250 XCF-W SIX DAYS USA 2011
SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF8175K9EN

ENGLISH
FRONT FORK DISSASSEMBLED HANDLEBAR, CONTROLS SIDE / CENTER STAND

TELEGABEL, GABELBRCKE

FRAME SHOCK ABSORBER DISASSEMBLED

SHOCK ABSORBER

SWING ARM
EXHAUST SYSTEM AIR FILTER

TANK, SEAT, COVERS

MASKE, KOTFLGEL
FRONT WHEEL REAR WHEEL WIRING HARNESS
BRAKE CALIPER FRONT HAND BRAKE CYLINDER

REAR BREAK CONTROL

BREAK CALIPER REAR
LIGHTING SYSTEM INSTRUMENTE / SCHLOSSSYSTEM

ACCESSORIES KIT

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 KTMSPORTMOTORCYCLE AG, Mattighofen only.
FIG 84 85* 92* PART NUMBER 14187J0025080356 0025080256S 7800109410028
DESCRIPTION FORK KTM 250/300 EXC/F/W 2010 HH COLLAR SCREW M8X25 TX40 HH COLLAR SCREW M8X35 TX40 HH COLLAR SCREW M8X25 TX40 AH SCREW DIN6912-M10X35 10.9 O-RING 25X3,55 NBREJOT PT SCREW K60X20 ALU WS=6 BOT. TRI. CLAMP CPL. X=19MM 09 TOP TRIPLE CLAMP D=54MM 09 STEER.HEAD SCREW M20X1,5 WS=27 HANDLEBAR CLAMP 28MM 05 HANDLEB.SUPP. D=28MM H=37MM 05 TAPERED ROLLER BEARING CPL. 06 O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F. SPEED. CABLE D=6MM 08 STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS=8 FORK PROTECT. L/S+R/S WHITE 09 QTY 1

095230110 / C115480113

* NEW PART

X AS REQUIRED

FRONT FORK DISSASSEMBLED
FIG 57 PART NUMBER 48600812S 48600557S 91410012S 91410013S 91410014S 91410015S 91410016S 91410017S 48600762S 40540486 48600764
DESCRIPTION ADJUSTING KNOB + SCREW VENT SCREW M4X8 O-RING NBR 3,7X1,6 OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING 08 DU-BUSH D48XD52X12DDL02 SUPPORT RING 50 X 57,6 X 1,5 OIL SEAL RING 48X57,8X9,LOCK WASHER SB58 DUST CAP D=48 58,4X11,8 DU-BUSH D47XD49X20DDL02 HYDR.STOP L=200 D=31,9 CPL. 07 ADJUSTING TUBE L=PISTON ROD D=12 L=554 ALU ADJUSTER NEEDLE 07 O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM WASHER 32X42X2,5 SPRING 3,8N/MM SET D=4,9MM SPRING 4,0N/MM SET D=5,0MM SPRING 4,2N/MM SET D=5,0MM SPRING 4,4N/MM SET D=5,1MM SPRING 4,6N/MM SET SPRING 4,8N/MM SET INTERM. RING 26,2 X 43 X 3 GUIDING BUSH REBOUND SPRING SCREW SLEEVE M27X,08 L=100 KPL O-RING 6X1,2 NBR REBOUND SPRING L=32 C=17 PISTON ROD REBOUND SHUTTLE VALVE SPRING C=0,4 PISTON RING 5X1X68 PISTON REBOUND SX 2007 NUT M6X0,5 REBOUND ADAPTER SLEEVE D23/D28 QTY x x x x x x 2

095030130 / C117800130

FIG 99 PART NUMBER 48600860SA 48600861S48600586S 48600141 48600765S1 48600431S48600053 T511 R14016
DESCRIPTION PIPE D23/LO-RING NBR 46 X 2 AXLE CLAMP L/S + TUBE CPL. AXLE CLAMP R/S + TUBE CPL. 09 HH COLLAR SCREW M8X25 TX40 CHECK VALVE NUT M6X0,5 D=2 SPRING CHECK VALVE D=0,7 TAP COMPRESSION CPL. 07 PISTON COMPRESSION D=27,9 O-RING NBR 21X2 O-RING NBR 24X2 COPPER WASHER 29,5X33,5X1 RUBBER CAP D=35MM FORK OIL SAE5 5L 2008 PRE-LOAD ADJ. M51X1,SPACER 42X26,5X10 SPACER 42X26,5X5 SPACER 42X26,5X2,5 SPACER 42X26,5X1,5 SILICONE GREASE F. DUST STRI REPAIR-KIT EXC FRONT FORK 2009 QTY 1

HANDLEBAR, CONTROLS

FIG 1 2* 92 PART NUMBER 77002091000
DESCRIPTION HANDLEBAR NEKEN D=28MM EXC 07 BAR PAD CPL. SHORT CIRCUIT BUTTON 02 HOSE 7X11,5X15 THROTTLE GRIP CPL. 4-ST. 09 CABLE TIE 300/4,8MM BLACK GRIP-SET GRAY/ORANGE 09 CABLE TIE 14072,5MM BLACK CABLE TIE 200/3,6MM BLACK SPACER BUSHING 6X10X5 HAND GUARDS CPL.L/S+R/S OR. 06 MASTER CYLINDER CPL. 06 CLUTCH LEVER CPL. BREMBO 06 REP. KIT PISTON 06 COVER HYD. CLUTCH CPL. VALVE BOLT KPL. BRAKE FLUID DOT5.1 0,25L PROTECTION CAP 06 LEVER SCREW CPL. 06 PUSH ROD CPL. CLAMP CPL. 06 CLUTCH PIPE 06 STARTER CONTROL 04 THROTTLE CABLE 250 SXF 2005 QTY 1 x 1 x x 1 1

117800214 / C117800214

SIDE / CENTER STAND
FIG 29 PART NUMBER 0019080266S 78003023055 50303018000
DESCRIPTION SIDE STAND CPL. 08 SCREW M5X14 TORX SPRING BRACKET F. SIDE ST. 08 SIDE STAND BUSHING EXC USA 08 O-RING 18,00X2,00 NBR 70 SPACER BUSH. SPRING BRACKET SIDE STAND SPRING EYE MOVEABLE ONLY FOR EXC SIDE STAND STOP SCREW M10X12 COUNTER-SUNK SCREW ISA45 M8X26 HH COLLAR SCREW M8X30 TX40 ONLY FOR EU O-RING 12,00X2,00 NBR 70 WASHER F. SIDE STAND 12,2X29,5 O-RING 12,5X1,5 NBR SIDE STAND BUSHING EXC-EU 08 ONLY FOR EU SIDE STAND SPRING 08 ONLY FOR XC STAND BASE RUBBER L=145MM QTY 1

085230360 / C105230360

FIG 64 PART NUMBER 0019080206S 77303094100 77303053010
DESCRIPTION FRAME ORANGE "GB08" SUB FRAME SX "Q7" 07 SUB FRAME APPLICATION LEFT 08 SUB FRAME APPLICATION RIGHT 08 REINFORCING B. 250 SX-F 09 ADH. FOIL TRANSP. 80X80 MM 04 SPECIAL SCREW M8X26 WS=10 HEXAGON NUT DIN0934-M 8 WASHER 8,5X18X1 INOX ENGINE BRAC.SCR. M10X105 WS=13 FLAT HEAD SCREW M. ISA45 M8X20 COLLAR SCREW M8X42 WS=13 10.9 BLIND PLUG-IN NUT M5 WN 22A 03 CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X25 BUSH F. FRAME PROTECTION 03 PLASTIC CAP SFL10 SELF LOCKING NUT M8 10.9 SELF LOCKING NUT M10 CU WS=14 HH COLLAR SCREW M8X30 TX40 HH COLLAR SCREW M6X40 TX30 FOOTREST L/S 08 FOOTREST R/S 08 BOLT FOR FOOT PED 03 FOOTREST SPRING L/S & R/S WASHER DIN0125-A10,5 PIN DIN0094-3,2X25 STEEL FOOTREST L/S + R/S CPL. 09 ANGLE PIECE '97 PVC-HOSE 7X10 PER METER SPROCKET COVER 250 SX-F 07 CHAIN SLIDING PIECE BELOW 07 BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET CHAIN SLIDING P. BELOW CPL. 07 QTY 1 x 1

097800313 / C117800314

SHOCK ABSORBER DISASSEMBLED
FIG 8 12* 81 PART NUMBER 50180733S4 50180213SR50180520S 91210053S 91210054S 91210068S 91210069S 91210070S 50180273 50180463S 50180603S 50180604 50180605S 50180606
DESCRIPTION TOP PART CPL. M57,5X1 H30,DCC-COMPR.DAMP.CONTROL CPL. 07 ADAPTOR BUSH KGW 12X24 REP. KIT BEAR./SEAL UP. 07 BLEED PLUG R 1/8 WP CAUTION (PDS KTM) O-RING NBR 5,28X1,78 SCREW PLUG M5X6 RUBBER CAP "DO NOT OPEN" SPRING RETAINER M57,5X1 +SCREW AH SCREW M5X30 DIN912 INTERM.RING SCREW SPRING RET. SPRING 250 63N/MM ORANGE SPRING 250 66N/MM ORANGE SPRING 250 69N/MM ORANGE SPRING 250 72N/MM ORANGE SPRING 250 76N/MM CIRCLIP 58,2X2 SPRING RET. D=80 W. O-RING 05 O-RING VITON 66,27X3,53 PISTON ROD NUT M20X1 O-RING VITON 44,17X1,78 PISTON RING 50-8 PISTON D=20 TAP D20 M20X1 L45,REBOUND DISC D43 H0 T4 PISTON 6+6X7/4,5 ADAPTOR CPL. D=50 H=STEEL DISC 18X,5X43,7X6 REBOUND RUBBER SHIM D29,75 X D19 X T0,SEAL D18X30XO-RING 41X5 DU-BUSH 18X20X12 DUST SEAL QTY x x x x x 1 1

095030430 / C105030430

FIG PART NUMBER 50180600 50180512S50180434S 50180342S1 R12015
DESCRIPTION CIRCLIP 53X1,75 RESERVOIR CAP D=50 H=BUMP RUBBER D58 D17 HSHOCK ABS. LOWER PART CPL. 09 THREADED BUSH M12 PDS RUBBER PLUG D=8 STEEL BALL D=3MM SPRING D=2,9 L=7,9 O-RING NBR 4X1,5 ADJUSTING SCREW REBOUND TRAVEL SHOCK ABSORBER FLUID 5 LT '03 REPAIR KIT 5018 PDS 08 QTY 1 1

FIG PART NUMBER 0025120506S 12187J0401
DESCRIPTION HH COLLAR SCREW M12X50 TX45 MONOSH. PDS B07MA250/300EXC 10 QTY 2 1

085030410 / C105480414

FIG 12 14* 17 18* PART NUMBER 54603055051 54804230210
DESCRIPTION SWINGARM CPL. 07 CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR.07 SPECIAL SCREW M 5,0X10 BRAKE HOSE GUIDE LOWER 07 SPECIAL SCREW M6X13 WS=8 10.9 BUCKET F. SHAFT SEAL RING 03 SHAFT SEAL RING 25X32X7 BUSHING SLEEVE F. SWING ARM 03 NEEDLE BEARING HK 2216 STOP DISK 22,2X31,7X1 CHAIN GUIDE CPL. SPECIAL SCREW M6X19 WS=8 10.9 HH COLLAR SCREW M6X45 TX30 BUSH. F. CHAIN FAIL. PROT. 07 PIVOT BEARING + BUSH.PDS 11 TOOL BEARING MOUNTING PDS PLUG SFL13 SWINGARM BOLT M16X1,SELF LOCK.NUT M16X1,5 WS=CLOSING COVER ROUND 03 CHAIN GUARD CPL. 06 PRESS IN NUT M6 STEEL ZINC SWINGARM REPAIR KIT 05-10 QTY 1 x

085030490 / C117800492

EXHAUST SYSTEM
FIG PART NUMBER 0025080256 59405069000
DESCRIPTION EXHAUST SILENCER SPARKY XCF-W THERMAL PROTECTION FOIL 07 SILENCER HOUSING XC-F USA 08 SIL. CONNECT. CAP CPL.EXC-F 07 SPRING WASHER DIN0137-B 6 BUSHING 7.5x12x28x7.EXHAUST BRACKET RUBBER BLACK HH COLLAR SCREW M6X30 TX30 THROTTLE ELEMENT CPL. EXC 07 SIL. ELEMENT EXC-F 07 TEN.SPRING L=62MM EY.MOVEABLE SCREW TORX M5XENDCAP SPARKY ATV 08 STUFFINGYARN 315 GRAMS STUFFING YARN EXC-F 07 EXHAUST MANIFOLD 250 EXC-F 07 HH COLLAR SCREW M8X25 TX40 BUSHING FOR EXHAUST SUPPORT 03 QTY 1 2

087800511 / C117800515

AIR FILTER
FIG 79 PART NUMBER 77306010000 78006015000A 77304066050
DESCRIPTION AIR BOX PART BLACK AIR BOX COVER SX BLACK 07 REAR PART FILTER BOX 07 QUICK RELEASE-NIPPLE 03 BLIND RIVET 3,3X9,7 GROOVED 04 QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX AIR FILTER PRE-OILED FILTER CARRIER 4S SX 07 FILTER SUPPORT CPL. 07 FILTER SUPPORT BUSH 07 FASTEN. DEVICE FILTER S. SX 07 CABURETOR CONNECTING 07 HOSE CLAMP 45-65MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 BUSHING F. CHAIN SLIDING PR.07 QTY x 1 2

087800610 / C117800611

FIG 8* 38 50* PART NUMBER 78007008044X7730805410004F 0025060166 0024060273
DESCRIPTION FUEL TANK CPL. 9L XCF-W USA 08 GAS COCK ON/OFF/RES 08 O-RING 11X2 VITON PVC-HOSE 5,6X10X270MM TANK PLUG ORANGE/BLACK TANK BUSHING 07 TANK ROLLER 12X26X12 '98 FUEL PREFORMED HOSE EPA CLAMP YDNAC 13,7MM EJOT PT SCREW K60X20 WS=6 HH COLLAR SCREW M 5X12 WS=6 ANGLE PIECE 90 DEGREE M10X1 SEAT SIX-DAYS 08 SEAT COVER SIX-DAYS 08 SPOILER KIT ORANGE SIX-DAY 11 WITHOUT DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X16 TX30 COLLAR SCREW M6X27 TX QTY 1

087800710 / C117800715

FIG 30 PART NUMBER 78008016000
DESCRIPTION START NUMBER PLATE ORANGE 07 HEAD LIGHT MASK ORANGE 08 BRAKE HOSE GUIDE ORANGE 07 EJOT PT SCREW K60X20 WS=6 HH COLLAR SCREW M6X10 TX30 MASK RUBBER UFO WP '95 BRAKE HOSE GUIDE ORANGE 08 SPACER BUSHING 03 FRONT FENDER 07 HH COLLAR SCREW M6X20 TX30 WASHER DIN0125-A 6,4 COLLAR BUSH. F.REAR FENDER 07 COLLAR BUSHING 4,5/12,6/23 REAR PART EXC WHITE 11 HH COLLAR SCREW M5X20 TX30 COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING 03 HH COLLAR SCREW M6X25 TX30 BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 NUMBER PL. CARRIER TOP PART 08 QTY 1

117700810 / C117700810

FIG 1* 2* PART NUMBER 52308399400 77008391100
DESCRIPTION DECAL SET EXC/XC-W SIXDAY 2011 DISPLACEM.STI. 250 XCF-W SD 11 QTY 1 1

117800832 / C117800832

FRONT WHEEL
FIG 40 PART NUMBER 54809081070
DESCRIPTION FRONT WHEEL CPL.1,6X21"EXC.10 FRONT WHEEL HUB CPL. BEA.SPACERTUBE 35X2 L=79,GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL 08 SPOKE M4,5x226-21" 08 SPOKE NIPPLE M4,5X0,75 8X21 RIM FRONT 1,6X21" EXCEL AL7 RIM BAND 21" FRONT WHEEL REP. KIT RIM LOCK VM1 (1,60") NUT FOR WHEEL HOLDER '96 BRAKE DISC FRONT 260 MM 08 SPECIAL SCREW M6X13 WS=8 10.9 WHEEL SPIN.FR. D=26 M24x1,SPINDLE SCREW M24X1,5 WS=PLUG BUSHING WS=FRONT AXLE PULL 26MM 04 PLUG FOR RIM AUXILIARY SCREW FRONT 06 QTY x x 1

117800910 / C117800910

REAR WHEEL
FIG 43 PART NUMBER 5841005105204 0019080266S 58414030000
DESCRIPTION REAR WHEEL CPL. 2,15X18"EXC.09 REAR WHEEL HUB CPL. BUSHING SPACER TUBE 121,5MM 01 GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN0472-47X1,75 SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB 08 SPOKE M5X193- 18" SPOKE NIPPLE M5-TA 8X21MM RIM 2,15X18" EXCEL AL7 BLACK BRAKE DISC REAR 220 SPECIAL SCREW M6X13 WS=8 10.9 RIM BAND 18" AND 19" REAR WHEEL REP. KIT REAR SPROCKET ORANGE 38-T REAR SPROCKET ORANGE 40-T REAR SPROCKET ORANGE 42-T REAR SPROCKET ORANGE 44-T REAR SPROCKET ORANGE 48-T REAR SPROCKET ORANGE 49-T REAR SPROCKET ORANGE 50-T REAR SPROCKET ORANGE 51-T REAR SPROCKET ORANGE 52-T COUNTER-SUNK SCREW ISA45 M8X26 HEXAGON NUT DIN EN1661 M8 SW13 CHAIN DID 118 ROLLS CONNECTING LINK F. 78010167118 RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER '96 PLUG FOR RIM COVERING CAP SFL16 WHEEL SPINDLE RE. CPL.265MM 07 CHAIN TENSIONER R/S 2000 SCREW M10X1,25X50 WS=10 HH COLLAR NUT M10X1,25 WS=13 QTY x x x x x x x x x x 2

085481010 / C117801010

FIG 44 PART NUMBER 50310099000
DESCRIPTION HEXAGON NUT M20X1,5 '98 QTY 1

WIRING HARNESS

FIG 96 PART NUMBER 0017060204
DESCRIPTION WIRING HARNESS RACING USA 05 VOLTAGE REGULATOR 04 CABLE TIE 200/3,6MM BLACK CABLE TIE 300/4,8MM BLACK FUSE 10 A 2000 WIRING HOLDER 16MM CABLE SUPPORT KHS NR.150-47610 BATTERY 12V 4AH YTX5L-BS RUBBER L=145MM BARRERY CASING WIRING HARNESS BATTERY DUKE'99 STARTER RELAY 12V '99 STARTERCABLE 700 MM '97 GROUND CABLE D=6MM L=140MM '97 CONTACT WASHER M6 VSV-K6 PROTECTION CAP F. STARTER ENG. SELF LOCK. NUT DIN0985-M 6 AH OVAL SCREW ISO 7380 M 6X8 HH COLLAR SCREW M6X10 TX30 HH COLLAR SCREW M6X12 TX30 EJOT PT SCREW K60X20 ALU WS=6 QTY x x 2 x 3

087801110 / C097801112

BRAKE CALIPER FRONT
FIG PART NUMBER 0025080356S 50213025000
DESCRIPTION BRAKE CAL. FR. - WITHOUT PADS REPAIR KIT 28MM REPAIR KIT PISTON 28MM BOLT CPL. 6X56 RETAINING PLATE SET BREMBO BRAKEP.SET FR.TOSHIBA TT2701HH BLEEDER SCREW WITH CAP CUP SET SHORT HH COLLAR SCREW M8X35 TX40 BRAKEHO. FRONT 1300MM 2000 COPPER GASKET DIN7603-10X14X1 HOLLOW SCREW M10X1X19 QTY 2 1

095031360 / C105031360

HAND BRAKE CYLINDER
FIG PART NUMBER 54802051000 00062030000
DESCRIPTION HAND BRAKE CYLINDER CPL. SX 09 HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=9MM 2009 CLAMP CPL. NATURE HH COLLAR SCREW M6X25 TX30 LEVER SCREW CPL. 2001 HAND BRAKE LEVER + SPRING 2009 ADJUSTING SCREW CPL. SX 2009 PROTECTION CAP HAND BRAKE CYL. BRAKEHO. FRONT 1300MM 2000 BANJO SCREW 08 COPPER GASKET DIN7603-10X14X1 VALVE BRAKE FLUID DOT5.1 0,25L QTY 1 1

097701310 / C117801310

FIG 17 18* 80 PART NUMBER 54813055000 0032100406S 00062030000
DESCRIPTION REAR BRAKE CYLINDER CPL. 2004 REPAIR KIT PISTON 13MM 06 REAR BRAKE CYL. COVER CPL. 04 FOOT-BRAKE CYL. GASKET SX 03 HOLLOW SCREW BLACK M10X1X19 BRAKE HOSE REAR 655MM 03 COPPER GASKET DIN7603-10X14X1 FOOT BRAKE LEVER CPL. 07 STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX30 RETURN SPRING FOR BRAKE LEVER HH COLLAR SCREW M6X20 TX30 PUSH ROD L=28MM 03 HEXAGON NUT DIN0934-M 6 SWIVEL HEAD KAAH-COLLAR SCREW M10X40 ISA45 SPECIAL SCREW M8X26 WS=10 COLLAR NUT M8 WS=10 BALL BEARING SKF 6000-2RS1 COLLAR NUT M10 WS=13 HH COLLAR SCREW M6X12 TX30 BELLOWS FOR REPAIR KIT 06 BRAKE FLUID DOT5.1 0,25L QTY 1

085031330 / C117801331

FIG 12 13* PART NUMBER 0603100141 50313082200
DESCRIPTION BRAKE CAL. RE. - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER 03 BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM 2003 RETAINING SPRING SET 2003 BRAKE CALIPER SUPPORT REAR CUP SET SHORT BRAKE HOSE REAR 655MM 03 BLEEDER SCREW CPL. 05 COPPER GASKET DIN7603-10X14X1 BRAKE PAD RETAINING PIN QTY 2 1

117801390 / C117801390

LIGHTING SYSTEM

FIG 29 PART NUMBER 0017060203
DESCRIPTION HEAD LIGHT CPL. EXC-EU 08 RUBBER CAP FOR HEAD LIGHT 05 BILUX-BULB 12V 35/35W BA20D SCREW FOR PLASTIC D=5X18 DRAIN HOLE COVER BULB 12V 5W (W2,1X9,5D) PHIL. CABLE FOR HEAD LIGHT 2005 REAR LIGHT EXC-EU 2008 EJOT PT SCREW K60X20 WS=6 QTY 2

085231410 / C095231410

INSTRUMENTE / SCHLOSSSYSTEM
FIG PART NUMBER 31008060000 54813026000
DESCRIPTION SPEEDOMETER MPH F. 21" 2005 REPROGRAMMABLE: MPH - KM/H BATTERY COVER F. SPEEDOM. 2005 BATTERY F. SPEEDOM. M.A.E. 02 SPEEDOMETER TOP PART 05 CABLE FOR DIGITAL SPEEDOM. 06 CLAMP D=6/8MM, BLACK MAGNET FOR DIGITAL SPEEDOM. 03 CIRCLIP DIN0471- 9X1 INOX WASHER DIN9021-A 5,3 SCREW FOR PLASTIC K50X12 T20 RUBBER GROMMET 16X10,8XHH COLLAR SCREW M6X20 TX30 BUSHING F. SPROCKET COVER RAC. SPEEDOMETER BRACKET 05 RUBBER SLEEVE D=8MM OPEN CABLE SUPPORT 10/6MM 06 QTY 2 2

095231431 / C117701430

FIG 0* 0 0* 0* 0* 0 0* 0* 34 PART NUMBER 7730801003304A SXS08125610 3211606EN 3CF8175K9EN 3CM089311KEN 60029070200 77029072000
DESCRIPTION AIR FILTER OIL 100ML DOCUMENTS BAG 2006 KTM BALLPOINT PEN ORANGE CUSTOMER WELCOME LETTER BRAKE PAD RETAINING PIN FRONT AXLE PULL 26MM 04 BATTERY 12V 4AH YTX5L-BS HAND GUARDS CPL.L/S+R/S OR. 06 BAR PAD CPL. PLASTIC FRAME PROTECTION SET FRONT FENDER CPL. SIX DAYS 11 MOUNTING KIT FRONT FENDER FOOTREST L/S + R/S CPL. 09 BLEEDER VALVE SET OWN.MAN. 250 XCF-W/EXC-F 2011 ETK FGST. 250 XCF-W SIX-DAY 11 ETK MOTOR 250 EXC-F EU 2011 TOOL KIT 07 GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F WRENCH WS=13 B&F + OPENER T-WRENCH WS=6/8/10 TX=45 B&F SPARK PLUG KEY 250 SX-F QTY 1

087802001 / C117802008

250 EXC-F 2011
SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM089311KEN

SPECIAL TOOLS
ENGINE CASE CRANKSHAFT, PISTON ZYLINDER

CARBURETOR CLUTCH

TRANSMISSION I

TRANSMISSION II

KICK STARTER SHIFTING MECHANISM

KHLSYSTEM

VALVE DRIVE

STEUERTRIEB

ZYLINDERKOPF LUBRICATING SYSTEM IGNITION SYSTEM

ELECTRIC STARTER

FIG PART NUMBER DESCRIPTION ASSY SUPPORT (WITHOUT HOLDER) FIXING ARM FRONT FIXING ARM REAR PROTECTION CAP FOR CAMSHAFT SPECIAL CIRCLIP PLIER EXTRACTOR FOR TIMING GEAR PISTON RING COMPRESSOR CPL. 03 LOCTITE 243 BLUE 6CCM BUSHING EXTRACTOR INTERN.BEAR.PULLER 12-16 MM INTERN.BEAR.PULLER 18-23 MM INTERN.BEAR.PULLER 5-7 MM LIMIT PLUG GAUGE F.VALVE GUIDE SEAL.RING PRESS PUNCH WAT.PUMP FEELER GAUGE SET10,12,15,20,25 INSERT FOR VALVE SPRING LEVER VALVE SPRING LEVER MOUNTING TOOL INNER RING NJ206 % 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 '98 WRENCH F.MIXTURE CONTROL SCREW SP. WRENCH F.HOSE CONNECTOR 07 SPARK PLUG KEY 250 SX-F INSERT F. PISTON LOCK RING

QTY 1 1

087702910 / C097702910

ENGINE CASE

FIG 60 PART NUMBER 77030099000 DESCRIPTION ENGINE CASE CPL. EXC-F/XC-F 07 DOWEL 9,8 X 7 X 10 OILDRAIN PLUG W.MAG. M 12X1,5 CU-SEAL RING DIN7603-12X18X1,5 HH COLLAR SCREW M6X45 TX30 HH COLLAR SCREW M6X8 TX30 LOCATING SCREW M8 L=23 CU-SEAL RING 8 X 14 X 3 CIRCLIP OIL LEVEL GLASS 03 OIL LEVEL GLASS G 1777 Y DOWEL 17 X 19 X 12 GASKET FOR CLUTCH COVER 05 OIL JET 70 M6X0,75 WSDOWEL BUSHING 13,8X11X12 CASE BUSH JET 100 BING(44-031/180) M4 JET 44-031/150 O-RING 12,00X2,00 NBR 70 SCREW PLUG OIL SCREEN 11,8x44,5MM O-RING 9X1,5 NBR CLUTCH COVER CPL. CHAIN DAMPERSHEET EXC-F 07 HH COLLAR SCREW M6X35 TX30 HH COLLAR SCREW M6X65 TX30 HH COLLAR SCREW M6X50 TX30 HH COLLAR SCREW M6X40 TX30 HH COLLAR SCREW M6X30 TX30 VALVE PISTON D=10MM PRESSURE SPRING L=25MM D=1MM PLUG DIN0908-M12X1,5 CU-SEAL RING DIN7603-12X18X1,5 HH COLLAR SCREW M6X25 TX30 HH COLLAR SCREW M6X95 TX30 GASKET SET 05

097703011 / C107703011

FIG 69 PART NUMBER 0025060606 DESCRIPTION CLUTCH COVER OUTSIDE 09 MOLDED RING 05 HH COLLAR SCREW M6X55 TX30 O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R CU-SEAL RING DIN7603-6X10X1 HH COLLAR SCREW M6X60 TX30

CRANKSHAFT, PISTON

FIG PART NUMBER I 77030007700 II 0760142460 DESCRIPTION CRANKSHAFT CPL. EXC-F CON. ROD REP. SET 05 THRUST WASHER 30,5X45X0,10 THRUST WASHER 30,7X47X0,15 THRUST WASHER 30,5X45X0,30 CYL.ROLLER BEAR.NJ206 ET2XCS46 HEX.NUT L/SH M18X1,5 LOCK WASHER VSK 18 SH.SEAL RING 35X42X4 B10FNIB WOODRUFF KEY 5X6,5 HARDED SH. SEAL RING 30X42X4 B10F COLLAR NUT M12X1 R/S SPRING WASHER DIN0137-B12 WOODRUFF KEY DIN6888-3X5X13 PRIMARY GEAR 22T. 05 PISTON PIN BOLT D=16mm 05 CIRCLIP 05 PISTON D=76 PISTON D=76 OIL SCRAPER RING COMPRESSION RING SHAFT SEAL RING 14X24X6 B

QTY x x x 1 x 1

097703060 / C107703061

ZYLINDER

FIG PART NUMBER DESCRIPTION CYLINDER AND PISTON CPL. CYLINDER BASE GASKET DOWEL 10,2X12,5XHH COLLAR SCREW M6X25 TX30

QTY 4 1

107703040 / C117703040

CARBURETOR

FIG 29 PART NUMBER 59031051085 DESCRIPTION CARBURETOR FCR-MX 3900K,TPS 08 CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL. 06 COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL.07 SLIDE STOP 03 THROTTLE VALVE CPL. FCRMX 2007 BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE 04 GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBEKP JET NEEDLE KEIHIN OBEKT JET NEEDLE KEIHIN OBETP JET NEEDLE KEIHIN OBETN JET NEEDLE KEIHIN OBETQ JET NEEDLE KEIHIN OBDYS BAR CLIP NEEDLE SET SCREW CPL. NEEDLE JET FCR-MX MAIN JET 160 KEIHIN MAIN JET 162 KEIHIN MAIN JET 165 KEIHIN MAIN JET 168 KEIHIN MAIN JET 170 KEIHIN MAIN JET 172 KEIHIN MAIN JET 175 KEIHIN MAIN JET 178 KEIHIN IDLE JET 38 KEIHIN IDLE JET 40 KEIHIN IDLE JET 42 KEIHIN STARTER JET 65 STARTER JET 70 STARTER JET 75 STARTER JET 80 STARTER JET 85
QTY x x x x x x 1 x x x x x x x x x x x x x x x x

087703111 / C107703111

FIG 88 PART NUMBER 57331056000 SXSDESCRIPTION IDLE AIR JET 100 KEIHIN ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL. ARM PIN FLOAT STARTER VALVE CPL. FLOAT NEEDLE CLAMP DRAIN SCREW + O-RING COVER ACCELERATOR PUMP DIAPHRAGM ACCELERATOR PUMP FLOAT CHAMBER CPL. 08 JET POWER JET CLOSED KEIHIN JET POWER JET 50 KEIHIN JET POWER JET 60 KEIHIN JET POWER JET 70 KEIHIN COIL SPRING STARTER VALVE SHORT CPL. BREATH.HOSE FCR-MX KEIHIN CPL. FLAT HEAD SCREW DIN0965-M 5X10 PLUG M 18X1 INTERMEDIATE LEVER CPL. LINK LEVER SXS ACCELERATION PUMP SPRING SPRING INTERMEDIATE LEVER CARBURETOR COVER 06 WASHER LINK LEVER E-CLIP 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

QTY x x x x 1

FIG 99 PART NUMBER 57331099000 DESCRIPTION STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 190MM 2006 GASKET SET FCR-MX KEIHIN

CLUTCH

FIG 99 PART NUMBER 0993012000 DESCRIPTION OUTER CLUTCH CPL. INNER CLUTCH HUB PRESSURE PLATE INTERMEDI. DISC STEEL 05 LINING DISC 3,0MM 05 INNER RING 20X26X25,9 '98 SHEET METAL LOCK 1,5MM '98 HEXAGON NUT DIN0936-M18X1,5 R. STOP DISK 20X39,6X3 '98 PRIMARY GEAR 22T. 05 GASKET FOR SLAVE CYLINDER CLUTCH KIT 250 SXF/XCF/XCF-W WASHER 6,2X18X2 PUSH ROD 05 PRESSURE PIECE 125-380 '98 O-RING 30,00X1,50 NBR 70 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X35 TX30 HH COLLAR SCREW M6X25 TX30 VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING PISTON CPL. OUTPUT CYLINDER CPL. 06 O-RING PRESSURE SPRING CU-SEAL RING DIN7603-10X16X1 BLEEDER SCREW CPL. 05 NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK 1226 AXIAL WASHER AS1226 12X26X1 CIRCLIP DIN7993-RW12

097703210 / C107703210

FIG 90 PART NUMBER 50133090000 DESCRIPTION MAIN SHAFT CPL. Z=13 "B13" IDLER G. 5TH G=23 "5B23" SLIDING G.3/4. G19/23-T"B1923" IDLER G. 6TH G.26 "6B26" SOLID GEAR 2ND G.17-T"2B17" NEEDLE BEAR.K 22X26X10 DIVIDED GROOVED BALL BEARING 16003 Z BALL BEARING 6004 TN9 C4 NEEDLE CAGE K18X22X10 PARTED STOP DISC 05 STOP DISK 17,2X24X1 STOP GEAR 22X28.5XLOCK RING 22X1,2

087703340 / C087703340

FIG 91 PART NUMBER 0471250120 DESCRIPTION COUNTER SHAFT 05 IDLER G. 4TH 6.28-T "4B28" IDLER G. 3RD G.29-T "3B29" SLIDING G. 6TH 6.22-T "6B26" IDLER G. 2ND 6. 33-T "2B33" IDLER G. 1ST G. 33-T "1B33" SLIDING G. 5TH G.23-T "5B23" NEEDLE BEARING K20X24X10 NEEDLE BEAR.K 22X26X10 DIVIDED IDLER GEAR BUSHING 25X28X9,7 D SCREW 10.9+SPRING WASHER FRONT SPROCKET 13-T FRONT SPROCKET 14-T FRONT SPROCKET 15-T BALL BEARING 6003 TN9 C4 BALL BEARING 6205 C3 NTN SHAFT SEAL RING 32X45X7 BSLNBR SPACER BUSHING 12MM O-RING 23,00X2,00 NBR70 STOP DISC 17,2X30X1 SHIM 20X32X1 STOP DISC 25,2X32X1 THRUST WASH. DIN0988-25X35X1,0 AXIAL-CIRCLIP 25X1,65 CIRCLIP DIN0471-25X1,2

QTY 1 x x x 1

087703370 / C087703370

KICK STARTER

FIG 75 PART NUMBER 0019080206S DESCRIPTION STOP DISK 17,2X24X1 CIRCLIP DIN0471-17X1 THRUST WASHER DIN0988-16X22X1 SPACER BUSHING 16X23X26X6,1 FLAT HEAD SCREW M. ISA45 M8X20 HH COLLAR SCREW M6X16 TX30 KICKSTARTER SHAFT 05 KICKSTART. GEAR 28-T 05 KICKSTARTER RATCHET INTERMEDIATE GEAR 05 KICKSTARTER SPRING 05 DRIVING HUB 05 SPRING 1,4MM '98 STOP MET.SHEET 4MM 125/200'98 KICK STARTER CPL. SHAFT SEAL RING 17X28X7 B WASHER 8MM GALVANIZED

097703390 / C097703390

SHIFTING MECHANISM
FIG 40 PART NUMBER 59009062016 DESCRIPTION SHIFTING FORK 5TH/6TH GEAR 05 SHIFTING FORK 2ND/3RD GEAR 05 SHIFTING FORK 1ST/4TH GEAR 05 NEEDLE ROLLER DIN5402 6X14,8 SHIFTING SHAFT CPL. 05 PRESSURE SPRING 0,9MM SLIDING PLATE CPL. TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 6903 C4 SHIFT ROLLER 05 BALL BEARING 61805 C3 RETURN SPRING 2,2MM '95 SHIFTING SHAFT CPL. 05 AH SCREW DIN6912 M6X30 8.8 HH COLLAR SCREW M6X8 TX30 SHIFT. RAIL MAIN SHAFT 250/300 SHIFTING MAIN L=93MM 05 LOCKING LEVER SPRING LOCKING LEVER CPL. 08 SLEEVE FOR LOCKING LEVER WASHER DIN7349-5X15X2 HH COLLAR SCREW M5X20 TX30 SHIFT LEVER CPL. 2-STROKE 2001 STEP PLATE FOR SHIFT LEVER 250 BOLT 6X25 FOR SHIFT LEVER SHIFTING LEVER SPRING 250 STOP DISK 14X30X1 NEEDLE BEAR.HK 1412 14X20X12 SHAFT SEAL RING 14X24X6 B STEEL WASHER 6,4X17X3 PAIR OF WASHERS M 6 NORDLOCK SPECIAL SCREW M6X16 WS=8 10.9

097703410 / C107703411

COOLING SYSTEM
FIG 32 34* PART NUMBER DESCRIPTION RADIATOR L/S 250 SX-F RADIATOR R/S "45556" 08 RADIATOR CAP SMALL 1,8 BAR HOSE CLAMP GEMI 10-16 T-CONNECTOR CPL. 07 HOSE CLAMP GEMI 16-27 HOSE CLAMP NORMA 12/22 RADIATOR HOSE L/S 250SXF 05 ANGLE PIECE '97 PVC-HOSE 6X9 MM PER METER THERMOSTAT CPL. 75C 08 THERMOSTAT 70 DEGREE 04 RADIATOR HOSE R/S 07 ALU SEALRING DIN7603-14X20X1,5 THERMOSWITCH 95-100 DG O-RING 32,00X2,00 SCREW FOR PLASTIC D=4X18 RADIATOR PROTECTION L/S+R/S SX HOSE CONNECTOR 4 STROKE 07 RUBBER SLEEVE D=12MM WASHER FOR RADIATOR 08 COLLAR SCREW M6X12 TX FAN SUPPORT EXC 08 SCREW FOR PLASTIC D=5X18 RIVET 4,0X 8 ALU FAN CPL. 12V LCFAN WIRING HARNESS FUSE 5 A 2003

QTY 1 x 1 1

107703531 / C117803531
FIG PART NUMBER DESCRIPTION VALVE LEVER SHAFT 05 VALVE LEVER SHIM D=8,9/1,72 SHIM D=8,9/1,76 SHIM D=8,9/1,80 SHIM D=8,9/1,84 SHIM D=8,9/1,88 SHIM D=8,9/1,92 SHIM D=8,9/1,96 SHIM D=8,9/2,00 SHIM D=8,9/2,04 SHIM D=8,9/2,08 SHIM D=8,9/2,12 SHIM D=8,9/2,16 SHIM D=8,9/2,20 SHIM D=8,9/2,24 SHIM D=8,9/2,28 SHIM D=8,9/2,32 SHIM D=8,9/2,36 SHIM D=8,9/2,40 SHIM D=8,9/2,44 SHIM D=8,9/2,48 SHIM D=8,9/2,52 SHIM D=8,9/2,56 SHIM D=8,9/2,60 VALVE COLLET 05 VALVE SPRING KIT 08 VALVE-STEM SEALING 05 INTAKE VALVE TITAN 05 EXHAUST VALVE TITAN 05 VALVE SPRING RETAINER VALVE SPRING INSIDE VALVE SPRING HOLDER VALVE KIT 08-10
QTY x x x x x x x x x x x x x x x x x x x x x x x 2 x x x 1

107703610 / C107703610

FIG 36 PART NUMBER 0471100010 DESCRIPTION TIMING CHAIN GUIDE TOP 05 SPACER BUSHING GUIDE RAIL 05 CAMSHAFT GEAR SCREW 08 CAMSHAFT GEAR BALL BEARING 6004 NR CCAMSHAFT INTAKE 2009 NEEDLE ROOLER DIN5402 NRB 4X6 CAMSHAFT EXHAUST AUTO DECOMPRESSION AUTO DECO WEIGHT 05 SPRING FOR AUTO DECOMPR. 05 BUSHING SCREW AUTODEC. M5X0,8 TIMING CHAIN GUIDE 05 BUSHING SCREW 06 SEAL RING CU DIN7603- 8X12X1 HH COLLAR SCREW M6X25 TX30 SPACER BUSHING 6,1X8,2X13,1 SECURING PROTECTION 05 TIMING CHAIN TENSIONER 05 SPACER BUSHING 6.1X8.2X9.HH COLLAR SCREW M6X40 TX30 CHAIN ADJUSTER HOLDING BOLT CU SEAL-RING DIN7603 A24X29X2 CHAIN ADJUSTER HYD. 05 O-RING 18,00X2,00 NBR 70 TIMING VALVE JACKSHAFT 08 STOP DISK 18,2X30XWOODRUFF KEY DIN6888-3X3,7 TIMING VALVE TWIN WHEEL TIMING CHAIN 108 ROLLS BALL BEARING 6203 JR2 C3 NEEDLE BEAR.HK1812 18/24/NEEDLE ROL.DIN5402 NRB 3X17,8 WATER PUMP ROTOR 05 CIRCLIP DIN0471-10X1

097703621 / C117703620

FIG PART NUMBER DESCRIPTION SHAFT SEAL RING 12X30X7 PTFE MOLDED RING WATER PUMP 05 WATER PUMP COVER 05 HH COLLAR SCREW M6X30 TX30 HH COLLAR SCREW M6X20 TX30 CU-SEAL RING DIN7603-6X10X1

QTY 2 1

ZYLINDERKOPF
FIG 1* 8* 32 PART NUMBER 77031050000 DESCRIPTION CYLINDER HEAD CPL. CYLINDER HEAD GASKET 05 VALVE COVER 06 VALVE COVER GASKET 05 VALVE COVER SCR. M6X12 WSRUBBER GASKET FOR SCREW 05 COVER PLATE BREATHER 05 EJOT SPIRAL SCREW SF M5X10-K ANGLE CONNECTOR LCO-RING 8X2 SILICONE SPECIAL SCREW M7X73 WS 10 SPECIAL SCREW M7X40 WS10 COLLAR NUT 7XSTUD 7XBUSH SUPPORT A.BRIDGE CPL '05 NEEDLE ROLLER DIN5402 5X9,8 OIL JET DOWEL(BUSH BRIDGE)7/9/VALVE GUIDE INTAKE VALVE GUIDE OUTLET CYLINDER HEAD SCREW 05 WASHER 10,8X18,8X1,5 GASKET EXHAUST FLANGE 06 EXHAUST FLANGE CPL. 05 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X25 TX30 INTAKE BOOT 06 CLAMP D=56MM B=9MM M4X25 ENGINE BREATHER TUBE

097703630 / C117703631

LUBRICATING SYSTEM
FIG PART NUMBER 0025050166 0984050123S DESCRIPTION OIL PUMP SHAFT EXC-F OILPUMP ROTOR CPL. 10MM G-73R OILPUMP ROTOR 15MM G-164 OIL PUMP GEAR 14T 08 OIL PUMP COVER L/S 05 OIL PUMP COVER R/S 05 HH COLLAR SCREW M5X16 TX30 CYLIND. SCR. DIN6912 M5X12 8.8 OIL FILTER COVER RACING OIL FILTER WITH GASKET 06 NEEDLEROL.DIN5402 NRA 2,5X19,8 NEEDLE ROLLER DIN5402 2,5X11,8 OILPUMP IDLER GEAR 08 SHIM WASHER DIN0988-12X18X0,50 CIRCLIP DIN0471-12X1 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 O-RING 32,00X2,00 HH COLLAR SCREW M5X12 TX30

QTY 1 2

097703810 / C107703810

IGNITION SYSTEM

FIG 16 20* 39 PART NUMBER 0603061001 DESCRIPTION IGNITION COVER EXC 09 IGNITION COVER GASKET EXC-F STATOR 2007 FLYWHEEL PULSER COIL 08 CDI UNIT 250 EXC-F 09 SPARK PLUG CONNECT. VD05EG 03 SPARK PLUG NGK CR9EKB 05 WIRE RETAINING BRACKET 06 HH COLLAR SCREW M6X8 TX30 WIRING HARNESS FOR CDI EXC 04 WIRING HARNESS F. CDI-BOX 08 IGNITIONCOIL "IG5128" CABLE TIE 140/2,5MM BLACK FREEWHEEL HUB AH SCREW DIN6912-M5X8 10.9 DOWEL 9,8 X 7 X 10 HH COLLAR SCREW M6X50 TX30 HH COLLAR SCREW M6X30 TX30 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M5X16 TX30 HH COLLAR SCREW M6X10 TX30 HH COLLAR SCREW M6X25 TX30 HH COLLAR SCREW M6X95 TX30 CU-SEAL RING DIN7603-6X10X1

QTY x x 1 x 1

087703910 / C107703912
FIG 11 PART NUMBER 77040027000 DESCRIPTION E-STARTER ENGINE 2007 O-RING 25,00X3,00 NBR 70 HH COLLAR SCREW M6X20 TX30 BEARING BOLT NEEDLE BEARING K 10X13XINTERMEDIATE GEAR 36T 06 TORQUE LIMITER CPL. 06 NEEDLE BEARING HK 2216 FREE WHEEL GEAR FREE WHEEL 03 HOLDER FREE WHEEL GEAR 06

097704010 / C107704010

Rekluse Motor Sports z-Start Pro Tuning Chart KTM 250 SX-F/XC-F (see following page for XCF-W)
198-838 Manual Revision: 102910

Engagement RPM

Engagement Rate

Hard Soft

Spring(s)

C200L5 C200L5

MEDIUM*

Soft Hard Soft

C200L6

C200L6 C200M3 C200M3

*- Medium/Hard is the recommended initial setting.
Important Tuning Tip: Idle setting is a critical component in tuning your z-Start Pro. Setting your idle speed at or slightly above your Engagement RPM will yield engine braking close to stock. Setting your idle speed below your Engagement RPM will yield more of a freewheeling effect. Notes: Empty ball slots must be evenly spaced around the pressure plate. The pattern for the 27 ball setup is 9 balls followed by 1 empty slot. Customers with 315cc big bore kits: we recommend that you purchase an RMS251 Tungsten Carbide (TC) ball kit to eliminate excess slip from the increased torque your motorcycle is making at low engine speeds. To distinguish between steel balls and the heavier TC balls use a low powered magnet (magnetic screwdriver works well). With a low powered magnet, the TC balls do not seem magnetic. Definition of Terms Engagement RPM Low, Medium, High Refers to the engagement RPM of the clutch, i.e. the RPM at which the clutch starts to engage and move the bike forward. Low gives an engagement point at or below a normal engine idle speed. High raises the engagement point to above a normal engine idle speed. In general, off-road riders prefer a low-to-medium engagement RPM, while motocross riders prefer a medium-to-high engagement RPM. Refers to the engagement rate of the clutch. Hard gives full clutch lockup more quickly than Soft and therefore makes the bike feel more snappy. To maximize clutch plate life you should use Hard settings, as Soft settings allow the clutch to slip more.
Engagement Rate Hard, Soft
Rekluse Motor Sports z-Start Pro Tuning Chart KTM 250 XCF-W
198-838 Manual Revision: 102810

C200L3 C200L3

C200L4

C200L4 C200L5 C200L5