300 XC 2006 SPARE PARTS MANUAL: ENGINE ENGLISH ART.NO.: 3CM084622EN

Transcription

1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM084622EN ENGLISH

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3 INDEX 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

4 INDEX 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

5 SPECIAL TOOLS 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 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

6 ENGINE CASE 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

7 REED VALVE CASE 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

8 CLUTCH COVER 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

9 CRANKSHAFT, PISTON I PISTON I CPL. 300 VERTEX II PISTON II CPL. 300 VERTEX 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 R-RING 72,0MM / C * NEW PART X AS REQUIRED 7

10 CYLINDER, CYLINDERHEAD 4* INTERMEDIATE FLANGE 250/ CYLINDER CPL. W. FLANGE CYLINDER HEAD 300 "3003" 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 80,00X2,00 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

11 CARBURETOR KEIHIN 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

12 CARBURETOR KEIHIN 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

13 CLUTCH 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

14 KICKSTARTER 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

15 TRANSMISSION I 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

16 TRANSMISSION II 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

17 SHIFTING MECHANISM 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

18 COOLING SYSTEM 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

19 EXHAUST CONTROL 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 GEAR SEGMENT R/S GEAR SEGMENT L/S BEAR. SLEEVE F.CONTROL FLAP' O-RING 15,00X1,50 VITON CONTROL FLAP "3005" 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 AUXILIARY SPRING SOFT, RED x / C * NEW PART X AS REQUIRED 17

20 EXHAUST CONTROL AUXILIARY SPRING MID., YELLOW 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

21 IGNITION SYSTEM FLYWHEEL KOKUSAN 2K-3 ' STATOR KOKUSAN 2K SPARK PLUG CAP NGK REINFORC SEALING CUP FOR SPARK PLUG SPARK PLUG NGK BR7ES IGNI.COIL KOKU ' CDI UNIT 300 MXC/EXC 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

22 NOTICE

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24 KTM Group Partner *3CM084622EN* 3CM084622EN Art.Nr.: 3CM084622EN 6/2005 KTM-Sportmotorcycle AG A-5230 Mattighofen