150 SX USA 2010 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF6175J0EN

Transcription

1 150 SX USA 2010 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF6175J0EN ENGLISH

2 INDEX 150 SX USA 2010 FRONT FORK, TRIPLE CLAMP FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS FRAME 3x 4x 6x 7x SHOCK ABSORBER SWING ARM EXHAUST SYSTEM AIR FILTER 8x 9x 10x 11x TANK, SEAT, COVER MASK, FENDERS DECAL FRONT WHEEL 12x 13x 14x 15x 1

3 INDEX 150 SX USA 2010 REAR WHEEL REAR BRAKE CONTROL BRAKE CALIPER REAR HAND BRAKE CYLINDER 16x 17x 18x 19x BRAKE CALIPER FRONT ACCESSORIES KIT 20x 21x 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

4 FRONT FORK, TRIPLE CLAMP 150 SX USA * 14187J0101 FR. FORK KTM CC SX * HH COLLAR SCREW M8X50 TX HH COLLAR SCREW M8X25 TX40 8 4* HH COLLAR SCREW M8X40 TX S HH COLLAR SCREW M8X25 TX AH SCREW DIN6912-M10X O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS=6 2 32* BOTT.FORK PLATE VMT. X=22MM BL 1 34* TOP TRIPLE CLAMP X=22MM 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=8 6 92* FORK PROTECTION LE+RI BLACK / C * NEW PART X AS REQUIRED 3

5 FRONT FORK DISASSEMBLED 150 SX USA S ADJUSTING KNOB + SCREW OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB * DUST SEAL DU-BUSH D47XD49X20DDL 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 4,4 N/MM SET D=5,1MM x S SPRING 4,6 N/MM SET D=5,1MM x S POLISHED SPRING 4,8 N/MM x S SPRING 5,0 N/MM x S SPRING 4,0 N/MM SET x S SPRING 4,2 N/MM SET D=5,0MM x 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 / C * NEW PART X AS REQUIRED 4

6 FRONT FORK DISASSEMBLED 150 SX USA LOCK WASHER D=25, AH SCREW M4X O-RING NBR 21X PISTON COMPRESSION D=27, O-RING NBR 4X1, S PIN VALVE SET NUT M6X0,5 REBOUND GUIDE RING 44 X RING SPRING-SUPPORT WASHER 32X42X2,5 2 60* SA AXLE CLAMP LEFT + TUBE CPL. 1 61* SA AXLE CLAMP RIGHT + TUBE CPL HH COLLAR SCREW M8X25 TX * NUT VALVE M6X0,5 LH=1, SPRING CHECK VALVE D=0, PISTON ROD COMPRESSION PISTON REBOUND SX PISTON RING 5X1X RING D=23,45X2, * SHAFT SEAL RING 12MM 2 76* S SCREW SLEEVE M24,5X1 CPL DU BUSH FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D= SILICON CAP RUBBER CAP D=26, S1 FORK OIL SAE5 5L O-RING NBR 43X S1 SCREW CAP CPL. L= SCREW M4X MEMBRANE SLEEVE 2 98 T511 SILICONE GREASE F. DUST STRI 1 99* R14018 REPAIR KIT SEALS CC / C * NEW PART X AS REQUIRED 5

7 HANDLEBAR, CONTROLS 150 SX USA HANDLEBAR RENTHAL SX 28MM BAR PAD CPL WIRING HOLDER 12MM CLAMP 5/7 MM * THROTTLE GRIP CPL * TWIST GRIP COVER GRAY/ORA PROTECTION COVER ' THROTTLE C DOM./KEIH SHORT CIRCUIT BUTTON * FIXED GRIP GRAY/ORANGE CABLE TIE 200/3,6MM BLACK MASTER CYLINDER CPL. 9,5MM CLUTCH LEVER CPL REP.KIT PISTON 9,5MM COVER HYDR. CLUTCH CPL RUBBER FOR RESERVOIR OIL FOR HYD. CLUTCH 75ML MUD CAP LEVER SCREW SHORT CPL CLAMP, CYL. PIN, O-RING PUSH ROD CPL HH COLLAR SCREW M6X16 TX CLUTCH PIPE L=970MM / C * NEW PART X AS REQUIRED 6

8 FRAME 150 SX USA * FRAME BLACK M. "BA10" SUB FRAME SX "Q7" SUB FRAME APPLICATION LEFT SUB FRAME APPLICATION RIGHT REINFORCING B. 125 SX ADH. FOIL TRANSP. 80X80 MM SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M ENGINE BRAC.SCR. M10X105 WS= S FLAT HEAD SCREW M. ISA45 M8X COLLAR SCREW M8X42 WS= BLIND PLUG-IN NUT M5 WN 22A CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X BUSH F. FRAME PROTECTION SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X30 TX HH COLLAR SCREW M6X40 TX WASHER DIN0125-A 6, 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 ANGEL PIECE ' PVC-HOSE 7X10 PER METER x SPROCKET COVER 250 SX CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET CHAIN SLIDING P. BELOW CPL SXS0310 / C * NEW PART X AS REQUIRED 7

9 SHOCK ABSORBER 150 SX USA S HH COLLAR SCREW M12X50 TX * 12187J0101 MONOSHOCK 125 SX / C * NEW PART X AS REQUIRED 8

10 SWING ARM 150 SX USA SWINGARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR SPECIAL SCREW M 5,0X BRAKE HOSE GUIDE LOWER 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 PIVOT BEARING+BUSHES PDS ' TOOL BEARING MOUNTING PDS PLUG SFL SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC CHAIN GUIDE KIT REAR x SWINGARM REPAIR KIT x / C * NEW PART X AS REQUIRED 9

11 EXHAUST SYSTEM 150 SX USA EXHAUST PIPE CPL O-RING 44,00X3,00 VITON TEN.SPRING L=62MM EY.MOVEABLE RUBBER SLEEVE D=21MM/23MM ' SWINGELEMENT FOR EXHAUST PIPE HH COLLAR SCREW M6X15 TX HH COLLAR SCREW M6X10 TX RANGE CHANGE METAL NUT M EXHAUST SILENCER 125 SX SPRING WASHER DIN0137-B BUSHING 7.5x12x28x EXHAUST BRACKET RUBBER BLACK BUSHING SIL.-SMR REAR SILENCER ENDCAP 2-STROKE SILCENCER RUBBER 2-STROKE SILENCER DISC SILENCER SCREW 2-STROKE HH COLLAR SCREW M6X35 TX SILENCER CONNECTING-CAP STUFFING YARN / C * NEW PART X AS REQUIRED 10

12 AIR FILTER 150 SX USA * AIR BOX PART BLACK AIR BOX COVER SX BLACK REAR PART FILTER BOX QUICK RELEASE-NIPPLE BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX 1 15* AIR FILTER FILTER CARRIER 2S SX FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX CABURETOR CONNECTING 2S HOSE CLAMP 50-70MM EJOT PT SCREW K60X20 ALU WS=6 x EJOT PT SCREW K60X20 WS= BUSHING F. CHAIN SLIDING PR / C * NEW PART X AS REQUIRED 11

13 TANK, SEAT, COVER 150 SX USA GAS COCK MIKUNI ON/OFF O-RING 13,00X2, PVC-HOSE 5,6X10X270MM TANK PLUG ORANGE/BLACK TANK BUSHING FUEL TANK CPL. SX 7,5L TANK ROLLER 12X26X12 ' FUEL PREFORMED HOSE 2STROKE CLAMP YDNAC MM EJOT PT SCREW K60X20 ALU WS= EJOT PT SCREW K60X20 WS= ANGLE PIECE 90 DEGREE M10X SEAT SX SEAT COVER * I SPOILER KIT BLACK SX/XC 10 1 WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X12 TX COLLAR SCREW M6X27 TX / C * NEW PART X AS REQUIRED 12

14 MASK, FENDERS 150 SX USA START NUMBER PLATE ORANGE BRAKE HOSE GUIDE ORANGE EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M5X16 TX FRONT FENDER SPACER BUSHING HH COLLAR SCREW M6X20 TX 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 M6X25 TX BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX / C * NEW PART X AS REQUIRED 13

15 DECAL 150 SX USA * DECAL KIT SX/XC/XC-W * DISPLACEMENT STICKER 150 SX / C * NEW PART X AS REQUIRED 14

16 FRONT WHEEL 150 SX USA 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 SPOKE M4,5x226-21" SPOKE NIPPLE M4,5X0,75 8X RIM 1,6"X21" EXCEL SXS 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 AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 15

17 REAR WHEEL 150 SX USA REARWHEEL CPL.2,15X19 EXCEL REAR WHEEL HUB CPL BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL SPACER BUSHING SPOKE M5x206-19" SPOKE NIPPLE M5-TA 8X21MM RIM 2,15"X19" EXCEL SXS 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 S COUNTER-SUNK SCREW ISA45 M8X SELF LOCKING NUT M CHAIN 5/8X1/4" MX CONNECTING LINK F 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 SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= HEXAGON NUT M20X1,5 ' / C * NEW PART X AS REQUIRED 16

18 REAR BRAKE CONTROL 150 SX USA 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 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 AH SCREW DIN6912 M10X SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= BALL BEARING SKF RS COLLAR NUT M10 WS= HH COLLAR SCREW M6X12 TX BELLOWS FOR REPAIR KIT BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 17

19 BRAKE CALIPER REAR 150 SX USA BRAKE CAL. RE. - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM RETAINING SPRING SET BRAKE CALIPER SUPPORT REAR CUP SET SHORT BRAKE HOSE REAR 655MM BLEEDER SCREW CPL COPPER GASKET DIN X14X / C * NEW PART X AS REQUIRED 18

20 HAND BRAKE CYLINDER 150 SX USA HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=12MM 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 BANJO SCREW COPPER GASKET DIN X14X VALVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 19

21 BRAKE CALIPER FRONT 150 SX USA 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 20

22 ACCESSORIES KIT 150 SX USA DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER FOOTPEG L.+R. CPL PLASTIC FRAME PROTECTION SET 1 1* EN OWNER MANUAL SX * 3CF6175J0EN SPC CHASSIS 150 SX USA * 3CM081530JEN SPC ENGINE 150 SX ORIGINAL EQUIPMENT TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F WRENCH WS=13 B&F + OPENER T-WRENCH WS=6/8/10 TX=45 B&F / C * NEW PART X AS REQUIRED 21

23 150 SX 2010 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM081530JEN ENGLISH

24 INDEX 150 SX 2010 SPECIAL TOOLS ENGINE CASE CLUTCH COVER REED VALVE CASE 3x 4x 5x 6x CYLINDER, CYLINDER HEAD CRANKSHAFT, PISTON CARBURETOR CLUTCH 7x 8x 9x 11x TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT KICK STARTER SHIFTING MECHANISM 12x 13x 14x 15x 1

25 INDEX 150 SX 2010 COOLING SYSTEM EXHAUST CONTROL IGNITION SYSTEM 17x 18x 20x 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. x 2

26 SPECIAL TOOLS 150 SX ASSY SUPPORT WITH ENGINEHOLDER HOLD. PLATE CLUTCH 125/200 ' HOLDER FOR PRIMARY GEAR ' MAGNETIC PULLER M 27X1 KOKUSAN SPECIAL CIRCLIP PLIER HOLD. SPANNER ROTOR 2K-1/2/3/ DIAL GAUGE 0-10MM DIAL GAUGE SUPPORT LOCTITE 243 BLUE 6CCM SP. WRENCH F.HOSE CONNECTOR MOUNTING TOOL INNER RING NJ BRACKET FOR LOCATING DRUM ' / C * NEW PART X AS REQUIRED 3

27 ENGINE CASE 150 SX ENGINE CASE CPL W.TRAN.BEAR IGNITION COVER DOWEL BUSHING 13,8X11X OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, ENGINE CASE GASKET 0,5MM ' HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M6X60 TX OIL GUARD GROMMET 25X31 ' GASKET KIT / C * NEW PART X AS REQUIRED 4

28 CLUTCH COVER 150 SX CLUTCH COVER CPL. 125/ PLUG DIN0910-M 10X COPPER GASKET DIN X14X HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X12 TX CU-SEAL RING DIN7603-6X10X O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R O-RING 16,00X3,00 NBR CLUTCH COVER GASKET 0,5MM CLUTCH OUTSIDE COVER CLUTCH OUTS.COVER GASKET 1MM HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X30 TX WATER PUMP COVER 125/200 ' DOWEL 9,8 X 7 X / C * NEW PART X AS REQUIRED 5

29 REED VALVE CASE 150 SX REED VALVE ASSY V-FORCE RED VALVE-SET V-FORCE GASKET REED V.PLATE V-FORCE SPRING WASHER DIN0137-B HH COLLAR SCREW M6X25 TX CLAMP 52/12 GEMI INTAKE FLANGE / C * NEW PART X AS REQUIRED 6

30 CYLINDER, CYLINDER HEAD 150 SX INTERMEDIATE FLANGE * CYLINDER AND PISTON CYLINDER HEAD STUD DIN0835-M 8X O-RING 62,00X2,00 VITON CU-SEAL RING 7,3 X 12 X 0, O-RING 12X2 VITON GREEN CYLINDER BASE GASKET 0,20MM x CYLINDER BASE GASKET 0,25MM x CYLINDER BASE GASKET 0,40MM x CYLINDER BASE GASKET 0,50MM x CYLINDER BASE GASKET 0,75MM x O-RING 86X2 VITON75SHORE GREEN HH COLLAR SCREW M 5X20 WS= HH COLLAR NUT M 8 WS= INTERMED. GASKET RETAINING PLATE HH COLLAR SCREW M6X10 TX CU-SEAL RING DIN7603-6X10X CYL. HEAD BOLT M 7X30 WS= CYLINDER GASKET SET 125/ x / C * NEW PART X AS REQUIRED 7

31 CRANKSHAFT, PISTON 150 SX I PISTON I CPL II PISTON II CPL SPACER BUSHING 12MM CON.ROD REPAIR KIT 125' CRANKSHAFT CPL. 144 SX LOCKING RING VSK COLLAR NUT M12X1 R/S WOODRUFF KEY DIN6888-3X5X WOODRUFF KEY 5X6,5 HARDED PRIMARY PINION 23-T 125/ LOCKING RING VSK HEXAGON NUT M 16 X 1,5 - L/S TRAPEZOID RING x PISTON PIN NEEDLE BEARING KBK 15X19X SHAFT SEAL RING 25X35X7 BTSL SHAFT SEAL RING 32X45X6,5 BT WIRE LOCK RING 15X O-RING 25,00X2,00 NBR BALL BEARING 6305 JR2 CS CYL.ROLLER BEAR.NJ206 ET2XCS / C * NEW PART X AS REQUIRED 8

32 CARBURETOR 150 SX CARBUR. KEIHIN PWK 38S AG IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x IDLE JET 48 KEIHIN x IDLE JET 50 KEIHIN x IDLE JET 52 KEIHIN x ARM PIN FLOAT FLOAT CPL GASKET FLOAT CHAMBER FLOAT CHAMBER PWK38-S AG RETAINING PLATE FOR BLEEDER STARTER JET 85 KEIHIN HH COLLAR SCREW M 4X16 WS= SPRING FOR ADJUSTMENT SCREW ADJUSTMENT SCREW SPRING ADJUSTMENT SCREW M FLOAT NEEDLE CLAMP MAIN JET 170 KEIHIN x MAIN JET 172 KEIHIN x MAIN JET 175 KEIHIN x MAIN JET 178 KEIHIN x MAIN JET 180 KEIHIN x MAIN JET 182 KEIHIN x MAIN JET 185 KEIHIN x MAIN JET 188 KEIHIN x MAIN JET 190 KEIHIN x MAIN JET 192 KEIHIN x MAIN JET 195 KEIHIN x MAIN JET 198 KEIHIN x MAIN JET 210 KEIHIN x MAIN JET 212 KEIHIN x MAIN JET 215 KEIHIN x / C * NEW PART X AS REQUIRED 9

33 CARBURETOR 150 SX MAIN JET 200 KEIHIN x MAIN JET GR. 202 KEIHIN x MAIN JET 205 KEIHIN x MAIN JET 208 KEIHIN x SPECIAL-AH-SCREW M 4X THROTTLE CALBE HOLDER M6X0, CARBURETOR COVER PWK 38S AG GASKET FOR CARBURETOR COVER CLIP FOR JET NEEDLE SLIDING SPRING SPRING CAP NIPPLE JET NEEDLE NOZ F KEIHIN x JET NEEDLE NOZ G KEIHIN x JET NEEDLE NOZ H KEIHIN x JET NEEDLE NOZ I KEIHIN x JET NEEDLE NOZ J KEIHIN x JET NEEDLE NOZ K KEIHIN x THROTTLE VALVE 7 FOR 38 PJ '00 x THROTTLE VALVE 6.5 KEIHIN x STARTER PISTON CPL CLAMP 6 MM PVC-HOSE 4X6MM x PVC-HOSE 3X5MM x PLUG M 18X O-RING 18,00X2,30 NBR WASHER ADJUSTING SCREW O-RING ADJUSTING SCREW / C * NEW PART X AS REQUIRED 10

34 CLUTCH 150 SX OUTER CLUTCH H.73-T 125/200 1 WITHOUT PRIMARY PINION INNER CLUTCH HUB 125/200' PRESSURE PLATE INTERMEDI. DISC STEEL 1,5MM' * INTERMEDIATE DISC 1,5MM LINING DISC 3,0MM INNER RING 20X26X25,9 ' SHEET METAL LOCK 1,5MM ' HEXAGON NUT DIN0936-M18X1,5 R STOP DISK 20X39,6X3 ' PRIM. PINION 23-T 125/200' CLUTCH KIT 200 EXC WASHER 6,2X18X PUSH ROD L= / PRESSURE PIECE ' CYLINDER CPL. 125/200' HOLLOW SCREW CPL. M 10X1 ' CLUTCH RELEASE GASKET 0,3MM x CLUTCH RELEASE GASKET 0,5MM x CLUTCH RELEASE GASKET 0,75MM x BALL DIN CU-SEAL RING DIN X16X PISTON W. O-RING 125/ HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X25 TX VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING 2,4X40 200' NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X AXIAL WASHER 12,5X25,8X1,5 x CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 11

35 TRANSMISSION I - MAIN SHAFT 150 SX MAIN SHAFT CPL. 13-T ' IDLE GEAR 5.G. 5S19H SX SLIDING GEAR 3./4. G. SX 06 1 "3S17H"-"4S20H" IDLE GEAR 6TH G. 6S22H SX SOLID GEAR 2ND G.15-T"2S15" IDLER GEAR BUSH. 22X25X11,1 A GROOVED BALL B C4 J BALL BEARING 6004 TN9 C STOP DISC 22,2X27,8X1 A STOP DISC 17,2X26X1 B STOP DISK 22,2X27,8X LOCK RING 22X1, / C * NEW PART X AS REQUIRED 12

36 TRANSMISSION II - COUNTERSHAFT 150 SX COUNTER SHAFT 125/200 ' IDLE G.3RD G.28-T "3S28H" IDLE GEAR 4TH G. 4S28 SX SLIDING GEAR 6TH G. 6S24 SX IDLER G. 2ND G. 30-T "2S30"' IDLER G. 1ST G. 32-T "1S32+" SLIDING GEAR 5TH G.5S23H SX IDLER GEAR BUSHING 17X20X9,7 B IDLER GEAR BUSHING 22X25X8,1 C IDLER GEAR BUSHING 25X28X9,7 D LOCK RING DIN X1,64SD FRONT SPROCKET 13-T x FRONT SPROCKET 14-T x BALL BEARING 6003 TN9 C BALL BEARING 6205 TN9 C STOP RING SHAFT SEAL RING 32X45X7 BSLNBR SPACER BUSHING 12MM O-RING 23,00X2,00 NBR STOP DISC 22,2X27,8X1 A STOP DISC 17,2X26X1 B STOP DISK 22,2X28X1 C STOP DISC 25,2X32X STOP DISC 22,2X30X2, LOCK RING 22X1, LOCK RING 25X1, / C * NEW PART X AS REQUIRED 13

37 KICK STARTER 150 SX STOP DISK 17,2X24X CIRCLIP DIN X THRUST WASHER DIN X22X SPACER BUSHING 16X23X26X6, HH COLLAR SCREW M8X20 TX HH COLLAR SCREW M6X16 TX STOP DISC 17,2X26X1 B KICKSTARTER SHAFT 125/200' KICKSTART.GEAR 26-T 125/200' KICKSTARTER RATCHET INTERMEDIATE GEAR 27-T KICKSTARTER SPRING 2,6MM ' DRIVING HUB 125/200' SPRING 1,4MM ' STOP MET.SHEET 4MM 125/200' KICK STARTER CPL SHAFT SEAL RING 17X28X7 B WASHER 8,2X22X4,5 ' / C * NEW PART X AS REQUIRED 14

38 SHIFTING MECHANISM 150 SX SHIFTING FORK 5TH/6TH GEAR SHIFTING FORK 2ND/4TH GEAR SHIFTING FORK 1ST/3RD GEAR SHIFTING SHAFT 125/200' SPRING FOR RATCHET 0,5X11, RATCHET SUPPORT 125/200' STOP DISK 8,2X26X0, BUSHING 6X8X12X4, SHIFTING RATCHET 125/200' PRESSURE END PAD 4,1X5,6X8, SHIFTING DRUM LOCATING DRUM 125/200' RETURN SPRING 3MM SPECIAL SCREW M8X21,5 WS= SHIFTING GATE 3MM 125/200' NEEDLE ROLLER ZRB 6X SHIFTING ROD DRIVE 11,8X67, SHIFT. ROD DRIVE END 11,8X94, LOCATING LEVER SPRING 2,5MM' LOCATING LEVER CPL BALL BEARING 6000 RS1 C BALL BEARING C FLAT H.SCEW DIN7991-M5X LOCK RING DIN X1, SPRING WASHER 12,2X25X0, NEEDLE ROL.DIN5402 NRB 4X9, NEEDLE BEAR.HK X20X STOP DISK 14,3X20X LOCK WASHER DIN X STOP DISK 14,2X22X1, SHAFT SEAL RING 14X24X6 B SPECIAL SCREW M6X16 WS= PAIR OF WASHERS M 6 NORDLOCK HH COLLAR SCREW M6X16 TX WASHER DIN0125-A 8, WASHER DIN7349-5X15X / C * NEW PART X AS REQUIRED 15

39 SHIFTING MECHANISM 150 SX HH COLLAR SCREW M5X20 TX STEEL WASHER 6,4X17X SLEEVE FOR LOCKING LEVER SHIFT LEVER CPL. 2-STROKE SHIFTING LEVER SPRING BOLT 6X25 FOR SHIFT LEVER STEP PLATE FOR SHIFT LEVER / C * NEW PART X AS REQUIRED 16

40 COOLING SYSTEM 150 SX RADIATOR LEFT "VW1595" * RADIATOR RIGHT 45620U 1 9* RADIATOR CAP SMALL 1,8 BAR T-CONNECTOR CPL HOSE CLAMP GEMI HOSE CLAMP NORMA 12/ ANGEL PIECE ' PVC-HOSE 6X9 MM PER METER x RADIATOR HOSE 18X25 PER METRE x RADIATOR HOSE 18X25 125/200' RADIATOR HOSE 18x25x RADIATOR PROTECTION BLACK HOSE CONNECTOR 2 STROKE RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 17

41 EXHAUST CONTROL 150 SX STOP DISK 14,2X22X1, SIDE COVER R/S GASKET SIDE COVER R/S SIDE COVER LEFT GASKET SIDE COVER L/S ANGLE PIEC 90 DEGREE M10X O-RING 8,00X2,00 NBR HH COLLAR SCREW M 5X12 WS= NEEDLE ROL. DIN5402 NRB 5X15, TUBE RUBBER 6X9 DVOH 200MM CU-SEAL RING DIN X32X WASHER 5,2 X 12 X HH COLLAR SCREW M6X10 TX ECCENTRIC FOR CRANKBOLT 125' CRANK BOLT F.CONTROL FL.125' CONTROL FLAP 144 CPL AXLE FOR CONTRIL FLAP CU-SEAL RING DIN7603-6X10X GROOVED BALL BEAR RS C CIRCLIP DIN X WASHER DIN2093-8,2X16X0, SPACER BUSHING 8X12X2, BALL BEARING 608 RS C O-RINGSTRING 4MM NBR 70 PER/M x O-RING 16,00X3,00 NBR SHEET METAL GUIDE 3MM 125' CLOSING COVER ' CLOSING COVER GASKET 1MM CENTRIFUGAL TIMER CPL. 125' BUSHING HOLDER M 26X1 ' CLOSING NUT M 26X1 WS= CONTROL LEVER 125/200' CONTROL SHAFT M 6 WS=10 ' CONTROL SHAFT CPL.L/S CONTROL SHAFT CPL.R/S HH COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 18

42 EXHAUST CONTROL 150 SX LEVER F. CONTROL SEGMENT ' CONTROL SHAFT SEGMENT 125' DRIVE WHEEL 26-T 125/200' BUSHING SUPPORT WATER PUMP ' ROLLER GUIDE 5X6,1X8X4 ' SHAFT SEAL RING 8X24X7 A DUO BALL BEARING 6000/C O-RING 49,00X2,50 NBR WATER PUMP SHAFT 125/200' WATER PUMP WHEEL LOCK METAL SHEET 2MM ' / C * NEW PART X AS REQUIRED 19

43 IGNITION SYSTEM 150 SX FLYWHEEL KOKUSAN 2K-1/2K-4 ' STATOR KOKUSAN 2K SPARK PLUG CAP NGK REINFORC SEALING CUP FOR SPARK PLUG SPARK PLUG BR9ECMVX IGNITIONCOIL "IG5128" CDI UNIT 144 SX WIRING HARNESS F.CDI 2-ST.SX COLLAR SCREW M6X12 TX HH COLLAR SCREW M5X16 TX HH COLLAR SCREW M6X16 TX / C * NEW PART X AS REQUIRED 20