450 SX-F USA 2013 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CFF8475M5EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CFF8475M5EN ENGLISH

2

3 INDEX FRONT FORK, TRIPLE CLAMP FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 4x 5x 7x 8x SHOCK ABSORBER SHOCK ABSORBER DISASSEMBLED PRO LEVER LINKING SWING ARM 9x 10x 12x 13x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER FUEL PUMP 14x 15x 16x 17x 1

4 INDEX MASK, FENDERS DECAL FRONT WHEEL REAR WHEEL 18x 19x 20x 21x WIRING HARNESS HAND BRAKE CYLINDER BRAKE CALIPER FRONT REAR BRAKE CONTROL 23x 24x 25x 26x BRAKE CALIPER REAR ACCESSORIES KIT 27x 28x x 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, TRIPLE CLAMP 1* 14187M5901 FORK WP 450 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 05 x 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 4

7 FRONT FORK, TRIPLE CLAMP 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 %POLISHED SPRING 4,8 N/MM x S SPRING 5,0 N/MM 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 SHUTTLE VALVE SPRING C=0, S3 MEMBRANE HOLDER INKL. PIN SET LOCK WASHER D=25, AH SCREW M4X / C * NEW PART X AS REQUIRED 5

8 FRONT FORK, TRIPLE CLAMP 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 6

9 HANDLEBAR, CONTROLS 1* HANDLEBAR RENTHAL BLACK BAR PAD SHORT CIRCUIT BUTTON * STARTER BUTTON GREY HOLDER INDICATOR LIGHT SX SPECIAL SCREW M6X12,5 WS=8 1 8* INDICATOR LIGHT LED YELLOW FI 1 13* THROTTLE GRIP CPL. 1 17* GRIP-SET RENTHAL G092 FULL W. x 17* GRIP SET CABLE TIE 140/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x 30* MASTER CYLINDER CPL * CLUTCH LEVER CPL. BREMBO * REP. KIT PISTON * COVER HYD. CLUTCH CPL. 1 34* VALVE 1 36* BRAKE FLUID DOT5.1 0,25L 1 37* PROTECTION CAP * LEVER SCREW CPL * PUSH ROD CPL. 1 44* CLAMP CPL * CLUTCH PIPE 1 92* THROTTLE CABLE 4T / C * NEW PART X AS REQUIRED 7

10 FRAME 1* BE FRAME ANTRAZIT "789M3" 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 ENGINEBRAC.SCREW M10X123 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 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 50* CHAIN GUARD 450/500 EXC CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX x PLASTIC FRAME PROTECTION SET CHAIN SLIDING KIT BELOW CPL SPROCKET COVER KIT x / C * NEW PART X AS REQUIRED 8

11 SHOCK ABSORBER 1* 18187M5701 MONOSHOCK LINK 350 SX-F USA HH COLLAR SCREW M10X52 SW / C * NEW PART X AS REQUIRED 9

12 SHOCK ABSORBER DISASSEMBLED 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 D11,5 OR. x S SPRING N/MM D11,75 OR S SPRING N/MM ORANGE x CIRCLIP 58,2X VALVE SPRING D80 CLOSED PISTON ROD NUT M16X REBOUND DISC 16X34 T2 H0 x S PISTON D * REBOUND DISC D16X43 H S3 ADAPTER D50 H28 CPL SPRING RING REBOUND RUBBER SHIM D29,75 X D19 X T0, S SEAL D18X30X REBOUND SPRING O-RING 41X DU-BUSH 18X20X DUST SEAL CIRCLIP 53X1, RESERVOIR CAP D=50 H= BUMP RUBBER / C * NEW PART X AS REQUIRED 10

13 SHOCK ABSORBER DISASSEMBLED SA1 MONOSHOCK BOTTOM PART CPL ADAPTOR-BUSH M10x1,50, D= S1 SHOCK ABSORBER FLUID 5 LT 1 99 R12018 REPAIR-KIT / C * NEW PART X AS REQUIRED 11

14 PRO LEVER LINKING 1* 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 G22x28x4 2 19* STEEL WASHER 15,2X19X0,1 x 19* STEEL WASHER 15,2X19X0,2 x 19* STEEL WASHER 15,2X19X0,3 x TRIANGLE LEVER REP. KIT FRONT x PULL ROD REP. KIT SX/SX-F x / C * NEW PART X AS REQUIRED 12

15 SWING ARM 2* 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 13

16 EXHAUST SYSTEM 1* SILENCER THERMAL PROTECTION FOIL THERMAL PROTECTION FOIL 1 4* SILENCER JACKET ALUMINIUM 1 8* CONNECTING CAP CPL BUSHING 7.5x12x28x SPRING WASHER DIN0137-B BUSHING 7.5x12x20x DAMP. COMPON. BLACK O-RING 74,00X1,50 FKM 75SH HH COLLAR SCREW M6X30 TX EXHAUST BRACKET RUBBER BLACK 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 SX-F HH COLLAR SCREW M8X25 TX BUSHING FOR EXHAUST SUPPORT EXHAUST PARTS KIT 12 x / C * NEW PART X AS REQUIRED 14

17 AIR FILTER 1* 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 15

18 TANK, SEAT, COVER 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 16

19 FUEL PUMP 1* GASKET KIT 1 2* FILTER KIT 1 3* FUEL PUMP CPL. EXC 1 4* NUT F. FUEL PUMP M12 1 5* FUEL CONNECTOR M8 1 7* VARIABLE ONE-EAR CLAMP 15,7MM 3 8* FUEL HOSE TANK 1 9* O-RING VITON F. PLUG CPC * FUEL HOSE PREFORMED THR.BODY 1 11* CLUTCH CPC BLACK * CONNECTOR FUEL PUMP 1 13* CLAMP ABA 14MM 1 14* FUEL FILTER 1 20* EJOT PT SCREW K60X25-Z SW= / C * NEW PART X AS REQUIRED 17

20 MASK, FENDERS 1* 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 18

21 DECAL 1* DECAL NUMBER PLATE SX/XC * DECAL REAR PART 450 SX-F / C * NEW PART X AS REQUIRED 19

22 FRONT WHEEL 1* 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 20

23 REAR WHEEL 1* 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 x REAR SPROCKET 51-T x REAR SPROCKET 52-T 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 21

24 REAR WHEEL 44* COLLAR NUT M25X1,5 WS= * REAR WHEEL REP. KIT x 98* DRIVETRAIN KIT SX-F 14T/52T x SPOKE KIT REAR 19" x / C * NEW PART X AS REQUIRED 22

25 WIRING HARNESS 1* 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 1 12* INDICATOR LIGHT LED YELLOW FI HOLDER INDICATOR LIGHT SX 1 14* SPECIAL SCREW M6X12,5 WS=8 1 15* PLUG SFL 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 23

26 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 1235MM HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X VALVE BRAKE FLUID DOT5.1 0,25L / 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 1235MM COPPER GASKET DIN X14X HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 25

28 REAR BRAKE CONTROL 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 26

29 BRAKE CALIPER REAR 1* 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 27

30 ACCESSORIES KIT 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 BATTERY 12V 4AH YTX5L-BS PLASTIC FRAME PROTECTION SET BAR PAD BATTERY 12V 3AH YTX4L-BS PLUG-IN STAND SPARK PLUG SOCKET BATTERY CASE WASH CAP SET EN OWN.MAN. 450 SX-F/XC-F TOOL KIT 2012 x 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 28

31

32 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CFF8475M5EN* 3CFF8475M5EN Art.Nr.: 3CFF8475M5EN 5/2012

33 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089575MEN ENGLISH

34

35 INDEX ENGINE CASE CLUTCH COVER BALANCER SHAFT CYLINDER 3x 4x 5x 6x CRANKSHAFT, PISTON CLUTCH TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT 7x 8x 9x 10x SHIFTING MECHANISM WATER PUMP COOLING SYSTEM VALVE DRIVE 11x 12x 13x 14x 1

36 INDEX TIMING DRIVE CYLINDER HEAD LUBRICATING SYSTEM IGNITION SYSTEM 16x 17x 18x 20x ELECTRIC STARTER THROTTLE BODY 21x 22x 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

37 ENGINE CASE ENGINE CASE CPL MAIN JET OIL JET 70 M CASE BUSH DOWEL 21X DOWEL 6X8X11, DOWEL 17 X 13 X O-RING 3,5X2,00 NBR OIL JET ANGLED AH.SCREW DIN0912-M 4X CU-SEAL RING DIN X18X1, OILDRAIN PLUG W.MAG. M 12X1, INT. TORX OVAL HEAD M 5X TAB WASHER BEARING MAIN SHAFT TAB WASHER BEARING COUNT.SHAFT INT. TORX FLAT HEAD M5X HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X60 TX HH COLLAR SCREW M6X75 TX HH COLLAR SCREW M6X80 TX HH COLLAR SCREW M6X85 TX GASKET SET 450/500 EXC / C * NEW PART X AS REQUIRED 3

38 CLUTCH COVER CLUTCH COVER CPL CLUTCH COVER OUTSIDE GASKET - CLUTCH OUTER COVER CLUTCH COVER GASKET OIL LEVEL GLASS VITON CIRCLIP OIL LEVEL GLASS DOWEL 9,8 X 7 X O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R SHAFT SEAL RING 19X30X7 B SHAFT SEAL RING 14X24X7 VITON SHAFT SEAL RING 12X30X7 PTFE NEEDLE BUSH NK LOCATING SCREW HH COLLAR SCREW M6X25 TX CU-SEAL RING 8 X 14 X HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M6X60 TX KICK-STARTER PLUG O-RING 16,00X2,00 VITON O-RING 18,00X2,00 NBR CIRCLIP DIN X1, / C * NEW PART X AS REQUIRED 4

39 BALANCER SHAFT BALANCE SHAFT BALANCE SHAFT GEAR BALANCE SHAFT WOODRUFF KEY DIN6888-3X3, NEEDLE BUSH NK / C * NEW PART X AS REQUIRED 5

40 CYLINDER CYLINDER + PISTON CPL DOWEL 6X8X11, CYLINDER BASE GASKET DOWEL 10,2X12,5X / C * NEW PART X AS REQUIRED 6

41 CRANKSHAFT, PISTON CRANKSHAFT CPL CON. ROD. REP. KIT I PISTON I D=95MM II PISTON II D=95MM COMPRESSION RING OIL SCRAPER RING PISTON PIN CIRCLIP BALL BEARING 6207 TM-SX07E NUT PRIMARY WHEEL M20X1, PRIMARY GEAR TIMING GEAR 18T WOODRUFF KEY DIN6888-3X3, SHAFT SEAL RING 35X47X7 VITON WOODRUFF KEY DIN6888-3X5X PISTON KIT GR. I 450 SX-F 13 x PISTON KIT GR. II 450 SX-F 13 x CRANKSHAFT REP. KIT 450 SX-F13 x / C * NEW PART X AS REQUIRED 7

42 CLUTCH CLUTCH CAGE NEEDLE BEAR K 25X29X COLLARSLEEVE WASHER 21,8 X 37 X INNER CLUTCH HUB WASHER 112X118X PRESSURE PLATE DAMPING RUBBER SLEEVE 7,5X HH COLLAR SCREW M5X16 TX LINING DISC 2MM INTERMEDIATE DISC 1,4MM PUSH ROD TAB WASHER HEXAGON NUT DIN0936-M18X1,5 R O-RING 30,00X1,50 NBR GASKET FOR SLAVE CYLINDER OUTPUT CYLINDER CPL PISTON CPL O-RING PRESSURE SPRING COPPER GASKET DIN X14X CLUTCH PIPE BLEEDER SCREW CPL HH COLLAR SCREW M6X20 TX VENT INJEKTION HYDR. CLUTCH INTERMEDIATE DISC 1MM PRESSURE PIECE CPL SPRING RING BELLEVILLE SPRING 71X115X1,5 I HUB INTERMEDIATE DISC 1,2MM CLUTCH DISC KIT / C * NEW PART X AS REQUIRED 8

43 TRANSMISSION I - MAIN SHAFT MAIN SHAFT 16 T IDLER GEAR 5.G SLIDING GEAR 3/4 G SOLID GEAR 2.G STOP DISC 17,2X30X NEEDLE BEAR. K 22X26X13 TN SPACER SLEEVE CIRCLIP DIN X1, STOP DISK 26 X 32 X 1, BUSHING BALL BEARING 6205 C3 NTN TAB WASHER BEARING MAIN SHAFT INT. TORX FLAT HEAD M5X BALL BEARING 6203 RSH C / C * NEW PART X AS REQUIRED 9

44 TRANSMISSION II - COUNTERSHAFT COUNTERSHAFT IDLER GEAR 1.G SLIDING GEAR 5.G IDLER GEAR 3.G IDLER GEAR 4.G SHIFT COLLAR IDLER GEAR 2.G NEEDLE BEAR.K 22X26X10 DIVIDED CIRCLIP DIN X1, STOP DISK 26 X 32 X 1, STOP DISK 23 X 32 X 1, SHIM 20X32X NEEDLE BEARING K 20X26X STOP DISC 17,2X30X CIRCLIP DIN X1, BALL BEARING 6203 JR2 C TAB WASHER BEARING COUNT.SHAFT INT. TORX FLAT HEAD M5X CYL.ROLL BEARING NJ SHAFT SEAL RING 32X45X7 BSLNBR O-RING 25,12X1,78 NBR SPACER SLEEVE COUNTER FRONT SPROCKET 13-T x FRONT SPROCKET 14-T x FRONT SPROCKET 15-T x SCREW 10.9+SPRING WASHER COUNTER SHAFT REP.KIT 4 STROKE x / C * NEW PART X AS REQUIRED 10

45 SHIFTING MECHANISM SHIFT LEVER CPL.RACING SPECIAL SCREW M6X16 WS= STEEL WASHER 6,4X17X SHAFT SEAL RING 14X24X6 B NEEDLE BEAR.HK X20X STOP DISK 14X30X RETURN SPRING 2,2MM ' SPRING GUIDE TENSIONING SPRING 0,8MM SHIFT SHAFT CPL SLIDING PLATE CPL SHIFT RAIL 11,8X101, PRESSURE SPRING 0,9MM SHIFTING ROLLER 6X8X5, SHIFT DRUM LOCATING ALU CPL SHIFT ROLLER AH SCREW DIN0912-M 6X LOCKING LEVER CPL HH COLLAR SCREW M5X20 TX SLEEVE FOR LOCKING LEVER ARRESTING LEVER SPRING SHIFT RAIL 11,8X SHIFT FORK 5./6.GEAR WASHER DIN9021-A 5, SHIFT FORK 2./4.GEAR BALL BEARING C PAIR OF WASHERS M 6 NORDLOCK SHIFTING FORK 1ST/3RD GEAR / C * NEW PART X AS REQUIRED 11

46 WATER PUMP CAP NUT M6 STAINLESS STEEL WATER PUMP ROTOR DISC WATER PUMP SHAFT SEAL RING 12X30X7 PTFE WATER-PUMP GASKET WATER PUMP COVER CPL HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X65 TX CU-SEAL RING DIN7603-6X10X WATER PUMP REP. KIT 12 x / C * NEW PART X AS REQUIRED 12

47 COOLING SYSTEM 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 L/S RADIATOR HOSE R/S PREFORMED HOSE ENGINE/COOLER RADIATOR PROTECTION L/S+R/S SX x RADIATOR PROTECTION BLACK HOSE CONNECTOR L=172, RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 13

48 VALVE DRIVE INTAKE VALVE EXHAUST VALVE VALVE SPRING HOLDER VALVE-STEM SEALING RACING VALVE SPRING VALVE SPRING RETAINER VALVE COLLET ROCKER ARM EXHAUST CPL ROCKER ARM INTAKT ROCKER ARM EXHAUST ROCKER ARM INTAKE O-RING 15,00X1,50 VITON SCREW PLUG M18X SPECIAL SCREW M7X40 WS FIT BOLT M7X1X 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=8,9/2,24 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 / C * NEW PART X AS REQUIRED 14

49 VALVE DRIVE SHIM D=8,9/2,12 x SHIM D=8,9/2,16 x SHIM D=8,9/2,20 x VALVE SPR.-KIT 450 SX-F 13 x VALVE KIT 450 SX-F 13 x / C * NEW PART X AS REQUIRED 15

50 TIMING DRIVE CAMSHAFT W. AUTODECO HH COLLAR SCREW M6X20 TX RETAINING PLATE CAMSHAFT CPL GASKET TIMING CHAIN TENSIONER TIMINGCHAIN TENSIONER CPL.RAC HH COLLAR SCREW M6X16 TX NEEDLE SLEEVE HK1814RS18/24/ NEEDLE SLEEVE HK4012B40X47X TIMING CHAIN 110T TIMING CHAIN TENSIONER TIMING CHAIN GUIDE BUSHING SCREW M FAILURE PROTECTION / C * NEW PART X AS REQUIRED 16

51 CYLINDER HEAD CYLINDER HEAD CPL CYLINDER HEAD GASKET CYLINDER HEAD GASKET (DN95) x CYLINDER HEAD GASKET 1,15MM x VALVE COVER BLACK MATT VALVE COVER GASKET VALVE COVER SCREW DECOUPLING ELEMENT RUBBER BOOT EFI HH COLLAR SCREW M6X16 TX EXHAUST FLANGE EXHAUST FLANGE GASKET SCREW IN NOZZLE M20X1, OIL JET 70 M VALVE GUIDE INTAKE CYL. HEAD SCREW M10X1,25 L= WASHER 19X10,5X2, HH COLLAR SCREW M6X70 TX SCREW PLUG HOSE CLAMP GEMI 63MM HOSE CLAMP GEMI 58MM O-RING 10,00X2,00 SILCONE TEMPERAT.-SENSOR WATER LC CLAMP YDNAC (18MM) ENGINE BREATHER TUBE / C * NEW PART X AS REQUIRED 17

52 LUBRICATING SYSTEM OIL PUMP GEAR 17 T CYLIND.SCREW M3X8 ISO SS STOP SHEET MEMBRANE MEMBRANE MEMBRAN CRANKCASE TAB WASHER MEMBRAN CSC OIL PUMP SHAFT SP-DP NEEDLE ROLLER NRB 4X15,8 G ROTOR-SET CPL. 22MM O-RING 44,00X2,00 VITON OIL PUMP COVER SUCTION PUMP HH COLLAR SCREW M6X16 TX CU-SEAL RING DIN X18X1, OILDRAIN PLUG W.MAG. M 12X1, TAB WASHER DIN6799-RS 6, STOP DISK 8,1 X 15 X 0, IDLER GEAR 1 29Z OIL PUMP COVER OILPUMP ROTOR 12MM G-95R/ O-RING 12X2 VITON GREEN NEEDLE ROL.DIN5402 NRB 4X9, NEEDLE ROLLER DIN5402 2,5X11, O-RING 17,17X1,78 GLO OIL SCREEN CPL PLUG M20X1,5 WS= O-RING 17,00X2, O-RING 12,5X1,5 VITON V OIL SCREEN OIL FILTER WITH GASKET O-RING 39,34X2, OILFILTER CAP O-RING 12,5X1,5 NBR HH COLLAR SCREW M5X16 TX BALL DIN PRESSURE SPRING L=25MM D=1MM / C * NEW PART X AS REQUIRED 18

53 LUBRICATING SYSTEM CU-SEAL RING DIN X18X1, PLUG SCREW SAS M12X1, BUSHING PIN SHIM WASHER DIN X24X0, CIRCLIP DIN X AH SCREW DIN0912-M 6X20 SS OILFILTER SERVICE KIT SX-F 13 x / C * NEW PART X AS REQUIRED 19

54 IGNITION SYSTEM IGNITION COVER GASKET - IGNITION COVER PULSER COIL KOKUSAN 4K3-A/B SPARK PLUG CONNECTOR SPARK PLUG M12X1,25 LKAR8AI HH COLLAR SCREW M5X16 TX NEEDLE ROL.DIN5402 NRB 4X9, S FLAT HEAD SCREW ISA25 M4X RETAINING PLATE IGNITIONCOIL IG3826 KOKUSAN' ROTOR STATOR SPRING WASHER DIN0137-B COLLAR NUT M12X1 R/S WOODRUFF KEY DIN6888-3X5X AH SCREW DIN6912 M4x HH COLLAR SCREW M6X16 TX HH COLLAR SCREW M6X25 TX / C * NEW PART X AS REQUIRED 20

55 ELECTRIC STARTER E-STARTER CPL. 0,5KW HH COLLAR SCREW M6X25 TX O-RING 25,00X3,00 NBR AH SCREW DIN0912-M 6X40 A STOP DISC 6X23X BEARING BOLT AH SCREW DIN0912-M 6X20 SS SHIM WASHER DIN X24X0, TORQUE LIMITER CPL CIRCLIP DIN X IDLER GEAR 30-T CPL BUSHING PIN FREEWHEEL GEAR 66 C CPL FREE WHEEL / C * NEW PART X AS REQUIRED 21

56 THROTTLE BODY THROTTLE BODY MAP SENSOR CPL FUEL RAIL CPL INJECTOR KIT CPL TPS CPL THROTTLE COVER CPL STARTER VALVE COMP IDLING ADJUSTING SCREW CPL SEAL RING SCREW SHOULDER SPECIAL SCREW AH O-RING THROTTLE POS. SENSOR SPECIAL SCREW O-RING PLATE SPECIAL SCREW O-RING SEAL RING 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 STARTER VALVE COMP HH. COLLAR SCREW M5X25 ISA / C * NEW PART X AS REQUIRED 22

57 NOTICE

58 NOTICE

59

60 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM089575MEN* 3CM089575MEN Art.Nr.: 3CM089575MEN 5/2012