250 XC-F 2009 SPARE PARTS MANUAL: ENGINE ENGLISH ART.NO.: 3CM089315IEN

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1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089315IEN ENGLISH

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3 INDEX SPECIAL TOOLS ENGINE CASE CYLINDER CRANKSHAFT, PISTON 3x 4x 6x 7x CARBURETOR CLUTCH TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT 8x 11x 12x 13x KICK STARTER SHIFTING MECHANISM COOLING SYSTEM VALVE DRIVE 14x 15x 16x 17x 1

4 INDEX TIMING DRIVE CYLINDER HEAD LUBRICATING SYSTEM IGNITION SYSTEM 18x 20x 21x 22x ELECTRIC STARTER 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

5 SPECIAL TOOLS ASSY SUPPORT (WITHOUT HOLDER) FIXING ARM FRONT FIXING ARM REAR PROTECTION CAP FOR CAMSHAFT SPECIAL CIRCLIP PLIER EXTRACTOR FOR TIMING GEAR PISTON RING COMPRESSOR CPL LOCTITE 243 BLUE 6CCM BUSHING EXTRACTOR INTERN.BEAR.PULLER MM INTERN.BEAR.PULLER MM INTERN.BEAR.PULLER 5-7 MM LIMIT PLUG GAUGE F.VALVE GUIDE SEAL.RING PRESS PUNCH WAT.PUMP FEEL. GAUGE SET 10,12,15,20, INSERT FOR VALVE SPRING LEVER VALVE SPRING LEVER MOUNTING TOOL INNER RING NJ MIXT. CONTROL SCREW FACTORY FLYWHEEL EXTRACTOR SILICON GASKET THREE-BOND HOLDING SPANNER FOR SPROCKET SPARK PLUG WRENCH 16MM 1/2INCH VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML HOLD. PLATE CLUTCH 125/200 ' WRENCH F.MIXTURE CONTROL SCREW SP. WRENCH F.HOSE CONNECTOR SPARK PLUG KEY 250 SX-F INSERT F. PISTON LOCK RING / C * NEW PART X AS REQUIRED 3

6 ENGINE CASE ENGINE CASE CPL. EXC-F/XC-F DOWEL 9,8 X 7 X OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, HH COLLAR SCREW M6X45 TX HH COLLAR SCREW M6X8 TX LOCATING SCREW M8 L= CU-SEAL RING 8 X 14 X CIRCLIP OIL LEVEL GLASS OIL LEVEL GLASS G 1777 Y DOWEL 17 X 19 X GASKET FOR CLUTCH COVER OIL JET 70 M6X0,75 WS DOWEL BUSHING 13,8X11X * JET / O-RING 12,00X2,00 NBR SCREW PLUG OIL SCREEN 11,8x44,5MM O-RING 9X1,5 NBR 2 43* CLUTCH COVER CPL CHAIN DAMPERSHEET EXC-F HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X65 TX HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X30 TX VALVE PISTON D=10MM PRESSURE SPRING L=25MM D=1MM PLUG DIN0908-M12X1, CU-SEAL RING DIN X18X1, HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X95 TX GASKET SET * CLUTCH COVER OUTSIDE MOLDED RING HH COLLAR SCREW M6X55 TX / C * NEW PART X AS REQUIRED 4

7 ENGINE CASE O-RING 19,00X3,00 NBR PLUG M 24X CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M6X60 TX / C * NEW PART X AS REQUIRED 5

8 CYLINDER CYLINDER CYLINDER BASE GASKET DOWEL 10,2X12,5X HH COLLAR SCREW M6X25 TX / C * NEW PART X AS REQUIRED 6

9 CRANKSHAFT, PISTON 1* CRANKSHAFT CPL. EXC-F CON. ROD REP. SET THRUST WASHER 30,5X45X0,10 x THRUST WASHER 30,7X47X0,15 x THRUST WASHER 30,5X45X0,30 x CYL.ROLLER BEAR.NJ206 ET2XCS HEX.NUT L/SH M18X1, LOCK WASHER VSK SH.SEAL RING 35X42X4 B10FNIB WOODRUFF KEY 5X6,5 HARDED SH.SEAL RING 30X47X7 BSL VITON COLLAR NUT M12X1 R/S SPRING WASHER DIN0137-B WOODRUFF KEY DIN6888-3X5X PRIMARY GEAR 22T. 05 x PISTON PIN BOLT D=16mm CIRCLIP * I PISTON I CPL. 1 40* II PISTON II CPL. 1 41* OIL SCRAPER RING 1 42* COMPRESSIONRING D= SHAFT SEAL RING 14X24X6 B / C * NEW PART X AS REQUIRED 7

10 CARBURETOR CARBURETOR FCR-MX 3900K,TPS CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL SLIDE STOP THROTTLE VALVE CPL. FCRMX BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE GASKET WASHER THROTTLE VALVE 1 23* JET NEEDLE KEIHIN OBEKP x JET NEEDLE KEIHIN OBEKT x JET NEEDLE KEIHIN OBETP x JET NEEDLE KEIHIN OBETN x JET NEEDLE KEIHIN OBETQ x JET NEEDLE KEIHIN OBDYS x 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 IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x STARTER JET 65 x STARTER JET 70 x STARTER JET 75 x STARTER JET 80 x STARTER JET 85 x IDLE AIR JET 100 KEIHIN / C * NEW PART X AS REQUIRED 8

11 CARBURETOR ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL ARM PIN FLOAT STARTER VALVE CPL FLOAT NEEDLE CLAMP DRAIN SCREW FLOAT CHAMBER COVER ACCELERATOR PUMP DIAPHRAGM ACCELERATOR PUMP FLOAT CHAMBER CPL JET POWER JET CLOSED KEIHIN x JET POWER JET 50 KEIHIN x JET POWER JET 60 KEIHIN x JET POWER JET 70 KEIHIN x COIL SPRING STARTER VALVE SHORT CPL BREATH.HOSE FCR-MX KEIHIN CPL FLAT HEAD SCREW DIN0965-M 5X PLUG M 18X INTERMEDIATE LEVER CPL LINK LEVER 1 66* SXS SXS COIL SORING THROTTLE SHAFT SPRING INTERMEDIATE LEVER CARBURETOR COVER WASHER LINK LEVER E-CLIP ROD ACCELERATOR PUMP YDNAC-CLAMP (16MM) ' HOSE CONNECTOR CPL PLUG DIN0910-M 10X COPPER GASKET DIN X14X HOSE CONNECTOR KEIHIN ENGINE BREATHER TUBE STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 190MM / C * NEW PART X AS REQUIRED 9

12 CARBURETOR GASKET SET FCR-MX KEIHIN / C * NEW PART X AS REQUIRED 10

13 CLUTCH 1* OUTER CLUTCH CPL. 1 2* INNER CLUTCH HUB 1 3* PRESSURE PLATE INTERMEDI. DISC STEEL LINING DISC 3,0MM INNER RING 20X26X25,9 ' SHEET METAL LOCK 1,5MM ' HEXAGON NUT DIN0936-M18X1,5 R STOP DISK 20X39,6X3 ' PRIMARY GEAR 22T GASKET FOR SLAVE CYLINDER WASHER 6,2X18X PUSH ROD PRESSURE PIECE ' O-RING 30,00X1,50 NBR HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X25 TX VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING PISTON CPL OUTPUT CYLINDER CPL O-RING PRESSURE SPRING CU-SEAL RING DIN X16X BLEEDER SCREW CPL NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 11

14 TRANSMISSION I - MAIN SHAFT MAIN SHAFT CPL. T= IDLER G.5TH G.21-T * SLIDING GEAR 3./4.G. Z=17/ IDLER G.6TH G.22-T SOLID GEAR 2ND G.15-T NEEDLE BEAR.K 22X26X10 DIVIDED GROOVED BALL B C4 J BALL BEARING 6004 TN9 C NEEDLE CAGE K18X22X10 PARTED STOP DISC STOP DISK 17,2X24X STOP GEAR 22X28.5X LOCK RING 22X1, / C * NEW PART X AS REQUIRED 12

15 TRANSMISSION II - COUNTERSHAFT COUNTER SHAFT IDLER G. 4TH G.26-T * IDLER 3. GEAR T= SLIDING G. 6TH G.24-T IDLER G. 2ND G. 30-T IDLER G. 1ST G. 32-T SLIDING G. 5TH G.25-T NEEDLE BEARING K20X24X NEEDLE BEAR.K 22X26X10 DIVIDED IDLER GEAR BUSHING 25X28X9,7 D SCREW+SPRING WASHER SPROCKET 13-T x SPROCKET 14-T x SPROCKET 15-T x BALL BEARING 6003 TN9 C BALL BEARING 6205 C3 NTN SHAFT SEAL RING 32X45X7 BSLNBR SPACER BUSHING 12MM O-RING 25,12X1,78 NBR STOP DISC 17,2X30X SHIM 20X32X1 1 42* STOP DISC 25 X 32 X THRUST WASH. DIN X35X1, AXIAL-CIRCLIP 25X1, CIRCLIP DIN X1, / C * NEW PART X AS REQUIRED 13

16 KICK STARTER STOP DISK 17,2X24X CIRCLIP DIN X THRUST WASHER DIN X22X SPACER BUSHING 16X23X26X6, S FLAT HEAD SCREW M. ISA45 M8X HH COLLAR SCREW M6X16 TX KICKSTARTER SHAFT KICKSTART. GEAR 28-T KICKSTARTER RATCHET INTERMEDIATE GEAR KICKSTARTER SPRING DRIVING HUB SPRING 1,4MM ' STOP MET.SHEET 4MM 125/200' KICK STARTER CPL SHAFT SEAL RING 17X28X7 B WASHER 8MM GALVANIZED / C * NEW PART X AS REQUIRED 14

17 SHIFTING MECHANISM SHIFTING FORK 5TH/6TH GEAR SHIFTING FORK 2ND/3RD GEAR SHIFTING FORK 1ST/4TH GEAR NEEDLE ROLLER DIN5402 6X14, SHIFTING SHAFT CPL PRESSURE SPRING 0,9MM SLIDING PLATE CPL TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 6903 C SHIFT ROLLER BALL BEARING C RETURN SPRING 2,2MM ' SHIFTING SHAFT CPL AH SCREW DIN6912 M6X HH COLLAR SCREW M6X8 TX SHIFT. RAIL MAIN SHAFT 250/ SHIFTING MAIN L=93MM LOCKING LEVER SPRING LOCKING LEVER CPL SLEEVE FOR LOCKING LEVER WASHER DIN7349-5X15X HH COLLAR SCREW M5X20 TX SHIFT LEVER CPL. 250/ 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 15

18 COOLING SYSTEM RADIATOR L/S 250 SX-F RADIATOR R/S "45518U" RADIATOR CAP SMALL 1,8 BAR T-CONNECTOR CPL HOSE CLAMP GEMI HOSE CLAMP GEMI 12/ ANGEL PIECE ' PVC-HOSE 6X9 MM PER METER x RADIATOR HOSE L/S 250SXF HOSE ENGINE-RADIATOR RADIATOR HOSE R/S RAD. PR. L/S+R/S BLACK SX HOSE CONNECTOR 4 STROKE RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 16

19 VALVE DRIVE 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 VALVE COLLET VALVE SPRING KIT VALVE-STEM SEALING INTAKE VALVE TITAN EXHAUST VALVE TITAN VALVE SPRING RETAINER x VALVE SPRING INSIDE x VALVE SPRING HOLDER x / C * NEW PART X AS REQUIRED 17

20 TIMING DRIVE TIMING CHAIN GUIDE TOP SPACER BUSHING GUIDE RAIL CAMSHAFT GEAR SCREW * CAMSHAFT GEAR BALL BEARING 6004 NR C * CAMSHAFT INTAKE NEEDLE ROOLER DIN5402 NRB 4X6 2 8* CAMSHAFT EXHAUST 1 9* AUTO DECOMPRESSION 1 10* AUTO DECO WEIGHT SPRING FOR AUTO DECOMPR BUSHING SCREW AUTODEC. M5X0, TIMING CHAIN GUIDE BUSHING SCREW SEAL RING CU DIN7603-8X12X HH COLLAR SCREW M6X25 TX SPACER BUSHING 6,1X8,2X13, SECURING PROTECTION TIMING CHAIN TENSIONER SPACER BUSHING 6.1X8.2X HH COLLAR SCREW M6X40 TX CHAIN ADJUSTER HOLDING BOLT CU SEAL-RING DIN7603 A24X29X CHAIN ADJUSTER HYD O-RING 18,00X2,00 NBR TIMING VALVE JACKSHAFT STOP DISK 18,2X30X WOODRUFF KEY DIN6888-3X3,7 1 30* TIMING VALVE TWIN WHEEL 1 31* TIMING CHAIN 108 ROLLS BALL BEARING 6203 JR2 C NEEDLE BEAR.HK /24/ NEEDLE ROL.DIN5402 NRB 3X17, WATER PUMP ROTOR CIRCLIP DIN X SHAFT SEAL RING 12X30X7 PTFE / C * NEW PART X AS REQUIRED 18

21 TIMING DRIVE MOLDED RING WATER PUMP WATER PUMP COVER HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X20 TX CU-SEAL RING DIN7603-6X10X O-RING 10,00X1,00 NBR 70 SH HOLDING BOLT / C * NEW PART X AS REQUIRED 19

22 CYLINDER HEAD CYLINDERHEAD CPL CYLINDER HEAD GASKET VALVE COVER VALVE COVER GASKET VALVE COVER SCR. M6X12 WS RUBBER GASKET FOR SCREW COVER PLATE BREATHER SPECIAL SCREW M 5,0X ANGLE CONNECTOR LC O-RING 8X2 SILICONE SPECIAL SCREW M7X73 WS SPECIAL SCREW M7X40 WS COLLAR NUT 7X STUD 7X BUSH SUPPORT A.BRIDGE CPL ' NEEDLE ROLLER DIN5402 5X9, OIL JET DOWEL(BUSH BRIDGE)7/9/ VALVE GUIDE INTAKE VALVE GUIDE OUTLET CYLINDER HEAD SCREW WASHER 10,8X18,8X1, GASKET EXHAUST FLANGE EXHAUST FLANGE CPL HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X25 WS= INTAKE BOOT CLAMP D=56MM B=9MM M4X ENGINE BREATHER TUBE / C * NEW PART X AS REQUIRED 20

23 LUBRICATING SYSTEM OIL PUMP SHAFT EXC-F OILPUMP ROTOR CPL. 10MM G-73R OILPUMP ROTOR 15MM G OIL PUMP GEAR 14T OIL PUMP COVER L/S OIL PUMP COVER R/S HH COLLAR SCREW M5X16 TX AH SCREW DIN6912-M 5X OIL FILTER COVER RACING OIL FILTER WITH GASKET NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, OILPUMP IDLER GEAR SHIM WASHER DIN X18X0, CIRCLIP DIN X O-RING 40,00X2,50 NBR PLUG M20X1,5 WS= OIL SCREEN 15X83MM 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 32,00X2, HH COLLAR SCREW M5X20 TX / C * NEW PART X AS REQUIRED 21

24 IGNITION SYSTEM 1* IGNITION COVER EXC IGNITION COVER GASKET EXC-F STATOR FLYWHEEL PULSER COIL * CDI UNIT 250 SX-F SPARK PLUG CONNECT. VD05EG SPARK PLUG NGK CR9EKB WIRE RETAINING BRACKET HH COLLAR SCREW M6X8 TX WIRING HARNESS FOR CDI EXC 04 x WIRING HARNESS F. CDI-BOX 08 x IGNITIONCOIL KOKUSAN 4K3-A/B CABLE TIE 100/2,5MM BLACK x FREEWHEEL HUB AH SCREW DIN6912-M5X DOWEL 9,8 X 7 X HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M5X16 TX HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X95 TX CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M6X20 TX / C * NEW PART X AS REQUIRED 22

25 ELECTRIC STARTER E-STARTER ENGINE O-RING 25,00X3,00 NBR HH COLLAR SCREW M6X20 TX BEARING BOLT NEEDLE BEARING K 10X13X INTERMEDIATE GEAR 36T TORQUE LIMITER CPL NEEDLE BEARING HK FREE WHEEL GEAR FREE WHEEL HOLDER FREE WHEEL GEAR / C * NEW PART X AS REQUIRED 23

26 NOTICE

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28 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM089315IEN* 3CM089315IEN Art.Nr.: 3CM089315IEN 6/2008