FE 450e/6 USA 2008 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF2375H3EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF2375H3EN ENGLISH

2 INDEX FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS SIDE STAND 4x 6x 7x 8x FRAME MONOSHOCK DISASSEMBLED MONOSHOCK SWING ARM 9x 10x 12x 13x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER MASK, FENDERS 14x 15x 16x 17x 1

3 INDEX DECAL FRONT WHEEL REAR WHEEL WIRING HARNESS 18x 19x 20x 21x BRAKE CALIPER FRONT HAND BRAKE CYLINDER REAR BRAKE CONTROL BRAKE CALIPER REAR 22x 23x 24x 25x LIGHTING SYSTEM INSTRUMENTS / LOCK SYSTEM ACCESSORIES KIT 26x 27x 28x x 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 S SETTING KNOB + SCREW VENT SCREW M4X O-RING NBR 3,7X1,6 2 12* OUTER TUBE L577 D54/60MM 2L BL GUIDING RING D=58MM DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1,5 2 17* 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=549 ALU ADJUSTER NEEDLE O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM WASHER 32X42X2, S SPRING 4,4N/MM SET D=5,1MM x S SPRING 4,6N/MM SET D=5,1MM x S SPRING 4,2 N/MM SET D=5,0MM x INTERM. RING 26,2 X 43 X GUIDING BUSH REBOUND SPRING S SCREW SLEEVE M29,3X1 L=90 CPL O-RING 6X1,2 NBR 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 * S2 AXLE CLAMP L/S + TUBE CPL * S3 AXLE CLAMP R/S + TUBE CPL * HH COLLAR SCREW M8X25 TX / C * NEW PART X AS REQUIRED 4

6 FRONT FORK DISASSEMBLED 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 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* R14015 REPAIR-KIT EXC FRONT FORK / C * NEW PART X AS REQUIRED 5

7 FRONT FORK, TRIPLE CLAMP 1* 14457D02 FORK D=48 PA FE * HH COLLAR SCREW M8X35 TX * HH COLLAR SCREW M8X25 TX AH SCREW DIN6912-M10X BOT.TRIPLE CLAMP 22 OFFSET TOP TRIPLE CLAMP 21 OFFSET COLLAR SCREW M22X1/5H/WS27 ALU 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 HAND GUARDS CPL.L/S+R/S BLUE THROTTLE GRIP CPL. HUSABERG SHORT CIRCUIT BUTTON 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 LEVER CPL. RACING RUBBER GRIP SET CLUTCH PIPE HUSABERG STARTER CONTROL 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 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 8

10 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 M8X55 TX * HH COLLAR SCREW M8X50 TX 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 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 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 MONOSHOCK DISASSEMBLED S4 MONOSHOCK TOP PART CPL. FE S3 MCC-COMPR.DAMP.CONTROL CPL ADAPTOR BUSH KGW 12X OIL SEAL KGW D= WASHER KGW D= BUSHING KGW 1525 HD BLEED PLUG R 1/ WP CAUTION (PDS KTM) 58X O-RING NBR 5,28X1, SCREW PLUG M5X RUBBER CAP "DO NOT OPEN" CIRCLIP 50X1, SPRING GUIDANCE L= SPRING RETAINER M56X AH SCREW M5X30 DIN INTERM.RING SCREW SPRING RET S SPRING N/MM YELLOW x S SPRING N/MM YELLOW x 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, PISTON RING PISTON 6+6X3,5/4, HOLDER D=16 M16X1 L= SHIM D23XD16X REBOUND DISC D=34, H= PISTON 6+6X7/4, NEEDLE L= O-RING VITON 2,2X1, S ADAPTOR CPL. D=50 H= STEEL DISC 18X,5X43,7X REBOUND RUBBER BACKUPRING 22,55X1, / C * NEW PART X AS REQUIRED 10

12 MONOSHOCK DISASSEMBLED QUAD RING 18X2, O-RING 41X DU-BUSH 18X20X DUST SEAL CIRCLIP 53X1, COVER D= BUMP RUBBER D58 D17 H59 SXS S1 MONOSHOCK LOWER PART CPL THREADED BUSH M12 PDS RUBBER PLUG D= 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 11

13 MONOSHOCK 1* 12457D02 MONOSHOCK HUSABERG FE AH SCREW DIN0912-M10X S HH COLLAR M12X55 WS= / C * NEW PART X AS REQUIRED 12

14 SWING ARM SWINGARM CPL. HUSABERG * HH COLLAR SCREW M6X12 TX30 2 6* HH COLLAR SCREW M5x12 TX30 2 8* HH COLLAR SCREW M6X16 TX * HH COLLAR SCREW M6X50 TX 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 13

15 EXHAUST SYSTEM SILENCER SPARKY CPL EXH. COLLECTOR L/S 450 CPL EXH. COLLECTOR R/S 450 CPL SILENCER HOUSING SPARKY BUSHING SIL.-SMR FRONT SIL. CONNECT. CAP FC CPL TEN.SPRING L=62MM EY.MOVEABLE BUSHING SIL.-SMR REAR EXHAUST BRACKET RUBBER BLACK BUSHING 7,5X12X28X7,8 ' O-RING 74,00X1,50 FKM 75SH SIL. END CAP SPARKY CPL STUFFINGYARN 350 GRAMM ' STUFFING YARN 560X340X76G DUMMY RIVET 4,8X 8 NIRO SCREW TORX M5X * HH COLLAR SCREW M6X30 TX * HH COLLAR SCREW M6X40 TX SPRING WASHER DIN0137-B SELF LOCKING NUT M SELF LOCKING NUT M 6 COPPER SWINGELEMENT FOR EXHAUST PIPE RANGE CHANGE METAL NUT M WASHER DIN0125-A 6,4 2 50* HH COLLAR SCREW M6X15 TX * HH COLLAR SCREW M6X10 TX EXH.INT. TUBE CPL. HUSABERG / C * NEW PART X AS REQUIRED 14

16 AIR FILTER INTAKE THROTTLE AIR FILTER AIR FILTER CARRIER WASHER DIN9021-A 6, THUMB SCREW M6X * HH COLLAR SCREW M6X60 TX CARB. CONNECT. BOOT 450/ HOSE CLAMP 70-90MM HOSE CLAMP 50-70MM / C * NEW PART X AS REQUIRED 15

17 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 M6X12 TX CLAMP YDNAC 13,7MM * HH COLLAR SCREW M6X20 TX EJOT PT SCREW K60X20 WS= EJOT PT SCREW K60X20 ALU WS= 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 BLACK SPOILER RIGHT BLACK COLLAR BUSHING 6,2X10X15X RUBBER GROMMET FOR SPOILER / C * NEW PART X AS REQUIRED 16

18 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 x 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 6X11X16X7,5 1 59* HH COLLAR SCREW M6X12 TX * HH COLLAR SCREW M6X16 TX * HH COLLAR SCREW M6X15 TX * HH COLLAR SCREW M6X20 TX OVAL HEAD SCREW DIN0966-M 5X WASHER 6MM REFLECTOR RED LC4 ' BRACKET FOR REFLECTOR WASHER DIN0125-A 5, SELF LOCKING NUT DIN0985-M REFLECTOR YELLOW ' / C * NEW PART X AS REQUIRED 17

19 DECAL 1* DECAL SET FENDERS FE * DECAL SET FE / C * NEW PART X AS REQUIRED 18

20 FRONT WHEEL FRONT WHEEL.1,6X21"EXCEL 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" SPOKE NIPPLE M4,5X0,75 8X FRONT RIM 1,6X21" EXCEL AL RIM BAND 21" FRONT WHEEL REP. KIT x RIM LOCK VM1 (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 19

21 REAR WHEEL REAR WHEEL 2,15X18"EXCEL REAR HUB CPL BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB SPOKE M5X193-18" SPOKE NIPPLE M5-TA 8X21MM REAR RIM 2,15X18" EXCEL AL BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" REAR WHEEL REP. KIT 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 CHAIN 5/8X1/4" + MASTER LINK MASTER LINK 5/8X1/4" X-RING RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER ' PLUG FOR RIM x COVERING CAP SFL WHEEL SPINDEL REAR CPL CHAIN TENSIONER R/S SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= HEXAGON NUT M20X1,5 ' / C * NEW PART X AS REQUIRED 20

22 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= SPEEDOMETER BRACKET HH COLLAR SCREW M 6X20 WS= COVERING CAP SFL VOLTAGE REGULATOR STARTER CABLE L=190MM 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 CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x RUBBER BAND GROUND CABLE PROTECTION CAP F. STARTER ENG / C * NEW PART X AS REQUIRED 21

23 BRAKE CALIPER FRONT BRAKECALIPER FRONT BREMBO REPAIR KIT 28MM REPAIR KIT PISTON 28MM BOLT CPL. 6X RETAINING PLATE SET BREMBO BRAKEP.SET FR.TOSHIBA TT2701HH 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 22

24 HAND BRAKE CYLINDER HANDBRAKE CYL. NAT. SMALL HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=11 EXC CLAMP CPL. NATURE HH COLLAR SCREW M 6X25 WS= LEVER SCREW CPL HANDBRAKE LEVER SHORT ADJUSTING SCREW CPL. EXC PROTECTION CAP HAND BRAKE CYL CLAMP FOR MIRROR ' BRAKEHO. FRONT 1300MM HOLLOW SCREW M10X1X COPPER GASKET DIN X14X BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 23

25 REAR BRAKE CONTROL FOOTBRAKECYL. 13MM NATURE REPAIR KIT PISTON 13MM HOLLOW SCREW M10X1X COPPER GASKET DIN X14X BUSHING 6,2X10X2,5MM HOSE FOR RESERVOIR 6X1,5 x YDNAC CLAMP (9MM) BRAKE FLUID RESERVOIR ' * HH COLLAR SCREW M6X10 TX * HH COLLAR SCREW M6X20 TX 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 24