KTM 250/300 2-Stroke Z-START PRO CLUTCH RMS-836 Removed Parts
115-012 zSP 2 Inch Spring Locator 1 ###### ECN 100
2009-10-08
Quantity Part # Description Added/Changed
1 710-232 YZ450F z-Start Pro Pressure Plate Assembly - LIGHT 2007-01-17
     
1 465-653AA 0.065 zSP RMS Y450 Precision Drive Plate - labeled "for adjustment only"
1 482-103 7x7 4Mil Open End Bag
     
1 419-012B Center Clutch Retaining Ring 2008-08-27 ECN 147
     
1 730-003 z-Start Pro Y450 Measured Drive Plate Stack 2007-01-29 ECN 64
1 175-011E zSP KTM250+ 2 Stroke Center Clutch 2007-11-14 ECN 113
1 482-004 8x8 4Mil Reclosable Bag
1 730-836 z-Start Pro KTM 250/300 Anti-Squeal Kit  2008-06-20 ECN 116
     
1 741-716 7/16" Steel Ball Kit (27)
1 740-201 Hardware Kit, z-Start Pro Clutch Assemblies
1 414-130 1/2 " Flat Throwout Washer
1 414-139 19 mm Multiple Ext. Tab Lock Washer
1 482-001 2x3 4Mil Reclosable Bag
1 482-003 6x6 4Mil Reclosable Bag
   
1 441-416 2" Wave Spring-C200L5 - labeled "C200L5"
1 482-002 3x4 4Mil Reclosable Bag
1 441-417 2" Wave Spring-C200L6 - labeled "C200L6"
1 482-002 3x4 4Mil Reclosable Bag
1 441-421 2" Wave Spring -C200-M3-S17 - Stainless Steel - labeled "C200M3 "
1 482-002 3x4 4Mil Reclosable Bag
   
1 420-234 05' KTM 2S Big Bore 0.080 Gasket
1 191-836 zSP KTM250, 300 Install Manual
1 192-290 Safety Warning - z-Start Pro
1 193-292 Break-in and Maintenance
1 193-293 Tuning Guide - z-Start Pro
1 198-836 z-Start Pro Set-Up Chart KTM 250/300 2-Strokes
1 481-107 White Logo Clutch Box - Deep  14 x 8 5/8 x 2 1/2 2007-04-09 ECN #83
1 481-105 Box Insert
710-232 YZ450F z-Start Pro Pressure Plate Assembly - LIGHT
1 717-130C z-Start Pro Rotating Hub Assy 450 Class Bikes - LIGHT - spacing washer -  spring steel 2009-10-08 ECN 166
1 106-002B zSP 450 class Top Plate 2007-05-17 ECN 90
1 111-025 zSP  YZ450F Pressure Plate
2 411-126A M4 x 12 Torx Head Screws 2007-05-11
1 482-004 8x8 4Mil Reclosable Bag
717-130C   z-Start Pro Rotating Hub Assy 450 Class Bikes - LIGHT - spacing washer -  spring steel
1 126-100E zSP 450 class Rotating Hub 2008-07-29 ECN 141
1 131-001D Z-Start Pro Upper Thrust - No Pins - spring steel 2009-10-08 ECN 166
1 132-001A zSP Lower Thrust - spring steel   2009-10-08 ECN 166
1 419-013 Lower Assembly Retaining Ring
1 433-312 INA TC 3648 Needle Thrust Bearing
1 417-651B 450 Class 0.078" Belleville Spacing Washer 2009-10-08 ECN 166
2 444-004 zSP 450 Class Belleville - LIGHT (272 - 316) 2007-01-17
                            Note for 730-003 Assembly Below:                                                                                                     Goal = measure 8 drive plates that are 0.380+-.004"                                                                                                Start with 8 - 0.048s and exchange 0.040's or 0.055's till spec is met
730-003   z-Start Pro Y450 Measured Drive Plate Stack 2007-01-29 ECN 64
1[1] 465-403A 0.040 zSP RMS Y450 Precision Drive Plate
8[2] 465-483A 0.048 zSP RMS Y450 Precision Drive Plate
741-716 7/16" Steel Ball Kit (27)
27 431-310 7/16 Chrome Steel Ball Bearings
1 482-001 2x3 4Mil Reclosable Bag
740-201 Hardware Kit, z-Start Pro Clutch Assemblies
10 411-126A M4 x 12 Torx Head Screws 2007-05-11
1 411-904 T-20 Torx Bit
2 491-009 0.050 Wire Gauge - S shaped
1 491-001 Loctite 243 .02 fl oz
1 482-002 3x4 4Mil Reclosable Bag
730-836 z-Start Pro KTM 250/300 Anti-Squeal Kit 
1 465-403A 0.040 zSP Y450 Precision Drive Plate
3 418-802 Viton75 -006 X-Ring - Anti Squeal Boss Spring
6 414-002 Drive Plate Retention Belleville (0.25 x 0.128 x 0.008) 2008-10-09 ECN 149
2 491-005 0.040 Wire Gauge
1 195-832 Anti Squeal Kit Manual
1 482-003 6 x 6 4 mil Reclosable Bag
[1]
Process:
8 drive plates:
Max = .384"
Min =  .376

If 8 plates are over the max, exchange one for a 465-401
If 8 plates are under the min, exchange thinnest with a thicker
and re-measure
[2]
Process:
8 drive plates:
Max = .384"
Min = .376

If 8 plates are over the max, exchange one for a 465-401
If 8 plates are under the min, exchange thinnest with a thicker
and re-measure