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Manual KTM 525 EXC 2006

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Summary
  • KTM 525 EXC 2006 - page 1

    525 EXC 2006 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089428EN ENGLISH ...

  • KTM 525 EXC 2006 - page 2

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  • KTM 525 EXC 2006 - page 3

    INDEX 525 EXC 2006 SPECIAL TOOLS 3 x ENGINE CASE 4 x BLANCER SHAFT 6 x CRANKSHAFT, PISTON 7 x CYLINDER 8 x CARBURETTOR 9 x CLUTCH 11 x KICKSTARTER 12 x TRANSMISSION I 13 x TRANSMISSION II 14 x SHIFTING MECHANISM 15 x COOLING SYSTEM 16 x 1 ...

  • KTM 525 EXC 2006 - page 4

    INDEX 525 EXC 2006 VALVE DRIVE 17 x CYLINDER HEAD 18 x TIMING VALVE 19 x LUBRICATING SYSTEM 20 x IGNITION SYSTEM 21 x ELECTRIC STARTER 22 x x x x All information contained is without obligation. KTM-Sportmotorcy cle AG particularly reserves the right to modify any equipment , technical specifications, prices, colors, shapes, materials, services, se ...

  • KTM 525 EXC 2006 - page 5

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1* 56012001044 UNIVERSAL MOUNTING RACK CPL. 1 2 59029002000 ENGINE HOLDER FOR RA CING 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=89 MM 1 ...

  • KTM 525 EXC 2006 - page 6

    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-M ...

  • KTM 525 EXC 2006 - page 7

    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 065903000 / C065903000 * NEW PART X AS REQUIRED 5 ENGINE CASE ...

  • KTM 525 EXC 2006 - page 8

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 2 59030057044 BALANCER SHAFT CPL. RAC. 2001 1 4 0625160040 GROOVED BALL BEAR. TM 16004 C3 2 6 0760142460 SHAFT SEAL RING 14X24X6 B 1 065903008 / C065903002 * NEW PART X AS REQUIRED 6 BLANCER SHAFT ...

  • KTM 525 EXC 2006 - page 9

    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.0 0 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 30,7X ...

  • KTM 525 EXC 2006 - page 10

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59030005000 CYLINDER 95MM 520 RACI NG 2000 1 2 59030035050 CYLINDER BASE GASKET 0,5MM 1 3 59030023000 DOWEL 6X8X11,5 2 4 0015060403 HH COLLAR SCREW M 6X40 WS= 8 1 5 0015060453 HH COLLAR SCREW M 6X45 WS= 8 2 7 0402040980 NEEDLE ROL.DIN5402 NRB 4X9,8 2 8 0603061001 CU-SEAL RING DIN7603-6X10X1 2 9 0015060 ...

  • KTM 525 EXC 2006 - page 11

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1* 59031001300 CARBURETOR FCR-MX 3900F,TPS 06 1 5* 57331027044 CARBURETOR COVER WITH GASKET 1 12* 57331046100 THROTTLE SHAFT CPL. 06 1 14 57331046050 COIL SPRING THROTTLE SHAFT 1 16 57331035051 LINK ARM THROTTLE VALVE CPL. 1 18 59031029010 SLIDE STOP 03 1 19 57331035000 THROTTLE VALVE CPL. 1 20 590310350 ...

  • KTM 525 EXC 2006 - page 12

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 46 57331155000 DRAIN SCREW FLOAT CHAM BER 1 47 57331060000 COVER ACCELERATOR PUMP 1 49 57331011000 FLOAT CHAMBER CPL. SET 1 53 59031059000 COIL SPRING 1 55 57331048000 STARTER VALVE CPL. 1 56 57331098000 BREATH.HOSE FCR-MX KEIHI N CPL. 1 60 57331038100 SCREW F. COVER KEIHIN 1 61 54531699000 PLUG M 18X1 1 ...

  • KTM 525 EXC 2006 - page 13

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1* 59032000476 OUTER CLUTCH HUB 76-Z/20-Z 01 1 HARDED 2* 59032002250 INNER HUB 06 1 3 59032011100 LINING DISC 2MM 04 7 4 59032010100 INTERMEDIATE DISC 1MM 2002 4 5* 59032003350 PRESSURE CAP WITH OIL BORE 06 1 6 59032005000 CLUTCH SPRING 2,5X43MM 6 7* 59032006050 SPRING RETAINER 6,2X12X18X5,2 6 8* 5903201 ...

  • KTM 525 EXC 2006 - page 14

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 54833070044 KICKSTARTER CPL. '03 1 2 54610052000 SPROCKET SCREW-AH M8X20 WS =6 1 3 54633037000 WASHER 8MM GALVANIZED 1 4 0760193070 SHAFT SEAL RING 19X30X7 B 1 5 59033055000 DRIVING HUB 1 6 59033051039 KICKSTARTER GEAR 39-T 1 7 0471170010 CIRCLIP DIN0471-17X1 1 9 0988172405 SHIM WASHER DIN0988-17X ...

  • KTM 525 EXC 2006 - page 15

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59033001400 MAIN SHAFT-ZB 14-T 03 1 2 59033005034 IDLER GEAR 5.G 24-T "34 " 1 3 0405222613 NEEDLE BEAR. K 22X26X13 TN 2 4 59033031000 STOP DISC 25,2X32X1,5 1 5 59033003032 SLIDING GEAR 3/4.G 19/22-T"32" 1 6 0471250120 CIRCLIP DIN0471-25X1,2 2 7 59033030000 STOP DISC 25,2X32X1,5 1 9 ...

  • KTM 525 EXC 2006 - page 16

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59033010000 COUNTER SHAFT RACING 2000 1 2 59033012025 IDLER GEAR 2.G 31-T "25 " 1 3 0405222611 NEEDLE BEAR.K 22X26X10 DIVIDED 3 4 59033031000 STOP DISC 25,2X32X1,5 1 5 0471250120 CIRCLIP DIN0471-25X1,2 3 6 59033016026 SLIDING GEAR 6.G 21-T "26" 1 8 59033030000 STOP DISC 25,2X32X1,5 ...

  • KTM 525 EXC 2006 - page 17

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59034031000 SHIFTING LEVER CPL.RACING 2000 1 2 0933060165 HH SCREW DIN0933-M 6X16 10.9 1 3 50232050001 STEEL WASHER 6,4X17X3 1 4 0760142460 SHAFT SEAL RING 14X24X6 B 1 5 54632095000 NEEDLE BEAR.HK 1412 14X20X12 2 6 59034002000 SHIFT FORK 2./4.GEAR 2000 1 7 59034005044 SHIFT SHAFT CPL. RACING '03 1 ...

  • KTM 525 EXC 2006 - page 18

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59035007300 RADIATOR L/S 45.407 03 1 2 59035008400 RADIATOR R/S 45.409 03 1 3 59035024100 RADIATOR HOSE L/S RAD.-CYL. 03 1 4 59035124100 RADIATOR HOSE R/S RAD.-CYL. 03 1 5 54435024001 HOSE ID 7,5 PER METER 1 6 59035126100 RADIATOR HOSE RAD.-THERMOS. 04 2 7 59035025101 RADIATOR HOSE SECONDARY 0 4 1 RADI ...

  • KTM 525 EXC 2006 - page 19

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59036030000 INTAKE VALVE D=35MM 2 2 59036031000 EXHAUST VALVE D=30MM 2 3 59036027000 VALVE-STEM SEALING RACING 4 6 59036028244 VALVE SPRING KIT (1X)RAC. 2001 4 9 59036033000 VALVE COLLET KK 6 H 8 10 59036062000 ADJUSTMENT SCREW M6X0,75 4 11 59036062100 NUT M6X0,75 4 13 59036056000 ROCKER ARM SHAFT INTA ...

  • KTM 525 EXC 2006 - page 20

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59036020144 CYLINDER HEAD CPL.450/520 03 1 2 59030036000 CYLINDER HEAD GASKET 95,3 MM 1 3* 58036052200 VALVE COVER REAR 2 4 58036053000 VALVE COVER GASKET 2 5 0015060556 HH COLLAR SCR. M6X55 WS=8 10.9 2 6 0015060453 HH COLLAR SCREW M 6X45 WS= 8 2 7 0015060753 HH COLLAR SCREW M 6X75 WS= 8 1 8 0015060303 ...

  • KTM 525 EXC 2006 - page 21

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59036013000 TIMING CHAIN 96 ROLLS 1 3 59036001000 TIMING CHAIN GUIDE RACING 1 4 59036018000 SECURING GUIDE RACI NG 1 5 59036014000 TIMING GEAR 18-T 1 6 59036002000 TIMING CHAIN TENSIONER 1 7 59036003050 GASKET TIMING CHAIN TENSIONER 1 8 59036003000 TIMINGCHAIN TENSIONER CP L.RAC. 1 9 59036001050 SPACER ...

  • KTM 525 EXC 2006 - page 22

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59038002000 OIL PUMP SHAFT 1 2 59038011010 OILPUMP ROTOR CPL. 10MM G-73 R 1 3 59038011012 OILPUMP ROTOR 12MM G-95R/003 1 4 58438001000 OIL PUMP GEAR 26-T 1 5 59038004000 OIL PUMP COVER L/S 1 6 59038003000 OIL PUMP COVER R/S 8MM 1 7 0015050163 HH COLLAR SCREW M 5X16 WS= 8 6 8 0984050122 AH SCREW DIN6912 ...

  • KTM 525 EXC 2006 - page 23

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59030002000 IGNITION COVER 4K3B 2000 1 2 59030040000 IGNITION COVER GASKET 0,8MM 1 3* 59039104200 STATOR 4-K3-B 05 1 4 59039105200 FLYWHEEL 4K3B RACING 2004 1 5 59039034000 PULSER COIL KOKUSAN 4K3-A/B 1 6 59039031500 CDI UNIT 400/525 EXC 2005 1 8 59039090100 SPARK PLUG CONNECT. VD05EG 03 1 9 5903909310 ...

  • KTM 525 EXC 2006 - page 24

    525 EXC 2006 FIG PART NUMBER DESCRIPTION QTY 1 59040001000 E-STARTER ENGINE KPL. 0,45 KW 1 2* 59040022258 GEAR WHEEL 1 3 54633090000 STOP DISK 17,2X25X1 1 4 0471170010 CIRCLIP DIN0471-17X1 1 5* 59040016000 TORQUE LIMITER 06 1 8* 0405101310 NEEDLE BEARING K 10X13X10 02 2 9 59040029000 BEARING BOLT 1 10 59040025000 FREE WHEEL HUB 1 11 0912060106 AH S ...

  • KTM 525 EXC 2006 - page 25

    NOTICE 525 EXC 2006 ...

  • KTM 525 EXC 2006 - page 26

    NOTICE 525 EXC 2006 ...

  • KTM 525 EXC 2006 - page 27

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  • KTM 525 EXC 2006 - page 28

    KTM-Sportmotorcycle AG A-5230 Mattighofen www.ktm.at Art.Nr.: 3CM089428EN 6/2005 KTM Group Partner *3CM089428EN* 3CM089428EN ...

Manufacturer KTM Category Automobile Parts

Documents that we receive from a manufacturer of a KTM 525 EXC 2006 can be divided into several groups. They are, among others:
- KTM technical drawings
- 525 EXC 2006 manuals
- KTM product data sheets
- information booklets
- or energy labels KTM 525 EXC 2006
All of them are important, but the most important information from the point of view of use of the device are in the user manual KTM 525 EXC 2006.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals KTM 525 EXC 2006, service manual, brief instructions and user manuals KTM 525 EXC 2006. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product KTM 525 EXC 2006.

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A complete manual for the device KTM 525 EXC 2006, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use KTM 525 EXC 2006 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of KTM 525 EXC 2006.

A complete KTM manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual KTM 525 EXC 2006 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the KTM 525 EXC 2006, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the KTM 525 EXC 2006, that we can find in the current document
3. Tips how to use the basic functions of the device KTM 525 EXC 2006 - which should help us in our first steps of using KTM 525 EXC 2006
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with KTM 525 EXC 2006
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of KTM 525 EXC 2006 in a specific country, if it was not possible to solve the problem on our own.

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