525 XC ATV 2008 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF8575HQEN

Transcription

1 525 XC ATV 2008 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8575HQEN ENGLISH

2 INDEX 525 XC ATV 2008 HANDLEBAR, CONTROLS FRAME MONOSHOCK SWING ARM 3x 5x 6x 7x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER MASK, FENDERS 8x 9x 10x 11x DECAL FRONT WHEEL REAR WHEEL WIRING HARNESS 12x 13x 14x 15x 1

3 INDEX 525 XC ATV 2008 HAND BRAKE CYLINDER REAR BRAKE CONTROL BRAKE CALIPER FRONT BRAKE CALIPER REAR 16x 17x 18x 19x LIGHTING SYSTEM INSTRUMENTS/LOCK SYSTEM SPECIAL TOOLS ACCESSORIES KIT FRONT SECTION 2 20x 24x 21x 22x 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. 23x

4 HANDLEBAR, CONTROLS 525 XC ATV STEERING HEAD SCREW M20X1, WASHER F. STEERING BEARING HH COLLAR SCREW M10X30 WS= STEERING LEVER STEERING COLUMN HH COLLAR SCREW M8X25 TX BEARING BLOCK WITH BEARING SLIDE BEARING W.C. JFM CABLE GUIDE SPECIAL SCREW M6X12,5 WS= SELF LOCKING NUT DIN0985-M BUCKET RUBBER BUSH SPROCKET SCREW-AH M8X20 WS= HH COLLAR SCREW M 8X20 WS= HANDLE BAR BRIDGE STEER.HEAD SCREW M20X1,5 WS= SPACER TUBE 10.2X16X HANDLEBAR SUPPORT 28MM SC' AH SCREW DIN6912-M10X HANDLEBAR ATV HANDLEBAR CLAMP D=28MM HH COLLAR SCREW M8X30 TX HANDLE BAR GRIP ATV R/S LEFT HANDLE SWITCH HANDLE BAR GRIP ATV L/S CLUTCH LEVER LONG CPL SPRING FOR CLUTCH LEVER LEVER SCREW CPL ' PROTECT.CAP FOR LEVER PERCH' REP.KIT PISTON 9,5MM RAC CLAMP WITH PIN HH COLLAR SCREW M 6X20 WS= RUBBER FOR RESERVOIR ' COVER HYD.CLUTCH RACING FLAT HEAD SCREW DIN0965-M 4X / C * NEW PART X AS REQUIRED 3

5 HANDLEBAR, CONTROLS 525 XC ATV LEVER CPL. RACING CLUTCH PIPE CLUTCH SWITCH MASTER CYLINDER CPL SHAFT SEAL RING 38,5X55X CIRCLIP DIN X BALL BEARING 6006/32-2RS O-RING 32,00X1,50 VITON THUMB THROTTLE THROTTLE CABLE ATV OIL FOR HYD. CLUTCH 75ML / C * NEW PART X AS REQUIRED 4

6 FRAME 525 XC ATV FRAME ATV-XC "NC08" FOOTREST CPL. L/S FOOTREST CPL. R/S COLLAR SCREW M10X24 TX BUSHING 8,2X10X CHAIN SLIDING PIECE BELOW COLLAR SCREW M10X18 TX ENGINE SUPPORT L/S CPL ENGINE SUPPORT R/S CPL SPECIAL SCREW M6X12,5 WS= FRAME PROTECTION BELOW BEARING BUSHING INSIDE HH COLLAR SCREW M8X20 TX FRONT BUMPER BLACK HH COLLAR SCREW M8X16 TX SUB FRAME-BRACKET S HH COLLAR SCREW M8X35 TX LOCK WASHER 8MM FENDER BRACKET SUB FRAME CPL HEELGUARD FIXING L/S HEELGUARD FIXING R/S HH COLLAR SCREW M6X20 TX S COUNTER-SUNK SCREW ISA45 M8X S FLAT HEAD SCREW M. ISA45 M8X HH COLLAR SCREW M8X45 TX PROTECT.FILM F. FRAME L/S PROTECT.FILM F. FRAME R/S ENGINEBRAC.SCREW M10X123 WS= SELF LOCKING NUT M10 CU WS= / C * NEW PART X AS REQUIRED 5

7 MONOSHOCK 525 XC ATV MONOSHOCK CPL. REAR S HH COLLAR M12X55 WS= FRONT MONOSHOCK CPL COLLAR SCREW M10X45 TX / C * NEW PART X AS REQUIRED 6

8 SWING ARM 525 XC ATV SHAFT SEAL RING 2"X2,75"X0,25" INNER RING OUTER RING REAR WHEEL EXCENTRIC CPL GREASE FITTING M6 STRAIGHT SHAFT SEAL RING 2"X2,75"X0, HH COLLAR SCREW M8X45 TX RET. CLAMP F. BRAKE HOSE BLACK SPECIAL SCREW M 5,0X CIRCLIP DIN X2, BRAKE THRUST BEARING BRAKE CALIPER SUPPORT PLATE SWING ARM CPL STICKER FOR CHAIN TENSION SHAFT SEAL RING 25X32X BUCKET F. SHAFT SEAL RING NEEDLE BEARING HK BUSHING SLEEVE F. SWING ARM STOP DISK 22,2X31,7X CHAIN GUIDE CHAIN SLIDING GUARD SCREW RADIATOR BRACKET M DRIVE-IN NUT FOR GUARD ASM-GUARD HH COLLAR SCREW M6X55 TX WASHER DIN9021-A 6, BUSHING F. SWINGPROTECTION HH COLLAR SCREW M8X20 TX SWING ARM BOLT SELF LOCK.NUT M16X1,5 WS= / C * NEW PART X AS REQUIRED 7

9 EXHAUST SYSTEM 525 XC ATV ENDCAP SPARKY ATV SILENCER HOUSING SPARKY ATV STUFFING YARN EXC-F STUFFINGYARN 350 GRAMM ' SCREW TORX M5X CONNECTING CAP CPL. ATV HH COLLAR SCREW M6X30 TX SPRING WASHER DIN0137-B BUSHING 7,5X12X28X7,8 ' EXHAUST BRACKET RUBBER BLACK BUSHING FOR EXHAUST SUPPORT HH COLLAR SCREW M8X25 TX RANGE CHANGE METAL NUT M EXHAUST MANIFOLD R/S CPL TEN.SPRING L=62MM EY.MOVEABLE EXH. SIL. CPL. R/S ATV SPARKY SIL. ELEMENT EXC-F RANGE CHANGE METAL NUT M / C * NEW PART X AS REQUIRED 8

10 AIR FILTER 525 XC ATV CARBURETOR CONNECTION BOOT AIR FILTER BOX COVER FASTEN. DEVICE FILTER S. SX FILTER CARRIER 4S SX INTAKE MANIFOLD AIR FILTER SUPPORT BRACKET CPL FILTER SUPPORT BUSH AIR FILTER HOSE CLAMP 50-70MM / C * NEW PART X AS REQUIRED 9

11 TANK, SEAT, COVER 525 XC ATV SEAT ATV HH COLLAR SCREW M 5X20 WS= SPOILER BRACKET TANK PLUG CPL. EXC HH COLLAR SCREW M6X16 TX TANK ROLLER 12X26X12 ' SCREW FOR SEAT M6X11,5/ FUEL TANK CPL O-RING 11X1,8 NBR GAS COCK ON/OFF/RES HH COLLAR SCREW M 5X12 WS= RADIATOR SPOILER L/S BLACK RADIATOR SPOILER R/S BLACK HH COLLAR SCREW M6X10 TX BUSH FOR SPOILER 6X11X16X7, HH COLLAR SCREW M6X20 TX NIPPLE FOR VENTILATION HOSE FUEL HOSE VITON 6X1,5 PER/M x FUEL HOSE CABLE TIE 200/3,6MM BLACK x SPACER FUEL TANK SEAT COVER / C * NEW PART X AS REQUIRED 10

12 MASK, FENDERS 525 XC ATV HH COLLAR SCREW M6X12 TX BUSH FOR SPOILER 6X11X16X5 MM EJOT PT SCREW K60X20 WS= BUSH FOR SPOILER 6X11X16X7, AIR INTAKE L/S ORANGE AIR INTAKE R/S ORANGE REAR FENDER+AIR INTAKE ORANGE HEEL GUARD L/S BLACK HEEL GUARD R/S BLACK HEELGUARD FIXING L/S HEELGUARD FIXING R/S HH COLLAR SCREW M6X16 TX HH COLLAR SCREW M8X16 TX RANGE CHANGE METAL NUT M INSTRUMENTS BRACKET FRONT COVER BLACK CLIP NUT EASY BOSS 60X2X RUBBER SLEEVE D=12MM FRONT PLASTICPART ORANGE FRONT FENDER L/S ORANGE FRONT FENDER R/S ORANGE SCREW FOR PLASTIC 50X AIR FILTER BOX COVER FENDER-FRAME CONNECTION HH COLLAR SCREW M6X10 TX / C * NEW PART X AS REQUIRED 11

13 DECAL 525 XC ATV DECAL SET 525 ATV XC STICKER "WARNING LABEL 4" STICKER "WARNING LABEL 3" STICKER "WARNING LABEL 1" STICKER "WARNING LABEL 2" STICKER "OWNERS MANUAL" SAFETY PLAQUETTE ATV SAFETY TRAINING DVD / C * NEW PART X AS REQUIRED 12

14 FRONT WHEEL 525 XC ATV HH COLLAR NUT M10X1,25 WS= TIRE FRONT 21X7X10 4PR RIM FRONT 10X OUTER BRAKE DISK PROTECTOR SELF LOCKING NUT DIN0985-M SPACER BUSHING SHAFT SEAL RING BSL 22X40X7NBR BALL BEARING RSH/C BEARING SPACER BUSHING BALL BEARING RSH/C SPACER BUSHING SHAFT SEAL RING BSL 28X52X7NBR BRAKE DISK SPECIAL SCREW F. BRAKE DISK HH COLLAR SCREW M8X20 TX BRAKE DISK PROTECTOR FRONT WHEEL HUB CPL. SP VALVE / C * NEW PART X AS REQUIRED 13

15 REAR WHEEL 525 XC ATV HH COLLAR NUT M10X1,25 WS= TIRE REAR 20X11-9 4PR RIM REAR 8X9" SELF LOCK.NUT DIN0985-M18X1, WASHER DIN0125 A SPACER BUSHING REAR WHEEL HUB CPL CIRCLIP REAR AXLE AH SCREW DIN0912-M 6X TENSION NUT HH COLLAR SCREW M8X16 TX BRAKE DISK SUPPORT BRAKE DISK REAR D=200 MM SPECIAL NUT BRAKE DISK FIXING O-RING 39,34X2,62 NBR 70 SH REAR WHEEL AXLE FL.HEAD SCREW M10X1,25 L= SPROCKET 38T x SPROCKET SUPPORT CIRCLIP REAR AXLE SPROCKET SELF LOCK.NUT M10X1, CHAIN Z-RING 5/8X1/4" CONNECTING LINK F MASTER LINK FOR x VALVE CONUSRING REAR AXLE / C * NEW PART X AS REQUIRED 14

16 WIRING HARNESS 525 XC ATV BATTERY BOX RUBBER L=145MM MAIN WIRING HARNESS ATV XC LIGHTING WIRING HARNESS GROUND CABLE HH COLLAR SCREW M6X16 TX CONTACT WASHER M6 VSV-K VOLTAGE REGULATOR HH COLLAR SCREW M6X20 TX FUSE 10A FUSE 15A CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x STARTER RELAY 12V ' AH OVAL SCREW ISO 7380 M 6X STARTER CABLE BATTERY 12V 4AH YTX5L-BS SPECIAL SCREW M 5,0X BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X10 TX HEXAGON NUT DIN0934-M GROUND CABLE BULB 12V 1,2W (W2X4,6D) HH COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 15

17 HAND BRAKE CYLINDER 525 XC ATV HAND BRAKE CYL. MAGURA 12MM REPAIR KIT PISTON MAGURA 12MM COVER, MEMBRANE, SCREW CLAMP, CYL. PIN, O-RING ARRESTING LEVER, SPRING, SCREW BRAKE LIGHT SWITCH REAR ' HAND-BRAKE LEVER CPL. MAGURA CAP, ADJUSTING SCREW, SPRING HH COLLAR SCREW M6X16 TX BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 16

18 REAR BRAKE CONTROL 525 XC ATV COLLAR SCREW M10X30 TX BALL BEARING SKF RS SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= STEP PLATE FOOT BRAKE LEVER HH COLLAR SCREW M5x12 TX FOOT BRAKE LEVER CPL. ATV SELF LOCK. NUT DIN0985-M SWIVEL HEAD KA HH COLLAR SCREW M6X20 TX FOOT BRAKE CYL. MAGURA 13MM PUSH ROD REPAIR KIT PISTON MAGURA 13 MM COVER, MEMBRANE MAGURA HH COLLAR SCREW M6X16 TX COPPER GASKET BRAKE HOSE REAR 630MM BRAKE LIGHT SWITCH REAR ' RETURN SPRING F. BRAKE LEVER BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 17

19 BRAKE CALIPER FRONT 525 XC ATV SEALING RING 8X MAGURA 26MM PISTON KIT 4X MAGURA 26MM BRAKE PAD SET FRONT ORGANIC SET - BOLT 1X, PIN 2X HH COLLAR SCREW M8X20 TX CALIPER FRONT L/S MAGURA 26MM CALIPER FRONT R/S MAGURA 26MM BLEEDER SCREW WITH CAP COPPER GASKET HOLLOW SCREW + COPPER GASKET HH COLLAR SCREW M6X25 TX BRAKE PIPE FRONT 790 2X610MM BRAKE LINE GUIDE / C * NEW PART X AS REQUIRED 18

20 BRAKE CALIPER REAR 525 XC ATV HOLLOW SCREW CPL. M 10X1 ' COPPER GASKET BRAKE HOSE REAR 630MM BRAKE CALIPER MAGURA 28MM BRAKE PADS REAR ORGANIC ISOLATOR CPL CUP SET REPAIR KIT PISTON MAGURA 28MM / C * NEW PART X AS REQUIRED 19

21 LIGHTING SYSTEM 525 XC ATV HEADLIGHT ATV RUBBER CAP FOR HEAD LIGHT BILUX-BULB 12V 35/35W BA20D SCREW FOR PLASTIC K50X18 T BULB 12V 5W (W2,1X9,5D) PHIL CABLE FOR HEAD LIGHT EJOT PT SCREW K60X20 WS= TAILLIGHT SUPPORT BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X12 TX TAILLIGHT ATV / C * NEW PART X AS REQUIRED 20

22 INSTRUMENTS/LOCK SYSTEM 525 XC ATV KEY COVER CAP IGNITION LOCK NUT M24X WASHER F. IGNITION LOCK KEY BLANK BLACK "T" GRIP IGNITION LOCK H.BEAM INDICATOR LIGHT BLUE' NEUTRAL INDIC. LIGHT GREEN ' INDICATOR LIGHT ORANGE "ON" REVERSE GEAR CONTROL LAMP CABLE TIE 100/2,5MM BLACK x TETHER SWITCH / C * NEW PART X AS REQUIRED 21

23 SPECIAL TOOLS 525 XC ATV OPEN END WRENCH 46MM 1/2"DRIVE HOOK WRENCH F.BEARING ADJUSTM PRESS TOOL FOR REAR EXCENTRIC PRESS TOOL FR. WHEEL HUB BEAR CAL. F. CASTOR-/CAMBER ADJUST PRESS TOOL FOR STEERING BEAR WITHDRAWING SLEEVE BALL-HEAD PRESS TOOL FOR A-ARM BALL-HEAD SUPPORT DE/MOUNTING BALL-HEAD PRESS TOOL A-ARM NEEDLE BEAR PRESS OUT TOOL CPL / C * NEW PART X AS REQUIRED 22

24 ACCESSORIES KIT 525 XC ATV HH COLLAR SCREW M6X16 TX DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER CONTACT WASHER M6 VSV-K PROTECTION CAP F. STARTER ENG BATTERY 12V 4AH YTX5L-BS KEY COVER CAP GROUND CABLE CAL. F. CASTOR-/CAMBER ADJUST REP. INS. 450/525 XC ATV OWN. MAN. 450/525 XC ATV ATV SAFETY BROCHURE 1 1 3CF8575HQEN SPM CHASSIS ATV 525 XC CM089605HEN SPM ENGINE 525 XC ATV SAFETY PLAQUETTE TOOL SET GRIP ORANGE B&F WRENCH WS=17/21/27/ WRENCH WS=13/ T-WRENCH WS=6/8/10 TX=45 B&F SPARK PLUG SOCKET / C * NEW PART X AS REQUIRED 23

25 FRONT SECTION 525 XC ATV WHEEL CARRIER R/S CPL WHEEL CARRIER L/S CPL SELF LOCK.NUT M10X1, SELF LOCK.NUT M12X1, TRACK RODS CPL BALL HEAD M10X1, A-ARM TOP R/S XC CPL A-ARM TOP L/S XC CPL CIRCLIP DIN X1, SPACER BUSHING F. BALLJOINT SWIVEL HEAD HEXAGON NUT DIN 936 M12x1, COLLAR SCREW M10X52 TX A-ARM DOWN R/S XC CPL A-ARM DOWN L/S XC CPL CIRCLIP DIN X1, BALL HEAD M12X1, BUCKET F. SHAFT SEAL RING COLLAR SCREW M10X70 TX SHAFT SEAL RING 17X26X STOP DISK 15,2X25,7X NEEDLE BEARING HMK BUSHING SLEEVE F. A/ARM / C * NEW PART X AS REQUIRED 24

26 525 EXC ATV 2008 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089605HEN ENGLISH

27 INDEX 525 EXC ATV 2008 SPECIAL TOOLS ENGINE CASE CLUTCH COVER BALANCER SHAFT 3x 4x 5x 6x CYLINDER CRANKSHAFT, PISTON CARBURETOR CLUTCH 7x 8x 9x 11x TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM COOLING SYSTEM 12x 13x 14x 16x 1

28 INDEX 525 EXC ATV 2008 VALVE DRIVE TIMING VALVE CYLINDER HEAD LUBRICATING SYSTEM 17x 18x 19x 20x IGNITION SYSTEM ELECTRIC STARTER 21x 22x 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

29 SPECIAL TOOLS 525 EXC ATV UNIVERSAL MOUNTING RACK CPL ENGINE HOLDER FOR RACING RIVETTING TOOL TIMING CHAIN MOUNTING SLEEVE SEAL RING SPECIAL CIRCLIP PLIER EXTRACTOR PRIM. GEAR CPL PISTON RING COMPRESSOR D=95MM LOCTITE 243 BLUE 6CCM BUSHING EXTRACTOR INTERN.BEAR.PULLER MM INTERN.BEAR.PULLER MM INTERN.BEAR.PULLER 5-7 MM LIMIT PLUG GAUGE F.VALVE GUIDE MOUNTING RING FOR INNER CLUTCH PROTECTION COVER F.MAIN SHAFT EXTRACTOR FOR TIMING GEAR VALVE SPRING LEVER MOUNTING TOOL INNER RING NJ MIXT. CONTROL SCREW FACTORY FLYWHEEL EXTRACTOR SILICON GASKET THREE-BOND HOLDING SPANNER FOR SPROCKET SPARK PLUG KEY 250 SX-F VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML CLUTCH HOLDER RACING WRENCH F.MIXTURE CONTROL SCREW PRESS PUNCH VALVE GUIDE ENGINE BLOCKING SCREW LOCATING SCREW M8 L= / C * NEW PART X AS REQUIRED 3

30 ENGINE CASE 525 EXC ATV ENGINE CASE WITH BEARING CPL DOWEL 17 X 13 X HANGER FOR VENT HOSE HH COLLAR SCREW M 6X15 WS= OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, CASE BUSH PLUG DIN0908-M12X1, DOWEL 17 X 19 X PRESSURE SPRING L=25MM D=1MM VALVE PISTON D=10MM OIL JET 70 M6X0,75 WS YDNAC-CLAMP (16MM) ' ENGINE BREATHER TUBE BLEEDER FLANGE M12X1,5 WS= HH COLLAR SCREW M 8X12 WS= CU-SEAL RING 8 X 14 X NEEDLE ROL.DIN5402 NRB 4X9, O-RING 12,00X2,00 NBR PLUG M16X1, OIL SCREEN 11,8X44,5MM O-RING 9X1,5 NBR SEAL RING DIN X18X HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X60 WS= HH COLLAR SCREW M 6X30 SW= HH COLLAR SCREW M 6X75 WS= HH COLLAR SCREW M 6X65 WS= GASKET SET CPL. ATV SUPPORT HH COLLAR SCREW M8X30 TX HH COLLAR SCREW M6X30 TX SPROCKET COVER 250 SX / C * NEW PART X AS REQUIRED 4

31 CLUTCH COVER 525 EXC ATV DOWEL 9,8 X 7 X NEEDLE ROLLER DIN5402 2,5X9, OIL LEVEL GLASS G 1777 Y OIL FILLER CAP M24x3 WITH O-R O-RING 19,00X3,00 NBR RET.BRACKET F.BRAKE LEVER HUB OUTER CLUTCH COVER CLUTCH COVER GASKET CLUTCH COVER CPL. GREY SHAFT SEAL RING 14X24X6 B AH SCREW DIN6912-M 6X GASKET F. OUTER CLUTCH COV HH COLLAR SCREW M 6X30 SW= HH COLLAR SCREW M 6X35 WS= KICK-STARTER PLUG O-RING 16,00X2,00 VITON CIRCLIP DIN X1, / C * NEW PART X AS REQUIRED 5

32 BALANCER SHAFT 525 EXC ATV BALANCER SHAFT CPL. RAC GROOVED BALL BEAR. TM C SHAFT SEAL RING 14X24X6 B / C * NEW PART X AS REQUIRED 6

33 CYLINDER 525 EXC ATV CYLINDER 95MM 520 RACING CYLINDER BASE GASKET 0,5MM DOWEL 6X8X11, HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X45 WS= NEEDLE ROL.DIN5402 NRB 4X9, CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X10 WS= / C * NEW PART X AS REQUIRED 7

34 CRANKSHAFT, PISTON 525 EXC ATV CRANKSHAFT CPL STROKE 72MM, WITHOUT WASHER CON.ROD REP.SET 250/520 RAC.00 1 WITH WASHER CYL.ROLLER BEAR.NJ206 ET2XCS DRIVE GEAR 32-T F.BALANC.SHAFT THRUST WASHER 30,5X45X0,10 x THRUST WASHER 30,7X47X0,15 x THRUST WASHER 30,5X45X0,30 x WOODRUFF KEY DIN6888-3X5X AH SCREW DIN7984-M 6X SH.SEAL RING 30X47X7 BSL VITON PRIMARY GEAR 31T CPL HH NUR M20X1,5 WS=27 LEFT WOODRUFF KEY 5X6,5 HARDED SHAFT SEAL RING 14X24X6 B CIRCLIP DIN X1, COLLAR NUT M12X1 R/S SPRING WASHER DIN0137-B PISTON PIN BOLT 20X15,8/12X CIRCLIP C20X1, I PISTON I 95MM CPL. FORGED II PISTON II 95MM CPL.FORGED OIL SCRAPER RING 95MM RECTANGULAR RING 95/87,2X1, / C * NEW PART X AS REQUIRED 8

35 CARBURETOR 525 EXC ATV CARBURETOR FCR-MX 3925H,TPS CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL THROTTLE VALVE CPL. FCRMX BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBEKP x JET NEEDLE KEIHIN OBEKQ x JET NEEDLE KEIHIN OBEKR x JET NEEDLE KEIHIN OBEKS x JET NEEDLE KEIHIN OBEKT x BAR CLIP NEEDLE SET SCREW CPL NEEDLE JET FCR-MX 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 MAIN JET 178 KEIHIN x MAIN JET 180 KEIHIN x IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x STARTER JET 85 x IDLE AIR JET 100 KEIHIN ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL ARM PIN FLOAT HOT-STARTER VALVE CPL FLOAT NEEDLE / C * NEW PART X AS REQUIRED 9

36 CARBURETOR 525 EXC ATV CLAMP DRAIN SCREW FLOAT CHAMBER COVER ACCELERATOR PUMP DIAPHRAGM ACCELERATOR PUMP FLOAT CHAMBER CPL JET POWER JET CLOSED KEIHIN x COIL SPRING STARTER VALVE SHORT CPL BREATH.HOSE FCR-MX KEIHIN CPL SCREW FOR COVER PLUG M 18X INTERMEDIATE LEVER CPL LINK LEVER SPRING LINK LEVER SPRING INTERMEDIATE LEVER COVER, GASKET, HOSE WASHER LINK LEVER E-CLIP GASKET FOR CARBURETOR COVER ROD ACCELERATOR PUMP YDNAC-CLAMP (16MM) ' HOSE CONNECTOR CPL PLUG DIN0910-M 10X COPPER GASKET DIN X14X HOSE CONNECTOR KEIHIN ENGINE BREATHER TUBE STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 190MM GASKET SET FCR-MX KEIHIN / C * NEW PART X AS REQUIRED 10

37 CLUTCH 525 EXC ATV CLUTCH CAGE 75 T INNER HUB - RACING LINING DISC 2MM INTERMEDIATE DISC 1MM PRESSURE CAP WITH OIL BORE CLUTCH SPRING 2,5X43MM SPRING RETAINER 6,2X12X18X5, INTERMEDIATE DISC 1,4MM PUSH ROD L=201MM HALF-WASHER SUPPORTWASHER 25X35X AH SCREW DIN6912 M6X NEEDLE BEAR K 25X29X PRIMARY GEAR 31T CPL OUTPUT CYLINDER CPL O-RING 30,00X1,50 NBR VENT INJEKTION HYDR. CLUTCH PISTON WITH O-RING AND BALL BLEEDER SCREW WITH CAP HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M 6X20 WS= STEPPED WASHER GASKET FOR SLAVE CYLINDER DRIVING SLEEVE D=8, L= CIRCLIP DIN7993-RW AXIAL WASHER AS X26X AXIAL NEEDLE BEARING AXK PRESSURE PIECE ' HEXAGON NUT DIN0936-M18X1,5 R LOCK WASHER HOLLOW SCREW + COPPER GASKET / C * NEW PART X AS REQUIRED 11

38 TRANSMISSION I - MAIN SHAFT 525 EXC ATV MAIN SHAFT 14T IDLER GEAR 5.G 23T NEEDLE BEAR. 21X25X13 SLOTTED STOP DISK 22,6X30X1,5 15T SLIDING GEAR 3. G. 19T CIRCLIP SW IDLER GEAR 4.G 21T SOLID GEAR 2.G 17T STOP DISK 17,2X27,7,X BALL BEARING 6203 JR2 C BALL BEARING 6205 C3 NTN HH COLLAR SCREW M 6X8 WS= / C * NEW PART X AS REQUIRED 12

39 TRANSMISSION II - COUNTERSHAFT 525 EXC ATV COUNTERSHAFT IDLER GEAR 2.G. 33T NEEDLE BEAR. 22X26X10 SLOTTED NEEDLE BEAR. 22X26X13 SLOTTED CIRCLIP SW SLIDING GEAR 4. G. 28T DISTANCE DISK 25X30X0,2 x DISTANCE DISK 25X30X0,3 x STOP DISK 22,6X30X1,5 18T IDLER GEAR 3.G. 30T SOLID GEAR 5.G. 26T IDLER GEAR REVERSE-GEAR SLIDING SLEEVE REVERSE-GEAR STOP DISK 20,2X31,X1, NEEDLE BEAR. 22X26X IDLER GEAR 1.G. 35T STOP DISK 17,2X30X1, SPACER BUSHING 12MM SPROCKET 13-T x SPROCKET 14-T SPROCKET 15-T x SCREW+SPRING WASHER O-RING 25,12X1,78 NBR BALL BEARING 6203 RSH C CYL.ROLL BEARING NJ SHAFT SEAL RING 32X45X7 BSLNBR / C * NEW PART X AS REQUIRED 13

40 SHIFTING MECHANISM 525 EXC ATV SHIFTING SHAFT CPL TENSIONING SPRING 0,8MM SLIDING PLATE CPL RETURN SPRING 2,2MM ' SPRING GUIDE STOP DISK 14X30X NEEDLE BEAR.HK X20X SHAFT SEAL RING 14X24X6 B SHIFT LEVER CPL. ATV STEEL WASHER 6,4X17X PAIR OF WASHERS M 6 NORDLOCK SPECIAL SCREW M6X16 WS= WASHER DIN0125-A 5, FLAT HEAD SCREW DIN7985-M 5X SHIFTING DRUM ATV CONTACT SPRING 3,6X14MM CONTACT BOLT BALL BEARING 6806 C BALL BEARING C SHIP DRUM LOCATING CPL AH SCREW DIN6912 M 6X LOCKING LEVER CPL SLEEVE FOR LOCKING LEVER SPRING 2,3MM HH COLLAR SCREW M 5X20 WS= WASHER DIN7349-5X15X SHIFTING ROD WITH LOCK SHIFTING MAIN L=93MM PRESSURE SPRING 0,9MM SHIFT FORK SHIFT FORK SHIFT FORK SHIFTING ROLLER 6X8X5, GEAR-POSITION SENSOR ATV O-RING 25,07X2,62 FPM 75SH ABUTMENT / C * NEW PART X AS REQUIRED 14

41 SHIFTING MECHANISM 525 EXC ATV HH COLLAR SCREW M 5X16 WS= SHAFT SEAL RING 10X18X4 BSL V DECOMPRESSION LEVER SPRING LEVER LOCK-SHAFT WASHER DIN9021-A 5, SUPPORT REVERSE GEAR WHEEL GROOVED PIN DIN1472 3x REVERSE GEAR AXLE LOCK WASHER DIN X NEEDLE BEAR. 14X18X STOP DISK 14,1X24X BUS CABLE F. REVERSE GEAR / C * NEW PART X AS REQUIRED 15

42 COOLING SYSTEM 525 EXC ATV THERMOSTAT 70 DEGREES O-RING 32,00X2, SCREW FOR PLASTIC D=4X COOLING WATER HOSE SYSTEM R/S PREFORMED HOSE RADIATOR-CYL HOSE 6X10 EPDM 03 x EXPANSION TANK ANGLE CONNECTION EXPANS. TANK PLUG F. EXPANSION TANK RUBBER GROMMET 6X9X13MM DISTANCE HOLDER 10/10 BLACK YDNAC-CLAMP MM FAN L/S HH COLLAR SCREW M6X20 TX FAN COWL ATV RANGE CHANGE METAL NUT M RADIATOR ATV RADIATOR PROTECTOR SCREW RADIATOR BRACKET M EJOT PT SCREW K60X20 WS= SPECIAL SCREW T60 6X30 WS= RADIAT.CAP 20,3PSI (1,4BAR) RUBBER SLEEVE D=12MM AIR CONDUCTION COWL ATV COLLAR SCREW M6X12 TX HOSE CLAMP GEMI THERMOSWITCH DG / C * NEW PART X AS REQUIRED 16

43 VALVE DRIVE 525 EXC ATV INTAKE VALVE D=35MM EXHAUST VALVE D=30MM VALVE-STEM SEALING RACING VALVE SPRING KIT (4X) ATV VALVE COLLET KK 6 H ADJUSTMENT SCREW M6X0, NUT M6X0, ROCKER ARM SHAFT INTAKE ROCKER ARM SHAFT EXHAUST END CAP ROCKER ARM SHAFT O-RING 19,10X1,60 NBR SHIM ALU 5,2X10X AH SCREW DIN 912 M 5X ROCKER ARM INTAKE CPL ROCKER ARM EXHAUST CPL / C * NEW PART X AS REQUIRED 17

44 TIMING VALVE 525 EXC ATV TIMING CHAIN 96 ROLLS TIMING CHAIN GUIDE RACING SECURING GUIDE RACING TIMING GEAR 18-T TIMING CHAIN TENSIONER GASKET TIMING CHAIN TENSIONER TIMINGCHAIN TENSIONER CPL.RAC SPACER BUSHING 6,1X8,2X13, HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 5X16 WS= SUPPORTING SLEEVE 5,2X7X10X7, CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X25 WS= CAMSHAFT 590/ CAMSHAFT GEAR AUTO DECOMPRESSION SHAFT AH SCREW DIN7984-M 8X WASHER 26,7X34X1, GASKET SUPPORT BALL BEARING SPRING FOR AUTODECOMPRESSION O-RING 29,10X1,60 NBR O-RING 25,12X1,78 NBR SHAFT SEAL RING 10X18X4 BSL V RIVET LINK FOR TIMING CHAIN NEEDLE ROL.DIN5402 NRB 3X17, WATER PUMP WHEEL CPL. RAC CIRCLIP DIN X / C * NEW PART X AS REQUIRED 18

45 CYLINDER HEAD 525 EXC ATV CYLINDER HEAD CPL. ATV CYLINDER HEAD GASKET 95,3 MM VALVE COVER REAR VALVE COVER GASKET HH COLLAR SCR. M6X55 WS= HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X75 WS= HH COLLAR SCREW M 6X30 SW= HH COLLAR SCREW M 6X50 WS= VALVE GUIDE INTAKE VALVE GUIDE EXHAUST INTAKE BOOT CLAMP D=56MM B=9MM M4X EXHAUST FLANGE CPL. 450/ GASKET EXHAUST FLANGE HH COLLAR SCREW M 6X20 WS= CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X16 WS= DOWEL 6X8X11, VENT SCREW M6X10 CPL CU-SEAL RING 6 X 10 X WASHER 10,8X18,8X1, WATER PUMP COVER RACING WATER PUMP COVER GASKET 0,8MM CYL. HEAD SCREW M10X158 WS= / C * NEW PART X AS REQUIRED 19

46 LUBRICATING SYSTEM 525 EXC ATV OIL PUMP SHAFT OILPUMP ROTOR CPL. 10MM G-73R OILPUMP ROTOR 15MM G OIL PUMP GEAR 26-T OIL PUMP COVER L/S OIL PUMP COVER R/S 8MM HH COLLAR SCREW M 5X16 WS= AH SCREW DIN6912-M 5X OIL FILTER COVER RACING OIL FILTER LONG OIL FILTER SHORT NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, BANJO BOLT M8X JET SCREW "100" M8X1 WS= SEAL RING CU DIN7603-8X12X OIL LINE STEEL CASE-CYL.HEAD O-RING 40,00X2,50 NBR SCREW PLUG OIL SCREEN 15X83MM O-RING 12,5X1,5 NBR O-RING 17,17X1,78 GLO STOP DISK 8,1 X 15 X 0, TAB WASHER DIN6799-RS 6, RUBBERBUFFER 8X17X10 SILENC' / C * NEW PART X AS REQUIRED 20

47 IGNITION SYSTEM 525 EXC ATV IGNITION COVER GREY IGNITION COVER GASKET STATOR ROTOR PULSER COIL KOKUSAN 4K3-A/B SPARK PLUG NGK DCPR8E SUPPORT FOR WIRE CYL.HEAD SCREW DIN0084-M 4X 6A CABLE TIE 100/2,5MM BLACK x NEEDLE ROL.DIN5402 NRB 4X9, AH SCREW DIN6912-M 8X HH COLLAR SCREW M 6X30 SW= HH COLLAR SCREW M 5X16 WS= CDI-BOX ATV COLLAR SCREW M6X12 TX WIRING HAR. F. CDI-BOX 525 ATV IGNITIONCOIL KOKUSAN 4K3-A/B HH COLLAR SCREW M6X16 TX SPARK PLUG CONNECT. VD05EG / C * NEW PART X AS REQUIRED 21

48 ELECTRIC STARTER 525 EXC ATV E-STARTER ENGINE KPL. 0,45 KW GEAR WHEEL STOP DISK 17,2X25X CIRCLIP DIN X TORQUE LIMITER NEEDLE BEARING K 10X13X BEARING BOLT PRIMARY GEAR 31T CPL NEEDLE BEARING HK 3016 B FREE-WHEEL FWD BLS FREEWHEEL GEAR HH COLLAR SCREW M 6X20 WS= O-RING 25,00X3,00 NBR / C * NEW PART X AS REQUIRED 22