KTM 525 EXC 2006- Manuals

Page 3 - INDEX

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 5 - SPECIAL

525 EXC 2006 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....

Page 6 - ENGINE

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 RIN...

Page 8 - BLANCER SHAFT

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 - PISTON

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.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...

Page 10 - CYLINDER

525 EXC 2006 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 8 060...

Page 11 - CARBURETTOR

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...

Page 13 - CLUTCH

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* 5903...

Page 14 - KICKSTARTER

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...

Page 15 - TRANSMISSION

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...

Page 17 - SHIFTING MECHANISM

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 ...

Page 18 - COOLING SYSTEM

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 ...

Page 19 - VALVE

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 ...

Page 20 - CYLINDER HEAD

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 00150...

Page 21 - TIMING

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 RACING 1 5 59036014000 TIMING GEAR 18-T 1 6 59036002000 TIMING CHAIN TENSIONER 1 7 59036003050 GASKET TIMING CHAIN TENSIONER 1 8 59036003000 TIMIN...

Page 22 - LUBRICATING

525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59038002000 OIL PUMP SHAFT 1 2 59038011010 OILPUMP ROTOR CPL. 10MM G-73R 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 S...

Page 23 - IGNITION SYSTEM

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 590390...

Page 24 - ELECTRIC STARTER

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 ...

Page 25 - NOTICE