TE 300 USA 2012 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF2475L9EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF2475L9EN ENGLISH

2 INDEX FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 4x 6x 7x 8x SIDE / CENTER STAND SHOCK ABSORBER SHOCK ABSORBER DISASSEMBLED SWING ARM 9x 10x 11x 13x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER MASK, FENDERS 14x 15x 16x 17x 1

3 INDEX DECAL FRONT WHEEL REAR WHEEL WIRING HARNESS 18x 19x 20x 21x HAND BRAKE CYLINDER BRAKE CALIPER FRONT BRAKE CALIPER REAR REAR BRAKE CONTROL 22x 23x 24x 25x INSTRUMENTS / LOCK SYSTEM ACCESSORIES KIT 26x 27x x x 2

4 INDEX x x x x x x x x 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. 3 x

5 FRONT FORK DISASSEMBLED S ADJUSTING KNOB + SCREW OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING D45 SKF LOCK WASHER SB DUST SEAL DL D48 SKF 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 REBOUND NEEDLE SX O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM S SPRING 4,4 N/MM SET D=5,1MM x S SPRING 4,0 N/MM SET x S SPRING 4,2 N/MM SET D=5,0MM 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, S3 MEMBRANE HOLDER INKL. PIN SET LOCK WASHER D=25, AH SCREW M4X / C * NEW PART X AS REQUIRED 4

6 FRONT FORK DISASSEMBLED O-RING NBR 21X PISTON COMPRESSION D=27, O-RING NBR 4X1, S PIN KIT NUT M6X0,5 REBOUND GUIDE RING 44 X RING SPRING-SUPPORT WASHER 32X42X2, SA AXLE CLAMP LEFT + TUBE CPL SA AXLE CLAMP RIGHT + TUBE CPL HH COLLAR SCREW M8X25 TX NUT VALVE M6X0,5 LH=1, SPRING CHECK VALVE D=0, PISTON ROD COMPRESSION PISTON REBOUND SX PISTON RING 5X1X RING D=23,45X2, SHAFT SEAL RING 12MM 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 R14019 REPAIR KIT SEALS MXMA CC / C * NEW PART X AS REQUIRED 5

7 FRONT FORK, TRIPLE CLAMP K0401 FORK HUSABERG TE HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X35 TX S HH COLLAR SCREW M8X25 TX S AH-COLLAR SCREW M10X35 ISA HH COLLAR SCREW M8X40 TX O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS= BOT. TRIPLE CLAMP CPL. 22MM TOP TRIPLE CLAMP X=22MM BLACK STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP 28MM 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 FOR SPEED CABLE D=6MM STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS= FORK PROTECTION L/S+R/S BLUE / C * NEW PART X AS REQUIRED 6

8 HANDLEBAR, CONTROLS HANDLEBAR NEKEN D=28MM EXC BAR PAD CPL SHORT CIRCUIT BUTTON CLAMP 5/7 MM THROTTLE GRIP CPL PROTECTION COVER ' THROTTLE C. 2STROKE DOM./KEIH GRIP SET CABLE TIE 200/3,6MM BLACK HANDGUARDS CPL.LE+RI WHITE 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 / C * NEW PART X AS REQUIRED 7

9 FRAME DA FRAME "CB08" YELLOW SUB FRAME SX "Q7" SUB FRAME APPLICATION LEFT SUB FRAME APPLICATION RIGHT REINFORCING B. 250 SX 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 CYLINDER HEAD SCREW M8X BLIND PLUG-IN NUT M5 WN 22A CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X BUSH F. FRAME PROTECTION PLASTIC CAP SFL SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X30 TX HH COLLAR SCREW M6X30 TX FOOTREST L/S FOOTREST R/S BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTREST L/S + R/S CPL ANGLE PIECE ' PVC-HOSE 7X10 PER METER x SPROCKET COVER 250 SX CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET CHAIN SLIDING KIT BELOW CPL SPROCKET COVER KIT / C * NEW PART X AS REQUIRED 8

10 SIDE / CENTER STAND SIDE STAND CPL SCREW M5X14 TORX SPRING BRACKET F. SIDE ST SIDE STAND BUSHING EXC USA O-RING 18,00X2,00 NBR SPACER BUSH. SPRING BRACKET SIDE STAND SPRING EYE MOVEABLE SIDE STAND STOP SCREW M10X S COUNTER-SUNK SCREW ISA45 M8X O-RING 12,00X2,00 NBR WASHER F. SIDE STAND 12,2X29, O-RING 12,5X1,5 NBR SIDE STAND BUSHING EXC-EU SIDE STAND SPRING 08 1 ONLY FOR USA STAND BASE RUBBER L=145MM / C * NEW PART X AS REQUIRED 9

11 SHOCK ABSORBER S HH COLLAR SCREW M12X50 TX K0401 MONOSHOCK HUSABERG TE / C * NEW PART X AS REQUIRED 10

12 SHOCK ABSORBER DISASSEMBLED SA TOP PART CPL. M57,5X1 H30, S10 DCC-COMPR.DAMP.CONTROL CPL ADAPTOR BUSH KGW 12X R12012 REP. KIT BEAR./SEAL UP BLEED PLUG R 1/ WP CAUTION (PDS KTM) 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 SPACER RING FOR SPRING S SPRING N/MM YELLOW x S SPRING N/MM YELLOW S SPRING N/MM(64/62)YELLOW 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 D 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 CIRCLIP 53X1, / C * NEW PART X AS REQUIRED 11

13 SHOCK ABSORBER DISASSEMBLED RESERVOIR CAP D=50 H= BUMP RUBBER D58 D17 H SA2 SHOCK ABS. LOWER PART CPL THREADED BUSH M12 PDS 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 1 99 R12015 REPAIR KIT 5018 PDS / C * NEW PART X AS REQUIRED 12

14 SWING ARM SWING ARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR EJOT SPIRAL SCREW SF M5X10-K 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 CPL SPECIAL SCREW M6X19 WS= HH COLLAR SCREW M6X45 TX INSERTION NUT F. CHAIN GUIDE PIVOT BEARING+BUSH. PDS ' PLUG SFL SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC CHAIN GUIDE KIT REAR SWINGARM REPAIR KIT x / C * NEW PART X AS REQUIRED 13

15 EXHAUST SYSTEM MAIN SILENCER EXC HH COLLAR SCREW M6X30 TX SPRING WASHER DIN0137-B ENDCAP CPL SCREW TORX M5X SILENCER HOUS. CPL. W. HANGING DUMMY RIVET 4,8X 8 NIRO O-RING 74,00X1,50 FKM 75SH HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M6X15 TX SWINGELEMENT FOR EXHAUST PIPE RANGE CHANGE METAL NUT M SILICON SLEEVE D=29/31MM EXHAUST MANIFOLD TEN.SPRING L=62MM EY.MOVEABLE O-RING 44,00X3,00 VITON ROCKWOOL 315G / C * NEW PART X AS REQUIRED 14

16 AIR FILTER AIR BOX PART BLACK AIR 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 THROTTLE CAP CPL. EXC AIR FILTER FILTER CARRIER 2S SX FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX CABURETOR CONNECTING 2S HOSE CLAMP 50-70MM EJOT PT SCREW K60X20 ALU WS=6 x EJOT PT SCREW K60X20 WS= BUSHING F. CHAIN SLIDING PR / C * NEW PART X AS REQUIRED 15

17 TANK, SEAT, COVER FUEL TANK CPL. 11 LIT. TE GAS COCK ON/OFF/RES O-RING 11X2 VITON TANK PLUG CPL. HUSABERG PVC-HOSE 5,6X10X270MM TANK BUSHING TANK ROLLER 12X26X12 ' FUEL PREFORMED HOSE SX YDNAC-CLAMP MM CLAMP YDNAC MM EJOT PT SCREW K60X20 WS= EJOT PT SCREW K60X20 ALU WS= ANGLE PIECE 90 DEGREE M10X SEAT TE SEATCOVER TE C SPOILER SET BLUE 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 16

18 MASK, FENDERS NUMBER PLATE BLACK FRONT FENDER BRAKE HOSE GUIDE HH COLLAR SCREW M6X40 TX FENDER BRACE BLACK ' HH COLLAR SCREW M6X20 TX NUT FENDER BRACE M8 WS= SCREW FEND.BRACE M8X9 WS= SPACER BUSHING HH COLLAR SCREW M6X20 TX REAR PART EXC BLACK COLLAR BUSH. F.REAR FENDER BUSH FOR SPOILER 6X11X16X5 MM COLLAR BUSHING 4,5/12,6/ FENDER FOR FILTER BOX BUSHING F. CHAIN SLIDING PR EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M6X13 TX COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M5X16 TX / C * NEW PART X AS REQUIRED 17

19 DECAL DECAL KIT HUSABERG TE DISPLACEM. STICKER TE / C * NEW PART X AS REQUIRED 18

20 FRONT WHEEL FRONT WHEEL CPL. 1,60X21" FRONT WHEEL HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL SPOKE M4,5x226-21" SPOKE NIPPLE M4,5 AL RIM FRONT 1,6X1" DID AL7 BLUE RIM BAND 21" FRONT WHEEL REP. KIT x 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= AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 19

21 REAR WHEEL REAR WHEEL CPL. 2,15X18" REAR WHEEL HUB CPL BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB SPOKE M4,5X193-18" SPOKE NIPPLE M4,5 AL RIM 2,15X18" DID AL7 BLUE BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" REAR WHEEL REP. KIT x 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 REAR SPROCKET 51-T x REAR SPROCKET 52-T x S COUNTER-SUNK SCREW ISA45 M8X HEXAGON NUT DIN EN1661 M8 SW CHAIN DID 118 ROLLS CONNECTING LINK F RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER COVERING CAP SFL 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 20

22 WIRING HARNESS WIRING HARNESS RACING USA WIRING HOLDER 16MM x BATTERY CASING VOLTAGE REGULATOR EJOT PT SCREW K60X20 WS= HH COLLAR SCREW M6X12 TX PULL SWITCH LOOSE SPEC. NUT F. PULL SWITCH WS= CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x SPEEDOMETER BRACKET XC-W FUSE 10 A BATTERY 12V 3AH YTX4L-BS RUBBER L=145MM WIRING HARNESS BATTERY DUKE' STARTER RELAY 12V ' STARTERCABLE 1100MM % SPECIAL SCREW M 5,0X GROUND CABLE D=6MM L=140MM ' CONTACT WASHER M6 VSV-K PROTECTION CAP F. STARTER ENG SELF LOCK. NUT DIN0985-M AH OVAL SCREW ISO 7380 M 6X / C * NEW PART X AS REQUIRED 21

23 HAND BRAKE CYLINDER HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=9MM 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 1300MM % BANJO SCREW COPPER GASKET DIN X14X VALVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 22

24 BRAKE CALIPER FRONT CALIPER NAT. WITHOUT PADS BRAKE CALIPER SUPPORT FRONT REP. KIT SEALS 24MM REP. KIT PISTON 24MM BOLT CPL RETAINING PLATE SET BREMBO BRAKE PADS TOYO B BLEEDER SCREW WITH CAP CUP SET SHORT S HH COLLAR SCREW M8X35 TX BRAKEHO. FRONT 1300MM COPPER GASKET DIN X14X % BANJO SCREW / C * NEW PART X AS REQUIRED 23

25 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 24

26 REAR BRAKE CONTROL REAR BRAKE CYLINDER CPL REPAIR KIT PISTON 13MM REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX % BANJO SCREW 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 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 BELLOWS FOR REPAIR KIT BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 25

27 INSTRUMENTS / LOCK SYSTEM SPEEDOMETER MPH F. 21" REPROGRAMMABLE: MPH - KM/H BATTERY COVER F. SPEEDOM BATTERY F. SPEEDOM. M.A.E SPEEDOMETER TOP PART CABLE FOR DIGITAL SPEEDOM CLAMP D=6/8MM, BLACK MAGNET FOR DIGITAL SPEEDOM CIRCLIP DIN0471-9X1 INOX WASHER DIN9021-A 5, SCREW FOR PLASTIC K50X12 T RUBBER GROMMET 16X10,8X HH COLLAR SCREW M6X20 TX BUSHING F. SPROCKET COVER RAC SPEEDOMETER BRACKET XC-W SPACER TUBE SPEEDOM. XC-W CABLE SUPPORT 10/6MM / C * NEW PART X AS REQUIRED 26

28 ACCESSORIES KIT PRINT LABEL 60X51 MM SCREW FEND.BRACE M8X9 WS= NUT FENDER BRACE M8 WS= MAP SWITCH SKID PLATE PLASTIC PLASTIC FRAME PROTECTION SET MOUNTING KIT FRONT FENDER BATTERY 12V 3AH YTX4L-BS FOOTREST L/S + R/S CPL HANDGUARDS CPL.LE+RI WHITE BAR PAD CPL C FRONT FENDER BLUE BAG HUSABERG 1 0 H HUSABERG BALLPOINT PEN EN OWN. MANUAL TE 250/ TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F OPENER HUSABERG / C * NEW PART X AS REQUIRED 27

29 HUSABERG TE SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM084690LEN ENGLISH

30 INDEX HUSABERG TE ENGINE CASE CLUTCH COVER CRANKSHAFT, PISTON CYLINDER, CYLINDER HEAD 3x 4x 5x 6x REED VALVE CASE CARBURETOR CLUTCH TRANSMISSION I - MAIN SHAFT 7x 8x 10x 11x TRANSMISSION II - COUNTERSHAFT KICK STARTER SHIFTING MECHANISM COOLING SYSTEM 12x 13x 14x 15x 1

31 INDEX HUSABERG TE EXHAUST CONTROL IGNITION SYSTEM ELECTRIC STARTER 16x 18x 19x x x x x x 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

32 ENGINE CASE HUSABERG TE ENGINE CASE CPL. 250/ BUSHING PIN AH SCREW DIN0912-M 6X AH SCREW DIN0912-M 6X40 A CLUTCH COVER GASKET DOWEL BUSHING 13,8X11X DOWEL 21X ENGINE CASE GASKET RETAINING PLATE HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M6X60 TX GASKET SET 250/ x / C * NEW PART X AS REQUIRED 3

33 CLUTCH COVER HUSABERG TE INTERM. CLUTCH COVER CPL OIL FILLER CAP M24x3 WITH O-R O-RING 19,00X3,00 NBR DOWEL 9,8 X 7 X PLUG DIN0910-M 10X COPPER GASKET DIN X14X OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, GASKET F. CLU.COVER 250/ CLUTCH COVER OUTSIDE GASKET WAPU-COVER WATERPUMP COVER 250/ SEALING ELEMENT BOTTOM SEALING CARRIER CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M6X12 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M6X60 TX / C * NEW PART X AS REQUIRED 4

34 CRANKSHAFT, PISTON HUSABERG TE I PISTON CPL. GR 1 D= II PISTON CPL. GR 2 D= WIRE LOCK RING C18X1, PISTON PIN HEX.NUT L/SH M18X1, LOCK WASHER VSK SPACER SLEEVE 28X38X SHAFT SEAL RING 38X52X7BTSL BALL BEARING 32X65X17 NTN CRANKSHAFT 250/300 EXC-MXC NEEDLE BEARING KBK 18X22X WOODRUFF KEY DIN6888-3X5X CYLIND.ROL.BEAR. NJ207ET2XCS WOODRUFF KEY 5X6,5 HARDED SHAFT SEAL RING 25X35X7 BTSL LOCKING RING VSK COLLAR NUT M12X1 R/S CONROD REP. KIT 250/ O-RING 25,00X1,50 NBR R-RING 72,0MM / C * NEW PART X AS REQUIRED 5

35 CYLINDER, CYLINDER HEAD HUSABERG TE INTERMEDIATE FLANGE 250/ * CYLINDER + PISTON CPL CYLINDERHEAD 300 XC/EXC CONTROL COVER R/S GASKET FOR CONTROL COVER R/S CONTROL COVER L/S GASKET FOR CONTROL COVER L/S COLLAR SCREW M 8X35 WS= CU-SEAL RING 8 X 16 X O-RING 78,00X2,00 VIT. BLACK O-RING 105,00X2, VACUUM CONNECTION M 6X PVC-HOSE 6X9 x ANGLE PIECE ' STUD DIN0835-M10X COLLAR NUT M10 WS= GASKET CYLINDER BASE 0,2MM 03 x GASKET CYLINDER BASE 0,4MM 03 x GASKET CYLINDER BASE 0,5MM 03 x GASKET CYLINDER BASE 0,75MM 03 x O-RING 11,3 X2,4 SILICON O-RING 44,00X3,00 VITON RETAINING PLATE AH SCREW DIN0912-M 6X SCREW M5X14 TORX NEEDLE ROL.DIN5402 NRB 4X9, GASKET SET CYL. 300EX-E / C * NEW PART X AS REQUIRED 6

36 REED VALVE CASE HUSABERG TE INTAKE FLANGE V-FORCE * MEMBRAN V-FORCE CPL. 1 32* REED VALVE SET V-FORCE 46X64MM CLAMP 52/12 GEMI HH COLLAR SCREW M6X20 TX GASKET REED VALVE CASE / C * NEW PART X AS REQUIRED 7

37 CARBURETOR HUSABERG TE CARBURETOR KEIHIN PWK36S AG IDLE JET 35 KEIHIN x IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x IDLE JET 48 KEIHIN x IDLE JET 50 KEIHIN x IDLE JET SIZE 38X38 KEIHIN x ARM PIN FLOAT FLOAT CPL GASKET FLOAT CHAMBER FLOAT CHAMBER PWK38-S AG RETAINING PLATE FOR BLEEDER STARTER JET 50 KEIHIN x STARTER JET 85 KEIHIN x HH COLLAR SCREW M 4X16 WS= SPRING FOR ADJUSTMENT SCREW STOP SCREW CPL SPRING ADJUSTMENT SCREW M FLOAT NEEDLE CLAMP MAIN JET 115 KEIHIN x MAIN JET 150 KEIHIN x MAIN JET 152 KEIHIN x MAIN JET 155 KEIHIN x MAIN JET 158 KEIHIN x MAIN JET 160 KEIHIN x MAIN JET 162 KEIHIN x MAIN JET 165 KEIHIN x MAIN JET 168 KEIHIN x MAIN JET 170 KEIHIN x MAIN JET 172 KEIHIN x MAIN JET 175 KEIHIN x / C * NEW PART X AS REQUIRED 8

38 CARBURETOR HUSABERG TE SPECIAL-AH-SCREW M 4X THROTTLE CALBE HOLDER M6X0, CARBURETOR COVER PWK36-S AG GASKET FOR CARBURETOR COVER CLIP FOR JET NEEDLE SLIDING SPRING SPRING CAP NIPPLE JET NEEDLE KEIHIN N2ZW 08 x JET NEEDLE KEIHIN N2ZJ 08 x JET NEEDLE KEIHIN N2ZG 08 x JET NEEDLE KEIHIN N2ZH 08 x JET NEEDLE KEIHIN N2ZK 08 x JET NEEDLE KEIHIN N2ZL 11 x JET NEEDLE KEIHIN N84K x THROTTLE VALVE 7 FOR 38 PJ ' CABLE F. COLD START ACT ONLY FOR EU+AUS CONNECT. COLD START CABLE CPL. 1 ONLY FOR EU+AUS STARTER PISTON CPL CLAMP 6 MM PVC-HOSE 4X6MM PVC-HOSE 3X5MM x PLUG M 18X O-RING 18,00X2,30 NBR SLIDE STOP L=38MM x SLIDE STOP L=36 08 x O-RING 6,00X1,78 x WASHER ADJUSTING SCREW O-RING ADJUSTING SCREW / C * NEW PART X AS REQUIRED 9

39 CLUTCH HUSABERG TE OUTER CLUTCH HUB 72-T CPL INNER CLUTCH HUB 546/ PRESSURE CAP OUTER CLUTCH HUB LOOSE PRIMARY GEAR 26T SPRING RETAINER 6,2 X 20 X 3, CLUTCH SPRING 2,5X43 8,75T LINING DISC FCC STEEL DISC SUPPORTWASHER 22,2X35X3 HARDE HEXAGON NUT DIN0936-M18X1,5 R LOCK WASHER CLUTCH RIVET DIN7338-6X DAMPING ELEMENT RETAINING PLATE NEEDLE BEARING K26X30X22ZW.KSE INNER RING WITH COLLAR VENT INJEKTION HYDR. CLUTCH AXIAL NEEDLE BEARING AXK PRESSURE PIECE ' PUSH ROD AXIAL WASHER AS X26X CIRCLIP DIN7993-RW OUTPUT CYLINDER CPL BLEEDER SCREW CPL O-RING PISTON CPL O-RING 30,00X1,50 NBR PRESSURE SPRING HH COLLAR SCREW M6X16 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X20 TX COPPER GASKET DIN X14X CLUTCH KIT 250/300 '04-'11 x / C * NEW PART X AS REQUIRED 10

40 TRANSMISSION I - MAIN SHAFT HUSABERG TE MAIN SHAFT CPL SOLID GEAR SLIDING GEAR 3./4.GANG,Z=20/ IDLER GEAR 5.G, Z = IDLER GEAR 6. G, Z= BALL BEARING 6205 C3 NTN NEEDLE BEAR. K 22X26X13 TN STOP DISK 20,2X33X1, CIRCLIP SW GROOVED BALL BEAR. TM C STOP DISC 25X31X1, STOP DISC 25X0,8X30X30X7H / C * NEW PART X AS REQUIRED 11

41 TRANSMISSION II - COUNTERSHAFT HUSABERG TE COUNTER SHAFT CPL IDLER GEAR 2. G., Z= SLIDING GEAR 5.G., Z= IDLER GEAR 4.G., Z= IDLER GEAR 3.G., Z= SLIDING GEAR 6.G., Z= IDLER GEAR 1. G, Z= NEDDLE BEAR. K24X28X11,9 DIV STOP DISC 25X31X1, CIRCLIP SW STOP DISC 25X0,8X30X30X7H NEEDLE BEAR.K 22X26X10 DIVIDED STOP DISC 20,2X30X NEEDLE BEARING K 20X26X STOP DISC 17,2X30X BALL BEARING TM-SC05C20C4 NTN SHAFT SEAL RING 32X45X6,5 BTSL O-RING 25,00X2,00 NBR SPACER SLEEVE DRIVE END FRONT SPROCKET 13-T x FRONT SPROCKET 14-T x LOCK RING DIN X1,64SD COUNTER SHAFT REP.KIT 2 STROKE x / C * NEW PART X AS REQUIRED 12

42 KICK STARTER HUSABERG TE KICKSTARTER CPL S FLAT HEAD SCREW M. ISA45 M8X WASHER 8MM GALVANIZED SHAFT SEAL RING 19X30X7 B CIRCLIP DIN X CIRCLIP DIN X1, SPRING HANGER % NEEDLE BEARING K 22X26X10 A BUMP PART INTERMEDIATE GEAR KICKSTARTER SPRING DRIVING HUB RATCHET GEAR SPRING 1,2 MM STOP DISK 22,2 X 30 X 1, SHIM 20X32X STOP DISK 17,2X25X SHIM WASHER DIN X24X0, KICKSTARTER SHAFT KICKSTARTER GEAR 34-T RATCHET GEAR KICKSTARTER HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M6X20 TX / C * NEW PART X AS REQUIRED 13

43 SHIFTING MECHANISM HUSABERG TE SHIFT FORK 5./6.G SHIFT FORK 2./4.G SHIFT FORK 1./3. G NEEDLE ROLLER DIN5402 6X14, SHIFTING SHAFT CPL PRESSURE SPRING 0,9MM SLIDING PLATE CPL TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 6903 C SHIFTING DRUM % BALL BEARING 6805 C3 JR RETURN SPRING SHIFT LOCATING DRUM AH SCREW DIN6912 M6X AH SCREW DIN0912-M 6X RETAINING PLATE SHIFT. RAIL MAIN SHAFT 250/ SHIFT. RAIL C. SHAFT 250/ LOCKING LEVER SPRING LOCATING LEVER CPL SLEEVE FOR LOCKING LEVER WASHER DIN7349-5X15X HH COLLAR SCREW M5X20 TX SHIFT LEVER CPL. 250/ STEP PLATE FOR SHIFT LEVER BOLT 6X25 FOR SHIFT LEVER SHIFTING LEVER SPRING STOP DISK 14X30X NEEDLE BEAR.HK X20X SHAFT SEAL RING 14X24X6 B STEEL WASHER 6,4X17X PAIR OF WASHERS M 6 NORDLOCK SPECIAL SCREW M6X16 WS= / C * NEW PART X AS REQUIRED 14

44 COOLING SYSTEM HUSABERG TE RADIATOR L/S "55562" RADIATOR R/S "55620" RADIATOR CAP SMALL 1,8 BAR T-CONNECTOR CPL HOSE CLAMP GEMI HOSE CLAMP NORMA 12/ ANGLE PIECE ' % PVC-HOSE 6X9 MM PER METER x RADIATOR H. 250 W. THERM THERMOSTAT 55 C RADIATOR HOSE 18X25X130 MM O-RING 32,00X2, SCREW FOR PLASTIC D=4X RADIATOR PROTECTION BLACK HOSE CONNECTOR 2 STROKE RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 15

45 EXHAUST CONTROL HUSABERG TE INT. TORX FLAT HEAD M 5X RETAINING PLATE 300 R/S RETAINING PLATE 300 L/S O-RING 16,00X2,00 VITON CONTROL VALVE 300 L/S CPL CONTROL VALVE 300 R/S CPL AH SCREW DIN0912-M 6X SPRING SLEEVE OVERLOAD SPRING RETAIN.PLATE CONTROL FLAP ' CONTROL LEVER WITH BALL TYPE BUSHING SLEEVE GEAR SEGMENT RIGHT CPL GEAR SEGMENT 300 L/S BEAR. SLEEVE F.CONTROL FLAP' O-RING 15,00X1,50 VITON CONTROL FLAP AH SCREW DIN0912-M 6X WASHER 6,5X11X AH SCREW DIN0912-M 6X HH COLLAR SCREW M 5X12 WS= WASHER DIN7349-5X15X WATER PUMP WHEEL SHAFT SEAL RING 8X24X7 A DUO SPRING WASHER DIN0137-B 6 x BALL BEARING C CENTRIFUGAL TIMER CPL. 250/ CIRCLIP DIN X DISTANCE BUSH. CENTRIFUG.TIMER AXIAL WASHER AS AXIAL NEEDLE BEARING AXK BALL BEARING 626LLBC3/5K HH COLLAR SCREW M 5X20 WS= COVER LID ' SPRING GUIDE 250/ / C * NEW PART X AS REQUIRED 16

46 EXHAUST CONTROL HUSABERG TE O-RING 12,37X2,62 NBR O-RING 24,00X2,00 NBR ADJUST. SPRING AUXILIARY SPRING MID., YELLOW AUXILIARY SPRING SOFT, RED x AUXILIARY SPRING HARD, GREEN x SPRING INSERT ANGLE LEVER CPL. ' SHIM WASHER DIN988 10X16X NEEDLE SLEEVE HK CONTROL LEVER * CONNECTING ROD CPL SECURING DIN S / C * NEW PART X AS REQUIRED 17

47 IGNITION SYSTEM HUSABERG TE FLYWHEEL KOKUSAN STATOR KOKUSAN IGNITI.COVER GASKET DOWEL 9,8 X 7 X IGNITION COVER IGN. OUT SIDE COV. GASKET OUTER IGNITION COVER CPL SPARK PLUG CAP NGK REINFORC SEALING CUP FOR SPARK PLUG SPARK PLUG NGK BR7ES IGNITIONCOIL "IG5128" COLLAR BUSHING CDI UNIT 300 EXC/XC WIRING HARNESS F.CDI 2-ST.SX VOLTAGE REGULATOR HH COLLAR SCREW M6X12 TX COLLAR SCREW M6X12 TX HH COLLAR SCREW M 5X12 WS= HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X16 TX HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X70 TX / C * NEW PART X AS REQUIRED 18

48 ELECTRIC STARTER HUSABERG TE E-STARTER ENGINE KPL * BENDIX CROWN WHEEL E-STARTER STARTER DRIVE COVER CPL O-RING 25,00X3,00 NBR WASHER DIN0125-A 6, SELF LOCK. NUT DIN0985-M BUSH FOR SPOILER 6X11X16X5 MM THRUST WASHER 8X14X0,1 x THRUST WASHER 8X14X0,2 x THRUST WASHER 8X14X0,3 x THRUST WASHER 8X14X0,5 x BENDIXSPRING BRUSH SET FOR STARTER / C * NEW PART X AS REQUIRED 19