Bulletin #WPP-0310-3 March 2010
New Product New Clutch Basket for KTM 400/ 450/ 505/ 530 Models

Motorcycle

WPP3050 Retail Price: $239.20 KTM 400 XC-W 2009 KTM 450 SX-F 2007-09 KTM 450 XC-F 2008-09 KTM 450 XC-W 2008-09 KTM 450 EXC 2008-09 KTM 505 SX-F 2008-09 KTM 530 XC-W 2008-09 KTM 530 EXC-R 2008-09
Wiseco Forged Clutch baskets, inner hubs, and pressure plates Now with a LIFETIME GUARANTEE against notching or breaking! Wiseco forged clutch components have greater strength due to feature aligned grain flow. Compared to castings or products machined from billet, Wiseco forged clutch components are lighter and still have increased mechanical properties resulting in higher strength, ductility, and resistance to impact and fatigue. Hard anodized and Teflon coated for a long life of smooth clutch operation through the elimination of wear on contact surfaces. We GUARANTEE it! Specifically designed to capitalize on detailed features that can only be produced by the precision forging process.

Clutch Basket

Inner Clutch Hub

Pressure Plate

Cushion Kit

Frictions

Steels (WPPS) & Alloys (WPPA)

Clutch Spring Kit

Cover (WPPC) & Gasket (W)

Clutch Pack Kit

Performance Extreme Clutch Clutch Kit Kit
400 XC-W 450 SX-F 450 XC-F 450 XC-W 450 EXC 505 SX-F 505 XC-F 530 XC-W 530 EXC-R
2009 2007-09 2008-09 2008-09 2008-09 2007-09 2008-09 2008-09 2008-09 WPP3050 WPP3050 WPP3050 WPP3050 WPP3050 WPP3050 WPP3050 WPP3050 WPP3050
Copyright 2010 Wiseco Piston Co., Inc. 7201 Industrial Park Blvd. Mentor, OH 44060-5396 440-951-6600 Fax: 440-951-6606 www.wiseco.com

400 XC-W USA 2010

SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF8375J8EN

ENGLISH
FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS SIDE / CENTER STAND

FRONT FORK DISASSEMBLED

FRAME SHOCK ABSORBER DISASSEMBLED

SHOCK ABSORBER

SWING ARM
EXHAUST SYSTEM AIR FILTER

TANK, SEAT, COVER

MASK, FENDERS
FRONT WHEEL REAR WHEEL WIRING HARNESS
REAR BRAKE CONTROL HAND BRAKE CYLINDER

BRAKE CALIPER FRONT

BRAKE CALIPER REAR
INSTRUMENTS / LOCK SYSTEM 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 5 6* 40 42* PART NUMBER 48600812S 48600428 48600557S 91410012S 91410013S 91410014S 91410015S 91410016S 91410017S 48600830S 40540486 48600764
DESCRIPTION ADJUSTING KNOB + SCREW VENT SCREW M4X8 O-RING NBR 3X1,5 O-RING NBR 45X2 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 M27X0,8 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 2 x x x x x x 2

105230130 / C105230130

* NEW PART

X AS REQUIRED

FIG 60* 61* 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 42X26,5X2,5 SPACER 42X26,5X5 SPACER 42X26,5X10 SPACER 42X26,5X1,5 SILICONE GREASE F. DUST STRI REPAIR-KIT EXC FRONT FORK 2009 QTY 2 x x x x 1 1

FRONT FORK, TRIPLE CLAMP

FIG 1* 85* 92* PART NUMBER 14187J0025080356 0025080256S 7800109410030
DESCRIPTION FORK KTM450/530EXC/XC-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 PROTECTION LE+RI BLACK QTY 1

095230110 / C107830111

HANDLEBAR, CONTROLS
FIG 1* 5 6* 12* 13* 17* 92 PART NUMBER 77002091000
DESCRIPTION HANDLEBAR D=28MM BAR PAD CPL. STARTER CONTROL 04 SHORT CIRCUIT BUTTON 02 HAND GUARDS CPL.L/S+R/S OR. 06 TWIST GRIP COVER GRAY/ORA.09 THROTTLE GRIP CPL. 4-ST. 09 FIXED GRIP GRAY/ORANGE 09 CABLE TIE 100/2,5MM BLACK CABLE TIE 200/3,6MM BLACK 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 CLAMP CPL. 06 PUSH ROD CPL. CLUTCH PIPE 06 THROTTLE CABLE 250 SXF 2005 QTY x x 1

107860210 / C107860210

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

097800361 / C107800361

FIG 1* 36* 40* 45* PART NUMBER 0019080206S 77303053010
DESCRIPTION FRAME BLACK MATT "DB10" SUB FRAME SX "Q7" 07 SUB FRAME APPLICATION LEFT 08 SUB FRAME APPLICATION RIGHT 08 ADH. FOIL TRANSP. 80X80 MM 04 SPECIAL SCREW M8X26 WS=10 HEXAGON NUT DIN0934-M 8 ENGINEBRAC.SCREW M10X123 WS=13 FLAT HEAD SCREW M. ISA45 M8X20 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 M10 CU WS=14 HH COLLAR SCREW M8X30 TX40 HH COLLAR SCREW M6X35 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 ANGEL PIECE '97 PVC-HOSE 7X10 PER METER CHAIN SPR. COV. 450/525 EXC-F SPACER BUSH. F. SPEEDOMET.BRA. CHAIN SLIDING PIECE BELOW 07 BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET CHAIN SLIDING P. BELOW CPL. 07 QTY 2 x 1 x 1 1

107860310 / C107860310

SHOCK ABSORBER DISASSEMBLED
FIG 1* 12* PART NUMBER 50180733SA 50180213SR50180520S 50180114 91210053S 91210054S 91210055S 91210068S 91210069S 91210070S 50180273 50180463S 50180603S 50180604 50180605S 50180103 46180119
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. INTERM.RING SCREW SPRING RET. SPRING 250 63N/MM ORANGE SPRING 250 66N/MM ORANGE SPRING 250 60N/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 QTY 1 x x x x x x 1

105230430 / C105230430

FIG 90* 99 PART NUMBER 50180512SA50180222 50180434S 50180342S1 R12015
DESCRIPTION DUST SEAL CIRCLIP 53X1,75 RESERVOIR CAP D=50 H=BUMP RUBBER D58 D17 HSHOCK ABS. LOWER PART CPL. 10 THREADED BUSH M12 PDS 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 8 10* PART NUMBER 0025120506S 12187J0601
DESCRIPTION HH COLLAR SCREW M12X50 TX45 MONOSH.PDS B07MA450/530EXC-F10 QTY 2 1

085030410 / C107800412

FIG 99 PART NUMBER 59404230110
DESCRIPTION SWING ARM CPL. 08 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 BEARING SLEEVE 17X22X38,NEEDLE BEARING HK2212V STOP DISK 22,2X31,7X1 CHAIN GUIDE CPL. SPECIAL SCREW M6X19 WS=8 10.9 HH COLLAR SCREW M6X45 TX30 INSERTION NUT F. CHAIN GUIDE PIVOT BEARING+BUSHES PDS '99 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 CHAIN GUIDE KIT REAR 08 SWINGARM-REPAIR KIT 05-07 QTY 1

087800491 / C107860490

EXHAUST SYSTEM
FIG 40 PART NUMBER 78005007000
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 RANGE CHANGE METAL NUT M8 HH COLLAR SCREW M6X30 TX30 THROTTLE ELEMENT CPL. EXC 07 SIL. ELEMENT EXC-F 07 TEN.SPRING L=62MM EY.MOVEABLE HH COLLAR SCREW M8X25 TX40 SCREW TORX M5XBUSHING FOR EXHAUST SUPPORT 03 ENDCAP SPARKY ATV 08 STUFFINGYARN 315 GRAMS STUFFING YARN EXC-F 07 EXHAUST PIPE 450 EXC-F 08 QTY 1

107830510 / C107830510

AIR FILTER
FIG 1* 15* 79 PART NUMBER 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 FILTER CARRIER 4S SX 07 FILTER SUPPORT CPL. 07 FILTER SUPPORT BUSH 07 FASTEN. DEVICE FILTER S. SX 07 CARBURETOR CONNECTING 08 HOSE CLAMP 45-65MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 BUSHING F. CHAIN SLIDING PR.07 QTY 2

107860610 / C107860610

FIG 50* PART NUMBER 7730805410004B 0025060356 78003001055

DESCRIPTION FUEL TANK CPL.9,5L EXC-FUSA 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 HH COLLAR SCREW M 5X12 WS=6 EJOT PT SCREW K60X20 WS=6 ANGLE PIECE 90 DEGREE M10X1 SEAT SX 07 SEAT COVER 07 SPOILER KIT ORANGE EXC/XC-W 10 WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X12 TX30 COLLAR SCREW M6X27 TX HH COLLAR SCREW M6X35 TX30 SUPPORT BUSH. TANK ROLL450/530 QTY 1

097800710 / C107830711

FIG 33 PART NUMBER 0017060204
DESCRIPTION START NUMBER PLATE ORANGE 07 BRAKE HOSE GUIDE ORANGE 07 HH COLLAR SCREW M5X16 TX30 FRONT FENDER 07 SPACER BUSHING 03 WASHER DIN9021-A 6,4 HH COLLAR SCREW M6X40 TX30 HH COLLAR SCREW M6X20 TX30 COLLAR BUSH. F.REAR FENDER 07 COLLAR BUSHING 4,5/12,6/23 REAR PART EXC ORANGE 08 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 EJOT PT SCREW K60X20 ALU WS=6 QTY 1

095230810 / C097800810

FIG 1* 2* PART NUMBER 52308399100 78308091200
DESCRIPTION DECAL KIT EXC/XC-W 2010 DISPLACEM. STICKER 400 XC-W 10 QTY 1 1

107830831 / C107830831

FRONT WHEEL
FIG 1* 2* 12* 40 PART NUMBER 55003135000 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 SPECIAL SCREW M6X13 WS=8 10.9 WHEEL SPIN.FR. D=26 M24x1,SPINDLE SCREW M24X1,5 WS=PLUG BUSHING WS=PLUG FOR RIM AUXILIARY SCREW FRONT 06 QTY x 1 x 1

085030910 / C105030912

REAR WHEEL
FIG 1* 2* 9 10* 22 23* 24* 44 PART NUMBER 58310151052 0019080266S 58414030000 50310099000
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 38-T REAR SPROCKET 42-T REAR SPROCKET 40-T REAR SPROCKET 45-T REAR SPROCKET 48-T REAR SPROCKET 49-T REAR SPROCKET 50-T REAR SPROCKET 51-T REAR SPROCKET 52-T COUNTER-SUNK SCREW ISA45 M8X26 SELF LOCKING NUT M8 10.9 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 HEXAGON NUT M20X1,5 '98 QTY 1 x x x x x x x x x x x x 1

085481010 / C107831010

WIRING HARNESS
FIG PART NUMBER 0009050103 0017060203
DESCRIPTION WIRING HARNESS RACING USA 05 PULL SWITCH LOOSE SPEC. NUT F. PULL SWITCH WS=17 VOLTAGE REGULATOR 04 SPEEDOMETER BRACKET XC-W 08 HH COLLAR SCREW M6X12 TX30 CABLE TIE 100/2,5MM BLACK CABLE TIE 200/3,6MM BLACK FUSE 10 A 2000 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 SPECIAL SCREW M 5,0X10 EJOT PT SCREW K60X20 WS=6 QTY x x 1 3

097801110 / C097801110

REAR BRAKE CONTROL
FIG 80 PART NUMBER 54603062000 0025060206S 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. 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 SELF LOCK. NUT DIN0985-M 6 SWIVEL HEAD KAAH SCREW DIN6912 M10X40 10.9 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 / C097801330

HAND BRAKE CYLINDER
FIG 1* 9 10* 15 20* 21* 31* 32 34* 80 PART NUMBER 54802051000 00062030000
DESCRIPTION HAND BRAKE CYLINDER CPL. SX 09 HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=12MM 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 / C105231310

FIG 1* 2* 5* 6* 7* 8* 9 10* 35 PART NUMBER 54613218000 0025080356S 50213025000
DESCRIPTION CALIPER NAT. WITHOUT PADS BRAKE CALIPER SUPPORT FRONT 09 REP. KIT SEALS 24MM REP. KIT PISTON 24MM BOLT CPL. 09 RETAINING PLATE SET BREMBO BRAKE PADS TOYO B153 BLEEDER SCREW WITH CAP CUP SET SHORT HH COLLAR SCREW M8X35 TX40 BRAKEHO. FRONT 1300MM 2000 COPPER GASKET DIN7603-10X14X1 HOLLOW SCREW M10X1X19 QTY 1

097701361 / C105231360

FIG 12 PART NUMBER 0603100141
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 QTY 2

095031390 / C107801390

INSTRUMENTS / LOCK SYSTEM
FIG PART NUMBER 54814060051 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 XC-W 08 SPACER TUBE SPEEDOM. XC-W 08 CABLE SUPPORT 10/6MM 06 QTY 1 2

095231430 / C095231430

ACCESSORIES KIT
FIG 0 1* 1* 1* PART NUMBER 78003040033 3211467EN 3CF8375J8EN 3CM089535JEN 60029070200 78029072000
DESCRIPTION DOCUMENTS BAG 2006 KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER BATTERY 12V 4AH YTX5L-BS HAND GUARDS CPL.L/S+R/S OR. 06 PLASTIC FRAME PROTECTION SET FRONT FENDER 07 MOUNTING KIT FRONT FENDER FOOTREST L/S + R/S CPL. 09 OWN.MAN. 400-530 XC-W/EXC 2010 SPC CHASSIS 400 XC-W USA 2010 SPC ENGINE 400 EXC 2010 % TOOL SET 08 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 SOCKET QTY 1 1

087802001 / C107832001

400 EXC 2010
SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM089535JEN

SPECIAL TOOLS
CLUTCH COVER BALANCER SHAFT CYLINDER
ENGINE CASE CRANKSHAFT, PISTON

SECONDARY AIR SYSTEM SAS

CARBURETOR

CLUTCH KICK STARTER

TRANSMISSION I - MAIN SHAFT
TRANSMISSION II - COUNTERSHAFT
WATER PUMP COOLING SYSTEM CYLINDER HEAD

SHIFTING MECHANISM

VALVE DRIVE TIMING DRIVE

LUBRICATING SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER

FIG PART NUMBER DESCRIPTION ASSY SUPPORT (WITHOUT HOLDER) SUPPORT CPL. GEAR SEGMENT CPL. 04 EXTRACTOR PRIM. CPL. WRENCH F.MIXTURE CONTROL SCREW MIXT. CONTROL SCREW FACTORY 04 BUSHING EXTRACTOR INTERN.BEAR.PULLER 18-23 MM INTERN.BEAR.PULLER 28 MM ON TENSIONER PL. CYLINDER HEAD PRESS OUT PUNCH CPL. VALVE SPRING TENSION APPLICAT. VALVE SPRING LEVER SEPARATOR PLATE CRANKSHAFT MOUNTING SLEEVE SSR CS FLYWHEEL EXTRACTOR PRESS. TOOL F. CRANKS. CPL. PRESS OUT PLATE CS CPL. SPARK PLUG WRENCH PULLER CLUTCH HOLDER % CASING DISMOUNTING TOOL 07 LOCTITE 243 BLUE 6CCM LOCTITE 648 GREEN 24ML LOCTITE 5910 50ML PRESS. TOOL F. CRANKSHAFT PRESS PUNCH CAMSHAFT BEAR. SM. PRESS PUNCH CAMSH. BEAR. LARGE ENGINE BLOCKING SCREW PLUG IN FUSE PISTON PIN

QTY x x x 1

097802910 / C097802910

CLUTCH COVER

FIG 52 PART NUMBER 0025060306 DESCRIPTION CLUTCH COVER GREY CPL. 09 OUTER CLUTCH COVER GASKET OUTER CLUTCH COVER CLUTCH COVER GASKET 08 HH COLLAR SCREW M6X20 TX30 SPRING HANGER HH COLLAR SCREW M6X8 TX30 CU-SEAL RING DIN7603-6X10X1 DOWEL 9,8 X 7 X 10 CU-SEAL RING 8 X 14 X 3 LOCATING SCREW HH COLLAR SCREW M6X25 TX30 HH COLLAR SCREW M6X30 TX30

087803020 / C097833020

BALANCER SHAFT
FIG 9 PART NUMBER 0760203261 DESCRIPTION BALANCE SHAFT BALANCE WEIGHT TAB WASHER 08 HEXAGON NUT DIN0439-M10X1 A2 BALL BEARING TAB WASHER INT. TORX FLAT HEAD M 5X10 8.8 NEEDLE BEARING 25X32X12 HK2512 SHAFT SEAL RING 20X32X6 RUBBER

087803030 / C097833030

CYLINDER
FIG PART NUMBER DESCRIPTION CYLINDER AND PISTON KIT CPL. DOWEL 6X8X11,5 CYLINDER BASE GASKET DOWEL 10,2X12,5X10 2001

QTY 1 2

107803040 / C107803040

ENGINE CASE

FIG 1* 4* PART NUMBER DESCRIPTION ENGINE CASE CPL. W.BEARINGS 10 MAIN JET 125 OIL JET 70 M5 VACUUM CONNECTION M6 CASE BUSH DOWEL 21XDOWEL 6X8X11,5 DOWEL 17 X 13 X 12 PLUG CPL. M24X3 O-RING 19,00X3,00 NBR CU-SEAL RING DIN7603-12X18X1,5 OILDRAIN PLUG W.MAG. M 12X1,5 PLUG DIN0906-M10X1 T-PIECE 10/10/8MMM ENGINE BREATH HOSE EXC 08 CARBURETOR BREATH HOSE EXC 08 ENGINE CASE BREATH HOSE EXC 08 HH COLLAR SCREW M6X75 TX30 HH COLLAR SCREW M6X60 TX30 GASKET SET 450/530 EXC 08

QTY 10 1

087803010 / C107833010

CRANKSHAFT, PISTON

FIG 13* 14* PART NUMBER 78330007000 I 78330007000 II DESCRIPTION CRANKSHAFT CPL. CON ROD REP.-KIT PISTON D=95MM SIZE 1 PISTON D=95MM SIZE 2 COMPRESSION RING 08 OIL SCRAPER RING PISTON PIN 08 CIRCLIP BALL BEARING 6207 TM-SX07E 39 SHAFT SEAL RING 35X47X7 A-DUO RETAINING PLATE F. CS BEARING INT. TORX FLAT HEAD M 5X10 8.8 NUT PRIMARY WHEEL M20X1,5 PRIMARY WHEEL TIMING GEAR 18T. WOODRUFF KEY DIN6888-3X3,7 SHAFT SEAL RING 14X24X6 B SHAFT SEAL RING 35X47X7 VITON

QTY 1 1

097833060 / C107833060

FIG 1 PART NUMBER 78005024044 DESCRIPTION SAS-VALVE CPL. ONLY FOR EU 08

087803130 / C087803130

FIG PART NUMBER DESCRIPTION CARBURETOR FCR-MX 3900W TPS 09 CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL. 06 COIL SPRING THROTTLE SHAFT SPECIAL-AH-SCREW M 4X12 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 OBDTN JET NEEDLE KEIHIN OBDTP JET NEEDLE KEIHIN OBDTQ JET NEEDLE KEIHIN OBDTR JET NEEDLE KEIHIN OBDYU JET NEEDLE KEIHIN OBDZT BAR CLIP NEEDLE SET SCREW CPL. NEEDLE JET FCR-MX MAIN JET 170 KEIHIN MAIN JET 172 KEIHIN MAIN JET 175 KEIHIN MAIN JET 178 KEIHIN MAIN JET 180 KEIHIN MAIN JET 182 KEIHIN MAIN JET 185 KEIHIN MAIN JET 188 KEIHIN IDLE JET 38 KEIHIN IDLE JET 40 KEIHIN IDLE JET 42 KEIHIN IDLE JET 48 KEIHIN STARTER JET 65 STARTER JET 70 STARTER JET 75 STARTER JET 80
QTY 1 x x x x x x 1 x x x x x x x x x x x x x x x x

097833110 / C097833110

FIG 86 PART NUMBER 0603100141 DESCRIPTION STARTER JET 85 IDLE AIR JET 100 KEIHIN ADJUST SCREW CPL. FCR-MX BUFFER PLATE FLOAT CPL. ARM PIN FLOAT STARTER VALVE CPL. ONLY FOR EU FLOAT NEEDLE CLAMP SPECIAL-AH-SCREW M 4X8 DRAIN SCREW + O-RING COVER ACCELERATOR PUMP DIAPHRAGM ACCELERATOR PUMP FLOAT CHAMBER CPL. 08 JET POWER JET CLOSED KEIHIN JET POWER JET 40 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 SPRING LINK LEVER SPRING INTERMEDIATE LEVER CARBURETOR COVER 06 WASHER LINK LEVER E-CLIP ROD ACCELERATOR PUMP HOSE CONNECTOR CPL. PLUG DIN0910-M 10X1 COPPER GASKET DIN7603-10X14X1

QTY x 1 x x x x x 1 1

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

CLUTCH

FIG 1* 10 11* 31 32* 33* PART NUMBER DESCRIPTION CLUTCH CAGE NEEDLE BEARING K26X30X22ZW.KSE INNER RING STOP DISC 08 INNER CLUTCH HUB JUDDER SPRING CPL. PRESSURE PLATE CLUTCH SPRING 08 WASHER 6,5 X 20 X 2 HH COLLAR SCREW M6X30 TX30 LINING DISC TURNED OFF FRICTION PLATE STEEL PUSH ROD L=186 RETAINING PLATE HEXAGON NUT DIN0936-M18X1,5 R. PRESSURE PIECE AXIAL NEEDLE BEARING AXK 1226 AXIAL WASHER AS1226 12X26X1 CIRCLIP DIN7993-RW12 O-RING 30,00X1,50 NBR 70 GASKET FOR SLAVE CYLINDER OUTPUT CYLINDER CPL. 06 PISTON CPL. O-RING PRESSURE SPRING COPPER GASKET DIN7603-10X14X1 CLUTCH PIPE 06 BLEEDER SCREW CPL. 05 HH COLLAR SCREW M6X20 TX30 VENT INJEKTION HYDR. CLUTCH LINING DISC STEEL DISK TEMPERED 1,4MM PRESSURE PIECE CPL. 08 CLUTCH-KIT

107863210 / C107863210

KICK STARTER
FIG PART NUMBER 77033170044 0019080206S DESCRIPTION KICK STARTER CPL. FLAT HEAD SCREW M. ISA45 M8X20 WASHER 8MM GALVANIZED SHAFT SEAL RING 19X30X7 B DRIVING HUB KICKSTARTER GEAR 39-T CIRCLIP DIN0471-19X1,2 SHIM WASHER DIN0988-17X24X0,5 INTERMEDIATE GEAR CPL. BUSHING PIN KICKSTARTER SPRING SPRINGHOLDER 08 AH SCREW DIN0912-M 6X12 SHIM 20X32X1 NEEDLE BEARING K 22X26X10 A BUMP PART STOP DISK 22,2 X 30 X 1,5 RATCHET GEAR SPRING 1,2 MM RATCHET GEAR KICK STARTER HH COLLAR SCREW M6X20 TX30 CIRCLIP DIN0471-17X1 KICKSTARTER SHAFT

097803390 / C097833390

FIG 1 2* 3 4* 23 PART NUMBER 0625062036 DESCRIPTION MAIN SHAFT 14 T IDLER GEAR 5. GEAR SLIDING GEAR 3/4 G. 08 IDLER GEAR 6. GEAR SOLID GEAR 2.G. 08 STOP DISC 17,2X30X1 NEEDLE BEAR. K 22X26X13 TN STOP DISK 23 X 32 X 1,5 CIRCLIP DIN0471-25X1,2 STOP DISK 26 X 32 X 1,5 BUSHING BALL BEARING 6205 C3 NTN TAB WASHER BEARING MAIN SHAFT INT. TORX FLAT HEAD M 5X10 8.8 BALL BEARING 6203 RSH C3

087803330 / C107803330

FIG 1 2* 7* 28 PART NUMBER DESCRIPTION COUNTERSHAFT 08 IDLER GEAR 1. GEAR SLIDING GEAR 5.G. 08 IDLER GEAR 3.G. 08 IDLER GEAR 4.G. 08 SLIDING GEAR 6.G. 08 IDLER GEAR 2. GEAR NEEDLE BEARING K 22X26X10 A CIRCLIP DIN0471-25X1,2 STOP DISK 26 X 32 X 1,5 STOP DISK 23 X 32 X 1,5 SHIM 20X32X1 NEEDLE BEARING K 20X26X12 STOP DISC 17,2X30X1 CIRCLIP DIN 0471-17X1, 5 BALL BEARING 6203 JR2 C3 TAB WASHER BEARING COUNT.SHAFT INT. TORX FLAT HEAD M 5X10 8.8 CYL.ROLL BEARING NJ205 SHAFT SEAL RING 32X45X7 BSLNBR O-RING 25,12X1,78 NBR70 SPACER BUSHING 12MM FRONT SPROCKET 13-T FRONT SPROCKET 14-T FRONT SPROCKET 15-T SCREW 10.9+SPRING WASHER

087803360 / C107803360

FIG PART NUMBER DESCRIPTION SHIFT LEVER CPL.RACING 2000 SPECIAL SCREW M6X16 WS=8 10.9 STEEL WASHER 6,4X17X3 SHAFT SEAL RING 14X24X6 B NEEDLE BEAR.HK 1412 14X20X12 STOP DISK 14X30X1 RETURN SPRING 2,2MM '95 SPRING GUIDE TENSIONING SPRING 0,8MM SHIFT SHAFT CPL. SLIDING PLATE CPL. SHIFT RAIL 11,8X101,5 PRESSURE SPRING 0,9MM SHIFTING ROLLER 6X8X5,2 SHIFT DRUM LOCATING ALU CPL. SHIFT ROLLER AH SCREW DIN6912 M6X30 8.8 LOCKING LEVER CPL. 08 HH COLLAR SCREW M5X20 TX30 SLEEVE FOR LOCKING LEVER ARRESTING LEVER SPRING 03 SHIFT RAIL 11,8X85 SHIFT FORK 5./6.GEAR 2000 WASHER DIN7349-5X15X2 SHIFT FORK 2./4.GEAR 2000 BALL BEARING 61805 C3 PAIR OF WASHERS M 6 NORDLOCK SHIFTING FORK 1ST/3RD GEAR

087803410 / C097803410

WATER PUMP
FIG 17 PART NUMBER 0603061001 DESCRIPTION WATER PUMP COVER GREY GASKET WAPU-COVER 08 HH CAP NUT DIN1587-M 6 SS. WATER-PUMP WHEEL 07 SHAFT SEAL RING 10X24X5,5 SHAFT SEAL RING 10X24X4 SPACER SHIM BALL BEARING 6000/C3 DRIVE WHEEL WAPU PLASTIC MAT. NEEDLE ROLLER DIN5402 3X21,8 WATER PUMP SHAFT LOCK WASHER DIN0471-14X1 HH COLLAR SCREW M6X25 TX30 HH COLLAR SCREW M6X55 TX30 CU-SEAL RING DIN7603-6X10X1

QTY x x x x x x x x x x

TIMING DRIVE
FIG 13 14* 21* PART NUMBER 78036005100 DESCRIPTION CAMSHAFT CPL. W. AUTO DECO AH SCREW DIN0912-M 6X20 SS RETAINING PLATE CAMSHAFT CPL. HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH CHAIN ADJUSTER HOLDING BOLT CU SEAL-RING DIN7603 A24X29X2 CHAIN ADJUSTER O-RING 18,00X2,00 NBR 70 NEEDLE SLEEVE HK1814RS18/24/14 NEEDLE SLEEVE HK4012B40X47X12 TIMING CHAIN 110T 08 TIMING CHAIN TENSIONER GUIDE RAIL SPACER BUSHING 6.1X8.2X9.AH SCREW DIN6912-M 6X20 8.8 FAILURE PROTECTION

097803620 / C107833620

FIG 7 10* PART NUMBER 0984050163S 0908120153 DESCRIPTION OIL PUMP GEAR 17 T OIL PUMP COVER CPL. O-RING 32,7X1,3 VITON 75SHORE OIL PUMP SHAFT SP-DP NEEDLE ROLLER NRB 4X15,8 G2 ROTOR-SET 19MM 03 O-RING 44,00X2,00 VITON OIL PUMP COVER SUCTION PUMP CYL. SCREW DIN6912 M5X16 8.8 TAB WASHER DIN6799-RS 6,0 STOP DISK 8,1 X 15 X 0,5 OIL PUMP GEAR 27T OIL PUMP COVER TRANSM. PUMP OILPUMP ROTOR CPL. 10MM G-73R OIL PUMP SHAFT TRANSM. PUMP NEEDLEROL.DIN5402 NRA 2,5X19,8 NEEDLE ROLLER DIN5402 2,5X11,8 O-RING 12,50X2,00 NBR 70 SCREW PLUG M16 SCREW PLUG M17 O-RING 12,50X2,00 NBR 70 O-RING 9X1,5 NBR OIL SCREEN 12,5X56,5MM OIL SCREEN 11,8x44,5MM OIL FILTER O-RING 33,05X1,78 OIL FILTER COVER 08 HH COLLAR SCREW M6X16 TX30 BALL DIN5401-9 PRESSURE SPRING L=25MM D=1MM CU-SEAL RING DIN7603-12X18X1,5 PLUG DIN0908-M12X1,5

097803810 / C107833810

FIG PART NUMBER 0019040106S 0025060406 DESCRIPTION IGNITION COVER EXC PLUG CPL. M24X3 O-RING 19,00X3,00 NBR GASKET IGNITION COVER 08 PULSER COIL KOKUSAN "PU5165" CDI UNIT 400 EXC 09 OIL LEVEL GLASS 30XCIRCLIP OIL LEVEL GLASS 03 SPARK PLUG CONNECT. AP-TRS1908 SPARK PLUG M12X1,25 LKAR8AI-9 HH COLLAR SCREW M5X16 TX30 NEEDLE ROL.DIN5402 NRB 4X9,8 FLAT HEAD SCREW ISA25 M4X10 WIRING RETAINING BRACKET WIRING HARNESS F. CDI-BOX 08 IGNITIONCOIL "IG5128" FLYWHEEL STATOR HUSABERG FS/FE 04 SPRING WASHER DIN0137-B12 COLLAR NUT M12X1 R/S WOODRUFF KEY DIN6888-3X5X13 COLLAR SCREW M6X12 TX HH COLLAR SCREW M6X16 TX30 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X25 TX30 HH COLLAR SCREW M6X40 TX30

QTY 8 2

097803910 / C097833910
FIG PART NUMBER DESCRIPTION E-START. ENGINE CPL. 0,45KW 08 HH COLLAR SCREW M6X20 TX30 O-RING 25,12X1,78 NBR70 AH SCREW DIN0912-M 6X40 A2 STOP DISC 6X23X2 BEARING BOLT BRUSH HOLDER F. STARTER SHIM WASHER DIN0988-17X24X0,5 TORQUE LIMITER CPL. CIRCLIP DIN0471-17X1 IDLER GEAR 30-T CPL. BUSHING PIN FREEWHEEL GEAR CPL. FREE WHEEL