450 SX-F 2007 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF8401G5EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8401G5EN ENGLISH

2 INDEX FRONT FORK FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS FRAME, SUB FRAME 3x 4x 6x 7x MONOSHOCK SWING ARM MANIFOLD EXHAUST SILENCER 8x 9x 10x 11x AIR FILTER BOX TANK, SEAT, COVER MASK, FENDERS DECAL 12x 13x 14x 15x 1

3 INDEX FRONT WHEEL REAR WHEEL WIRING HARNESS BRAKE CALIPER REAR 16x 17x 19x 20x HAND BRAKE CYLINDER REAR BRAKE CONTROL BRAKE CALIPER FRONT ACCESSORIES 21x 22x 23x 24x 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

4 FRONT FORK DISASSEMBLED SETTING KNOB 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 MEMBRANE S SCREW BUSH M20X1 L=33 CPL COPPER WASHER 20,5X26X ADJUSTING TUBE L= PISTON ROD SXS COUNTERNUT M12X1 WS ADJUSTER NEEDLE O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM S POLISHED SPRING 4,2 N/MM2 CC x S POLISHED SPRING 4,4 N/MM2 CC x S POLISHED SPRING 4,6 N/MM2 CC x S POLISHED SPRING 4,8 N/MM x SPACER 43X35X2, GUIDING BUSH REBOUND SPRING SPACER 43X35X SPRING SUPPORT O-RING 6X1,2 NBR SPRING REB. L=32 C=37 DI=13, PISTON ROD REBOUND VALVE SPRING S1 MEMBRANE HOLDER LOCK WASHER D=25, AH SCREW M4X O-RING NBR 21X PISTON COMPRESSION D=27, O-RING NBR 4X1, / C * NEW PART X AS REQUIRED 4

5 FRONT FORK DISASSEMBLED S PIN VALVE SET NUT M6X0,5 REBOUND GUIDE RING 44,2 X39, RING SPRING-SUPPORT O-RING NBR 46 X S1 AXLE CLAMP L/S + TUBE CPL S1 AXLE CLAMP R/S + TUBE CPL HH COLLAR SCREW M 8X25 WS= CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0, PISTON ROD COMPRESSION PISTON REBOUND SX PISTON RING 5X1X O-RING 6X1,2 NBR RING D=23,45X2, PISTON ROD SEALING S SCREW SLEEVE M24,5X1 CPL DU_BUS FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D= RUBBER CAP D=35MM S1 FORK OIL SAE S1 SCREW CAP CPL. L= AH SCREW M4X SCREW M4X MEMBRANE SLEEVE 2 98 T511 SILICONE GREASE F. DUST STRI 1 99 R14014 REPAIR-KIT GASKET 48MM / C * NEW PART X AS REQUIRED 5

6 HANDLEBAR, CONTROLS HANDLEBAR D=28MM SX HANDLEBAR PAD SHORT CIRCUIT BUTTON STARTER BUTTON 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 DECO.LEVER CPL. RACING MASTER CYLINDER CPL. RACING CLUTCH LEVER SHORT CPL x CLUTCH LEVER LONG CPL x REP.KIT PISTON 9,0MM 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 HH COLLAR SCREW M 6X20 WS= FLAT HEAD SCREW DIN0965-M 4X CLUTCH PIPE RACING HOT START CABLE THROTTLE CABLE 250 SXF / C * NEW PART X AS REQUIRED 6

7 FRAME, SUB FRAME FRAME 450 SX-F "JA07" SUB FRAME SX "Q7" SUB FRAME APPLICATION L/S SUB FRAME APPLICATION R/S ENGINE BRACE 450 SX-F ADH. FOIL TRANSP. 80X80 MM SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M ENGINEBRAC.SCREW M10X123 WS= S FLAT HEAD SCREW M. ISA45 M8X COLLAR SCREW M8X42 WS= SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M 8X30 WS= FOOT PED L/S SILVER FOOT PED R/S SILVER BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTREST L.+R. CPL ANGEL PIECE ' PVC-HOSE 7X10 PER METER x CHAIN SPROCKET COVER CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX x FRAME PROTECTION STICK. SET CHAIN SLIDING P. BELOW CPL / C * NEW PART X AS REQUIRED 7

8 MONOSHOCK S HH COLLAR M12X50 ISA C05 MONOSHOCK WP PDS 450 SXF / C * NEW PART X AS REQUIRED 8

9 SWING ARM SWINGARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR SPECIAL SCREW M 5,0X BRAKE HOSE GUIDE LOWER 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 HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X45 WS= PIVOT BEARING+BUSHES PDS ' TOOL BEARING MOUNTING PDS INSERTION NUT F. CHAIN GUIDE SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC / C * NEW PART X AS REQUIRED 9

10 MANIFOLD EXHAUST MANIFOLD 450 SX-F TEN.SPRING L=62MM EY.MOVEABLE HH COLLAR SCREW M 8X25 WS= BUSHING FOR EXHAUST SUPPORT EXHAUST BRACKET RUBBER BLACK BLIND RIVET NUT M8 HUC/ROF 5 0 x / C * NEW PART X AS REQUIRED 10

11 EXHAUST SILENCER EXHAUST SILENCER 450 SX-F THERMAL PROTECTION FOIL SILENCER HOUSING 450 SX-F CONNECTING CAP CPL SPRING WASHER DIN0137-B BUSHING 7.5x12x28x EXHAUST BRACKET RUBBER BLACK HH COLLAR SCREW M 6X30 WS= TEN.SPRING L=62MM EY.MOVEABLE SCREW TORX M5X ENDCAP STUFFING YARN HGS STUFF.YARN 550GRAMM L=550MM SX / C * NEW PART X AS REQUIRED 11

12 AIR FILTER BOX FILTER WALL ORANGE SX FILTER BOX COVER ORANGE SX REAR PART FILTER BOX QUICK RELEASE-NIPPLE BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX AIR FILTER FILTER CARRIER 4S SX FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX AIRFILTER BOOT HOSE CLAMP 40-60MM EJOT PT SCREW K60X20 ALU WS= BUSHING F. CHAIN SLIDING PR / C * NEW PART X AS REQUIRED 12

13 TANK, SEAT, COVER GAS COCK MIKUNI ON/OFF O-RING 13,00X2, PVC-HOSE 6X9 MM PER METER x FILLER CAP CPL TANK BUSHING FUEL TANK CPL. 7,5L SX TANK ROLLER 12X26X12 ' FUEL PREFORMED HOSE 450 SX-F CLAMP YDNAC MM EJOT PT SCREW K60X20 ALU WS= EJOT PT SCREW K60X20 WS= ANGLE PIECE 90 DEGREE M10X SEAT SX SEAT COVER A SPOILER LEFT BLACK SX A SPOILER RIGHT BLACK SX BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X12 WS= COLLAR SCREW M6X27 ISA TOOL KIT / C * NEW PART X AS REQUIRED 13

14 MASK, FENDERS NUMBER PLATE CPL. ORANGE BRAKE HOSE GUIDE ORANGE EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M 6X10 WS= FRONT FENDER SPACER BUSHING HH COLLAR SCREW M 6X15 WS= COLLAR BUSH. F.REAR FENDER COLLAR BUSHING 4,5/12,6/ REAR FENDER SX 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 6X20 WS= / C * NEW PART X AS REQUIRED 14

15 DECAL DISPLANCEME.STICKER 450 SX-F / C * NEW PART X AS REQUIRED 15

16 FRONT WHEEL FRONT WHEEL CPL.1,6X21EXCEL FRONT HUB SX CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING SPOKE M4, 5X226-21" SPOKE NIPPLE M4,5X0,75 8X RIM 1,60X21"EXCEL AL4 BLACK RIM BAND 21" FRONT WHEEL REP. KIT 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 16

17 REAR WHEEL REAR WHEEL CPL.2,15X19"EXCEL REAR HUB SX CPL BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL SPACER BUSHING SPOKE M5x207-19" SPOKE NIPPLE M5-TA (8X21MM) RIM 2,15X19"EXCEL AL4 BLACK 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 CHAIN Z-RING 118 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 WHEEL SPINDLE RE. CPL.265MM CHAIN TENSIONER R/S / C * NEW PART X AS REQUIRED 17

18 REAR WHEEL SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= HEXAGON NUT M20X1,5 ' / C * NEW PART X AS REQUIRED 18

19 WIRING HARNESS CDI UNIT KOKUSAN 450 SX-F COLLAR SCREW M6x12 ISA WIRING HARNESS FOR CDI-BOX MAIN WIRING HARNESS 450 SX-F BATTERY 12V 4(5)AH TX5L-BS x BARRERY CASING x BATTERY 12V 4AH BATTERY CASING EJOT PT SCREW K60X20 ALU WS= RUBBER L=145MM STARTER RELAY 12V ' FUSE 10 A AH OVAL SCREW ISO 7380 M 6X WIRING HARNESS BATTERY DUKE' GROUND CABLE D=6MM L=140MM ' HH COLLAR SCREW M 6X10 WS= VOLTAGE REGULATOR "RS 2759 " HH COLLAR SCREW M 6X20 WS= STARTERCABLE 700 MM ' SELF LOCK. NUT DIN0985-M PROTECTION CAP F. STARTER ENG CABLE TIE 100/2,5MM BLACK CABLE TIE 200/3,6MM BLACK / C * NEW PART X AS REQUIRED 19

20 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 20

21 HAND BRAKE CYLINDER HAND BRAKE CYLINDER CPL. SX 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 BRAKEHO. FRONT 1235MM HOLLOW SCREW M10X1X CU-SEAL RING DIN X16X BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 21

22 REAR BRAKE CONTROL REAR BRAKE CYLINDER CPL REPAIR KIT PISTON 13MM REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX HOLLOW SCREW BLACK M10X1X 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 22

23 BRAKE CALIPER FRONT BRAKECALIPER FRONT BREMBO REPAIR KIT 28MM REPAIR KIT PISTON 28MM BOLT CPL. 6X RETAINING PLATE SET BREMBO BRAKEP.SET FR.TOSHIBATT2701HHB BLEEDER SCREW WITH CAP CUP SET SHORT HH COLLAR SCREW M 8X35 WS= BRAKEHO. FRONT 1235MM CU-SEAL RING DIN X16X CU-SEAL RING DIN X16X1, HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 23

24 ACCESSORIES DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER OWNER MANUAL 250/450 SX-F CF8401G5EN SPC CHASSIS 1 0 3CM089250GEN SPC MOTOR 450 SX-F / C * NEW PART X AS REQUIRED 24

25 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089250GEN ENGLISH

26 INDEX SPECIAL TOOLS ENGINE CASE CLUTCH COVER CRANKSHAFT, PISTON 3x 4x 5x 6x CYLINDER CARBURETOR CLUTCH TRANSMISSION I - MAIN SHAFT 7x 8x 10x 12x TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM WATER PUMP COOLING SYSTEM 13x 14x 15x 16x 1

27 INDEX CYLINDER HEAD VALVE DRIVE TIMING VALVE LUBRICATING SYSTEM 17x 18x 19x 20x IGNITION SYSTEM ELECTRIC STARTER 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

28 SPECIAL TOOLS UNIVERSAL MOUNTING RACK ' FIXING ARM CPL. 450 SX-F 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 VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML HOLD. PLATE CLUTCH 450 SX-F PROTECTOR CAP F.CRANKSHAFT ASSEMB. PIN F. GUID. AGW-ZR-KS DEGREE DISK 360DEG - 1/2 INCH WRENCH F.MIXTURE CONTROL SCREW SP. WRENCH F.HOSE CONNECTOR RIVET TOOL CPL. 450 SX-F ADJUST BUSH BRIDGE UNLOCK CHAIN TENSIONER ENGINE BLOCKING SCREW / C * NEW PART X AS REQUIRED 3

29 ENGINE CASE ENGINE CASE CPL. W.TR.BEAR OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, BUSHING RETAINING PLATE BUSHING RETAINING PLATE INT. TORX FLAT HEAD M 5X BUSHING RETAINING PLATE BUSHING RETAINING PLATE RETAINING PLATE HH COLLAR SCREW M 5X10 WS= AH SCREW DIN6912-M 8X SEAL RING CU DIN7603-8X12X DOWEL 17 X 19 X OIL JET DOWEL BUSHING 13,8X11X JET 100 BING(44-031/180) M HH COLLAR SCREW M7X1X HH COLLAR SCREW M 6X70 WS= HH COLLAR SCREW M 6X55 WS= CYLINDER ROLLER ZRO. 8,0X12 M GASKET SET 450 SX-F THROTTLE M5X10X CASE BUSH DOWEL 6X8X11, / C * NEW PART X AS REQUIRED 4

30 CLUTCH COVER CLUTCH COVER CPL SHAFT SEAL RING 12x24x4/5, SHAFT SEAL RING 12x24x BALL BEARING 6202 C0 2RSH RETAINING PLATE FOR WAPUSTOCK SHAFT SEAL RING 20X30X CIRCLIP 30X1, SHAFT SEAL RING 12x35x7 BSL VI INT. TORX FLAT HEAD M 5X O-RING 8,00X1,5 NBR CYLINDER ROLLER ZRO. 8,0X12 M OIL LEVEL GLASS G 1777 Y CIRCLIP OIL LEVEL GLASS HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M7X1X HH COLLAR SCREW M 6X30 WS= CLUTCH COVER OUTSIDE CLUTCH CASE GASKET O-RING 19,00X3,00 NBR PLUG CPL. M24X BLEEDER FLANGE M12X1,5 WS= ENGINE BREATHER TUBE YDNAC-CLAMP (16MM) ' QUAD-RING 28,3X1,78 VITON SPRING BRACKET / C * NEW PART X AS REQUIRED 5

31 CRANKSHAFT, PISTON CRANKSHAFT CPL CONNECTING ROD REPAIR SET THRUST WASHER 30X42X0,1 x THRUST WASHER 30X42X0,2 x THRUST WASHER 30X42X0,3 x CYL. ROLLER BEARING NJ206 ECP COLLAR NUT M27X DRIVE WHEEL AGZR KS Z= SHAFT SEAL RING A40x55x6 VITON FLYWHEEL SCREW WOODRUFF KEY DIN6888-3X3, PISTON PIN CIRCLIP I PISTON I CPL. D=97MM II PISTON II CPL. D=97MM OIL SCRAPER RING COMPRESSIONRING D= / C * NEW PART X AS REQUIRED 6

32 CYLINDER CYLINDER CYLINDER ROLLER ZRO. 8,0X12 M O-RING 107,67x1,78 VITON GASKET GEAR CASE / C * NEW PART X AS REQUIRED 7

33 CARBURETOR CARBURETOR FCR-MX 4125G,TPS CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL THROTTLE VALVE CPL BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBDTM x JET NEEDLE KEIHIN OBDTN x JET NEEDLE KEIHIN OBDTP JET NEEDLE KEIHIN OBDTQ x JET NEEDLE KEIHIN OBDTR x BAR CLIP NEEDLE SET SCREW CPL NEEDLE JET FCR-MX MAIN JET 180 KEIHIN x MAIN JET 182 KEIHIN x MAIN JET 185 KEIHIN MAIN JET 188 KEIHIN x MAIN JET 190 KEIHIN x MAIN JET 192 KEIHIN x MAIN JET 195 KEIHIN x IDLE JET 40 KEIHIN IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x STARTER JET IDLE AIR JET 100 KEIHIN ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL ARM PIN FLOAT HOT-STARTER VALVE FLOAT NEEDLE CLAMP / C * NEW PART X AS REQUIRED 8

34 CARBURETOR DRAIN SCREW FLOAT CHAMBER COVER ACCELERATOR PUMP FLOAT CHAMBER CPL. SET 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 SPRING LINK LEVER SPRING INTERMEDIATE LEVER CARBURETOR COVER WASHER LINK LEVER E-CLIP ROD ACCELERATOR PUMP HOSE CONNECTOR CPL STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 190MM GASKET SET FCR-MX KEIHIN / C * NEW PART X AS REQUIRED 9

35 CLUTCH OUTER CLUTCH CPL INNER CLUTCH HUB PRESSURE PLATE INTERMEDI. DISC STEEL LINING DISC 3,0MM INNER RING RETAINING PLATE HEXAGON NUT DIN0936-M18X1,5 R WASHER 21,7X38X PRIMARY GEAR CPL O-RING 38,00X2,00 NBR 70 SH OUTPUT CYLINDER CPL CIRCLIP DIN X1, SHAFT SEAL RING 6X15X4 VITON O-RING 30,00X1,50 NBR WASHER BALL D= PISTON SEAL RING COIL SPRING RIVET OUTER CLUTCH OUTER CLUTCH DAMPING RUBBER CLUTCH WHEEL T= RETAINING PLATE WASHER 6,2X18X PUSH ROD PRESSURE PIECE PRESSURE PIECE CPL HH COLLAR SCREW M 6X25 WS= HH COLLAR SCREW M 6X25 WS= VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING CU-SEAL RING DIN X16X BLEEDER HOLLOW SCREW M10X NEEDLE BEARING K26X30X22ZW.KSE / C * NEW PART X AS REQUIRED 10

36 CLUTCH AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 11

37 TRANSMISSION I - MAIN SHAFT MAIN SHAFT GUIDE BUSHING SPACER SLEEVE 25X29X21, SOLID GEAR 4.G 23Z SPACER BUSHING 25X29X2, SOLID GEAR 3.G 21Z SOLID GEAR 2.G. 19Z STOP DISC 32X17X INT. TORX FLAT HEAD M 5X BALL BEARING 6205 C3 NTN BUSHING RETAINING PLATE BALL BEARING 6203 RSH C / C * NEW PART X AS REQUIRED 12

38 TRANSMISSION II - COUNTERSHAFT STOP DISC 32X17X2, STOP DISC 35X25X IDLER GEAR 1ST G 32-T NEEDLE BEAR. K 22X26X13 TN CIRCLIP DIN X1, SHIFT RING IDLER GEAR 4 G 26-T IDLER GEAR 3 G 28-T CIRCLIP DIN X1, IDLER GEAR 2 G 30-T COUNTERSHAFT INT. TORX FLAT HEAD M 5X BUSHING RETAINING PLATE BALL BEARING 6203 RSH C CYL.ROLLER BEARING NUP205E C SHAFT SEAL RING 35X47X7 TC O-RING 25,00X1,50 NBR SPACER BUSHING SPROCKET 13-T x SPROCKET 14-T SPROCKET 15-T x SCREW+SPRING WASHER SHIFT RING / C * NEW PART X AS REQUIRED 13

39 SHIFTING MECHANISM SHIFTING FORK CYLINDER ROLLER 6X SHIFT SHAFT CPL PRESSURE SPRING 0,9MM SLIDING PLATE CPL TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING SHIFT ROLLER 4G BALL BEARING 6805 C4 NTN JAPAN RETURN SPRING SHIFT LOCATING DRUM CPL AH SCREW DIN6912 M 6X INT. TORX FLAT HEAD M 5X BUSHING RETAINING PLATE SHIFT RAIL ARRESTING LEVER SPRING LOCATING LEVER CPL SLEEVE FOR LOCKING LEVER WASHER DIN9021-A 5, HH COLLAR SCREW M 5X20 WS= 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 HH SCREW DIN0933-M 6X / C * NEW PART X AS REQUIRED 14

40 WATER PUMP WATER-PUMP COVER SCREW IN NOZZLE M20X1, WATER-PUMP GASKET CAP NUT M6 DIN WATER-PUMP WHEEL NUT M14 X 1 FOR BALANCER BALANCER GEAR KS 32-T HH COLLAR SCREW M 6X55 WS= HH COLLAR SCREW M 6X16 WS= CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X10 WS= NEEDLE BEARING RNA / C * NEW PART X AS REQUIRED 15

41 COOLING SYSTEM RADIATOR L/S 250 SX-F RADIATOR R/S "45518U" RADIATOR CAP SMALL 20,3 PSI T-CONNECTOR CPL HOSE CLAMP GEMI HOSE CLAMP GEMI 12/ ANGEL PIECE ' PVC-HOSE 6X9 MM PER METER x RADIATOR HOSE R/S HOSE ENGINE-RADIATOR RADIATOR HOSE L/S RAD. PR. L/S+R/S BLACK SX HOSE CONNECTOR 4 STROKE RUBBER SLEEVE D=12MM HH COLLAR SCREW M 6X12 WS= / C * NEW PART X AS REQUIRED 16

42 CYLINDER HEAD CYLINDER HEAD CPL CYL. HEAD GASKET S=0, VALVE COVER VALVE COVER GASKET VALVE COVER SCREW RUBBER GASKET FOR SCREW GASKET SPARK-PLUG SHAFT O-RING 25X2 VITON COLLAR SCREW M7X1X BUSHING HOLDER AH SCREW DIN0912-M 5X COLLAR NUT M10X1,25 SW WASHER 19X10,5X2, STUD SCREW M VALVE GUIDE AH SCREW DIN0912-M 4X OIL JET O-RING 1,5x INTAKE BOOT HOSE CLAMP GEMI 56MM CYLINDER ROLLER ZRO 5X SCREW PLUG O-RING 9X1,5 NBR PLUG SCREW IN NOZZLE M20X1, GASKET EXHAUST FLANGE EXHAUST FLANGE CPL HH COLLAR SCREW M 6X20 WS= COLLAR NUT M6X1 SW WASHER DIN0125-A 6, STUD SCREW M RETAINING PLATE HH COLLAR SCREW M 5X10 WS= O-RING 9X1,5 NBR SCREW PLUG THROTTLE M6X10X0, / C * NEW PART X AS REQUIRED 17

43 VALVE DRIVE INTAKE VALVE EXHAUST VALVE 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 SPRING KIT VALVE COLLET VALVE-STEM SEALING RACING VALVE LEVER VALVE LEVER INTAKE VALVE LEVER SHAFT EXHAUST VALVE LEVER SHAFT / C * NEW PART X AS REQUIRED 18

44 TIMING VALVE CAMSHAFT INTAKT CAMSHAFT EXHAUST CPL PLUG DECO SPRING FOR AUTO DECOMPR DECO SPRING PIN L=10, DECO SPINDEL DECO LEVER CAMSHAFT EXHAUST CYL.ROLL BEARING RNU203ETVP CAMSHAFT GEAR COLLAR SCREW M10X1X NEEDLE BEAR K 18X22X NEEDLE BEARING K 18X22X DOUBLE GEAR W.CPL. Z18/Z AXLE FOR TIMING VALVE O-RING 15,00X1, HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH HOLDING BOLT M24X1, CU SEAL-RING DIN7603 A24X29X CHAIN ADJUSTER HYD TENSIONER RAIL CPL TIMING CHAIN GUIDE RAIL O-RING 12,00X1,50 NBR BUSHING SCREW BUSHING SCREW BALANCER GEAR STOP DISC 18/32/1,4/2, O-RING 18,00X2,00 NBR / C * NEW PART X AS REQUIRED 19

45 LUBRICATING SYSTEM OIL PUMP SHAFT SUCTION PUMP GASKET PRESSURE PUMP CASE PRESSURE PUMP PUMP COVER AH SCREW DIN0912-M 5X NEEDLE ROLLER DIN5402 3X15, OIL PUMP GEAR 18-T WASHER 10,2X18X TAB WASHER DIN6799 RS PRESSURE PUMP CASE NEEDLE ROL.DIN5402 NRB 4X9, GASKET PRESSURE PUMP COVER PRESSURE PUMP COVER HH COLLAR SCREW M 6X40 WS= OILPUMP IDLER GEAR 24-T NEEDLE BEARING K 10X13X LOCK WASHER BEARING BOLT BEARING BOLT OIL INTAKE SNORKEL O-RING 23,00X1,50 NBR OIL SCREEN CPL O-RING 30X2,0 FPM PLUG SCREW BALL D=10 DIN COIL SPRING CU-SEAL RING 14X20X1,5 LC PLUG SCREW M14X1,5 ALU AH OIL FILTER O-RING 34X1,5 VITON OIL FILTER COVER HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 20

46 IGNITION SYSTEM IGNITION COVER IGNITION COVER GASKET STATOR SX ROTOR SX PULSER COIL KOKUSAN "PU5165" CDI UNIT KOKUSAN 450 SX-F ADAPTER PULSER COIL SPARK PLUG NGK-XD05EMGK SPARK PLUG NGK CR9EKB WIRE RETAINING BRACKET HH COLLAR SCREW M 5X10 WS= WIRING HARNESS FOR CDI EXC HH COLLAR SCREW M 5X25 WS= O-RING 22,00X2,00 B SCREW PLUG M24X1,5 PA IGNITIONCOIL KOKUSAN NEEDLE ROL.DIN5402 NRB 4X9, HH COLLAR SCREW M 6X20 WS= AH SCREW DIN0912-M 5X HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X16 WS= RETAINING PLATE F.PICKUPCABEL HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 21

47 ELECTRIC STARTER E-STARTER ENGINE KPL NEEDLE BUSH HK 0810 DIN DRIVE WHEEL AGZR KS Z= COLLAR NUT M27X H FREE WHEEL CLUTCH MECHANISM NEEDLE BEAR. K25X32X STARTING GEAR Z= TORQUE LIMITER CPL HH COLLAR SCREW M 6X25 WS= O-RING 25,00X3,00 NBR INTERMEDIATE STARTING GEAR BEARING BOLT / C * NEW PART X AS REQUIRED 22