450 EXC RACING USA 2007

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8475G7EN ENGLISH

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3 INDEX FRONT FORK FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS SIDE STAND 4x 5x 7x 8x FRAME, SUB FRAME SWING ARM MONOSHOCK EXHAUST MANIFOLD 9x 11x 12x 13x SILENCER AIR FILTER BOX TANK, SEAT, COVER MASK, FENDERS 14x 15x 16x 17x 1

4 INDEX DECAL FRONT WHEEL REAR WHEEL WIRING HARNESS 18x 19x 20x 22x HAND BRAKE CYLINDER BRAKE CALIPER REAR REAR BRAKE CONTROL BRAKE CALIPER FRONT 23x 24x 25x 26x LIGHTING SYSTEM SPEEDOMETER EVAPORATIVE CANISTER ACCESSORIES 27x 28x 29x 30x 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 1* 14187C06 FORK KPL. WP D EXC HH COLLAR SCREW M 8X25 WS= HH COLLAR SCREW M 8X30 WS= HH COLLAR SCREW M 8X35 WS= AH SCREW DIN6912-M10X25,10.9,L EJOT PT SCREW K60X20 WS= BOT.TRIP.CL.CPL. X=20MM/D=60MM FORK TUBE L=244 ' TOP TRIPLE CLAMP X=20MM/D=54MM STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP D=28MM HANDLEBAR SUPPORT 28MM SC' TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F.SPEED.CABLE ORANGE STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS= FORK PROT. L/S +R/S ORG / C * NEW PART X AS REQUIRED 4

7 FRONT FORK DISASSEMBLED 3* S SETTING KNOB + SCREW 2 4* VENT SCREW M4X6 2 5* O-RING NBR 3,7X1, E OUTER TUBE L=577 D=54/ GUIDING RING D=58MM DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, 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=554 ALU 2 33* ADJUSTER NEEDLE * O-RING 2X1,5 NBR 2 35* 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 2 42* S SCREW SLEEVE M29,3X1 L=90 CPL. 2 43* O-RING 6X1,2 NBR 2 44* 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 * S1 AXLE CLAMP L/S + TUBE CPL / C * NEW PART X AS REQUIRED 5

8 FRONT FORK DISASSEMBLED 61* S1 AXLE CLAMP R/S + TUBE CPL HH COLLAR SCREW M 8X25 WS= CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0,7 2 69* 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 SAE * S SCREW CAP M51X1,5 CPL SPACER 42X26,5X SPACER 42X26,5X SPACER 42X26,5X2, SPACER 42X26,5X1, T511 SILICONE GREASE F. DUST STRI 1 99 R14013 REPAIR-KIT GASKET 4860 MXMA / C * NEW PART X AS REQUIRED 6

9 HANDLEBAR, CONTROLS 1* HANDLEBAR MAGURA SX 28MM SL TWIST GRIP COVER RENTHAL THROTTLE GRIP CPL. RACING FIXED GRIP RENTHAL CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x SPACER BUSHING 6X10X CLAMP FOR MIRROW ' MIRROR L/S MIRROR R/S SUPPORT FOR MIRROR LC4 ' MASTER CYLINDER CPL CLUTCH LEVER CPL. BREMBO 06 x REP. KIT PISTON COVER HYD. CLUTCH CPL VALVE BOLT KPL BRAKE FLUID DOT PROTECTION CAP LEVER SCREW CPL CLAMP CPL HH COLLAR SCREW M 6X20 WS= PUSH ROAD CPL LIGHT SWITCH CLUTCH PIPE ENGINE STOP SWITCH CEV CLAMP ENGINE STOP SWITCH FLAT HEAD SCREW DIN7985-M 4X STARTER CONTROL THR.CABLE"OPEN-CLOSE"KEIHIN / C * NEW PART X AS REQUIRED 7

10 SIDE STAND BUSHING WITH SCREW EXC EU SIDE STAND L=377MM ' BOLT SIDE ST.SPRING M5 EGS' SIDE STAND BRACKET CPL BRACKET FOR SPRING EGS ' RUBBER L=145MM SIDESTAND SPRING EXC' STAND SPRING SHORT SELF LOCKING NUT M / C * NEW PART X AS REQUIRED 8

11 FRAME, SUB FRAME FRAME EXC RAC. EU/AUS "DC06" PLUG 37MM ADH. FOIL TRANSP. 80X80 MM STEERING HEAD LOCK CPL. ZADI PLASTIC CAP x SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M ANGEL PIECE ' PVC-HOSE 7X10 PER METER ENGINEBRAC.SCREW M10X123 WS= SELF LOCKING NUT M10 CU WS= FRAME PROTECTION SET HH COLLAR SCREW M 5X25 WS= BUSH F. FRAME PROTECTION BLIND PLUG-IN NUT M5 WN 22A HH COLLAR SCREW M 6X35 WS= BUSHING F. SPROCKET COVER RAC CHAIN ROLL 30MM CPL BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL SUB FRAME CPL. EXC+MXC "M5" SPROCKET SCREW-AH M8X26 WS= SPROCKET SCREW-AH M8X20 WS= CHAIN SLIDING PIECE BELOW CPL CHAIN SLIDING PIECE BELOW ' BUSHING 8,2X10X HH COLLAR SCREW M 8X35 WS= SELF LOCKING NUT M CHAIN ROLL D=30MM HH COLLAR SCREW M 8X30 WS= LOCK WASHER 8MM BUSHING 8.2 X 12 X GROOVED BALL BEAR RS C WASHER DIN0125-A 6, / C * NEW PART X AS REQUIRED 9

12 FRAME, SUB FRAME FOOTREST L.+R. CPL FOOT PED L/S SILVER FOOT PED R/S SILVER / C * NEW PART X AS REQUIRED 10

13 SWING ARM SWINGARM CPL CHAIN GUARD CPL CHAIN GUARD BUCKET NEEDLE BEARING HK2212V BEARING SLEEVE 17X22X38, BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X STOP DISK 22,2X31,7X PIVOT BEARING+BUSHES PDS ' CHAIN GUIDE REAR CPL CHAIN GUIDE REAR ' RETAINING PLATE CPL RETAIN.CLAMP FOR BRAKE HOSE' * SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND CHAIN GUARD LARGE EGS CHAIN GUARD SMALL EXC HOLLOW RIVET TWO PARTS SELF LOCK. NUT DIN0985-M WASHER DIN9021-A 6, TOOL BEARING MOUNTING PDS SPECIAL SCREW M 5,0X HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X50 WS= / C * NEW PART X AS REQUIRED 11

14 MONOSHOCK S HH COLLAR M12X55 WS= * 12187C06 MONOSHOCK WP PDS EXC / C * NEW PART X AS REQUIRED 12

15 EXHAUST MANIFOLD EXHAUST PIPE TEN.SPRING L=62MM EY.MOVEABLE HH COLLAR SCREW M 8X25 WS= BUSHING FOR EXHAUST SUPPORT EXHAUST BRACKET RUBBER BLACK RANGE CHANGE METAL NUT M / C * NEW PART X AS REQUIRED 13

16 SILENCER 1* SILENCER SPARKY STR.LEG * SILENCER HOUSING SPARKY SILENCENER CONNECT. CAP CPL SPRING WASHER DIN0137-B BUSHING 7,5X12X28X7,8 ' EXHAUST BRACKET RUBBER BLACK RANGE CHANGE METAL NUT M HH COLLAR SCREW M 6X30 WS= TEN.SPRING L=62MM EY.MOVEABLE DUMMY RIVET 4,8X 8 NIRO SPECIAL SCREW M 5,0X * SILENCER END CAP SPARKY S.L STUFFINGYARN 350 GRAMM ' STUFFING YARN 560X340X76G O-RING 74,00X1,50 FKM 75SH / C * NEW PART X AS REQUIRED 14

17 AIR FILTER BOX FILTER WALL FILTER BOX COVER REAR PART FILTER BOX QUICK RELEASE-NIPPLE * BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX ' THROTTLE CAP EGS CPL.98 x AIR FILTER RACING FILTER CARRIER RAC FILTER SUPPORT CPL.2-STROKE' FILTER SUPPORT BUSH ' FASTEN. DEVICE FILTER SUPPORT CARBURETOR CONNECTION BOOT HOSE CLAMP 40-60MM EJOT PT SCREW K60X20 WS= SPECIAL SCREW M 5,0X WASHER DIN9021-A 6, BUCKET / C * NEW PART X AS REQUIRED 15

18 TANK, SEAT, COVER FUEL TANK CPL. RACING 8,0L SCREW SEAT FASTENING D=6X23/ TANK ROLLER 12X26X12 ' HH COLLAR SCREW M 6X12 WS= FILLER CAP CPL. WITH VALVE GASKET FOR FILLER CAP HIGH PVC-HOSE 6X9 MM PER METER x ANGLE PIECE 90 DEGREE M10X SUPORT BUSHING TANKROLLER HH COLLAR SCREW M 6X45 WS= GAS COCK ON/OFF/RES O-RING 11X2 VITON EJOT PT SCREW K60X20 WS= CLAMP YDNAC MM FUEL HOSE 7,5X13MM SEAT BLACK WITHOUT KTM-LOGO SEAT COV.BLACK WITHOUT LOGO SPOILER L/S ORANGE SPOILER R/S ORANGE BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M 6X20 WS= EJOT PT SCREW K60X20 ALU WS=6 8 30* TOOL KIT / C * NEW PART X AS REQUIRED 16

19 MASK, FENDERS FOAM 4X9MM PER METER H.LIGHT MASK ORANGE EXC/EGS' BRAKE HOSE GUIDE SPACER BUSHING 7X10X7, HH COLLAR SCREW M 6X20 WS= MASK RUBBER UFO WP ' FENDER FRONT WIDE ORANGE FENDER BRACE BLACK ' SCREW FEND.BRACE M8X9 WS= NUT FENDER BRACE M8 WS= REFLECTOR YELLOW ' REAR PART EXC ORANGE COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M 6X25 WS= BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M 6X16 WS= METAMOLL 90X45X3MM SIDE REFLECTOR RED REAR BRACKET SIDE REFLECTOR NUMBER PLATE CARRIER LONG BUSH FOR FENDER 6X11X20X5 MM EJOT PT SCREW K60X20 WS= REFLECTOR RED LC4 ' OVAL HEAD SCREW DIN0966-M 5X WASHER 6MM BRACKET FOR REFLECTOR WASHER DIN0125-A 5, SELF LOCKING NUT DIN0985-M / C * NEW PART X AS REQUIRED 17

20 DECAL 1* SPOILER DECAL * DISPLACEMENT DECAL 450 EXC / C * NEW PART X AS REQUIRED 18

21 FRONT WHEEL 1* FRONTWHEEL CPL.1,6X21 EXCEL FRONT HUB CPL. SX SILVER 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 M4,5X228-15G 21" DDE SPOKE NIPPLE M4,5X0,75 8X * FRONT RIM 1,6X21" EXCEL AL RIM BAND 21" 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 40* AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 19

22 REAR WHEEL 1* R. WHEEL CPL.2,15X18" EXCEL REAR WHEEL HUB CPL. SX, EXC BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB SPOKE M5X195-10G 18" DDE SPOKE NIPPLE M5-TA (8X21MM) 36 10* REAR RIM 2,15X18" EXCEL AL7 1 11* 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" MX 118 LINKS ROLLS CHAIN Z-RING 118 ROLLS ROLLS CONNECT. LINK FOR MASTER LINK FOR RIVET LINK FOR RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER ' PLUG FOR RIM x COVERING CAP SFL16 x / C * NEW PART X AS REQUIRED 20

23 REAR WHEEL 40* WHEEL SPINDLE RE. CPL.265MM CHAIN TENSIONER R/S * SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= HEXAGON NUT M20X1,5 ' / C * NEW PART X AS REQUIRED 21

24 WIRING HARNESS 5* WIRING HARNESS EXC-S USA FLASHER UNIT SUPPORT BRACKET EXC PVC-CLAMP 7,9 MM HEYCO BRACKET FOR FLASHER RELAISE VOLTAGE REGULATOR CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x FUSE 10 A WIRING HOLDER 12MM x WIRING HOLDER 16MM x CABLE SUPPORT KHS NR BATTERY 12V 4(5)AH TX5L-BS RUBBER L=145MM BATTERY CARRIER PLAST.BLACK WIRING HARNESS BATTERY DUKE' STARTER RELAY 12V ' STARTERCABLE 700 MM ' DC HORN 12V K80/L LEB BRACKET RANGE CHANGE METAL NUT M GROUND CABLE D=6MM L=140MM ' CONTACT WASHER M6 VSV-K PROTECTION CAP F. STARTER ENG SELF LOCK. NUT DIN0985-M FLASH. WIRINGHARNESS REAR AH SCREW DIN 912 M 5X AH OVAL SCREW ISO 7380 M 6X HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X15 WS= HH COLLAR SCREW M 6X12 WS= EJOT PT SCREW K60X20 WS= / C * NEW PART X AS REQUIRED 22

25 HAND BRAKE CYLINDER HAND BRAKE CYLINDER CPL.EXC HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=10MM CLAMP CPL. NATURE HH COLLAR SCREW M 6X25 WS= LEVER SCREW CPL HAND BRAKE LEVER + SPRING ADJUSTING SCREW CPL. EXC PROTECTION CAP HAND BRAKE CYL CLAMP FOR MIRROW '94 x BRAKEHO. FRONT 1300MM HOLLOW SCREW M10X1X CU-SEAL RING DIN X16X BRAKE LIGHT SWITCH FRONT BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 23

26 BRAKE CALIPER REAR BRAKE CALIPER REAR CPL REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM RETAINING SPRING SET CUP SET SHORT BRAKE HOSE REAR 655MM BLEEDER HOLLOW SCREW M10X CU-SEAL RING DIN X16X / C * NEW PART X AS REQUIRED 24

27 REAR BRAKE CONTROL REAR BRAKE CYLINDER CPL REPAIR KIT PISTON 13MM REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX BRAKE LIGHT SWITCH REAR ' BRAKE HOSE REAR 655MM CU-SEAL RING DIN X16X FOOT BRAKE LEVER CPL STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M 5X12 WS= RETURN SPRING FOR BRAKE LEVER HH COLLAR SCREW M 6X20 WS= PUSH ROD L=28MM HEXAGON NUT DIN0934-M SWIVEL HEAD KA AH SCREW DIN6912 M10X SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= BALL BEARING SKF RS COLLAR NUT M10 WS= HH COLLAR SCREW M 6X12 WS= BELLOWS FOR REPAIR KIT BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 25

28 BRAKE CALIPER FRONT BRAKECALIPER FRONT BREMBO REPAIR KIT 28MM REPAIR KIT PISTON 28MM BOLT CPL. 6X RETAINING PLATE SET BREMBO 1 9* BRAKEP.SET FR.TOSHIBATT2701HHB BLEEDER SCREW WITH CAP CUP SET SHORT HH COLLAR SCREW M 8X35 WS= CU-SEAL RING DIN X16X CU-SEAL RING DIN X16X1, HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 26

29 LIGHTING SYSTEM HEADLIGHT CPL. CEV 394 ' BULB H4 12V 60/55W (P43T) HEADLIGHT BRACKET ' HH COLLAR SCREW M 6X16 WS= SHEET MET.SCR.DIN7981 3,5x BULB 12V 5W (W2,1X9,5D) PHIL CABLE FOR HEAD LIGHT EXC-S REAR LIGHT CPL. EXC REAR LIGHT LENS EGS' WASHER DIN9021-A 6, SELF LOCK. NUT DIN0985-M WIRING HARNESS REAR ' BULB 12V 21/5W (BAY15S)REINFO SHEET MET. SCR. DIN7981 3,5X FLASHER CPL.FRONT L/S REAR R/S FLASHER CPL.FRONT R/S REAR L/S BULB 12V ORANGE (RY10W) WASHER DIN0125-A10, LOCK WASHER DIN6797-J10,5 ZI HH COLLAR NUT M10X1,25 WS= FLASHER LENS L/S R/S TRANSP / C * NEW PART X AS REQUIRED 27

30 SPEEDOMETER SPEEDOMETER MPH F. 21" REPROGRAMMABLE: KM/H - MPH BATTERY COVER F. SPEEDOM BATTERY F. SPEEDOM. M.A.E SPEEDOMETER TOP PART CABLE SUPPORT 10/6MM CABLE FOR DIGITAL SPEEDOM CLAMP D=6/8MM, BLACK MAGNET FOR DIGITAL SPEEDOM CIRCLIP DIN0471-9X1 INOX WASHER DIN9021-A 5, SPEEDOM.BRACKET 625 SXC+SMC SCREW FOR PLASTIC 50X RUBBER GROMMET 16X10,8X RUBBER SLEEVE D=8MM OPEN HH COLLAR SCREW M 6X25 WS= SPACER BUSH. F. SPEEDOMET.BRA FLASHER BRACKET PLUG CAP KV H.BEAM INDICATOR LIGHT BLUE' FLASHER INDICAT.LIGHT GREEN' IGNITION LOCK CPL. ZADI ' IGNITION LOCK NUT M24X WASHER F. IGNITION LOCK SPRING L=16MM SPRING WASHER DIN137 B GROOVED NAIL RIVETO AF KEY BLANK BLACK "T" GRIP / C * NEW PART X AS REQUIRED 28

31 EVAPORATIVE CANISTER Evaporative Canister univ METAMOLL 90X45X3MM * Evap. Canist. Hose Set cpl T-Connector NORMA TS YDNAC CLAMP (9MM) HOSE CLAMP YDNAC MM RUBBER CABLE TIE 75MM ANGLE PIECE 90 DEGREE M10X VALVE MIKUNI CI HH COLLAR SCREW M 5X20 WS= HOSE NBR 5,4X9,4 PER METER x HOSE 3,2X8,5 PER METER x VACUUM CONECTION M6/3MM ' * Intercepting Tank universal RING 74,00X2,00 SILICONE EJOT PT SCREW K60X20 WS= HH COLLAR SCREW M 6X25 WS= SPACER BUSH. F. SPEEDOMET.BRA HH COLLAR SCREW M 6X10 WS= O-RING 6,00X1, / C * NEW PART X AS REQUIRED 29

32 ACCESSORIES DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER OWNERS MANUAL RAC CF8475G7EN SPC CHASSIS 450 EXC STR.LEG CM089241GEN SPC MOTOR 450 EXC-S / 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 *3CF8475G7EN* 3CF8475G7EN Art.Nr.: 3CF8475G7EN 7/2006