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Tools, spares, o-rings, seals, gaskets and hardware

for the KTM Racing Four Stroke

John Davies' KTM Page                                                                  Rev 07/19/05

Please see the NOTES at end of these pages.                                                                                                             

Figure

Qty

Description

Part Number

Price

 

 

SPECIAL TOOLS**********************

 

 

E45-26

1

Clutch bleed kit

503.29.050.000

$35.56

E45-18

1

Flywheel puller

580.12.009.000

$45.74

E45-3

1

Timing chain riveting tool

590.29.020.000

$146.93

 

 

 

 

 

 

 

SPARE PARTS*************************

 

 

E45-8

1

Loctite 243 Blue 6 ml

Source locally

 

E29-9

1

Spark Plug NGK DCPR8E

590.39.093.100

$13.62

E22-13

3

Oil filter short                              (CycleZone KTM $8.30/ pr)

590.38.046.000

$12.62

E22-12

3

Oil filter long                                         (Cycle Zone KTM $8.30/pr)

580.38.005.000

$11.25

E26-99

1

Carburetor gasket set FCR-MX 39

573.31.099.000

$65.41

E25-24

2

Carburetor needle e-clip

590.31.029.000

$3.66

E25-25

1

Carburetor needle set screw kit

573.31.032.000

$38.60

E25-5

2

Carburetor needle cover screw

?????

???

E42-1

1

Shift Lever

590.34.031.000

$46.78

E31-2

1

Starter Intermediate Gear 2002

(2003+ gear PN 590.40.022.158

There have been a number of reported tooth failures of the 2003+ gear.

590.40.022.058

$47.02

C11-83

1

Fork oil SAE 5

Source locally

 

C11-99

1

Fork Repair Gasket kit

R140.09

$161.02

C12-31

1

Clutch lever long

590.02.031.000

$39.93

C12-32

1

Clutch master cylinder piston repair kit

590.02.032.100

$59.60

C12-36

1

Clutch fluid (mineral oil)

Source locally

 

C12-92

1

Throttle cable set

590.02.091.300

$52.93

C13-20

1

Brake lever and spring

548.13.002.000

$31.61

C13-10

1

Front brake master cylinder repair kit

548.13.008.000

$27.91

C13-80

1

Brake fluid DOT 5.1

Source locally

 

C16-29

2

Sidestand and  battery rubber strap

503.03.018.000

$4.41

C15-38

2

Chain roller bearing

0625 006087

$17.66

C17-6

1

Chain guard

503.04.066.100

$12.08

C17-11

4

Swingarm needle bearing

590.04.031.100

$5.77

C17-20

1

Swingarm Heim bearing

503.04.090.044

$42.43

C17-26

1

Chain guide rear

546.07.066.100

$24.68

C18-2

1

Rear brake master cylinder repair kit

548.13.061.000

$29.92

C26-34

1

Muffler packing

Source locally

 

C26-35

1

Muffler packing

Source locally

 

C24-5

2

Exhaust spring

503.05.016.000

$5.63

C27-15

1

Air filter

590.06.015.000

$24.67

C30-3

1

Fuel tank rubber isolation mount

503.07.014.000

$8.28

C30-15

1

Fuel hose, pre-formed – 7.5x13

590.07.016.000

$7.02

C31-6

2

Headlight mask rubber strap

502.11.086.000

$4.05

C33-4

2

Front wheel bearing

0625 069068

$24.13

C33-13

1

21 “ rim strip

503.09.073.000

$8.03

C34-7

1

Front brake pad retaining pin and clips

546.13.210.100

$16.05

C35-4

2

Rear wheel bearing

0625 060058

$20.78

C35-13

1

18” rim strip

503.10.073.200

$11.22

C36-24

2

Master Link, X ring chain - 5/8x1/4

503.10.266.000

$5.10

C37-3

1

Rear brake pad retaining pin and clips

548.13.082.000

$22.00

C38-3

1

Headlight bulb – 12v 35/35w BA20D

Source locally

 

C38-25

1

Tail light bulb – 12v21/5w  BA15S

Source locally

 

 

 

 

 

 

 

 

O-RINGS*******************************

 

 

E22-20

4

Oil filter cover o-ring - 40x2.5

0770 400025

$0.37

E5-24

2

Oil filler cap o-ring - 19x3

0770 191015

$0.35

E5-38

1

Seal ring (oil pressure relief) -12x18x3

0603 121830

$0.67

E5-34

2

Oil screen o-ring -12x2

0770 120020

$2.03

E5-37

4

Oil screen o-ring - 9x1.5

0770 090015

$0.12

E22-23

4

Oil screen o-ring -12.5x1.5

0770 125015

$0.12

E22-24

2

Oil screen o-ring -17.17x1.78

0770 020170

$1.36

E31-16

1

Electric starter o-ring - 25x3

0770 250030

$1.85

E32-17

1

Clutch slave cylinder o-ring - 30x1.5

0770 300015

$1.06

E40-25

1

Countershaft o-ring – 25.12x1.78

0770 020220

$1.65

E44-10

1

Thermostat o-ring – 32x2

0770 320020

$1.13

C9-2

2

Fork cap o-ring – 45x2

4681.0340

$2.93

C9-9

2

Fork bleeder o-ring – 3.7x1.6

4860.0009

$0.73

C10-59

2

Fork tube o-ring, lower – 46x2

4860.0048

$1.58

C18-4

1

Rear brake master cylinder filler plug o ring

548.13.063.000

$7.90

C30-12

1

Fuel tap o-ring – 13x2.3

0770 130023

$2.30

C34-5

1

Front brake caliper seal kit 28 mm

546.13.205.000

$18.92

C37-2

1

Rear brake caliper seal kit 26 mm

503.13.081.200

$10.18

C40-69

1

E Starter cable boot

584.40.099.000

$2.60

C40-39

5

Fuse 5 amp electric fan ATC-5

Source locally

 

C40-40

5

Fuse 10 amp main ATC-10

Source locally

 

 

 

 

 

 

 

 

CRUSH WASHERS*******************

 

 

E5-20

1

Seal ring Cu - 8x14x3

580.30.081.000

$1.15

E12-8

E14-18

6

Seal ring Cu (coolant drain plug, valve cover gasket etc) - 6x10x1

0603 061001

$0.76

E5-7

2

Seal ring Cu (oil pressure relief, oil drain plug) -12x18x1.5

580.38.022.000

$1.15

E22-18

4

Seal ring Cu (oil line) - 8x12x1

0603 082121

$2.20

E44-31

1

Seal ring Al (temp sender) – 14x20x1.5

0603 142015

$1.09

C13-32

4

Seal ring Cu (front, rear brake hose) – 10x16x1

420.13.226.000

$1.14

C34-31

1

Seal ring Cu (front brake hose) – 10x16x1.5

420.13.026.000

$1.30

 

 

 

 

 

 

 

GASKETS,  SEALS******************

 

 

E14-4

2

Valve cover gasket

580.36.053.000

$2.69

E14-41

1

Water pump gasket

590.35.053.000

$1.50

E29-2

1

Stator cover gasket

590.30.040.000

$6.00

E32-24

1

Clutch slave cylinder gasket

590.32.065.000

$0.83

E32-4

1

Kickstarter shaft seal – 19x30x7

0760 193070

$3.83

E40-32

1

Countershaft seal – 32x45x7

0760 324571

$2.37

E42-4

1

Shifter shaft seal – 14x24x6

0760 142460

$7.37

C5-84

1

Steering head seal upper

546.01,184.000

$5.29

C5-82

1

Steering head seal lower

546.01.084.000

$18.10

C9-17

2

Fork seal – 48x57.8x9.5

4860.0399

$22.12

C9-19

2

Fork dust scraper – 48x58.4x11.8

4860.0400

$22.12

C17-15

6

Swingarm shaft seal

0760 253270

$4.87

C30-6

1

Fuel cap gasket

590.07.009.000

$5.03

C33-6

4

Front and rear axle seal - 32x47x7

0760 354771

$6.46

 

 

 

 

 

 

 

HARDWARE**************************

 

 

E42-2

1

Shifter bolt - 6X16

0933 060165

$0.55

E42-3

1

Shifter washer – 6.4x17x3

502.32.050.001

$3.66

E42-29

1 pr

Shifter lock washers

502.33.041.000

$2.38

E33-2

1

Kickstarter bolt - 8x20

546.10.052.000

$1.81

E33-3

1

Kickstarter washer - 8 mm galvanized

546.33.037.000

$3.99

E22-7

2

Bolt (oil filter cover) - 5x16

0015 050163

$1.13

E29-35

4

Bolt - 6x10

0015 060103

$1.08

E44-16

1

Bolt 6x12

0015 060123

$1.43

E29-36

2

Bolt 6x16

0015 060163

$0.98

E14-17

E20-10

6

Bolt - 6x20 (valve cover, water pump cover, timing chain tensioner, etc)

0015 060203

$0.98

C31-24

1

Bolt - 6x25

0015 060253

$0.78

E29-31

1

Bolt 6x30

0015 060303

$0.78

E29-30

1

Bolt 6x35

0015 060353

$0.95

C17-81

2

Bolt – 6x50

0015 060503

$1.13

E32-32

1

Clutch hub lock washer

565.32.018.000

$3.93

E32-22

1

Countershaft bolt with washer

590.33.034.044

$3.92

C14-14

1

Frame guard screw - 5x25

0014 050253

$1.79

C14-16

1

Frame guard blind nut

548.03.092.050

$2.99

C16-22

1

Sidestand bolt with bushing

503.03.023.280

$11.99

C16-30

1

Sidestand spring

503.03.024.000

$4.48

C17-75

2

Chain guard bushing

0015 060103

$1.08

C19-8

1

Rear shock mount bolt

0015 120556

$2.96

C26-22

2

Muffler screw - special 5x10

0009 050103

$0.78

C26-12

2

Muffler bracket rubber bushing

546.05.068.000

$2.38

C27-51

2

Screw for plastic – 6x20

0017 060203

$1.05

C30-2

1

Seat screw – 6x23

503.07.011.000

$5.82

C30-23

2

Spoiler bushing – Al 6x11x16x5

503.08.052.000

$5.99

C30-24

2

Spoiler screw – Al 6x20

0015 060203

$0.98

C30-25

4

Screw for plastic – Al 6x20

0017 060204

$1.01

C31-9

2

Front fender bushing - Al

548.08.020.000

$1.76

C31-22

1

Seat mount collar nut – Al 12x1

503.14.057.050

$3.53

C31-23

1

Seat mount hollow bolt - Al

548.07.048.000

$8.21

C33-32

1

Front axle nut - Al 24x1.5

548.09.082.000

$6.18

C35-44

1

Rear axle nut - Al 20x1.5

503.10.099.000

$5.98

Notes:

I compiled this list with the idea of stocking a (VERY) well-equipped home shop. It does NOT include items that a race team would consider essential, but it does include parts that an owner/ mechanic might need during normal maintenance or to correct common problems like a lost kick starter bolt or an oil leak. It is designed for a 2005 525 EXC – other years, or models like the SX, will require different parts.

Other KTM owners will have vastly different priorities, and they may alter or add to this list as they see fit. Many of the parts are prohibitively (and unbelievably) expensive and other sources should be considered. If you have found a cheaper source for a quality replacement engine or chassis part please EMAIL me at spokanisterNOSPAM@yahoo.com and I will try to amend this list. Or you can send me a Private Message at http://ktmtalk.com/

E = 2005 EXC Engine Parts Manual

C = 2005 EXC Chassis Parts Manual

BOLD = My highest priority

(Blue) = Lowest price I have found

Quantities are roughly based on usage through-out the bike – more common fasteners get a higher number. The Figure number is based on the first page(s) in the manual in which the part appears. The same part will likely also appear in other sections.

In case you are curious, the total for all the BOLD items is $776.28, so don’t rush out and order everything at once ;)

Legal disclaimer: I have made every attempt to make sure these part numbers and prices are correct as of this date, but use this data SOLELY at your own risk. If you find an error, please contact me so I can correct it. 

KTM Parts Sources and Dealers (only a partial listing - many of these dealers have online stores): 

Slaven’s Racing CO

http://www.slavensracing.com/

Munn Racing TX; 1-888-850-7437

http://www.munnracing.com/index.html

Barry Higgins’ KTM World GA

http://www.ktminfo.com/ktm.asp

Cycle Zone KS; 1-866-843-7433  

http://www.cyclezonektm.com/home_arcticcat.asp  

NW European Motorcycles WA; 1-877-531-4688

http://www.europeancycles.com/side2.htm

Lynnwood Motoplex WA; 1-425-774-0505

http://www.motoplex.net/

MotoSports ID 1-800-203-2353

http://www.motosports-boise.com/

Cascade Motorsports OR 1-541-389-0088

http://www.cascademotorsportsinc.com/657540.html

Plessinger Cycles OH 1-513-844-1143 

http://www.plessingercycles.com/

Elite Motorsports CO (Use Online order for 10% discount, free shipping over $150)

http://store.elitektm.com/

AND of course,  KTMTalk Team Members can use the “Get A Quote” button and save 15%:

http://ktmtalk.com/

Here is a link to the original Word document, so you can edit, add, or delete entries, as you wish. It "should be" virus free, but I can make no guarantees so please scan it before opening!

KTM RFS Spares Chart 07-19-05.doc

return to John Davies' KTM Index Page