250 XC USA 2006 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF6375F0EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF6375F0EN ENGLISH

2 INDEX FRONT FORK WP FORK LEGS WP HANDLEBAR, CONTROLS FRAME, SUB FRAME 3x 4x 7x 8x SWINGARM MONOSHOCK WP MONOSHOCK DISASSEMBLED EXHAUST SILENCER 9x 10x 11x 15x EXHAUST PIPE AIR FILTER BOX TANK, SEAT, COVER MASK, FENDERS 16x 17x 18x 19x 1

3 INDEX DECAL FRONT WHEEL REAR WHEEL REAR BRAKE CONTROL 20x 21x 22x 23x BRAKE CALIPER REAR HAND BRAKE CYLINDER BRAKE CALIPER FRONT 24x 25x 26x 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

4 FRONT FORK WP 1* 14187B28LS FORK LEG L/S WP * 14187B28RS FORK LEG R/S WP HH COLLAR SCREW M 8X25 WS= HH COLLAR SCREW M 8X35 WS= * S HH COLLAR SCREW M8X25 WS=10 06 x 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= 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 81* 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 3

5 FORK LEGS WP O-RING NBR 45X KNOB REBOUNG ADJUSTER STEEL BALL D=3MM SPRING D=2,9 L=7, O-RING NBR 6X1, 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 SPRING REBOUND NEEDLE C=4N/MM WASHER 32X42X2, SPACER 42X26,5X2, 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 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 / C * NEW PART X AS REQUIRED 4

6 FORK LEGS WP TAB REBOUND D= * SHUTTLE VALVE SPRING C=0, CHECK VALVE 8X24X0, CHECK VALVE 8X18X0, CHECK VALVE 8X20X0, CHECK VALVE 8X22X0, CHECK VALVE 8X11X0, CHECK VALVE 8X11X0, SHIM 6X12X0,1 x SHIM 6X14X0,1 x SHIM 6X16X0,1 x SHIM 6X18X0,1 x SHIM 6X16X0,25 x SHIM 6X18X0,25 x 50* 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, O-RING NBR 21X O-RING NBR 24X TAP COMPRESSION / C * NEW PART X AS REQUIRED 5

7 FORK LEGS WP 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 S PRE-LOAD ADJUSTER CPL.(1 PC.) VENT SCREW M4X O-RING NBR 3X1, SCREW CAP M51X1, S ADAPTER ADJUST. KNOB + BUSHING O-RING NBR 26X CIRCLIP 49X1, LOCKNUT SUPPORT RING FOR SPRING 2 98 T511 SILICONE GREASE F. DUST STRIP. 1 99* R14013 REPAIR-KIT GASKET 4860 MXMA / C * NEW PART X AS REQUIRED 6

8 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 7

9 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 8

10 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 SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND / C * NEW PART X AS REQUIRED 9

11 MONOSHOCK WP 8* S HH COLLAR M12X55 WS= * 12187B25 MONOSHOCK WP 250/300 XC / C * NEW PART X AS REQUIRED 10

12 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 SHIM 16X30X0, / C * NEW PART X AS REQUIRED 11

13 MONOSHOCK DISASSEMBLED BACKPLATE 16X21X0, SHIM 16X32X0, SHIM 16X34X0, SHIM 16X36X0, WASHER 16X21X 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 BACKPLATE 16X20X0,30 x SHIM 16X34X0,15 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 16X32X0,25 x SHIM 16X34X0,25 x / C * NEW PART X AS REQUIRED 12

14 MONOSHOCK DISASSEMBLED SHIM 16X34X0,20 x SHIM 16X36X0,25 x SHIM 16X38X0,25 x SHIM 16X44X0,25 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 13

15 MONOSHOCK DISASSEMBLED 99* R12011 REPAIR KIT GASKET 5018 PDS / C * NEW PART X AS REQUIRED 14

16 EXHAUST SILENCER 1* EXHAUST SILENCER 250 SX 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 330 GRAM / C * NEW PART X AS REQUIRED 15

17 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 16

18 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 17

19 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 18

20 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 19

21 DECAL 1* SPOILER DECAL XC * DISCAPLEME. STICKER 250XC / C * NEW PART X AS REQUIRED 20

22 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 21

23 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 22

24 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 23

25 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 24

26 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 25

27 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 26

28 250 XC 2006 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM083631EN ENGLISH

29 INDEX 250 XC 2006 SPECIAL TOOLS ENGINE CASE REED VALVE CASE CLUTCH COVER 3x 4x 5x 6x CRANKSHAFT, PISTON CYLINDER, CYLINDERHEAD CARBURETOR KEIHIN CLUTCH 7x 8x 9x 11x KICKSTARTER TRANSMISSION I TRANSMISSION II SHIFTING MECHANISM 12x 13x 14x 15x 1

30 INDEX 250 XC 2006 COOLING SYSTEM EXHAUST CONTROL IGNITION SYSTEM 16x 17x 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

31 SPECIAL TOOLS 250 XC UNIVERSAL MOUNTING RACK CPL CLUTCH HOLDER 250 ' GEAR WHEEL SEGMENT MAGNETIC PULLER M 27X1 KOKUSAN SPECIAL CIRCLIP PLIER HOLD. SPANNER ROTOR 2K-1/2/3/ TIMING DEGREE DISC PROTECTION CAP CRANKSHAFT M ADJUSTING PLATE DIAL GAUGE 0-10MM DIAL GAUGE SUPPORT LOCTITE 648 GREEN 24ML LOCTITE 243 BLUE 6CCM RIVETTING TOOL FOR CLUTCH MOUNTING TOOL F.BEARING NJ / C * NEW PART X AS REQUIRED 3

32 ENGINE CASE 250 XC ENGINE CASE CPL. WITH BEAR IGNITION COVER 250/ IGNITI.COVER GASKET 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 * CHAIN FAIL. PROTECTION RETAINING PLATE HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X55 WS= HH COLLAR SCREW M 6X60 WS= GASKET SET 250/ / C * NEW PART X AS REQUIRED 4

33 REED VALVE CASE 250 XC HH COLLAR SCREW M 6X16 WS= RUBBER BOOT CPL. BOYESEN REED VALVE ASSY BOYESEN CPL REED VALVE CPL. BOYESEN GASKET REED VALVE CASE / C * NEW PART X AS REQUIRED 5

34 CLUTCH COVER 250 XC INTERM. CLUTCH COVER CPL PLUG M 24X 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 RING 18,72X2, CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X12 WS= HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X25 WS= HH COLLAR SCREW M 6X55 WS= HH COLLAR SCREW M 6X60 WS= / C * NEW PART X AS REQUIRED 6

35 CRANKSHAFT, PISTON 250 XC * I PISTON CPL RINGS * II PISTON CPL RINGS WIRE LOCK RING C18X1,5 2 4* PISTON PIN HEX.NUT L/SH M18X1, LOCK WASHER VSK SPACER SLEEVE 28X38X SHAFT SEAL RING 38X52X7BTSL BALL BEARING 32X65X17 NTN 1 13* CRANKSHAFT 250/ 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 SQUARE RING 66,4MM / C * NEW PART X AS REQUIRED 7

36 CYLINDER, CYLINDERHEAD 250 XC * INTERMEDIATE FLANGE 1 5* CYLINDER CPL. W. FLANGE * CYLINDER HEAD 250 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 76,00X2,00 VITON O-RING 114,00X2,00 SILICONE VACUUM CONNECTION M 6X PVC-HOSE 6X9 MM PER METER x ANGEL PIECE ' STUD DIN0835-M10X 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 HH COLLAR SCREW M 5X12 WS= / C * NEW PART X AS REQUIRED 8

37 CARBURETOR KEIHIN 250 XC CARBURETOR PWK36-S 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 ARM PIN FLOAT FLOAT CPL GASKET FLOAT CHAMBER FLOAT CHAMBER PWK38-S AG RETAINING PLATE FOR BLEEDER HH COLLAR SCREW M 4X16 WS= SPRING FOR ADJUSTMENT SCREW ADJUSTMENT SCREW SPRING ADJUSTMENT SCREW M FLOAT VALVE CPL. PWK 38 AG PJ CLAMP 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 SPECIAL-AH-SCREW M 4X THROTTLE CALBE HOLDER M6X0, CARBURETOR COVER PWK36-S AG GASKET FOR CARBURETOR COVER CLIP FOR JET NEEDLE / C * NEW PART X AS REQUIRED 9

38 CARBURETOR KEIHIN 250 XC SLIDING SPRING SPRING CAP NIPPLE 1 34* JET NEEDLE KEIHIN N8RF 06 x 34* JET NEEDLE KEIHIN N8RG 06 x 34* JET NEEDLE KEIHIN N8RE 06 x 34* JET NEEDLE KEIHIN N8RH 06 x THROTTLE VALVE 7 FOR 38 PJ ' STARTER PISTON CPL CLAMP 6 MM PVC-HOSE 4X6MM PVC-HOSE 3X5MM x 49* PLUG M 18X O-RING 18,00X2,30 NBR SLIDE STOP L=38MM x O-RING 6,00X1,78 x WASHER ADJUSTING SCREW O-RING ADJUSTING SCREW / C * NEW PART X AS REQUIRED 10

39 CLUTCH 250 XC 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 1,2 MM 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 HOLLOW SCREW M10X1 1 65* O-RING 1 66* PISTON CPL O-RING 30,00X1,50 NBR * PRESSURE SPRING HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X20 WS= CU-SEAL RING DIN X16X / C * NEW PART X AS REQUIRED 11

40 KICKSTARTER 250 XC KICKSTARTER CPL. ' SPROCKET SCREW-AH M8X20 WS= 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 RACING KICKSTARTER GEAR 34-T RATCHET GEAR KICKSTARTER HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X20 WS= / C * NEW PART X AS REQUIRED 12

41 TRANSMISSION I 250 XC MAIN SHAFT 14-T "1S14" * SOLID GEAR 2.ND 15-Z "2S15" SLIDING GEAR 3RD G.18-T "3S18" IDLER GEAR 4TH G. 21-T "4S21" IDLER GEAR 5TH G. 22-T "5S22" BALL BEARING 6205 C3 NTN NEEDLE BEAR. K 22X26X13 TN NEDDLE BEAR. K24X28X11,9 DIV STOP DISK 20,2X33X1, AXIAL-CIRCLIP 25X1, GROOVED BALL BEAR. TM C STOP DISC 25,2X32X1, STOP DISC 25,2X32X / C * NEW PART X AS REQUIRED 13

42 TRANSMISSION II 250 XC COUNTERSHAFT IDLER GEAR 1ST G. 28-T "1S28" 1 12* IDLER GEAR 2.G 24-Z "2S24" IDLER GEAR 3RD G. 24-T "3S24" SLIDING GEAR 4TH G.24-T "4S24" SLIDING GEAR 5TH G.21-T "5S21" AXIAL-CIRCLIP 25X1, NEEDLE BEAR. K20X24X NEDDLE BEAR. K24X28X11,9 DIV NEEDLE BEAR. K 22X26X13 TN BALL BEARING TM-SC05C20C4 NTN BALL BEARING 6203 JR2 C LOCK RING DIN X1,64SD SPROCKET 13-T SPROCKET 14-T SPROCKET 15-T x STOP DISC 25,2X32X1, STOP DISC 17,2X30X SPACER SLEEVE DRIVE END SHAFT SEAL RING 32X45X6,5 BTSL O-RING 28,80X2,20 P431 NBR SHIM 20X32X STOP DISC 25,2X32X / C * NEW PART X AS REQUIRED 14

43 SHIFTING MECHANISM 250 XC SHIFTING FORK 4TH/5TH GEAR SHIFTING FORK 2ND GEAR SHIFTING FORK 1ST/3RD GEAR NEEDLE ROLLER DIN5402 6X14, SHIFTING SHAFT CPL PRESSURE SPRING 0,9MM SLIDING PLATE CPL TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 6903 C SHIFT ROLLER BALL BEARING 6805 C4 NTN JAPAN RETURN SPRING SHIFT LOCATING DRUM AH SCREW DIN6912 M 6X AH SCREW DIN0912-M 6X RETAINING PLATE SHIFT. RAIL MAIN SHAFT 250/ SHIFT. RAIL C. SHAFT 250/ LOCKING LEVER SPRING LOCATING LEVER CPL. 125/200' SLEEVE FOR LOCKING LEVER WASHER DIN7349-5X15X HH COLLAR SCREW M 5X20 WS= 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 HH SCREW DIN0933-M 6X / C * NEW PART X AS REQUIRED 15

44 COOLING SYSTEM 250 XC RADIATOR L/S NATURE (45286)' RADIATOR R/S NATURE (45285)' RADIAT.CAP 20,3PSI (1,4BAR) HOSE CLAMP GEMI ANGEL PIECE ' PVC-HOSE 6X9 MM PER METER x RADIATOR HOSE 18X25 PER METRE x RADIATOR - RADIATOR RADIATOR HOSE INCL. Y-PART RADIATOR HOSE 18X25X130 MM 03 1 WATER PUMP - RADIATOR COVER FOR RADIATOR L/S BLACK x FOR WINTER OPERATION 34* RADIATOR PROTECTOR L. BLACK x 35* RADIATOR PROTECTOR BLACK 06 x CABLE TIE 200/3,6MM BLACK x RUBBER SLEEVE D=12MM WASHER DIN9021-A 6, HH COLLAR SCREW M 6X25 WS=8 4 43* SPACER BUSHING / C * NEW PART X AS REQUIRED 16

45 EXHAUST CONTROL 250 XC FLAT H.SCEW DIN7991-M5X RETAINING PLATE R/S RETAINING PLATE L/S O-RING 16,00X2,00 VITON CONTR.VALVE L/S "L"300/360/ CONTROL VALVE R/S 300/360/ CYLINDER PIN DIN 7-5X16MM (M6) AH SCREW DIN0912-M 6X SPRING SLEEVE OVERLOAD SPRING RETAIN.PLATE CONTROL FLAP ' CONTROL LEVER WITH BALL TYPE BUSHING SLEEVE 1 16* GEAR SEGMENT R/S * GEAR SEGMENT L/S BEAR. SLEEVE F.CONTROL FLAP' O-RING 15,00X1,50 VITON 2 20* CONTROL CLAP 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/ BALL BEARING 626LLBC3/5K HH COLLAR SCREW M 5X20 WS= COVER LID ' SPRING GUIDE 250/ O-RING 12,37X2,62 NBR O-RING 24,00X2,00 NBR * % ADJUST.SPRING L=65MM D=2MM ' AUXILIARY SPRING MID., YELLOW / C * NEW PART X AS REQUIRED 17

46 EXHAUST CONTROL 250 XC AUXILIARY SPRING SOFT, RED x 47* AUXILIARY SPRING HARD, GREEN x SPRING INSERT ANGLE LEVER CPL. ' SHIM WASHER DIN988 10X16X NEEDLE SLEEVE HK CONTROL LEVER CONNECT.ROD CPL. L=109,5MM ' SECURING DIN S / C * NEW PART X AS REQUIRED 18

47 IGNITION SYSTEM 250 XC FLYWHEEL KOKUSAN 2K-2 CPL. ' STATOR KOKUSAN 2K SPARK PLUG CAP NGK REINFORC SEALING CUP FOR SPARK PLUG SPARK PLUG NGK BR7ES IGNI.COIL KOKU ' CDI UNIT 250 SXS WIRING HARNESS FOR CDI 2-ST VOLTAGE REGULATOR KOKU.EXC USA HH COLLAR SCREW M 6X10 WS=8 x HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 19