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KTM 525 EXC 2006 manual

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Table of contents for the manual

  • Page 1

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

  • Page 2

    [...]

  • Page 3

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

  • Page 4

    INDEX 525 EXC 2006 VALVE DRIVE 17 x CYLINDER HEAD 18 x TIMING VALVE 19 x LUBRICATING SYSTEM 20 x IGNITION SYSTEM 21 x ELECTRIC STARTER 22 x x x x All information contained is without obligation. KTM-Sportmotorcy cle AG particularly reserves the right to modify any equipment , technical specifications, prices, colors, shapes, materials, services, se[...]

  • Page 5

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1* 56012001044 UNIVERSAL MOUNTING RACK CPL. 1 2 59029002000 ENGINE HOLDER FOR RA CING 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=89 MM 1[...]

  • Page 6

    525 EXC 2006 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-M[...]

  • Page 7

    525 EXC 2006 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 ENGINE CASE[...]

  • Page 8

    525 EXC 2006 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 BLANCER SHAFT[...]

  • Page 9

    525 EXC 2006 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.0 0 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 30,7X[...]

  • Page 10

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59030005000 CYLINDER 95MM 520 RACI NG 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 0015060[...]

  • Page 11

    525 EXC 2006 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 590310350[...]

  • Page 12

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 46 57331155000 DRAIN SCREW FLOAT CHAM BER 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 KEIHI N CPL. 1 60 57331038100 SCREW F. COVER KEIHIN 1 61 54531699000 PLUG M 18X1 1[...]

  • Page 13

    525 EXC 2006 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* 5903201[...]

  • Page 14

    525 EXC 2006 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 DIN0988-17X[...]

  • Page 15

    525 EXC 2006 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 [...]

  • Page 16

    525 EXC 2006 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 [...]

  • Page 17

    525 EXC 2006 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[...]

  • Page 18

    525 EXC 2006 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 0 4 1 RADI[...]

  • Page 19

    525 EXC 2006 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 INTA[...]

  • Page 20

    525 EXC 2006 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[...]

  • Page 21

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59036013000 TIMING CHAIN 96 ROLLS 1 3 59036001000 TIMING CHAIN GUIDE RACING 1 4 59036018000 SECURING GUIDE RACI NG 1 5 59036014000 TIMING GEAR 18-T 1 6 59036002000 TIMING CHAIN TENSIONER 1 7 59036003050 GASKET TIMING CHAIN TENSIONER 1 8 59036003000 TIMINGCHAIN TENSIONER CP L.RAC. 1 9 59036001050 SPACER[...]

  • Page 22

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59038002000 OIL PUMP SHAFT 1 2 59038011010 OILPUMP ROTOR CPL. 10MM G-73 R 1 3 59038011012 OILPUMP ROTOR 12MM G-95R/003 1 4 58438001000 OIL PUMP GEAR 26-T 1 5 59038004000 OIL PUMP COVER L/S 1 6 59038003000 OIL PUMP COVER R/S 8MM 1 7 0015050163 HH COLLAR SCREW M 5X16 WS= 8 6 8 0984050122 AH SCREW DIN6912[...]

  • Page 23

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59030002000 IGNITION COVER 4K3B 2000 1 2 59030040000 IGNITION COVER GASKET 0,8MM 1 3* 59039104200 STATOR 4-K3-B 05 1 4 59039105200 FLYWHEEL 4K3B RACING 2004 1 5 59039034000 PULSER COIL KOKUSAN 4K3-A/B 1 6 59039031500 CDI UNIT 400/525 EXC 2005 1 8 59039090100 SPARK PLUG CONNECT. VD05EG 03 1 9 5903909310[...]

  • Page 24

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59040001000 E-STARTER ENGINE KPL. 0,45 KW 1 2* 59040022258 GEAR WHEEL 1 3 54633090000 STOP DISK 17,2X25X1 1 4 0471170010 CIRCLIP DIN0471-17X1 1 5* 59040016000 TORQUE LIMITER 06 1 8* 0405101310 NEEDLE BEARING K 10X13X10 02 2 9 59040029000 BEARING BOLT 1 10 59040025000 FREE WHEEL HUB 1 11 0912060106 AH S[...]

  • Page 25

    NOTICE 525 EXC 2006[...]

  • Page 26

    NOTICE 525 EXC 2006[...]

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    [...]

  • Page 28

    KTM-Sportmotorcycle AG A-5230 Mattighofen www.ktm.at Art.Nr.: 3CM089428EN 6/2005 KTM Group Partner *3CM089428EN* 3CM089428EN[...]