250 SX-F USA 2009 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF8175I5EN

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1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8175I5EN ENGLISH

3 INDEX FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 3x 5x 6x 7x ENGINE GUARD SHOCK ABSORBER DISASSEMBLED SWING ARM SHOCK ABSORBER 8x 9x 11x 12x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER MASK, FENDERS 13x 14x 15x 16x 1

INDEX DECAL FRONT WHEEL REAR WHEEL REAR BRAKE CONTROL 17x 18x 19x 20x BRAKE CALIPER REAR HAND BRAKE CYLINDER BRAKE CALIPER FRONT ACCESORIES KIT 21x 22x 23x 24x All information contained is without

4 INDEX DECAL FRONT WHEEL REAR WHEEL REAR BRAKE CONTROL 17x 18x 19x 20x BRAKE CALIPER REAR HAND BRAKE CYLINDER BRAKE CALIPER FRONT ACCESORIES KIT 21x 22x 23x 24x 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 KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 2

5 FRONT FORK DISASSEMBLED 3* S ADJUSTING KNOB + SCREW 2 12* OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB DUST CAP D=48 58,4X11, DU-BUSH D47XD49X20DDL 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 SXS COUNTERNUT M12X1 WS ADJUSTER NEEDLE O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM S SPRING 4,4 N/MM SET D=5,1MM x S SPRING 4,6 N/MM SET D=5,1MM x S POLISHED SPRING 4,8 N/MM x S SPRING 5,0 N/MM x S SPRING 4,0 N/MM SET x S SPRING 4,2 N/MM SET D=5,0MM 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 SPRING CHECK VALVE D=0, SHUTTLE VALVE SPRING C=0, / C * NEW PART X AS REQUIRED 3

6 FRONT FORK DISASSEMBLED S3 MEMBRANE HOLDER LOCK WASHER D=25, AH SCREW M4X O-RING NBR 21X PISTON COMPRESSION D=27, O-RING NBR 4X1, S PIN VALVE SET NUT M6X0,5 REBOUND 2 56* GUIDE RING 44 X RING SPRING-SUPPORT 2 59* WASHER 32X42X2,5 2 60* S2 AXLE CLAMP L/S + TUBE CPL * S2 AXLE CLAMP R/S + 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 D=23,45X2, 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 SAE5 5L O-RING NBR 43X S1 SCREW CAP CPL. L= SCREW M4X MEMBRANE SLEEVE 2 98 T511 SILICONE GREASE F. DUST STRI 1 99 R14014 REPAIR-KIT GASKET 48MM / C * NEW PART X AS REQUIRED 4

7 FRONT FORK, TRIPLE CLAMP 1* 14187E2201 FORK KTM CC HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X35 TX S HH COLLAR SCREW M8X25 TX AH SCREW DIN6912-M10X STE.HEAD SCR. M20X1,5 WS=27 SL 1 SELF-LOCKING O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS=6 2 32* BOTTOM TRIPLE CLAMP D=60MM FORK TUBE L=237MM * TOP TRIPLE CLAMP D=54MM STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP 28MM HANDLEB.SUPP. D=28MM H=32MM 05 x HANDLEB.SUPP. D=28MM H=37MM 05 x 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 PROT. L/S+R/S BLACK / C * NEW PART X AS REQUIRED 5

8 HANDLEBAR, CONTROLS HANDLEBAR RENTHAL SX 28MM HANDLEBAR PAD 05 x SHORT CIRCUIT BUTTON HOSE 7X11,5X TWIST GRIP COVER RENTHAL THROTTLE GRIP CPL. RACING FIXED GRIP RENTHAL CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x SPACER BUSHING 6X10X5 1 20* HAND GUARDS CPL.L/S+R/S OR HOT START LEVER CPL 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 STARTER CONTROL HOT START CABLE THROTTLE CABLE 250 SXF / C * NEW PART X AS REQUIRED 6

9 FRAME FRAME 250 SX-F "GA07" SUB FRAME SX "Q7" SUB FRAME APPLICATION LEFT SUB FRAME APPLICATION RIGHT REINFORCING B. 250 SX-F * WASHER 8,5X18X1 INOX ADH. FOIL TRANSP. 80X80 MM SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M ENGINE BRAC.SCR. M10X105 WS= S FLAT HEAD SCREW M. ISA45 M8X COLLAR SCREW M8X42 WS= * BLIND PLUG-IN NUT M5 WN 22A * CABLE TIE 300/4,8MM BLACK 3 18* COU.SUNK SCR. AH ISO7380 M5X * BUSH F. FRAME PROTECTION SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M 8X30 WS= FOOT PED L/S SILVER FOOT PED R/S SILVER BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTREST L.+R. CPL ANGEL PIECE ' PVC-HOSE 7X10 PER METER x SPROCKET COVER 250 SX-F CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX x 63* PLASTIC FRAME PROTECTION SET CHAIN SLIDING P. BELOW CPL / C * NEW PART X AS REQUIRED 7

10 ENGINE GUARD 1* SKID PLATE 250 SX-F / C * NEW PART X AS REQUIRED 8

11 SHOCK ABSORBER DISASSEMBLED 1* S3 TOP PART CPL. M57,5X1 H30, * S11 DCC-COMPR.DAMP.CONTROL CPL ADAPTOR BUSH KGW 12X R12012 REP. KIT BEAR./SEAL UP BLEED PLUG R 1/ WP CAUTION (PDS KTM) 58X O-RING NBR 5,28X1, SCREW PLUG M5X RUBBER CAP "DO NOT OPEN" S SPRING RETAINER M57,5X1 +SCREW AH SCREW M5X30 DIN INTERM.RING SCREW SPRING RET S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM x CIRCLIP 58,2X S SPRING RET. D=80 W. O-RING O-RING VITON 66,27X3, * PISTON ROD NUT M20X O-RING VITON 44,17X1, PISTON RING * PISTON D= * TAP D20 M20X1 L45, * REBOUND DISC D43 H0 T PISTON 6+6X7/4, S ADAPTOR CPL. D=50 H= STEEL DISC 18X,5X43,7X REBOUND RUBBER SHIM D29,75 X D19 X T0, S SEAL D18X30X O-RING 41X DU-BUSH 18X20X DUST SEAL / C * NEW PART X AS REQUIRED 9

12 SHOCK ABSORBER DISASSEMBLED CIRCLIP 53X1, * RESERVOIR CAP D=50 H= BUMP RUBBER D58 D17 H59 SXS * S2 SHOCK ABS. LOWER PART CPL ONLY FOR 250 SX 90* S3 SHOCK ABS. LOWER PART CPL THREADED BUSH M12 PDS RUBBER PLUG D= STEEL BALL D=3MM SPRING D=2,9 L=7, O-RING NBR 4X1, S ADJUSTING SCREW REBOUND TRAVEL S1 SHOCK ABSORBER FLUID 5 LT ' R12014 REPAIR KIT 5018 PDS / C * NEW PART X AS REQUIRED 10

13 SWING ARM SWINGARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR SPECIAL SCREW M 5,0X BRAKE HOSE GUIDE LOWER SPECIAL SCREW M6X13 WS= BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X BUSHING SLEEVE F. SWING ARM NEEDLE BEARING HK STOP DISK 22,2X31,7X CHAIN GUIDE REAR CPL SPECIAL SCREW M6X19 WS= HH COLLAR SCREW M6X45 TX BUSH. F. CHAIN FAIL. PROT PIVOT BEARING+BUSHES PDS ' TOOL BEARING MOUNTING PDS PLUG SFL SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC SWINGARM REPAIR KIT x / C * NEW PART X AS REQUIRED 11

14 SHOCK ABSORBER S HH COLLAR SCREW M12X50 TX * 12187E22 SHOCK ABSORBER 250 SX-F USA / C * NEW PART X AS REQUIRED 12

15 EXHAUST SYSTEM % EXH SILENCER CPL.250SXF THERMAL PROTECTION FOIL SILENCER HOUSING 250 SX-F SILENCENER C. CPL. 250 SX-F SPRING WASHER DIN0137-B BUSHING 7.5x12x28x EXHAUST BRACKET RUBBER BLACK HH COLLAR SCREW M6X30 TX TEN.SPRING L=62MM EY.MOVEABLE SCREW TORX M5X ENDCAP STUFFING YARN HGS STUFFING YARN 250SX-F EXHAUST MANIFOLD 250 SX-F HH COLLAR SCREW M8X25 TX BUSHING FOR EXHAUST SUPPORT / C * NEW PART X AS REQUIRED 13

16 AIR FILTER FILTER WALL SX BLACK FILTER BOX COVER SX BLACK REAR PART FILTER BOX QUICK RELEASE-NIPPLE BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX AIR FILTER FILTER CARRIER 4S SX FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX CABURETOR CONNECTING HOSE CLAMP 45-65MM EJOT PT SCREW K60X20 ALU WS=6 x EJOT PT SCREW K60X20 WS= BUSHING F. CHAIN SLIDING PR / C * NEW PART X AS REQUIRED 14

17 TANK, SEAT, COVER GAS COCK MIKUNI ON/OFF O-RING 13,00X2, PVC-HOSE 5,6X10X270MM TANK PLUG ORANGE/BLACK TANK BUSHING FUEL TANK CPL. SX 7,5L TANK ROLLER 12X26X12 ' FUEL PREFORMED HOSE 450 SX-F CLAMP YDNAC MM EJOT PT SCREW K60X20 ALU WS= EJOT PT SCREW K60X20 WS= ANGLE PIECE 90 DEGREE M10X SEAT SX SEAT COVER * E SPOILER KIT BLACK SX 09 1 WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X12 TX COLLAR SCREW M6X27 TX / C * NEW PART X AS REQUIRED 15

18 MASK, FENDERS NUMBER PLATE CPL. ORANGE BRAKE HOSE GUIDE ORANGE EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M5X16 TX FRONT FENDER SPACER BUSHING HH COLLAR SCREW M6X20 TX COLLAR BUSH. F.REAR FENDER COLLAR BUSHING 4,5/12,6/ REAR FENDER SX ORANGE COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M6X25 TX BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX / C * NEW PART X AS REQUIRED 16

19 DECAL 1* DECAL KIT * DACAL 250 SX-F/USA / C * NEW PART X AS REQUIRED 17

20 FRONT WHEEL 1* FRONTWHEEL CPL.1,6X21EXCEL FRONT WHEEL HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM FRONT WHEEL REP. KIT SHAFT SEAL RING 35X47X7 TC SPACER BUSHING * SPOKE M4,5x226-21" SPOKE NIPPLE M4,5X0,75 8X * RIM 1,6"X21" EXCEL SXS RIM BAND 21" RIM LOCK VM1 (1,60") NUT FOR WHEEL HOLDER ' BRAKE DISC FRONT SPECIAL SCREW M6X13 WS= WHEEL SPIN.FR. D=26 M24x1, SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= PLUG FOR RIM x AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 18

21 REAR WHEEL 1* REARWHEEL CPL.2,15X19 EXCEL REAR HUB CPL BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL SPACER BUSHING * SPOKE M5x206-19" * SPOKE NIPPLE M5-TA 8X21MM 36 10* RIM 2,15"X19" EXCEL SXS BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" REAR WHEEL REP. KIT REAR SPROCKET 38-T x REAR SPROCKET 42-T x REAR SPROCKET 40-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 21* S COUNTER-SUNK SCREW ISA45 M8X SELF LOCKING NUT M CHAIN 5/8X1/4" MX CONNECTING LINK F RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER ' PLUG FOR RIM x COVERING CAP SFL16 x WHEEL SPINDLE RE. CPL.265MM CHAIN TENSIONER R/S SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= HEXAGON NUT M20X1,5 ' / C * NEW PART X AS REQUIRED 19

22 REAR BRAKE CONTROL REAR BRAKE CYLINDER CPL REPAIR KIT PISTON 13MM REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX HOLLOW SCREW BLACK M10X1X BRAKE HOSE REAR 655MM 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 AH SCREW DIN6912 M10X SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= BALL BEARING SKF RS COLLAR NUT M10 WS= HH COLLAR SCREW M6X12 TX BELLOWS FOR REPAIR KIT BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 20

23 BRAKE CALIPER REAR BRAKE CAL. RE. - 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 SUPPORT REAR CUP SET SHORT BRAKE HOSE REAR 655MM BLEEDER SCREW CPL COPPER GASKET DIN X14X / C * NEW PART X AS REQUIRED 21

24 HAND BRAKE CYLINDER 1* HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE 1 10* REP.SET PISTON D=12MM CLAMP CPL. NATURE HH COLLAR SCREW M6X25 TX LEVER SCREW CPL * HAND BRAKE LEVER + SPRING * ADJUSTING SCREW CPL. SX PROTECTION CAP HAND BRAKE CYL BRAKEHO. FRONT 1235MM * HOLLOW SCREW COPPER GASKET DIN X14X1 2 34* VALVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 22

25 BRAKE CALIPER FRONT 1* CALIPER NAT. WITHOUT PADS 1 2* BRAKE CALIPER SUPPORT FRONT * REP. KIT SEALS 24MM 1 6* REP. KIT PISTON 24MM 1 7* BOLT CPL * RETAINING PLATE SET BREMBO 1 9* BRAKE PADS FRONT TOYO B * BLEEDER SCREW WITH CAP CUP SET SHORT S HH COLLAR SCREW M8X35 TX BRAKEHO. FRONT 1235MM COPPER GASKET DIN X14X HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 23

26 ACCESORIES KIT DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER FOOTREST L.+R. CPL PLASTIC FRAME PROTECTION SET EN OWNERS MAN.250SX/XC/EXC-F-W CF8175I5EN SPM CHASSIS 1 1 3CM089308IEN SPM ENGINE 250 SX-F TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F WRENCH WS=13/ T-WRENCH WS=6/8/10 TX=45 B&F SPARK PLUG KEY 250 SX-F / C * NEW PART X AS REQUIRED 24

28 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CF8175I5EN* 3CF8175I5EN Art.Nr.: 3CF8175I5EN 4/2008

450 SX-F EU 2009 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF8401I5EN

450 SX-F EU 2009 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF8401I5EN SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8401I5EN ENGLISH INDEX FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 3x 5x 6x 7x ENGINE GUARD SHOCK ABSORBER DISASSEMBLED SWING ARM