250 SX-F USA 2013 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CFF8175M5EN

Transcription

1 250 SX-F USA 2013 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CFF8175M5EN ENGLISH

2

3 INDEX 250 SX-F USA 2013 FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 4x 6x 7x 8x SHOCK ABSORBER DISASSEMBLED SHOCK ABSORBER PRO LEVER LINKING SWING ARM 10x 12x 13x 14x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER FUEL PUMP 15x 16x 17x 18x 1

4 INDEX 250 SX-F USA 2013 DECAL MASK, FENDERS FRONT WHEEL REAR WHEEL 19x 20x 21x 22x WIRING HARNESS HAND BRAKE CYLINDER BRAKE CALIPER FRONT REAR BRAKE CONTROL 24x 25x 26x 27x BRAKE CALIPER REAR ACCESORIES KIT 28x 29x x x 2

5 INDEX 250 SX-F USA 2013 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 250 SX-F USA S ADJUSTING KNOB + SCREW 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 MEMBRANE O-RING NBR 9,5X1, O-RING NBR 17X2 PA S SCREW BUSH M20X1 L=33 CPL COPPER WASHER 20,5X26X ADJUSTING TUBE L= PISTON ROD SXS COUNTERNUT M12X1 WS REBOUND NEEDLE SX O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM S SPRING D43.2 L N/MM x S SPRING 4,4 N/MM SET D=5,1MM x S SPRING 4,6 N/MM SET D=5,1MM x S %POLISHED SPRING 4,8 N/MM x S SPRING 5,0 N/MM x S SPRING 4,0 N/MM SET x S SPRING 4,2 N/MM SET D=5,0MM x SPACER 43X35X2,5 x SPACER 43X35X5 x SPACER 43X35X1,5 x GUIDING BUSH REBOUND SPRING SPRING SUPPORT O-RING 6X1,2 NBR SPRING REB. L=32 C=37 DI=13, PISTON ROD REBOUND / C * NEW PART X AS REQUIRED 4

7 FRONT FORK DISASSEMBLED 250 SX-F USA SHUTTLE VALVE SPRING C=0, S3 MEMBRANE HOLDER INKL. PIN SET LOCK WASHER D=25, AH SCREW M4X O-RING NBR 21X PISTON COMPRESSION D=27, O-RING NBR 4X1, S PIN KIT NUT M6X0,5 REBOUND GUIDE RING 44 X RING SPRING-SUPPORT WASHER 32X42X2, SA AXLE CLAMP LEFT + TUBE CPL SA AXLE CLAMP RIGHT + TUBE CPL HH COLLAR SCREW M8X25 TX * NUT VALVE M6X0, SPRING CHECK VALVE D=0, PISTON ROD COMPRESSION PISTON REBOUND SX PISTON RING 5X1X RING 23,45X8, SHAFT SEAL RING 12MM S SCREW SLEEVE M24,5X1 CPL DU BUSH FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D= SILICON CAP RUBBER CAP D=26,4 2 83* S1 FORK OIL SAE4 5L O-RING NBR 43X S1 SCREW CAP CPL. L= SCREW M4X MEMBRANE SLEEVE 2 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 250 SX-F USA * 14187M5501 FORK WP 250 SX-F USA HH COLLAR SCREW M8X50 TX HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X40 TX S HH COLLAR SCREW M8X25 WS= S AH-COLLAR SCREW M10X35 ISA O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS=6 2 32* TRIPLE CL. BOTT. CPL. X=22 BL. 1 34* TRIPLE CLAMP TOP X=22 BLACK 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 250 SX-F USA * HANDLEBAR RENTHAL BLACK BAR PAD SHORT CIRCUIT BUTTON * STARTER BUTTON GREY HOLDER INDICATOR LIGHT SX SPECIAL SCREW M6X12,5 WS= INDICATOR LIGHT LED YELLOW FI 1 13* THROTTLE GRIP CPL. 1 17* GRIP SET CABLE TIE 140/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x 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 * THROTTLE CABLE 4T / C * NEW PART X AS REQUIRED 7

10 FRAME 250 SX-F USA * BE FRAME ANTRAZIT "777M3" SUB FRAME SX SUB FRAME APPLICATION LEFT SUB FRAME APPLICATION RIGHT * REINFORCING RUBBER CABLE TIE 75MM TANK REST RUBBER S HH COLLAR SCREW M8X16 TX WIRING HOLDER 16MM ENGINE BRAC.SCR. M10X 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 SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X30 TX WASHER DIN0125-A 6, HH COLLAR SCREW M6X25 TX FOOT PEG L/S SILVER FOOT PEG R/S SILVER BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTPEG L.+R. CPL ANGLE PIECE ' PVC-HOSE 7X10 PER METER x SPROCKET COVER 350 SX-F CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX x PLASTIC FRAME PROTECTION SET / C * NEW PART X AS REQUIRED 8

11 FRAME 250 SX-F USA CHAIN SLIDING KIT BELOW CPL SPROCKET COVER KIT x / C * NEW PART X AS REQUIRED 9

12 SHOCK ABSORBER DISASSEMBLED 250 SX-F USA S1 MONOSHOCK UPPER PART CPL. 1 2* S17 DCC COMPR.DAMP.CON. SX 13 USA BUSH KGW 10X R12012 REP. KIT BEAR./SEAL UP BLEED PLUG R 1/ STICKER WP MONOSHOCK 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 ADJUSTING NUT S SPRING N/MM ORANGE x S SPRING N/MM D11,25 OR. x S SPRING N/MM D11,5 OR. x S SPRING N/MM D11,75 OR. x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x CIRCLIP 58,2X VALVE SPRING D80 CLOSED PISTON ROD NUT M16X REBOUND DISC 16X34 T2 H S PISTON D REBOUND DISC D16X43 H * SA ADAPTER D50 H28 CPL SPRING RING REBOUND RUBBER SHIM D29,75 X D19 X T0, S SEAL D18X30X REBOUND SPRING O-RING 41X5 1 80* DU-BUSHING 18X20X DUST SEAL / C * NEW PART X AS REQUIRED 10

13 SHOCK ABSORBER DISASSEMBLED 250 SX-F USA CIRCLIP 53X1, RESERVOIR CAP D=50 H= BUMP RUBBER SA1 MONOSHOCK BOTTOM PART CPL ADAPTOR-BUSH M10x1,50, D= S1 SHOCK ABSORBER FLUID 5 LT 1 99* R12020 REPAIR KIT / C * NEW PART X AS REQUIRED 11

14 SHOCK ABSORBER 250 SX-F USA * 18187M5501 MONOSHOCK LINK 250 SX-F USA HH COLLAR SCREW M10X52 SW / C * NEW PART X AS REQUIRED 12

15 PRO LEVER LINKING 250 SX-F USA * TRIANGLE LEVER CPL. SX PULL ROD CPL PULL ROD ANCHOR BOLT NEEDLE BUSH HK SHIM 20X32X SHAFT SEAL RING 25X32X7 4 7* BUCKET SHAFT SEAL RING 25X BUSHING SLEEVE 15 X 20 X SHIM D29,75 X D19 X T0, SHAFT SEAL RING 24X30X BUCKET FOR SHAFT SEAL RING 2 12* BOLT FOR CANTILEVER M * HEX NUT M14X1.5 SW BEARING SLEEVE 10X18X25, NEEDLE BUSH HN1816 RS 18/24/ BEARING SLEEVE NEEDLE BEARING HK X28X SHAFT SEAL RING G22x28x STEEL WASHER 15,2X19X0,1 x STEEL WASHER 15,2X19X0,2 x STEEL WASHER 15,2X19X0,3 x TRIANGLE LEVER REP. KIT REAR x TRIANGLE LEVER REP. KIT FRONT x PULL ROD REP. KIT SX/SX-F x / C * NEW PART X AS REQUIRED 13

16 SWING ARM 250 SX-F USA * SWINGARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR EJOT SPIRAL SCREW SF M5X10-K BRAKE LINE GUIDE 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 REAR CPL SPECIAL SCREW M6X19 WS= HH COLLAR SCREW M6X45 TX BUSH. F. CHAIN FAIL. PROT SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC CHAIN GUIDE KIT REAR SWINGARM REPAIR KIT x / C * NEW PART X AS REQUIRED 14

17 EXHAUST SYSTEM 250 SX-F USA * SILENCER THERMAL PROTECTION FOIL THERMAL PROTECTION FOIL 1 4* SILENCER HOUSING 1 8* CONNECTING CAP CPL. 1 9* BUSHING 8.5x12x28x SPRING WASHER DIN0137-B BUSHING 7.5x12x28x DAMP. COMPON. BLACK O-RING 74,00X1,50 FKM 75SH HH COLLAR SCREW M6X30 TX TEN.SPRING L=62MM EY.MOVEABLE TEN.SPRING L=75MM EY.MOVEABLE 1 22* SCREW TORX M5X * ENDCAP CPL. 1 34* ROCKWOOL PREFORMED 1 40* EXHAUST MANIFOLD SX 1 43* BUSHING 8.5x12x28x RANGE CHANGE METAL NUT M EXHAUST PARTS KIT x / C * NEW PART X AS REQUIRED 15

18 AIR FILTER 250 SX-F USA * A AIR BOX COVER R/S SX/XC COLLAR BUSH. F.REAR FENDER * A AIR BOX COVER L/S SX/XC * 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 AIR FILTER FILTER CARRIER FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX * INTAKEBOOT HOSE CLAMP 45-65MM 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 250 SX-F USA SCREW SEAT FASTENING D=6X23/ PVC-HOSE 5,6X10X270MM 1 8* X4 TANK PLUG CPL. BLACK SX * FUEL TANK CPL. 7,5L EFI SX TANK ROLLER 12X26X12 ' EJOT PT SCREW K60X20 ALU WS= ANGLE PIECE 90 DEGREE M10X SEAT CPL SEAT COVER 1 50* A SPOILER KIT SX/XC WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 17

20 FUEL PUMP 250 SX-F USA * GASKET KIT FILTER KIT 1 3* FUEL PUMP CPL. EXC 1 4* NUT F. FUEL PUMP M12 1 5* FUEL CONNECTOR M VARIABLE ONE-EAR CLAMP 15,7MM O-RING VITON F. PLUG CPC * FUEL HOSE DKK CLUTCH CPC BLACK * CONNECTOR FUEL PUMP 1 14* FUEL FILTER EJOT PT SCREW K60X25-Z SW= / C * NEW PART X AS REQUIRED 18

21 DECAL 250 SX-F USA * DECAL NUMBER PLATE SX/XC * DECAL REAR PART 250 SX-F / C * NEW PART X AS REQUIRED 19

22 MASK, FENDERS 250 SX-F USA * START NUMBER PLATE WHITE SX * BRAKE HOSE GUIDE BLACK EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M5X16 TX30 2 7* FRONT FENDER ORANGE * HH COLLAR SCREW M6X16 TX COLLAR BUSH. F.REAR FENDER * REARPART ORANGE SX COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M6X25 TX / C * NEW PART X AS REQUIRED 20

23 FRONT WHEEL 250 SX-F USA * FRONTWHEEL CPL.1,6X21EXCEL FRONT WHEEL HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM FRONT WHEEL REP. KIT SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL * SPOKE M4,5X226-21" BLACK SPOKE NIPPLE M4,5 AL RIM 1,6"X21" EXCEL RIM BAND 21" 1 15* SPOKE KIT FRONT "21" BLACK 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 21

24 REAR WHEEL 250 SX-F USA * REAR WHEEL CPL.2,15X19"EXC * REAR WHEEL HUB CPL * BEARING DISTANCE TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL 2 7* DISTANCE BUSHING REAR WHEEL 2 8* SPOKE M4,5x205-19" BLACK SPOKE NIPPLE M4,5 AL RIM 2,15"X19" EXCEL BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" 1 16* DISTANCE RING 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 5/8X1/4" MX CONNECTING LINK F * RIM LOCK 2,15" NUT FOR WHEEL HOLDER PLUG FOR RIM x COVERING CAP SFL16 x 40* WHEEL SPINDLE CPL. ' * CHAIN TENSIONER R/S SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= / C * NEW PART X AS REQUIRED 22

25 REAR WHEEL 250 SX-F USA * COLLAR NUT M25X1,5 WS= REAR WHEEL REP. KIT x DRIVETRAIN KIT 125 SX 13T/50T x SPOKE KIT REAR 19" x / C * NEW PART X AS REQUIRED 23

26 WIRING HARNESS 250 SX-F USA * WIRING HARNESS SX-F VOLTAGE REGULATOR CABLE TIE 140/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x CABLE GUIDE WIRING HOLDER 16MM x 7* RETAINING PLATE CONDENSATOR 1 8* CONDENSATOR 1 9* HH COLLAR SCREW M5X30 TX HH COLLAR SCREW M6X20 TX * ELECTRIC CASE INDICATOR LIGHT LED YELLOW FI HOLDER INDICATOR LIGHT SX SPECIAL SCREW M6X12,5 WS= GROUND CABLE D=6MM L=140MM ' CONTACT WASHER M6 VSV-K EJOT SPIRAL SCREW SF M5X10-K SELF LOCK. NUT DIN0985-M PROTECTION CAP F. STARTER ENG STARTERCABLE 700 MM ' STARTER RELAY 12V ' FUSE 10 A RELAY CM1A-R-12V-H WIRING HARNESS BATTERY DUKE' BATTERY 12V 3AH YTX4L-BS RUBBER L=145MM BATTERY BOX EJOT PT SCREW K60X20 WS= AH OVAL SCREW ISO 7380 M 6X DUMMY PLUG MAPSELECTSWITCH END PLUG CAN-BUS * HH COLLAR SCREW M5X12 TX * BUSHING CONENSATOR BRACKET / C * NEW PART X AS REQUIRED 24

27 HAND BRAKE CYLINDER 250 SX-F USA 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 1235MM HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X VALVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 25

28 BRAKE CALIPER FRONT 250 SX-F USA 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 1235MM COPPER GASKET DIN X14X HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 26

29 REAR BRAKE CONTROL 250 SX-F USA REAR BRAKE CYLINDER CPL.SX REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX HOLLOW SCREW BLACK M10X1X BRAKE HOSE REAR XXXMM COPPER GASKET DIN X14X FOOT BRAKE LEVER CPL STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX RETURN SPRING FOR BRAKE LEVER S 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 BRAKE CALIPER REAR 250 SX-F USA * BRAKE CAL. REAR - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO 1 5* BRAKE PISTON 26MM * RETAINING SPRING * BRAKE CALIPER BRACKET REAR CUP SET SHORT BRAKE HOSE REAR XXXMM BLEEDER SCREW CPL COPPER GASKET DIN X14X / C * NEW PART X AS REQUIRED 28

31 ACCESORIES KIT 250 SX-F USA AIR FILTER OIL 100ML PRINT LABEL 60X51 MM HH COLLAR SCREW M5X12 TX DOCUMENTS BAG KTM BALLPOINT PEN ORANGE * CUSTOMER WELCOME LETTER FOOTPEG L.+R. CPL CONTACT WASHER M6 VSV-K PLASTIC FRAME PROTECTION SET SPARK PLUG WRENCH BAR PAD BATTERY 12V 3AH YTX4L-BS PLUG-IN STAND WASH CAP SET EN OWN. MAN. 250 SX-F/XC-F 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 29

32 NOTICE 250 SX-F USA 2013

33 NOTICE 250 SX-F USA 2013

34 NOTICE 250 SX-F USA 2013

35

36 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CFF8175M5EN* 3CFF8175M5EN Art.Nr.: 3CFF8175M5EN 5/2012

37 250 SX-F 2013 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089330MEN ENGLISH

38

39 INDEX 250 SX-F 2013 DIAGNOSTIC TOOL ENGINE CASE CYLINDER CRANKSHAFT, PISTON 3x 4x 5x 6x CLUTCH COVER CLUTCH TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT 7x 8x 10x 11x SHIFTING MECHANISM COOLING SYSTEM VALVE DRIVE TIMING DRIVE 12x 13x 14x 16x 1

40 INDEX 250 SX-F 2013 CYLINDER HEAD LUBRICATING SYSTEM IGNITION SYSTEM ELECTRIC STARTER 18x 19x 21x 22x THROTTLE BODY 23x 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

41 DIAGNOSTIC TOOL 250 SX-F DIAGNOSTIC TOOL HUSABERG/KTM DIAGNOSTIC TOOL KTM BREAKOUT-BOX KPL BREAKOUT-BOX TEMPLATE LC8 / RC TEMPLATE LC TEMPLATE HUSABERG ADAPTER LC4 EFI ADAPTER LC4 EPT/HUSABERG EFI ADAPTER LC DIAGNOSTIC HASP DONGLE XC POWERSUPPLY 220V/12V FOR AVL EXTENSION CABLE DIAGNOSTIC CABLE HUSABERG DIAGNOSTIC CABLE KTM CASE FOR DIAGNOSTIC-TOOL DIAGN. CABLE EXT. POWER SUPPLY DVD KTM XC-1 UPDATE V FRAME XC_1 SCANBOX KTM ADAPTER LC / C * NEW PART X AS REQUIRED 3

42 ENGINE CASE 250 SX-F * ENGINE CASE CPL. 1 2* LOCATING SCREW M8 L= CU-SEAL RING 8 X 14 X NEEDLE ROL.DIN5402 NRB 4X9, PLUG DIN0906-M10X HOLDING BOLT M14X1, O-RING 1,5x11 SILICON HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M6X65 TX OIL JET "60" M THROTTLE M5X10X0,5 1 12* OIL JET ANGLED O-RING 3,5X2,00 NBR AH.SCREW DIN0912-M 4X OIL JET JET 100 BING(44-031/180) M DOWEL 17 X 19 X DOWEL BUSHING 13,8X11X DOWEL 6X8X11, CASE BUSH CU-SEAL RING DIN X18X1, OILDRAIN PLUG W.MAG. M 12X1, OIL INTAKEPIPE CYLINDER ROLLER ZRO 5X HH COLLAR SCREW M6X85 TX * JET / GASKET SET 350 SX-F / C * NEW PART X AS REQUIRED 4

43 CYLINDER 250 SX-F * CYLINDER AND PISTON 1 2* DOWEL BUSHING 10,2X12,5X CYLINDER BASE GASKET / C * NEW PART X AS REQUIRED 5

44 CRANKSHAFT, PISTON 250 SX-F * CRANKSHAFT CPL. 1 2* CONNECTING ROD REPAIR SET THRUST WASHER 30,5X45X0,10 x THRUST WASHER 30,7X47X0,15 x THRUST WASHER 30,5X45X0,30 x 4* BEARING NJ 206 ECP/HN3C4HVA NUT PRIMARY WHEEL SH.SEAL RING 30X47X7 BSL VITON SHAFT SEAL RING A40x55x6 VITON SPACER BUSHING PRIMARY GEAR INT. TORX FLAT HEAD M5X RETAINING PLATE F. CS BEARING FLYWHEEL SCREW WOODRUFF KEY DIN6888-3X3, PRIMARY GEAR 24T. 1 33* PISTON PIN * CIRCLIP 2 40* I PISTON CPL. 250 x 40* II PISTON CPL. 250 x 41* SCRAPER RING * COMPRESSIONRING PISTON KIT GR.I 250 SX-F 13 x PISTON KIT GR.II 250 SX-F 13 x / C * NEW PART X AS REQUIRED 6

45 CLUTCH COVER 250 SX-F * CLUTCH COVER CPL. 1 4* CIRCLIP DIN X * SHAFT SEAL RING 14X24X5 VITON 1 6* CLUTCH COVER GASKET OIL LEVEL GLASS CIRCLIP OIL LEVEL GLASS HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X45 TX HH COLLAR SCREW M6X25 TX CLUTCH COVER OUTSIDE GASKET FOR OUTER CLUTCH COVER O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R HH COLLAR SCREW M6X40 TX BALL BEARING 6202 C * CIRCLIP 30X1, SHAFT SEAL RING 15X30X4.5 BAUD / C * NEW PART X AS REQUIRED 7

46 CLUTCH 250 SX-F OUTER CLUTCH CPL INNER CLUTCH HUB PRESSURE PLATE DRIVING SLEEVE D=7,95 L= INTERMEDIATE DISC 1,4MM INTERMEDIATE DISC 1MM LINING DISC 2MM INNER RING NUT PRIMARY WHEEL SHEET METAL LOCK HEXAGON NUT M18X1, WASHER 21,8 X 37 X PRIMARY GEAR 24T GASKET F. OUTPUT CYLINDER O-RING 30,00X1,50 NBR CLUTCH KIT 350 SX-F SPRING RETAINER 6,2X12X18X3, PUSH ROD PRESSURE PIECE HH COLLAR SCREW M6X16 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X25 TX VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING 2,4X40 200' PISTON CPL OUTPUT CYLINDER CPL O-RING PRESSURE SPRING CU-SEAL RING DIN X16X BLEEDER SCREW CPL CLUTCH PIPE NEEDLE BEARING K26X30X22ZW.KSE PRESSURE PIECE CPL AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X / C * NEW PART X AS REQUIRED 8

47 CLUTCH 250 SX-F CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 9

48 TRANSMISSION I - MAIN SHAFT 250 SX-F * MAIN SHAFT CPL. 1 2* SOLID GEAR 2ND G. T=16 1 3* SLIDING GEAR 3/4 G. T="17/19" 1 4* IDLER GEAR 5TH G. T=21 1 5* IDLER GEAR 6TH G. CPL BUSHING RETAINING PLATE F. CS BEARING INT. TORX FLAT HEAD M5X BALL BEARING 6205 C3 NTN 1 11* IDLER GEAR BUSHING 1 12* IDLER GEAR BUSHING 1 16* LOCK RING 22X1,2 2 19* BUSHING GROOVED BALL BEAR. TM C SPACER SHIM 21X42X * STOP DISC 1 43* STOP DISC / C * NEW PART X AS REQUIRED 10

49 TRANSMISSION II - COUNTERSHAFT 250 SX-F * COUNTERSHAFT TAB WASHER BEARING COUNT.SHAFT INT. TORX FLAT HEAD M5X * SLIDING GEAR 6.G.,Z= * IDLER GEAR 2ND G. T= * IDLER GEAR 4.G. Z= * SLIDING GEAR 5.G.,Z= * IDLER GEAR 3.G. Z= * CIRCLIP WS * IDLER GEAR 1ST G. T= SCREW 10.9+SPRING WASHER 1 21* NEEDLE BEARING K 20X26X NEDDLE BEAR. K24X28X11,9 DIV. 1 23* NEEDLE BEAR.K 22X26X10 DIVIDED CYL.ROLL BEARING NJ BALL BEARING 6203 JR2 C CIRCLIP DIN X1, FRONT SPROCKET 13-T FRONT SPROCKET 14-T x 30* STOP DISC 23,4X31X1,5 2 31* STOP DISK 17,2X30X1, SPACER BUSHING 12MM SHAFT SEAL RING 32X45X7 BSLNBR O-RING 25,12X1,78 NBR * STOP DISC 20,2X30X1 1 43* STOP DISC 24X32X1, COUNTER SHAFT REP.KIT 4 STROKE x / C * NEW PART X AS REQUIRED 11

50 SHIFTING MECHANISM 250 SX-F * SHIFTING FORK 5TH/6TH GEAR 1 2* SHIFT FORK 2./4.G. 1 3* SHIFT FORK 1./3.GEAR NEEDLE ROLLER DIN5402 6X14, SHIFTING SHAFT CPL PRESSURE SPRING 0,9MM SLIDING PLATE CPL TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 6903 C4 1 12* SHIFT ROLLER BALL BEARING C RETURN SPRING SHIFT LOCATING DRUM CPL AH SCREW DIN0912-M 6X INT. TORX FLAT HEAD M5X RETAINING PLATE F. CS BEARING SHIFT. RAIL MAIN SHAFT 250/ SHIFT. RAIL C. SHAFT 250/ ARRESTING LEVER SPRING LOCATING LEVER CPL SLEEVE FOR LOCKING LEVER WASHER DIN9021-A 5, HH COLLAR SCREW M5X20 TX SHIFT LEVER CPL. 2-STROKE 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 12

51 COOLING SYSTEM 250 SX-F * RADIATOR L/S "55623U" * RADIATOR R/S "55637U" 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 CPL.+Y-CONNECT PREFORMED HOSE ENG. Y-CONNECT RADIATOR PROTECTION L/S+R/S SX x RADIATOR PROTECTION BLACK 07 x HOSE CONNECTOR L=172, RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 13

52 VALVE DRIVE 250 SX-F VALVE LEVER SHAFT VALVE LEVER SHIM D=8,9/1,72 x SHIM D=8,9/1,76 x SHIM D=8,9/1,80 x SHIM D=8,9/1,84 x SHIM D=8,9/1,88 x SHIM D=8,9/1,92 x SHIM D=8,9/1,96 x SHIM D=8,9/2,00 x SHIM D=8,9/2,04 x SHIM D=8,9/2,08 x SHIM D=8,9/2,12 x SHIM D=8,9/2,16 x SHIM D=8,9/2,20 x SHIM D=8,9/2,24 x SHIM D=8,9/2,28 x SHIM D=8,9/2,32 x SHIM D=8,9/2,36 x SHIM D=8,9/2,40 x SHIM D=8,9/2,44 x SHIM D=8,9/2,48 x SHIM D=8,9/2,52 x SHIM D=8,9/2,56 x SHIM D=8,9/2,60 x 4* VALVE COLLET * VALVE SPRING KIT EXHAUST 2 6* VALVE-STEM SEALING * INTAKE VALVE 2 8* EXHAUST VALVE 2 9* VALVE SPRING PLATE 4 10* VALVE SPRING NHK HUB 11MM AL 2 11* VALVE SPRING NHK HUB 11MM EL 2 12* VALVE SPRING HOLDER 4 13* VALVE SPRING KIT INTAKE / C * NEW PART X AS REQUIRED 14

53 VALVE DRIVE 250 SX-F * VALVE LEVER VALVE KIT 250 SX-F / C * NEW PART X AS REQUIRED 15

54 TIMING DRIVE 250 SX-F * TIMING CHAIN GUIDE TOP 1 2* COPPER WASHER SB42 1 3* BREATHER PLATE 1 5* O-RING 40,00X1,00 VITON 1 6* CAMSHAFT INTAKE 1 8* CAMSHAFT EXHAUST CPL. 1 9* DECOMPRESSION LEVER CPL. 1 10* NEEDLE ROLLER NRB 5X18,8 G2 1 11* DECO SPRING PIN L=10, * SPRING FOR AUTO DECOMPR. 1 13* DECO SCREW PLUG TIMING CHAIN GUIDE BUSHING SCREW M BUSHING SCREW M SECURING PROTECTION TENSIONING RAIL HH COLLAR SCREW M6X40 TX HOLDING BOLT M24X1, CU SEAL-RING DIN7603 A24X29X CHAIN ADJUSTER HYD O-RING 18,00X2,00 NBR NEEDLE ROL.DIN5402 NRB 4X9, WOODRUFF KEY DIN6888-3X3, TIMING VALVE TWIN WHEEL TIMING CHAIN BALL BEARING 6202 C NEEDLE BEARING NK16/ CIRCLIP 30X1, WATER PUMP ROTOR CAP NUT M6 STAINLESS STEEL SHAFT SEAL RING 15X30X4.5 BAUD GASKET FOR WATER PUMP COVER WATER PUMP COVER HH COLLAR SCREW M6X25 TX CU-SEAL RING DIN7603-6X10X / C * NEW PART X AS REQUIRED 16

55 TIMING DRIVE 250 SX-F O-RING 10,00X1,00 NBR 70 SH SCREW PLUG WEAR BUSHING WAPU O-RING 9x1,5 V75 SH DIN ANGLE PIECE F. BREATHER SYSTEM DISC WATER PUMP BALANCER SHAFT CPL WATER PUMP REP. KIT x / C * NEW PART X AS REQUIRED 17

56 CYLINDER HEAD 250 SX-F * CYLINDER HEAD CPL. 1 2* CYLINDER HEAD GASKET 1 3* VALVE COVER 1 4* VALVE COVER GASKET VALVE COVER SCREW RUBBER GASKET FOR SCREW VALVE GUIDE INTAKT 4 8* INSERT SPARK-PLUG SHAFT GASKET SPARK-PLUG SHAFT O-RING 1,5x HH COLLAR SCREW M7X1X O-RING 9x1,5 V75 SH DIN SCREW PLUG COLLAR NUT M10X1,25 SW WASHER 19X10,5X2, STUD SCREW M10X1, OIL JET RUBBER BOOT EFI HOSE CLAMP GEMI 63MM * DOWEL(BUSH BRIDGE)7/9/ O-RING 10,00X2,00 SILCONE TEMPERAT.-SENSOR WATER LC SCREW PLUG SCREW IN NOZZLE M20X1, GASKET EXHAUST FLANGE 1 29* ENGINEFLANGE HH COLLAR SCREW M6X16 TX COLLAR NUT M6X1 SW WASHER DIN0125-A 6, STUD SCREW M ENGINE BREATHER TUBE * CLAMP YDNAC (18MM) HOSE CLAMP GEMI 58MM / C * NEW PART X AS REQUIRED 18

57 LUBRICATING SYSTEM 250 SX-F OIL PUMP SHAFT OILPUMP ROTOR 12MM G-95R/ ROTOR-SET CPL. 22MM OIL PUMP GEAR 14T OIL PUMP COVER SUCTION PUMP OIL PUMP COVER R/S HH COLLAR SCREW M6X16 TX S CYLIND. SCR. DIN6912 M5X AXIAL-CIRCLIP OIL FILTER COVER OIL FILTER NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, NEEDLE ROLLER NRB 4X15,8 G OILPUMP IDLER GEAR SHIM WASHER DIN X18X0, CIRCLIP DIN X O-RING 33,05X1, PLUG M20X1,5 WS= OIL SCREEN 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, O-RING 44,00X2,00 VITON S CYL. SCREW DIN6912 M5X INT. TORX OVAL HEAD M 5X BUSHING PIN OIL INTAKEPIPE BALL DIN PRESSURE SPRING L=25MM D=1MM CU-SEAL RING DIN X18X1, PLUG DIN0908-M12X1, O-RING 1,5x11 SILICON HOLDING BOLT M14X1, / C * NEW PART X AS REQUIRED 19

58 LUBRICATING SYSTEM 250 SX-F OILFILTER-GASKET SET 350 SX-F x / C * NEW PART X AS REQUIRED 20

59 IGNITION SYSTEM 250 SX-F ROTOR EFI FLYWHEEL SCREW IGNITION COVER GASKET AH SCREW DIN6912 M4x STATOR HH COLLAR SCREW M5X16 TX WIRING RETAINING BRACKET HH COLLAR SCREW M6X16 TX OIL JET "60" M IGNITION COVER THREAD PIN DIN 913 M5X NEEDLE ROL.DIN5402 NRB 4X9, GASKET TORQUE LIMITER COVER TORQUE LIMITER HH COLLAR SCREW M6X25 TX O-RING 24X2,5 VITON FACTORY IGNITION COVER PLUG 1 18* SPARK PLUG CONNECTOR PLUG NGK LMAR9AI HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X30 TX IGNITIONCOIL IG3826 KOKUSAN' HH COLLAR SCREW M6X40 TX / C * NEW PART X AS REQUIRED 21

60 ELECTRIC STARTER 250 SX-F E-STARTER ENGINE CPL O-RING 25,00X3,00 NBR HH COLLAR SCREW M6X25 TX NEEDLE BUSH HK 0810 DIN TORQUE LIMITER BUSHING PIN HH COLLAR SCREW M 6X16 WS= INTERMEDIATE STARTING GEAR STOP DISK 17,2X25X CIRCLIP DIN X1 1 12* NEEDLE BUSH HK /32/ * FREEWHEEL GEAR ROLLER FREE WHEEL / C * NEW PART X AS REQUIRED 22

61 THROTTLE BODY 250 SX-F * THROTTLE BODY 1 2* MAP SENSOR CPL * FUEL RAIL CPL. 1 4* INJECTOR KIT CPL. 1 5* TPS CPL THROTTLE COVER CPL STARTER VALVE COMP. 1 8* IDLING ADJUSTING SCREW CPL. 1 9* SEAL RING 1 10* SCREW SHOULDER SPECIAL SCREW AH O-RING THROTTLE POS. SENSOR SPECIAL SCREW O-RING 1 15* PLATE SPECIAL SCREW O-RING SEAL RING 1 19* SCREW SHOULDER TIMING CHARGER EFI RUBBER BRACKET ECU AMBIENT-AIR TEMPERATURE SENSOR HH COLLAR SCREW M5X16 TX ROLLOVER SENSOR HH COLLAR SCREW M6X20 TX * PROTECTION CAP TPS 1 29* STARTER VALVE COMP. 1 30* HH COLLAR SCREW M5X25 ISA / C * NEW PART X AS REQUIRED 23

62 NOTICE 250 SX-F 2013

63

64 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM089330MEN* 3CM089330MEN Art.Nr.: 3CM089330MEN 5/2012