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525 EXC 2006
SPARE PARTS MANUAL: ENGINE
ART.NO.: 3CM089428EN
ENGLISH
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525 EXC 2006 INDEX 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 COO
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525 EXC 2006 INDEX 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, p
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525 EXC 2006 SPECIAL TOOLS FIG PART NUMBER DESCRIPTION QTY 1* 56012001044 UNIVERSAL MOUNTING RACK CPL. 1 2 59029002000 ENGINE HOLDER FOR RACING 2000 1 3 59029020000 RIVETTING TOOL TIMING CHAIN 1 4 59029005010 MOUNTING SLEEVE SEAL RING 1 5 51012011000 SPECIAL CIRCLIP PLIER 1 6 59029021044 EXTRACTOR PRIM. GEAR CPL. 1 7 58012015089 PISTON RING COMPRESSOR D=89MM 1 7 58012015095 PISTON RING COMPRESSOR D=95MM 1 7 59829015075 PISTON R. COMPR
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525 EXC 2006 ENGINE CASE FIG PART NUMBER DESCRIPTION QTY 1* 59030000444 ENGINE CASE 2006 1 2 51030026100 DOWEL 17 X 13 X 12 1 3 49030090000 DOWEL 9,8 X 7 X 10 4 4 59030090000 HANGER FOR VENT HOSE 1 5 0014060153 HH COLLAR SCREW M 6X15 WS=8 1 6 58030021000 OILDRAIN PLUG W.MAG. M 12X1,5 1 7 58038022000 CU-SEAL RING DIN7603-12X18X1,5 2 9 0908120153 PLUG DIN0908-M12X1,5 1 10 59030024000 DOWEL 17 X 19 X
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525 EXC 2006 ENGINE CASE FIG PART NUMBER DESCRIPTION QTY 52 0015060303 HH COLLAR SCREW M 6X30 WS=8 10 53 0015060353 HH COLLAR SCREW M 6X35 WS=8 2 54 0015060753 HH COLLAR SCREW M 6X75 WS=8 1 60 59030099000 GASKET SET CPL. RACING 2000 1 065903000 / C065903000 * NEW PART X AS REQUIRED 5
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525 EXC 2006 BLANCER SHAFT FIG PART NUMBER DESCRIPTION QTY 2 59030057044 BALANCER SHAFT CPL. RAC. 2001 1 4 0625160040 GROOVED BALL BEAR. TM 16004 C3 2 6 0760142460 SHAFT SEAL RING 14X24X6 B 1 065903008 / C065903002 * NEW PART X AS REQUIRED 6
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525 EXC 2006 CRANKSHAFT, PISTON FIG PART NUMBER DESCRIPTION QTY 1* 59030018500 CRANKSHAFT CPL. 520 RAC. 2006 1 STROKE 72MM, WITHOUT WASHER 2 59030015044 CON.ROD REP.SET 250/520 RAC.00 1 WITH WASHER 4 50330082000 CYL.ROLLER BEAR.NJ206 ET2XCS46 2 5 59030055000 DRIVE GEAR 32-T F.BALANC.SHAFT 1 6 56030081000 THRUST WASHER 30,5X45X0,10 x 6 56030081100 THRUST WASHER 30,7X47X0,15 x 6 56030081200 THRUST WASHER 30,5X45X0,30 x 7 088803
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525 EXC 2006 CYLINDER FIG PART NUMBER DESCRIPTION QTY 1 59030005000 CYLINDER 95MM 520 RACING 2000 1 2 59030035050 CYLINDER BASE GASKET 0,5MM 1 3 59030023000 DOWEL 6X8X11,5 2 4 0015060403 HH COLLAR SCREW M 6X40 WS=8 1 5 0015060453 HH COLLAR SCREW M 6X45 WS=8 2 7 0402040980 NEEDLE ROL.DIN5402 NRB 4X9,8 2 8 0603061001 CU-SEAL RING DIN7603-6X10X1 2 9 0015060103 HH COLLAR SCREW M 6X10 WS=8 1 05590306 / C065903016 * NEW PA
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525 EXC 2006 CARBURETTOR FIG PART NUMBER DESCRIPTION QTY 1* 59031001300 CARBURETOR FCR-MX 3900F,TPS 06 1 5* 57331027044 CARBURETOR COVER WITH GASKET 1 12* 57331046100 THROTTLE SHAFT CPL. 06 1 14 57331046050 COIL SPRING THROTTLE SHAFT 1 16 57331035051 LINK ARM THROTTLE VALVE CPL. 1 18 59031029010 SLIDE STOP 03 1 19 57331035000 THROTTLE VALVE CPL. 1 20 59031035050 BUSHING THROTTLE VALVE 4 21 57331035153 GASKET
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525 EXC 2006 CARBURETTOR FIG PART NUMBER DESCRIPTION QTY 46 57331155000 DRAIN SCREW FLOAT CHAMBER 1 47 57331060000 COVER ACCELERATOR PUMP 1 49 57331011000 FLOAT CHAMBER CPL. SET 1 53 59031059000 COIL SPRING 1 55 57331048000 STARTER VALVE CPL. 1 56 57331098000 BREATH.HOSE FCR-MX KEIHIN CPL. 1 60 57331038100 SCREW F. COVER KEIHIN 1 61 54531699000 PLUG M 18X1 1 64 57331062000 INTERME
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525 EXC 2006 CLUTCH FIG PART NUMBER DESCRIPTION QTY 1* 59032000476 OUTER CLUTCH HUB 76-Z/20-Z 01 1 HARDED 2* 59032002250 INNER HUB 06 1 3 59032011100 LINING DISC 2MM 04 7 4 59032010100 INTERMEDIATE DISC 1MM 2002 4 5* 59032003350 PRESSURE CAP WITH OIL BORE 06 1 6 59032005000 CLUTCH SPRING 2,5X43MM 6 7* 59032006050 SPRING RETAINER 6,2X12X18X5,2 6 8* 59032010200 INTERMEDIATE DISC 1,4MM
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525 EXC 2006 KICKSTARTER FIG PART NUMBER DESCRIPTION QTY 1 54833070044 KICKSTARTER CPL. '03 1 2 54610052000 SPROCKET SCREW-AH M8X20 WS=6 1 3 54633037000 WASHER 8MM GALVANIZED 1 4 0760193070 SHAFT SEAL RING 19X30X7 B 1 5 59033055000 DRIVING HUB 1 6 59033051039 KICKSTARTER GEAR 39-T 1 7 0471170010 CIRCLIP DIN0471-17X1 1 9 0988172405 SHIM WASHER DIN0988-17X24X0,5 2 10 59033053000 INTERMEDIATE GEAR
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525 EXC 2006 TRANSMISSION I FIG PART NUMBER DESCRIPTION QTY 1 59033001400 MAIN SHAFT-ZB 14-T 03 1 2 59033005034 IDLER GEAR 5.G 24-T "34" 1 3 0405222613 NEEDLE BEAR. K 22X26X13 TN 2 4 59033031000 STOP DISC 25,2X32X1,5 1 5 59033003032 SLIDING GEAR 3/4.G 19/22-T"32" 1 6 0471250120 CIRCLIP DIN0471-25X1,2 2 7 59033030000 STOP DISC 25,2X32X1,5 1 9 59033006035 IDLER GEAR 6.G 26-T "35" 1 10 59033002021 SOLID GEAR 2.G 17
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525 EXC 2006 TRANSMISSION II FIG PART NUMBER DESCRIPTION QTY 1 59033010000 COUNTER SHAFT RACING 2000 1 2 59033012025 IDLER GEAR 2.G 31-T "25" 1 3 0405222611 NEEDLE BEAR.K 22X26X10 DIVIDED 3 4 59033031000 STOP DISC 25,2X32X1,5 1 5 0471250120 CIRCLIP DIN0471-25X1,2 3 6 59033016026 SLIDING GEAR 6.G 21-T "26" 1 8 59033030000 STOP DISC 25,2X32X1,5 2 9 59033014033 IDLER GEAR 4.G 26-T "33" 1 10 59033013028 IDLER GEAR 3.G 28
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525 EXC 2006 SHIFTING MECHANISM FIG PART NUMBER DESCRIPTION QTY 1 59034031000 SHIFTING LEVER CPL.RACING 2000 1 2 0933060165 HH SCREW DIN0933-M 6X16 10.9 1 3 50232050001 STEEL WASHER 6,4X17X3 1 4 0760142460 SHAFT SEAL RING 14X24X6 B 1 5 54632095000 NEEDLE BEAR.HK 1412 14X20X12 2 6 59034002000 SHIFT FORK 2./4.GEAR 2000 1 7 59034005044 SHIFT SHAFT CPL. RACING '03 1 8 59034003000 SHIFT FORK 1./3.GEAR 2000 1 9 54634050000 STOP DISK 14X30X1
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525 EXC 2006 COOLING SYSTEM FIG PART NUMBER DESCRIPTION QTY 1 59035007300 RADIATOR L/S 45.407 03 1 2 59035008400 RADIATOR R/S 45.409 03 1 3 59035024100 RADIATOR HOSE L/S RAD.-CYL. 03 1 4 59035124100 RADIATOR HOSE R/S RAD.-CYL. 03 1 5 54435024001 HOSE ID 7,5 PER METER 1 6 59035126100 RADIATOR HOSE RAD.-THERMOS. 04 2 7 59035025101 RADIATOR HOSE SECONDARY 04 1 RADIATOR-THERMOSTAT 8 59035025100 RADIATOR HOSE THERMOS.-HEAD 0
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525 EXC 2006 VALVE DRIVE FIG PART NUMBER DESCRIPTION QTY 1 59036030000 INTAKE VALVE D=35MM 2 2 59036031000 EXHAUST VALVE D=30MM 2 3 59036027000 VALVE-STEM SEALING RACING 4 6 59036028244 VALVE SPRING KIT (1X)RAC. 2001 4 9 59036033000 VALVE COLLET KK 6 H 8 10 59036062000 ADJUSTMENT SCREW M6X0,75 4 11 59036062100 NUT M6X0,75 4 13 59036056000 ROCKER ARM SHAFT INTAKE 1 14 59036057000 ROCKER ARM SH
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525 EXC 2006 CYLINDER HEAD FIG PART NUMBER DESCRIPTION QTY 1 59036020144 CYLINDER HEAD CPL.450/520 03 1 2 59030036000 CYLINDER HEAD GASKET 95,3 MM 1 3* 58036052200 VALVE COVER REAR 2 4 58036053000 VALVE COVER GASKET 2 5 0015060556 HH COLLAR SCR. M6X55 WS=8 10.9 2 6 0015060453 HH COLLAR SCREW M 6X45 WS=8 2 7 0015060753 HH COLLAR SCREW M 6X75 WS=8 1 8 0015060303 HH COLLAR SCREW M 6X30 WS=8 2 9 0015060503 HH COLLAR SCREW M 6X
