nos Alloy Folding Shift Lever

  fits 1987-97 125engines

#502-34-022-200 -   $65 each

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

A

B

C

D

Reproduction

 Water Pump Gaskets and Impellers

  for1980s water cooled engines

 A #501-35-003-000 - gasket   $2 each

         for 125 engine type 501

 A #501-35-005-000 - impeller  $10 each

 B #502-35-003-000 - gasket   $2 each

         for 125 engine type 502

 B #502-35-005-000 - impeller  $10 each

 C #543-35-005-000 - impeller  $20 each

         for 250 engine type 543

 D #565-35-003-000 - gasket   $2 each

         for 500 engine type 565

 D #565-35-005-000 - impeller  $10 each

 used 125 Engine Case

for 1998-99 engines with transmission bearings

#503-30-000-044 -   Sold out

  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

   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.  Clutch Case Cover

for 1998-2001 KTM 125 and 200 engines

#503-30-001-044 -   $ 130    each

used Outer Clutch Case Cover

for 1998-2001 KTM 125 and 200 engines 

#503-30-026-000 - used cover  $ 65 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 1984-86 125GS engines type 501

   black plastic cover

#501-30-102-000 -   $ 25  each

 n.o.s.  Ignition Case Cover

for 2000 engines

#590-30-001-100 -   $ 66    each

 used  Ignition Case Cover

for 2001-2004 engines

525 & 450 MXC

#590-30-002-000 -   $ 60    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 -   $ 60    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   - $19 each

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

can be purchased separately

1981-82 KTM 250 Case Gaskets

#541-30-025-000  clutch case gasket  -   $4 each

#541-30-039-000  center case gasket -    $6 each

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

1983-89 KTM 500 Case Gaskets

#565-30-025-000  clutch case gasket  -   $4 each

#565-30-039-000  center case gasket -    $9 each

#565-30-036-000  cylinder head gasket -    $3 each

#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

     for use with 1988-89 MX engines

     for connecting DeLorto carb

#545-30-050-000-  1988-89  240cc & 250cc -    $79 each

     for use on 1985-86 type 543 & 544 engines

     for use with 545-30-050-000 intake manifold

    #542-30-051-000-  1985-86 250s-    $121 each

     for use with 2002-2004 KTM engine with

     64mm bore - water cooled

#544-30-005-000-  2002-2004 200cc -    $500

     for use with 1984-86 KTM engine with

     67mm bore - water cooled, reed valve

#544-30-005-000-  1984-86  250cc -    $400

     for use with 1984-86 KTM engine with

     69.5mm bore - water cooled, reed valve, power valve

#546-30-005-300-  1990-94  250cc -    $500

     for use with 1985-86 KTM engine with

     89mm bore - water cooled, reed valve

#565-30-005-000-  1985-86  500cc -    $500

     for use with 2000-03 KTM engine with

     89mm bore - water cooled

#595-30-005-000-  2000-03  400cc -    $700

     for use with 2000-03 KTM engine with

     95mm bore - water cooled

#590-30-005-000-  2000-03  400cc -    $700

     for use with 1998-2001 KTM engine type 503

#503-30-018-200-  1998-2001 -    $375

 KTM Rod Kits 

kit includes: top end bearing, bottom end bearing

lower pin, & spacer washers

#502-30-015-644 -  1987-95  125cc -         $200

      for use in 125 engine types 502 & 503

#540-30-015-044 -  1980-82  250cc -         $208

      for use in engine types 541 & 542

#543-30-015-044 -  1983-89  240 -250 - 300 - 350        $208

      for use in engine types 543, 544, 545

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

           A                       B

n.o.s.  KTM 125 Piston

     Mahle single ring pistons for early 1980's liquid cooled

     includes - ring + wrist pin + clips

  A   #500-30-607-201 - 54.25 mm      $ 160 each

       long piston for type 500 KTM 125

  B   #502-30-007-500 - 54.25mm    $185 each

      teflon coated piston for type 502 KTM 125s

  #510-30-032-201 - 54.25 ring  - $ 28 each

n.o.s.  KTM 125 Piston

  for 1998 type 503 engines  -  teflon coated

     includes - ring + wrist pin + clips

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

  #510-30-032-201 - 54.25 ring  - $ 28 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 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

nos Alloy Kick Start Lever

  fits 1987-97 125engines

#502-33-036-244 -   $98 each

    A                 B              C             D

1980 + KTM 520 Counter Shaft Sprockets

                for shafts requiring snap ring   $32 each
A - #500-33-029-012 –    12 tooth
B - #500-33-029-013 –    13 tooth  Sold Out
C - #500-33-029-014 –    14 tooth  Sold Out

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

1983-84 KTM Engine type 543 Case Protector

      for mounting on engine case in front of sprocket

#543-30-047-000 –   $22 each 

1988-91 KTM 350 500 Engine Case Protector Kit

      for mounting on engine case in front of sprocket    $24 each

     kit contains alloy spacers and plate with 60mm c to c mouting holes

Also fits  440 / 500/ 550 engines

 #545-30-047-013 –  for use with 13 tooth sprockets
 #545-30-047-014 –  for use with 14 tooth sprockets