KTM 525 EXC 2006 User Manual

525 EXC 2006

SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM089428EN

ENGLISH

SPECIAL TOOLS

ENGINE CASE

BLANCER SHAFT

525 EXC 2006

CRANKSHAFT, PISTON

CYLINDER

TRANSMISSION I

3x

CARBURETTOR

8x

TRANSMISSION II

4x

CLUTCH

9x

SHIFTING MECHANISM

6x

11x

7x

KICKSTARTER

12x

COOLING SYSTEM

1

13x

14x

15x

16x

VALVE DRIVE

CYLINDER HEAD

TIMING VALVE

525 EXC 2006

LUBRICATING SYSTEM

IGNITION SYSTEM

17x

21x

ELECTRIC STARTER

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical
specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local
conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing
certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations,
descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
© 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of
KTM-SPORTMOTORCYCLE AG, Mattighofen only.

18x

22x

19x

x

20x

x

x

2

SPECIAL TOOLS

525 EXC 2006

FIG PART NUMBER DESCRIPTION QTY

1* 56012001044 UNIVERSAL MOUNTING RACK CPL. 1

2 59029002000 ENGINE HOLDER FOR RACING 2000 1
3 59029020000 RIVETTING TOOL TIMING CHAIN 1
4 59029005010 MOUNTING SLEEVE SEAL RING 1
5 51012011000 SPECIAL CIRCLIP PLIER 1
6 59029021044 EXTRACTOR PRIM. GEAR CPL. 1
7 58012015089 PISTON RING COMPRESSOR D=89MM 1
7 58012015095 PISTON RING COMPRESSOR D=95MM 1
7 59829015075 PISTON R. COMPRESSOR D=75MM 02 1
8 6899785 LOCTITE 243 BLUE 6CCM 1

9 15112017000 BUSHING EXTRACTOR 1
10 15112018000 INTERN.BEAR.PULLER 12-16 MM 1
10 15112018100 INTERN.BEAR.PULLER 18-23 MM 1
10 15112018200 INTERN.BEAR.PULLER 5-7 MM 1
11 59029026006 LIMIT PLUG GAUGE F.VALVE GUIDE 1
12 59029035000 MOUNTING RING FOR INNER CLUTCH 1
13 59029036000 PROTECTION COVER F.MAIN SHAFT 1
14 59029033000 EXTRACTOR FOR TIMING GEAR 1
15 59029019000 VALVE SPRING LEVER 1
16 58429037037 MOUNTING TOOL INNER RING NJ206 1
17 59031017200 MIXT. CONTROL SCREW FACTORY 04 1
18 58012009000 FLYWHEEL EXTRACTOR 1
19 309098 SILICON GASKET THREE-BOND 1
20 51012012000 HOLDING SPANNER FOR SPROCKET 1
21 59029072000 SPARK PLUG WRENCH 13/16 1
26 50329050000 VENT INJEKTION HYDR. CLUTCH 1
27 58429059000 LOCTITE 648 GREEN 24ML 1
28 59029003100 CLUTCH HOLDER RACING 2004 1
34 59029034000 WRENCH F.MIXTURE CONTROL SCREW 1

35* 59029018000 PRESS PUNCH VALVE GUIDE 1

3

065902900 / C065902900

* NEW PART

X AS REQUIRED

ENGINE CASE

525 EXC 2006

FIG PART NUMBER DESCRIPTION QTY

1* 59030000444 ENGINE CASE 2006 1

2 51030026100 DOWEL 17 X 13 X 12 1

3 49030090000 DOWEL 9,8 X 7 X 10 4

4 59030090000 HANGER FOR VENT HOSE 1

5 0014060153 HH COLLAR SCREW M 6X15 WS=8 1

6 58030021000 OILDRAIN PLUG W.MAG. M 12X1,5 1

7 58038022000 CU-SEAL RING DIN7603-12X18X1,5 2

9 0908120153 PLUG DIN0908-M12X1,5 1
10 59030024000 DOWEL 17 X 19 X 12 1
11 58038023300 PRESSURE SPRING L=25MM D=1MM 1
12 58038028000 VALVE PISTON D=10MM 1

13* 59030054000 JET 60 DELLORTO M6X0,75 1

17 59031050100 ENGINE BREATHER TUBE 00 1
18 59030022100 BLEEDER FLANGE M12X1,5 WS=13 1
19 58030080000 LOCATING SCREW M8 L=23 1
20 58030081000 CU-SEAL RING 8 X 14 X 3 1
21 0402025980 NEEDLE ROLLER DIN5402 2,5X9,8 1
22 59030019000 OIL LEVEL GLASS G 1777 Y 1
23 58030020000 PLUG M 24X3 1
24 0770191015 O-RING 19,00X3,00 NBR 1
26 0402040980 NEEDLE ROL.DIN5402 NRB 4X9,8 2
29 0125050003 WASHER DIN0125-A 5,3 1
30 0985050083 FLAT HEAD SCREW DIN7985-M 5X 8 1
31 0015060083 HH COLLAR SCREW M 6X8 WS=8 1
33 59030001090 RET.BRACKET F.BRAKE LEVER HUB 1
34 0770120020 O-RING 12,00X2,00 NBR 70 1
35 59038014000 PLUG M16X1,5 1
36 59038015000 OIL SCREEN 11,8X44,5MM 1
37 0770090015 O-RING 9X1,5 NBR 2
38 0603121830 SEAL RING DIN7603 12X18X3 1
41 59030025100 GASKET FOR CLUTCH COVER 1
42 59030039100 ENGINE CASE GASKET NS92-24 1
43 59030001000 CLUTCH COVER RACING 2000 1

44* 59030047100 CHAIN DAMPING PLATE RAC. 2005 1

50 0015060453 HH COLLAR SCREW M 6X45 WS=8 6
51 0015060603 HH COLLAR SCREW M 6X60 WS=8 4

4

065903000 / C065903000

* NEW PART

X AS REQUIRED

ENGINE CASE

525 EXC 2006

FIG PART NUMBER DESCRIPTION QTY

52 0015060303 HH COLLAR SCREW M 6X30 WS=8 10
53 0015060353 HH COLLAR SCREW M 6X35 WS=8 2
54 0015060753 HH COLLAR SCREW M 6X75 WS=8 1
60 59030099000 GASKET SET CPL. RACING 2000 1

5

065903000 / C065903000

* NEW PART

X AS REQUIRED

BLANCER SHAFT

525 EXC 2006

FIG PART NUMBER DESCRIPTION QTY

2 59030057044 BALANCER SHAFT CPL. RAC. 2001 1

4 0625160040 GROOVED BALL BEAR. TM 16004 C3 2

6 0760142460 SHAFT SEAL RING 14X24X6 B 1

6

065903008 / C065903002

* NEW PART

X AS REQUIRED

,

CRANKSHAFT

PISTON

525 EXC 2006

FIG PART NUMBER DESCRIPTION QTY

1* 59030018500 CRANKSHAFT CPL. 520 RAC. 2006 1

STROKE 72MM, WITHOUT WASHER

2 59030015044 CON.ROD REP.SET 250/520 RAC.00 1

WITH WASHER
4 50330082000 CYL.ROLLER BEAR.NJ206 ET2XCS46 2
5 59030055000 DRIVE GEAR 32-T F.BALANC.SHAFT 1
6 56030081000 THRUST WASHER 30,5X45X0,10 x
6 56030081100 THRUST WASHER 30,7X47X0,15 x
6 56030081200 THRUST WASHER 30,5X45X0,30 x
7 0888030050 WOODRUFF KEY DIN6888-3X5X13 2
8 0984060162 AH SCREW DIN7984-M 6X16 2
9 0760304772 SH.SEAL RING 30X47X7 BSL VITON 1

13 59032000033 PRIMARY GEAR 33-T 1
15 59030029100 HH NUR M20X1,5 WS=27 LEFT 1
16 6946005 WOODRUFF KEY 5X6,5 HARDED 1
17 0760142460 SHAFT SEAL RING 14X24X6 B 1
18 0471250120 CIRCLIP DIN0471-25X1,2 1
20 49030021000 COLLAR NUT M12X1 R/S 1
21 0137120000 SPRING WASHER DIN0137-B12 1
33 59030033000 PISTON PIN BOLT 20X15,8/12X50 1
34 59030074000 CIRCLIP C20X1,5 2
50 59030007000 I PISTON I 95MM CPL. FORGED 2000 1
50 59030007000 II PISTON II 95MM CPL.FORGED 2000 1
51 58030631000 OIL SCRAPER RING 95MM 1
52 59030032000 RECTANGULAR RING 95/87,2X1,25 1

7

065903004 / C065903011

* NEW PART

X AS REQUIRED