HUSABERG FE 450-E 2008

Transcription

1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM090021HEN ENGLISH

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3 INDEX SPECIAL TOOLS ENGINE CASE CLUTCH COVER BALANCER SHAFT 3x 4x 5x 6x CRANKSHAFT, PISTON CARBURETOR CLUTCH TRANSMISSION I - MAIN SHAFT 7x 8x 11x 12x TRANSMISSION II - COUNTERSHAFT KICKSTARTER SHIFTING MECHANISM COOLING SYSTEM 13x 14x 15x 16x 1

4 INDEX VALVE DRIVE TIMING VALVE CYLINDER HEAD LUBRICATING SYSTEM 17x 18x 19x 20x IGNITION SYSTEM 21x 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 ' 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 SPARK PLUG KEY 250 SX-F / C * NEW PART X AS REQUIRED 3

6 ENGINE CASE ENGINE CASE CPL STOP SHEET MEMBRANE MEMBRANE CYLINDER LINER 100MM O-RING 102,00X2,00 VITON 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

7 CLUTCH COVER CLUTCH COVER CPL SLIDING SLEEVE PLASTIC-COAT CIRCLIP OIL LEVEL GLASS OIL LEVEL GLASS G 1777 Y 1 20* OIL PLUG 1 21* 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, 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 SW= HH COLLAR SCREW M 6X45 WS= / C * NEW PART X AS REQUIRED 5

8 BALANCER SHAFT NUT M16X1 WS= WOODRUFF KEY DIN6888-3X5X WOODRUFF KEY 5X6,5 HARDED CIRCLIP DIN X1, O-RING 10, 00X1, 20 NBR BALL BEARING 6905 J1LLUC BALANCER SHAFT CPL MAIN SHAFT BALANCER SHAFT GEAR WHEEL B.SH.-SHAFT 29-T / C * NEW PART X AS REQUIRED 6

9 CRANKSHAFT, PISTON I PISTON I CPL. 100 MM II PISTON II CPL. 100 MM CRANKSHAFT 450 FE CPL CONROD REP. KIT 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 7

10 CARBURETOR 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 OBDVR x JET NEEDLE KEIHIN OBDVT BAR CLIP NEEDLE SET SCREW CPL NEEDLE JET FCR-MX 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 MAIN JET 178 KEIHIN x MAIN JET 180 KEIHIN x MAIN JET 182 KEIHIN x MAIN JET 185 KEIHIN x MAIN JET 188 KEIHIN x MAIN JET 190 KEIHIN x IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x STARTER JET / C * NEW PART X AS REQUIRED 8

11 CARBURETOR 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 DIAPHRAGM 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 9

12 CLUTCH 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 10

13 TRANSMISSION I - MAIN SHAFT 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 SPA25-SD1, / C * NEW PART X AS REQUIRED 11

14 TRANSMISSION II - COUNTERSHAFT 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 SPA25-SD1, CIRCLIP DIN X1, / C * NEW PART X AS REQUIRED 12

15 KICKSTARTER 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 13

16 SHIFTING MECHANISM 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 14

17 COOLING SYSTEM 4* RUBBER L=145MM 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 * MOUNTING BOLT RADIATOR PROTEC 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 15

18 VALVE DRIVE 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 16

19 TIMING VALVE TIMING CHAIN GUIDE TENSIONER TIMINGCHAIN TENSIONER CPL.RAC CAMSHAFT 450/501/ CAMSHAFT GEAR TIMING CHAIN 64L 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 17

20 CYLINDER HEAD CYLINDER HEAD CPL HOSE CLAMP GEMI VENT SCREW M6X10 CPL HOSE CLAMP 40-60MM FILTER FOR BREATHER SYSTEM BREATHER HOSE ENGINE CLOSING COVER O-RING 29,10X1,60 NBR COLLAR SCREW M10X80 WS= WASHER 10,8X18,8X1, DOWEL 6X8X11, CIRCLIP DIN7993-RW VALVE GUIDE EXHAUST 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 18

21 LUBRICATING SYSTEM 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 19

22 IGNITION SYSTEM 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 SW= HH COLLAR SCREW M 6X35 WS= / C * NEW PART X AS REQUIRED 20

23 ELECTRIC STARTER 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 21

24 NOTICE

25 NOTICE

26 NOTICE

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28 KTM Group Partner HUSABERG a company of the KTM Group A-5230 Mattighofen *3CM090021HEN* 3CM090021HEN Art.Nr.: 3CM090021HEN 6/2007