HUSABERG TE 300 USA 2013

Transcription

1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM084691MEN ENGLISH

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3 INDEX CRANKSHAFT, PISTON ENGINE CASE CLUTCH COVER CYLINDER, CYLINDER HEAD 3x 4x 5x 6x REED VALVE CASE CARBURETOR CLUTCH KICK STARTER 7x 8x 10x 12x TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM COOLING SYSTEM 13x 14x 15x 16x 1

4 INDEX EXHAUST CONTROL IGNITION SYSTEM ELECTRIC STARTER 17x 19x 20x 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 CRANKSHAFT, PISTON 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 CRANKSHAF REP. KIT x / C * NEW PART X AS REQUIRED 3

6 ENGINE CASE ENGINE CASE CPL. 250/ HH COLLAR SCREW M6X12 TX STEEL WASHER 6,4X17X 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 4

7 CLUTCH COVER 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, CLUTCH COVER GASKET 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 5

8 CYLINDER, CYLINDER HEAD 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

9 REED VALVE CASE INTAKE FLANGE V-FORCE MEMBRAN V-FORCE CPL REED VALVE SET V-FORCE 46X64MM CLAMP 52/12 GEMI HH COLLAR SCREW M6X25 TX GASKET REED VALVE CASE / C * NEW PART X AS REQUIRED 7

10 CARBURETOR CARBURET.KEIH.PWK 36S AG BC5 x 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

11 CARBURETOR 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 ' CONNECT. COLD START CABLE CPL. 1 ONLY FOR EU 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

12 CLUTCH CLUTCH CAGE INCL. PRIM. WHEEL INNER CLUTCH HUB PRESSURE PLATE CLUTCH HUB DAMPING RUBBER SLEEVE 7,5X WASHER 112X118X INTERMEDIATE DISC 1MM INTERMEDIATE DISC 1,4MM INTERMEDIATE DISC 1,2MM LINING DISC 1,95 MM COLLARSLEEVE NEEDLE BEARING K26X30X22ZW.KSE TAB WASHER HEXAGON NUT DIN0936-M18X1,5 R WASHER 21.7 X 37 X PRIMARY GEAR 26T O-RING 30,00X1,50 NBR SPRING RING PUSH ROD PRESSURE PIECE HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M5X16 TX VENT INJEKTION HYDR. CLUTCH BELLEVILLE SPRING 71X115X1,5 I PISTON CPL OUTPUT CYLINDER CPL O-RING PRESSURE SPRING COPPER GASKET DIN X14X BLEEDER SCREW CPL CLUTCH PIPE CLUTCH KIT 250/ x PRESSURE PIECE CPL / C * NEW PART X AS REQUIRED 10

13 CLUTCH AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 11

14 KICK STARTER 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 12

15 TRANSMISSION I - MAIN SHAFT MAIN SHAFT CPL. 14T 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 WS GROOVED BALL BEAR. TM C STOP DISC 25X31X1, STOP DISC 25X0,8X30X30X7H / C * NEW PART X AS REQUIRED 13

16 TRANSMISSION II - COUNTERSHAFT 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 WS 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 32X45X7 BSLNBR O-RING 25,00X2,00 NBR SPACER SLEEVE DRIVE END FRONT SPROCKET 13-T FRONT SPROCKET 14-T x LOCK RING DIN X1,64SD BALL BEARING 6203 JR2 C COUNTER SHAFT REP.KIT 2 STROKE x / 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 C RETURN SPRING SHIFT DRUM LOC. CPL. 250/ AH SCREW DIN0912-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 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 15

18 COOLING SYSTEM RADIATOR L/S "55562" RADIATOR R/S "55620" RADIATOR CAP SMALL 1,8 BAR Y-CONNECOTOR CPL HOSE CLAMP GEMI HOSE CLAMP NORMA 12/ CLAMP YDNAC 10096F (9,6MM) ANGLE PIECE ' PVC-HOSE 6X9 x RADIATOR HOSE W. THERMO THERMOSTAT 55 C RADIATOR HOSE 18X25X130 MM O-RING 32,00X2, SCREW FOR PLASTIC D=4X RADIATOR PROTECTION L/S+R/S SX x RADIATOR PROTECTION BLACK HOSE CONNECTOR 2 STROKE RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX RADIATOR KIT x / C * NEW PART X AS REQUIRED 16

19 EXHAUST CONTROL INT. TORX FLAT HEAD M5X 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 17

20 EXHAUST CONTROL 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 WATER PUMP REP. KIT SX x / C * NEW PART X AS REQUIRED 18

21 IGNITION SYSTEM 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 ELEKTRONICBOX 300EXC/XC WIRING HARNESS FOR CDI 2-ST VOLTAGE REGULATOR COLLAR SCREW M6X13 ISA EJOT DELTA PT SCREW 45X12-Z 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 COLLAR SCREW M6X18 ISA / C * NEW PART X AS REQUIRED 19

22 ELECTRIC STARTER STARTER MORIC 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 / C * NEW PART X AS REQUIRED 20

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24 KTM Group Partner HUSABERG a company of the KTM Group A-5230 Mattighofen *3CM084691MEN* 3CM084691MEN Art.Nr.: 3CM084691MEN 7/2012