FE 550e/6 USA 2007 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF2475G3EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF2475G3EN ENGLISH

2 INDEX FRONT FORK DISASSEMBLED FRONT FORK HANDLEBAR, CONTROLS FRAME 4x 6x 7x 8x SIDE STAND SWING ARM MONOSHOCK MONOSHOCK DISASSEMBLED 10x 11x 12x 13x EXHAUST MANIFOLD EXHAUST SILENCER AIR FILTER TANK, SEAT, COVER 16x 17x 18x 19x 1

3 INDEX MASK, FENDERS DECAL FRONT WHEEL REAR WHEEL 20x 21x 22x 23x WIRING HARNESS HAND BRAKE CYLINDER REAR BRAKE CONTROL BRAKE CALIPER FRONT 24x 25x 26x 27x BRAKE CALIPER REAR LIGHTING SYSTEM SPEEDOMETER ACCESSORIES 28x 29x 30x 31x 2

4 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

5 FRONT FORK DISASSEMBLED 3* S SETTING KNOB + SCREW 2 4* VENT SCREW M4X8 2 5* O-RING NBR 3,7X1, E OUTER TUBE L=577 D=54/ GUIDING RING D=58MM DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB DUST CAP D=48 58,4X11, DU-BUSH D47XD49X20DDL * S HYDR.STOP L=200 D=31,9 CPL * ADJUSTING TUBE L= * PISTON ROD D=12 L=554 ALU 2 33* ADJUSTER NEEDLE * O-RING 2X1,5 NBR 2 35* REBOUND SPRING C=4N/MM WASHER 32X42X2, 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 INTERM. RING 26,2 X 43 X * GUIDING BUSH REBOUND SPRING 2 42* S SCREW SLEEVE M29,3X1 L=90 CPL. 2 43* O-RING 6X1,2 NBR 2 44* REBOUND SPRING L=32 C= * TAP REBOUND SPRING CHECK VALVE D=0, PISTON RING 5X1X PISTON REBOUND D=27, NUT M6X0,5 REBOUND TUBE 29,3X1X390 D=8,5MM O-RING NBR 46 X * S1 AXLE CLAMP L/S + TUBE CPL * S1 AXLE CLAMP R/S + TUBE CPL HH COLLAR SCREW M 8X25 WS= / C * NEW PART X AS REQUIRED 4

6 FRONT FORK DISASSEMBLED CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0,7 2 69* S TAP COMPRESSION CPL PISTON COMPRESSION D=27, O-RING NBR 21X O-RING NBR 24X COPPER WASHER 29,5X33,5X RUBBER CAP D=35MM S1 FORK OIL SAE * S1 PRE-LOAD ADJ. M51X1,5 CPL SPACER 42X26,5X SPACER 42X26,5X SPACER 42X26,5X2, SPACER 42X26,5X1, T511 SILICONE GREASE F. DUST STRI 1 99 R14013 REPAIR-KIT GASKET 4860 MXMA / C * NEW PART X AS REQUIRED 5

7 FRONT FORK 1* 14457C02 FORK D=48 PA FE HH COLLAR SCREW M 8X30 WS= AH SCREW DIN6912-M10X * BOT.TRIPLE CLAMP 22 OFFSET 1 34* TOP TRIPLE CLAMP 21 OFFSET COLLAR SCREW M22X1/5H/WS27 ALU 1 38* HANDLEBAR CLAMP 28MM * HANDLEB.SUPP. D=28MM H=37MM TAPERED ROLLER BEARING CPL STEERING HEAD COVER SPACER STEARING HEAD ADJUSTING NUT STEERING HEAD EJOT PT SCREW K60X20 ALU WS= SPECIAL SCREW M6X12,5 WS= FORK PROTECT. L/S+R/S BLACK CLAMP F.SPEED.CABLE D=6MM / C * NEW PART X AS REQUIRED 6

8 HANDLEBAR, CONTROLS HANDLEBAR 28MM HIGH HANDLEBAR PAD TWIST GRIP COVER DOMINO HUS HAND GUARD CPL. L/S+R/S BLUE THROTTLE GRIP CPL. HUSABERG HH COLLAR SCREW M 6X20 WS= FLAT HEAD SCREW DIN0965-M 4X MASTER CYLINDER CPL. RACING CLUTCH LEVER SHORT CPL x CLUTCH LEVER LONG CPL REP.KIT PISTON 9,5MM RAC COVER HYD.CLUTCH RACING RUBBER FOR RESERVOIR ' SPRING FOR CLUTCH LEVER OIL FOR HYD. CLUTCH 75ML PROTECT.CAP FOR LEVER PERCH' LEVER SCREW CPL ' CLAMP WITH PIN DECO.LEVER CPL. RACING FIXED GRIP DOMINO HUSABERG CLUTCH PIPE HUSABERG CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x THR.CABLE"OPEN-CLOSE"KEIHIN DECOMPR. CABLE RACING / C * NEW PART X AS REQUIRED 7

9 FRAME FRAME FE/FS-USA BLACK (HC04) ENGINE MOUNTING SPACER ENGINE MOUNT. L=87MM ENGINE BRACKET SCREW M8X ENGINE BRACKET SCREW M8X SELF LOCKING NUT M WASHER DIN0125-A 5, AH SCREW DIN0912-M 5X HH COLLAR SCREW M 5X12 WS= HH COLLAR SCREW M 8X50 WS= HH COLLAR SCREW M 8X50 WS= INTERCEPTING TANK CPL BRACKET F.INTERCEPTING TANK O-RING 80,00X2,00 VITON HH COLLAR SCREW M 6X10 WS= EJOT PT SCREW K60X20 WS= SPACER BUSH. F. SPEEDOMET.BRA HH COLLAR SCREW M 6X15 WS= HEXAGON NUT DIN0934-M SPECIAL SCREW M8X26 WS= FOOT PED L/S SILVER FOOT PED R/S SILVER FOOTREST L.+R. CPL FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL BOLT FOR FOOT PED DISTANCE SPACER 22X8,2X16MM WASHER DIN9021-A 5, WASHER DIN9021-A 8, BUSHING 8.2 X 12 X GROOVED BALL BEAR RS C CHAIN ROLL D=35MM ' LOCK WASHER 8MM DISTANCE SPACER 8MM RUBBER SLEEVE D=12MM / C * NEW PART X AS REQUIRED 8

10 FRAME SELF LOCKING NUT DIN0985-M RUBBER GROMMET 16X10,8X BRACKET FOR REAR PART CABLE TIE 200/3,6MM BLACK FRAME PROTECTION L/S BLACK FRAME PROTECTION R/S BLACK TAB FOR FILTER PROTECTION BRAKE HOSE GUIDE LOWER / C * NEW PART X AS REQUIRED 9

11 SIDE STAND RUBBER L=145MM SIDE STAND FE LONG INNER SIDE STAND SPRING OUTER SIDE STAND SPRING SPECIAL SCREW M8X28 WS= SPRING CLIP SIDE STAND / C * NEW PART X AS REQUIRED 10

12 SWING ARM SWINGARM CPL. HUSABERG HH COLLAR SCREW M 6X12 WS= HH COLLAR SCREW M 5X12 WS= HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X45 WS= SPECIAL SCREW M6X12,5 WS= NEEDLE BEARING HK BUSH. SLEEVE SWINGARM BEAR STOP DISK 22,2X31,7X SHAFT SEAL RING 25X32X SWINGARM BOLT L=237MM SELF LOCK.NUT M16X1,5 WS= O-RING 25,30X2,40 NBR CLOSING COVER SWINGARM CLOSING COVER ROUND CHAIN GUARD CHAIN SLIDING GUARD BUSH FOR CHAIN SLIDER GUARD RETAINING PLATE CHAIN GUIDE' CHAIN GUIDE REAR ' RETAIN.CLAMP FOR BRAKE HOSE' BUSHING SUPPORT MONOSH BUCKET F. SHAFT SEAL RING / C * NEW PART X AS REQUIRED 11

13 MONOSHOCK 1* 12457C02 MONOSHOCK HUSABERG FE AH SCREW DIN0912-M10X S HH COLLAR M12X55 WS= / C * NEW PART X AS REQUIRED 12

14 MONOSHOCK DISASSEMBLED SHOCK ABS.CASE 30,5 B21 82GR S6 DCC-COMPR.DAMP.CONTROL CPL ADAPTOR-BUSH 12X OIL SEAL KGW D= WASHER KGW D= BUSHING KGW 1525 HD BLEED PLUG R 1/ O-RING NBR 45X WP CAUTION (PDS KTM) 58X S RESERVOIR SCREW L140 d O-RING VITON 35X SEPARATION PISTON D=46, 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, NEEDLE D=11,4 D=6, L= SCREW CAP M20X1 D=11,5 H= LOCK WASHER TUBE L=195 PDS CIRCLIP 50X1, SPRING GUIDANCE L= SPRING RETAINER M56X AH SCREW DIN0912-M 5X INTERM.RING SCREW SPRING RET. 2 40* S SPRING N/MM YELLOW x 40* S SPRING N/MM YELLOW x 40* S SPRING N/MM YELLOW x CIRCLIP 58,2X S SPRING RET. D=80 W. O-RING O-RING VITON 66,27X3, PISTON ROD NUT M16X O-RING VITON 44,17X1, / C * NEW PART X AS REQUIRED 13

15 MONOSHOCK DISASSEMBLED PISTON RING BACKPLATE 16X20X0,30 x SHIM 16X30X0,20 x SHIM 16X32X0,20 x SHIM 16X34X0,20 x SHIM 16X36X0,20 x WASHER 16X21X1 x PISTON 6+6X7/4,5 VB 1, BACKPLATE 16X20X0,30 x SHIM 16X32X0,25 x SHIM 16X38X0,25 x SHIM 16X40X0,30 x HOLDER D=16 M16X1 L= BACKPLATE D=23 D=16 H BACKPLATE 16X20X0,30 x SHIM 16X28X0,15 x SHIM 16X28X0,20 x SHIM 16X32X0,20 x SHIM 16X34X0,20 x SHIM 16X36X0,25 x SHIM 16X28X0,20 x SHIM 16X30X0,20 x SHIM 16X32X0,20 x SHIM 16X34X0,20 x SHIM 16X36X0,20 x SHIM 16X40X0,20 x SHIM 16X42X0,20 x SHIM 16X38X0,25 x SHIM 16X44X0,25 x REBOUND DISC D=34, H= PISTON 6+6X3,5/4, PISTON ROD D=18 L=146 M16X BUSH M8X O-RING VITON 7X1, NEEDLE SEAT M8X1 D=5, S TUBE M8X1 L=145, / C * NEW PART X AS REQUIRED 14

16 MONOSHOCK DISASSEMBLED O-RING NBR 8X TUBE ADAPTOR M8X1 L= NEEDLE L= O-RING VITON 2,2X1, S ADAPTOR CPL. D=50 H= REBOUND RUBBER STEEL DISC 18X,5X43,7X BACKUPRING 22,55X1, QUAD RING 18X2, O-RING 41X DU-BUSH 18X20X DUST SEAL ADAPTOR-BUSH KGW 32X10X SHAFT SEAL RING KGW D= CIRCLIP KGW D= CIRCLIP 53X1, COVER D= BUMP RUBBER SXS NUT M18X S SHOCK ABS. BOTTOM 54X20X PIVOT BEARING KGW 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 R12011 REPAIR KIT GASKET 5018 PDS / C * NEW PART X AS REQUIRED 15

17 EXHAUST MANIFOLD EXH. COLLECTOR L/S 550 CPL EXH. COLLECTOR R/S 550 CPL SWINGELEMENT FOR EXHAUST PIPE TEN.SPRING L=62MM EY.MOVEABLE SELF LOCKING NUT M 6 COPPER SNAP-NUT HOLDER M6 KP WASHER DIN0125-A 6, HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X12 WS= EXH.INT. TUBE CPL. HUSABERG / C * NEW PART X AS REQUIRED 16

18 EXHAUST SILENCER SILENCER SPARKY CPL SILENCER HOUSING SPARKY BUSHING SIL.-SMR FRONT 2004 x SIL. CONNECT. CAP FC CPL TEN.SPRING L=62MM EY.MOVEABLE EXHAUST BRACKET RUBBER BLACK x BUSHING 7,5X12X28X7,8 '96 x O-RING 74,00X1,50 FKM 75SH SIL. END CAP SPARKY CPL STUFFINGYARN 350 GRAMM ' STUFFING YARN 560X340X76G DUMMY RIVET 4,8X 8 NIRO SPECIAL SCREW M 5,0X HH COLLAR SCREW M 6X25 WS= SPRING WASHER DIN0137-B SELF LOCKING NUT M / C * NEW PART X AS REQUIRED 17

19 AIR FILTER INTAKE THROTTLE 04 1 FE+FS (EU+AUS) AIR FILTER AIR FILTER CARRIER WASHER DIN9021-A 6, THUMB SCREW M6X HH COLLAR SCREW M 6X60 WS= CARB. CONNECT. BOOT 550/ CARB. CONNECT. BOOT 450/ HOSE CLAMP 70-90MM HOSE CLAMP 50-70MM / C * NEW PART X AS REQUIRED 18

20 TANK, SEAT, COVER O-RING 13,00X2,30 x GAS COCK MIKUNI ON/OFF FUEL COCK CPL. SMALL RALLYE' O-RING 11X1,8 NBR FILLER CAP CPL. WITH VALVE GASKET FOR FILLER CAP HIGH VARIABLE ONE-EAR CLAMP 14,0MM CLAMP YDNAC MM FUEL TANK CPL. 9 LIT. YELLOW TANK ROLLER 12X26X12 ' T-CONNECTOR FOR FUEL LINE FUEL PREFORMED HOSE HOSE ID 7,5 PER METER x FUEL HOSE VITON 6X1,5 PER/M x SCREW FOR PLASTIC D=5X HH COLLAR SCREW M 6X12 WS= CLAMP YDNAC 13,7MM HH COLLAR SCREW M 6X20 WS= EJOT PT SCREW K60X20 WS=6 x EJOT PT SCREW K60X20 ALU WS=6 x NIPPLE FOR VENTILATION HOSE SEAT CPL. HUSABERG SEAT COVER SCREW SEAT FASTENING D=6X23/ SCREW PLUG FOR SEAT BUSHING FOR SEAT DIRT-FILTER SEAT * SPOILER LEFT YELLOW * SPOILER RIGHT YELLOW COLLAR BUSHING 6,2X10X15X RUBBER GROMMET FOR SPOILER TOOL SET HUSABERG / C * NEW PART X AS REQUIRED 19

21 MASK, FENDERS HEAD LIGHT MASK BLUE SCREW FEND.BRACE M8X9 WS= NUT FENDER BRACE M8 WS= FENDER BRACE BLACK ' FENDER FRONT WIDE BLUE * REAR PART BLUE NUMBER PLATE CARRIER SHORT MASK RUBBER UFO WP ' BRAKE HOSE GUIDE SPACER BUSHING FRONT FENDER RANGE CHANGE METAL NUT M BUCKET SPLASH PROTECT.FOR FILTER BOX SPLASH PROTECTION TOP-PART BUSH FOR SPOILER 6X11X16X5 MM BUSH FOR SPOILER 6X11X16X7, HH COLLAR SCREW M 6X12 WS= HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X15 WS= HH COLLAR SCREW M 6X20 WS= REFLECTOR YELLOW ' / C * NEW PART X AS REQUIRED 20

22 DECAL DECAL SET FENDERS FE DECAL SET FE / C * NEW PART X AS REQUIRED 21

23 FRONT WHEEL FRONT WHEELCPL.1,6X21"EXCEL FRONT HUB CPL. SX SILVER BEA.SPACERTUBE 35X2 L=79, SPACER BUSHING F. FR. WHEEL GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC PLUG FOR RIM x BRAKE DISC FRONT D=260MM SPECIAL SCREW M6X13 WS= FRONT RIM 1,6X21" EXCEL AL SPOKE M4,5X228-15G 21" DDE SPOKE NIPPLE M4,5X0,75 8X RIM BAND 21" WHEEL SPIN.FR. D=26 M24X1, SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= RIM LOCK VM1 (1,60") NUT FOR WHEEL HOLDER ' / C * NEW PART X AS REQUIRED 22

24 REAR WHEEL REAR WHEEL CPL. 2,15X18" EXC REAR WHEEL HUB CPL. SX, EXC BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, BUSHING FOR HUB SHAFT SEAL RING 32X47X7 BSL PLUG FOR RIM x 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 BRAKE DISC REAR PERFORATED SPECIAL SCREW M6X13 WS= CHAIN 5/8X1/4" + MASTER LINK MASTER LINK 5/8X1/4" X-RING REAR RIM 2,15X18" EXCEL AL SPOKE M5X195-10G 18" DDE SPOKE NIPPLE M5-TA (8X21MM) RIM BAND 18" AND 19" HEXAGON NUT M20X1,5 ' HH COLLAR NUT M10X1,25 WS= SCREW M10X1,25X50 WS= CHAIN TENSIONER R/S WHEEL SPINDEL REAR CPL COVERING CAP SFL RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER ' / C * NEW PART X AS REQUIRED 23

25 WIRING HARNESS IGNITION WIRING HARNESS MAIN WIRING FE/FS-USA 05 1 CPL STARTER WIRING HARNESS WIRING HARNESS REAR ' FUSE 10 A SPEC. NUT F. PULL SWITCH WS= HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X12 WS= HH COLLAR SCREW M 6X20 WS= VOLTAGE REGULATOR STARTER CABLE L=190MM STARTER CABLE L=165MM / BATTERY CABLE L=155MM AH OVAL SCREW ISO 7380 M 6X SELF LOCK. NUT DIN0985-M RUBBER SLEEVE D=12MM BATTERY 12V/7AH BATTERY CARRIER DAMPING RUBBER DISTANCE SPACER 6MM BRACKET FOR STARTER RELAY STARTER RELAY 12V ' PULL SWITCH LOOSE STARTER CONTROL CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x RUBBER BAND SHORT CIRCUIT BUTTON GROUND CABLE PROTECTION CAP F. STARTER ENG / C * NEW PART X AS REQUIRED 24

26 HAND BRAKE CYLINDER HANDBRAKE CYL. NAT. SMALL HANDBRAKE LEVER SHORT HANDBRAKE CYL.COVER CPL.NATURE PROTECTION CAP HAND BRAKE CYL CLAMP CPL. NATURE LEVER SCREW CPL ADJUSTING SCREW CPL. EXC REP.SET PISTON D=11 EXC BRAKEHO. FRONT 1300MM HOLLOW SCREW M10X1X CU-SEAL RING DIN X16X HH COLLAR SCREW M 6X25 WS= CLAMP FOR MIRROW ' BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 25

27 REAR BRAKE CONTROL FOOTBRAKECYL. 13MM NATURE REPAIR KIT PISTON 13MM BRAKE LIGHT SWITCH REAR ' CU-SEAL RING DIN X16X BUSHING 6,2X10X2,5MM HOSE FOR RESERVOIR 6X1,5 x YDNAC CLAMP (9MM) BRAKE FLUID RESERVOIR ' HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X20 WS= FLAT HEAD SCREW DIN7991-M 6X FLAT HEAD SCREW DIN7991-M 8X ECCENTRIC BRAKE LEVER STOP TOOTH LOCK WASH. DIN6797-A 6, REAR BRAKE LEVER CPL BRAKE LEVER PEDAL RETAIN.SPRING REAR BR.LEVER COLLAR. BUSH.8,2X13X24X5, DISTANCE SPACER 8,2X16X3 MM FORK PART REAR BRAKE CONTR PRESSURE ROD REAR BRAKE CON MOUNTING BOLT SPECIAL WASHER SL-CIRCLIP 6 MBO GROOVED BALL BEAR RS C SPRING WASHER DIN137 B RIVET DIN0660-5,0X HEXAGON NUT DIN0934-M SELF LOCKING NUT M / C * NEW PART X AS REQUIRED 26

28 BRAKE CALIPER FRONT BRAKECALIPER FRONT BREMBO REPAIR KIT 28MM REPAIR KIT PISTON 28MM BRAKEHO. FRONT 1300MM RETAINING PLATE SET BREMBO CUP SET SHORT BLEEDER SCREW WITH CAP BOLT CPL. 6X HOLLOW SCREW M10X1X CU-SEAL RING DIN X16X CU-SEAL RING DIN X16X1, BRAKE PAD SET FR. TOSHIBA H38 x BRAKEP.SET FR.TOSHIBATT2701HHB BRAKE PAD SET FR. FERODO ID450 x BRAKE PAT SET FR. SINTER 03 x HH COLLAR SCREW M 8X35 WS= / C * NEW PART X AS REQUIRED 27

29 BRAKE CALIPER REAR BRAKE CALIPER CPL. REAR L/S BRAKE PISTON 34MM REPAIR KIT SEALING RINGS 34MM BOLT SET CUP SET SHORT BLEEDER SCREW WITH CAP HOLLOW SCREW M10X1X CU-SEAL RING DIN X16X CU-SEAL RING DIN X16X1, BRAKE HOSE REAR 695MM BRAKE PAD REAR TOSHIBA TTH38GF x BRAKE PAD SET REAR ID BRAKE PAD SET REAR SINTER 03 x / C * NEW PART X AS REQUIRED 28

30 LIGHTING SYSTEM HEAD LIGHT 186(RI)" R" HEAD LIGHT SUPPORT COVERING CAP SFL BULB 12V 5W (W2,1X9,5D) PHIL BULB HOLDER RUBBER CAP BULB HS1 12V 35/35W WHITE BULB 12V 21/5W (BAY15S)REINFO SCREW FOR PLASTIC D=4X HH SCREW DIN0933-M 6X WASHER DIN0125-A 6, WIRING HARNESS REAR ' EJOT PT SCREW K60X20 WS= LAMP HOLDER REAR LIGHT LENS / C * NEW PART X AS REQUIRED 29

31 SPEEDOMETER SPEEDOMETER KM/H F. 21" REPROGRAMMABLE: KM/H - MPH SPEEDOMETER KM/H F. 17" 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, SPEEDOMETER BRACKET SCREW FOR PLASTIC 50X RUBBER GROMMET 16X10,8X RUBBER SLEEVE D=8MM OPEN HH COLLAR SCREW M 6X25 WS= SPACER BUSH. F. SPEEDOMET.BRA PULL SWITCH LOOSE SPEC. NUT F. PULL SWITCH WS= COVERING CAP SFL / C * NEW PART X AS REQUIRED 30

32 ACCESSORIES SERVICE MANUAL HUSABERG CF2475G3EN SPM CHASSIS FE550e/6HUSABERG CM090023GEN SPM ENGINE FE 550-E HUSABERG BACKPACK "HUSABERG" / C * NEW PART X AS REQUIRED 31

33 HUSABERG FE 550-E 2007 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM090023GEN ENGLISH

34 INDEX HUSABERG FE 550-E 2007 SPECIAL TOOLS ENGINE CASE CLUTCH COVER CRANKSHAFT, PISTON 3x 4x 5x 6x BALANCER SHAFT CYLINDER LINER CARBURETOR CLUTCH 7x 8x 9x 12x TRANSMISSION I TRANSMISSION II KICKSTARTER SHIFTING MECHANISM 13x 14x 15x 16x 1

35 INDEX HUSABERG FE 550-E 2007 COOLING SYSTEM CYLINDER HEAD VALVE DRIVE TIMING VALVE 17x 18x 19x 20x BREATHER SYSTEM LUBRICATING SYSTEM IGNITION SYSTEM 21x 22x 23x 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

36 SPECIAL TOOLS HUSABERG FE 550-E UNIVERSAL MOUNTING RACK ' ENGINDE HOLDER HUSABERG CLUTCH HOLDER GEAR SEGMENT CPL MOUNT.SLEEVE F. LEFT SSR C.S MOUNT.SLEEVE F. RIGHT SSR C.S MOUNT.SLEEVE F. SSR KICKST.-S MOUNTING SLEEVE SEAL RING FLYWHEEL EXTRACTOR LOCATING SCREW M8 L= SPECIAL CIRCLIP PLIER PISTON RING COMPRESSOR CPL BUSHING EXTRACTOR INTERN.BEAR.PULLER MM VALVE SPRING LEVER HOUSING SEPARATING TOOL LIMIT PLUG GAUGE F.VALVE GUIDE RIVETTING TOOL TIMINIG CHAIN PROTECTION COVER F. CRANKSHAFT EXTRACTOR FOR TIMING GEAR PRESS OUT TOOL CONROD BEARING PRESS IN TOOL CONROD BEARING MOUNTING TOOL INNER RING NJ FEEL. GAUGE SET 10,12,15,20, VENT INJEKTION HYDR. CLUTCH SAFETY-TORX TX LOCTITE 243 BLUE 6CCM LOCTITE 2701 GREEN 5ML SILICON GASKET THREE-BOND 1 72* SPARK PLUG KEY 250 SX-F / C * NEW PART X AS REQUIRED 3

37 ENGINE CASE HUSABERG FE 550-E ENGINE CASE CPL STOP SHEET MEMBRANE MEMBRANE BUSHING PIN OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, DOWEL 6X8X11, PLUG DIN0908-M12X1, BUSHING 12X15X9, SPRING OIL PRES.RELIEF HUSA BALL D=10 DIN ENGAGMENT SLEDGE INT. TORX FLAT HEAD M 5X AH SCREW DIN0912-M 4X AH SCREW DIN0912-M 8X AH SCREW DIN0912-M 6X40 A CU-SEAL RING 8 X 14 X OIL JET "60" M NEEDLE BEARING HK BOW FOR BREATHER HOSE DOWEL 10,5X12X DOWEL ENGINE CASE REAR DOWL 9X13X15, DOWEL 16,1X22X DOWEL ENGINE CASE FRONT HH COLLAR SCREW M 5X12 WS= HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X50 WS= HH COLLAR SCREW M 6X60 WS= HH COLLAR SCREW M 6X65 WS= GASKET SET HUSABERG / C * NEW PART X AS REQUIRED 4

38 CLUTCH COVER HUSABERG FE 550-E CLUTCH COVER CPL SLIDING SLEEVE PLASTIC-COAT CIRCLIP OIL LEVEL GLASS OIL LEVEL GLASS G 1777 Y PLUG M 24X O-RING 19,00X3,00 NBR DOWEL 6X8X11, GASKET CLUTCH COVER OUTER CLUTCH COVER GASKET OUTER CLUTCH COVER WATER PUMP COVER GASKET WATER PUMP COVER CIRCLIP DIN X WATER PUMP GEAR NEEDLEROL.DIN5402 NRA 2,5X19,8 1 60* SHAFT SEAL RING 10X18X4 BSL V BALL BEARING SPEC.B.B.SKF O-RING 17,30X2,40 NBR 70 SH NEEDLE BEARING HK BUSHING 12X15X9, HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X25 WS= HH COLLAR SCREW M 6X30 WS= HH COLLAR SCREW M 6X45 WS= / C * NEW PART X AS REQUIRED 5

39 CRANKSHAFT, PISTON HUSABERG FE 550-E I PISTON I CPL. 100 MM II PISTON II CPL. 100 MM CRANKSHAFT 550 FE, FS CPL CONROD REP.KIT 501/ NUT M16X1 WS= COLLAR NUT M12X1 LEFT WS= PRIMARY GEAR 29-T OIL SCRAPER RING D=100MM RECTANGULAR RING 100X1, PISTON PIN BOLT 20X15,8/12X CIRCLIP C20X1, SHAF.SEAL RING 25X40X7 BAUM3SL SHAFT SEAL RING 30X52X SPRING WASHER DIN0137-B THRUST WASHER 31X36X0,10 x THRUST WASHER 31X36X0,20 x THRUST WASHER 31X36X0,30 x THRUST WASHER 30,5X45X0,10 x THRUST WASHER 30,7X47X0,15 x THRUST WASHER 30,5X45X0,30 x CYL.ROLLBEAR.NJ206ECP/C3HVC WOODRUFF KEY 5X6,5 HARDED WOODRUFF KEY DIN6888-3X5X / C * NEW PART X AS REQUIRED 6

40 BALANCER SHAFT HUSABERG FE 550-E NUT M16X1 WS= WOODRUFF KEY DIN6888-3X5X WOODRUFF KEY 5X6,5 HARDED CIRCLIP DIN X1, * O-RING 10, 00X1, 20 NBR BALL BEARING 6905 J1LLUC3 1 57* BALANCER SHAFT CPL MAIN SHAFT BALANCER SHAFT GEAR WHEEL B.SH.-SHAFT 29-T / C * NEW PART X AS REQUIRED 7

41 CYLINDER LINER HUSABERG FE 550-E CYLINDER LINER 100MM O-RING 102,00X2,00 VITON / C * NEW PART X AS REQUIRED 8

42 CARBURETOR HUSABERG FE 550-E CARBURETOR KEIHIN FCR-MX * CARBURETOR COVER WITH GASKET BRACKET PLATE FOR THR. CABLE SCREW M 5 X THROTTLE SHAFT CPL COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL SLIDE STOP L=44MM FE+FS (EU+AUS) THROTTLE VALVE CPL BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBEKR x JET NEEDLE KEIHIN OBDVT FE+FS BAR CLIP NEEDLE SET SCREW CPL NEEDLE JET FCR-MX MAIN JET 160 KEIHIN FE+FS 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 MAIN JET 178 KEIHIN FE+FS MAIN JET 180 KEIHIN x MAIN JET 182 KEIHIN FE MAIN JET 185 KEIHIN x MAIN JET 188 KEIHIN x MAIN JET 190 KEIHIN x IDLE JET 38 KEIHIN FE+FS / C * NEW PART X AS REQUIRED 9

43 CARBURETOR HUSABERG FE 550-E IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x STARTER JET IDLE AIR JET 100 KEIHIN MAIN AIR JET 200 KEIHIN ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL ARM PIN FLOAT HOT-STARTER VALVE CPL NEEDLE VALVE CPL COVER ACCELERATOR PUMP FLOAT CHAMBER CPL. SET AIR CUT VALVE ONLY FOR 650 FE+FS COIL SPRING STARTER VALVE CPL BREATH.HOSE FCR-MX KEIHIN CPL FLAT HEAD SCREW DIN0965-M 5X PLUG M 18X INTERMEDIATE LEVER CPL LINK LEVER SPRING LINK LEVER SPRING INTERMEDIATE LEVER CARBURETOR COVER WASHER LINK LEVER E-CLIP ROD ACCELERATOR PUMP INTAKE FUNNEL FCR/FCR-MX 02 1 SIDEWARDS CLOSED O-RING FOR INTAKE FUNNEL AH SCREW DIN0912-M 5X STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 140MM GASKET SET FCR-MX KEIHIN / C * NEW PART X AS REQUIRED 10

44 CLUTCH HUSABERG FE 550-E OUTER CLUTCH HUB * INNER HUB - RACING * PRESSURE CAP WITH OIL BORE DRIVING SLEEVE D=8,L= CLUTCH SPRING 2,5X43MM SPRING RETAINER 6,2X12X18X5, HALF-WASHER STEPPED WASHER INTERMEDIATE DISC 1MM LINING DISC 2MM NEEDLE BEAR K 25X29X SUPPORTWASHER 25X35X LOCK WASHER HEXAGON NUT DIN0936-M18X1,5 R PRIMARY GEAR 29-T AH SCREW DIN0912-M 5X AH SCREW DIN6912 M6X PUSH ROD PRESSURE PIECE ' OUTPUT CYLINDER CPL O-RING 45,00X1,50 NBR BLEEDER SCREW WITH CAP PISTON + O-RING AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 11

45 TRANSMISSION I HUSABERG FE 550-E MAIN SHAFT SOLID GEAR 2ND G 17-T SLIDING GEAR 3RD/4TH G 19/23-T IDLER GEAR 5TH G 24-T IDLER GEAR 6TH G 27-T STOP DISC 25X30X STOP DISC 21X28X BALL BEARING 6205 C3 NTN BALL BEARING 6203 JR C NEEDLE BEAR. K20X24X NEEDLE BEAR. K 22X26X13 TN CIRCLIP SW / C * NEW PART X AS REQUIRED 12

46 TRANSMISSION II HUSABERG FE 550-E COUNTERSHAFT IDLER GEAR 1ST G 33-T IDLER GEAR 2ND G 30-T IDLER GEAR 4TH G 25-T IDLER GEAR 3RD G 26-T SLIDING GEAR 6TH G 20-T SLIDING GEAR 5TH G 22-T BUSHING 25X28X STOP DISC 25X30X STOP DISC 21X28X SPACER BUSHING 11MM SH.SEAL RING 30X42X7 BAU2SLX BALL BEARING 6203 JR C CYL.ROLL BEARING NJ SPROCKET 13-T SPROCKET 14-T SPROCKET 15-T SPROCKET 16-T O-RING 22,10X1,60 NBR 70 SH NEEDLE BEARING K20X24X NEEDLE BEAR. K 22X26X13 TN CIRCLIP SW CIRCLIP DIN X1, / C * NEW PART X AS REQUIRED 13

47 KICKSTARTER HUSABERG FE 550-E KICKSTARTER CPL NEEDLE BEARING K 18X22X NEEDLE BEARING K 17X21X SHAFT SEAL RING 18X24X LOCKING PAWL KICK RATCHET SPRING HH COLLAR SCREW M 6X25 WS= KICKSTARTER SHAFT KICKSTARTER GEAR INTERMEDIATE GEAR KICKSTARTER SPRING STOP DISK 17,2X25X CIRCLIP DIN X STEPPED WASHER KICKSTARTER / C * NEW PART X AS REQUIRED 14

48 SHIFTING MECHANISM HUSABERG FE 550-E SHIFTING FORK 03 x SPECIAL SCREW RETAINING SPRING SHIFTING SHAFT CPL SLIDING PLATE SPRING GUIDE SHIFTING DRUM TENSIONING SPRING RETAINING SPRING POSITIONING STAR WASHER POS. STAR 6,4X24X1, SHIFTING ROLLER 6X8X5,2 x SHIFT RAIL MAIN SHAFT SHIFT RAIL COUNTERSHAFT SPRING FOR LOCKING LEVER LOCKING LEVER CPL SPECIAL SCREW M 6X HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X25 WS= SHIFTING LEVER CPL SHIFTING LEVER SPRING STEP PLATE FOR SHIFT LEVER BOLT 6X25 FOR SHIFT LEVER BALL BEARING 6806 C SHAFT SEAL RING 12 X 22 X 7 B CIRCLIP SW30X1, TENSION PIN DIN1481 3X22 1 ONLY FOR 4 GEAR SLEEVE FOR LOCKING LEVER / C * NEW PART X AS REQUIRED 15

49 COOLING SYSTEM HUSABERG FE 550-E O-RING 32,00X2, THERMOSTAT 70 DEGREES RADIATOR "45493B" SCREW FOR PLASTIC D=4X THERMOSTAT CPL RADIATOR CAP SMALL 20,3 PSI HOSE CLAMP GEMI HOSE CLAMP GEMI T-CONNECTOR HOSE CYLINDER-THERMOST HOSE 2 THERMOSTAT HOSE 1 THERMOSTAT PVC-HOSE 6X9 MM PER METER x HOSE 3 THERMOSTAT HOSE THERMOSTAT- RADIATOR RADIATOR PROTECTOR L/S RADIATOR PROTECTOR R/S BOLT FOR RADIAT. PROTECTOR HH COLLAR SCREW M 6X10 WS= O-RING 10,00X1,50 NBR 70 SH SELF LOCK. NUT DIN0985-M WASHER DIN9021-A 6, VIBRAT. DAMP. 25X15M6X10/ / C * NEW PART X AS REQUIRED 16

50 CYLINDER HEAD HUSABERG FE 550-E CYLINDER HEAD CPL VENT SCREW M6X10 CPL CLOSING COVER O-RING 29,10X1,60 NBR COLLAR SCREW M10X80 WS= WASHER 10,8X18,8X1, DOWEL 6X8X11, CIRCLIP DIN7993-RW * VALVE GUIDE EXHAUST 2 29* VALVE GUIDE INTAKE CU-SEAL RING DIN7603-6X10X CU-SEAL RING 6 X 10 X CYLINDER HEAD GASKET INTAKE BOOD 450/501/ VALVE COVER GASKET FOR VALVE COVER CLAMP D=56MM B=9MM M4X STUD DIN939-M 6X AH SCREW DIN0912-M 5X HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X25 WS= HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X45 WS= HH COLLAR SCR. M6X55 WS= HH COLLAR SCREW M 6X60 WS= / C * NEW PART X AS REQUIRED 17

51 VALVE DRIVE HUSABERG FE 550-E VALVE-STEM SEALING RACING VALVE SPRING CONICAL CPL INTAKE VALVE D=35MM EXHAUST VALVE D=30MM VALVE COLLET KK 6 H DECOMPRESSION SHAFT CPL O-RING 5,10X1,60 NBR AH SCREW DIN 912 M 5X SHIM ALU 5,2X10X O-RING 19,10X1,60 NBR END CAP ROCKER ARM SHAFT ROCKER ARM SHAFT INTAKE ROCKER ARM SHAFT EXHAUST CIRCLIP DIN0471-8X0, DECOMPRESSION LEVER SPRING ROCKER ARM INTAKE CPL ROCKER ARM EXHAUST CPL ADJUSTMENT SCREW M6X0, NUT M6X0, / C * NEW PART X AS REQUIRED 18

52 TIMING VALVE HUSABERG FE 550-E TIMING CHAIN GUIDE TENSIONER TIMINGCHAIN TENSIONER CPL.RAC CAMSHAFT 450/501/ CAMSHAFT GEAR TIMING CHAIN 66L DID LINK FOR TIMING CHAIN DID 05 1 DID-CHAIN BALL BEARING AUTO DECOMPRESSION SHAFT SPRING FOR AUTODECOMPRESSION SPACER BUSHING TIM.CH.GUIDE STEPPED SPACER BUSHING GASKET TIMING CHAIN TENSIONER SHIM ALU 5,2X10X TIMING CHAIN GEAR AH SCREW DIN7984-M 8X HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M 6X12 WS= HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 19

53 BREATHER SYSTEM HUSABERG FE 550-E HOSE CLAMP 40-60MM FILTER FOR BREATHER SYSTEM BREATHER HOSE ENGINE HOSE CLAMP GEMI / C * NEW PART X AS REQUIRED 20

54 LUBRICATING SYSTEM HUSABERG FE 550-E OIL PUMP GEAR OIL PUMP CPL OIL PUMP COVER OIL FILTER LONG STOP DISK 8,1 X 15 X 0, TAB WASHER DIN6799-RS 6, NEEDLEROL.DIN5402 NRA 2,5X19, OIL SCREEN 15X83MM PLUG M20X1,5 WS= O-RING 12,5X1,5 NBR O-RING 17,17X1,78 GLO O-RING 38,00X2,00 NBR 70 SH OIL FILTER COVER AH SCREW DIN912-M5X HH COLLAR SCREW M 4X13 WS= / C * NEW PART X AS REQUIRED 21

55 IGNITION SYSTEM HUSABERG FE 550-E IGNITION COVER ALU SUPPORT FOR STATOR WIRE IGNI.COIL KOKU. IG IGNITION COVER GASKET STATOR HUSABERG FS/FE FLYWHEEL HUSABERG FS/FE DOWEL 6X8X11, RUBBER HOLDER FOR CDI CDI UNIT PULSER COIL KOKUSAN 4K3-A/B SPARK PLUG NGK DCPR8E SPARK PLUG CONNECT. SD05EG AH SCREW DIN0912-M 6X HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X20 WS=8 x HH COLLAR SCREW M 6X25 WS= HH COLLAR SCREW M 6X30 WS= HH COLLAR SCREW M 6X35 WS= / C * NEW PART X AS REQUIRED 22

56 ELECTRIC STARTER HUSABERG FE 550-E E-STARTER ENGINE CPL BRACKET ELEC. STARTER ENG FREE WHEEL GEAR GEAR WHEEL TORQUE LIMITER NEEDLE BEARING K 10X13X FREE WHEEL HUB FREE WHEEL O-RING 24,20X3,00 NBR PLUG ELECTRIC STARTER CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X25 WS= / C * NEW PART X AS REQUIRED 23