250 XC-W USA 2006 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF7375F3EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF7375F3EN ENGLISH

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3 INDEX FRONT FORK WP FORK LEGS WP HANDLEBAR, CONTROLS SIDE STAND 4x 5x 8x 9x FRAME, SUB FRAME SWINGARM MONOSHOCK WP MONOSHOCK DISASSEMBLED 10x 11x 12x 13x EXHAUST SILENCER EXHAUST PIPE AIR FILTER BOX TANK, SEAT, COVER 17x 18x 19x 20x 1

4 INDEX MASK, FENDERS DECAL FRONT WHEEL REAR WHEEL 21x 22x 23x 24x WIRING HARNESS REAR BRAKE CONTROL BRAKE CALIPER REAR HAND BRAKE CYLINDER 25x 26x 27x 28x BRAKE CALIPER FRONT SPEEDOMETER 29x 30x x x 2

5 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

6 FRONT FORK WP 1* 14187B04LS FORK LEG L/S WP * 14187B04RS FORK LEG R/S WP HH COLLAR SCREW M 8X25 WS= HH COLLAR SCREW M 8X30 WS= HH COLLAR SCREW M 8X35 WS= AH SCREW DIN6912-M10X25,10.9,L EJOT PT SCREW K60X20 WS= BOT.TRIP.CL.CPL. X=20MM/D=60MM FORK TUBE L=244 ' TOP TRIPLE CLAMP X=20MM/D=54MM STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP D=28MM HANDLEBAR SUPPORT 28MM SC' * TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP 1 85* CLAMP F.SPEED.CABLE ORANGE STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS=8 6 92* FORK PROTECTION L/S ORANGE / C * NEW PART X AS REQUIRED 4

7 FORK LEGS WP 1* S1 SCREW CAP M51X1,5 CPL O-RING NBR 45X KNOB REBOUNG ADJUSTER S1 SCREW CAP M51X1,5 CPL STEEL BALL D=3MM SPRING D=2,9 L=7, O-RING NBR 6X1, VENT SCREW M4X O-RING NBR 3,7X1, O-RING NBR 12X1, HOLDER F.ADJUSTMENT TUBE D=4MM 2 12* E OUTER TUBE L=577 D=54/ GUIDING RING D=58MM 2 15* DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB DUST STRIPPER D=48 58,4X11,8 2 22* DU-BUSH D47XD49X20DDL * INNER TUBE D=48 L= S HYDR.STOP L=200MM D=31,9 CPL ADJUSTMENT TUBE L=517MM PISTON ROD D=14 L=551 M11X NEEDLE REBOUND O-RING NBR 3X1, SPRING REBOUND NEEDLE C=4N/MM WASHER 32X42X2, SPACER 42X26,5X2, SPACER 42X26,5X SPACER 42X26,5X SPACER 42X26,5X1, S SPRING 3,6N/MM SET x S SPRING 3,8N/MM SET D=4,9MM x S SPRING 4,0N/MM SET D=5,0MM x S SPRING 4,2N/MM SET D=5,0MM x S SPRING 4,4N/MM SET D=5,1MM x / C * NEW PART X AS REQUIRED 5

8 FORK LEGS WP S SPRING 4,6N/MM SET x S SPRING 4,8N/MM SET x INTERM. RING 26,2 X 43 X S SCREW SLEEVE M29,3X1 L=90 CPL O-RING NBR 8X1, REBOUND SPRING D=15MM L=34,5MM TAB REBOUND D= SPRING CHECK VALVE D=0, CHECK VALVE 8X24X0, CHECK VALVE 8X18X0, CHECK VALVE 8X20X0, CHECK VALVE 8X22X0, SHIM 6X14X0,1 x SHIM 6X16X0,1 x SHIM 6X18X0,1 x SHIM 6X16X0,25 x SHIM 6X18X0,25 x SHIM 6X9X0,3 x SHIM 6X9,5X0,3 x SHIM 6X24X0,1 x SHIM 6X22X0,1 x SHIM 6X20X0,1 x SHIM 6X24X0,1 DELTA x PISTON RING 5X1X PISTON REBOUND D=27, NUT M6X0,5 REBOUND TUBE 29,3X1X390 D=8,5MM O-RING NBR 46 X S AXLE CLAMP L/S CPL. USD S AXLE CLAMP R/S CPL. USD HH COLLAR SCREW M 8X25 WS= CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0, S1 TAP COMPRESSION CPL CHECK VALVE 8X24X0, PISTON COMPRESSION D=27, / C * NEW PART X AS REQUIRED 6

9 FORK LEGS WP O-RING NBR 21X O-RING NBR 24X TAP COMPRESSION NEEDLE COMPRESSION O-RING NBR 8X LOCK WASHER RB COMPRESSION ADJ. SCREW COPPER WASHER 29,5X33,5X RUBBER CAP D=35MM S1 FORK OIL SAE T511 SILICONE GREASE F. DUST STRIP. 1 99* R14013 REPAIR-KIT GASKET 4860 MXMA / C * NEW PART X AS REQUIRED 7

10 HANDLEBAR, CONTROLS 1* HANDLEBAR 28MM HIGH FATBAR PAD WIRING HOLDER 12MM THR.TWIST CRIP CPL. W.O.CA TWIST GRIP COVER RENTHAL PROTECTION COVER ' THROTTLE C DOM./KEIH SHORT CIRCUIT BUTTON FIXED GRIP RENTHAL CABLE TIE 200/3,6MM BLACK SPACER BUSHING 6X10X5 1 30* MASTER CYLINDER CPL * CLUTCH LEVER CPL. BREMBO * REP. KIT PISTON * COVER HYD. CLUTCH CPL. 1 34* VALVE 1 35* BOLT KPL BRAKE FLUID DOT * PROTECTION CAP * LEVER SCREW CPL * PUSH ROAD CPL. 1 44* CLAMP CPL * CLUTCH PIPE / C * NEW PART X AS REQUIRED 8

11 SIDE STAND BUSHING WITH SCREW EXC USA SIDE STAND L=377MM ' BOLT SIDE ST.SPRING M5 EXC' SIDE STAND BRACKET CPL RUBBER L=145MM SIDESTAND SPRING EXC' SELF LOCKING NUT M / C * NEW PART X AS REQUIRED 9

12 FRAME, SUB FRAME 1* FRAME 250/300 "CB06" USA SUB FRAME CPL. 2-T. EXC REINFORCING BRACKET ADH. FOIL TRANSP. 80X80 MM SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M ENGINE BRAC.SCR. M10X105 WS= SPROCKET SCREW-AH M8X20 WS= SPROCKET SCREW-AH M8X26 WS= COLLAR SCREW M8X42 WS= PLUG 37MM SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M 8X35 WS= * GROOVED BALL BEAR RS C 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 ANGEL PIECE ' PVC-HOSE 7X10 PER METER x FRAME PROTECTION SET BLIND PLUG-IN NUT M5 WN 22A BUSHING F. SPROCKET COVER RAC HH COLLAR SCREW M 5X25 WS= BUSH F. FRAME PROTECTION HH COLLAR SCREW M 6X40 WS= CHAIN SLIDING PIECE BELOW ' BUSHING 8,2X10X * BUSHING 8.2 X 12 X * CHAIN ROLL D=30MM / C * NEW PART X AS REQUIRED 10

13 SWINGARM SWINGARM CPL CHAIN GUARD BUCKET HH COLLAR SCREW M 6X10 WS= RETAIN.CLAMP FOR BRAKE HOSE' SPECIAL SCREW M 5,0X10 x 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 ' RETAINING PLATE CPL HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X50 WS= PIVOT BEARING+BUSHES PDS ' TOOL BEARING MOUNTING PDS CHAIN GUARD SMALL EXC SELF LOCK. NUT DIN0985-M WASHER DIN9021-A 6, SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND / C * NEW PART X AS REQUIRED 11

14 MONOSHOCK WP 8* S HH COLLAR M12X55 WS= * 12187B04 MONOSHOCK WP250/300EXC / C * NEW PART X AS REQUIRED 12

15 MONOSHOCK DISASSEMBLED MONOSHOCK TOP H=30,5 M54X S6 DCC-COMPR.DAMP.CONTROL CPL ADAPTOR BUSH KGW 12X OIL SEAL KGW D= WASHER KGW D= BUSHING KGW 1525 HD BLEED PLUG R 1/ O-RING NBR 48X WP CAUTION (PDS KTM) 58X * RESERV. SCREW L=120 D=52 BLACK O-RING VITON 41X SEPARATION PISTON D=52, H= PISTON RING 3,9X1,5X RESERVOIR CAP D= O-RING NBR 5,28X1, SCREW PLUG M5X RUBBER CAP "DO NOT OPEN" O-RING 52X WASHER 16X8,2X0,6 1 27* NEEDLE D=11,4 D=6, L= SCREW CAP M20X1 D=11,5 H= LOCK WASHER TUBE PDS L= CIRCLIP 50X1, SPRING GUIDANCE L= SPRING RETAINER M56X AH SCREW DIN0912-M 5X INTERM.RING SCREW SPRING RET. 2 40* SPRING250 76N/MM D12,5 (62)ORA CIRCLIP 58,2X2 1 43* S SPRING RET. D=80 W. O-RING O-RING VITON 66,27X3, PISTON ROD NUT M16X O-RING VITON 44,17X1, PISTON RING WASHER 16X21X / C * NEW PART X AS REQUIRED 13

16 MONOSHOCK DISASSEMBLED BACKPLATE 16X21X0, SHIM 16X30X0, SHIM 16X32X0, SHIM 16X34X0, SHIM 16X36X0, PISTON 6+6X3,5/4, BACKPLATE 16X21X0,30 x BACKPLATE 16X22X0,30 x SHIM 16X23X0,30 x SHIM 16X40X0,25 x SHIM 16X30X0,30 x SHIM 16X32X0,30 x SHIM 16X34X0,30 x SHIM 16X36X0,30 x SHIM 16X38X0,30 x SHIM 16X40X0,30 x 51* HOLDER D=16 M16X1 L= * BACKPLATE D=23 D=16 H BACKPLATE 16X20X0,30 x SHIM 16X28X0,15 x SHIM 16X28X0,20 x SHIM 16X30X0,20 x SHIM 16X32X0,20 x SHIM 16X34X0,20 x SHIM 16X36X0,25 x SHIM 16X34X0,20 x SHIM 16X36X0,20 x SHIM 16X38X0,20 x SHIM 16X40X0,20 x SHIM 16X42X0,20 x SHIM 16X44X0,20 x SHIM 16X28X0,25 x SHIM 16X30X0,25 x SHIM 16X36X0,25 x SHIM 16X38X0,25 x SHIM 16X44X0,25 x / C * NEW PART X AS REQUIRED 14

17 MONOSHOCK DISASSEMBLED BACKPLATE 16X20X0,30 x SHIM 16X34X0,15 x SHIM 16X32X0,25 x SHIM 16X34X0,25 x REBOUND DISC D=34, H=8 1 58* PISTON 6+6X7/4,5 VB 1,0 1 60* PISTON ROD D=18 L=146 M16X BUSH M8X O-RING VITON 7X1, NEEDLE SEAT M8X1 D=5, * TUBE M8X1 L=145, O-RING NBR 8X TUBE ADAPTOR M8X1 L= * NEEDLE L= O-RING VITON 2,2X1, S ADAPTOR CPL. D=50 H= STEEL DISC 18X,5X43,7X REBOUND RUBBER BACKUPRING 22,55X1, QUAD RING 18X2, O-RING 41X DU-BUSH 18X20X DUST SEAL CIRCLIP 53X1, * COVER D= * BUMP RUBBER SXS * NUT M18X1 1 90* FORK PART L=55,5 B=32,5 D= THREADED BUSH M12 PDS RUBBER PLUG D= STEEL BALL D=3MM SPRING D=2,9 L=7, RESERVOIR CAP M14X O-RING NBR 4X1, ADJUSTING SCREW 80 DEG. L= * S1 SHOCK ABSORBER FLUID 5 LT ,33 LITRE / C * NEW PART X AS REQUIRED 15

18 MONOSHOCK DISASSEMBLED 99* R12011 REPAIR KIT GASKET 5018 PDS / C * NEW PART X AS REQUIRED 16

19 EXHAUST SILENCER 3* EXH. SILENCER CPL. EXC HH COLLAR SCREW M 6X30 WS= BUSHING 7,5X12X28X7,8 ' EXHAUST BRACKET RUBBER BLACK RANGE CHANGE METAL NUT M SPRING WASHER DIN0137-B SILENCER ENDCAP 2-STROKE SILCENCER RUBBER 2-STROKE SILENCER CONNECTING-CAP SILENCER DISC SILENCER SCREW 2-STROKE RING 55,00X2,00 NBR STUFFING YARN-SET 450 GRAM / C * NEW PART X AS REQUIRED 17

20 EXHAUST PIPE EXHAUST PIPE 250 SX O-RING 44,00X3,00 VITON SWINGELEMENT FOR EXHAUST PIPE TEN.SPRING L=62MM EY.MOVEABLE SILICON SLEEVE D=25/27MM RANGE CHANGE METAL NUT M SNAP-NUT HOLDER M6 KP HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X15 WS= / C * NEW PART X AS REQUIRED 18

21 AIR FILTER BOX FILTER WALL FILTER BOX COVER REAR PART FILTER BOX QUICK RELEASE-NIPPLE * BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX ' THROTTLE CAP EGS CPL.98 x AIR FILTER RACING FILTER CARRIER 2-STROKE FILTER SUPPORT CPL.2-STROKE' FILTER SUPPORT BUSH ' FASTEN. DEVICE FILTER SUPPORT CARBU.CONNECT.BOOT ' HOSE CLAMP 50-70MM EJOT PT SCREW K60X20 WS= SPECIAL SCREW M 5,0X BUCKET / C * NEW PART X AS REQUIRED 19

22 TANK, SEAT, COVER GAS COCK ON/OFF/RES O-RING 11X2 VITON PVC-HOSE 6X9 MM PER METER x 8* FILLER CAP CPL SCREW SEAT FASTENING D=6X23/ * FUEL TANK CPL. 11,5L TANK ROLLER 12X26X12 ' FUEL PREFORMED HOSE SX CLAMP YDNAC MM EJOT PT SCREW K60X20 WS= ANGLE PIECE 90 DEGREE M10X1 1 35* SEAT BLACK WITHOUT KTM-LOGO * SEAT COV.BLACK WITHOUT LOGO * SPOILER L/S ORANGE * SPOILER R/S ORANGE BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X12 WS= ORIGINAL EQUIPMENT TOOL KIT / C * NEW PART X AS REQUIRED 20

23 MASK, FENDERS NUMBER PLATE CPL. ORANGE BRAKE HOSE GUIDE BLACK EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M 6X15 WS= FENDER FRONT WIDE ORANGE SPACER BUSHING HH COLLAR SCREW M 6X20 WS= FENDER BRACE BLACK ' SCREW FEND.BRACE M8X9 WS= NUT FENDER BRACE M8 WS= REAR PART SX ORANGE COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M 6X25 WS= BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 21

24 DECAL 1* SPOILER DECAL XC * DISCAPLEME. STICKER 250XC-W / C * NEW PART X AS REQUIRED 22

25 FRONT WHEEL 1* FRONT WHEEL 1,6X21" EXCEL * FRONT HUB CPL. SX SILVER BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL SPOKE M4,5X228-15G 21" DDE SPOKE NIPPLE M4,5X0,75 8X FRONT RIM 1,6X21" EXCEL AL RIM BAND 21" RIM LOCK VM1 (1,60") NUT FOR WHEEL HOLDER ' BRAKE DISC FRONT D=260MM SPECIAL SCREW M6X13 WS= WHEEL SPIN.FR. D=26 M24X1, SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= PLUG FOR RIM x 40* AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 23

26 REAR WHEEL 1* REAR WHEEL 2,15X18" EXCEL * REAR WHEEL HUB CPL. SX, EXC BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB SPOKE M5X195-10G 18" DDE SPOKE NIPPLE M5-TA (8X21MM) REAR RIM 2,15X18" EXCEL AL BRAKE DISC REAR D=220MM SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" 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 SPROCKET SCREW-AH M8X26 WS= SELF LOCKING NUT M CHAIN 5/8X1/4" + MASTER LINK CONNECTING LINK 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 24

27 WIRING HARNESS WIRING HARNESS EXC-USA 2K CABLE SUPPORT KHS NR WIRING HOLDER 12MM x WIRING HOLDER 16MM x RETAINING PLATE FOR BATTERY' VOLTAGE REGULATOR KOKU.EXC USA HH COLLAR SCREW M 6X10 WS= 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 COVERING CAP SFL / C * NEW PART X AS REQUIRED 25

28 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 CU-SEAL RING DIN X16X FOOT BRAKE LEVER CPL STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M 5X12 WS= RETURN SPRING FOR BRAKE LEVER HH COLLAR SCREW M 6X20 WS= PUSH ROD L=28MM HEXAGON NUT DIN0934-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 M 6X12 WS=8 2 64* BELLOWS FOR REPAIR KIT BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 26

29 BRAKE CALIPER REAR BRAKE CALIPER REAR CPL REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM RETAINING SPRING SET CUP SET SHORT BRAKE HOSE REAR 655MM BLEEDER HOLLOW SCREW M10X CU-SEAL RING DIN X16X / C * NEW PART X AS REQUIRED 27

30 HAND BRAKE CYLINDER 1* HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE 1 10* REP.SET PISTON D=10MM CLAMP CPL. NATURE HH COLLAR SCREW M 6X25 WS= LEVER SCREW CPL * HAND BRAKE LEVER + SPRING * ADJUSTING SCREW CPL. EXC PROTECTION CAP HAND BRAKE CYL CLAMP FOR MIRROW '94 x BRAKEHO. FRONT 1300MM HOLLOW SCREW M10X1X CU-SEAL RING DIN X16X BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 28

31 BRAKE CALIPER FRONT BRAKECALIPER FRONT BREMBO REPAIR KIT 28MM REPAIR KIT PISTON 28MM BOLT CPL. 6X RETAINING PLATE SET BREMBO BRAKE P.SET FR. TOSHIBA TT * BLEEDER SCREW WITH CAP CUP SET SHORT HH COLLAR SCREW M 8X35 WS= BRAKEHO. FRONT 1300MM CU-SEAL RING DIN X16X CU-SEAL RING DIN X16X1, HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 29

32 SPEEDOMETER SPEEDOMETER KM/H F. 21" REPROGRAMMABLE: KM/H - MPH 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 D=5X RUBBER GROMMET 16X10,8X HH COLLAR SCREW M 6X25 WS=8 2 26* SPEEDOMETER BRACKET / C * NEW PART X AS REQUIRED 30

33 NOTICE

34 NOTICE

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36 KTM Group Partner *3CF7375F3EN* 3CF7375F3EN Art.Nr.: 3CF7375F3EN 6/2005 KTM-Sportmotorcycle AG A-5230 Mattighofen