525 EXC-G RACING USA 2006

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8575F8EN ENGLISH

2 INDEX TELESCOPIC FORK FORK LEGS WP USD 48 HANDLEBAR, CONTROLS FRAME, SUB FRAME 4x 5x 8x 9x SIDE STAND SWING ARM SHOCK ABSORBER SHOCK ABSORBER DISASSEMBLED 10x 11x 12x 13x SILENCER EXHAUST MANIFOLD AIR FILTER BOX TANK, SEAT, COVER 16x 17x 18x 19x 1

3 INDEX MASK, FENDERS DECAL FRONT WHEEL REAR WHEEL 20x 21x 22x 23x WIRING HARNESS HAND BRAKE CYLINDER FRONT BRAKE CALIPER REAR BRAKE CALIPER 25x 26x 27x 28x REAR BRAKE CONTROL LIGHTING SYSTEM SPEEDOMETER 29x 30x 31x x 2

4 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

5 TELESCOPIC FORK 1* 14187B06LS FORK LEG L/S WP48 EXC, XC * 14187B06RS FORK LEG R/S WP48 EXC, XC 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 1 85* CLAMP F.SPEED.CABLE ORANGE STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS=8 6 92* FORK PROTECTION L/S ORANGE / C * NEW PART X AS REQUIRED 4

6 FORK LEGS WP USD 48 1* S1 SCREW CAP M51X1,5 CPL O-RING NBR 45X KNOB REBOUNG ADJUSTER S1 SCREW CAP M51X1,5 CPL STEEL BALL D=3MM SPRING D=2,9 L=7, O-RING NBR 6X1, VENT SCREW M4X O-RING NBR 3,7X1, O-RING NBR 12X1, HOLDER F.ADJUSTMENT TUBE D=4MM 2 12* E OUTER TUBE L=577 D=54/ GUIDING RING D=58MM 2 15* DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB DUST STRIPPER D=48 58,4X11,8 2 22* DU-BUSH D47XD49X20DDL * INNER TUBE D=48 L= * S1 HYDR.STOP L=200MM D=31,9 CPL ADJUSTMENT TUBE L=517MM PISTON ROD D=14 L=551 M11X NEEDLE REBOUND O-RING NBR 3X1, SPRING REBOUND NEEDLE C=4N/MM WASHER 32X42X2, SPACER 42X26,5X2, SPACER 42X26,5X SPACER 42X26,5X SPACER 42X26,5X1, S SPRING 3,6N/MM SET x 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 S SPRING 4,4N/MM SET D=5,1MM x / C * NEW PART X AS REQUIRED 5

7 FORK LEGS WP USD S SPRING 4,6N/MM SET x S SPRING 4,8N/MM SET x INTERM. RING 26,2 X 43 X S SCREW SLEEVE M29,3X1 L=90 CPL O-RING NBR 8X1, REBOUND SPRING D=15MM L=34,5MM TAB REBOUND D= SPRING CHECK VALVE D=0, CHECK VALVE 8X24X0, CHECK VALVE 8X18X0, CHECK VALVE 8X20X0, CHECK VALVE 8X22X0, SHIM 6X14X0,1 x SHIM 6X16X0,1 x SHIM 6X18X0,1 x SHIM 6X16X0,25 x SHIM 6X18X0,25 x SHIM 6X9,5X0,3 x SHIM 6X24X0,1 x SHIM 6X22X0,1 x SHIM 6X20X0,1 x SHIM 6X24X0,1 DELTA x PISTON RING 5X1X PISTON REBOUND D=27, NUT M6X0,5 REBOUND TUBE 29,3X1X390 D=8,5MM O-RING NBR 46 X S AXLE CLAMP L/S CPL. USD S AXLE CLAMP R/S CPL. USD HH COLLAR SCREW M 8X25 WS= CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0, S1 TAP COMPRESSION CPL CHECK VALVE 8X24X0, PISTON COMPRESSION D=27, O-RING NBR 21X / C * NEW PART X AS REQUIRED 6

8 FORK LEGS WP USD O-RING NBR 24X TAP COMPRESSION NEEDLE COMPRESSION O-RING NBR 8X LOCK WASHER RB COMPRESSION ADJ. SCREW COPPER WASHER 29,5X33,5X RUBBER CAP D=35MM S1 FORK OIL SAE T511 SILICONE GREASE F. DUST STRI 1 99* R14013 REPAIR-KIT GASKET 4860 MXMA / C * NEW PART X AS REQUIRED 7

9 HANDLEBAR, CONTROLS HANDLEBAR 28MM HIGH TWIST GRIP COVER RENTHAL THROTTLE GRIP CPL. RACING SHORT CIRCUIT BUTTON FIXED GRIP RENTHAL CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x SPACER BUSHING 6X10X MASTER CYLINDER CPL. RACING CLUTCH LEVER SHORT CPL x CLUTCH LEVER LONG CPL REP.KIT PISTON 9,0MM RAC * COVER HYD.CLUTCH 2T 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 STARTER CONTROL THR.CABLE"OPEN-CLOSE"KEIHIN / C * NEW PART X AS REQUIRED 8

10 FRAME, SUB FRAME 1* FRAME EXC RAC.USA "DB06" PLUG 37MM ADH. FOIL TRANSP. 80X80 MM 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 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 SUB FRAME CPL. EXC+MXC "M5" SPROCKET SCREW-AH M8X26 WS= SPROCKET SCREW-AH M8X20 WS= 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

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

12 SWING ARM 1* SWINGARM 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 ' RETAINING PLATE CPL RETAIN.CLAMP FOR BRAKE HOSE' SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER ROUND CHAIN GUARD SMALL EXC 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

13 SHOCK ABSORBER 8* S HH COLLAR M12X55 WS= * 12187B06 MONOSHOCK EXC RAC / C * NEW PART X AS REQUIRED 12

14 SHOCK ABSORBER DISASSEMBLED MONOSHOCK TOP H=30,5 M54X S3 MCC-COMPR.DAMP.CONTROL CPL ADAPTOR BUSH KGW 12X OIL SEAL KGW D= WASHER KGW D= BUSHING KGW 1525 HD BLEED PLUG R 1/ O-RING NBR 48X WP CAUTION (PDS KTM) 58X * RESERV. SCREW L=120 D=52 BLACK O-RING VITON 41X SEPARATION PISTON D=52, H= PISTON RING 3,9X1,5X RESERVOIR CAP D= O-RING NBR 5,28X1, SCREW PLUG M5X RUBBER CAP "DO NOT OPEN" O-RING 52X WASHER 16X8,2X0,6 1 27* NEEDLE D=11,4 D=6, L= SCREW CAP M20X1 D=11,5 H= LOCK WASHER TUBE PDS L= CIRCLIP 50X1, SPRING GUIDANCE L= SPRING RETAINER M56X AH SCREW DIN0912-M 5X INTERM.RING SCREW SPRING RET. 2 40* SPRING N/MM (62) ORANGE x 40* SPRING250 72N/MM D12,5 (62)ORA x 40* SPRING250 76N/MM D12,5 (62)ORA x 40* SPRING250 80N/MM D12,5 (62)ORA 1 ORANGE 40* SPRING N/MM (62) ORANGE x CIRCLIP 58,2X2 1 43* S SPRING RET. D=80 W. O-RING / C * NEW PART X AS REQUIRED 13

15 SHOCK ABSORBER DISASSEMBLED O-RING VITON 66,27X3, PISTON ROD NUT M16X O-RING VITON 44,17X1, PISTON RING BACKPLATE 16X20X0,30 x SHIM 16X30X0,20 x SHIM 16X32X0,20 x SHIM 16X34X0,20 x SHIM 16X36X0,20 x WASHER 16X21X1 x PISTON 6+6X3,5/4,5 1 50* BACKPLATE 16X20X0,30 x 50* SHIM 16X32X0,20 x SHIM 16X40X0,25 x 51* HOLDER D=16 M16X1 L= * BACKPLATE D=23 D=16 H3 1 54* SHIM 16X26X0,20 x BACKPLATE 16X20X0,30 x SHIM 16X28X0,15 x SHIM 16X28X0,20 x SHIM 16X30X0,20 x SHIM 16X32X0,20 x SHIM 16X34X0,20 x 54* SHIM 16X36X0,20 x SHIM 16X36X0,25 x 56* BACKPLATE 16X20X0,30 x 56* SHIM 16X28X0,20 x 56* SHIM 16X30X0,20 x 56* SHIM 16X32X0,20 x SHIM 16X34X0,20 x SHIM 16X36X0,20 x SHIM 16X38X0,20 x SHIM 16X40X0,20 x SHIM 16X42X0,20 x 56* SHIM 16X38X0,25 x 56* SHIM 16X40X0,25 x / C * NEW PART X AS REQUIRED 14

16 SHOCK ABSORBER DISASSEMBLED 56* SHIM 16X42X0,25 x SHIM 16X44X0,25 x 57* REBOUND DISC D=34, H=2 1 58* PISTON 6+6X7/4,5 VB 1,0 1 60* PISTON ROD D=18 L=146 M16X BUSH M8X O-RING VITON 7X1, NEEDLE SEAT M8X1 D=5, * TUBE M8X1 L=145, O-RING NBR 8X TUBE ADAPTOR M8X1 L= NEEDLE L= O-RING VITON 2,2X1, S ADAPTOR CPL. D=50 H= STEEL DISC 18X,5X43,7X REBOUND RUBBER BACKUPRING 22,55X1, QUAD RING 18X2, O-RING 41X DU-BUSH 18X20X DUST SEAL CIRCLIP 53X1, * COVER D= * BUMP RUBBER SXS * NUT M18X1 1 90* FORK PART L=55,5 B=32,5 D= THREADED BUSH M12 PDS RUBBER PLUG D= STEEL BALL D=3MM SPRING D=2,9 L=7, RESERVOIR CAP M14X O-RING NBR 4X1, ADJUSTING SCREW 80 DEG. L= * S1 SHOCK ABSORBER FLUID 5 LT ,33 LITRE 99* R12011 REPAIR KIT GASKET 5018 PDS / C * NEW PART X AS REQUIRED 15

17 SILENCER SILENCER SPARKY 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 8,0 NIRO SPECIAL SCREW M 5,0X STUFFINGYARN 350 GRAMM ' STUFFING YARN 560X340X76G O-RING 74,00X1,50 FKM 75SH / C * NEW PART X AS REQUIRED 16

18 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 17

19 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 1 26* CARBURETOR CONNECTION BOOT 1 27* 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 18

20 TANK, SEAT, COVER 1* FUEL TANK CPL.RAC 10L USA SCREW SEAT FASTENING D=6X23/ TANK ROLLER 12X26X12 ' HH COLLAR SCREW M 6X12 WS=8 1 5* FILLER CAP CPL 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= ORIGINAL EQUIPMENT TOOL KIT / C * NEW PART X AS REQUIRED 19

21 MASK, FENDERS NUMBER PLATE CPL. ORANGE HEAD LIGHT MASK ORANGE BRAKE HOSE GUIDE BLACK EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M 6X15 WS= MASK RUBBER UFO WP ' FENDER FRONT WIDE ORANGE SPACER BUSHING HH COLLAR SCREW M 6X20 WS= FENDER BRACE BLACK ' SCREW FEND.BRACE M8X9 WS= NUT FENDER BRACE M8 WS= REFLECTOR YELLOW ' REAR PART SX ORANGE 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 NUMBER PLATE CARRIER SHORT BUSH FOR FENDER 6X11X20X5 MM EJOT PT SCREW K60X20 WS= / C * NEW PART X AS REQUIRED 20

22 DECAL 1* SPOILER DECAL EXC * DISPLACEME. STICKER 525 EXC / C * NEW PART X AS REQUIRED 21

23 FRONT WHEEL 1* FRONT WHEEL 1,6X21" EXCEL * FRONT HUB CPL. SX SILVER BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM 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 D=260MM SPECIAL SCREW M6X13 WS= WHEEL SPIN.FR. D=26 M24X1, SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= PLUG FOR RIM x / C * NEW PART X AS REQUIRED 22

24 REAR WHEEL 1* REAR WHEEL 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) REAR RIM 2,15X18" EXCEL AL BRAKE DISC REAR D=220MM SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" 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" + MASTER LINK ROLLS CHAIN Z-RING 118 ROLLS ROLLS CONNECTING LINK CONNECTING LINK X-RING 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 23

25 REAR WHEEL SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= HEXAGON NUT M20X1,5 ' / C * NEW PART X AS REQUIRED 24

26 WIRING HARNESS WIRING HARNESS RACING USA VOLTAGE REGULATOR CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x FUSE 10 A 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 ' GROUND CABLE D=6MM L=140MM ' CONTACT WASHER M6 VSV-K PROTECTION CAP F. STARTER ENG SELF LOCK. NUT DIN0985-M AH OVAL SCREW ISO 7380 M 6X HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X12 WS= EJOT PT SCREW K60X20 WS= / C * NEW PART X AS REQUIRED 25

27 HAND BRAKE CYLINDER 1* HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE 1 10* REP.SET PISTON D=10MM CLAMP CPL. NATURE HH COLLAR SCREW M 6X25 WS= LEVER SCREW CPL HAND BRAKE LEVER + SPRING ADJUSTING SCREW CPL. SX 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 26

28 FRONT BRAKE CALIPER BRAKECALIPER FRONT BREMBO REPAIR KIT 28MM REPAIR KIT PISTON 28MM BOLT CPL. 6X RETAINING PLATE SET BREMBO BRAKE P.SET FR. TOSHIBA TT * 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 27

29 REAR BRAKE CALIPER 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 28

30 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=8 2 64* BELLOWS FOR REPAIR KIT * BRAKE FLUID DOT / C * NEW PART X AS REQUIRED 29

31 LIGHTING SYSTEM HEAD LIGHT CPL RUBBER CAP FOR HEAD LIGHT BILUX-BULB 12V 35/35W BA20D SCREW FOR PLASTIC D=5X HH COLLAR SCREW M 5X60 WS= SPACER HOSE F. HEAD LIGHT MASK 1 7* BULB 12V 5W (W2,1X9,5D) PHIL CABLE FOR HEAD LIGHT WIRING HARNESS REAR ' BULB 12V 21/5W (BAY15S)REINFO REAR LIGHT LENS LAMP HOLDER EJOT PT SCREW K60X20 WS= / C * NEW PART X AS REQUIRED 30

32 SPEEDOMETER SPEEDOMETER KM/H F. 21" REPROGRAMMABLE: KM/H - MPH BATTERY COVER F. SPEEDOM BATTERY F. SPEEDOM. M.A.E SPEEDOMETER TOP PART * CABLE FOR DIGITAL SPEEDOM CLAMP D=6/8MM, BLACK MAGNET FOR DIGITAL SPEEDOM CIRCLIP DIN0471-9X1 INOX WASHER DIN9021-A 5, SPEEDOMETER BRACKET SCREW FOR PLASTIC D=5X RUBBER GROMMET 16X10,8X RUBBER SLEEVE D=8MM OPEN HH COLLAR SCREW M 6X25 WS= SPACER BUSH. F. SPEEDOMET.BRA PULL SWITCH LOOSE SPEC. NUT F. PULL SWITCH WS= COVERING CAP SFL / C * NEW PART X AS REQUIRED 31

33 525 EXC 2006 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089428EN ENGLISH

34 INDEX 525 EXC 2006 SPECIAL TOOLS ENGINE CASE BLANCER SHAFT CRANKSHAFT, PISTON 3x 4x 6x 7x CYLINDER CARBURETTOR CLUTCH KICKSTARTER 8x 9x 11x 12x TRANSMISSION I TRANSMISSION II SHIFTING MECHANISM COOLING SYSTEM 13x 14x 15x 16x 1

35 INDEX 525 EXC 2006 VALVE DRIVE CYLINDER HEAD 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

36 SPECIAL TOOLS 525 EXC * UNIVERSAL MOUNTING RACK CPL ENGINE HOLDER FOR RACING RIVETTING TOOL TIMING CHAIN MOUNTING SLEEVE SEAL RING SPECIAL CIRCLIP PLIER EXTRACTOR PRIM. GEAR CPL PISTON RING COMPRESSOR D=89MM PISTON RING COMPRESSOR D=95MM PISTON R. COMPRESSOR D=75MM 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 MOUNTING RING FOR INNER CLUTCH PROTECTION COVER F.MAIN SHAFT EXTRACTOR FOR TIMING GEAR 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 13/ VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML CLUTCH HOLDER RACING WRENCH F.MIXTURE CONTROL SCREW 1 35* PRESS PUNCH VALVE GUIDE / C * NEW PART X AS REQUIRED 3

37 ENGINE CASE 525 EXC * ENGINE CASE DOWEL 17 X 13 X DOWEL 9,8 X 7 X HANGER FOR VENT HOSE HH COLLAR SCREW M 6X15 WS= OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, PLUG DIN0908-M12X1, DOWEL 17 X 19 X PRESSURE SPRING L=25MM D=1MM VALVE PISTON D=10MM 1 13* JET 60 DELLORTO M6X0, ENGINE BREATHER TUBE BLEEDER FLANGE M12X1,5 WS= LOCATING SCREW M8 L= CU-SEAL RING 8 X 14 X NEEDLE ROLLER DIN5402 2,5X9, OIL LEVEL GLASS G 1777 Y PLUG M 24X O-RING 19,00X3,00 NBR NEEDLE ROL.DIN5402 NRB 4X9, WASHER DIN0125-A 5, FLAT HEAD SCREW DIN7985-M 5X HH COLLAR SCREW M 6X8 WS= RET.BRACKET F.BRAKE LEVER HUB O-RING 12,00X2,00 NBR PLUG M16X1, OIL SCREEN 11,8X44,5MM O-RING 9X1,5 NBR SEAL RING DIN X18X GASKET FOR CLUTCH COVER ENGINE CASE GASKET NS CLUTCH COVER RACING * CHAIN DAMPING PLATE RAC HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X60 WS= / C * NEW PART X AS REQUIRED 4

38 ENGINE CASE 525 EXC HH COLLAR SCREW M 6X30 WS= HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X75 WS= GASKET SET CPL. RACING / C * NEW PART X AS REQUIRED 5

39 BLANCER SHAFT 525 EXC BALANCER SHAFT CPL. RAC GROOVED BALL BEAR. TM C SHAFT SEAL RING 14X24X6 B / C * NEW PART X AS REQUIRED 6

40 CRANKSHAFT, PISTON 525 EXC * CRANKSHAFT CPL. 520 RAC STROKE 72MM, WITHOUT WASHER CON.ROD REP.SET 250/520 RAC.00 1 WITH WASHER CYL.ROLLER BEAR.NJ206 ET2XCS DRIVE GEAR 32-T F.BALANC.SHAFT THRUST WASHER 30,5X45X0,10 x THRUST WASHER 30,7X47X0,15 x THRUST WASHER 30,5X45X0,30 x WOODRUFF KEY DIN6888-3X5X AH SCREW DIN7984-M 6X SH.SEAL RING 30X47X7 BSL VITON PRIMARY GEAR 33-T HH NUR M20X1,5 WS=27 LEFT WOODRUFF KEY 5X6,5 HARDED SHAFT SEAL RING 14X24X6 B CIRCLIP DIN X1, COLLAR NUT M12X1 R/S SPRING WASHER DIN0137-B PISTON PIN BOLT 20X15,8/12X CIRCLIP C20X1, I PISTON I 95MM CPL. FORGED II PISTON II 95MM CPL.FORGED OIL SCRAPER RING 95MM RECTANGULAR RING 95/87,2X1, / C * NEW PART X AS REQUIRED 7

41 CYLINDER 525 EXC CYLINDER 95MM 520 RACING CYLINDER BASE GASKET 0,5MM DOWEL 6X8X11, HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X45 WS= NEEDLE ROL.DIN5402 NRB 4X9, CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X10 WS= / C * NEW PART X AS REQUIRED 8

42 CARBURETTOR 525 EXC * CARBURETOR FCR-MX 3900F,TPS * CARBURETOR COVER WITH GASKET 1 12* THROTTLE SHAFT CPL COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL SLIDE STOP THROTTLE VALVE CPL BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBDTM x JET NEEDLE KEIHIN OBDVR x JET NEEDLE KEIHIN OBDVT x JET NEEDLE KEIHIN OBDTN x JET NEEDLE KEIHIN OBDTP x JET NEEDLE KEIHIN OBDTQ x JET NEEDLE KEIHIN OBDTR x BAR CLIP NEEDLE SET SCREW CPL NEEDLE JET FCR-MX 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 IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN IDLE JET 45 KEIHIN x STARTER JET * IDLE AIR JET 100 KEIHIN ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL ARM PIN FLOAT 1 42* FLOAT NEEDLE 1 43* CLAMP / C * NEW PART X AS REQUIRED 9

43 CARBURETTOR 525 EXC DRAIN SCREW FLOAT CHAMBER COVER ACCELERATOR PUMP FLOAT CHAMBER CPL. SET COIL SPRING STARTER VALVE CPL BREATH.HOSE FCR-MX KEIHIN CPL SCREW F. COVER KEIHIN PLUG M 18X INTERMEDIATE LEVER CPL LINK LEVER SPRING LINK LEVER SPRING INTERMEDIATE LEVER 1 68* CARBURETOR COVER WASHER LINK LEVER E-CLIP ROD ACCELERATOR PUMP YDNAC-CLAMP (16MM) ' HOSE CONNECTOR CPL. 1 85* PLUG DIN0910-M 10X1 1 86* COPPER GASKET DIN X14X1 1 87* HOSE CONNECTOR KEIHIN ENGINE BREATHER TUBE STOP SCREW CPL. FCR-MX 1 96* THROTTLE POSITION SENSOR GASKET SET FCR-MX KEIHIN / C * NEW PART X AS REQUIRED 10

44 CLUTCH 525 EXC * OUTER CLUTCH HUB 76-Z/20-Z 01 1 HARDED 2* INNER HUB LINING DISC 2MM INTERMEDIATE DISC 1MM * PRESSURE CAP WITH OIL BORE CLUTCH SPRING 2,5X43MM 6 7* SPRING RETAINER 6,2X12X18X5,2 6 8* INTERMEDIATE DISC 1,4MM * PUSH ROD 7x189,6 MM HALF-WASHER SUPPORTWASHER 25X35X AH SCREW DIN6912 M6X NEEDLE BEAR K 25X29X PRIMARY GEAR 33-T OUTPUT CYLINDER CPL O-RING 30,00X1,50 NBR VENT INJEKTION HYDR. CLUTCH PISTON WITH O-RING AND BALL BLEEDER SCREW WITH CAP HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X20 WS= STEPPED WASHER GASKET FOR SLAVE CYLINDER 1 26* DRIVING SLEEVE D=8, L= CIRCLIP DIN7993-RW AXIAL WASHER AS X26X AXIAL NEEDLE BEARING AXK PRESSURE PIECE ' HEXAGON NUT DIN0936-M18X1,5 R LOCK WASHER HOLLOW SCREW HYDR. CLUTCH CPL / C * NEW PART X AS REQUIRED 11

45 KICKSTARTER 525 EXC KICKSTARTER CPL. ' SPROCKET SCREW-AH M8X20 WS= WASHER 8MM GALVANIZED SHAFT SEAL RING 19X30X7 B DRIVING HUB KICKSTARTER GEAR 39-T CIRCLIP DIN X SHIM WASHER DIN X24X0, INTERMEDIATE GEAR 24-T KICKSTARTER SPRING SPRING HANGER HH COLLAR SCREW M 6X12 WS= SHIM 20X32X CIRCLIP DIN X1, NEEDLE BEARING K 22X26X10 A BUMP PART STOP DISK 22,2 X 30 X 1, RATCHET GEAR SPRING 1,2 MM RATCHET GEAR KICKSTARTER HH COLLAR SCREW M 6X20 WS= KICKSTARTER SHAFT RACING / C * NEW PART X AS REQUIRED 12

46 TRANSMISSION I 525 EXC MAIN SHAFT-ZB 14-T IDLER GEAR 5.G 24-T "34" NEEDLE BEAR. K 22X26X13 TN STOP DISC 25,2X32X1, SLIDING GEAR 3/4.G 19/22-T"32" CIRCLIP DIN X1, STOP DISC 25,2X32X1, IDLER GEAR 6.G 26-T "35" SOLID GEAR 2.G 17-T "21" STOP DISC 17,2X30X BALL BEARING 6203 JR2 C BALL BEARING 6205 C3 NTN / C * NEW PART X AS REQUIRED 13

47 TRANSMISSION II 525 EXC COUNTER SHAFT RACING IDLER GEAR 2.G 31-T "25" NEEDLE BEAR.K 22X26X10 DIVIDED STOP DISC 25,2X32X1, CIRCLIP DIN X1, SLIDING GEAR 6.G 21-T "26" STOP DISC 25,2X32X1, IDLER GEAR 4.G 26-T "33" IDLER GEAR 3.G 28-T "28" SLIDING GEAR 5.G 23-T "29" SHIM 20X32X NEEDLE BEARING K 20X26X IDLER GEAR 1.G 34-T "30" STOP DISC 17,2X30X SPACER BUSHING 12MM SPROCKET 13-T x SPROCKET 14-T x SPROCKET 15-T x SCREW+SPRING WASHER O-RING 25,12X1,78 NBR BALL BEARING 6203 JR2 C CYL.ROLL BEARING NJ SHAFT SEAL RING 32X45X7 BSLNBR / C * NEW PART X AS REQUIRED 14

48 SHIFTING MECHANISM 525 EXC SHIFTING LEVER CPL.RACING HH SCREW DIN0933-M 6X STEEL WASHER 6,4X17X SHAFT SEAL RING 14X24X6 B NEEDLE BEAR.HK X20X SHIFT FORK 2./4.GEAR SHIFT SHAFT CPL. RACING ' SHIFT FORK 1./3.GEAR STOP DISK 14X30X RETURN SPRING 2,2MM ' TENSIONING SPRING 0,8MM SHIFT RAIL 11,8X105MM PRESSURE SPRING 0,9MM SHIFTING ROLLER 6X8X5, SHIFT LOCATING DRUM ALU CPL SLIDING PLATE CPL AH SCREW DIN6912 M 6X BALL BEARING C LOCKING LEVER CPL ' HH COLLAR SCREW M 5X20 WS= SLEEVE FOR LOCKING LEVER SPRING 2,3MM SHIFT RAIL 11,8X89MM SHIFT FORK 5./6.GEAR SHIFTROLLER 6-GEAR SPRING GUIDE WASHER DIN7349-5X15X PAIR OF WASHERS M 6 NORDLOCK FLAT HEAD SCREW DIN7985-M 5X WASHER DIN0125-A 5, / C * NEW PART X AS REQUIRED 15

49 COOLING SYSTEM 525 EXC RADIATOR L/S RADIATOR R/S RADIATOR HOSE L/S RAD.-CYL RADIATOR HOSE R/S RAD.-CYL HOSE ID 7,5 PER METER RADIATOR HOSE RAD.-THERMOS RADIATOR HOSE SECONDARY 04 1 RADIATOR-THERMOSTAT RADIATOR HOSE THERMOS.-HEAD THERMOSTAT 70 DEGREES O-RING 32,00X2, SCREW FOR PLASTIC D=4X THERMOSTAT CPL. 70 DEGREES HOSE CLAMP GEMI HOSE CLAMP GEMI HOSE CLAMP YDNAC MM HH COLLAR SCREW M 6X12 WS= WASHER DIN9021-A 6, RUBBER SLEEVE D=12MM PVC-HOSE 6X9 MM PER METER RADIAT.CAP 20,3PSI (1,4BAR) RADIAT. PROTECT.RAC. ORANGE 03 x RADIAT. PROTECT. RAC. BLACK THERMOSWITCH DG ' ALU SEALRING DIN X20X1, FAN CPL. 12V LC x FAN CAP 2001 x FAN FLAP RUBBER LC x SCREW FOR PLASTIC D=5X18 x EJOT PT SCREW K60X20 WS=6 x FAN CPL. RACING 2001 x FAN WIRING HARNESS 2001 x FUSE 5 A 2003 x / C * NEW PART X AS REQUIRED 16

50 VALVE DRIVE 525 EXC INTAKE VALVE D=35MM EXHAUST VALVE D=30MM VALVE-STEM SEALING RACING VALVE SPRING KIT (1X)RAC VALVE COLLET KK 6 H ADJUSTMENT SCREW M6X0, NUT M6X0, ROCKER ARM SHAFT INTAKE ROCKER ARM SHAFT EXHAUST END CAP ROCKER ARM SHAFT O-RING 19,10X1,60 NBR SHIM ALU 5,2X10X AH SCREW DIN 912 M 5X DECOMPRESSION SHAFT CPL O-RING 5,10X1,60 NBR DECOMPRESSION LEVER SPRING CIRCLIP DIN0471-8X0, ROCKER ARM INTAKE CPL ROCKER ARM EXHAUST CPL / C * NEW PART X AS REQUIRED 17

51 CYLINDER HEAD 525 EXC CYLINDER HEAD CPL.450/ CYLINDER HEAD GASKET 95,3 MM 1 3* VALVE COVER REAR VALVE COVER GASKET HH COLLAR SCR. M6X55 WS= HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X75 WS= HH COLLAR SCREW M 6X30 WS= HH COLLAR SCREW M 6X50 WS=8 1 10* VALVE GUIDE INTAKE 2 11* VALVE GUIDE EXHAUST 2 12* INTAKE BOOT CLAMP D=56MM B=9MM M4X EXHAUST FLANGE CPL. 450/ GASKET EXHAUST FLANGE HH COLLAR SCREW M 6X20 WS= CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X16 WS= DOWEL 6X8X11, VENT SCREW M6X10 CPL CU-SEAL RING 6 X 10 X WASHER 10,8X18,8X1, WATER PUMP COVER RACING WATER PUMP COVER GASKET 0,8MM CYL. HEAD SCREW M10X158 WS= / C * NEW PART X AS REQUIRED 18

52 TIMING VALVE 525 EXC TIMING CHAIN 96 ROLLS TIMING CHAIN GUIDE RACING SECURING GUIDE RACING TIMING GEAR 18-T TIMING CHAIN TENSIONER GASKET TIMING CHAIN TENSIONER TIMINGCHAIN TENSIONER CPL.RAC SPACER BUSHING 6,1X8,2X13, HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 5X16 WS= SUPPORTING SLEEVE 5,2X7X10X7, CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M 6X25 WS= CAMSHAFT 590/ CAMSHAFT GEAR AUTO DECOMPRESSION SHAFT AH SCREW DIN7984-M 8X WASHER 26,7X34X1, GASKET SUPPORT BALL BEARING SPRING FOR AUTODECOMPRESSION O-RING 29,10X1,60 NBR O-RING 25,12X1,78 NBR SHAFT SEAL RING 10X18X4 BSL RIVET LINK FOR TIMING CHAIN NEEDLE ROL.DIN5402 NRB 3X17, WATER PUMP WHEEL CPL. RAC CIRCLIP DIN X / C * NEW PART X AS REQUIRED 19

53 LUBRICATING SYSTEM 525 EXC OIL PUMP SHAFT OILPUMP ROTOR CPL. 10MM G-73R OILPUMP ROTOR 12MM G-95R/ OIL PUMP GEAR 26-T OIL PUMP COVER L/S OIL PUMP COVER R/S 8MM HH COLLAR SCREW M 5X16 WS= AH SCREW DIN6912-M 5X OIL FILTER COVER RACING 2 12* OIL FILTER LONG 1 13* OIL FILTER SHORT NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, BANJO BOLT M8 X 1 DIN JET SCREW "100" M8X1 WS= SEAL RING CU DIN7603-8X12X OIL LINE STEEL CASE-CYL.HEAD 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, RUBBERBUFFER 8X17X10 SILENC' / C * NEW PART X AS REQUIRED 20

54 IGNITION SYSTEM 525 EXC IGNITION COVER 4K3B IGNITION COVER GASKET 0,8MM 1 3* STATOR 4-K3-B FLYWHEEL 4K3B RACING PULSER COIL KOKUSAN 4K3-A/B CDI UNIT 400/525 EXC SPARK PLUG CONNECT. VD05EG SPARK PLUG NGK DCPR8E SUPPORT FOR WIRE CYL.HEAD SCREW DIN0084-M 4X 6A WIRING HARNESS FOR CDI EXC IGNITIONCOIL KOKUSAN 4K3-A/B CABLE TIE 100/2,5MM BLACK x DOWEL 9,8 X 7 X HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X30 WS= HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M 6X10 WS= HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 21

55 ELECTRIC STARTER 525 EXC E-STARTER ENGINE KPL. 0,45 KW 1 2* GEAR WHEEL STOP DISK 17,2X25X CIRCLIP DIN X1 1 5* TORQUE LIMITER * NEEDLE BEARING K 10X13X BEARING BOLT FREE WHEEL HUB AH SCREW DIN0912-M 6X NEEDLE BEARING HK 3016 B FREE-WHEEL FWD BLS 1 14* FREEWHEEL GEAR HH COLLAR SCREW M 6X20 WS= O-RING 25,00X3,00 NBR CAP COVER HH COLLAR SCREW M 6X12 WS= WASHER DIN0125-A 6, / C * NEW PART X AS REQUIRED 22