300 XC-W USA 2013 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CFF7475M3EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CFF7475M3EN ENGLISH

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3 INDEX FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS SIDE / CENTER STAND 4x 6x 7x 8x FRAME SHOCK ABSORBER SHOCK ABSORBER DISASSEMBLED SWING ARM 9x 11x 12x 14x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER MASK, FENDERS 15x 16x 17x 18x 1

4 INDEX DECAL FRONT WHEEL REAR WHEEL WIRING HARNESS 19x 20x 21x 23x BRAKE CALIPER REAR BRAKE CALIPER FRONT HAND BRAKE CYLINDER REAR BRAKE CONTROL 24x 25x 26x 27x LIGHTING SYSTEM INSTRUMENTS / LOCK SYSTEM ACCESSORIES KIT 28x 29x 30x x 2

5 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

6 FRONT FORK DISASSEMBLED S ADJUSTING KNOB + SCREW VENT SCREW M4X O-RING NBR 3X1, O-RING NBR 45X OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING GUIDING BUSH 48X52X12 R SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING D48 SKF LOCK WASHER SB DUST SEAL DL D48 SKF GUIDING BUSH 47X49X20 R S HYDR.STOP L=200 D=31,9 CPL ADJUSTING TUBE L= PISTON ROD D=12 L=554 ALU ADJUSTER NEEDLE O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM WASHER 32X42X2, S SPRING 3,8N/MM SET D=4,9MM x S SPRING 4,0N/MM SET D=5,0MM x 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 S SCREW SLEEVE M27X0, O-RING 6X1,2 NBR REBOUND SPRING L=32 C= PISTON ROD REBOUND SHUTTLE VALVE SPRING C=0, PISTON RING 5X1X PISTON REBOUND SX NUT M6X0,5 REBOUND ADAPTER SLEEVE D23/D / C * NEW PART X AS REQUIRED 4

7 FRONT FORK DISASSEMBLED PIPE D23/L O-RING NBR 46 X SA AXLE CLAMP L/S + TUBE CPL S1 AXLE CLAMP R/S + TUBE CPL HH COLLAR SCREW M8X25 TX CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0, 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 SAE5 5L S2 PRE-LOAD ADJ. M51X1, SPACER 42X26,5X2,5 x SPACER 42X26,5X5 x SPACER 42X26,5X10 x SPACER 42X26,5X1,5 x 98 T511 SILICONE GREASE F. DUST STRI 1 99 R14020 SXS SERVICE KIT / C * NEW PART X AS REQUIRED 5

8 FRONT FORK, TRIPLE CLAMP L6301 FORK WP 250/300EXC HH COLLAR SCREW M8X30 TX HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X35 TX S AH-COLLAR SCREW M10X35 ISA O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS=6 2 32* BOTTTOM FORK PLATE CPL. X=20MM 1 34* TOP TRIPLE CLAMP X=20MM STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP 28MM HANDLEB.SUPP. D=28MM H=32MM 05 x HANDLEB.SUPP. D=28MM H=37MM HANDLEB.SUPP. D=28MM H=42MM 05 x TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F. SPEED. CABLE D=6MM STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS= FORK PROTECT. L/S+R/S WHITE HANDLEBAR SUPPORT KIT D28/H37 x STEARING HEAD REP. KIT x / C * NEW PART X AS REQUIRED 6

9 HANDLEBAR, CONTROLS HANDLEBAR D=28MM BAR PAD CPL HANDGUARDS CPL.LE+RI ORANGE * STARTER BUTTON GREY CLAMP 5/7 MM WIRING HOLDER 16MM 1 10* THROTTLE GRIP CPL PROTECTION COVER ' * O-RING 40,94X2,62 NBR * THROTTLE CABLE 2T.DOM/KEIH SHORT CIRCUIT BUTTON * GRIP SET CABLE TIE 200/3,6MM BLACK MASTER CYLINDER CPL CLUTCH LEVER CPL. BREMBO REP. KIT PISTON COVER HYD. CLUTCH CPL VALVE BOLT KPL BRAKE FLUID DOT5.1 0,25L PROTECTION CAP LEVER SCREW CPL PUSH ROD CPL CLAMP CPL CLUTCH PIPE / C * NEW PART X AS REQUIRED 7

10 SIDE / CENTER STAND SIDE STAND CPL SCREW M5X14 TORX SPRING BRACKET F. SIDE ST SIDE STAND BUSHING EXC USA O-RING 18,00X2,00 NBR SPACER BUSH. SPRING BRACKET SIDE STAND SPRING EYE MOVEABLE 1 ONLY FOR EXC SIDE STAND STOP SCREW M10X S FLAT HEAD SCREW M. ISA45 M8X S COUNTER-SUNK SCREW ISA45 M8X26 1 ONLY FOR O-RING 12,00X2,00 NBR WASHER F. SIDE STAND 12,2X29, O-RING 12,5X1,5 NBR SIDE STAND BUSHING EXC-EU SIDE STAND SPRING 08 1 ONLY FOR XC STAND BASE RUBBER L=145MM / C * NEW PART X AS REQUIRED 8

11 FRAME FRAME BLACK M. "CB11" SUB FRAME SX SUB FRAME APPLICATION LEFT SUB FRAME APPLICATION RIGHT REINFORCING B. 250 EXC TANK REST RUBBER SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M BUSHING F.REINFORCING ENGINE BRAC.SCR. M10X105 WS= S FLAT HEAD SCREW M. ISA45 M8X HH COLLAR SCREW M 8X44 WS BLIND PLUG-IN NUT M5 WN 22A CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X BUSH F. FRAME PROTECTION CABLE TIE 140/2,5MM BLACK x SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X30 TX HH COLLAR SCREW M6X40 TX WASHER DIN0125-A 6, FOOTREST L/S FOOTREST R/S BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTREST L/S + R/S CPL ANGLE PIECE ' PVC-HOSE 7X10 PER METER x SPROCKET COVER 250 SX CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET / C * NEW PART X AS REQUIRED 9

12 FRAME CHAIN SLIDING KIT BELOW CPL SPROCKET COVER KIT x / C * NEW PART X AS REQUIRED 10

13 SHOCK ABSORBER S HH COLLAR SCREW M12X50 TX L6301 MONOSHOCK 5018 PDS 250/300EXC / C * NEW PART X AS REQUIRED 11

14 SHOCK ABSORBER DISASSEMBLED SA2 MONOSHOCK UPPER PART CPL S10 DCC-COMPR.DAMP.CONTROL CPL ADAPTOR BUSH KGW 12X R12012 REP. KIT BEAR./SEAL UP O-RING 27X1,5 VITON BLEED PLUG R 1/ WP CAUTION (PDS KTM) O-RING NBR 5,28X1, SCREW PLUG M5X RUBBER CAP "DO NOT OPEN" ADJUSTING NUT PLASTIC TENSIONING RING D64 H ALLENHEAD SCREW M5 L=20 STAINL SPACER RING SPRING 61,3X78X SPACER RING FOR SPRING S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x S SPRING N/MM x CIRCLIP 58,2X S SPRING RET. D=80 W. O-RING O-RING VITON 66,27X3, PISTON ROD NUT M20X O-RING VITON 44,17X1, PISTON RING PISTON D= SUPPORT D20 M20X1 L51,3 PDS REBOUND DISC D PISTON 6+6X7/4, S ADAPTOR CPL. D=50 H= STEEL DISC 18X,5X43,7X REBOUND RUBBER SHIM D29,75 X D19 X T0, S SEAL D18X30X / C * NEW PART X AS REQUIRED 12

15 SHOCK ABSORBER DISASSEMBLED O-RING 41X DU-BUSH 18X20X DUST SEAL CIRCLIP 53X1, RESERVOIR CAP D=50 H= BUMP RUBBER D58 D17 H SA4 SHOCK ABS. LOWER PART CPL THREADED BUSH M12 PDS STEEL BALL D=3MM SPRING D=2,9 L=7, O-RING NBR 4X1, S ADJUSTING SCREW REBOUND TRAVEL S1 SHOCK ABSORBER FLUID 5 LT 1 99 R12015 REPAIR KIT 5018 PDS / C * NEW PART X AS REQUIRED 13

16 SWING ARM SWING ARM CPL. PDS CHAIN SLID.GUARD PDS BUSHING F. CHAIN SLIDING PR EJOT SPIRAL SCREW SF M5X10-K BRAKE HOSE GUIDE LOWER SPECIAL SCREW M6X13 WS= BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X BUSHING SLEEVE F. SWING ARM NEEDLE BEARING HK STOP DISK 22,2X31,7X CHAIN GUIDE CPL SPECIAL SCREW M6X19 WS= HH COLLAR SCREW M6X45 TX INSERTION NUT F. CHAIN GUIDE PIVOT BEARING+BUSH. PDS ' SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER CHAIN SLIDING GUARD KIT x PRESS IN NUT M6 STEEL ZINC CHAIN GUIDE KIT REAR x SWINGARM REPAIR KIT x / C * NEW PART X AS REQUIRED 14

17 EXHAUST SYSTEM MAIN SILENCER EXC HH COLLAR SCREW M6X30 TX SPRING WASHER DIN0137-B ENDCAP CPL SCREW TORX M5X SILENCER HOUS. CPL. W. HANGING DUMMY RIVET 4,8X 8 NIRO O-RING 74,00X1,50 FKM 75SH HH COLLAR SCREW M6X13 TX HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M6X15 TX SWINGELEMENT FOR EXHAUST PIPE RANGE CHANGE METAL NUT M SILICON SLEEVE D=29/31MM EXHAUST MANIFOLD TEN.SPRING L=62MM EY.MOVEABLE O-RING 44,00X3,00 VITON ROCKWOOL 315G EXHAUST HARDWARE KIT x / C * NEW PART X AS REQUIRED 15

18 AIR FILTER 1* C AIRFIL.BOX COV. R/S PDS EXC COLLAR BUSH. F.REAR FENDER * G AIRFILTERBOX COVER L/S EXC * FILTER BOX CPL. WHITE HH COLLAR SCREW M6X20 TX QUICK RELEASE-NIPPLE BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX TROTTLE VALVE AIR FILTER FILTER CARRIER FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX CABURETOR CONNECTING HOSE CLAMP 50-70MM EJOT PT SCREW K60X20 ALU WS= BUSHING F. CHAIN SLIDING PR SPLASH PROTECTOR KIT SX/EXC x / C * NEW PART X AS REQUIRED 16

19 TANK, SEAT, COVER 1* FUEL TANK CPL. TRANSP. 10L * GAS COCK ON/OFF/RES O-RING 11X2 VITON 1 7* SCREW SEAT FASTENING D=6X23/ X4 TANK PLUG ORANGE/BLACK 1 9* PVC-HOSE 5,6X10X270MM TANK ROLLER 12X26X12 ' * FUEL PREFORMED HOSE SX CLAMP YDNAC MM EJOT PT SCREW K60X20 WS= EJOT PT SCREW K60X20 ALU WS= ANGLE PIECE 90 DEGREE M10X1 1 35* SEAT CPL. 1 38* SEAT COVER 1 50* B SPOILER KIT EXC/XC-W WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X12 TX * HH COLLAR SCREW M6X20 TX / C * NEW PART X AS REQUIRED 17

20 MASK, FENDERS 2* HEAD LIGHT MASK WHITE EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M5X20 TX30 2 7* BRAKE HOSE GUIDE WHITE 1 8* SCREW FOR PLASTIC K50X18 T SPACER BUSHING FRONT FENDER HH COLLAR SCREW M6X20 TX * WASHER DIN0125-A 6,4 1 13* MASK RUBBER UFO WP ' COLLAR BUSH. F.REAR FENDER REAR PART ORANGE COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M6X25 TX * NUMBER PLATE CARRIER TOP 1 33* EJOT PT SCREW K60X20 WS= / C * NEW PART X AS REQUIRED 18

21 DECAL 1* DECAL HEADLIGHT MASK EXC * DECAL REAR PART 300 XC-W / C * NEW PART X AS REQUIRED 19

22 FRONT WHEEL 1* FRONT WHEEL CPL. 1,6X21" XC FRONT WHEEL HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL * SPOKE M4,5X226-21" BLACK SPOKE NIPPLE M4,5 AL * RIM FRONT 1,6X21" EXCEL AL RIM BAND 21" 1 14* SPOKE KIT FRONT "21" BLACK x FRONT WHEEL REP. KIT x 16* RIM LOCK 1,60" NUT FOR WHEEL HOLDER BRAKE DISC FRONT SPECIAL SCREW M6X13 WS= WHEEL SPIN.FR. D=26 M24x1, SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= PLUG FOR RIM x AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 20

23 REAR WHEEL 1* REAR WHEEL CPL.2,15X18" XC-W REAR WHEEL HUB CPL BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB * SPOKE M4,5X193-18" BLACK SPOKE NIPPLE M4,5 AL * RIM REAR 2,15X18" BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" REAR WHEEL REP. KIT 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 REAR SPROCKET 51-T x REAR SPROCKET 52-T x S COUNTER-SUNK SCREW ISA45 M8X HEXAGON NUT DIN EN1661 M8 SW CHAIN DID 118 ROLLS CONNECTING LINK F * RIM LOCK 2,15" NUT FOR WHEEL HOLDER PLUG FOR RIM x COVERING CAP SFL16 x WHEEL SPINDLE RE. CPL.265MM CHAIN TENSIONER R/S SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= / C * NEW PART X AS REQUIRED 21

24 REAR WHEEL HEXAGON NUT M20X1,5 ' DRIVETRAIN KIT EXC/XC 14T/50T x SPOKE KIT REAR 18" BLACK x / C * NEW PART X AS REQUIRED 22

25 WIRING HARNESS 2* WIRING HARNESS 250/300 XC-W CABLE TIE 140/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK VOLTAGE REGULATOR * ELECTRIC CASE PULL SWITCH LOOSE SPEC. NUT F. PULL SWITCH WS= SPEEDOMETER BRACKET XC-W WIRING HOLDER 16MM x 26* BATTERY 12V 3AH YTX4L-BS 1 27* GROUND CABLE D=6MM L=140MM ' * CONTACT WASHER M6 VSV-K6 3 29* EJOT SPIRAL SCREW SF M5X10-K 1 30* HH COLLAR SCREW M5X12 TX * BATTERY BOX 1 32* WIRING HARNESS FOR CDI 2-ST * RUBBER L=145MM 1 36* HH COLLAR SCREW M6X12 TX * COLLAR SCREW M6X13 ISA * EJOT DELTA PT SCREW 45X12-Z 2 39* RUBBER GROMMET 16X10,8X * FUSE 10 A * WIRING HARNESS BATTERY DUKE' * STARTER RELAY 12V ' * STARTERCABLE 1100MM * PROTECTION CAP F. STARTER ENG. 1 73* SELF LOCK. NUT DIN0985-M * AH OVAL SCREW ISO 7380 M 6X / C * NEW PART X AS REQUIRED 23

26 BRAKE CALIPER REAR BRAKE CAL. RE. - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM RETAINING SPRING SET BRAKE CALIPER SUPPORT REAR CUP SET SHORT BRAKE HOSE REAR 655MM BLEEDER SCREW CPL COPPER GASKET DIN X14X / C * NEW PART X AS REQUIRED 24

27 BRAKE CALIPER FRONT CALIPER NAT. WITHOUT PADS BRAKE CALIPER SUPPORT FRONT REP. KIT SEALS 24MM REP. KIT PISTON 24MM BOLT CPL RETAINING PLATE SET BREMBO BRAKE PADS TOYO B BLEEDER SCREW WITH CAP CUP SET SHORT S HH COLLAR SCREW M8X35 TX BRAKEHO. FRONT 1300MM COPPER GASKET DIN X14X HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 25

28 HAND BRAKE CYLINDER HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=9MM CLAMP CPL. NATURE HH COLLAR SCREW M6X25 TX LEVER SCREW CPL HAND BRAKE LEVER + SPRING ADJUSTING SCREW CPL. SX PROTECTION CAP HAND BRAKE CYL BRAKEHO. FRONT 1300MM HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X VALVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 26

29 REAR BRAKE CONTROL 1* REAR BRAKE CYLINDER CPL.SX REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX HOLLOW SCREW BLACK M10X1X BRAKE HOSE REAR 655MM COPPER GASKET DIN X14X FOOT BRAKE LEVER CPL STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX RETURN SPRING FOR BRAKE LEVER HH COLLAR SCREW M6X20 TX PUSH ROD L=28MM SELF LOCK. NUT DIN0985-M SWIVEL HEAD KA S AH-COLLAR SCREW M10X40 ISA SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= BALL BEARING SKF RS COLLAR NUT M10 WS= HH COLLAR SCREW M6X12 TX BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 27

30 LIGHTING SYSTEM 1* HEAD LIGHT CPL. EXC-EU * RUBBER CAP FOR HEAD LIGHT * BILUX-BULB 12V 35/35W BA20D 1 4* SCREW FOR PLASTIC K50X18 T20 3 5* DRAIN HOLE COVER 1 7* BULB 12V 5W (W2,1X9,5D) PHIL. 1 8* CABLE FOR HEAD LIGHT * O-RING 35,00X32,00 NBR 1 20* REAR LIGHT 1 29* EJOT PT SCREW K60X25-Z SW= / C * NEW PART X AS REQUIRED 28

31 INSTRUMENTS / LOCK SYSTEM SPEEDOMETER MPH F. 21" REPROGRAMMABLE: MPH - KM/H 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 1 21* EJOT DELTA PT SCREW 45X12-Z RUBBER GROMMET 16X10,8X HH COLLAR SCREW M6X20 TX BUSHING F. SPROCKET COVER RAC SPEEDOMETER BRACKET XC-W SPACER TUBE SPEEDOM. XC-W CABLE SUPPORT 10/6MM / C * NEW PART X AS REQUIRED 29

32 ACCESSORIES KIT AIR FILTER OIL 100ML PRINT LABEL 60X51 MM HH COLLAR SCREW M5X12 TX DOCUMENTS BAG KTM BALLPOINT PEN ORANGE * CUSTOMER WELCOME LETTER CONTACT WASHER M6 VSV-K BAR PAD CPL PLASTIC FRAME PROTECTION SET FRONT FENDER MOUNTING KIT FRONT FENDER BATTERY 12V 3AH YTX4L-BS FOOTREST L/S + R/S CPL HANDGUARDS CPL.LE+RI ORANGE U6912PPO 2012 PP OFFROAD CATALOG USA EN OWNERS MAN EXC/XC-W TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F T-WRENCH WS=6/8/10/TX45/SK4X SPOKE-SPANNER WS 7/ / C * NEW PART X AS REQUIRED 30

33 NOTICE

34 NOTICE

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36 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CFF7475M3EN* 3CFF7475M3EN Art.Nr.: 3CFF7475M3EN 5/2012