450 SMR 2008
SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF8403H0EN

ENGLISH
FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS FRAME

FRONT FORK, TRIPLE CLAMP

MONOSHOCK SWING ARM

MONOSHOCK DISASSEMBLED

EXHAUST SYSTEM
AIR FILTER TANK, SEAT, COVER

MASK, FENDERS

FRONT WHEEL
REAR WHEEL WIRING HARNESS BRAKE CALIPER REAR
HAND BRAKE CYLINDER BRAKE CALIPER FRONT

REAR BRAKE CONTROL

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 92 PART NUMBER 14187D0025080356 0025080256S 5900109400004 DESCRIPTION FORK WP D=SMR 2008 HH COLLAR SCREW M8X25 TX40 HH COLLAR SCREW M8X35 TX40 HH COLLAR SCREW M8X25 TX40 AH SCREW DIN6912-M10X35 10.9 STE.HEAD SCR. M20X1,5 WS=27 SL SELF-LOCKING O-RING 25X3,55 NBREJOT PT SCREW K60X20 ALU WS=6 BOTTOM TRIPLE CLAMP 14-16 FORK TUBE SMR 1MM ECC. 2008 TOP TRIPLE CLAMP 14-16 OFFSET STEER.HEAD SCREW M20X1,5 WS=27 HANDLEBAR CLAMP 28MM 05 HANDLEB.SUPP. D=28MM H=32MM 05 HANDLEB.SUPP. D=28MM H=37MM 05 HANDLEB.SUPP. D=28MM H=42MM 05 TAPERED ROLLER BEARING CPL. 06 O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F.SPEED.CABLE ORANGE 06 STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS=8 FORK PROT. L/S +R/S ORG 02

QTY 2 x 2 x 1

087730110 / C087730112

* NEW PART

X AS REQUIRED

FRONT FORK DISASSEMBLED

FIG PART NUMBER 48600280S 48600444 91410054S 91410058S 48600519SDESCRIPTION SETTING KNOB OUTER TUBE L577 D54/60MM 2L BL 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 MEMBRANE O-RING NBR 9,5X1,5 O-RING NBR 17X2 PA SCREW BUSH M20X1 L=33 CPL. COPPER WASHER 20,5X26X1 ADJUSTING TUBE L=371 PISTON ROD D=12 M9X1 L=385 COUNTERNUT M12X1 WS17 ADJUSTER NEEDLE 07 O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM SPRING 4,8 N/MM SET D=5,25MM SPRING 5,0 N/MM SET SPACER 43X35X2,5 SPACER 43X35X5 SPACER 43X35X1,5 GUIDING BUSH REBOUND SPRING SPRING SUPPORT O-RING 6X1,2 NBR SPRING REB. L=32 C=37 DI=13,9 PISTON ROD REBOUND SPRING CHECK VALVE D=0,5 SHUTTLE VALVE SPRING C=0,4 MEMBRANE HOLDER LOCK WASHER D=25,5 AH SCREW M4X6 O-RING NBR 21X2

QTY x x x x x 4

087800132 / C087800136
FIG 99 PART NUMBER 48600518S 48600697S1 48600691S48600471 48600546S 48600692 48600401S48600516ST511 R14014 DESCRIPTION PISTON COMPRESSION D=27,9 O-RING NBR 4X1,5 PIN VALVE SET NUT M6X0,5 REBOUND GUIDE RING 44,2 X39,3 RING SPRING-SUPPORT O-RING NBR 46 X 2 AXLE-CL. MA AXIAL BR.+INN.TUBE AXLE CLAMP R/S + TUBE CPL. 08 HH COLLAR SCREW M8X25 TX40 CHECK VALVE NUT M6X0,5 D=2 SPRING CHECK VALVE D=0,7 PISTON ROD COMPRESSION PISTON REBOUND SX 2007 PISTON RING 5X1X68 RING D=23,45X2,65 PISTON ROD SEALING SCREW SLEEVE M24,5X1 CPL. DU BUSH FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D=20 SILICON CAP RUBBER CAP D=26,4 FORK OIL SAE5 5L 2005 O-RING NBR 43X2 SCREW CAP CPL. L=125 AH SCREW M4X6 SCREW M4X10 MEMBRANE SLEEVE SILICONE GREASE F. DUST STRI REPAIR-KIT GASKET 48MM 0

HANDLEBAR, CONTROLS

FIG 92 PART NUMBER 77002091000 DESCRIPTION HANDLEBAR D=28 MM RENTHAL 796 TWIST GRIP COVER RENTHAL 04 THROTTLE GRIP CPL. RACING 2004 STARTER BUTTON 06 SHORT CIRCUIT BUTTON 02 FIXED GRIP RENTHAL 04 CABLE TIE 100/2,5MM BLACK CABLE TIE 200/3,6MM BLACK HOSE 7X11,5X15 HANDGUARD L/S+R/S CPL.BLACK 04 LEVER CPL. RACING 2000 MASTER CYLINDER CPL. SXC/SM 03 CLUTCH LEVER SHORT CPL. 2003 CLUTCH LEVER LONG CPL. 2003 REP.KIT PISTON 9,5MM RAC. 2000 COVER HYD.CLUTCH RACING 2000 RUBBER FOR RESERVOIR '98 SPRING FOR CLUTCH LEVER 03 OIL FOR HYD. CLUTCH 75ML PROTECT.CAP FOR LEVER PERCH'98 LEVER SCREW CPL. 125-200 '98 CLAMP WITH PIN 2000 HH COLLAR SCREW M6X20 TX30 FLAT HEAD SCREW DIN0965-M 4X12 CLUTCH PIPE RACING 2003 HOT START CABLE 05 THROTTLE CABLE 250 SXF 2005

QTY x x x 1 1

087730211 / C087730212
FIG 64 PART NUMBER 59003013000 0019080206S 77303053010 DESCRIPTION FRAME SMR "JE08" 08 SUB FRAME SX "Q7" 07 SUB FRAME APPLICATION LEFT 08 SUB FRAME APPLICATION RIGHT 08 ENGINE BRACE 450 SX-F 07 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 COLLAR SCREW M8X42 WS=13 10.9 SELF LOCKING NUT M8 10.9 SELF LOCKING NUT M10 CU WS=14 HH COLLAR SCREW M8X30 TX40 HH COLLAR SCREW M6X40 TX30 INTERCEPTING TANK CPL. 2004 EJOT PT SCREW K60X20 WS=6 O-RING 80,00X2,00 VITON HH COLLAR SCREW M6X10 TX30 SPACER BUSH. F. SPEEDOMET.BRA. HH COLLAR SCREW M6X25 TX30 FOOT PED L/S SILVER 02 FOOT PED R/S SILVER 02 BOLT FOR FOOT PED 03 FOOTREST SPRING L/S & R/S WASHER DIN0125-A10,5 PIN DIN0094-3,2X25 STEEL FOOTREST L.+R. CPL. 03 ANGEL PIECE '97 HOSE EPA D=6/10 PER METER CHAIN SPROCKET COVER CHAIN SLIDING PIECE BELOW 07 BLIND RIVET NUT EM6-60LF/HX FRAME PROTECTION STICK. SET 07 CHAIN SLIDING P. BELOW CPL. 07

QTY 2 x x 1 1

087730310 / C087730312

MONOSHOCK

FIG PART NUMBER 0025120506S 12187D15 DESCRIPTION HH COLLAR SCREW M12X50 TX45 MONOSHOCK PDS B07DA 450SMR 08

QTY 2 1

085030410 / C087730412

SWING ARM

FIG PART NUMBER 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 BUSHING SLEEVE F. SWING ARM 03 NEEDLE BEARING HK 2216 STOP DISK 22,2X31,7X1 CHAIN GUIDE REAR CPL. 07 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 CHAIN STOP GUARD SMR 2008 EJOT PT SCREW K60X20 WS=6 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 05-07

QTY 1 1

087730490 / C087730491
FIG PART NUMBER 50180597S3 50180213SR50180520S 91210070S 91210072S 91210073S 50180273 50180463S 50180616S 50180603S 50180604 50180605S 50180511 DESCRIPTION TOP PART CPL. M57,5X1 H30,DCC-COMPR.DAMP.CONTROL CPL. 03 ADAPTOR BUSH KGW 12X24 REP. KIT BEAR./SEAL UP. 07 BLEED PLUG R 1/8 WP CAUTION (PDS KTM) 58X83 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 76N/MM SPRING N/MM SPRING N/MM CIRCLIP 58,2X2 SPRING RET. D=80 W. O-RING 05 O-RING VITON 66,27X3,53 O-RING VITON 44,17X1,78 PISTON RING 50-8 BLEED SCREW M6 PISTON ROD NUT M16X1 CPL. REBOUND DISC D=34, H=8 PISTON 6+6X7/4,5 NEEDLE L=171 O-RING VITON 2,2X1,6 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 CIRCLIP 53X1,75 COVER D=50 07

QTY x x x 1

087800434 / C087800438
FIG PART NUMBER 50180480 50180512S50180434S 50180342S1 R12014 DESCRIPTION BUMP RUBBER D58 D17 H59 SXS 05 MONOSHOCK LOWER PART CPL. 07 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 06
FIG 44 PART NUMBER 54603048000 DESCRIPTION SILENCER EXC-F THROTTLED 07 THERMAL PROTECTION FOIL 07 SILENCER HOUSING EXC-F 07 BUSHING SIL.-SMR REAR 2004 SIL. CONNECT. CAP CPL.EXC-F 07 SPRING WASHER DIN0137-B 6 BUSHING 7.5x12x28x7.EXHAUST BRACKET RUBBER BLACK RANGE CHANGE METAL NUT M6 HH COLLAR SCREW M6X30 TX30 THROTTLE ELEMENT CPL. EXC 07 SIL. ELEMENT EXC-F 07 TEN.SPRING L=62MM EY.MOVEABLE SCREW TORX M5XENDCAP EXC-F 07 STUFFINGYARN 350 GRAMM '99 STUFFING YARN EXC-F 07 EXHAUST MANIFOLD 450 SX-F 07 HH COLLAR SCREW M8X25 TX40 BUSHING FOR EXHAUST SUPPORT 03 RANGE CHANGE METAL NUT M8

087730512 / C087730512

AIR FILTER
FIG 79 PART NUMBER 77304066050 DESCRIPTION FILTER WALL SX BLACK 07 FILTER 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 FASTEN. DEVICE FILTER S. SX 07 EDGE PROTECTOR 14X9,5X66 MM 06 CARB. CONNECT. BOOT 450 SMR 08 HOSE CLAMP 40-60MM AIR FILTER SPACER RING SMR 08 AIR FILTER 660 SM FACTORY 02 HOSE CLAMP 70-90MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 BUSHING F. CHAIN SLIDING PR.07

QTY x 1 2

087730610 / C087730611

TANK, SEAT, COVER

FIG PART NUMBER DESCRIPTION GAS COCK MIKUNI ON/OFF 2001 O-RING 13,00X2,30 PVC-HOSE 5,6X10X270MM TANK PLUG CPL. XCF-W 08 TANK BUSHING 07 FUEL TANK CPL. SX 7,5L 08 TANK ROLLER 12X26X12 '98 FUEL PREFORMED HOSE 450 SX-F CLAMP YDNAC 10128 12MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 ANGLE PIECE 90 DEGREE M10X1 SEAT SX 07 SEAT COVER 07 SPOILER L/S BLACK 07 SPOILER R/S BLACK 07 BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X12 TX30 COLLAR SCREW M6X27 TX

087800712 / C087730711

FIG 26 PART NUMBER 0025060206 DESCRIPTION NUMBER PLATE CPL. BLACK BRAKE HOSE GUIDE ORANGE 07 EJOT PT SCREW K60X20 ALU WS=6 HH COLLAR SCREW M6X10 TX30 HH COLLAR SCREW M 5X16 WS=6 FENDER FRONT SMR 08 SPACER BUSHING 03 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X10 TX30 RETAINER F.NUMBER PLATE SMR 08 COLLAR BUSHING 4,5/12,6/23 REAR FENDER SX ORANGE 07 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

087730810 / C087730810

FIG PART NUMBER DESCRIPTION DISPLACEM. STICKER 450 SMR 08 SPOILER DECAL 450 SMR 08

087730834 / C087730834

FIG 40 PART NUMBER 54809081070 DESCRIPTION FRONT WHEEL 3,5X16,5 SMR 08 FRONT WHEEL HUB CPL. 08 BEA.SPACERTUBE 35X2 L=79,GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL 08 SPOKE M4,5X164- 16,5" 08 SPOKE NIPPLE M4,5X0,75 8X21 FRONT RIM 3,5X16,5" RIM BAND 17" FRONT WHEEL REP. KIT BRAKE DISC FRONT 310MM SMR 07 SPECIAL SCREW M6X16 WS=8 10.9 WHEEL SPIN.FR. D=26 M24x1,SPINDLE SCREW M24X1,5 WS=PLUG BUSHING WS=AUXILIARY SCREW FRONT 06

QTY x 1 1

087730910 / C087730910

REAR WHEEL

FIG 44 PART NUMBER 58310151052 0019080266S 50310099000 DESCRIPTION REAR WHEEL CPL. 5X17 SMR 08 REAR HUB CPL. 08 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 M5X174-13,5G 17" SPOKE NIPPLE M5-TA (8X21MM) RIM 5X17" SMR 07 BRAKE DISC REAR 220 SPECIAL SCREW M6X13 WS=8 10.9 RIM BAND 17" 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 5/8X1/4" MX CHAIN Z-RING 5/8X1/4" CONNECTING LINK F. 50310165118 CONNECTING LINK F. 50310800118 MASTER LINK FOR 50310800118 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 2 1

087731010 / C087731011

WIRING HARNESS
FIG 96 PART NUMBER 0017060203 DESCRIPTION MAIN WIRING HARNESS 450 SX-F VOLTAGE REGULATOR "RS 2759 "06 CABLE TIE 200/3,6MM BLACK CABLE TIE 300/4,8MM BLACK FUSE 10 A 2000 BATTERY CASING BATTERY 12V 3AH YTX4L-BS 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 HH COLLAR SCREW M6X20 TX30 EJOT PT SCREW K60X20 WS=6

QTY x x 3

087731111 / C087731111

BRAKE CALIPER REAR

FIG PART NUMBER DESCRIPTION BRAKE CALIPER REAR CPL. 2005 REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER 03 BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM 2003 RETAINING SPRING SET 2003 CUP SET SHORT BRAKE HOSE REAR 655MM 03 BLEEDER HOLLOW SCREW M10X1 COPPER GASKET DIN7603-10X14X1

QTY 1 2

085481390 / C085481390

HAND BRAKE CYLINDER

FIG PART NUMBER DESCRIPTION HANDBRAKECYLINDER MAGURA 07 HOLLOW SCREW + COPPER GASKET BRAKEHOSE FRONT 1160MM 07 CLAMP 07 HH COLLAR SCREW M6X16 TX30 HANDBRAKE LEVER CPL. 07 LEVER SCREW CPL. 05 ROCKER CPL. FOR BRAKE LEVER 07 ADJUSTING SCREW CPL. REP. SET PISTON D=12MM 2007 BRAKE FLUID RESERVOIR CPL.2007 O-RING+SCREW+SLEEVE 07 BLEEDER SCREW WITH CAP BRAKE FLUID DOT5.1 0,25L

QTY 1 x

087731310 / C087731310

BRAKE CALIPER FRONT

FIG PART NUMBER DESCRIPTION BRAKE CALIPER FRONT MAGURA 07 WASHER 10,2X20X2,5 MM 04 COLLAR SCREW M10X1,25X55 TX BRAKE PAD SINTER 07 FIXING FOR BRAKE PAD 07 PISTON WITH GASKET MAGURA 07 SEAL RING KIT CPL. MAGURA 07 BRAKEHOSE FRONT 1160MM 07 HOLLOW SCREW CPL. M 10X1 '98 COPPER GASKET

087731360 / C087731360

FIG 80 PART NUMBER 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 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

085031330 / C087801332

FIG 34 PART NUMBER 3211243 3CF8403H0EN 3CM089260HEN DESCRIPTION DOCUMENTS BAG 2006 KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER FOOTREST L.+R. CPL. 03 BATTERY 12V 4AH YTX5L-BS INTERCEPTING TANK CPL. 2004 HAND GUARD L/S CPL.W.FAST. 04 HAND GUARD R/S CPL.W.FAST. 04 PROTECTIVE FILM FRAME LEFT 07 PROTECTIVE FILM FRAME RIGHT 07 BATTERY 12V 3AH YTX4L-BS BARRERY CASING OWNER MANUAL 450 SMR 2008 SPM CHASSIS 450 SMR 2008 SPM ENGINE 450 SMR 2008 BORDTOOL 07 GRIP ORANGE B&F WRENCH WS=17/21/27/32 WRENCH WS=13/17 T-WRENCH WS=6/8/10 TX=45 B&F SPARK PLUG WRENCH

087732000 / C087732004

SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM089260HEN

SPECIAL TOOLS
ENGINE CASE CLUTCH COVER CYLINDER
CRANKSHAFT, PISTON CARBURETOR

CLUTCH

TRANSMISSION I - MAIN SHAFT
TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM

WATER PUMP

COOLING SYSTEM

VALVE DRIVE

TIMING VALVE CYLINDER HEAD LUBRICATING SYSTEM
IGNITION SYSTEM ELECTRIC STARTER
FIG PART NUMBER DESCRIPTION UNIVERSAL MOUNTING RACK '96 FIXING ARM CPL. 450 SX-F 07 PLASTIGAUGE - MEASURING STRIP 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 INTERN.BEAR.PULLER 8-12 MM LIMIT PLUG GAUGE F.VALVE GUIDE MOUNT.SLEEVE F. SH.S.RING WAPU FEEL. GAUGE SET 10,12,15,20,25 INSERT FOR VALVE SPRING LEVER 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 VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML HOLD. PLATE CLUTCH 450 SX-F 07 PROTECTOR CAP F.CRANKSHAFT 07 ASSEMB. PIN F. GUID. AGW-ZR-KS DEGREE DISK 360DEG - 1/2 INCH WRENCH F.MIXTURE CONTROL SCREW SP. WRENCH F.HOSE CONNECTOR 07 ADJUST BUSH BRIDGE UNLOCK CHAIN TENSIONER LOCATING SCREW SPECIAL SOCKET F. PRIMARY GEAR PLUG IN FUSE PISTON PIN

077732900 / C087732910

FIG PART NUMBER DESCRIPTION ADAPTOR F.OIL PRESSURE GAUGE EFI PRESSURE TESTER

ENGINE CASE

FIG 1* 68 PART NUMBER DESCRIPTION ENGINE CASE CPL. W.TR.BEAR. 08 OILDRAIN PLUG W.MAG. M 12X1,5 CU-SEAL RING DIN7603-12X18X1,5 BUSHING RETAINING PLATE BUSHING RETAINING PLATE INT. TORX FLAT HEAD M 5X10 8.8 BUSHING RETAINING PLATE BUSHING RETAINING PLATE RETAINING PLATE HH COLLAR SCREW M 5X10 WS=8 AH SCREW DIN6912-M 8X20 SEAL RING CU DIN7603- 8X12X1 DOWEL 17 X 19 X 12 OIL JET DOWEL BUSHING 13,8X11X12 JET 100 BING(44-031/180) M4 HH COLLAR SCREW M7X1X70 HH COLLAR SCREW M 6X70 WS=8 HH COLLAR SCREW M 6X55 WS=8 CYLINDER ROLLER ZRO. 8,0X12 M4 GASKET SET 450SX-F THROTTLE M5X10X1 CASE BUSH DOWEL 6X8X11,5

077733000 / C087733010

CLUTCH COVER
FIG 36 PART NUMBER 77303026054 DESCRIPTION CLUTCH COVER CPL. SHAFT SEAL RING 12x24x4 SHAFT SEAL RING 12x24x4/5,5 BALL BEARING 6202 C0 2RSH RETAINING PLATE FOR WAPUSTOCK SHAFT SEAL RING 20X30X7 CIRCLIP 30X1,2 SHAFT SEAL RING 12x35x7 BSL VI INT. TORX FLAT HEAD M 5X10 8.8 O-RING 8,00X1,5 NBR 70 CYLINDER ROLLER ZRO. 8,0X12 M4 OIL LEVEL GLASS G 1777 Y CIRCLIP OIL LEVEL GLASS 03 HH COLLAR SCREW M 6X20 WS=8 HH COLLAR SCREW M7X1X45 HH COLLAR SCREW M 6X30 SW=8 CLUTCH COVER OUTSIDE 07 CLUTCH CASE GASKET O-RING 19,00X3,00 NBR PLUG CPL. M24X3 BLEEDER FLANGE M12X1,5 WS=13 ENGINE BREATHER TUBE YDNAC-CLAMP 10173 (16MM) '98 QUAD-RING 28,3X1,78 VITON SPRING BRACKET

077733001 / C087733020

CYLINDER
FIG PART NUMBER DESCRIPTION CYLINDER CYLINDER ROLLER ZRO. 8,0X12 M4 O-RING 107,67x1,78 VITON GASKET GEAR CASE

077733003 / C087733040

CRANKSHAFT, PISTON
FIG 42 PART NUMBER I 77330007200 II DESCRIPTION CRANKSHAFT CPL. CONNECTING ROD REPAIR SET THRUST WASHER 30X42X0,1 THRUST WASHER 30X42X0,2 THRUST WASHER 30X42X0,3 CYL. ROLLER BEARING NJ206 ECP COLLAR NUT M27X1 PRIMARY GEAR CPL. 07 SHAFT SEAL RING A40x55x6 VITON FLYWHEEL SCREW WOODRUFF KEY DIN6888-3X3,7 PISTON PIN CIRCLIP PISTON CPL. D=97MM PISTON CPL. D=97MM OIL SCRAPER RING COMPRESSIONRING D=97 2007

087733060 / C087733061

CARBURETOR
FIG 1* 14 16* 19* PART NUMBER DESCRIPTION CARBURETOR FCR-MX 4125I,TPS 08 CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL. 06 COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL.07 THROTTLE VALVE CPL. FCRMX 2007 BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE 04 GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBDTM 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 180 KEIHIN MAIN JET 182 KEIHIN MAIN JET 185 KEIHIN MAIN JET 188 KEIHIN MAIN JET 190 KEIHIN MAIN JET 192 KEIHIN MAIN JET 195 KEIHIN IDLE JET 40 KEIHIN 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 HOT-STARTER VALVE FLOAT NEEDLE CLAMP
QTY 1 x x x x x 1 x x x x x x x x x x 1

087733110 / C087733110

FIG 46* 49* 99 PART NUMBER 57331099000 DESCRIPTION DRAIN SCREW FLOAT CHAMBER COVER ACCELERATOR PUMP DIAPHRAGM ACCELERATOR PUMP FLOAT CHAMBER CPL. 08 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. STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 190MM 2006 GASKET SET FCR-MX KEIHIN

FIG 1* 2* PART NUMBER DESCRIPTION OUTER CLUTCH CPL. 08 INNER CLUTCH HUB 08 PRESSURE PLATE INTERMEDI. DISC STEEL LINING DISC 3,0MM INNER RING RETAINING PLATE HEXAGON NUT DIN0936-M18X1,5 R. WASHER 21,7X38XPRIMARY GEAR CPL. 07 O-RING 38,00X2,00 NBR 70 SH OUTPUT CYLINDER CPL. PISTON CPL. WASHER 6,2X18X2 PUSH ROD 07 PRESSURE PIECE PRESSURE PIECE CPL. HH COLLAR SCREW M 6X25 WS=8 VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING CU-SEAL RING DIN7603-10X16X1 BLEEDER HOLLOW SCREW M10X1 NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK 1226 AXIAL WASHER AS1226 12X26X1 CIRCLIP DIN7993-RW12

077733200 / C087733210

FIG PART NUMBER 0405242813G 0019050103 DESCRIPTION MAIN SHAFT GUIDE BUSHING NEEDLE BEAR.K 24X28X13 DIVIDED IDLER GEAR 3G STOP DISK 26 X 32 X 1,5 CIRCLIP SW25 SLIDING GEAR 4G STOP DISK 23 X 32 X 1,5 NEEDLE BEAR. K 22X26X13 TN IDLER GEAR 5G SOLID GEAR STOP DISC 17,2X30X1 BALL BEARING 6203 RSH C3 BALL BEARING 6205 C3 NTN BUSHING RETAINING PLATE INT. TORX FLAT HEAD M 5X10 8.8

087733330 / C087733332

TRANSMISSION II - COUNTERSHAFT
FIG 21 PART NUMBER 77333415000 DESCRIPTION STOP DISC 17,1X32X2,6 IDLER GEAR 2G IDLER GEAR 1G NEEDLE BEAR. K 22X26X13 TN STOP DISC 22,2X32X1,5 SLIDING GEAR 3G CIRCLIP SW25 STOP DISK 23 X 32 X 1,5 CIRCLIP DIN 0471-17X1, 5 IDLER GEAR 4G COUNTERSHAFT INT. TORX FLAT HEAD M 5X10 8.8 BUSHING RETAINING PLATE BALL BEARING 6203 RSH C3 CYL.ROLLER BEARING NUP205E C3 SHAFT SEAL RING 35X47X7 TC O-RING 25,00X1,50 NBR 70 SPACER BUSHING SPROCKET 13-T SPROCKET 14-T SPROCKET 15-T SCREW+SPRING WASHER SLIDING GEAR 5G

087733360 / C087733363

SHIFTING MECHANISM
FIG PART NUMBER DESCRIPTION SHIFTING FORK 2ND/4TH GEAR SHIFTING FORK 3RD/5TH GEAR 03 SHIFT SHAFT CPL. 07 SHIFTING FORK 1ST.GEAR PRESSURE SPRING 0,9MM SLIDING PLATE CPL. TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 61806 SHIFT ROLLER 5G 08 BALL BEARING 6805 C4 NTN JAPAN RETURN SPRING 03 SHIFT LOCATING DRUM CPL. AH SCREW DIN6912 M 6X30 INT. TORX FLAT HEAD M 5X10 8.8 BUSHING RETAINING PLATE SHIFTING ROLLER 6X8X5,2 SHIFT RAIL FRONT SHIFT RAIL ARRESTING LEVER SPRING 03 LOCATING LEVER CPL. 08 SLEEVE FOR LOCKING LEVER WASHER DIN9021-A 5,3 HH COLLAR SCREW M 5X20 WS=8 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

087733411 / C087733412

FIG 7* 12 PART NUMBER DESCRIPTION WATER-PUMP COVER 07 SCREW IN NOZZLE M20X1,5 WATER-PUMP GASKET 06 CAP NUT M6 DINWATER-PUMP WHEEL 07 NUT M14 X 1 FOR BALANCER. 06 BALANCER GEAR KS 32-T 07 HH COLLAR SCREW M 6X55 WS=8 HH COLLAR SCREW M 6X16 WS=8 CU-SEAL RING DIN7603-6X10X1 HH COLLAR SCREW M 6X10 WS=8 NEEDLE BEARING RNA 4900

077733500 / C087733510

FIG 41* 42* PART NUMBER DESCRIPTION RADIATOR L/S "45519U" 07 RADIATOR R/S "45518U" 07 RADIATOR CAP SMALL 1,8 BAR T-CONNECTOR CPL. 07 HOSE CLAMP GEMI 16-27 HOSE CLAMP GEMI 12/22 ANGEL PIECE '97 PVC-HOSE 6X9 MM PER METER RADIATOR HOSE R/S HOSE ENGINE-RADIATOR 07 RADIATOR HOSE L/S RAD. PR. L/S+R/S BLACK SX 07 HOSE CONNECTOR 4 STROKE 07 RUBBER SLEEVE D=12MM WASHER DIN9021-A 6,4 COLLAR SCREW M6X12 TX

QTY 1 x 4 4

087733530 / C087733530
FIG PART NUMBER DESCRIPTION INTAKE VALVE 07 EXHAUST VALVE 07 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 SPRING KIT VALVE COLLET 07 VALVE-STEM SEALING RACING VALVE LEVER VALVE LEVER INTAKE VALVE LEVER SHAFT EXHAUST VALVE LEVER SHAFT
QTY x x x x x x x x x x x x x x x x x x x x x x x 1

077733601 / C087733610

TIMING VALVE
FIG 1 2* 27 28* PART NUMBER DESCRIPTION CAMSHAFT INTAKT 07 CAMSHAFT EXHAUST CPL. 08 CYL.ROLL BEARING RNU203ETVP2 CAMSHAFT GEAR 07 COLLAR SCREW M10X1X39 NEEDLE BEAR K 18X22X13 NEEDLE BEARING K 18X22XDOUBLE GEAR W.CPL. Z18/ZAXLE FOR TIMING VALVE 06 O-RING 15,00X1,80 HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH HOLDING BOLT M24X1,5 CU SEAL-RING DIN7603 A24X29X2 CHAIN ADJUSTER HYD. 05 TENSIONER RAIL CPL. 07 TIMING CHAIN 07 GUIDE RAIL 07 O-RING 12,00X1,50 NBR BUSHING SCREW BUSHING SCREW BALANCER GEAR STOP DISC 18/32/1,4/2,7 O-RING 18,00X2,00 NBR 70

077733602 / C087733620

CYLINDER HEAD
FIG PART NUMBER DESCRIPTION CYLINDER HEAD CPL. CYL. HEAD GASKET S=0,VALVE COVER VALVE COVER GASKET VALVE COVER SCREW RUBBER GASKET FOR SCREW 05 GASKET SPARK-PLUG SHAFT O-RING 25,00X1,50 NBR 70 COLLAR SCREW M7X1X38 BUSHING HOLDER AH SCREW DIN0912-M 5X10 COLLAR NUT M10X1,25 SW13 WASHER 19X10,5X2,5 STUD SCREW M10 VALVE GUIDE AH SCREW DIN0912-M 4X12 OIL JET O-RING 1,5x6 INTAKE BOOT HOSE CLAMP GEMI 56MM 03 CYLINDER ROLLER ZRO 5X8 SCREW PLUG O-RING 9X1,5 NBR PLUG 00 SCREW IN NOZZLE M20X1,5 GASKET EXHAUST FLANGE EXHAUST FLANGE CPL. HH COLLAR SCREW M 6X20 WS=8 COLLAR NUT M6X1 SW8 WASHER DIN0125-A 6,4 STUD SCREW M6 RETAINING PLATE HH COLLAR SCREW M 5X10 WS=8 THROTTLE M6X10X0,6

087733630 / C087733630

LUBRICATING SYSTEM
FIG PART NUMBER DESCRIPTION OIL PUMP SHAFT SUCTION PUMP GASKET PRESSURE PUMP CASE PRESSURE PUMP PUMP COVER 07 AH SCREW DIN0912-M 5X12 NEEDLE ROLLER DIN5402 3X15,8 OIL PUMP GEAR 18-T WASHER 10,2X18X1 TAB WASHER DIN6799 RS8 PRESSURE PUMP CASE NEEDLE ROL.DIN5402 NRB 4X9,8 GASKET PRESSURE PUMP COVER PRESSURE PUMP COVER HH COLLAR SCREW M 6X40 WS=8 OILPUMP IDLER GEAR 24-T. NEEDLE BEARING K 10X13XLOCK WASHER BEARING BOLT BEARING BOLT OIL INTAKE SNORKEL O-RING 23,00X1,50 NBR 70 OIL SCREEN CPL. O-RING 30X2,0 FPM PLUG SCREW BALL D=10 DIN 5401 COIL SPRING CU-SEAL RING 14X20X1,5 LCPLUG SCREW M14X1,5 ALU AH OIL FILTER O-RING 34X1,5 VITON OIL FILTER COVER HH COLLAR SCREW M 6X16 WS=8

077733800 / C087733810

IGNITION SYSTEM
FIG 33 35* 36* PART NUMBER 0015060163 DESCRIPTION IGNITION COVER IGNITION COVER GASKET STATOR SX 06 FLYWHEEL 05 PULSER COIL KOKUSAN "PU5165" CDI UNIT KOKUSAN 450 SX-F 07 ADAPTER PULSER COIL SPARK PLUG NGK-XD05EMGK SPARK PLUG NGK CR9EKB 05 WIRE RETAINING BRACKET HH COLLAR SCREW M 5X10 WS=8 WIRING HARNESS FOR CDI-BOX HH COLLAR SCREW M 5X25 WS=8 O-RING 22,00X2,00 B70 SCREW PLUG M24X1,5 PA 6.6 IGNITIONCOIL KOKUSAN 4K3-A/B NEEDLE ROL.DIN5402 NRB 4X9,8 HH COLLAR SCREW M 6X20 WS=8 AH SCREW DIN0912-M 5X25 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X16 TX30 RETAINING PLATE F.PICKUPCABEL HH COLLAR SCREW M 6X16 WS=8

077733900 / C087733910

ELECTRIC STARTER
FIG PART NUMBER HDESCRIPTION E-STARTER ENGINE CPL. 07 NEEDLE BUSH HK 0810 DIN 618 DRIVE WHEEL AGZR COLLAR NUT M27X1 FREE WHEEL CLUTCH MECHANISM 97 NEEDLE BEAR. K25X32X16 STARTING GEAR Z=52 TORQUE LIMITER CPL. 07 HH COLLAR SCREW M 6X25 WS=8 O-RING 25,00X3,00 NBR 70 INTERMEDIATE STARTING GEAR BEARING BOLT

077734000 / C087734011

450 SMR 2009
SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF8403I0EN

ENGLISH
FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS FRAME

FRONT FORK, TRIPLE CLAMP

SWING ARM SHOCK ABSORBER
SHOCK ABSORBER DISASSEMBLED

EXHAUST SYSTEM

AIR FILTER TANK, SEAT, COVER

MASK, FENDERS

FRONT WHEEL
REAR WHEEL WIRING HARNESS HAND BRAKE CYLINDER
REAR BRAKE CONTROL BRAKE CALIPER REAR

BRAKE CALIPER FRONT

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 1* 82* 92 PART NUMBER 14187E0025080356 0025080256S 5900109400004 DESCRIPTION FORK KTM 450 SMR 2009 HH COLLAR SCREW M8X25 TX40 HH COLLAR SCREW M8X35 TX40 HH COLLAR SCREW M8X25 TX40 AH SCREW DIN6912-M10X35 10.9 STE.HEAD SCR. M20X1,5 WS=27 SL SELF-LOCKING O-RING 25X3,55 NBREJOT PT SCREW K60X20 ALU WS=6 BOTTOM TRIPLE CLAMP 14-16 FORK TUBE SMR 1MM EXZ. 08 TOP TRIPLE CLAMP 14-16 OFFSET STEER.HEAD SCREW M20X1,5 WS=27 HANDLEBAR CLAMP 28MM 05 HANDLEB.SUPP. D=28MM H=32MM 05 HANDLEB.SUPP. D=28MM H=37MM 05 HANDLEB.SUPP. D=28MM H=42MM 05 TAPERED ROLLER BEARING CPL. 06 O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F.SPEED.CABLE ORANGE 06 STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS=8 FORK PROT. L/S +R/S ORG 02

QTY 2 x 2 x 1

087730110 / C097730112

* NEW PART

X AS REQUIRED

FRONT FORK DISASSEMBLED

FIG 3 11* 12* 50 PART NUMBER 46810811 48600280S 48600444 91410054S 91410058S 48600519S48600542 DESCRIPTION SETTING KNOB GUIDING RING D=58MM OUTER TUBE L577 D54/60MM 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 MEMBRANE O-RING NBR 9,5X1,5 O-RING NBR 17X2 PA SCREW BUSH M20X1 L=33 CPL. COPPER WASHER 20,5X26X1 ADJUSTING TUBE L351 PISTON ROD D=12 M9X1 L=385 COUNTERNUT M12X1 WS17 ADJUSTER NEEDLE 07 O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM SPRING 4,8 N/MM SET D=5,25MM SPRING D43.2 L465 5N/MM SET SPACER 43X35X2,5 SPACER 43X35X5 SPACER 43X35X1,5 GUIDING BUSH REBOUND SPRING SPRING SUPPORT O-RING 6X1,2 NBR SPRING REB. L=32 C=37 DI=13,9 PISTON ROD REBOUND SPRING CHECK VALVE D=0,5 SHUTTLE VALVE SPRING C=0,4 MEMBRANE HOLDER LOCK WASHER D=25,5 AH SCREW M4X6

QTY 2 x x x x x 2 2

097730130 / C097730130
FIG 60* 61* PART NUMBER 50180222 48600518S 48600697S2 48600691S48600471 48600546S 48600692 48600401S48600516ST511 R14014 DESCRIPTION O-RING NBR 21X2 PISTON COMPRESSION D=27,9 O-RING NBR 4X1,5 PIN VALVE SET NUT M6X0,5 REBOUND GUIDE RING 44 X39 RING SPRING-SUPPORT O-RING NBR 46 X 2 AXLE CLAMP L/S + TUBE CPL. 09 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 PISTON ROD COMPRESSION PISTON REBOUND SX 2007 PISTON RING 5X1X68 RING D=23,45X2,65 PISTON ROD SEALING SCREW SLEEVE M24,5X1 CPL. DU BUSH FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D=20 SILICON CAP RUBBER CAP D=26,4 FORK OIL SAE5 5L 2005 O-RING NBR 43X2 SCREW CAP CPL. L=125 AH SCREW M4X6 SCREW M4X10 MEMBRANE SLEEVE SILICONE GREASE F. DUST STRI REPAIR-KIT GASKET 48MM 0

QTY 1 1

HANDLEBAR, CONTROLS
FIG 21* 30* 31* 32* 33* 34* 36 37* 38* 39* 40* 41* 92 PART NUMBER 77002091000 DESCRIPTION HANDLEBAR D=28 MM RENTHAL 796 TWIST GRIP COVER RENTHAL 04 THROTTLE GRIP CPL. RACING 2004 STARTER BUTTON 06 SHORT CIRCUIT BUTTON 02 FIXED GRIP RENTHAL 04 CABLE TIE 100/2,5MM BLACK CABLE TIE 200/3,6MM BLACK HOSE 7X11,5X15 HANDGUARD L/S+R/S CPL.BLACK 04 HOT START LEVER CPL. 09 MASTER CYLINDER CPL. 10,5MM 09 CLUTCH LEVER CPL. 2009 REP.KIT PISTON 10,5MM 09 COVER HYDR. CLUTCH CPL. 09 RUBBER FOR RESERVOIR 09 OIL FOR HYD. CLUTCH 75ML MUD CAP 09 LEVER SCREW CPL. 09 CLAMP + PIN + O-RING 09 PUSH ROD CPL. 09 HH COLLAR SCREW M6X16 TX30 CLUTCH PIPE RACING 2003 HOT START CABLE 05 THROTTLE CABLE 250 SXF 2005

QTY x x 1

097730211 / C097730212
FIG 5* 16* 17* 18* 19* 28* PART NUMBER 59003013000 0019080206S DESCRIPTION FRAME SMR "JE08" 08 SUB FRAME SX "Q7" 07 SUB FRAME APPLICATION LEFT 08 SUB FRAME APPLICATION RIGHT 08 ENGINE BRACE 450 SX-F 09 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 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 M6X35 TX30 EXPANSION TANK CPL. 2004 EJOT PT SCREW K60X20 WS=6 O-RING 80,00X2,00 VITON HH COLLAR SCREW M6X10 TX30 SPACER BUSH. F. SPEEDOMET.BRA. HH COLLAR SCREW M6X25 TX30 FOOT PEG L/S SILVER 02 FOOT PEG R/S SILVER 02 BOLT FOR FOOT PED 03 FOOTREST SPRING L/S & R/S WASHER DIN0125-A10,5 PIN DIN0094-3,2X25 STEEL FOOTPEG L.+R. CPL. 03 ANGEL PIECE '97 HOSE EPA D=6/10 L=2000MM CHAIN SPROCKET COVER

QTY 1 x x 1

097730312 / C097730312
FIG 63* 64 PART NUMBER DESCRIPTION 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 1

SWING ARM
FIG PART NUMBER 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 BUSHING SLEEVE F. SWING ARM 03 NEEDLE BEARING HK 2216 STOP DISK 22,2X31,7X1 CHAIN GUIDE REAR CPL. 07 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 CHAIN STOP GUARD SMR 2008 EJOT PT SCREW K60X20 WS=6 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 05-07

087730490 / C087730491

SHOCK ABSORBER
FIG 8 10* PART NUMBER 0025120506S 12187E15 DESCRIPTION HH COLLAR SCREW M12X50 TX45 MONOSHOCK PDS B07DA 450 SMR 09

QTY 2 1

085030410 / C097730413
FIG 1* 86 PART NUMBER 50180733S5 50180213SR50180520S 91210070S 91210072S 91210073S 50180273 50180463S 50180616S 50180603S 50180604 50180605S 50180511 DESCRIPTION TOP PART CPL. M57,5X1 SMR 09 DCC-COMPR.DAMP.CONTROL CPL. 03 ADAPTOR BUSH KGW 12X24 REP. KIT BEAR./SEAL UP. 07 BLEED PLUG R 1/8 WP CAUTION (PDS KTM) 58X83 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 76N/MM SPRING N/MM SPRING N/MM CIRCLIP 58,2X2 SPRING RET. D=80 W. O-RING 05 O-RING VITON 66,27X3,53 O-RING VITON 44,17X1,78 PISTON RING 50-8 BLEED SCREW M6 PISTON ROD NUT M16X1 CPL. REBOUND DISC D=34, H=8 PISTON 6+6X7/4,5 NEEDLE L=171 O-RING VITON 2,2X1,6 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 CIRCLIP 53X1,75 COVER D=50 07

QTY x x x 1

087800434 / C097730430
FIG PART NUMBER 50180480 50180512S50180434S 50180342S1 R12014 DESCRIPTION BUMP RUBBER D58 D17 H59 SXS 05 MONOSHOCK LOWER PART CPL. 07 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 06
FIG 4 8* 22 30* 34* 44 PART NUMBER DESCRIPTION SILENCER EXC-F THROTTLED 07 THERMAL PROTECTION FOIL 07 SILENCER HOUSING EXC-F 07 CONNECTING CAP CPL. EXC-F 08 SPRING WASHER DIN0137-B 6 BUSHING 7.5x12x28x7.EXHAUST BRACKET RUBBER BLACK RANGE CHANGE METAL NUT M6 HH COLLAR SCREW M6X30 TX30 THROTTLE ELEMENT CPL. EXC 07 SIL. ELEMENT EXC-F 07 TEN.SPRING L=62MM EY.MOVEABLE SCREW TORX M5XENDCAP W. SILENCER ELEMENT 09 STUFFINGYARN 315 GRAMS STUFFING YARN EXC-F 07 EXHAUST MANIFOLD 450 SX-F 07 HH COLLAR SCREW M8X25 TX40 BUSHING FOR EXHAUST SUPPORT 03 RANGE CHANGE METAL NUT M8

097730511 / C097730513

AIR FILTER
FIG 27* PART NUMBER 77304066050 DESCRIPTION AIR BOX PART RIGHT 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 FASTEN. DEVICE FILTER S. SX 07 EDGE PROTECTOR 14X9,5X66 MM 06 CARB. CONNECT. BOOT 450 SMR 08 HOSE CLAMP 45-65MM AIR FILTER SPACER RING SMR 08 AIR FILTER HOSE CLAMP 70-90MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 BUSHING F. CHAIN SLIDING PR.07

QTY x 1 2

087730610 / C097730611

TANK, SEAT, COVER

FIG 63 PART NUMBER 7730805400030E DESCRIPTION GAS COCK MIKUNI ON/OFF 2001 O-RING 13,00X2,30 PVC-HOSE 5,6X10X270MM TANK PLUG ORANGE/BLACK TANK BUSHING 07 FUEL TANK CPL. SX 7,5L 08 TANK ROLLER 12X26X12 '98 FUEL PREFORMED HOSE 450 SX-F CLAMP YDNAC 10128 12MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 ANGLE PIECE 90 DEGREE M10X1 SEAT SX 07 SEAT COVER 07 SPOILER KIT BLACK SMR 2008 WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X12 TX30 COLLAR SCREW M6X27 TX

087800712 / C087730711

FIG PART NUMBER DESCRIPTION DISPLACEM. STICKER 450 SMR 08 SPOILER DECAL 450 SMR 08

087730834 / C087730834

FIG 6* PART NUMBER 0025060206 DESCRIPTION START NUMBER PLATE CPL. BLACK BRAKE HOSE GUIDE ORANGE 07 EJOT PT SCREW K60X20 ALU WS=6 HH COLLAR SCREW M6X10 TX30 HH COLLAR SCREW M5X20 TX30 FENDER FRONT SMR 08 SPACER BUSHING 03 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X10 TX30 RETAINER F.NUMBER PLATE SMR 08 COLLAR BUSHING 4,5/12,6/23 REAR FENDER SX ORANGE 07 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

087730810 / C097730810

FIG 40 PART NUMBER 54809081070 DESCRIPTION FRONT WHEEL 3,5X16,5 SMR 08 FRONT WHEEL HUB CPL. 08 BEA.SPACERTUBE 35X2 L=79,GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL 08 SPOKE M4,5X164-16,5" 08 SPOKE NIPPLE M4,5X0,75 8X21 FRONT RIM 3,5X16,5" RIM BAND 17" FRONT WHEEL REP. KIT BRAKE DISC FRONT 310MM SMR 07 SPECIAL SCREW M6X16 WS=8 10.9 WHEEL SPIN.FR. D=26 M24x1,SPINDLE SCREW M24X1,5 WS=PLUG BUSHING WS=AUXILIARY SCREW FRONT 06

QTY x 1 1

087730910 / C087730910

REAR WHEEL

FIG PART NUMBER 58310151052 0019080266S DESCRIPTION REAR WHEEL CPL. 5X17 SMR 08 REAR HUB CPL. 08 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 M5X174-13,5G 17" SPOKE NIPPLE M5-TA 8X21MM REAR RIM 5,0X17" BRAKE DISC REAR 220 SPECIAL SCREW M6X13 WS=8 10.9 RIM BAND 17" 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 5/8X1/4" MX CONNECTING LINK F. 50310165118 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 1

087731010 / C097731010

WIRING HARNESS
FIG 96 PART NUMBER 0017060203 DESCRIPTION MAIN WIRING HARNESS 450 SX-F VOLTAGE REGULATOR "RS2759" 06 CABLE TIE 200/3,6MM BLACK CABLE TIE 300/4,8MM BLACK FUSE 10 A 2000 BATTERY CASING BATTERY 12V 3AH YTX4L-BS 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 HH COLLAR SCREW M6X20 TX30 EJOT PT SCREW K60X20 WS=6

QTY x x 3

087731111 / C087731111

HAND BRAKE CYLINDER

FIG PART NUMBER DESCRIPTION HANDBRAKECYLINDER MAGURA 07 HOLLOW SCREW + COPPER GASKET BRAKEHOSE FRONT 1160MM 07 CLAMP 07 HH COLLAR SCREW M6X16 TX30 HANDBRAKE LEVER CPL. 07 LEVER SCREW CPL. 05 ROCKER CPL. FOR BRAKE LEVER 07 ADJUSTING SCREW CPL. REP. SET PISTON D=12MM 2007 BRAKE FLUID RESERVOIR CPL.2007 O-RING+SCREW+SLEEVE 07 BLEEDER SCREW WITH CAP BRAKE FLUID DOT5.1 0,25L

QTY 1 x

087731310 / C087731310

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

085031330 / C087801332

BRAKE CALIPER REAR
FIG 1* 11* 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

095031390 / C095031390

FIG 1* 14 PART NUMBER DESCRIPTION BRAKE CAL. FR. - WITHOUT PADS WASHER 10,2X20X2,5 MM 04 COLLAR SCREW M10X1,25X55 TX BRAKE PAD SINTER 07 FIXING FOR BRAKE PAD 07 PISTON WITH GASKET MAGURA 07 SEAL RING KIT CPL. MAGURA 07 BRAKEHOSE FRONT 1160MM 07 HOLLOW SCREW CPL. M 10X1 '98 COPPER GASKET

097731360 / C097731360

FIG 0 1* 1* 1* PART NUMBER 78011055000 3211363EN 3CF8403I0EN 3CM089260IEN DESCRIPTION DOCUMENTS BAG 2006 KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER FOOTPEG L.+R. CPL. 03 BATTERY 12V 4AH YTX5L-BS EXPANSION TANK CPL. 2004 HAND GUARD L/S CPL.W.FAST. 04 HAND GUARD R/S CPL.W.FAST. 04 PLASTIC FRAME PROTECTION SET BATTERY 12V 3AH YTX4L-BS BARRERY CASING OWNERS MANUAL 450 SMR 2009 SPC CHASSIS 450 SMR 2009 SPC ENGINE 450 SMR 2009 BORDTOOL 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 WRENCH

087732000 / C097732004

SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM089260IEN

SPECIAL TOOLS
CYLINDER ENGINE CASE CLUTCH COVER
CRANKSHAFT, PISTON CARBURETOR

CLUTCH

TRANSMISSION I - MAIN SHAFT
TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM

WATER PUMP

COOLING SYSTEM

VALVE DRIVE

TIMING DRIVE CYLINDER HEAD LUBRICATING SYSTEM
IGNITION SYSTEM ELECTRIC STARTER
FIG PART NUMBER DESCRIPTION ASSY SUPPORT (WITHOUT HOLDER) FIXING ARM CPL. 450 SX-F 07 PLASTIGAUGE - MEASURING STRIP 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 INTERN.BEAR.PULLER 8-12 MM LIMIT PLUG GAUGE F.VALVE GUIDE MOUNT.SLEEVE F. SH.S.RING WAPU FEELER GAUGE SET10,12,15,20,25 INSERT FOR VALVE SPRING LEVER 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 EXTRUDE PLATE BASE F. CRANKSH. EXTRUDE PLATE TOP F. CRANKSH. VENT INJEKTION HYDR. CLUTCH LOCTITE 648 GREEN 24ML HOLD. PLATE CLUTCH 450 SX-F 07 PROTECTOR CAP F.CRANKSHAFT 07 ASSEMB. PIN F. GUID. AGW-ZR-KS DEGREE DISK 360DEG - 1/2 INCH WRENCH F.MIXTURE CONTROL SCREW SP. WRENCH F.HOSE CONNECTOR 07 ADJUST BUSH BRIDGE UNLOCK CHAIN TENSIONER LOCATING SCREW

087732910 / C087732910

FIG PART NUMBER DESCRIPTION SPECIAL SOCKET F. PRIMARY GEAR PLUG IN FUSE PISTON PIN ADAPTOR F.OIL PRESSURE GAUGE EFI PRESSURE TESTER

CYLINDER

FIG PART NUMBER DESCRIPTION CYLINDER CYLINDER ROLLER ZRO. 8,0X12 M4 O-RING 107,67x1,78 VITON GASKET GEAR CASE

087733040 / C087733040

ENGINE CASE
FIG PART NUMBER DESCRIPTION ENGINE CASE CPL. W.TR.BEAR. 08 OILDRAIN PLUG W.MAG. M 12X1,5 CU-SEAL RING DIN7603-12X18X1,5 BUSHING RETAINING PLATE BUSHING RETAINING PLATE INT. TORX FLAT HEAD M 5X10 8.8 BUSHING RETAINING PLATE BUSHING RETAINING PLATE RETAINING PLATE COLLAR SCREW M5X12 ISA30 AH SCREW DIN6912-M 8X20 SEAL RING CU DIN7603- 8X12X1 DOWEL 17 X 19 X 12 OIL JET DOWEL BUSHING 13,8X11X12 JET 100 BING(44-031/180) M4 SCREW M7-1,0X70 HH COLLAR SCREW M6X70 TX30 HH COLLAR SCREW M6X55 TX30 CYLINDER ROLLER ZRO. 8,0X12 M4 GASKET SET 450SX-F THROTTLE M5X10X1 CASE BUSH DOWEL 6X8X11,5

087733010 / C097733011

CLUTCH COVER
FIG 1* 6* 16 17* 22* 36 PART NUMBER DESCRIPTION CLUTCH COVER CPL. SHAFT SEAL RING 12x24x4 SHAFT SEAL RING 12x24x4/5,5 BALL BEARING 6202 C0 2RSH RETAINING PLATE FOR WAPUSTOCK SHAFT SEAL RING 20X30X7 SHAFT SEAL RING 12x35x7 BSL VI INT. TORX FLAT HEAD M 5X10 8.8 O-RING 8,00X1,5 NBR 70 CYLINDER ROLLER ZRO. 8,0X12 M4 OIL LEVEL GLASS G 1777 Y CIRCLIP OIL LEVEL GLASS 03 HH COLLAR SCREW M6X20 TX30 SCREW M7-1,0X45 HH COLLAR SCREW M6X30 TX30 CLUTCH COVER OUTSIDE 09 CLUTCH CASE GASKET O-RING 19,00X3,00 NBR PLUG CPL. M24X3 BLEEDER FLANGE M12X1,5 WS=13 ENGINE BREATHER TUBE YDNAC-CLAMP 10173 (16MM) '98 QUAD-RING 28,3X1,78 VITON SPRING BRACKET

097733020 / C097733020

CRANKSHAFT, PISTON
FIG 6 7* 8 14* 22 23* 40* 40* 41* 42 PART NUMBER 77330007500 I 77330007500 II DESCRIPTION CRANKSHAFT CPL. CONNECTING ROD REPAIR SET THRUST WASHER 30X42X0,1 THRUST WASHER 30X42X0,2 THRUST WASHER 30X42X0,3 CYL. ROLLER BEARING NJ206 ECP COLLAR NUT M27X1 DRIVE WHEEL AGZR KS Z=32 SHAFT SEAL RING A40x55x6 VITON FLYWHEEL SCREW WOODRUFF KEY DIN6888-3X3,7 PRIMARY GEAR PISTON PIN CIRCLIP PISTON 450 SIZE I PISTON 450 SIZE II SCRAPER RING 450 COMPRESSIONRING D=97 2007

097733060 / C097733061

CARBURETOR
FIG PART NUMBER DESCRIPTION CARBURETOR FCR-MX 4125I,TPS 08 CARBURETOR COVER WITH GASKET THROTTLE SHAFT CPL. 06 COIL SPRING THROTTLE SHAFT LINK ARM THROTTLE VALVE CPL.07 THROTTLE VALVE CPL. FCRMX 2007 BUSHING THROTTLE VALVE GASKET PLATE THROTTLE VALVE 04 GASKET WASHER THROTTLE VALVE JET NEEDLE KEIHIN OBDTM 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 180 KEIHIN MAIN JET 182 KEIHIN MAIN JET 185 KEIHIN MAIN JET 188 KEIHIN MAIN JET 190 KEIHIN MAIN JET 192 KEIHIN MAIN JET 195 KEIHIN IDLE JET 40 KEIHIN 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 HOT-STARTER VALVE FLOAT NEEDLE CLAMP
QTY 1 x x x x x 1 x x x x x x x x x x 1

097733110 / C097733110

FIG 99 PART NUMBER 57331099000 DESCRIPTION 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 O-RING U-RING COIL SPRING O-RING ADJUSTING SCREW 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. STOP SCREW CPL. FCR-MX TPS-SENSOR FCRMX 190MM 2006 GASKET SET FCR-MX KEIHIN

QTY x x x x x 1 1

FIG 23* 24* PART NUMBER DESCRIPTION OUTER CLUTCH CPL. 08 INNER HUB PRESSURE CAP OUTER HUB STEEL DISC NITRIDE INTERMEDI. DISC STEEL AJ SYSTEM CPL. LINING DISC 2,7MM TURNED LINING DISC INNER RING WASHER SMALL 5,5X12X1 WASHER LARGE 13X18X1 WASHER LARGE 13X18X1,5 SAFETY SCREW APTC 2004 SPECIAL NUT M18X1.5 WASHER 21,7X38XPRIMARY GEAR DRIVE WHEEL AGZR KS Z=32 O-RING 38,00X2,00 NBR 70 SH OUTPUT CYLINDER CPL. PISTON CPL. CLUTCH SPRINGS APTC CPL. PUSH ROD 07 PRESSURE PIECE PRESSURE PIECE CPL. HH COLLAR SCREW M5X25 ISA30 HH COLLAR SCREW M6X25 TX30 VENT INJEKTION HYDR. CLUTCH 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

097733211 / C097733211

FIG PART NUMBER 0405242813G 0019050103 DESCRIPTION MAIN SHAFT GUIDE BUSHING NEEDLE BEAR.K 24X28X13 DIVIDED IDLER GEAR 3G STOP DISK 26 X 32 X 1,5 CIRCLIP SW25 SLIDING GEAR 4G STOP DISK 23 X 32 X 1,5 NEEDLE BEAR. K 22X26X13 TN IDLER GEAR 5G SOLID GEAR STOP DISC 17,2X30X1 BALL BEARING 6203 RSH C3 BALL BEARING 6205 C3 NTN BUSHING RETAINING PLATE INT. TORX FLAT HEAD M 5X10 8.8

QTY 1 2

087733330 / C087733332
TRANSMISSION II - COUNTERSHAFT
FIG 21 PART NUMBER 77333415000 DESCRIPTION STOP DISC 17,1X32X2,6 IDLER GEAR 2G IDLER GEAR 1G NEEDLE BEAR. K 22X26X13 TN STOP DISC 22,2X32X1,5 SLIDING GEAR 3G CIRCLIP SW25 STOP DISK 23 X 32 X 1,5 CIRCLIP DIN 0471-17X1, 5 IDLER GEAR 4G COUNTERSHAFT INT. TORX FLAT HEAD M 5X10 8.8 BUSHING RETAINING PLATE BALL BEARING 6203 RSH C3 CYL.ROLLER BEARING NUP205E C3 SHAFT SEAL RING 35X47X7 TC O-RING 25,00X1,50 NBR 70 SPACER BUSHING FRONT SPROCKET 13-T FRONT SPROCKET 14-T FRONT SPROCKET 15-T SCREW 10.9+SPRING WASHER SLIDING GEAR 5G

QTY x x x 1 1

087733360 / C087733363

SHIFTING MECHANISM

FIG 13* 40 PART NUMBER DESCRIPTION SHIFTING FORK 2ND/4TH GEAR SHIFTING FORK 3RD/5TH GEAR 03 SHIFT SHAFT CPL. 07 SHIFTING FORK 1ST.GEAR PRESSURE SPRING 0,9MM SLIDING PLATE CPL. TENSIONING SPRING 0,8MM SPRING GUIDE BALL BEARING 61806 SHIFT ROLLER 5G 08 BALL BEARING 6805 C3 JR RETURN SPRING 03 SHIFT LOCATING DRUM CPL. AH SCREW DIN6912 M6X30 8.8 INT. TORX FLAT HEAD M 5X10 8.8 BUSHING RETAINING PLATE SHIFTING ROLLER 6X8X5,2 SHIFT RAIL FRONT SHIFT RAIL ARRESTING LEVER SPRING 03 LOCATING LEVER CPL. 08 SLEEVE FOR LOCKING LEVER WASHER DIN9021-A 5,3 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

087733411 / C097733412

FIG 1* 4* PART NUMBER DESCRIPTION WATER-PUMP COVER 09 SCREW IN NOZZLE M20X1,5 WATER-PUMP GASKET 06 HH CAP NUT DIN1587-M 6 SS. WATER-PUMP WHEEL 07 NUT M14 X 1 FOR BALANCER. 06 BALANCER GEAR KS 32-T 07 HH COLLAR SCREW M6X55 TX30 HH COLLAR SCREW M6X16 TX30 CU-SEAL RING DIN7603-6X10X1 HH COLLAR SCREW M6X10 TX30 NEEDLE BEARING RNA 4900

087733510 / C097733511

FIG PART NUMBER DESCRIPTION RADIATOR L/S "45519U" 07 RADIATOR R/S "45518U" 07 RADIATOR CAP SMALL 1,8 BAR T-CONNECTOR CPL. 07 HOSE CLAMP GEMI 16-27 HOSE CLAMP NORMA 12/22 ANGEL PIECE '97 PVC-HOSE 6X9 MM PER METER RADIATOR HOSE R/S HOSE ENGINE-RADIATOR 07 RADIATOR HOSE L/S RADIATOR PROTECTION BLACK 07 HOSE CONNECTOR 4 STROKE 07 RUBBER SLEEVE D=12MM WASHER FOR RADIATOR 08 COLLAR SCREW M6X12 TX

QTY 1 x 4 4

087733530 / C097733531
FIG 3 6* PART NUMBER DESCRIPTION INTAKE VALVE 07 EXHAUST VALVE 07 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 SPRING KIT 09 VALVE COLLET 07 VALVE-STEM SEALING RACING VALVE LEVER VALVE LEVER INTAKE VALVE LEVER SHAFT EXHAUST VALVE LEVER SHAFT

QTY x x x x x x x x x x x x x x x x x x x x x x x 1

097733610 / C097733610

TIMING DRIVE
FIG 1* 2* 11* 30 PART NUMBER DESCRIPTION CAMSHAFT INTAKE CAMSHAFT EXHAUST CPL. CYL.ROLL BEARING RNU203ETVP2 CAMSHAFT GEAR 07 SCREW MW M10-1,0X38 NEEDLE BEAR K 18X22X13 NEEDLE BEARING K 18X22XDOUBLE GEAR W.CPL. Z18/ZAXLE FOR TIMING VALVE 06 O-RING 15,00X1,80 HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH HOLDING BOLT M24X1,5 CU SEAL-RING DIN7603 A24X29X2 CHAIN ADJUSTER HYD. 05 TENSIONER RAIL CPL. 07 TIMING CHAIN 07 GUIDE RAIL 07 O-RING 12,00X1,50 NBR BUSHING SCREW BUSHING SCREW BALANCER GEAR STOP DISC 18/32/1,4/2,7 O-RING 18,00X2,00 NBR 70

077733602 / C097733621

CYLINDER HEAD
FIG 1* 18* 21* 28 29* 38 PART NUMBER DESCRIPTION CYLINDER HEAD CPL. CYL. HEAD GASKET S=0,VALVE COVER VALVE COVER GASKET VALVE COVER SCREW RUBBER GASKET FOR SCREW 05 GASKET SPARK-PLUG SHAFT O-RING 25,00X1,50 NBR 70 SCRW M7-1,0X38 BUSHING HOLDER AH SCREW DIN0912-M 5X10 COLLAR NUT M10X1,25 SW13 WASHER 19X10,5X2,5 STUD SCREW M10 VALVE GUIDE AH SCREW DIN7984-M 4X12 OIL JET O-RING 1,5x6 INTAKE BOOT HOSE CLAMP GEMI 56MM 03 CYLINDER ROLLER ZRO 5X8 SCREW PLUG O-RING 9X1,5 NBR PLUG 00 SCREW IN NOZZLE M20X1,5 GASKET EXHAUST FLANGE EXHAUST FLANGE CPL. SX-F 08 HH COLLAR SCREW M6X16 TX30 COLLAR NUT M6X1 SW8 WASHER DIN0125-A 6,4 STUD SCREW M6 RETAINING PLATE COLLAR SCREW M5X12 ISA30 THROTTLE M6X10X0,6

087733630 / C097733631

LUBRICATING SYSTEM
FIG 1* 2* 3 4* 30* 31* 32 PART NUMBER 0025060166 DESCRIPTION OIL PUMP SHAFT SUCTION PUMP CPL. GASKET PRESSURE PUMP CASE PRESSURE PUMP PEEK D=9MM PUMP COVER 07 AH SCREW DIN0912-M 5X12 NEEDLE ROLLER DIN5402 3X15,8 OIL PUMP GEAR 18-T WASHER 10,2X18X1 TAB WASHER DIN6799 RS8 PRESSURE PUMP CASE NEEDLE ROL.DIN5402 NRB 4X9,8 GASKET PRESSURE PUMP COVER PRESSURE PUMP COVER HH COLLAR SCREW M6X40 TX30 OILPUMP IDLER GEAR 24-T. LOCK WASHER BEARING BOLT BEARING BOLT OIL INTAKE SNORKEL O-RING 23,00X1,50 NBR 70 OIL SCREEN CPL. O-RING 30X2,0 FPM PLUG SCREW BALL D=10 DIN 5401 COIL SPRING CU-SEAL RING 14X20X1,5 LCPLUG SCREW M14X1,5 ALU AH OIL FILTER O-RING 33,05X1,78 OIL FILTER COVER 08 HH COLLAR SCREW M6X16 TX30

097733810 / C097733811

IGNITION SYSTEM
FIG 1* 37 PART NUMBER DESCRIPTION IGNITION COVER 09 IGNITION COVER GASKET STATOR SX 06 FLYWHEEL 05 PULSER COIL KOKUSAN "PU5165" CDI UNIT KOKUSAN 450 SX-F 07 ADAPTER PULSER COIL SPARK PLUG NGK-XD05EMGK SPARK PLUG NGK CR9EKB 05 WIRE RETAINING BRACKET COLLAR SCREW M5X12 ISA30 WIRING HARNESS FOR CDI-BOX HH COLLAR SCREW M5X25 ISA30 O-RING 22,00X2,00 B70 SCREW PLUG M24X1,5 PA 6.6 IGNITIONCOIL "IG5128" NEEDLE ROL.DIN5402 NRB 4X9,8 HH COLLAR SCREW M6X20 TX30 AH SCREW DIN0912-M 5X25 COLLAR SCREW M6X12 TX HH COLLAR SCREW M6X16 TX30 RETAINING PLATE F.PICKUPCABEL

097733911 / C097733911

ELECTRIC STARTER
FIG 9* 14* PART NUMBER HDESCRIPTION E-STARTER ENGINE CPL. 07 NEEDLE BUSH HK 0810 DIN 618 DRIVE WHEEL AGZR KS Z=32 COLLAR NUT M27X1 FREE WHEEL CLUTCH MECHANISM 97 NEEDLE BEAR. K25X32X16 STARTING GEAR Z=52 TORQUE LIMITER CPL. HH COLLAR SCREW M6X25 TX30 O-RING 25,00X3,00 NBR 70 INTERMEDIATE STARTING GEAR BEARING BOLT

087734010 / C097734011