3 - OIL SEALS & 'O' RINGS

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Brittney Gilmore
6 years ago
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1 Example of model year (not year of manufacture): > 05 = up to = 2005 and onwards W = on the Web site as well with photo and part description. ITEM DESCRIPTION RETAIL 1 - VALVE GEAR 30mm valve mm valve Not available 35mm valve mm valve Auto de comp lobe Auto de comp spring Cam Cam support block > Camshaft Sprocket Camshaft Sprocket bolts Cotters/collets (8 off to a head) ea-0.72 Exhaust valve guide Inlet valve guide Rocker arm (ex.) incomplete Rocker arm (in) incomplete ( 03) all Rocker arm (In)? ( 01-03) All Rocker arm (in.) incomplete Rocker arm(ex)incomplete( 01-03) Rocker arm(ex)incomplete( 01-03) Rocker arm(ex)incomplete(> 00) Rocker cover > Rocker cover spigots Rocker shaft end cap bolts Rocker shaft end caps Rocker shafts (old style) Rocker shafts exhaust (new style) Rocker shafts inlet (new style) Tappet nuts Tappet pads Valve guide - exhaust Valve guide - inlet Valve guide (phosphor bronze) u/size? Ventilation sleeve Water pump impellor/vein > GASKETS Base gasket ' W18.49 Cam chain tensioner gasket OEM W2.25 Gasket set Gasket set Head gasket (86mm) W40.54 Head gasket (92mm) 400cc W13.79 Head gasket (92mm) early 501 > 93? W28.20 Head gasket (95mm) late 501/600 > W28.98 Head gasket (95mm) last W19.16 Head gasket (100mm) W22.84 Ignition cover gasket W3.06 Rocker inspection W1.71 Side cover gasket > W7.61 Side cover gasket W13.69 W/P gasket W2.70 W/P gasket W1.92 W/P gasket > W OIL SEALS & 'O' RINGS Cam cap O ring Clutch cover Seal

2 Clutch slave body O ring Clutch slave piston 'O' ring Crank oil seal (large late left) 30/52/ Crank oil seal (right) 25/40/ Crank seal (small early left) Gear selector seal Gearbox output Seal r 4.32 Gearbox output Seal > Intermediate shaft O ring 0.50 Kick start seal Liner 'O' rings Oil filler bung O ring Oil Filter Housing O ring or Rocker end cap 'O' ring Starter bung O ring for crankcase Strainer (long) O rings Strainer (short) O rings Sump bung O ring Swing arm seals VGOS new VGOS old > Water pump seal BEARINGS & BUSHES All big end PIN & BEARING kits under crankcases Balancer W15.72 Balancer modified x2 W60.00 Big end (bearing only) 30mm ID W52.59 Big end (bearing only) 32mm ID W35.54 Cam bearings 6201RS2/C W5.83 CFB mm ( ) W22.30 CFB - > mm W30.59 Clutch basket needle rollers 25X29X W3.72 Clutch bush > W23.61 Gear selector bearing W11.68 Gearbox - Clutch 6205/C3 ball W9.13 Gearbox 6203/C W8.36 Gearbox output NJ205ECP/C W34.11 Gearlever Bush W2.38 Idler gear needle roller W6.17 Intermediate inner W13.79 Kick start needle roller W5.40 Little end bush 18mm (400 only) W23.61 Little end bush 20mm W40.04 Little end bush 20mm aftermarket W25.53 Main - BALL 6206TMB206JR2 NTN specials W48.13 Mn - RLR 6206-NJ206ECP/C3HVC058 - spcl W51.84 Sprague (starter clutch) needle shelled HK W3.62 Sprague bearing W53.69 Sprague bearing > W Sprague needle open (black) or W4.51 Water pump outer (polymide) W BIKE BEARINGS Brake arm LEFT COVER Anti-hopping clutch Bush > Sprague/freewheel for bearing Cam chain guide (front) Cam chain guide screw

3 Cam chain guide screw collar Cam sprocket (bottom) CCTB CCTB 450/ Clutch drum > 02 - teeth & Clutch drum tube See below Clutch drum 06 only See below Clutch drum Clutch friction early (1.8mm)> ea Clutch friction late (2mm) 04+ OEM ea Clutch half washers ea-1.23 Clutch basket ( 03>) Clutch basket ( 02 only) Clutch locking tab Clutch outer cover Clutch plate kit ` Clutch pressure plate Clutch pressure plate See above Clutch pushrod shim H =1,5mmH =2,0 mmh =2,5mm 4.90 Clutch radial thrust washer 6.50 Clutch steels - early teeth > 03 (1mm) (41.36) 5.17 Clutch steels - late tubes 03+ (1mm) (31.68) 3.96 Clutch steels - later tubes 03+ (1.4mm) (24.43) 3.05 Clutch stepped washer Clutch tubes Crank nut (left) Crank primary gear ? Crank primary gear > Dowels - sidecover Freewheel sprague inner hub Freewheel sprague inner hub Gear selector arm replaces Gear selector alloy sleeve Gear selector bush Gear selector star or Gear selector spring Idler circlip Idler gear Idler post Intermediate gear????? Intermediate shaft Kick start arm Kick start buffer - plastic Kick start gear Kick start large spring Kick start pawl tiny spring Kick start pawl-sledge key Kick start shaft Kick start washer Oil filler bung c/w O ring Oil nipple crank Oil pump Oil pump front plate Oil pump gear - plastic Reed valve Sledge - kick-start Sledge screws Sprague outer gear Starter Clutch assembly Tensioner blade pivot shoulder/nipple Tensioner guide (front)

4 Water pump impellor/vein Water pump vein location pin Water pump circlip Water pump cover Woodruffe key - crank/intermediate gear Woodruff key lower cam sprocket RIGHT SIDE *Stator Bradford Ignitions p/ex Clutch slave body Clutch slave cylinder 'O' ring FC flywheel FC ignition cover FC ignition stator FE flywheel FE ignition cover Flywheel nut Flywheel spring washer Ignition cover ' Magnetic bung Oil bung (old) Oil bung inc washer (new) Oil filter W6.50 Oil filter housing bolts Oil pressure bung Oil pressure relief spring Sprocket circlip Starter motor wide bracket Strainer (long) Strainer (short) Woodruffe key - flywheel CRANKCASES 400/470 rod kit - OEM / /470 rod kit See e-bay item 450 rod kit OEM ( 04-05) ( 06+) rod > discontinued 600 rod >2001 discontinued 501/550 rod kit OEM 01+ the same or Rod kit rod (32mm big end) rod (35mm big end) Balancer assembly 450 > Balancer assembly 650 > Balancer assembly Balancer bearings See e-bay item Barrel 501 > Cam chain tensioner Circlip - 20mm Clip for carb breathers Crank Crank Crank 550 FC Crank Crank Crank Pin & bearing kit 30mm W Crank Pin & bearing kit 32mm W Crank Pin & bearing kit 35mm W Crank shims /020/030 =.3mm 1.23 Crankcase plug (MX) Crankcases Crankshaft oil control screw *15.75

5 Cylinder head dowel Engine and bike BOLT kit Intermediate shaft Gudgeon pin 100mm Kit; 380 (liner, piston, HG) 1 set left for ever! Liner 380/ Liner Liner Liner Liner OEM 400 Piston domed 92mm (380 kit) OEM 450 Piston domed 100mm OEM 550 Piston flat 100mm / II OEM 650 Piston dished 100mm / I or II OEM 95mm piston complete / OEM compression ring 95mm OEM oil ring 95mm OEM rings 92mm 01> OEM rings 92mm> / OEM rings -100mm x 2.5mm - oil OEM rings -100mm x 1.25mm -comp Oil jet in cases # GEARBOX st gear input T output - 5 th T output 3 rd T output 4 th T output 6 th Selector star Selector fork rings Selector Rod - mainshaft Selector Rod - countershaft Stop disc E Stop disc Spring circlips Gearshaft washer CARBURETTOR A - KEIHIN Inlet rubber 04> W7.56 Intake boot 450/501 04> Intake boot 550/650 04> B - DELL ORTO Eurocarb Atomiser (any) Banjo filter 3.05 Brass tube over atomiser Carb cap 6.74 CD1 jet 8.42 Cheaper alloy slide Choke flick lever c/w plunger Eurocarb cheaper Choke jet 6.12 Choke jet O ring 0.51 Float arm 9.60 Float arm pin 1.79 Float bowl Float bowl O ring 2.53 Float on post - clips 0.36 Floats on posts Ea8.16 Gasket Kit 9.60 Inlet rubber

6 Mixture screw 'O' ring 0.82 Mixture screw washer 0.77 MJ (any) 4.35 Needle Needle valve assembly PJ (any) 4.35 Spring (soft) Throttle cable Throttle tube (oem) Twistgrip assembly dell orto/trials T80/ BIKE PARTS Air filter cage or Chain guide rear lower aluminium > Chain guide rear lower plastic Chain guide cupped washer Chain roller See e-bay item Chain safety (lower) Clevis Pin - brake Clutch cable Clutch M/C - Standard Clutch M/C - Supermoto Clutch M/C cap Clutch M/C repair kit (AKA ) Clutch M/C repair kit Crown nut - yokes Decomp cable (bars) Decomp lever Dowel / Engine mounting bolt (long) Engine mounting plate Footrests L or R R= (L = 040) Front axle nut > Front engine bolt Front wheel spacer - 20mm > Fuel cap gasket Gearlever - end knob ( 04+ type) Gearlever - pin ( 04+ type) Gearlever - spring ( 04+ type) Gearlever OEM ( 04+ type) Handlebar bolts - short Handlebars SX bend Headlamp straps L/H header MX axle prop stand - triangular Oil trap 04+ (twin) Oil trap > Oil trap sponge R/H header Rad flexi mounts Rad panel washers Rad rubber Radiator Hose - lower Radiator Hose - upper Rear wheel spacer Rear wheel spindle Rear wheel spindle nut Seat Bolt Seat Bush Shock adjuster ring Side stand - long Side stand - short

7 Side stand U piece Side stand bolt Side stand spring - large outer Side stand spring - small inner Spacer for engine plate Speedo cable or Speedo Magnet Spoke Spoke Spoke Spoke Spoke nipple Swing arm Swing arm bush/sleeves Swing arm extension screws Swing arm guard (around front) Swing arm nut Swing arm pin Swing arm shims Swing arm small alloy spacers Throttle cable Throttle cable Top hats in shrouds (3 could be a 2?) 1.58 Wheel rim front Wheel spoke Yoke bottom (inc post) Yoke - top OEM Coil 650FE 01? OEM Coil 650FE 02-03? Plug cap 90d Positive HT lead Rear lens comp. > ? Rear light assembly (laid flat) Rear light assembly > (traditional) Rectifier Regulator or Regulator/rectifier unit Solenoid Solenoid mount BRAKES Beringer floating pins Circlip - brake Disc float pins Fork part rear brake control Front brake M/C c/w lever (enduro) Front caliper repair kit (28mm x 2) Front M/C repair kit (10mm) Hexagon nut - brake Mounting bolt dowel Pressure rod rear brake ,70 Radial pads OEM Rear brake lever Rear brake M/C repair kit (34mm) Rear M/C repair kit (13mm) PLASTICS Battery cover Black plastics kit mudguard, seat pan, h/lamp wrap, 2 panels, fork guards Chain guard upper middle Chain guard upper middle >

8 Decals FE force ride Decals FS force ride Fork guards L/S+R/S - black / Frame guards - blue (2) L = R = Front brace; mudguard black Front mudguard - SM - black / Front mudguard - SM yellow Fuel tank - black / Headlamp wrap - yellow Headlamp wrap - black / KTM fox eye mask/wrap KTM; KTM black 1-peice shrouds & Ea 7.76 Left and right spoiler - yellow (R=051, L=050) Ea Louvre left yellow L/S Louvre right yellow R/S Mask rubbers KTM; Rear Mud flap Rear mudguard / # plate mount Seat Seat - tall in black Seat cover - black Seat cover - blue Seat cover 04 (yel/blu) Seat pan - black / Seat proper complete - black SM front mud guard - black / SM front mud guard - blue / SM front mud guard - yellow / Splash guard Spoiler left black /30 Ea Spoiler left black > /30 Ea Spoiler left yellow > /80 Ea Spoiler right black /30 Ea Spoiler right black > /30 Ea Spoiler right yellow > /80 Ea Swing arm guard front (modern) Swing arm guard front (old) Swing arm guard front? SUSPENSION Fork MV soft springs Delta shim 20mm MV piston ring Compression Piston O ring TOOLS Clutch locking tool Crank stopper bolt Flywheel puller - new W15.32 Flywheel puller - old W12.77 Gear locking tool Spark plug box socket W piston kit head gasket base gasket

Parts Diagrams RR/RS Models

Parts Diagrams RR/RS Models Parts Diagrams 2008-2009 RR/RS Models Table Of Contents Description Page # front fork 1 handlebar, clutch pump, meter (RR Models) 2 handlebar, clutch pump, meter (RS Models) 3 frame, subframe 4 rear shock,