525 EXC 2006
SPARE PARTS MANUAL: ENGINE
ART.NO.: 3CM089428EN
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525 EXC 2006
CRANKSHAFT, PISTON
SPECIAL TOOLS
ENGINE CASE
BLANCER SHAFT
3x
8x
4x
9x
6x
11x
15x
7x
12x
16x
CYLINDER
CARBURETTOR
CLUTCH
KICKSTARTER
TRANSMISSION I
TRANSMISSION II
SHIFTING MECHANISM
COOLING SYSTEM
13x
14x
1
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525 EXC 2006
LUBRICATING SYSTEM
VALVE DRIVE
CYLINDER HEAD
TIMING VALVE
17x
21x
x
18x
22x
19x
x
20x
x
IGNITION SYSTEM
ELECTRIC STARTER
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.
© 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of
KTM-SPORTMOTORCYCLE AG, Mattighofen only.
2
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525 EXC 2006
SPECIAL TOOLS
FIG PART NUMBER
DESCRIPTION
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1* 56012001044
UNIVERSAL MOUNTING RACK CPL.
ENGINE HOLDER FOR RACING 2000
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 02
LOCTITE 243 BLUE 6CCM
2
3
4
5
6
7
7
7
8
9
59029002000
59029020000
59029005010
51012011000
59029021044
58012015089
58012015095
59829015075
6899785
15112017000
BUSHING EXTRACTOR
10 15112018000
10 15112018100
10 15112018200
11 59029026006
12 59029035000
13 59029036000
14 59029033000
15 59029019000
16 58429037037
17 59031017200
18 58012009000
19 309098
20 51012012000
21 59029072000
26 50329050000
27 58429059000
28 59029003100
34 59029034000
35* 59029018000
INTERN.BEAR.PULLER 12-16 MM
INTERN.BEAR.PULLER 18-23 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 NJ206
MIXT. CONTROL SCREW FACTORY 04
FLYWHEEL EXTRACTOR
SILICON GASKET THREE-BOND
HOLDING SPANNER FOR SPROCKET
SPARK PLUG WRENCH 13/16
VENT INJEKTION HYDR. CLUTCH
LOCTITE 648 GREEN 24ML
CLUTCH HOLDER RACING 2004
WRENCH F.MIXTURE CONTROL SCREW
PRESS PUNCH VALVE GUIDE
065902900 / C065902900
* NEW PART
X
AS REQUIRED
3
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525 EXC 2006
ENGINE CASE
FIG PART NUMBER
DESCRIPTION
QTY
1
1
4
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
6
4
1* 59030000444
ENGINE CASE 2006
DOWEL 17 X 13 X 12
DOWEL 9,8 X 7 X 10
2
3
4
5
6
7
9
51030026100
49030090000
59030090000
0014060153
58030021000
58038022000
0908120153
HANGER FOR VENT HOSE
HH COLLAR SCREW M 6X15 WS=8
OILDRAIN PLUG W.MAG. M 12X1,5
CU-SEAL RING DIN7603-12X18X1,5
PLUG DIN0908-M12X1,5
DOWEL 17 X 19 X 12
PRESSURE SPRING L=25MM D=1MM
VALVE PISTON D=10MM
JET 60 DELLORTO M6X0,75
10 59030024000
11 58038023300
12 58038028000
13* 59030054000
17 59031050100
18 59030022100
19 58030080000
20 58030081000
21 0402025980
22 59030019000
23 58030020000
24 0770191015
26 0402040980
29 0125050003
30 0985050083
31 0015060083
33 59030001090
34 0770120020
35 59038014000
36 59038015000
37 0770090015
38 0603121830
41 59030025100
42 59030039100
43 59030001000
44* 59030047100
50 0015060453
51 0015060603
ENGINE BREATHER TUBE
00
BLEEDER FLANGE M12X1,5 WS=13
LOCATING SCREW M8 L=23
CU-SEAL RING 8 X 14 X 3
NEEDLE ROLLER DIN5402 2,5X9,8
OIL LEVEL GLASS G 1777 Y
PLUG M 24X3
O-RING 19,00X3,00 NBR
NEEDLE ROL.DIN5402 NRB 4X9,8
WASHER DIN0125-A 5,3
FLAT HEAD SCREW DIN7985-M 5X 8
HH COLLAR SCREW M 6X8 WS=8
RET.BRACKET F.BRAKE LEVER HUB
O-RING 12,00X2,00 NBR 70
PLUG M16X1,5
OIL SCREEN 11,8X44,5MM
O-RING 9X1,5 NBR
SEAL RING DIN7603 12X18X3
GASKET FOR CLUTCH COVER
ENGINE CASE GASKET NS92-24
CLUTCH COVER RACING
2000
CHAIN DAMPING PLATE RAC. 2005
HH COLLAR SCREW M 6X45 WS=8
HH COLLAR SCREW M 6X60 WS=8
065903000 / C065903000
* NEW PART
X
AS REQUIRED
4
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525 EXC 2006
ENGINE CASE
FIG PART NUMBER
52 0015060303
53 0015060353
54 0015060753
60 59030099000
DESCRIPTION
QTY
10
2
1
1
HH COLLAR SCREW M 6X30 WS=8
HH COLLAR SCREW M 6X35 WS=8
HH COLLAR SCREW M 6X75 WS=8
GASKET SET CPL. RACING 2000
065903000 / C065903000
* NEW PART
X
AS REQUIRED
5
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525 EXC 2006
BLANCER SHAFT
FIG PART NUMBER
DESCRIPTION
QTY
1
2
2
4
6
59030057044
0625160040
0760142460
BALANCER SHAFT CPL. RAC. 2001
GROOVED BALL BEAR. TM 16004 C3
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
STROKE 72MM, WITHOUT WASHER
CON.ROD REP.SET 250/520 RAC.00
WITH WASHER
1
2
59030015044
1
4
5
6
6
6
7
8
9
50330082000
59030055000
56030081000
56030081100
56030081200
0888030050
0984060162
0760304772
CYL.ROLLER BEAR.NJ206 ET2XCS46
DRIVE GEAR 32-T F.BALANC.SHAFT
THRUST WASHER 30,5X45X0,10
THRUST WASHER 30,7X47X0,15
THRUST WASHER 30,5X45X0,30
WOODRUFF KEY DIN6888-3X5X13
AH SCREW DIN7984-M 6X16
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 DIN0471-25X1,2
2
1
x
x
x
2
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
13 59032000033
15 59030029100
16 6946005
17 0760142460
18 0471250120
20 49030021000
21 0137120000
33 59030033000
34 59030074000
50 59030007000 I
50 59030007000 II
51 58030631000
52 59030032000
COLLAR NUT M12X1 R/S
SPRING WASHER DIN0137-B12
PISTON PIN BOLT 20X15,8/12X50
CIRCLIP C20X1,5
PISTON I 95MM CPL. FORGED 2000
PISTON II 95MM CPL.FORGED 2000
OIL SCRAPER RING 95MM
RECTANGULAR RING 95/87,2X1,25
065903004 / C065903011
* NEW PART
X
AS REQUIRED
7
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525 EXC 2006
CYLINDER
FIG PART NUMBER
DESCRIPTION
QTY
1
1
2
1
2
2
2
1
1
2
3
4
5
7
8
9
59030005000
59030035050
59030023000
0015060403
0015060453
0402040980
0603061001
0015060103
CYLINDER 95MM 520 RACING 2000
CYLINDER BASE GASKET 0,5MM
DOWEL 6X8X11,5
HH COLLAR SCREW M 6X40 WS=8
HH COLLAR SCREW M 6X45 WS=8
NEEDLE ROL.DIN5402 NRB 4X9,8
CU-SEAL RING DIN7603-6X10X1
HH COLLAR SCREW M 6X10 WS=8
05590306 / C065903016
* NEW PART
X
AS REQUIRED
8
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525 EXC 2006
CARBURETTOR
FIG PART NUMBER
1* 59031001300
5* 57331027044
12* 57331046100
14 57331046050
16 57331035051
18 59031029010
19 57331035000
20 59031035050
21 57331035153
22 59031035052
23 59031021000
23 59031022000
23 59031023200
23 59031034000
23 59031034400
23 59031034500
23 59031034600
24 59031029000
25 57331032000
26 59031121000
27 54531623175
27 54531623178
27 54531623180
27 54531623182
27 54531623185
28 54531607040
28 54531607042
28 54531607045
29 59031051085
30* 57331107100
32 59031017100
35 57331085000
39 57331009000
40 57331008000
42* 54631220000
43* 54531621000
DESCRIPTION
CARBURETOR FCR-MX 3900F,TPS 06
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 04
GASKET WASHER THROTTLE VALVE
JET NEEDLE KEIHIN OBDTM
JET NEEDLE KEIHIN OBDVR
JET NEEDLE KEIHIN OBDVT
JET NEEDLE KEIHIN OBDTN
JET NEEDLE KEIHIN OBDTP
JET NEEDLE KEIHIN OBDTQ
JET NEEDLE KEIHIN OBDTR
BAR CLIP
NEEDLE SET SCREW CPL.
NEEDLE JET FCR-MX
MAIN JET 175 KEIHIN
MAIN JET 178 KEIHIN
MAIN JET 180 KEIHIN
MAIN JET 182 KEIHIN
MAIN JET 185 KEIHIN
IDLE JET 40 KEIHIN
QTY
1
1
1
1
1
1
1
4
1
1
x
x
x
x
x
x
x
1
1
1
x
x
x
x
x
x
1
x
1
1
1
1
1
1
1
1
06
03
IDLE JET 42 KEIHIN
IDLE JET 45 KEIHIN
STARTER JET 85
IDLE AIR JET 100 KEIHIN
ADJUST SCREW CPL. FCR-MX
BUFFER PLATE
FLOAT CPL.
ARM PIN FLOAT
FLOAT NEEDLE
CLAMP
065903101 / C065903101
* NEW PART
X
AS REQUIRED
9
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525 EXC 2006
CARBURETTOR
FIG PART NUMBER
46 57331155000
47 57331060000
49 57331011000
53 59031059000
55 57331048000
56 57331098000
60 57331038100
61 54531699000
64 57331062000
65 57331056000
66 57331059000
67 57331159000
68* 57331038200
69 57331087000
70 57331084000
72 57331061000
79 58431082100
83 59031013044
85* 0910100003
86* 0603100141
87* 59031040300
88 59031050100
90 57331025000
96* 59031077200
99 57331099000
DESCRIPTION
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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 18X1
INTERMEDIATE LEVER CPL.
LINK LEVER
SPRING LINK LEVER
SPRING INTERMEDIATE LEVER
CARBURETOR COVER
WASHER LINK LEVER
E-CLIP
06
ROD ACCELERATOR PUMP
YDNAC-CLAMP 10173 (16MM) '98
HOSE CONNECTOR CPL.
PLUG DIN0910-M 10X1
COPPER GASKET DIN7603-10X14X1
HOSE CONNECTOR KEIHIN
ENGINE BREATHER TUBE
STOP SCREW CPL. FCR-MX
00
THROTTLE POSITION SENSOR 06
GASKET SET FCR-MX KEIHIN
065903101 / C065903101
* NEW PART
X
AS REQUIRED
10
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525 EXC 2006
CLUTCH
FIG PART NUMBER
DESCRIPTION
QTY
1* 59032000476
OUTER CLUTCH HUB 76-Z/20-Z 01
HARDED
1
2* 59032002250
INNER HUB 06
LINING DISC 2MM
INTERMEDIATE DISC 1MM 2002
PRESSURE CAP WITH OIL BORE 06
CLUTCH SPRING 2,5X43MM
SPRING RETAINER 6,2X12X18X5,2
INTERMEDIATE DISC 1,4MM 2002
PUSH ROD 7x189,6 MM
HALF-WASHER
SUPPORTWASHER 25X35X1
AH SCREW DIN6912 M6X25
NEEDLE BEAR K 25X29X10
PRIMARY GEAR 33-T
1
7
4
1
6
6
4
1
2
1
6
2
1
1
1
1
1
1
1
2
1
1
12
1
1
1
1
1
1
1
3
4
59032011100
59032010100
04
5* 59032003350
59032005000
6
7* 59032006050
8* 59032010200
10* 59032054200
11 59032007000
12 59032017000
13 0984060252
14 0405252910
15 59032000033
16 59032061044
17 0770300015
18 50329050000
19 59032066000
20 54732064000
21 0015060353
22 0015060203
23 59032009000
24 59032065000
26* 59032004300
27 0993012000
28 54637098200
29 54637097200
30 50332054051
31 0936181505
32 56532018000
33 59032062000
06
03
OUTPUT CYLINDER CPL. 2003
O-RING 30,00X1,50 NBR 70
VENT INJEKTION HYDR. CLUTCH
PISTON WITH O-RING AND BALL 03
BLEEDER SCREW WITH CAP
HH COLLAR SCREW M 6X35 WS=8
HH COLLAR SCREW M 6X20 WS=8
STEPPED WASHER
03
GASKET FOR SLAVE CYLINDER
DRIVING SLEEVE D=8, L=33 06
CIRCLIP DIN7993-RW12
AXIAL WASHER AS1226 12X26X1
AXIAL NEEDLE BEARING AXK 1226
PRESSURE PIECE 125-380 '98
HEXAGON NUT DIN0936-M18X1,5 R.
LOCK WASHER
HOLLOW SCREW HYDR. CLUTCH CPL.
065903200 / C065903200
* NEW PART
X
AS REQUIRED
11
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525 EXC 2006
KICKSTARTER
FIG PART NUMBER
DESCRIPTION
QTY
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
3
4
5
6
7
9
54833070044
54610052000
54633037000
0760193070
59033055000
59033051039
0471170010
0988172405
KICKSTARTER CPL.
'03
SPROCKET SCREW-AH M8X20 WS=6
WASHER 8MM GALVANIZED
SHAFT SEAL RING 19X30X7 B
DRIVING HUB
KICKSTARTER GEAR 39-T
CIRCLIP DIN0471-17X1
SHIM WASHER DIN0988-17X24X0,5
INTERMEDIATE GEAR 24-T
KICKSTARTER SPRING
10 59033053000
12 59033054000
13 59033074000
14 0015060123
15 59033080000
16 0471190120
17 0405222610
18 59033069000
19 58033031000
20 58033028000
21 59033052000
23 0015060203
24 59033050000
SPRING HANGER
HH COLLAR SCREW M 6X12 WS=8
SHIM 20X32X1
CIRCLIP DIN0471-19X1,2
NEEDLE BEARING K 22X26X10 A
BUMP PART
STOP DISK 22,2 X 30 X 1,5
RATCHET GEAR SPRING 1,2 MM
RATCHET GEAR KICKSTARTER
HH COLLAR SCREW M 6X20 WS=8
KICKSTARTER SHAFT RACING 2000
05590330 / C065903300
* NEW PART
X
AS REQUIRED
12
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525 EXC 2006
TRANSMISSION I
FIG PART NUMBER
DESCRIPTION
MAIN SHAFT-ZB 14-T
IDLER GEAR 5.G 24-T "34"
NEEDLE BEAR. K 22X26X13 TN
STOP DISC 25,2X32X1,5
SLIDING GEAR 3/4.G 19/22-T"32"
CIRCLIP DIN0471-25X1,2
STOP DISC 25,2X32X1,5
IDLER GEAR 6.G 26-T "35"
SOLID GEAR 2.G 17-T "21"
STOP DISC 17,2X30X1
BALL BEARING 6203 JR2 C3
BALL BEARING 6205 C3 NTN
QTY
1
1
2
1
1
2
1
1
1
1
1
1
1
2
3
4
5
6
7
9
59033001400
59033005034
0405222613
59033031000
59033003032
0471250120
59033030000
59033006035
03
10 59033002021
11 56033030000
12 0625062035
13 0625062054
05590333 / C065903301
* NEW PART
X
AS REQUIRED
13
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525 EXC 2006
TRANSMISSION II
FIG PART NUMBER
DESCRIPTION
QTY
1
1
3
1
3
1
2
1
1
1
1
1
1
1
1
x
x
x
1
1
1
1
1
1
2
3
4
5
6
8
9
59033010000
59033012025
0405222611
59033031000
0471250120
59033016026
59033030000
59033014033
COUNTER SHAFT RACING 2000
IDLER GEAR 2.G 31-T "25"
NEEDLE BEAR.K 22X26X10 DIVIDED
STOP DISC 25,2X32X1,5
CIRCLIP DIN0471-25X1,2
SLIDING GEAR 6.G 21-T "26"
STOP DISC 25,2X32X1,5
IDLER GEAR 4.G 26-T "33"
IDLER GEAR 3.G 28-T "28"
SLIDING GEAR 5.G 23-T "29"
SHIM 20X32X1
NEEDLE BEARING K 20X26X12
IDLER GEAR 1.G 34-T "30"
STOP DISC 17,2X30X1
SPACER BUSHING 12MM
SPROCKET 13-T
SPROCKET 14-T
SPROCKET 15-T
SCREW+SPRING WASHER
O-RING 25,12X1,78 NBR70
BALL BEARING 6203 JR2 C3
CYL.ROLL BEARING NJ205
SHAFT SEAL RING 32X45X7 BSLNBR
10 59033013028
13 59033015029
14 59033080000
15 0405202612
16 59033011030
17 56033030000
18 54633014100
20 50033029013
20 50033029014
20 50033029015
22 59033034044
25 0770020220
30 0625062035
31 49030023000
32 0760324571
05590336 / C065903302
* NEW PART
X
AS REQUIRED
14
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525 EXC 2006
SHIFTING MECHANISM
FIG PART NUMBER
DESCRIPTION
QTY
1
1
1
1
2
1
1
1
1
1
1
1
4
3
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
2
3
4
5
6
7
8
9
59034031000
0933060165
50232050001
0760142460
54632095000
59034002000
59034005044
59034003000
54634050000
SHIFTING LEVER CPL.RACING 2000
HH SCREW DIN0933-M 6X16 10.9
STEEL WASHER 6,4X17X3
SHAFT SEAL RING 14X24X6 B
NEEDLE BEAR.HK 1412 14X20X12
SHIFT FORK 2./4.GEAR 2000
SHIFT SHAFT CPL. RACING '03
SHIFT FORK 1./3.GEAR 2000
STOP DISK 14X30X1
RETURN SPRING 2,2MM '95
TENSIONING SPRING 0,8MM
SHIFT RAIL 11,8X105MM
PRESSURE SPRING 0,9MM
SHIFTING ROLLER 6X8X5,2
SHIFT LOCATING DRUM ALU CPL.00
SLIDING PLATE CPL.
AH SCREW DIN6912 M 6X30
BALL BEARING 61805 C3
LOCKING LEVER CPL '96
HH COLLAR SCREW M 5X20 WS=8
SLEEVE FOR LOCKING LEVER
SPRING 2,3MM
SHIFT RAIL 11,8X89MM
SHIFT FORK 5./6.GEAR 2000
SHIFTROLLER 6-GEAR
10 54634014100
12 56534013100
13 59034020000
14 58038023200
15 50334018100
16 59034015044
17 54634008044
18 0984060302
19 0625618050
20 54634024144
21 0015050203
22 54634052300
23 59034023000
24 59034019000
25 59034001000
26 59034012000
27 54634020000
28 0349000050
29 50233041000
30 0985050083
31 0125050003
SPRING GUIDE
WASHER DIN7349-5X15X2
PAIR OF WASHERS M 6 NORDLOCK
FLAT HEAD SCREW DIN7985-M 5X 8
WASHER DIN0125-A 5,3
065903400 / C065903400
* NEW PART
X
AS REQUIRED
15
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525 EXC 2006
COOLING SYSTEM
FIG PART NUMBER
DESCRIPTION
RADIATOR L/S 45.407
RADIATOR R/S 45.409
RADIATOR HOSE L/S RAD.-CYL. 03
RADIATOR HOSE R/S RAD.-CYL. 03
HOSE ID 7,5 PER METER
RADIATOR HOSE RAD.-THERMOS. 04
RADIATOR HOSE SECONDARY 04
RADIATOR-THERMOSTAT
QTY
1
1
1
1
1
2
1
1
2
3
4
5
6
7
59035007300
59035008400
59035024100
59035124100
54435024001
59035126100
59035025101
03
03
8
9
59035025100
59435017000
RADIATOR HOSE THERMOS.-HEAD 04
1
1
1
3
1
10
2
2
4
4
4
1
1
x
2
1
1
x
x
x
THERMOSTAT 70 DEGREES
04
10 0770320020
11 0016040183
12 59435013044
13 10001020000
14 58335099000
15 50231005000
16 0015060123
17 0021060003
18 41001052000
19 31007107001
20 59035009000
22 5903504000004
22 5903504000030
30 58035045000
31 0603142015
40 58435041000
41 59035044000
44 58435044050
45 0081500181
46 0017060203
47 59035041044
60 59011079000
61 58011109105
O-RING 32,00X2,00
SCREW FOR PLASTIC D=4X18
THERMOSTAT CPL. 70 DEGREES 04
HOSE CLAMP GEMI 16-27
HOSE CLAMP GEMI 10-16
HOSE CLAMP YDNAC 10119 11MM
HH COLLAR SCREW M 6X12 WS=8
WASHER DIN9021-A 6,4
RUBBER SLEEVE D=12MM
PVC-HOSE 6X9 MM PER METER
RADIAT.CAP 20,3PSI (1,4BAR) 03
RADIAT. PROTECT.RAC. ORANGE 03
RADIAT. PROTECT. RAC. BLACK 06
THERMOSWITCH 80-85 DG '94
ALU SEALRING DIN7603-14X20X1,5
FAN CPL. 12V LC4
FAN CAP
2000
2001
FAN FLAP RUBBER LC4
2000
SCREW FOR PLASTIC D=5X18
EJOT PT SCREW K60X20 WS=6
x
x
x
x
FAN CPL. RACING
FAN WIRING HARNESS
2001
2001
FUSE 5 A
2003
x
065903500 / C065903500
* NEW PART
X
AS REQUIRED
16
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525 EXC 2006
VALVE DRIVE
FIG PART NUMBER
DESCRIPTION
QTY
2
2
4
4
1
2
3
6
9
59036030000
59036031000
59036027000
59036028244
59036033000
INTAKE VALVE D=35MM
EXHAUST VALVE D=30MM
VALVE-STEM SEALING RACING
VALVE SPRING KIT (1X)RAC. 2001
VALVE COLLET KK 6 H
8
10 59036062000
11 59036062100
13 59036056000
14 59036057000
15 59036061095
16 0770191016
17 59036060010
18 0912050083
19 59036050000
20 0770051016
22 59036059000
23 0471080000
30 59036060144
31 59036061144
ADJUSTMENT SCREW M6X0,75
NUT M6X0,75
ROCKER ARM SHAFT INTAKE
ROCKER ARM SHAFT EXHAUST
END CAP ROCKER ARM SHAFT
O-RING 19,10X1,60 NBR 70
SHIM ALU 5,2X10X2
AH SCREW DIN 912 M 5X8
DECOMPRESSION SHAFT CPL.
O-RING 5,10X1,60 NBR 70
DECOMPRESSION LEVER SPRING
CIRCLIP DIN0471- 8X0,8
ROCKER ARM INTAKE CPL.
ROCKER ARM EXHAUST CPL.
4
4
1
1
2
2
2
2
1
1
1
1
1
1
05590363 / C065903601
* NEW PART
X
AS REQUIRED
17
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525 EXC 2006
CYLINDER HEAD
FIG PART NUMBER
DESCRIPTION
QTY
1
1
1
2
59036020144
59030036000
CYLINDER HEAD CPL.450/520 03
CYLINDER HEAD GASKET 95,3 MM
VALVE COVER REAR
3* 58036052200
2
4
5
6
7
8
9
58036053000
0015060556
0015060453
0015060753
0015060303
0015060503
VALVE COVER GASKET
2
2
2
1
2
1
2
2
1
2
1
1
10
9
3
2
HH COLLAR SCR. M6X55 WS=8 10.9
HH COLLAR SCREW M 6X45 WS=8
HH COLLAR SCREW M 6X75 WS=8
HH COLLAR SCREW M 6X30 WS=8
HH COLLAR SCREW M 6X50 WS=8
VALVE GUIDE INTAKE
10* 59036025101
11* 59036026101
12* 77036044000
13 59030061000
15 59436039000
16 59036041000
17 0015060203
18 0603061001
19 0015060163
21 59030023000
30 59036006090
31 58036065100
35 59036090000
40 59035052000
41 59035053000
43 59036079000
VALVE GUIDE EXHAUST
INTAKE BOOT
06
CLAMP D=56MM B=9MM M4X25
EXHAUST FLANGE CPL. 450/525 03
GASKET EXHAUST FLANGE
HH COLLAR SCREW M 6X20 WS=8
CU-SEAL RING DIN7603-6X10X1
HH COLLAR SCREW M 6X16 WS=8
DOWEL 6X8X11,5
VENT SCREW M6X10 CPL.
CU-SEAL RING 6 X 10 X 2
WASHER 10,8X18,8X1,5
1
1
4
1
1
4
WATER PUMP COVER RACING 2000
WATER PUMP COVER GASKET 0,8MM
CYL. HEAD SCREW M10X158 WS=13
065903600 / C065903606
* NEW PART
X
AS REQUIRED
18
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525 EXC 2006
TIMING VALVE
FIG PART NUMBER
DESCRIPTION
QTY
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
2
1
1
2
1
1
1
2
1
1
1
1
1
3
4
5
6
7
8
9
59036013000
59036001000
59036018000
59036014000
59036002000
59036003050
59036003000
59036001050
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 6,1X8,2X13,1
HH COLLAR SCREW M 6X20 WS=8
HH COLLAR SCREW M 5X16 WS=8
SUPPORTING SLEEVE 5,2X7X10X7,7
CU-SEAL RING DIN7603-6X10X1
HH COLLAR SCREW M 6X25 WS=8
CAMSHAFT 590/5521
CAMSHAFT GEAR
AUTO DECOMPRESSION SHAFT
AH SCREW DIN7984-M 8X10
WASHER 26,7X34X1,3
GASKET SUPPORT
BALL BEARING 6201
SPRING FOR AUTODECOMPRESSION
O-RING 29,10X1,60 NBR 70
O-RING 25,12X1,78 NBR70
SHAFT SEAL RING 10X18X4 BSL
RIVET LINK FOR TIMING CHAIN
NEEDLE ROL.DIN5402 NRB 3X17,8
WATER PUMP WHEEL CPL. RAC.2001
CIRCLIP DIN0471-10X1
10 0015060203
11 0015050163
12 59036018050
15 0603061001
16 0015060253
24 59036010000
26 59036011100
27 59036016000
29 0984080103
32 59036082000
33 59036081100
34 0625062014
35 59036017000
37 0770291016
38 0770020220
40 0760101843
41 59036013050
43 0402031780
44 59035055144
45 0471100010
2000
2003
065903602 / C065903611
* NEW PART
X
AS REQUIRED
19
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525 EXC 2006
LUBRICATING SYSTEM
FIG PART NUMBER
DESCRIPTION
QTY
1
1
1
1
1
1
6
2
2
1
1
1
2
1
1
4
1
2
1
1
2
1
1
1
1
1
2
3
4
5
6
7
8
59038002000
59038011010
59038011012
58438001000
59038004000
59038003000
0015050163
0984050122
OIL PUMP SHAFT
OILPUMP ROTOR CPL. 10MM G-73R
OILPUMP ROTOR 12MM G-95R/003
OIL PUMP GEAR 26-T
OIL PUMP COVER L/S
OIL PUMP COVER R/S 8MM
HH COLLAR SCREW M 5X16 WS=8
AH SCREW DIN6912-M 5X12
OIL FILTER COVER RACING
OIL FILTER LONG
11 59038041000
12* 58038005100
13* 59038046100
14 0402251980
15 0402251180
16 58038030000
17 59038029000
18 0603082121
19 59038035000
20 0770400025
21 59038017000
22 59038016000
23 0770125015
24 0770020170
25 58038007755
26 0799060000
27 58405098000
OIL FILTER SHORT
NEEDLEROL.DIN5402 NRA 2,5X19,8
NEEDLE ROLLER DIN5402 2,5X11,8
BANJO BOLT M8 X 1 DIN7643
JET SCREW "100" M8X1 WS=12
SEAL RING CU DIN7603- 8X12X1
OIL LINE STEEL CASE-CYL.HEAD
O-RING 40,00X2,50 NBR 70
PLUG M20X1,5 WS=13
OIL SCREEN 15X83MM
O-RING 12,5X1,5 NBR
O-RING 17,17X1,78 GLO
STOP DISK 8,1 X 15 X 0,5
TAB WASHER DIN6799-RS 6,0
RUBBERBUFFER 8X17X10 SILENC'97
05590380 / C065903800
* NEW PART
X
AS REQUIRED
20
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525 EXC 2006
IGNITION SYSTEM
FIG PART NUMBER
DESCRIPTION
IGNITION COVER 4K3B
QTY
1
1
1
1
1
1
1
1
1
1
1
1
x
2
2
2
2
2
2
2
1
2
59030002000
59030040000
2000
IGNITION COVER GASKET 0,8MM
STATOR 4-K3-B 05
FLYWHEEL 4K3B RACING 2004
PULSER COIL KOKUSAN 4K3-A/B
CDI UNIT 400/525 EXC 2005
SPARK PLUG CONNECT. VD05EG 03
SPARK PLUG NGK DCPR8E
SUPPORT FOR WIRE
CYL.HEAD SCREW DIN0084-M 4X 6A
WIRING HARNESS FOR CDI EXC 04
IGNITIONCOIL KOKUSAN 4K3-A/B
CABLE TIE 100/2,5MM BLACK
3* 59039104200
4
5
6
8
9
59039105200
59039034000
59039031500
59039090100
59039093100
03
10 59030002050
11 0084040063
12 59439032100
16 59039006000
20 44011076100
29 49030090000
30 0015060353
31 0015060303
32 0015060203
34 0015050163
35 0014060103
36 0015060163
DOWEL 9,8 X 7 X 10
HH COLLAR SCREW M 6X35 WS=8
HH COLLAR SCREW M 6X30 WS=8
HH COLLAR SCREW M 6X20 WS=8
HH COLLAR SCREW M 5X16 WS=8
HH COLLAR SCREW M 6X10 WS=8
HH COLLAR SCREW M 6X16 WS=8
065903900 / C065903900
* NEW PART
X
AS REQUIRED
21
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525 EXC 2006
ELECTRIC STARTER
FIG PART NUMBER
59040001000
2* 59040022258
DESCRIPTION
E-STARTER ENGINE KPL. 0,45 KW
GEAR WHEEL
QTY
1
1
1
3
4
54633090000
0471170010
STOP DISK 17,2X25X1
CIRCLIP DIN0471-17X1
TORQUE LIMITER
NEEDLE BEARING K 10X13X10 02
BEARING BOLT
1
1
1
2
5* 59040016000
8* 0405101310
9
06
59040029000
1
10 59040025000
11 0912060106
12 0618301617
13 58440026000
14* 59040020175
15 0015060203
16 0770250030
17 59040034000
18 0015060123
19 0125060003
FREE WHEEL HUB
1
6
1
1
1
2
1
1
AH SCREW DIN0912-M 6X10 10.9
NEEDLE BEARING HK 3016 B
FREE-WHEEL FWD 332008 BLS
FREEWHEEL GEAR
HH COLLAR SCREW M 6X20 WS=8
O-RING 25,00X3,00 NBR 70
CAP COVER
HH COLLAR SCREW M 6X12 WS=8
WASHER DIN0125-A 6,4
1
1
065904000 / C065904000
* NEW PART
X
AS REQUIRED
22
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525 EXC 2006
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525 EXC 2006
Download from Www.Somanuals.com. All Manuals Search And Download.
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*3CM089428EN*
KTM Group Partner
3CM089428EN
KTM-Sportmotorcycle AG
A-5230 Mattighofen
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