAGE WASHER 21,8 X 37 X HUB OUTSIDE SLEEVE HUB INSIDE PRESSURE PLATE OPENING SPRING APTC CLUTCH SPRING APTC WASHER 20 X 12,5 X WASHER 20 X 12,5 X 1,5 x WASHER 5,5X20X1, HH COLLAR SCREW M5X25 ISA TAB WASHER HEXAGON NUT DIN0936-M18X1,5 R LINING DISC 2MM INTERMEDIATE DISC 1,4MM INTERMEDIATE DISC 1MM INTERMEDIATE DISC 1MM PRESSURE PIECE CPL GASKET FOR SLAVE CYLINDER O-RING PISTON CPL PRESSURE SPRING OUTPUT CYLINDER CPL BLEEDER SCREW CPL CLUTCH PIPE COPPER GASKET DIN X14X HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X16 TX VENT INJEKTION HYDR. CLUTCH CLUTCH DISC KIT C ENGINE // 8

44 TRANSMISSION I - MAIN SHAFT 1* MAIN SHAFT 16 T. 1 2* IDLER GEAR 5.G SLIDING GEAR 3/4 G. 1 5* SOLID GEAR 2.G STOP DISC 17,2X30X NEEDLE BEAR. K 22X26X13 TN SPACER SLEEVE CIRCLIP DIN X1, STOP DISK 26 X 32 X 1, BUSHING BALL BEARING 6205 C3 NTN TAB WASHER BEARING MAIN SHAFT S INT. TORX FLAT HEAD M5X BALL BEARING 6203 RSH C C ENGINE // 9

45 TRANSMISSION II - COUNTERSHAFT COUNTERSHAFT * IDLER GEAR 1.G. 1 3* SLIDING GEAR 5.G IDLER GEAR 3.G IDLER GEAR 4.G SHIFT COLLAR 1 7* IDLER GEAR 2.G NEEDLE BEAR.K 22X26X10 DIVIDED CIRCLIP DIN X1, STOP DISK 26 X 32 X 1, STOP DISK 23 X 32 X 1, SHIM 20X32X NEEDLE BEARING K 20X26X STOP DISC 17,2X30X CIRCLIP DIN X1, BALL BEARING 6203 JR2 C TAB WASHER BEARING COUNT.SHAFT S INT. TORX FLAT HEAD M5X CYL.ROLL BEARING NJ SHAFT SEAL RING 32X45X7 BSLNBR O-RING 25,12X1,78 NBR SPACER SLEEVE COUNTER FRONT SPROCKET 13-T x FRONT SPROCKET 14-T FRONT SPROCKET 15-T x SCREW 10.9+SPRING WASHER COUNTER SHAFT REP.KIT 4 STROKE x C ENGINE // 10

46 SHIFTING MECHANISM SHIFT LEVER CPL.RACING * S HH COLLAR SCREW M6X16 ISA STEEL WASHER 6,4X17X SHAFT SEAL RING 14X24X6 B NEEDLE BEAR.HK X20X STOP DISK 14X30X RETURN SPRING 2,2MM ' SPRING GUIDE TENSIONING SPRING 0,8MM 1 10* % SHIFT SHAFT CPL SLIDING PLATE CPL SHIFT RAIL 11,8X101, PRESSURE SPRING 0,9MM SHIFTING ROLLER 6X8X5, SHIFT DRUM LOCATING ALU CPL SHIFT ROLLER % AH SCREW DIN6912 M6X LOCKING LEVER CPL HH COLLAR SCREW M5X20 TX SLEEVE FOR LOCKING LEVER ARRESTING LEVER SPRING SHIFT RAIL 11,8X SHIFT FORK 5./6.GEAR WASHER DIN9021-A 5, SHIFT FORK 2./4.GEAR BALL BEARING C PAIR OF WASHERS M 6 NORDLOCK SHIFTING FORK 1ST/3RD GEAR C ENGINE // 11

47 WATER PUMP CAP NUT M6 STAINLESS STEEL WATER PUMP ROTOR DISC WATER PUMP SHAFT SEAL RING 12X30X7 PTFE WATER-PUMP GASKET WATER PUMP COVER CPL HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X65 TX CU-SEAL RING DIN7603-6X10X WATER PUMP REP. KIT x C ENGINE // 12

48 COOLING SYSTEM RADIATOR L/S "55623U" RADIATOR R/S "55637U" RADIATOR CAP SMALL 1,8 BAR Y-CONNECTOR CPL HOSE CLAMP GEMI HOSE CLAMP NORMA 12/ CLAMP YDNAC 10096F (9,6MM) ANGLE PIECE ' PVC-HOSE 6X9 x RADIATOR HOSE L/S RADIATOR HOSE R/S PREFORMED HOSE ENGINE/COOLER RADIATOR PROTECTION BLACK RADIATOR PROTECTION L/S+R/S SX x HOSE CONNECTOR L=172, RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX C ENGINE // 13

49 VALVE DRIVE INTAKE VALVE EXHAUST VALVE VALVE SPRING HOLDER VALVE-STEM SEALING RACING VALVE SPRING VALVE SPRING RETAINER VALVE COLLET ROCKER ARM EXHAUST CPL ROCKER ARM SHAFT INTAKT ROCKER ARM SHAFT EXHAUST ROCKER ARM INTAKE O-RING 15,00X1,50 VITON SCREW PLUG M18X SPECIAL SCREW M7X40 WS FIT BOLT M7X1X SHIM D=8,9/1,72 x SHIM D=8,9/1,76 x SHIM D=8,9/1,80 x SHIM D=8,9/1,84 x SHIM D=8,9/1,88 x SHIM D=8,9/1,92 x SHIM D=8,9/1,96 x SHIM D=8,9/2,00 x SHIM D=8,9/2,04 x SHIM D=8,9/2,08 x SHIM D=8,9/2,12 x SHIM D=8,9/2,16 x SHIM D=8,9/2,20 x SHIM D=8,9/2,24 x SHIM D=8,9/2,28 x SHIM D=8,9/2,32 x SHIM D=8,9/2,36 x SHIM D=8,9/2,40 x SHIM D=8,9/2,44 x SHIM D=8,9/2,48 x SHIM D=8,9/2,52 x SHIM D=8,9/2,56 x SHIM D=8,9/2,60 x C ENGINE // 14

50 VALVE DRIVE VALVE SPR.-KIT 450 SX-F 13 x VALVE KIT 450 SX-F x C ENGINE // 15

51 TIMING DRIVE 1* CAMSHAFT W. AUTODECO S HH COLLAR SCREW M6X20 TX RETAINING PLATE CAMSHAFT CPL GASKET TIMING CHAIN TENSIONER TIMINGCHAIN TENSIONER CPL.RAC HH COLLAR SCREW M6X16 TX NEEDLE SLEEVE HK1814RS18/24/ NEEDLE SLEEVE HK4012B40X47X TIMING CHAIN 110T TIMING CHAIN TENSIONER TIMING CHAIN GUIDE 1 23* BUSHING SCREW M FAILURE PROTECTION C ENGINE // 16

52 CYLINDER HEAD CYLINDER HEAD CPL. 1 2* CYLINDER HEAD GASKET S= VALVE COVER BLACK MATT 1 4* VALVE COVER GASKET VALVE COVER SCREW DECOUPLING ELEMENT RUBBER BOOT EFI S HH COLLAR SCREW M6X16 ISA EXHAUST FLANGE EXHAUST FLANGE GASKET SCREW IN NOZZLE M20X1, OIL JET 70 M VALVE GUIDE INTAKE CYL. HEAD SCREW M10X1,25 L= WASHER 19X10,5X2, HH COLLAR SCREW M6X70 TX SCREW PLUG HOSE CLAMP GEMI 63MM HOSE CLAMP GEMI 58MM O-RING 10,00X2,00 SILCONE TEMPERAT.-SENSOR WATER LC CLAMP YDNAC (18MM) ENGINE BREATHER TUBE C ENGINE // 17

53 LUBRICATING SYSTEM OIL PUMP GEAR 17 T CYLIND.SCREW M3X8 ISO SS STOP SHEET MEMBRANE MEMBRANE MEMBRAN CRANKCASE TAB WASHER MEMBRAN CSC OIL PUMP SHAFT SP-DP NEEDLE ROLLER NRB 4X15,8 G ROTOR-SET CPL. 22MM O-RING 44,00X2,00 VITON OIL PUMP COVER SUCTION PUMP HH COLLAR SCREW M6X16 TX CU-SEAL RING DIN X18X1, OILDRAIN PLUG W.MAG. M 12X1, TAB WASHER DIN6799-RS 6, STOP DISK 8,1 X 15 X 0, IDLER GEAR 1 29Z OIL PUMP COVER OILPUMP ROTOR 12MM G-95R/ O-RING 12X2 VITON GREEN NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, O-RING 17,17X1,78 GLO OIL SCREEN CPL PLUG M20X1,5 WS= O-RING 17,00X2, O-RING 12,5X1,5 VITON V OIL SCREEN OIL FILTER WITH GASKET O-RING 39,34X2, OILFILTER CAP O-RING 12,5X1,5 NBR HH COLLAR SCREW M5X16 TX BALL DIN PRESSURE SPRING L=25MM D=1MM CU-SEAL RING DIN X18X1, PLUG SCREW SAS M12X1, BUSHING PIN C ENGINE // 18

54 LUBRICATING SYSTEM SHIM WASHER DIN X24X0, CIRCLIP DIN X AH SCREW DIN0912-M 6X20 SS OILFILTER SERVICEKIT SX-F 13 x C ENGINE // 19

55 IGNITION SYSTEM IGNITION COVER GASKET - IGNITION COVER PULSER COIL KOKUSAN 4K3-A/B SPARK PLUG CONNECTOR SPARK PLUG M12X1,25 LKAR8AI HH COLLAR SCREW M5X16 TX NEEDLE ROL.DIN5402 NRB 4X9, S FLAT HEAD SCREW ISA25 M4X RETAINING PLATE IGNITIONCOIL IG3826 KOKUSAN' ROTOR STATOR SPRING WASHER DIN0137-B COLLAR NUT M12X1 R/S WOODRUFF KEY DIN6888-3X5X AH SCREW DIN6912 M4x COLLAR SCREW M6X18 ISA HH COLLAR SCREW M6X25 TX C ENGINE // 20

56 ELECTRIC STARTER E-STARTER CPL. 0,5KW HH COLLAR SCREW M6X25 TX O-RING 25,00X3,00 NBR AH SCREW DIN0912-M 6X40 A STOP DISC 6X23X BEARING BOLT AH SCREW DIN0912-M 6X20 SS SHIM WASHER DIN X24X0, TORQUE LIMITER CPL CIRCLIP DIN X IDLER GEAR 30-T CPL BUSHING PIN FREEWHEEL GEAR 66 C CPL FREE WHEEL C ENGINE // 21

57 THROTTLE BODY THROTTLE BODY MAP SENSOR CPL FUEL RAIL CPL INJECTOR KIT CPL TPS CPL THROTTLE COVER CPL STARTER VALVE COMP IDLING ADJUSTING SCREW CPL SEAL RING SCREW SHOULDER SPECIAL SCREW AH O-RING THROTTLE POS. SENSOR SPECIAL SCREW O-RING PLATE SPECIAL SCREW O-RING 7,2x2, SEAL RING SCREW SHOULDER 2 20* TIMING CHARGER EFI ECU SAFETY COVER AMBIENT-AIR TEMPERATURE SENSOR HH COLLAR SCREW M5X16 TX ROLLOVER SENSOR HH COLLAR SCREW M6X20 TX PROTECTION CAP TPS 1 30* HH COLLAR SCREW M5X25 ISA C ENGINE // 22