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 ENGINE PARTS

for 1980 - 2003

 KTM motorcycles

 

(NOTE: parts are available only while supplies last - prices subject to change without notice)

 

Reproduction

 Alloy Folding Shift Lever

fits 1990-04 125, 250, 300, 360, SX & MXC

 

#546-34-031-044 -   $25 each

Reproduction

 Alloy Folding Shift Lever

fits LC4  400. 620. 625 and 640

 

#584-34-031-044 -   $25 each

 used 125 Engine Case

for 1998-99 engines with transmission bearings

 

#503-30-000-044 -   $ 250    each

  NOTE: only 1 in stock

  also available

 #503-30-025-000  clutch case gaskets  $6 each

 n.o.s. 200 Engine Case

for 1998-2002 engines with transmission bearings

 

#523-30-000-044 -   $ 400    each

 

 used 250 / 300 / 380 Engine Case

for 1997-98 engines with the following part number

inside of ignition area  546-30-003-800

inside of clutch side area 546-30-004-800

includes transmission bearings

 

#546-30-000-844 -   $ 400    each

  also available

 #503-30-039-200  center case gaskets  $8 each

                    KTM Liquid Cooled Clutch Case Covers

   Almost all KTM engines are made of magnesium. Water and magnesium do not get along with each other. Water (and moisture) will cause magnesium to corrode. This is a big problem with the Liquid Cooled KTM engines. The pump areas become corroded, eating holes into the case. Unless they are shown on this web site, replacement clutch cases are not available from me and as far as I know are not available anywhere in the USA. If the corrosion is not severe (metal around the seal eaten away), it will need to be cleaned up and repaired.

   Repairs can be made by first cleaning out all the corrosion. This can be done by bead blasting it (bead blasting can cause more damage to area if you are not careful) or vapor blasting (a recommended method that will not tear up metal). Repairing the damage can be accomplished by the most common method  of using "JB Weld" epoxy. Another method is to reweld the area with a magnesium rod by someone who has experience with welding magnesium.

If the corrosion damage is severe, you will have to find another engine with a clutch case that is not damaged.

   As a preventative measure, if your pump area is not damaged, it is recommended that you paint the inside pump area or coat it with "JB Weld" epoxy.

 n.o.s. 250 / 300 / 350 Clutch Case Cover

for 1985 - 240 / 250 / 300 engines

      1986 - 240 / 250 / 300 / 350 engines

#544-30-001-000 -  black   sold out

                           note: only 1 in stock

 also available

 #543-30-025-000  clutch case gaskets  $4 each

 n.o.s. 240 / 250  Clutch Case Cover

   for 1987-88 - 240 / 250  engines

     

#545-30-001-000 - blue     sold out

                           note: only 1 in stock

 also available

 #545-30-025-000  clutch case gaskets  $5 each

 n.o.s. LC4 Clutch Case

for 1998-2002 engines

 

#583-30-101-100 -   $200     each

  NOTE: only 1 in stock

 n.o.s.  Clutch Case

for 2000 engines

 

#590-30-001-000 -   $ 180    each

 

 n.o.s.  Ignition Case Cover

for 2000 engines

 

#590-30-001-100 -   $ 46    each

 

 used  Ignition Case Cover

for 2001-2004 engines

525 & 450 MXC

 

#590-30-002-000 -   $ 40    each

NOTE: the position of the 2 stator mounting holes inside cover

 

 used  Ignition Case Cover

for 2003-2005 engines

   400SX

 

#590-30-002-500 -   $ 40    each

NOTE: the position of the 2 stator mounting holes inside cover

 

 1980+ KTM 420 & 495 Gasket Set

Includes gaskets, seals, fiber washers, lock plates & o-rings

Does not include a head gasket (not required on 495)-

order one separately for 420, part #560-30-036-000

 

#560-30-100-000 -   420 & 495cc (1980+ models)   $118 ea

#560-30-025-100 extra clutch case gasket  -   $4 each

#560-30-039-000 extra center case gasket -    $6 each

#560-32-022-200 extra bearing plate gasket - $4 each

#560-30-036-000  head gasket for 420   - $12 each

 

Note: Individual gaskets, seals, washers, and o-rings

can be purchased separately

 

1980-81 KTM 350 Gasket Set

Includes gaskets, seals, fiber washers, lock plates & o-rings

 

#561-30-100-100 -   350 (1980-81 models)   $120 ea

#560-30-025-100 extra clutch case gasket  -   $4 each

#560-30-039-000 extra center case gasket -    $6 each

#560-32-022-200 extra bearing plate gasket - $4 each

 

Note: Individual gaskets, seals, washers, and o-rings

can be purchased separately

1982+ KTM 495 Gasket Set

for engines with reed valves

Includes gaskets, seals, fiber washers, lock plates & o-rings

 

#563-30-100-000 -   495cc (1982+ models only)    $90 ea

#560-30-025-100 extra clutch case gasket  -   $4 each

#560-32-022-200 extra bearing plate gasket -  $4 each

#563-30-039-000 extra center case gasket  -   $6 each

 

Note: Individual gaskets, seals, washers, and o-rings

can be purchased separately

    other KTM  Gasket Sets

#490-30-100-000 -   80cc (1986 models)    $80 ea

#500-30-100-000 -   125-RV (1981 models)    $75 ea

#500-30-600-000 -   125-LC (1981 models)    $79 ea

#541-30-100-000 -   250-II (1981 models)    $98 ea

#542-30-100-000 -   250-RV (1982 models)    $98 ea

#543-30-100-000 -   250-LC (1983 models)    $98 ea

#544-30-100-000 -   250-LC (1985 models)    $98 ea

 KTM Rod Kits 

kit includes: top end bearing, bottom end bearing

lower pin, & spacer washers

 

 

#540-30-015-044 -  1980-82  250cc -         $189

      for use in engine types 541 & 542

 

 

#543-30-015-044 -  1983-89  240 -250 - 300 - 350        $189

      for use in engine types 543, 544, 545

    NOTE: lower crank pin must be shortened by 1mm to match old pin

n.o.s.  KTM 125 Piston

  for 1998  engines  -  teflon coated

     includes - ring + wrist pin + clips

#503-30-007-000 - 54.25 mm      $ 200    each

   

   

n.o.s.  Mahle KTM 250 Piston

  for  1984 reed valve engines  -

     includes - ring + wrist pin + clips

#543-30-007-001 - 71.0 mm      $ 190   each

   

n.o.s.  KTM 250 Pistons

     includes - rings + wrist pin + clips

#546-30-007-200 - 67.5 mm      $ 220    each

    rounded dome top Note: only 1 in stock - for 1991+

#546-30-007-400 - 67.5 mm      $ 230    each

    Flat dome top Note: only 2 in stock - for 1996

#546-30-007-600 - 67.5 mm      $ 220    each

    Flat dome top Note: only 2 in stock - for 1999

n.o.s.  KTM 350 Piston

  for  1988+  engines  -

     includes - rings + wrist pin + clips

#555-30-007-000 - 75.0 mm      Sold out

 

n.o.s.  Mahle KTM 350 Piston

  for  1980+ air cooled engines  -

     includes - rings + clips  no wrist pin

#561-30-007-000 - 77.5 mm      $ 180   each

    Note: only 1 in stock

  n.o.s.  KTM Pistons

  for 2003 625 LC4 engines - teflon coated

     includes - rings + wrist pin + clips

#584-30-007-100 - 100.94 mm      $ 369    each

 

  n.o.s.  KTM Pistons

  for  LC4 engines  - teflon coated

     includes - rings + wrist pin + clips

#585-30-007-300 - 102.0 mm      $ 368    each

    Note: only 1 in stock

  n.o.s.  KTM 520 Pistons

  for 2000 520 LC4 engines  - teflon coated

     includes - rings + wrist pin + clips

#590-30-007-000 - 95.0 mm      $ 335    each

 

  n.o.s.  KTM 450 Pistons

  for 2003-06 450 LC4 engines  - teflon coated

     includes - rings + wrist pin + clips

#594-30-107-000 - 95.0 mm      $ 290    each

 

#594-30-107-100 - 95.0mm        $ 290    each

    Note: only 2 in stock

 

 

 

    A                 B              C             D

1980 + KTM 520 Counter Shaft Sprockets

                for shafts requiring snap ring   $32 each
A - #500-33-029-512     12 tooth
B - #500-33-029-513     13 tooth
C - #500-33-029-514     14 tooth


D - #520-33-096-000    snap ring  $ .55