250 SX-F 2007 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CF8101G9EN

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF8101G9EN ENGLISH

2 INDEX FRONT FORK HANDLEBAR, CONTROLS FRAME, SUB FRAME MONOSHOCK 3x 4x 5x 6x SWINGARM MANIFOLD EXHAUST SILENCER AIR FILTER BOX 7x 8x 9x 10x TANK, SEAT, COVER MASK, FENDERS DECAL FRONT WHEEL 11x 12x 13x 14x 1

3 INDEX REAR WHEEL BRAKE CALIPER REAR BRAKE CALIPER FRONT HAND BRAKE CYLINDER 15x 16x 17x 18x REAR BRAKE CONTROL ACCESSORIES 19x 20x 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 1* 14187C03 FRONT FORK WP CC 250SX+SX-F HH COLLAR SCREW M 8X25 WS= HH COLLAR SCREW M 8X35 WS= S HH COLLAR SCREW M8X25 WS=10 06 x AH SCREW DIN6912-M10X STE.HEAD SCR. M20X1,5 WS=27 SL 1 SELF-LOCKING O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS= BOTTOM TRIPLE CLAMP D=60MM FORK TUBE L=237MM TOP TRIPLE CLAMP D=54MM 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 ORANGE STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS= FORK PROT. L/S +R/S ORG / C * NEW PART X AS REQUIRED 3

5 HANDLEBAR, CONTROLS 1* HANDLEBAR D=28MM SX HANDLEBAR PAD 05 x SHORT CIRCUIT 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 HOT START LEVER CPL MASTER CYLINDER CPL CLUTCH LEVER CPL. BREMBO REP. KIT PISTON COVER HYD. CLUTCH CPL VALVE BOLT KPL BRAKE FLUID DOT PROTECTION CAP LEVER SCREW CPL PUSH ROAD CPL CLAMP CPL CLUTCH PIPE HOT START CABLE THROTTLE CABLE 250 SXF / C * NEW PART X AS REQUIRED 4

6 FRAME, SUB FRAME 1* FRAME 250 SX-F "GA07" * SUB FRAME SX "Q7" * SUB FRAME APPLICATION L/S * SUB FRAME APPLICATION R/S * REINFORCING B. 250 SX-F 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= 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 2 45* FOOTREST L.+R. CPL ANGEL PIECE ' PVC-HOSE 7X10 PER METER x 50* SPROCKET COVER 250 SX-F * CHAIN SLIDING PIECE BELOW * BLIND RIVET NUT EM6-60LF/HX x 63* FRAME PROTECTION STICK. SET * CHAIN SLIDING P. BELOW CPL / C * NEW PART X AS REQUIRED 5

7 MONOSHOCK 8* S HH COLLAR M12X50 ISA * 12187C03 MONOSHOCK WP 250 SX+250SX-F / C * NEW PART X AS REQUIRED 6

8 SWINGARM 2* SWINGARM CPL * CHAIN SLIDING PROTECTION 1 4* BUSHING F. CHAIN SLIDING PR * SPECIAL SCREW M 5,0X10 4 6* BRAKE HOSE GUIDE LOWER BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X BUSHING SLEEVE F. SWING ARM NEEDLE BEARING HK STOP DISK 22,2X31,7X1 2 14* CHAIN GUIDE REAR CPL HH COLLAR SCREW M 6X16 WS= HH COLLAR SCREW M 6X45 WS= PIVOT BEARING+BUSHES PDS ' TOOL BEARING MOUNTING PDS 1 22* INSERTION NUT F. CHAIN GUIDE 1 25* 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 7

9 MANIFOLD 1* MANIFOLD 250 SX-F TEN.SPRING L=62MM EY.MOVEABLE HH COLLAR SCREW M 8X25 WS= BUSHING FOR EXHAUST SUPPORT EXHAUST BRACKET RUBBER BLACK RANGE CHANGE METAL NUT M8 1 14* BLIND RIVET NUT M8 HUC/ROF 5 0 x / C * NEW PART X AS REQUIRED 8

10 EXHAUST SILENCER 1* EXHAUST SILENCER CPL.250SXF * SILENCER HOUSING 250 SX-F * SILENCENER C. CPL. 250 SX-F SPRING WASHER DIN0137-B BUSHING 7,5X12X28X7,8 ' EXHAUST BRACKET RUBBER BLACK HH COLLAR SCREW M 6X30 WS= TEN.SPRING L=62MM EY.MOVEABLE 2 22* SCREW TORX M5X * ENDCAP STUFFINGYARN 350 GRAMM ' / C * NEW PART X AS REQUIRED 9

11 AIR FILTER BOX 1* 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 2 10* FENDER FOR FILTER BOX 1 15* AIR FILTER * FILTER CARRIER 4S SX * FILTER SUPPORT CPL * FILTER SUPPORT BUSH * FASTEN. DEVICE FILTER S. SX * CABURETOR CONNECTING * HOSE CLAMP 40-60MM 1 51* EJOT PT SCREW K60X20 ALU WS=6 3 79* BUSHING F. CHAIN SLIDING PR / C * NEW PART X AS REQUIRED 10

12 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 M10X1 1 35* 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=8 2 63* HH COLLAR SCREW M 6X25 WS=8 1 80* TOOL KIT / C * NEW PART X AS REQUIRED 11

13 MASK, FENDERS 1* NUMBER PLATE CPL. ORANGE * BRAKE HOSE GUIDE ORANGE EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M 6X10 WS=8 1 7* FRONT FENDER SPACER BUSHING HH COLLAR SCREW M 6X15 WS=8 4 14* 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 12

14 DECAL 2* DISCAPLEME. STICKER 250SX-F / C * NEW PART X AS REQUIRED 13

15 FRONT WHEEL 1* FRONT WHEEL CPL.1,6X21EXCEL * FRONT HUB SX CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC 2 8* SPACER BUSHING * SPOKE M4, 5X226-21" SPOKE NIPPLE M4,5X0,75 8X RIM 1,60X21"EXCEL AL4 BLACK RIM BAND 21" 1 15* 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 14

16 REAR WHEEL 1* REAR WHEEL CPL.2,15X19"EXCEL07 1 2* REAR WHEEL HUB CPL. SX, EXC BUSHING SPACER TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL 2 7* SPACER BUSHING * SPOKE M5x207-19" SPOKE NIPPLE M5-TA (8X21MM) RIM 2,15X19"EXCEL AL4 BLACK 1 11* BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" 1 15* 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" + MASTER LINK CONNECTING LINK RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER ' PLUG FOR RIM x COVERING CAP SFL16 x 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 15

17 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 16

18 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 17

19 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 18

20 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 X16X1 2 10* 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 19

21 ACCESSORIES DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER OWNERS MANUAL RAC CF8101G9EN SPC CHASSIS 1 0 3CM089308GEN SPC ENGINE / C * NEW PART X AS REQUIRED 20

22 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089308GEN ENGLISH

23 INDEX SPECIAL TOOLS CRANKSHAFT, PISTON CYLINDER ENGINE CASE 3x 4x 5x 6x CARBURETOR CLUTCH KICKSTARTER TRANSMISSION I 8x 10x 11x 12x TRANSMISSION II SHIFTING MECHANISM COOLONG SYSTEM VALVE DRIVE 13x 14x 15x 16x 1

24 INDEX CYLINDER HEAD TIMING VALVE LUBRICATING SYSTEM IGNITION SYSTEM 17x 18x 20x 21x 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

25 SPECIAL TOOLS UNIVERSAL MOUNTING RACK ' FIXING ARM FRONT FIXING ARM REAR PROTECTION CAP FOR CAMSHAFT 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 16MM 1/2INCH VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML HOLD. PLATE CLUTCH 125/200 ' WRENCH F.MIXTURE CONTROL SCREW 1 35* SP. WRENCH F.HOSE CONNECTOR / C * NEW PART X AS REQUIRED 3

26 CRANKSHAFT, PISTON CRANKSHAFT CON. ROD REP. SET THRUST WASHER 30,5X45X0,10 x THRUST WASHER 30,7X47X0,15 x THRUST WASHER 30,5X45X0,30 x CYL.ROLLER BEAR.NJ206 ET2XCS HEX.NUT L/SH M18X1, LOCK WASHER VSK SH.SEAL RING 35X42X4 B10FNIB WOODRUFF KEY 5X6,5 HARDED SH.SEAL RING 30X47X7 BSL VITON COLLAR NUT M12X1 R/S SPRING WASHER DIN0137-B WOODRUFF KEY DIN6888-3X5X PRIMARY GEAR 22T. 05 x PISTON PIN BOLT D=16mm CIRCLIP I PISTON I CPL II PISTON II CPL OIL SCRAPER RING D= COMPRESSIONRING D= SHAFT SEAL RING 14X24X6 B / C * NEW PART X AS REQUIRED 4

27 CYLINDER CYLINDER CYLINDER BASE GASKET DOWEL 10,2X12,5X HH COLLAR SCREW M 6X25 WS= / C * NEW PART X AS REQUIRED 5

28 ENGINE CASE 1* ENGINE CASE CPL. W.TR.BEAR DOWEL 9,8 X 7 X OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1,5 1 11* HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X8 WS= LOCATING SCREW M8 L= CU-SEAL RING 8 X 14 X CIRCLIP OIL LEVEL GLASS OIL LEVEL GLASS G 1777 Y DOWEL 17 X 19 X GASKET FOR CLUTCH COVER OIL JET 70 M6X0,75 WS DOWEL BUSHING 13,8X11X JET 100 BING(44-031/180) M O-RING 12,00X2,00 NBR * PLUG M16X1, OIL SCREEN 11,8X44,5MM O-RING 9X1,5 NBR 2 43* CLUTCH COVER CPL HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X65 WS= HH COLLAR SCREW M 6X50 WS= HH COLLAR SCREW M 6X40 WS= HH COLLAR SCREW M 6X30 WS= VALVE PISTON D=10MM PRESSURE SPRING L=25MM D=1MM PLUG DIN0908-M12X1, CU-SEAL RING DIN X18X1, HH COLLAR SCREW M 6X25 WS= GASKET SET * CLUTCH COVER OUTSIDE MOLDED RING HH COLLAR SCREW M 6X25 WS= HH COLLAR SCREW M 6X55 WS= O-RING 19,00X3,00 NBR / C * NEW PART X AS REQUIRED 6

29 ENGINE CASE PLUG M 24X CU-SEAL RING DIN7603-6X10X / C * NEW PART X AS REQUIRED 7

30 CARBURETOR 1* CARBURETOR CARBURETOR COVER WITH GASKET 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 OBETP JET NEEDLE KEIHIN OBETN x JET NEEDLE KEIHIN OBETQ x BAR CLIP NEEDLE SET SCREW CPL NEEDLE JET FCR-MX MAIN JET 162 KEIHIN x MAIN JET 165 KEIHIN x MAIN JET 168 KEIHIN x MAIN JET 170 KEIHIN x MAIN JET 172 KEIHIN x MAIN JET 175 KEIHIN MAIN JET 178 KEIHIN x MAIN JET 180 KEIHIN x IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN 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

31 CARBURETOR COVER ACCELERATOR PUMP FLOAT CHAMBER CPL. 1 50* JET POWER JET CLOSED KEIHIN x JET POWER JET 50 KEIHIN x JET POWER JET 60 KEIHIN x JET POWER JET 70 KEIHIN COIL SPRING 1 55* STARTER VALVE CPL BREATH.HOSE FCR-MX KEIHIN CPL. 1 60* 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

32 CLUTCH OUTER CLUTCH CPL INNER CLUTCH HUB PRESSURE PLATE INTERMEDI. DISC STEEL LINING DISC 3,0MM INNER RING 20X26X25,9 ' SHEET METAL LOCK 1,5MM ' HEXAGON NUT DIN0936-M18X1,5 R STOP DISK 20X39,6X3 ' PRIMARY GEAR 22T WASHER 6,2X18X PUSH ROD PRESSURE PIECE ' O-RING 30,00X1,50 NBR HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M 6X25 WS= VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING PISTON CPL OUTPUT CYLINDER CPL O-RING PRESSURE SPRING CU-SEAL RING DIN X16X BLEEDER HOLLOW SCREW M10X NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 10

33 KICKSTARTER STOP DISK 17,2X24X CIRCLIP DIN X THRUST WASHER DIN X22X SPACER BUSHING 16X23X26X6,1 1 39* S FLAT HEAD SCREW M. ISA45 M8X HH COLLAR SCREW M 6X16 WS= KICKSTARTER SHAFT KICKSTART. GEAR 28-T KICKSTARTER RATCHET INTERMEDIATE GEAR KICKSTARTER SPRING DRIVING HUB SPRING 1,4MM ' STOP MET.SHEET 4MM 125/200' KICKSTARTER CPL SHAFT SEAL RING 17X28X7 B WASHER 8MM GALVANIZED / C * NEW PART X AS REQUIRED 11

34 TRANSMISSION I 1* MAIN SHAFT CPL. T=13 "C13" * IDLER G.5TH G.21-T "5C21" * SLIDING GEAR 3/4. GEAR 17/19-T 1 9* IDLER G.6TH G.22-T "6C22" * SOLID GEAR 2ND G.15-T"2C15" NEEDLE BEAR.K 22X26X10 DIVIDED GROOVED BALL BEARING C BALL BEARING 6004 TN9 C NEEDLE CAGE K18X22X10 PARTED STOP DISC STOP DISK 17,2X24X STOP GEAR 22X28.5X LOCK RING 22X1, / C * NEW PART X AS REQUIRED 12

35 TRANSMISSION II COUNTER SHAFT * IDLER G. 4TH G.26-T "4C26" * IDLER G. 3RD G.28-T * SLIDING G. 6TH G.24-T"6C24" * IDLER G. 2ND G. 30-T "2C30" * IDLER G. 1ST G. 32-T "1C32" * SLIDING G. 5TH G.25-T "5C25" NEEDLE BEARING K20X24X NEEDLE BEAR.K 22X26X10 DIVIDED IDLER GEAR BUSHING 25X28X9,7 D SCREW+SPRING WASHER SPROCKET 13-T x SPROCKET 14-T x SPROCKET 15-T x BALL BEARING 6003 TN9 C BALL BEARING 6205 C3 NTN SHAFT SEAL RING 32X45X7 BSLNBR SPACER BUSHING 12MM O-RING 25,12X1,78 NBR STOP DISC 17,2X30X SHIM 20X32X STOP DISC 25,2X32X THRUST WASH. DIN X35X1,0 1 90* AXIAL-CIRCLIP 25X1, CIRCLIP DIN X1, / C * NEW PART X AS REQUIRED 13

36 SHIFTING MECHANISM SHIFTING FORK 5TH/6TH GEAR SHIFTING FORK 2ND/3RD GEAR SHIFTING FORK 1ST/4TH GEAR NEEDLE ROLLER DIN5402 6X14, SHIFTING SHAFT CPL PRESSURE SPRING 0,9MM SLIDING PLATE CPL TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 6903 C SHIFT ROLLER BALL BEARING C RETURN SPRING 2,2MM ' SHIFT LOCATING DRUM CPL AH SCREW DIN6912 M 6X HH COLLAR SCREW M 6X8 WS= SHIFT. RAIL MAIN SHAFT 250/ SHIFTING MAIN L=93MM ARRESTING LEVER SPRING LOCKING LEVER CPL ' SLEEVE FOR LOCKING LEVER WASHER DIN7349-5X15X HH COLLAR SCREW M 5X20 WS= SHIFT LEVER CPL. 250/ 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 SPECIAL SCREW M6X16 WS= / C * NEW PART X AS REQUIRED 14

37 COOLONG SYSTEM 7* RADIATOR L/S 250 SX-F * RADIATOR R/S "45518U" RADIATOR CAP SMALL 20,3 PSI 1 19* T-CONNECTOR CPL HOSE CLAMP GEMI * HOSE CLAMP GEMI 12/ ANGEL PIECE ' PVC-HOSE 6X9 MM PER METER x RADIATOR HOSE L/S 250SXF * HOSE ENGINE-RADIATOR * RADIATOR PROT. L/S+R/S * HOSE CONNECTOR 4 STROKE HH COLLAR SCREW M 6X12 WS= / C * NEW PART X AS REQUIRED 15

38 VALVE DRIVE VALVE LEVER SHAFT VALVE LEVER 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 COLLET VALVE SPRING KIT VALVE-STEM SEALING INTAKE VALVE TITAN EXHAUST VALVE TITAN VALVE SPRING RETAINER 05 x VALVE SPRING INSIDE 05 x VALVE SPRING HOLDER 05 x / C * NEW PART X AS REQUIRED 16

39 CYLINDER HEAD 1* CYLINDER HEAD CPL CYLINDER HEAD GASKET * VALVE COVER VALVE COVER GASKET VALVE COVER SCR. M6X12 WS RUBBER GASKET FOR SCREW COVER PLATE BREATHER SPECIAL SCREW M 5,0X ANGLE CONNECTOR LC O-RING 8X2 SILICONE SPECIAL SCREW M7X73 WS SPECIAL SCREW M7X40 WS COLLAR NUT 7X STUD 7X BUSH SUPPORT A.BRIDGE CPL ' NEEDLE ROLLER DIN5402 5X9, OIL JET DOWEL(BUSH BRIDGE)7/9/ * VALVE GUIDE INTAKE VALVE GUIDE OUTLET CYLINDER HEAD SCREW WASHER 10,8X18,8X1, GASKET EXHAUST FLANGE EXHAUST FLANGE CPL HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X25 WS= INTAKE BOOT CLAMP D=56MM B=9MM M4X ENGINE BREATHER TUBE / C * NEW PART X AS REQUIRED 17

40 TIMING VALVE TIMING CHAIN GUIDE TOP SPACER BUSHING GUIDE RAIL CAMSHAFT GEAR SCREW CAMSHAFT GEAR BALL BEARING 6004 NR C * CAMSHAFT INTAKE NEEDLE ROOLER DIN5402 NRB 4X6 2 8* CAMSHAFT EXHAUST AUTO DECOMPRESSION AUTO DECO WEIGHT SPRING FOR AUTO DECOMPR BUSHING SCREW AUTODEC. M5X0, TIMING CHAIN GUIDE BUSHING SCREW SEAL RING CU DIN7603-8X12X HH COLLAR SCREW M 6X25 WS= SPACER BUSHING 6,1X8,2X13, SECURING PROTECTION TIMING CHAIN TENSIONER SPACER BUSHING 6.1X8.2X HH COLLAR SCREW M 6X40 WS= CHAIN ADJUSTER HOLDING BOLT CU SEAL-RING DIN7603 A24X29X CHAIN ADJUSTER HYD O-RING TIMING VALVE JACKSHAFT STOP DISK 18,2X30X WOODRUFF KEY DIN6888-3X3, TIMING VALVE TWIN WHEEL TIMING CHAIN IWIS 108 ROLLS BALL BEARING 6203 JR2 C NEEDLE BEAR.HK /24/ NEEDLE ROL.DIN5402 NRB 3X17, WATER PUMP ROTOR CIRCLIP DIN X SHAFT SEAL RING 12X30X7 VITON / C * NEW PART X AS REQUIRED 18

41 TIMING VALVE MOLDED RING WATER PUMP WATER PUMP COVER HH COLLAR SCREW M 6X30 WS= HH COLLAR SCREW M 6X20 WS= CU-SEAL RING DIN7603-6X10X / C * NEW PART X AS REQUIRED 19

42 LUBRICATING SYSTEM 1* OIL PUMP SHAFT EXC-F OILPUMP ROTOR CPL. 10MM G-73R OILPUMP ROTOR 15MM G OIL PUMP GEAR 14T OIL PUMP COVER L/S OIL PUMP COVER R/S HH COLLAR SCREW M 5X16 WS= AH SCREW DIN6912-M 5X OIL FILTER COVER RACING OIL FILTER NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, OILPUMP IDLER GEAR 17T SHIM WASHER DIN X18X0, CIRCLIP DIN X 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, O-RING 32,00X2, HH COLLAR SCREW M 5X12 WS= / C * NEW PART X AS REQUIRED 20

43 IGNITION SYSTEM 1* IGNITION COVER IGNITION COVER GASKET STATOR 4K3-A FLYWHEEL PULSER COIL KOKUSAN 4K3-A/B 1 6* CDI UNIT 250 SX-F SPARK PLUG CONNECT. VD05EG SPARK PLUG NGK CR9EKB WIRE RETAINING BRACKET HH COLLAR SCREW M 6X8 WS= 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 6X25 WS= HH COLLAR SCREW M 6X30 WS= AH SCREW DIN0912-M 5X HH COLLAR SCREW M 5X16 WS= HH COLLAR SCREW M 6X20 WS= HH COLLAR SCREW M 6X16 WS= / C * NEW PART X AS REQUIRED 21