REPAIR MANUAL 2011

690 SMC EU
690 SMC AUS/UK
Art. no. 3206122en

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 INTRODUCTION 1

Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION

This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.

The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.

© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

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 TABLE OF CONTENTS 2

8.3 Adjusting the rebound damping of the shock

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ..................................... 5

1.1 Symbols used ................................................... 5 absorber......................................................... 33
1.2 Formats used.................................................... 5 8.4 Measuring the unloaded rear wheel sag ............. 33
2 SAFETY ADVICE........................................................... 6 8.5 Checking the static sag of the shock absorber .... 33
2.1 Repair Manual .................................................. 6 8.6 Checking the riding sag of the shock absorber.... 34
2.2 Safety advice.................................................... 6 8.7 Adjusting the spring preload of the shock
2.3 Degrees of risk and symbols ............................... 6 absorber......................................................... 34
2.4 Work rules........................................................ 6 8.8 Adjusting the riding sag ................................... 35
3 IMPORTANT NOTES..................................................... 7 8.9 Removing the shock absorber ........................... 35
3.1 Guarantee, warranty .......................................... 7 8.10 Installing the shock absorber............................ 36
3.2 Operating and auxiliary substances ..................... 7 8.11 Servicing the shock absorber............................ 38
3.3 Spare parts, accessories .................................... 7 8.12 Removing the spring........................................ 38
3.4 Figures ............................................................ 7 8.13 Dismantling the damper .................................. 39
4 SERIAL NUMBERS ...................................................... 8 8.14 Disassembling the piston rod ........................... 40
4.1 Chassis number ................................................ 8 8.15 Checking the damper ...................................... 41
4.2 Type label ........................................................ 8 8.16 Removing the heim joint.................................. 42
4.3 Engine number ................................................. 8 8.17 Installing the heim joint................................... 43
4.4 Key number...................................................... 8 8.18 Assembling the piston rod................................ 44
4.5 Fork part number .............................................. 8 8.19 Assembling the damper ................................... 45
4.6 Shock absorber part number .............................. 9 8.20 Bleeding and filling the damper ....................... 47
5 MOTORCYCLE ........................................................... 10 8.21 Filling the damper with nitrogen ....................... 49
5.1 Raising the motorcycle with the rear wheel 8.22 Installing the spring ........................................ 50
stand ............................................................. 10 9 EXHAUST .................................................................. 52
5.2 Taking the motorcycle off of the rear wheel 9.1 Removing the manifold.................................... 52
stand ............................................................. 10 9.2 Installing the manifold .................................... 53
5.3 Raising the motorcycle with the front wheel 9.3 Removing the main silencer ............................. 54
stand ............................................................. 10 9.4 Installing the main silencer.............................. 54
5.4 Taking the motorcycle off of the front wheel 10 AIR FILTER ............................................................... 56
stand ............................................................. 10 10.1 Removing the air filter ..................................... 56
5.5 Raising the motorcycle with the lift stand.......... 11 10.2 Installing the air filter...................................... 56
5.6 Removing the motorcycle from the lift stand...... 11 10.3 Removing the air filter box ............................... 56
5.7 Raising the motorcycle with the work stand ....... 11 10.4 Installing the air filter box................................ 57
5.8 Removing the motorcycle from the work stand ... 12 11 FUEL TANK, SEAT, TRIM ........................................... 59
5.9 Starting.......................................................... 12 11.1 Opening the filler cap...................................... 59
5.10 Starting the motorcycle to make checks ............ 13 11.2 Closing filler cap............................................. 59
6 FORK, TRIPLE CLAMP ............................................... 14 11.3 Removing the seat .......................................... 59
6.1 Adjusting the compression damping of the 11.4 Mounting the seat ........................................... 60
fork ............................................................... 14 11.5 Taking off the side cover.................................. 60
6.2 Adjusting the rebound damping of the fork ........ 14 11.6 Mounting the side cover................................... 60
6.3 Bleeding the fork legs...................................... 14 11.7 Checking the fuel pressure............................... 60
6.4 Cleaning the dust boots of the fork legs............. 15 11.8 Changing the fuel filter.................................... 61
6.5 Removing the fork protector ............................. 15 11.9 Changing the fuel pump .................................. 64
6.6 Installing the fork protector.............................. 15 12 WHEELS ................................................................... 68
6.7 Removing fork legs.......................................... 16 12.1 Checking the tire air pressure........................... 68
6.8 Installing the fork legs ..................................... 17 12.2 Checking the tire condition .............................. 68
6.9 Servicing the fork............................................ 18 12.3 Checking the brake discs ................................. 69
6.10 Disassembling the fork legs.............................. 19 12.4 Checking the spoke tension.............................. 69
6.11 Checking the fork legs ..................................... 22 12.5 Checking the rim run-out ................................. 70
6.12 Assembling the fork legs.................................. 23 12.6 Front wheel .................................................... 70
6.13 Checking the steering head bearing play............ 27 12.6.1 Removing front wheel.................................. 70
6.14 Adjusting the steering head bearing play ........... 28 12.6.2 Installing the front wheel ............................. 71
7 HANDLEBAR, CONTROLS........................................... 29 12.6.3 Removing the brake disc of the front brake.... 72
7.1 Handlebar position.......................................... 29 12.6.4 Installing the brake disc of the front brake .... 72
7.2 Adjusting handlebar position ............................ 29 12.7 Rear wheel ..................................................... 72
7.3 Checking the routing of the throttle cable.......... 29 12.7.1 Removing rear wheel ................................... 72
7.4 Checking the play in the throttle cable .............. 30 12.7.2 Installing the rear wheel .............................. 73
7.5 Adjusting the play in the throttle cable.............. 30 12.7.3 Removing the brake disc of the rear brake ..... 73
8 SHOCK ABSORBER, SWINGARM ................................ 32 12.7.4 Installing the brake disc of the rear brake...... 74
8.1 Adjusting the high-speed compression 12.7.5 Checking the chain tension.......................... 74
damping of the shock absorber......................... 32
12.7.6 Adjusting the chain tension ......................... 74
8.2 Adjusting the low-speed compression damping
12.7.7 Adjusting chain guide.................................. 75
of the shock absorber ...................................... 32

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 TABLE OF CONTENTS 3

12.7.8 Checking the chain, rear sprocket, engine 16.3.11 Removing water pump wheel...................... 109
sprocket, and chain guide............................ 75 16.3.12 Removing clutch cover .............................. 109
12.7.9 Cleaning the chain ...................................... 77 16.3.13 Removing spacer and spring ...................... 109
12.7.10 Checking the rear hub rubber dampers.......... 77 16.3.14 Removing spark plug................................. 110
13 WIRING HARNESS, BATTERY..................................... 79 16.3.15 Removing timing chain tensioner................ 110
13.1 Removing the battery ...................................... 79 16.3.16 Removing camshafts ................................. 110
13.2 Installing the battery ....................................... 79 16.3.17 Removing cylinder head ............................ 110
13.3 Disconnecting the battery ................................ 79 16.3.18 Removing piston ....................................... 111
13.4 Connecting the battery .................................... 80 16.3.19 Removing rotor ......................................... 111
13.5 Recharging the battery .................................... 80 16.3.20 Removing timing chain rails....................... 112
13.6 Checking the charging voltage .......................... 81 16.3.21 Removing timing chain and timing chain
13.7 Changing the main fuse ................................... 82 sprocket................................................... 112
13.8 Changing fuses of individual power 16.3.22 Removing crankshaft position sensor .......... 112
consumers...................................................... 82 16.3.23 Removing clutch cage ............................... 113
13.9 Adjusting the engine characteristic ................... 83 16.3.24 Removing primary gear .............................. 114
14 BRAKE SYSTEM ........................................................ 85 16.3.25 Removing starter drive............................... 114
14.1 Checking the front brake linings ....................... 85 16.3.26 Removing shift shaft ................................. 114
14.2 Changing the brake linings of the front brake..... 85 16.3.27 Removing shift drum locating..................... 114
14.3 Adjusting the basic position of the hand brake 16.3.28 Removing locking lever.............................. 115
lever .............................................................. 86 16.3.29 Removing oil pumps.................................. 115
14.4 Checking the front brake fluid level .................. 86 16.3.30 Removing left engine case ......................... 115
14.5 Adding front brake fluid................................... 87 16.3.31 Removing crankshaft and balancer shaft ..... 116
14.6 Changing the front brake fluid .......................... 88 16.3.32 Removing transmission shafts .................... 116
14.7 Checking the rear brake linings ........................ 88 16.4 Work on individual parts ................................ 117
14.8 Changing the rear brake linings ........................ 89 16.4.1 Work on the right section of the engine
14.9 Checking the free travel of foot brake lever ........ 90 case ........................................................ 117
14.10 Adjusting the basic position of the foot brake 16.4.2 Work on the left section of the engine
lever .............................................................. 91 case ........................................................ 119
14.11 Checking rear brake fluid level ......................... 91 16.4.3 Work on the clutch cover ........................... 120
14.12 Adding rear brake fluid .................................... 92 16.4.4 Removing crankshaft bearing inner ring ...... 121
14.13 Changing the rear brake fluid ........................... 92 16.4.5 Removing balancer shaft drive wheel .......... 121
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 94 16.4.6 Changing the connecting rod, conrod
15.1 Combination instrument .................................. 94 bearing, and crank pin .............................. 121
15.1.1 Setting kilometers or miles .......................... 94 16.4.7 Checking crankshaft run-out at bearing
15.1.2 Setting the clock ........................................ 94 pin .......................................................... 123
15.1.3 Setting/resetting display TRIP 1 ................... 94 16.4.8 Installing balancer shaft drive wheel ........... 123
15.1.4 Setting/resetting display TRIP 2 ................... 94 16.4.9 Installing crankshaft bearing inner ring ....... 123
15.1.5 Setting the wheel circumference .................. 95 16.4.10 Measuring axial clearance of crankshaft
15.2 Checking the headlight setting ......................... 96 and balancer shaft .................................... 124
15.3 Adjusting the headlight range........................... 96 16.4.11 Cylinder - Nikasil® coating ......................... 124
15.4 Removing the headlight mask with the 16.4.12 Checking/measuring the cylinder ................ 125
headlight........................................................ 96 16.4.13 Checking/measuring the piston................... 125
15.5 Installing the headlight mask with the 16.4.14 Checking piston ring end gap ..................... 126
headlight........................................................ 97 16.4.15 Checking piston/cylinder mounting
15.6 Changing the parking light bulb........................ 97 clearance ................................................. 126
15.7 Changing the headlight bulb ............................ 98 16.4.16 Checking oil pumps for wear ...................... 127
15.8 Changing the turn signal bulb .......................... 99 16.4.17 Replacing autodecompressor...................... 127
16 ENGINE .................................................................. 100 16.4.18 Preparing timing chain tensioner for
16.1 Removing the engine..................................... 100 installation ............................................... 128
16.2 Installing the engine...................................... 102 16.4.19 Checking timing assembly ......................... 128
16.3 Engine disassembly....................................... 106 16.4.20 Removing rocker arm ................................ 129
16.3.1 Clamping the engine into the engine 16.4.21 Changing camshaft bearing........................ 129
assembly stand......................................... 106 16.4.22 Removing valves ....................................... 130
16.3.2 Draining the engine oil .............................. 106 16.4.23 Checking valves ........................................ 130
16.3.3 Removing starter motor ............................. 106 16.4.24 Checking valve springs .............................. 131
16.3.4 Removing valve cover ................................ 107 16.4.25 Checking valve spring retainer.................... 131
16.3.5 Removing the alternator cover .................... 107 16.4.26 Checking cylinder head ............................. 131
16.3.6 Removing spacer ...................................... 107 16.4.27 Installing valves ........................................ 132
16.3.7 Removing gear position sensor ................... 107 16.4.28 Installing rocker arm ................................. 133
16.3.8 Removing oil filter .................................... 108 16.4.29 Disassembling the antihopping clutch......... 133
16.3.9 Removing thermostat ................................ 108 16.4.30 Checking the clutch .................................. 133
16.3.10 Setting engine to ignition top dead center ... 108 16.4.31 Preassembling the antihopping clutch......... 135

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 TABLE OF CONTENTS 4

16.4.32 Checking shift mechanism......................... 136 19.3 Checking the engine oil pressure .................... 165
16.4.33 Preassembling shift shaft .......................... 136 19.4 Changing the engine oil and filter, cleaning
16.4.34 Disassembling the main shaft .................... 137 the oil screens .............................................. 166
16.4.35 Dismantling countershaft........................... 137 19.5 Draining the engine oil .................................. 166
16.4.36 Checking the transmission ......................... 138 19.6 Removing the oil filter ................................... 167
16.4.37 Assembling the main shaft......................... 139 19.7 Installing the oil filter.................................... 167
16.4.38 Assembling countershaft ........................... 140 19.8 Cleaning the oil screens................................. 168
16.4.39 Checking the starter drive .......................... 141 19.9 Filling up with engine oil ............................... 169
16.4.40 Removing freewheel .................................. 141 19.10 Adding engine oil .......................................... 169
16.4.41 Checking freewheel ................................... 142 20 IGNITION SYSTEM................................................... 170
16.4.42 Installing freewheel................................... 142 20.1 Alternator - checking the stator winding .......... 170
16.5 Engine assembly ........................................... 143 20.2 Checking the spark plug connector ................. 170
16.5.1 Installing transmission shafts..................... 143 20.3 Ignition coil - checking the secondary
16.5.2 Installing crankshaft and balancer shaft ...... 144 winding........................................................ 171
16.5.3 Installing left engine case.......................... 145 21 TECHNICAL DATA.................................................... 172
16.5.4 Installing oil pumps .................................. 145 21.1 Engine ......................................................... 172
16.5.5 Installing locking lever .............................. 146 21.2 Engine tolerance, wear limits ......................... 172
16.5.6 Installing shift drum locating ..................... 146 21.3 Engine tightening torques .............................. 174
16.5.7 Installing shift shaft .................................. 146 21.4 Capacities .................................................... 175
16.5.8 Installing starter drive ............................... 146 21.4.1 Engine oil ................................................ 175
16.5.9 Installing primary gear............................... 147 21.4.2 Coolant .................................................... 175
16.5.10 Installing clutch cage ................................ 147 21.4.3 Fuel ........................................................ 175
16.5.11 Installing crankshaft position sensor ........... 148 21.5 Chassis ........................................................ 175
16.5.12 Installing timing chain and timing chain 21.6 Electrical system........................................... 176
sprocket................................................... 149 21.7 Tires ............................................................ 176
16.5.13 Installing timing chain rails ....................... 149 21.8 Fork............................................................. 177
16.5.14 Installing rotor .......................................... 149 21.9 Shock absorber ............................................. 177
16.5.15 Adjusting crankshaft position sensor 21.10 Chassis tightening torques ............................. 178
distance................................................... 150 22 CLEANING/PROTECTIVE TREATMENT....................... 180
16.5.16 Setting engine to top dead center ............... 150 22.1 Cleaning the motorcycle ................................ 180
16.5.17 Installing piston........................................ 150 22.2 Checks and maintenance steps for winter
16.5.18 Installing cylinder head ............................. 152 operation...................................................... 181
16.5.19 Installing camshafts.................................. 152 23 STORAGE ................................................................ 182
16.5.20 Installing timing chain tensioner ................ 153 23.1 Storage ........................................................ 182
16.5.21 Checking valve clearance........................... 153 23.2 Preparing for use after storage........................ 182
16.5.22 Adjusting valve clearance .......................... 154 24 SERVICE SCHEDULE ............................................... 183
16.5.23 Installing spark plug.................................. 155 24.1 Service schedule........................................... 183
16.5.24 Installing spacer and spring ....................... 155 25 WIRING DIAGRAM ................................................... 186
16.5.25 Installing clutch cover ............................... 155 25.1 Page 01 of 10 .............................................. 186
16.5.26 Mounting water pump cover ....................... 155 25.2 Page 02 of 10 .............................................. 188
16.5.27 Installing thermostat ................................. 156 25.3 Page 03 of 10 .............................................. 190
16.5.28 Installing the oil filter................................ 156 25.4 Page 04 of 10 .............................................. 192
16.5.29 Installing gear position sensor .................... 156 25.5 Page 05 of 10 .............................................. 194
16.5.30 Installing the spacer.................................. 157 25.6 Page 06 of 10 .............................................. 196
16.5.31 Installing oil screens ................................. 157 25.7 Page 07 of 10 .............................................. 198
16.5.32 Installing alternator cover .......................... 158 25.8 Page 08 of 10 .............................................. 200
16.5.33 Installing starter motor .............................. 158 25.9 Page 09 of 10 .............................................. 202
16.5.34 Installing valve cover................................. 159 25.10 Page 10 of 10 .............................................. 204
16.5.35 Removing the engine from the engine 26 SUBSTANCES ......................................................... 206
assembly stand......................................... 159 27 AUXILIARY SUBSTANCES ........................................ 208
17 CLUTCH .................................................................. 160 28 SPECIAL TOOLS ...................................................... 210
17.1 Checking/rectifying the fluid level of the 29 STANDARDS ........................................................... 222
hydraulic clutch............................................ 160 INDEX ............................................................................ 223
17.2 Changing the hydraulic clutch fluid ................ 160
18 WATER PUMP, COOLING SYSTEM ............................ 161
18.1 Draining the coolant ...................................... 161
18.2 Filling/bleeding the cooling system ................. 161
18.3 Checking the antifreeze and coolant level ........ 162
18.4 Checking the coolant level ............................. 163
19 LUBRICATION SYSTEM............................................ 164
19.1 Oil circuit..................................................... 164
19.2 Checking the engine oil level.......................... 164

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 1 MEANS OF REPRESENTATION 5

1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.

Name® Identifies a protected name.

Brand™ Identifies a trademark.

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 2 SAFETY ADVICE 6

2.1 Repair Manual

Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.

Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.

2.3 Degrees of risk and symbols

Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.

Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.

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 3 IMPORTANT NOTES 7

3.1 Guarantee, warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.

3.2 Operating and auxiliary substances

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.

3.3 Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.

The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com

3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.

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 4 SERIAL NUMBERS 8

4.1 Chassis number

The chassis number 1 is stamped on the steering head on the right.

100217-10

4.2 Type label

Type label 1 is located on the upper right frame tube below the seat.

100218-10

4.3 Engine number

The engine number 1 is stamped on the left side of the engine under the engine
sprocket.

600479-10

4.4 Key number

The key number 1 can be found on the KEYCODECARD.

Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.

100179-10

4.5 Fork part number

The fork part number 1 is stamped on the inner side of the fork stub.

600480-10

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 4 SERIAL NUMBERS 9

4.6 Shock absorber part number

The shock absorber part number 1 is on the right of the shock absorber.

100216-10

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 5 MOTORCYCLE 10

5.1 Raising the motorcycle with the rear wheel stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Insert the adapter into the rear wheel stand and screw into the swingarm on both
sides.
Adapter (61029055110) ( p. 212)
Rear wheel stand (61029055400) ( p. 213)
– Position the motorcycle upright, align the stand and raise the motorcycle.

600492-01

5.2 Taking the motorcycle off of the rear wheel stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Secure the motorcycle against falling over.

– Remove the rear wheel stand and lean the vehicle on the side stand.

5.3 Raising the motorcycle with the front wheel stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 10)
Main work
– Move the handlebar to the straight-ahead position. Align the front wheel stand with
the fork legs using the adapters.
Front wheel stand (61029055300) ( p. 212)

Info
Always raise the rear of the motorcycle first.

– Raise the front of the motorcycle.

600493-01

5.4 Taking the motorcycle off of the front wheel stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Secure the motorcycle against falling over.

– Remove the front wheel stand.

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 5 MOTORCYCLE 11

5.5 Raising the motorcycle with the lift stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Raise the motorcycle using the underride guard under the motorcycle.
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.

S00053-10

5.6 Removing the motorcycle from the lift stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Remove the motorcycle from the lift stand and rest it on its side stand.
– Remove the lift stand.

601873-11

5.7 Raising the motorcycle with the work stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Mount the special tool on the footrest.

Work stand adapter (75029036000) ( p. 215)

300579-10

– Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 213)

300201-10

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 5 MOTORCYCLE 12

5.8 Removing the motorcycle from the work stand

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Secure the motorcycle against falling over.

– Remove the work stand and lean the vehicle on the side stand.

300201-10

– Remove the special tool.

300579-10

5.9 Starting

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.

Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.

– Turn the emergency OFF switch to the position .

– Switch on the ignition by turning the ignition key to position ON .
After you switch on the ignition, you can hear the fuel pump working for about
two seconds. The function check of the combination instrument is run at the
same time.
– Shift gear to neutral.
The green idling speed indicator lamp N lights up.
– Press the electric starter button .
B00103-10

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 5 MOTORCYCLE 13

Info
Do not press the electric starter button until the combination instrument
function check is finished.
When starting, DO NOT open the throttle. If you open the throttle during the
starting procedure, fuel is not injected by the engine management system
and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds
before trying again.
This motorcycle is equipped with a safety starting system. You can only start
the engine if the transmission is in neutral or if the clutch lever is pulled
when a gear is engaged. If the side stand is folded out and you shift into
gear and release the clutch lever, the engine stops.

– Take the weight off the side stand and swing it back up with your foot as far as it
will go.

5.10 Starting the motorcycle to make checks

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.

Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.

– Turn the emergency OFF switch to the position .

– Shift gear to neutral.
– Switch on the ignition.
– Press the electric starter button .

Info
Do not open the throttle.

B00103-10

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 6 FORK, TRIPLE CLAMP 14

6.1 Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

– Turn adjusting screws 1 clockwise until they stop.

Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
600490-10 Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

6.2 Adjusting the rebound damping of the fork

Info
The hydraulic rebound damping determines the fork rebound behavior.

– Turn adjusting screws 1 clockwise until they stop.

Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
100244-10 Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

6.3 Bleeding the fork legs

Preparatory work
– Lean the motorcycle on the side stand.
Main work
– Briefly loosen bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.

Info
Carry out this action on both fork legs.

100844-10

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 6 FORK, TRIPLE CLAMP 15

6.4 Cleaning the dust boots of the fork legs

Preparatory work
– Jack up the motorcycle and secure it against falling over.
The front wheel is no longer in contact with the ground and the fork legs are no
longer under tension.
– Remove the fork protector. ( p. 15)
Main work
– Push dust boot 1 of both fork legs downwards.

Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.

Warning
L00350-10 Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.

– Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 209)
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 15)
– Remove the motorcycle from the lift stand. ( p. 11)

6.5 Removing the fork protector

– Remove screws 1 and take off clamp.
– Remove screws 2 on left fork leg. Remove the fork protector.
– Remove the screws on the right fork leg. Remove the fork protector.

600633-11

6.6 Installing the fork protector

– Position the fork protection on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line and cable harness. Put the clamp on, mount and tighten
screws 2.
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
600633-10

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 6 FORK, TRIPLE CLAMP 16

6.7 Removing fork legs

Preparatory work
– Raise the motorcycle with the work stand. ( p. 11)
– Tie the rear of the vehicle down.
Main work
– Remove screws 1 and spacers 2.
– Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Carefully pull the brake caliper backwards from the brake disc.

Info
Do not pull the handbrake lever when the brake caliper is removed.

201374-10

– Loosen screws 3 and 4.

– Unscrew screw 3 about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw 3.

Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.
201375-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove screws 5 and the clamp. Take the brake line and wiring harness out of the
holder.

201376-10

– Remove the screws of the wheel speed sensor 6. Hang the wheel speed sensor to
one side.

201377-10

– Remove screws 7. Take off the fork protector.

201378-10

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 6 FORK, TRIPLE CLAMP 17

– Loosen the screws 8 of the triple clamp. Remove the fork legs from the bottom.

201379-10

6.8 Installing the fork legs

– Slide the fork legs into the triple clamps on both sides.

Info
The bleeder screws must face forwards.
The topmost milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
The upper fork projection must be the same on both sides.

– Tighten screws 1 on both sides.

201379-11
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
– Position the fork protection. Mount and tighten screws 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

201378-11

– Position the wheel speed sensor. Mount and tighten screws 3.

Guideline
Screw, wheel speed sensor M4 1 Nm Loctite® 243™
(0.7 lbf ft)

201377-11

– Position the brake line, wiring harness and clamp.

– Mount and tighten screws 4.

201376-11

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 6 FORK, TRIPLE CLAMP 18

Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.

– Clean screw 5 and the wheel spindle.

– Position the front wheel and insert the wheel spindle.
201380-10 The brake linings are correctly positioned.
– Mount and tighten screw 5.
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
– Position the brake caliper and check that the brake linings are seated correctly.
– Mount screws 6 spacers 7 but do not tighten.
– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point. Fix the hand brake lever in the activated position.
The brake caliper straightens.
– Fully tighten screw 6.
Guideline
Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
201374-11 (33.2 lbf ft)
– Remove the fixation of the hand brake lever.
– Unload the rear of the vehicle.
– Remove the motorcycle from the work stand. ( p. 12)
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws 8.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)

201375-11

6.9 Servicing the fork

Info
These operations are the same on both fork legs.

Condition
The fork legs have been removed.

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 6 FORK, TRIPLE CLAMP 19

– Disassemble the fork legs. ( p. 19)

– Check the fork legs. ( p. 22)
– Assemble the fork legs. ( p. 23)

201240-01

6.10 Disassembling the fork legs

Info
These operations are the same on both fork legs.

Condition
The fork legs have been removed.
– Establish and note the current state of the rebound damping 1 and compression
damping 2.
– Completely open the adjusters of the rebound and compression damping.

200660-01

– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 221)

200643-10

– Loosen screw cover 3.

Info
The screw cover cannot be removed yet.

200644-12

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 6 FORK, TRIPLE CLAMP 20

– Release the fork leg and clamp it with the axle clamp.

Info
Use soft jaws.

200661-01

– Push the outer tube downward.

– Pull the spring downwards. Mount the special tool on the hexagon.
Open-end wrench (T14032) ( p. 221)

Info
The preload spacers 4 should be above the special tool.

200646-12

– Clamp the special tool in the vise. Loosen screw cover 3.

200647-12

– Remove screw cover 3 with preload spacers 4.

– Remove adjusting tube 5.

200648-12

– Pull the spring downward. Remove the special tool.

– Remove the spring.

200649-01

– Drain the fork oil.

Info
Pull out and push in the piston rod a few times to empty the cartridge.

200650-01

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 6 FORK, TRIPLE CLAMP 21

– Clamp the fork leg with the axle clamp.

– Remove screws 6 of the axle clamp.

200662-01

– Loosen screw 7 of the cartridge and remove it with the sealing ring.

Info
Place a container underneath to catch any oil that may run out.

200667-10

– Remove the cartridge.

200653-01

– Remove valve 8 of the rebound damping with the spring from the cartridge.

200654-12

– Remove dust boot 9.

200655-12

– Remove lock ring bk.

Info
The lock ring has a beveled end where a screwdriver can be applied.

200656-12

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 6 FORK, TRIPLE CLAMP 22

– Heat up the outer tube in area A of the lower sliding bushings.

Guideline
50 °C (122 °F)
– Pull the outer tube of the fork off of the inner tube with a jerk.

Info
The lower sliding bushing bl must be pulled from its bearing seat.

200668-10

– Remove the upper sliding bushing bm.

Info
Without using tools, carefully pull the stack apart by hand.

200658-12

– Take off the lower sliding bushing bl.

– Take off support ring bn.
– Take off seal ring bo.
– Take off lock ring bk.
– Take off dust boot 9.

200659-12

6.11 Checking the fork legs

Condition
The fork legs have been disassembled.
– Check the inner tube and the axle clamp for damage.
» If damage is found:
– Replace the inner tube.

200686-10

– Measure the external diameter of the inner tube in several places.

External diameter of inner tube 47.975… 48.005 mm (1.88878…
1.88996 in)
» If the measured value is less than the specified value:
– Replace the inner tube.

200684-10

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 6 FORK, TRIPLE CLAMP 23

– Measure the run-out of the inner tube.

Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in)
» If the measured value is greater than the specified value:
– Replace the inner tube.

200685-10

– Check the outer tube for damage.

» If damage is found:
– Replace the outer tube.

200632-10

– Check the surface of the sliding bushings.

» If the bronze-colored layer A under sliding layer B is visible:
– Replace the sliding bushings.

200665-10

– Check the spring length.

Guideline
Spring length with preload spacer(s) 480 mm (18.9 in)
» If the measured value is greater than the specified value:
– Reduce the strength of the pretensioning bushes.
» If the measured value is less than the specified value:
– Increase the strength of the preload spacers.
200666-10

6.12 Assembling the fork legs

Info
These operations are the same on both fork legs.

Preparatory work
– Check the fork legs. ( p. 22)
Main work
– Clamp the inner tube with the axle clamp.
– Mount special tool.
Protecting sleeve (T1401) ( p. 220)
– Grease and push on dust boot 1.
Lubricant (T511) ( p. 208)

200669-10
Info
Always replace the dust boot, seal ring, lock ring, and support ring.
Install the dust boot with the sealing lip and spring expander facing down-
ward.

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 6 FORK, TRIPLE CLAMP 24

– Push on lock ring 2.

– Grease and slide on seal ring 3.
Lubricant (T511) ( p. 208)

Info
Sealing ring downward, open side upward.

– Push on support ring 4.

– Remove the special tool.
– Sand the edges of the sliding bushings with 600-grain sandpaper, then clean and
grease them.
Fork oil (SAE 4) (48601166S1) ( p. 207)

200670-10

– Push on the lower sliding bushing 5.

– Mount the upper sliding bushing 6.

Info
Without using a tool, carefully pull the stack apart by hand.

200671-10

– Heat up the outer tube in area A of the lower sliding bushings.

Guideline
50 °C (122 °F)
– Slide the outer tube onto the inner tube.
– Hold the lower sliding bushing with the longer side of the special tool.
Assembly tool (T1402S) ( p. 220)
– Push the sliding bushing all the way into the outer tube.
200672-10

– Position the support ring.

– Hold the seal ring with the shorter side of the special tool.
Assembly tool (T1402S) ( p. 220)
– Push the seal ring and support ring all the way into the outer tube.

200673-10

– Mount lock ring 7.

Info
The lock ring must engage audibly.

200656-11

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 6 FORK, TRIPLE CLAMP 25

– Mount dust boot 8.

200655-11

– Grease the O-ring of valve 9 of the rebound damping.

Lubricant (T158) ( p. 208)
– Mount valve 9 of the rebound damping with the spring on adjusting tube bk.
– Mount valve 9 of the rebound damping from below in cartridge bl.
The adjusting tube protrudes 5 mm from the cartridge and can be pressed in
against the resistance of the spring.
The adjusting tube protrudes more than 7 mm from the cartridge and cannot
be pressed in against the resistance of the spring.
200674-10
– Screw on fluid barrier B as far as it will go.

Info
The fluid barrier must be tightened as much as possible. Do not use tools.

– Install the special tool on the cartridge.

Gripping tool (T14026S1) ( p. 220)

Info
The special tool must be used to prevent the adjusting tube from being
lifted and thus to prevent oil from reaching the piston rod.

200675-10

– Push the cartridge with the spring seat and preload spacer into the inner tube.
– Mount screw bm of the cartridge with the seal ring and tighten it.
Guideline
Cartridge screw M12x1 25 Nm
(18.4 lbf ft)

200683-10

– Grease and mount screws bn of the axle clamp but do not tighten.
Lubricant (T152) ( p. 209)

200682-10

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 6 FORK, TRIPLE CLAMP 26

– Clamp the fork vertically.

– Fill it with fork oil.
Fork oil per fork 634 ml Fork oil (SAE 4) (48601166S1)
leg (21.44 fl. oz.) ( p. 207)

Info
Pull out the piston rod and push back in a number of times to bleed the car-
tridge.
200677-10

– Remove pin C of the special tool.

Gripping tool (T14026S1) ( p. 220)
– Pull out the piston rod. Mount the spring. Mount the pin again.
Guideline
Spring rate
Soft 5.0 N/mm (28.6 lb/in)
Medium (standard) 5.2 N/mm (29.7 lb/in)
200678-10 Hard 5.4 N/mm (30.8 lb/in)
– Pull the spring down. Mount the special tool on the hexagonal part.
Open-end wrench (T14032) ( p. 221)
– Remove the special tool.
Gripping tool (T14026S1) ( p. 220)

200679-10

– Clamp the special tool in the vise.

– Grease the thread of the piston rod.
Lubricant (T159) ( p. 209)
– Grease the upper edge of the piston rod.
Lubricant (T158) ( p. 208)
– Screw the screw cover with the preload spacers on to the piston rod.

200680-10 Info
The screw cover must be screwed to the stop before the piston rod starts
to turn. If the thread of the piston rod is stiff, it must be held to prevent
it from turning. If the screw cover is not screwed to the stop, the rebound
adjustment will not work correctly.

– Tighten the screw cover.

Guideline
Screw cover on piston rod M12x1 25 Nm
(18.4 lbf ft)
– Release the special tool. Pull the spring downward and remove the special tool.

200646-11

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 6 FORK, TRIPLE CLAMP 27

– Push the outer tube upward.

– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 221)
– Grease the O-ring of the screw cover.
Lubricant (T511) ( p. 208)
– Screw on and tighten the screw cover.
Guideline
200681-10
Screw cover on outer tube M51x1.5 50 Nm
(36.9 lbf ft)
Alternative 1
– Turn the adjusting screw of rebound damping bo and the adjusting screw of
compression damping bp clockwise all the way.
– Turn back counterclockwise by the number of clicks corresponding to the fork
leg type.
Guideline
Rebound damping
Comfort 15 clicks
200660-11 Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the suspension compo-
nents can cause a serious deterioration in the handling characteris-
tics and overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.

– Turn the adjusting screws to the position they were in before dismantling.

6.13 Checking the steering head bearing play

Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
– Adjust the steering head bearing play without delay.

Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-
aged over time.

Preparatory work
– Raise the motorcycle with the work stand. ( p. 11)
– Push down the rear of vehicle, tighten it down in this position, and secure the
motorcycle against falling over.
The front wheel is no longer in contact with the ground and the fork legs are no
longer under tension.

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 6 FORK, TRIPLE CLAMP 28

Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
– Adjust the play of the steering head bearing. ( p. 28)
– Move the handlebar to and fro over the entire steering range.

600636-10 The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
» If click positions are noticeable:
– Adjust the play of the steering head bearing. ( p. 28)
– Check the steering head bearing and change if necessary.
Finishing work
– Release the rear of the vehicle.
– Remove the motorcycle from the work stand. ( p. 12)

6.14 Adjusting the steering head bearing play

Preparatory work
– Raise the motorcycle with the work stand. ( p. 11)
– Push down the rear of vehicle, tighten it down in this position, and secure the
motorcycle against falling over.
The front wheel is no longer in contact with the ground and the fork legs are no
longer under tension.
Main work
– Loosen screws 1. Remove screw 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw 1.
Guideline
100297-10
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Mount and tighten screw 2.
Guideline
Screw, steering stem M8 20 Nm
(14.8 lbf ft)
Finishing work
– Check the steering head bearing play. ( p. 27)
– Release the rear of the vehicle.
– Remove the motorcycle from the work stand. ( p. 12)

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 7 HANDLEBAR, CONTROLS 29

7.1 Handlebar position

On the upper triple clamp, there are 2 holes at a distance A to each other.
Distance A between holes 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance B from the center.

0
A B
0
Distance B between holes 3.5 mm (0.138 in)
The handlebar can be mounted in 4 different positions. In this way, the handlebar can
be installed in the position most comfortable for the rider.

400271-11

7.2 Adjusting handlebar position

– Remove the four screws 1. Remove the handlebar clamp. Remove the handlebar
and lay it to one side.
1 1
0 Info
2
0 2
0 Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.

– Remove the two screws 2. Remove the handlebar support.

– Place the handlebar support in the required position. Fit and tighten the two
B00375-10
screws 2.
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)

Info
Position the left and right handlebar supports evenly.

– Position the handlebar.

Info
Make sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Fit and evenly tighten the four screws 1.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)

7.3 Checking the routing of the throttle cable

Preparatory work
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)

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 7 HANDLEBAR, CONTROLS 30

Main work
– Check the routing of the throttle cable.
Both throttle cables must be routed side by side, downward behind the handle-
bars and between the air filter box and frame to the throttle valve body.
» If the throttle cable is not routed as specified:
– Correct the routing of the throttle cable.

S00121-10

Finishing work
– Mount the side cover. ( p. 60)
– Mount the seat. ( p. 60)

7.4 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Throttle cable play 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable. ( p. 30)

Danger
400192-10 Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. ( p. 30)

7.5 Adjusting the play in the throttle cable

Preparatory work
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)
– Check the routing of the throttle cable. ( p. 29)
Main work
– Move the handlebar to the straight-ahead position.
– Use the KTM diagnostics tool to set the motor drive to the basic position.
– Loosen counter nut 1.
– Set the play in the throttle cable by turning the adjusting screw 2.
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)

600631-10

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 7 HANDLEBAR, CONTROLS 31

– Tighten counter nut 1.

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 8 SHOCK ABSORBER, SWINGARM 32

8.1 Adjusting the high-speed compression damping of the shock absorber

Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

Info
The high-speed setting can be seen during the fast compression of the shock absorber.

– Turn adjusting screw 1 all the way clockwise using a socket wrench.

Info
Do not loosen nut 2!

– Turn back counterclockwise the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed
100246-10
Comfort 1.5 turns
Standard 1 turn
Sport 0.5 turn
Full payload 0.5 turn

Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.

8.2 Adjusting the low-speed compression damping of the shock absorber

Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.

– Turn the adjusting screw 1 clockwise with a screwdriver up to the last perceptible
click.

Info
Do not loosen nut 2!

– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
100245-10 Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

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 8 SHOCK ABSORBER, SWINGARM 33

8.3 Adjusting the rebound damping of the shock absorber

Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

– Turn adjusting screw 1 clockwise up to the last perceptible click.

– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
100247-10
Full payload 10 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

8.4 Measuring the unloaded rear wheel sag

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 11)
Main work
– Measure the distance – as vertical as possible – between the rear axle and a fixed
point, for example, a mark on the side cover.

A
0 – Note down the value as dimension A.

400988-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 11)

8.5 Checking the static sag of the shock absorber

– Measure distance A of rear wheel unloaded. ( p. 33)
– Hold the motorcycle upright with the aid of an assistant.
– Measure the distance between the rear axle and the fixed point again.
A
0 – Note down the value as dimension B.

Info
The static sag is the difference between measurements A and B.

– Check the static sag.

Static sag 20 mm (0.79 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( p. 34)

B
0

400989-10

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 8 SHOCK ABSORBER, SWINGARM 34

8.6 Checking the riding sag of the shock absorber

– Measure distance A of rear wheel unloaded. ( p. 33)
– With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up

A
0 and down a few times.
The rear wheel suspension levels out.
– Another person now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension C.

Info
The riding sag is the difference between measurements A and C.

– Check the riding sag.

Riding sag 70… 80 mm (2.76… 3.15 in)
» If the riding sag differs from the specified measurement:
C
0 – Adjust the riding sag. ( p. 35)

400990-10

8.7 Adjusting the spring preload of the shock absorber

Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

Preparatory work
– Raise the motorcycle with the work stand. ( p. 11)
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)
– Remove the shock absorber. ( p. 35)
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen locking ring 1.
– Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (T106S) ( p. 219)
– Measure the overall spring length without a load.
– Tension the spring by turning the adjusting ring 2 to the prescribed value.
Guideline
201271-11 Spring preload 18 mm (0.71 in)

Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.

– Tighten locking ring 1.

Finishing work
– Install the shock absorber. ( p. 36)
– Mount the side cover. ( p. 60)
– Mount the seat. ( p. 60)
– Remove the motorcycle from the work stand. ( p. 12)

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 8 SHOCK ABSORBER, SWINGARM 35

8.8 Adjusting the riding sag

Preparatory work
– Raise the motorcycle with the work stand. ( p. 11)
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)
– Remove the shock absorber. ( p. 35)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Soft 80 N/mm (457 lb/in)
Medium (standard) 85 N/mm (485 lb/in)
Hard 90 N/mm (514 lb/in)

201352-10 Info
The spring rate is shown on the outside of the spring.

Finishing work
– Install the shock absorber. ( p. 36)
– Mount the side cover. ( p. 60)
– Mount the seat. ( p. 60)
– Remove the motorcycle from the work stand. ( p. 12)
– Check the static sag of the shock absorber. ( p. 33)
– Adjust the rebound damping of the shock absorber. ( p. 33)

8.9 Removing the shock absorber

Preparatory work
– Raise the motorcycle with the work stand. ( p. 11)
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)
Main work
– Remove screws 1.

300562-10

– Lift the rear fairing.

– Remove screws 2.

300563-10

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 8 SHOCK ABSORBER, SWINGARM 36

– Remove screw 3.
– Repeat the operation on the opposite side.

300564-10

– Loosen screw 4.
– Remove screw 5.
– Remove screw 4.

300565-10

– Swing the rear end upwards.

– Lift shock absorber 6 upwards and remove.

300566-10

8.10 Installing the shock absorber

Main work
– Insert shock absorber 1 from above.

300566-11

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 8 SHOCK ABSORBER, SWINGARM 37

– Mount screw 2 but do not tighten yet.

– Mount and tighten screw 3.
Guideline
Screw, bottom shock M10 45 Nm Loctite® 243™
absorber (33.2 lbf ft)
– Tighten screw 2.
Guideline
Screw, top shock absorber M10 45 Nm Loctite® 243™
(33.2 lbf ft)

300565-11

– Mount and tighten screw 4.

Guideline
Screw, fuel tank, bottom M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Repeat the operation on the opposite side.

300564-11

– Lift the rear fairing.

– Mount and tighten screws 5.
Guideline
Screw, main silencer holder on fuel M8 25 Nm
tank (18.4 lbf ft)

300563-11

– Mount and tighten screws 6.

Guideline
Screw, side cover M6 5 Nm (3.7 lbf ft)

300562-11

Finishing work
– Mount the side cover. ( p. 60)
– Mount the seat. ( p. 60)
– Remove the motorcycle from the work stand. ( p. 12)

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 8 SHOCK ABSORBER, SWINGARM 38

8.11 Servicing the shock absorber

Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

Condition
The shock absorber has been removed.
– Remove the spring. ( p. 38)
– Dismantle the damper. ( p. 39)
– Disassemble the piston rod. ( p. 40)
– Check the damper. ( p. 41)
– Remove the heim joint. ( p. 42)
– Install the heim joint. ( p. 43)
– Assemble the piston rod. ( p. 44)
– Assemble the damper. ( p. 45)
– Install the spring. ( p. 50)

201289-01

8.12 Removing the spring

Condition
The shock absorber has been removed.
– Clamp the shock absorber in the vise using soft jaws for protection.
– Measure and note spring length in preloaded state.
– Loosen retaining ring 1 and the adjusting ring with the special tool.
Hook wrench (T106S) ( p. 219)
– Turn the retaining ring and adjusting ring until the spring is fully relieved of ten-
sion.

201271-10

– Remove spring retainer 2.

– Take off spring 3 with the retaining ring and adjusting ring 4.

201272-10

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 8 SHOCK ABSORBER, SWINGARM 39

8.13 Dismantling the damper

Preparatory work
– Remove the spring. ( p. 38)
Main work
– Establish and note the current state of the rebound damping and compression
damping.
– Completely open the adjusters of the rebound and compression damping.
– Remove rubber cap 1 of the reservoir.
– Open screw 2 slowly.
The pressurized nitrogen escapes.

201273-10

– Remove locking cap 3.

201274-10

– Press in seal ring retainer 4. Remove lock ring 5.

Info
Do not scratch the inner surface.

201276-10

– Remove screw 6. Drain the oil.

201277-10

– Remove the piston rod. Drain the remaining oil.

201278-10

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 8 SHOCK ABSORBER, SWINGARM 40

– Remove compression adjuster 7. Remove the spring, sleeve, and piston.

201279-10

8.14 Disassembling the piston rod

Preparatory work
– Remove the spring. ( p. 38)
– Dismantle the damper. ( p. 39)
Main work
– Clamp the piston rod with the heim joint in a vise.
– Remove nut 1.

300540-10

– Remove supporting plate 2 and rebound shim stack 3 together with piston 4.

Info
Thread the rebound shim set on a screwdriver and set the parts down
together.

300541-10

– Remove compression shim stack 6 with supporting plate 5.

Info
Thread the compression shim stack on a screwdriver and set the parts down
together.

200572-11

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 8 SHOCK ABSORBER, SWINGARM 41

– Remove seal ring retainer 7.

300542-10

– Remove locking cap 8 and rubber buffer 9.

300543-10

8.15 Checking the damper

Condition
The damper has been disassembled.
– Measure the inside diameter at both ends and in the center of the damper car-
tridge.
Damper cartridge
Minimum diameter 46.10 mm (1.815 in)
» If the measured value is greater than the specified value:
– Change the damper cartridge.
– Check the damper cartridge for damage and wear.
201280-10 » If there is damage or wear:
– Change the damper cartridge.
– Measure the diameter of the piston rod.
Piston rod
Diameter ≥ 17.95 mm (≥ 0.7067 in)
» If the specification is not reached:
– Change the piston rod.
– Measure the run-out of the piston rod.
Piston rod
300554-10
Run-out ≤ 0.03 mm (≤ 0.0012 in)
» If the measured value is greater than the specified value:
– Change the piston rod.
– Check the piston rod for damage and wear.
» If there is damage or wear:
– Change the piston rod.

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 8 SHOCK ABSORBER, SWINGARM 42

– Check the heim joint for damage and wear.

» If there is damage or wear:
– Change the heim joint.

300460-01

8.16 Removing the heim joint

Condition
The shock absorber has been removed.
– Clamp the shock absorber in the vise using soft jaws for protection.
– Remove collar bushing 1 of the heim joint.
Pin (T120) ( p. 219)
– Turn over the shock absorber and remove collar bushing 2 of the heim joint.
Pin (T120) ( p. 219)

200577-10

– Remove seal rings 3 on both sides.

200578-10

– Remove lock rings 4 on both sides.

200579-10

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 8 SHOCK ABSORBER, SWINGARM 43

– Place special tool 5 underneath and press out the heim joint with special tool 6.
Pressing tool (T1207S) ( p. 219)

200580-10

8.17 Installing the heim joint

– Place special tool 1 underneath and press in the heim joint as far as the center
using special tool 2.
Pressing tool (T1206) ( p. 219)
Pressing tool (T129) ( p. 220)

200581-10

– Mount lock rings 3 on both sides.

200579-11

– Mount seal rings 4 on both sides and grease them.

Lubricant (T158) ( p. 208)

200578-11

– Press in both collar sleeves 5 of the heim joint.

200582-10

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 8 SHOCK ABSORBER, SWINGARM 44

8.18 Assembling the piston rod

Preparatory work
– Check the damper. ( p. 41)
Main work
– Clamp the piston rod with the heim joint in a vise.
– Mount rubber buffer 1 and locking cap 2.

300543-11

– Position special tool 3 on the piston rod.

Mounting sleeve (T1515) ( p. 221)
– Grease the seal ring and push seal ring retainer 4 on to the piston rod.
Lubricant (T625) ( p. 209)
– Remove the special tool.

300548-10

– Mount supporting plate 5 with the rounded side facing downward.

– Mount the compression shim stack 6 with the smaller shims facing downward.

200572-11

– Sand both sides of the piston on a surface plate using 1200-grit sandpaper.
– Clean the piston.
– Assemble the piston.
Guideline
View A Piston from above
View B Piston from below

201270-10

– Mount the rebound shim stack 7 with the smaller shims facing upward.
– Install supporting plate 8.

300541-11

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 8 SHOCK ABSORBER, SWINGARM 45

– Mount and tighten nut 9.

Guideline
Piston rod nut M12x1 40 Nm
(29.5 lbf ft)

300540-11

8.19 Assembling the damper

Preparatory work
– Check the damper. ( p. 41)
– Assemble the piston rod. ( p. 44)
Main work
– Push the spring and sleeve onto the compression adjuster. Mount the piston.
– Mount and tighten compression adjuster 1.
Guideline
Compression adjuster M26x1 30 Nm
(22.1 lbf ft)

201279-11

– Mount and tighten screw 2.

Guideline
Filling port screw M10x1 14 Nm
(10.3 lbf ft)

201277-11

– Fill the damper cartridge about half full.

Shock absorber oil (SAE 2.5) (50180342S1) ( p. 207)

201288-10

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 8 SHOCK ABSORBER, SWINGARM 46

– Grease O-ring 3 of the seal ring retainer.

Lubricant (T158) ( p. 208)
– Mount the piston rod carefully.

201278-11

– Install the seal ring bearer 4 and push it under the ring groove.
– Mount lock ring 5.

Info
Do not scratch the inner surface.

– Pull out the piston rod so that the seal ring retainer rests against the lock ring.

201276-10

– Mount locking cap 6 of the damper cartridge.

– Bleed and fill the damper. ( p. 47)
– Fill the damper with nitrogen. ( p. 49)

201275-10

Alternative 1
– Turn adjusting screw 7 clockwise with a screwdriver up to the last perceptible
click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
Comfort 20 clicks
201287-10 Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
– Turn adjusting screw 8 all the way clockwise using a socket wrench.
– Turn back counterclockwise the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
Comfort 1.5 turns
Standard 1 turn
Sport 0.5 turn
Full payload 0.5 turn
– Turn adjusting screw 9 clockwise up to the last perceptible click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.

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 8 SHOCK ABSORBER, SWINGARM 47

Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the suspension compo-
nents can cause a serious deterioration in the handling characteris-
tics and overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.

– Turn adjusting screws 7, 8 and 9 to the position determined during disas-

sembly.
Finishing work
– Install the spring. ( p. 50)

8.20 Bleeding and filling the damper

Info
Before working with the vacuum pump, be sure to read the operating instructions carefully.
Completely open the adjusters of the rebound and compression damping.

– Remove the screw of the filling port.

– Install adapter 1 on the damper.

Info
Tighten only hand-tight, without the use of tools.

– Connect the adapter 1 to connector 2 of the vacuum pump.

Vacuum pump (T1240S) ( p. 220)

201286-10 – Clamp the damper with soft jaws or hold it as shown in the photo.

Info
Clamp the damper only lightly.
The filling port must be at the highest point.
The piston rod slides in and out during filling - do not hold it tight with your
hand!

– Place the control lever as shown in the photo.

The External tank 3 control lever is on Closed, Damper 4 on Vacuum,
and Oil reservoir 5 on Vacuum.
– Operate the On/Off switch 6.
The vacuum pump process starts.
Pressure gauge 7 falls to the specified value.
< 0 bar

200271-10
The vacuum gauge 8 falls to the specified value.
4 mbar

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 8 SHOCK ABSORBER, SWINGARM 48

– Measure distance A between the floating piston and reservoir hole with the special
tool.
Depth micrometer (T107S) ( p. 219)
The floating piston is positioned all the way at the bottom.

201285-10

– When the vacuum pressure gauge reaches the specified value, turn the Oil reser-
voir control lever 5 to Equalize pressure.
Guideline
4 mbar
The pressure gauge rises to the specified value.
0 bar

200267-10

– When the pressure gauge reaches the specified value, turn the Damper control
lever 4 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
The pressure gauge rises to the specified value.
3 bar
200268-10

– When the pressure gauge reaches the specified value, turn the Damper 4 control
lever to Vacuum.
Guideline
3 bar
The pressure gauge falls to the specified value.
0 bar

200269-10

– When the pressure gauge reaches the specified value, turn the Oil reservoir 5 con-
trol lever to Vacuum.
Guideline
0 bar
The vacuum gauge falls to the specified value.
4 mbar

200270-10

– When the vacuum pressure gauge reaches the specified value, turn the Oil reser-
voir control lever 5 to Equalize Pressure.
Guideline
4 mbar
The pressure gauge falls to the specified value.
0 bar

200267-10

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 8 SHOCK ABSORBER, SWINGARM 49

– When the pressure gauge reaches the specified value, turn the Damper control
lever 4 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
The pressure gauge rises to the specified value.
3 bar
200268-10

– When the pressure gauge reaches the specified value, turn the Damper 4 control
lever to Vacuum.
Guideline
3 bar
The pressure gauge falls to the specified value.
0 bar
– When the pressure gauge reaches the specified value, operate the On/Off switch.
200269-10 Guideline
0 bar
The vacuum pump is switched off.
– Slide O-ring B to the end of the special tool by the specified value (distance A
minus specified value).
Guideline
10 mm

Depth micrometer (T107S) ( p. 219)

– Slide the floating piston into the reservoir to the shortened position using the spe-
cial tool.
201284-10
Info
The floating piston must be positioned at exactly this point when the rod
is fully extended; otherwise, damage will occur during compression of the
shock absorber.

– Remove the special tool.

– Remove adapter 1 from connection 2 of the vacuum pump.

Info
Hold the damper so that the filling port is at the highest point.

– Remove the adapter.

– Mount and tighten screw 9.
Guideline
Filling port screw M10x1 14 Nm
201283-10 (10.3 lbf ft)

8.21 Filling the damper with nitrogen

– Screw in screw 1 by approx. 2 rotations but do not tighten.

Info
The piston rod is fully extended.

201282-10

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 8 SHOCK ABSORBER, SWINGARM 50

– Clamp special tool in the vise.

Nitrogen filling tool (T170S1) ( p. 221)
– Connect the special tool to the pressure regulator of the filling cylinder.
Filling gas - nitrogen
– Adjust pressure regulator.
Guideline
Gas pressure 10 bar (145 psi)
201281-10
– Position the damper in the special tool.
The hexagonal part of the tap handle A engages in the hexagon socket of the
filling port screw.
– Open filler tap B.
– Fill the damper for at least 15 seconds.
Guideline
Gas pressure 10 bar (145 psi)

Info
Watch the pressure regulator dial.
Make sure that the damper is filled to the specified pressure.

– Close the filling port screw using tap handle A.

– Close spigot B and take the damper out of the special tool.
– Tighten the filling port screw.
Guideline
Screw, reservoir filling port M5 3 Nm (2.2 lbf ft)
– Mount the rubber cap of the reservoir.

8.22 Installing the spring

– Clamp the damper in the vise using soft jaws.
– Install retaining ring 1 and turn it down as far as possible.
The collar points to the adjusting ring.
– Mount adjusting ring 2 and turn it down as far as possible.
The collar points to the spring.
– Measure the overall spring length without a load.
– Mount spring 3.
Guideline
201272-11
Spring rate
Soft 80 N/mm (457 lb/in)
Medium (standard) 85 N/mm (485 lb/in)
Hard 90 N/mm (514 lb/in)
– Mount spring retainer 4.
The open end is opposite the spring end.
Alternative 1
– Tension the spring to the prescribed amount by turning the adjusting ring.
Guideline
Spring preload 18 mm (0.71 in)

Hook wrench (T106S) ( p. 219)

201271-11

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 8 SHOCK ABSORBER, SWINGARM 51

Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the suspension compo-
nents can cause a serious deterioration in the handling characteris-
tics and overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.

– Tension the spring to the amount measured during dismantling by turning

adjusting ring 2.
Hook wrench (T106S) ( p. 219)
– Tighten lock nut 1 and the adjusting ring.

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 9 EXHAUST 52

9.1 Removing the manifold

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down. Do not touch hot components.

Preparatory work
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)
– Remove the air filter box. ( p. 56)
Main work
– Unplug connector 1 of the lambda sensor. Open the cable binder.

300210-10

– Remove screws 2.
– Remove the heat shield.

300207-10

– Remove nuts 3 of the manifold.

Info
Do not misplace the spacers.

300208-10

– Loosen screw 4.
– Remove the manifold.

300209-10

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 9 EXHAUST 53

9.2 Installing the manifold

Main work
– Position the manifold with the seals.

300209-11

– Position the spacer.

– Mount and tighten nuts 1.
Guideline
Nut, manifold on cylinder M8 20 Nm Copper paste
head (14.8 lbf ft)

300208-11

– Position the screw clamp.

– Tighten screw 2.
Guideline
Screw, main silencer M8 12 Nm Copper paste
clamp (8.9 lbf ft)

300209-12

– Plug in the connector of the lambda sensor 3. Secure the cable with the cable
binders.

300210-11

– Position the heat shield.

– Mount and tighten screws 4.
Guideline
Screw, exhaust heat shield M5 8 Nm Loctite® 243™
(5.9 lbf ft)

300207-11

Finishing work
– Install the air filter box. ( p. 57)
– Mount the side cover. ( p. 60)
– Mount the seat. ( p. 60)

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 9 EXHAUST 54

9.3 Removing the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down. Do not touch hot components.

– Remove screws 1.
– Take off the exhaust heat shield.

302044-10

– Loosen screw 2.

302045-10

– Remove screws 3.
– Lift the rear fairing.

302046-10

– Remove screws 4.
– Remove the main silencer.

302047-10

9.4 Installing the main silencer

– Position the main silencer.
– Mount and tighten screws 1.
Guideline
Screw, main silencer holder M8 25 Nm
(18.4 lbf ft)

302047-11

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 9 EXHAUST 55

– Position the screw clamp.

– Tighten screw 2.
Guideline
Screw, main silencer M8 12 Nm Copper paste
clamp (8.9 lbf ft)

302045-10

– Position the exhaust heat shield.

– Mount and tighten screws 3.
Guideline
Screw, exhaust heat shield M5 8 Nm Loctite® 243™
(5.9 lbf ft)

302044-11

– Mount and tighten screws 4.

Guideline
Rear fairing screw M6 5 Nm (3.7 lbf ft)

302046-11

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 10 AIR FILTER 56

10.1 Removing the air filter

Preparatory work
– Remove the seat. ( p. 59)
Main work
– Remove screws 1. Take off air filter box top 2.

100285-10

Note
Engine failure Unfiltered intake air has a negative effect on the service life of the
engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the
engine and result in increased wear.

– Remove air filter 3.

100286-10

10.2 Installing the air filter

Main work
– Clean the air filter box.
– Mount air filter 1.

Info
The air filter must lie flush against the air filter box along the entire sealing
surface A.
If the air filter is not correctly mounted, dust and dirt can enter the engine
and cause damage.
100287-10
– Hook air filter box top 2 into the front of the air filter box and swing down.
– Mount and tighten screws 3.
Guideline
Screw, air filter box top M6 2 Nm (1.5 lbf ft)

100285-11

Finishing work
– Mount the seat. ( p. 60)

10.3 Removing the air filter box

Preparatory work
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)

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 10 AIR FILTER 57

Main work
– Remove screws 1.
– Take off the voltage regulator and hang it to the side in a de-energized state.
– Detach and expose hose 2.

300202-10

– Remove screws 3.

300203-10

– Remove screws 4.

300204-10

– Loosen hose clip 5.

300205-10

– Raise the air filter box at the rear.

– Loosen the spring-loaded band-type clamp with the special tool and detach bleed
hose 6.
Pliers for spring band clamp (60029057100) ( p. 212)
– Detach connector 7 of the intake air temperature sensor.
– Take off the air filter box.

300206-10

10.4 Installing the air filter box

Main work
– Attach connector 1 of the intake air temperature sensor.
– Mount bleed hose 2. Mount the spring-loaded band-type clamp using the special
tool.
Pliers for spring band clamp (60029057100) ( p. 212)

300206-11

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 10 AIR FILTER 58

– Position the air filter box.

– Mount and tighten hose clip 3.

300205-11

– Mount and tighten screws 4.

Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

300204-10

– Mount and tighten screws 5.

Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

300203-11

– Position the voltage regulator.

– Mount and tighten screws 6.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Route and mount vent hose 7 without kinking.

300202-11

Finishing work
– Mount the side cover. ( p. 60)
– Mount the seat. ( p. 60)

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 11 FUEL TANK, SEAT, TRIM 59

11.1 Opening the filler cap

Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– Lift the cover of filler cap 1 and insert the ignition key.
– Turn the ignition key 90° counterclockwise and remove the filler cap.

Info
The filler cap has a fuel tank breather.

100227-10

11.2 Closing filler cap

– Put the filler cap back on and turn the ignition key 90° clockwise.
– Remove the ignition key and fold down the cover.

101070-01

11.3 Removing the seat

– Pull on strap 1 and raise the rear of the seat at the same time.
– Pull back the seat and lift it off.

100230-10

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 11 FUEL TANK, SEAT, TRIM 60

11.4 Mounting the seat

– Hook slot 1 of the seat onto screw 2, press the rear downward and at the same
time push it forward.
– Push locking pin 3 into lock housing 4 and push the back of the seat down until
the locking pin locks in place with an audible click.
– Finally, check that the seat is correctly mounted.

100276-10

11.5 Taking off the side cover

Preparatory work
– Remove the seat. ( p. 59)
Main work
– Remove screws 1.
– Pull off the side cover in area A and take off from above.
– Repeat the operation on the opposite side.

300198-10

11.6 Mounting the side cover

Main work
– Attach the side cover in area A and engage it in area B.
– Mount and tighten screws 1.
Guideline
Screw, side cover M6 5 Nm (3.7 lbf ft)
– Repeat the operation on the opposite side.

300198-11

Finishing work
– Mount the seat. ( p. 60)

11.7 Checking the fuel pressure

Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.

Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The ignition is on.
The diagnostics tool is connected.

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 11 FUEL TANK, SEAT, TRIM 61

– Press on the metal plate and disconnect the fuel hose connection 1.

Info
Remaining fuel may run out of the fuel hose.

302037-10

– Mount special tool 2.

3
0 Pressure testing tool (61029094000) ( p. 213)
– Mount special tool 3 with nozzle code 0,60.
Testing hose (61029093000) ( p. 213)
– Insert the hose end in a fuel canister.
2
0 Guideline
Minimum fuel canister capacity 10 l (2.6 US gal)
400926-10
– Perform the "Actuator Test" > "Function test of fuel pump control".
Guideline
Maximum duration of actuator test 3 min
– Check the fuel pressure with the filler cap closed.
Fuel pressure
When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)
» If the specification is not reached:
– Open the filler cap. ( p. 59)
– Check the fuel tank breather.

400927-01

– Check the fuel pressure with the filler cap open.

Fuel pressure
When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)
» If the specification is not reached:
– Check that the fuel line is clear.
– Change the fuel filter. ( p. 61)
– Change the fuel pump. ( p. 64)
400928-01 – Stop the "Function test of fuel pump control" actuator test by pressing the "Quit" but-
ton.
– Dismantle the special tools.
– Connect the fuel hose connection.

11.8 Changing the fuel filter

Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.

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 11 FUEL TANK, SEAT, TRIM 62

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
– Disconnect the battery. ( p. 79)
– Drain the fuel from the fuel tank into a suitable container.
Main work
– Remove screws 1.

300562-10

– Lift the rear fairing.

– Remove screws 2.

300563-10

– Remove screw 3 on both sides.

– Swing the rear end upwards and secure it.

300564-10

– Remove screws 4 and the splash protector.

202046-10

– Remove screws 5.
– Pull out the fuel pump.

202047-10

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 11 FUEL TANK, SEAT, TRIM 63

– Disconnect both fuel hose connections 6.

– Unplug connector 7. Remove the fuel pump.

202048-10

– Remove hose clamps 8.

– Remove fuel filter.
– Mount the new fuel filter.
Arrow A points away from the fuel pump.
– Mount hose clamps 8.
Hose clamp pliers (60029057000) ( p. 212)

202049-10

– Press locking mechanism 9 on both sides.

– Pull off the fuel pump housing.

202050-10

– Change fuel screen bk.

– Mount the fuel pump housing.

202051-10

– Connect both fuel hose connections 6.

– Attach connector 7.

202048-10

– Position the fuel pump.

– Mount and tighten screws 5.
Guideline
Screw, fuel pump M5 4 Nm (3 lbf ft)

202047-10

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 11 FUEL TANK, SEAT, TRIM 64

– Position the splash protector. Mount and tighten screws 4.

Guideline
Remaining screws, chassis M5 4 Nm (3 lbf ft)

202046-10

– Position the rear end.

– Mount and tighten screw 3 on both sides.
Guideline
Screw, fuel tank, bottom M8 25 Nm Loctite® 243™
(18.4 lbf ft)

300564-10

– Lift the rear fairing.

– Mount and tighten screws 2.
Guideline
Screw, main silencer holder on fuel M8 25 Nm
tank (18.4 lbf ft)

300563-10

– Mount and tighten screws 1.

Guideline
Screw, side cover M6 5 Nm (3.7 lbf ft)

300562-10

Finishing work
– Disconnect the battery. ( p. 80)
– Mount the seat. ( p. 60)
– Set the clock. ( p. 94)

11.9 Changing the fuel pump

Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.

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 11 FUEL TANK, SEAT, TRIM 65

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
– Disconnect the battery. ( p. 79)
– Drain the fuel from the fuel tank into a suitable container.
Main work
– Remove screws 1.

300562-10

– Lift the rear fairing.

– Remove screws 2.

300563-10

– Remove screw 3 on both sides.

– Swing the rear end upward and secure it.

300564-10

– Remove screws 4 and the splash protector.

202046-10

– Remove screws 5.
– Pull out the fuel pump.

202047-10

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 11 FUEL TANK, SEAT, TRIM 66

– Disconnect both fuel hose connections 6.

– Unplug connector 7. Remove the fuel pump.
– Connect the new fuel pump, attaching both fuel hose connections 6.
– Attach connector 7.

202048-10

– Position the fuel pump.

– Mount and tighten screws 5.
Guideline
Screw, fuel pump M5 4 Nm (3 lbf ft)

202047-10

– Position the splash protector. Mount and tighten screws 4.

Guideline
Remaining screws, chassis M5 4 Nm (3 lbf ft)

202046-10

– Position the rear end.

– Mount and tighten screw 3 on both sides.
Guideline
Screw, fuel tank, bottom M8 25 Nm Loctite® 243™
(18.4 lbf ft)

300564-10

– Lift the rear fairing.

– Mount and tighten screws 2.
Guideline
Screw, main silencer holder on fuel M8 25 Nm
tank (18.4 lbf ft)

300563-10

– Mount and tighten screws 1.

Guideline
Screw, side cover M6 5 Nm (3.7 lbf ft)

300562-10

Finishing work
– Disconnect the battery. ( p. 80)
– Mount the seat. ( p. 60)

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 11 FUEL TANK, SEAT, TRIM 67

– Set the clock. ( p. 94)

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 12 WHEELS 68

12.1 Checking the tire air pressure

Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove the protection cap.

– Check tire air pressure when tires are cold.
Tire air pressure, solo
Front 2.0 bar (29 psi)
Rear 2.0 bar (29 psi)

Tire air pressure with passenger / fully loaded

Front 2.0 bar (29 psi)
400695-01
Rear 2.2 bar (32 psi)
» If the tire pressure does not meet specifications:
– Correct tire pressure.
– Mount the protection cap.

12.2 Checking the tire condition

Warning
Danger of accidents Uncontrollable vehicle handling in the event of a flat tire.
– In the interest of safety, replace damaged or worn tires immediately.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.

Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be
roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not
achieved until the tires have been run in.

Info
The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.

– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tires exhibit cuts, run-in objects or other damage:
– Change the tires.
– Check the depth of the tread.

Info
Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum permissible depth:
– Change the tires.
– Check the age of the tires.

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Info
The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits refer
to the week of manufacture and last two digits refer to the year of manufac-
ture.
KTM recommends that the tires are changed regardless of the actual wear,
at the latest after 5 years.

» If a tire is more than 5 years old:

– Change the tires.

12.3 Checking the brake discs

Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay.

– Check the thickness of the front and rear brake discs in several places to ensure
that it conforms to measurement A.

Info
Wear reduces the thickness of the brake disc at the contact surface 1 of
the brake disc.

Brake discs - wear limit

Front 4.0 mm (0.157 in)
100135-10 Rear 4.5 mm (0.177 in)
» If the brake disc thickness is less than the specified value:
– Replace the brake disc.
– Check the front and rear brake discs for damage, cracks, and deformation.
» If damage, cracks, or deformation are visible on the brake disc:
– Replace the brake disc.

12.4 Checking the spoke tension

Warning
Danger of accidents Instable handling due to incorrect spoke tension.
– Ensure that the spoke tension is correct.

Info
A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– Briefly strike each spoke with a screwdriver blade.

Info
The frequency of the tone is a function of the spoke length and spoke diam-
eter.
If you hear different tone frequencies from individual spokes of the same
length and thickness, this is an indication of different spoke tensions.

You should hear a high note.

400694-01 » If the spoke tensions differ:
– Correct the spoke tension.

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12.5 Checking the rim run-out

Warning
Danger of accidents Instable handling due to incorrect spoke tension.
– Ensure that the spoke tension is correct.

Info
A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– Check the axial run-out and radial run-out of the rim.

Axial run-out
outside of the rim joint < 1.8 mm (< 0.071 in)

Radial run-out
outside of the rim joint < 1.8 mm (< 0.071 in)
» If the measured value is greater than the specified value:
– Center the rim.

Info
Center the rim by tightening the spoke nipple on the opposite side of
the rim run-out. Change the rim if it is excessively deformed.

– Correct the spoke tension.

400998-01

12.6 Front wheel

12.6.1 Removing front wheel
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 10)
– Raise the motorcycle with the front wheel stand. ( p. 10)
Main work
– Remove screws 1 and spacers 2.
– Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Pull the brake caliper carefully back from the brake disc and hang it to
one side.

Info
Do not pull the handbrake lever when the brake caliper is removed.

600621-10

– Loosen screws 3 and 4.

– Unscrew screw 3 about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw 3.

Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.
600622-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.

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 12 WHEELS 71

– Remove distance bushings 5.

600626-11

12.6.2 Installing the front wheel

Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Replace the wheel bearing.
– Clean and grease the shaft seal rings and bearing surface of the distance bush-
ings 1.
Long-life grease ( p. 208)
– Insert the spacers.
600626-10

– Clean and grease the thread of the wheel spindle and screw 2.
Long-life grease ( p. 208)
– Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount
and tighten screw 2.
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)

600621-11 – Position the brake caliper and check that the brake linings are seated correctly.
– Position spacers 3. Mount screws 4 but do not tighten.
– Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point. Fix the hand brake lever in the acti-
vated position.
The brake caliper straightens.
– Fully tighten screws 4.
Guideline
Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
– Remove the fixation of the hand brake lever.
– Take the motorcycle off of the front wheel stand. ( p. 10)
– Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
– Tighten screws 5.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)

600490-11

Finishing work
– Take the motorcycle off of the rear wheel stand. ( p. 10)

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 12 WHEELS 72

12.6.3 Removing the brake disc of the front brake

Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 10)
– Raise the motorcycle with the front wheel stand. ( p. 10)
– Remove front wheel. ( p. 70)
Main work
– Remove screws 1. Take off the brake disc.

306859-10

12.6.4 Installing the brake disc of the front brake

Main work
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward. Mount and tighten screws 1.
Guideline
Screw, front brake disc M6 14 Nm Loctite® 243™
(10.3 lbf ft)

306859-10

Finishing work
– Install the front wheel. ( p. 71)
– Take the motorcycle off of the rear wheel stand. ( p. 10)

12.7 Rear wheel

12.7.1 Removing rear wheel
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 10)
Main work
– Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
– Remove nut 1. Remove chain adjuster 2.
– Holding the rear wheel, withdraw the wheel spindle 3.

100267-10

– Push the rear wheel forwards as far as possible and take the chain off the rear
sprocket.

Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.

– Take the rear wheel out of the swing arm.

600627-01

Info
Do not operate the foot brake when the rear wheel is removed.

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 12 WHEELS 73

12.7.2 Installing the rear wheel

Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning
Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.

Main work
– Check the rear hub rubber dampers. ( p. 77)
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Replace the wheel bearing.
– Remove the bushing 1. Clean and grease the roll surfaces of the bushing and the
shaft seal ring 2.
Long-life grease ( p. 208)
– Clean and grease the thread of the wheel spindle and nut 3.
600628-10 Long-life grease ( p. 208)
– Install the rubber damper and rear sprocket carrier in the rear wheel.
– Position the rear wheel.
The brake linings are correctly positioned.
– Push the rear wheel forward as far as possible and lay the chain on the rear
sprocket.
– Mount the wheel spindle, chain adjusters and nuts.
Guideline
In order that the rear wheel is correctly aligned, the markings on the left and
right chain adjusters must be in the same position relative to the reference
marks A.

Info
100270-10
Mount the left and right chain adjusters 4 in the same position.

– Tighten nut 3.
Guideline
Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
Finishing work
– Take the motorcycle off of the rear wheel stand. ( p. 10)

12.7.3 Removing the brake disc of the rear brake

Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 10)
– Remove the rear wheel. ( p. 72)
Main work
– Remove screws 1. Take off the brake disc.

306860-10

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 12 WHEELS 74

12.7.4 Installing the brake disc of the rear brake

Main work
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward. Mount and tighten screws 1.
Guideline
Screw, rear brake disc M6 14 Nm Loctite® 243™
(10.3 lbf ft)

306860-10

Finishing work
– Install the rear wheel. ( p. 73)
– Take the motorcycle off of the rear wheel stand. ( p. 10)

12.7.5 Checking the chain tension

Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear-
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.

– Lean the motorcycle on the side stand.

– Shift gear to neutral.
– Push the chain upward at a distance B from the chain sliding guard and determine
the chain tension A.

Info
The upper chain section C must be taut.
Chain wear is not always even. Repeat this measurement at different chain
positions.

Chain tension 5 mm (0.2 in)

Distance to chain sliding guard 30 mm (1.18 in)

» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 74)

100249-10

12.7.6 Adjusting the chain tension

Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear-
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.

Preparatory work
– Check the chain tension. ( p. 74)

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 12 WHEELS 75

Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 on the left and right.
Guideline
Chain tension 5 mm (0.2 in)
Turn the left and right adjusting screws 3 so that the markings on the left
and right chain adjusters 4 are in the same position relative to the reference
marks C. The rear wheel is then correctly aligned.

Info
The upper chain section must be taut.
Chain wear is not always even. Repeat this measurement at different chain
positions.

– Tighten nuts 2.
– Make sure that the chain adjusters 4 are installed correctly on adjusting screws 3.
– Tighten nut 1.
Guideline
600597-10
Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)

12.7.7 Adjusting chain guide

– Remove screws 1 and 2. Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
– Insert nut 3 in hole A. Position the chain guide.
– Mount and tighten screws 1 and 2.
Guideline
Screw, chain guide M6 8 Nm (5.9 lbf ft)
Condition
Number of teeth: ≥ 45 teeth
– Insert nut 3 in hole B. Position the chain guide.
– Mount and tighten screws 1 and 2.
Guideline
Screw, chain guide M6 8 Nm (5.9 lbf ft)

600635-10

12.7.8 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 11)
Main work
– Shift the transmission to neutral.
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the power set.

Info
The engine sprocket, rear sprocket, and chain should always be
replaced together.
100132-10

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 12 WHEELS 76

– Pull on the upper section of the chain with the specified weight A.
Guideline
Weight of chain wear measurement 15 kg (33 lb.)

0
A – Measure distance B of 18 chain links in the lower chain section.

Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Maximum distance B at the longest 272 mm (10.71 in)

chain section
» If the distance B is greater than the specified measurement:
– Change the power set.

B
0 Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
1 2 3 16 17 18
400987-10

– Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
guard:
– Replace the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
Guideline
Screw, chain sliding M6 8 Nm Loctite® 243™
guard (5.9 lbf ft)

401170-01

– Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)

401171-01

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 12 WHEELS 77

– Check the chain guide for wear.

Info
Wear is visible on the front of the chain guide.

» If the light part of the chain guide is worn:

– Change the chain guide.

400985-01

– Check that the chain guide is firmly seated.

» If the chain guide is loose:
– Tighten the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

601273-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 11)

12.7.9 Cleaning the chain

Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
The service life of the chain depends largely on its maintenance.

– Clean the chain regularly.

– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
Chain cleaner ( p. 208)
– After drying, apply chain spray.
Chain lube for road use ( p. 208)

400725-01

12.7.10 Checking the rear hub rubber dampers

Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during
operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.

Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 10)
– Remove the rear wheel. ( p. 72)

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 12 WHEELS 78

Main work
– Check bearing 1.
» If the bearing is damaged or worn:
– Replace the bearings.
– Check rubber dampers 2 of the rear hub for damage and wear.
» If the rubber dampers of the rear hub are damaged or worn:
– Change all rubber dampers in the rear hub.

600623-10

– Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert
the wheel spindle in the hub.
– To check play A, hold the rear wheel tight and try to rotate the rear sprocket with
your hand.

Info
Measure the play on the outside of the rear sprocket.

Play in rubber dampers, rear wheel ≤ 5 mm (≤ 0.2 in)

600624-10
» If play A is larger than the specified value:
– Change all rubber dampers in the rear hub.
Finishing work
– Install the rear wheel. ( p. 73)
– Take the motorcycle off of the rear wheel stand. ( p. 10)

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 13 WIRING HARNESS, BATTERY 79

13.1 Removing the battery

Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
Main work
– Disconnect the negative (minus) cable of the battery.
– Pull plug 1 off upward.
– Remove screws 2.
– Pull the retaining bracket 3 of the battery forward and remove it.
– Take off the positive pole cover 4.
– Disconnect the positive (plus) cable of the battery.
– Push the wiring harness to the side and pull the battery out of the battery holder.
100277-10
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle is therefore no longer roadworthy.

13.2 Installing the battery

Main work
– Slide the battery into the battery holder.

Info
The battery terminals must be at the rear.

– Attach the positive cable and mount positive terminal cover 1.

– Position retaining bracket 2.
– Mount and tighten screws 3.
100277-11 Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Plug in connector 4.
– Attach the minus cable .
Finishing work
– Mount the seat. ( p. 60)
– Set the clock. ( p. 94)

13.3 Disconnecting the battery

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)

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 13 WIRING HARNESS, BATTERY 80

Main work
– Disconnect the negative (minus) cable 1 of the battery.

Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components can safety equipment can be dam-
aged. The vehicle is therefore no longer roadworthy.

300199-11

13.4 Connecting the battery

Main work
– Reconnect minus cable 1.

300199-11

Finishing work
– Mount the seat. ( p. 60)
– Set the clock. ( p. 94)

13.5 Recharging the battery

Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Even when there is no load on the battery, it still loses power steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
– Remove the battery. ( p. 79)

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 13 WIRING HARNESS, BATTERY 81

Main work
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.

Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing 2.

– Switch off and disconnect the charger after charging.

Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the 3 months
motorcycle is not in use

100151-10

Finishing work
– Install the battery. ( p. 79)
– Mount the seat. ( p. 60)
– Set the clock. ( p. 94)

13.6 Checking the charging voltage

Condition
The battery must be fully functional and completely charged.
Preparatory work
– Remove the seat. ( p. 59)
Main work
– Remove screws 1.
– Push the retaining bracket forward and take off the terminal cover.
– Start the motorcycle to make checks. ( p. 13)

302035-10

– Measure the voltage between the specified points.

Measuring point Plus (+) – Measuring point Ground (−)

Charging voltage
5,000 rpm 13.5… 15.0 V
» If the displayed value is less than the specified value:
– Check the plug-in connections from the alternator to the voltage regulator.
– Check the plug-in connections from the voltage regulator to the wiring har-
601014-10 ness.
– Check the stator winding of the alternator. ( p. 170)
» If the displayed value is greater than the specified value:
– Change the voltage regulator.

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 13 WIRING HARNESS, BATTERY 82

13.7 Changing the main fuse

Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Info
The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
Main work
– Remove protection covers 1.

600604-10

– Remove a defective main fuse 2 with needle nose pliers.

– Install a new main fuse.
Fuse (58011109130) ( p. 176)

Info
A reserve fuse 3 is located in the starter relay.

– Check the functioning of the electrical equipment.

600605-10 – Mount the protection covers.
Finishing work
– Mount the seat. ( p. 60)
– Set the clock. ( p. 94)

13.8 Changing fuses of individual power consumers

Info
The fuse box containing the fuses of individual power consumers is located under the seat.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
Main work
– Open fuse box cover 1.

600604-11

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 13 WIRING HARNESS, BATTERY 83

– Remove the defective fuse.

Guideline
Fuse 1 - 10 A - ignition, combination instrument
Fuse 2 - 10 A - clock, ignition (EFI control unit)
Fuse 3 - 10 A - EPT control unit
Fuse 4 - 10 A - fuel pump
Fuse 5 - 10 A - radiator fan
Fuse 6 - 10 A - horn, brake light, turn signal
Fuse 7 - 15 A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 8 - 10 A - for supplementary equipment (accessories connected with igni-
tion switch)
Fuse 9 - 10 A - for accessories (permanent positive)
Fuse 10 - not used
Fuse SPARE - 10 A/15 A - spare fuses

Info
A defective fuse is indicated by a burned-out fuse wire A.
600606-10

Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are
used.
– Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.

– Replace with a spare fuse of the right rating.

Fuse (75011088010) ( p. 176)
Fuse (75011088015) ( p. 176)

Tip
Put a new spare fuse in the fuse box for future use if needed.

– Check the function of power consumers.

– Close the fuse box cover.
Finishing work
– Mount the seat. ( p. 60)

13.9 Adjusting the engine characteristic

Preparatory work
– Switch off the ignition by turning the ignition key to position OFF .
– Remove the seat. ( p. 59)
Main work
– Pull the Map‑Select switch and holder 1 upward off of the retaining bracket.
– Pull the Map‑Select switch out of the holder.

600641-10

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 13 WIRING HARNESS, BATTERY 84

– Turn the adjusting wheel until the desired digit is next to marking 2.
Set the Map‑Select switch to Soft.
– Set the adjusting wheel to position 1.
Soft – reduced homologated peak performance for better driveability.
Set the Map‑Select switch to Advanced.
– Set the adjusting wheel to position 2.
Advanced – homologated performance with extremely direct responsive-
ness.
100238-10 Set the Map‑Select switch to Standard.
– Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.
Standard – homologated performance with balanced responsiveness.
Set the Map‑Select switch to poor fuel quality.
– Set the adjusting wheel to position 0.
Poor fuel quality – homologated performance is reduced in accordance with
the fuel quality, use for no more than 1 tank of fuel
– Position the Map‑Select switch in the holder.
– Slide the Map‑Select switch with the holder downward onto the retaining bracket.
Finishing work
– Mount the seat. ( p. 60)

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 14 BRAKE SYSTEM 85

14.1 Checking the front brake linings

Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately.

Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the brake linings of the front brake. ( p. 85)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the brake linings of the front brake. ( p. 85)
600625-10

14.2 Changing the brake linings of the front brake

Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

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 14 BRAKE SYSTEM 86

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover with membrane 2.
– Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.

306861-10

– Push the spring hanger forward from spring 3 and pull out pin 4.
– Remove springs 3. Remove brake linings 5.
– Clean the brake caliper.
– Insert new brake linings 5. Position springs 3 and mount pins 4.

Info
The spring hanger of springs 3 must be positioned upward.

400421-10

– Add brake fluid to level A.

Guideline
Level A 5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 206)

– Position the cover with the membrane. Mount and tighten the screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.
100254-12

14.3 Adjusting the basic position of the hand brake lever

– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing wheel 1.

Info
Pull the hand brake lever forward and turn the adjusting wheel.
Do not make any adjustments while riding!

600598-10

14.4 Checking the front brake fluid level

Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.

Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.

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 14 BRAKE SYSTEM 87

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer 1.
» When the brake fluid level drops below the MIN mark:
– Add front brake fluid. ( p. 87)

600603-10

14.5 Adding front brake fluid

Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

Preparatory work
– Check the front brake linings. ( p. 85)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Measurement of A 5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 206)

– Position the cover with the membrane. Mount and tighten the screws.
100254-10
Info
Clean up overflowed or spilt brake fluid immediately with water.

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 14 BRAKE SYSTEM 88

14.6 Changing the front brake fluid

Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 210)
Brake fluid DOT 4 / DOT 5.1 ( p. 206)

301891-10

– Pull off protection cap 4 and connect a commercially available suction device
(standard workshop equipment).
– Release bleeder screw 5 and draw out the old brake fluid.

Info
During suction, ensure that the brake fluid reservoir is always filled with a
sufficient amount of fresh brake fluid.

– Tighten the bleeder screw. Remove the suction device and mount the protection
cap.
302042-10

– Add brake fluid to level A.

Guideline
Measurement A 5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 206)

– Position the cover with the membrane. Mount and tighten the screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.
100254-12

14.7 Checking the rear brake linings

Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately.

Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.

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 14 BRAKE SYSTEM 89

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings. ( p. 89)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the rear brake linings. ( p. 89)
100260-10

14.8 Changing the rear brake linings

Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

– Stand the vehicle upright.

– Remove screw cap 1 with membrane 2.
– Press the brake caliper by hand onto the brake disc in order to retract the brake
piston. Ensure that brake fluid does not flow out of the brake fluid reservoir,
extracting it by suction if it does.

Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
100259-10

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 14 BRAKE SYSTEM 90

– Remove cotter pin 3, remove pin 4 toward the left by striking it, and remove the
brake linings.
– Clean brake caliper and brake caliper support.

100288-10

– Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake
caliper support are seated correctly.

400419-11

– Insert the brake linings, insert the pin, and mount the cotter pin.
– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
– Adjust the brake fluid level to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 206)
– Mount the screw cap with the membrane.

Info
100289-01 Clean up overflowed or spilt brake fluid immediately with water.

14.9 Checking the free travel of foot brake lever

Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

– Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel A.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

Info
You will know that contact has been made with the foot brake cylinder pis-
ton when there is increased resistance when you activate the foot brake
lever.
600599-10
» If the free travel does not meet specifications:
– Adjust the basic position of the foot brake lever. ( p. 91)

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 14 BRAKE SYSTEM 91

14.10 Adjusting the basic position of the foot brake lever

Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

– Loosen fitting 3 on foot brake cylinder 4.

– To adjust the basic position of the foot brake lever individually, loosen nut 1 and
turn screw 2 accordingly.

Info
The range of adjustment is limited. The screw must be screwed into the
footrest bracket by at least four turns.

– Position foot brake cylinder 4 so that the foot brake lever has the necessary free
travel. Hold screws 3 in place and tighten the nuts.
Guideline
Screw connection, foot brake cylinder M6 10 Nm (7.4 lbf ft)
– Check the free travel of the foot brake lever. ( p. 90)
– Tighten nut 1.

B01291-10

14.11 Checking rear brake fluid level

Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.

Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.

– Stand the vehicle upright.

– Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN marking 1:
– Add rear brake fluid. ( p. 92)

100258-10

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 14 BRAKE SYSTEM 92

14.12 Adding rear brake fluid

Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

Preparatory work
– Check the rear brake linings. ( p. 88)
Main work
– Stand the vehicle upright.
– Remove screw cap 1 with the washer and membrane 2.
– Add brake fluid to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 206)
– Mount the screw cap with the washer and membrane.

Info
100259-10 Clean up overflowed or spilt brake fluid immediately with water.

14.13 Changing the rear brake fluid

Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

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 14 BRAKE SYSTEM 93

– Remove screw cap 1 with washer 3 and membrane 2.

– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 210)
Brake fluid DOT 4 / DOT 5.1 ( p. 206)

301893-10

– Pull off protection cap 4 and connect a commercially available suction device
(standard workshop equipment).
– Release bleeder screw 5 and draw out the old brake fluid.

Info
During suction, ensure that the brake fluid reservoir is always filled with a
sufficient amount of fresh brake fluid.

– Tighten the bleeder screw. Remove the suction device and mount the protection
cap.
302043-10
– Add brake fluid to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 206)
– Mount the screw cap with the washer and membrane.
– Activate the foot brake lever until there is a firm pressure point.

Info
Clean up overflowed or spilt brake fluid immediately with water.

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 15 LIGHTING SYSTEM, INSTRUMENTS 94

15.1 Combination instrument

15.1.1 Setting kilometers or miles

Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.

Condition
The motorcycle is stationary.
– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button pressed until the display mode changes from km/h to mph or
from mph to km/h.

400839-01

15.1.2 Setting the clock

Condition
The motorcycle is stationary.
– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button and the SET button pressed simultaneously.
The time display begins to flash.
– Press the MODE button to set the hour.
– Press the SET button to set the minute.
– Keep the MODE button and the SET button pressed simultaneously.
The time is set.
400838-01

15.1.3 Setting/resetting display TRIP 1

Info
The TRIP 1 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value
999.9 is reached, the trip counter starts at 0.0 again.

– Switch on the ignition by turning the ignition key to position ON .

– Press the MODE button repeatedly until the TRIP 1 mode is active.
– Keep the SET button pressed.
The TRIP 1 display is set to 0.0.

400840-01

15.1.4 Setting/resetting display TRIP 2

Info
The TRIP 2 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value
999.9 is reached, the trip counter starts at 0.0 again.

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 15 LIGHTING SYSTEM, INSTRUMENTS 95

– Switch on the ignition by turning the ignition key to position ON .

– Press the MODE button repeatedly until the TRIP 2 mode is active.
– Keep the SET button pressed.
The TRIP 2 display is set to 0.0.

400841-01

15.1.5 Setting the wheel circumference

Danger
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub-
lic roads in the homologated version.
– If the vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle
owner and rider of this.
– If you undertake any modifications, please insist on receiving a signed workshop order from your customer in which you
inform the customer in writing that these modifications are performed at the customer's own risk and that the vehicle will
no longer be approved for use on public roads once modified.

Condition
The motorcycle is stationary.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 96)
Main work
– Unplug connector ED from the combination instrument.
– Unlock pin 18 A and remove it from connector ED.
– Plug connector ED into the combination instrument.
– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the TRIP 1 display mode is active.
– Press and hold the MODE button for 10 seconds.
The wheel circumference is displayed in millimeters.
302064-10

Increasing the wheel circumference

– Press the MODE button 1.
Reducing the wheel circumference
– Press the SET button 2.
– Keep the MODE button and the SET button pressed simultaneously.
The settings are saved and the Setup menu is closed.
– Switch off the ignition by turning the ignition key to position OFF .
– Unplug connector ED from the combination instrument.
302053-10 – Connect pin 18 to connector ED.
– Plug connector ED into the combination instrument.
Finishing work
– Install the headlight mask with the headlight. ( p. 97)
– Check the headlight setting. ( p. 96)

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 15 LIGHTING SYSTEM, INSTRUMENTS 96

15.2 Checking the headlight setting

– Stand the vehicle upright on a horizontal surface in front of a light wall and make a
mark at the height of the center of the low beam headlight.
– Make another mark at a distance B under the first mark.
Guideline
Distance B 5 cm (2 in)
– Position the vehicle vertically at a distance A in front of the wall.
Guideline
Distance A 5 m (16 ft)
400726-10
– The rider, with luggage and a passenger if applicable, now sits down on the motor-
cycle.
– Switch on the low beam.
– Check the headlight setting.
For a ready-to-operate motorcycle with a rider, and with luggage and a passenger
if applicable, the light-dark boundary must lie exactly on the lower mark.
» If the boundary between light and dark does not meet specifications:
– Adjust the headlight range. ( p. 96)

15.3 Adjusting the headlight range

Preparatory work
– Check the headlight setting. ( p. 96)
Main work
– Turn adjusting screw 1 to adjust the headlight range.
Guideline
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with a rider (instructions on how to apply the mark: Checking the
headlight setting).

Info
Turn clockwise to increase the headlight range; turn counterclockwise to
800084-10
reduce the headlight range.
If you have a heavy payload, you will need to correct the headlight range.

15.4 Removing the headlight mask with the headlight

Preparatory work
– Switch off all power consumers and switch off the engine.
Main work
– Cover the fender with a cloth to protect it from damage.
– Remove screws 1 on both sides.
– Tip the headlight mask forward.

100296-11

– Disconnect the connectors of turn signals 2 and headlight 3.

– Remove the headlight mask.

100294-10

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 15 LIGHTING SYSTEM, INSTRUMENTS 97

15.5 Installing the headlight mask with the headlight

Main work
– Connect the connectors of headlight 1 and turn signal lights 2.
– Check lighting function.

100294-11

– Remove the cloth from the fender and position the headlight mask.
Holding lugs 3 reach into the headlight mask.

100295-10

– Position groove 4 on counterpiece 5.

700543-01

– Position brake line guide 6. Mount and tighten screws 7.

Guideline
Screw, headlight mask M5 5 Nm (3.7 lbf ft)

100296-10

Finishing work
– Check the headlight setting. ( p. 96)

15.6 Changing the parking light bulb

Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease
before mounting.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 96)

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 15 LIGHTING SYSTEM, INSTRUMENTS 98

Main work
– Remove protection cap 1.

600610-12

– Pull bulb socket 2 out of the reflector.

– Pull parking light bulb 3 out of the bulb socket.
– Insert a new parking light bulb in the bulb socket.
Parking light (W5W / socket W2.1x9.5d) ( p. 176)
– Insert the bulb socket in the reflector.
– Insert the protection cap.

600612-10

Finishing work
– Install the headlight mask with the headlight. ( p. 97)
– Check the headlight setting. ( p. 96)

15.7 Changing the headlight bulb

Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease
before mounting.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 96)
Main work
– Pull off connector 1.
– Take off protection cap 2 of the headlight bulb.

600610-10

– Detach spring bar 3.

– Remove headlight bulb 4.
– Insert a new headlight bulb into the headlight housing.
Headlight (H4 / socket P43t) ( p. 176)
– Fix the headlight bulb in the headlight using the spring bar.
– Mount the protection cap. Attach the connector.

600611-10

Finishing work
– Install the headlight mask with the headlight. ( p. 97)
– Check the headlight setting. ( p. 96)

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 15 LIGHTING SYSTEM, INSTRUMENTS 99

15.8 Changing the turn signal bulb

Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease
before mounting.

Main work
– Remove the screw on the rear of the turn signal housing.
– Carefully swing turn signal glass 1 forward and take it off.
– Press the turn signal bulb carefully into the socket, turn it counterclockwise by
about 30°, and take it out of the socket.

Info
Do not touch the reflector with your fingers, and keep it free from grease.

100160-10 – Press the new turn signal bulb carefully into the socket and turn it clockwise until
it stops.
Turn signal (RY10W / socket BAU15s) ( p. 176)
– Position the turn signal glass.
– Insert the screw and turn it counterclockwise first until it engages in the thread.
Tighten the screw slightly.
Finishing work
– Check the turn signal system function.

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 16 ENGINE 100

16.1 Removing the engine

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 59)
– Disconnect the battery. ( p. 79)
– Raise the motorcycle with the work stand. ( p. 11)
– Take off the side cover. ( p. 60)
– Remove the air filter box. ( p. 56)
– Remove the manifold. ( p. 52)
– Drain the coolant. ( p. 161)
Main work
– Loosen the spring-loaded band-type clamp 1 using the special tool. Detach the
radiator hoses.
Pliers for spring band clamp (60029057100) ( p. 212)

300211-10

– Remove screws 2.

300212-10

– Remove screws 3.
– Take off the engine sprocket cover.
– Remove screw 4.
– Take off the shift lever.

300213-10

– Have an assistant operate the rear brake.

– Bend up the lock washer.
– Remove the nut of the engine sprocket with the lock washer.
– Remove screws 5.

300214-10

– Remove nut 6. Remove the chain adjuster.

– Pull out the wheel spindle only far enough to allow the rear wheel to be pushed for-
ward.
– Push the rear wheel forward as far as possible and take the chain off the rear
sprocket.

Info
The rear wheel must be fully removed.

300215-10

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 16 ENGINE 101

– Take off the engine sprocket.

– Take off the clutch slave cylinder and hang it to the side.

Info
Do not bend the clutch line.
Do not activate the clutch lever if the clutch slave cylinder has been
removed.

– Take off the clutch push rod.

– Unscrew the electrical connection 7 from the starter motor.
– Remove ground wire 8 from the starter motor.

300216-10

– Loosen hose clip 9.

– Pull off the throttle valve body from the rear.

300217-10

– Disconnect connector bk of the gear position sensor, the crankshaft position sensor,
and the alternator.
– Remove the cable binders and release the cables.

300218-10

– Pull of the spark plug connector.

– Unplug the connector of the engine coolant temperature sensor bl.

300188-10

– Loosen the spring-loaded band-type clamp bm from the breather, SLS and oil return
line with the special tool.
Pliers for spring band clamp (60029057100) ( p. 212)

300220-10

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 16 ENGINE 102

– Remove screws bn. Remove the engine bearer.

300221-10

– Position the floor jack under the engine and fix it using the special tool.
Floor jack attachment (75029055000) ( p. 217)

300222-10

– Remove nut bo of the lower engine bracket. Remove the screw.

300223-10

– Remove screw bp of the swingarm pivot.

– Remove the swingarm pivot.

300225-10

– Lower the engine.

Info
You should have an assistant for this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments from damage.

300224-10

16.2 Installing the engine

Preparatory work
– Raise the engine onto the special tool and fix it.
Floor jack attachment (75029055000) ( p. 217)

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 16 ENGINE 103

Main work
– Position the engine in the frame.
– Mount swingarm pivot 1.
– Mount the screw of the swingarm pivot but do not tighten yet.

300225-11

– Install the screw and nut 2 of the lower engine bracket, but do not tighten them
yet.

300223-11

– Remove the floor jack with the special tool.

Floor jack attachment (75029055000) ( p. 217)

300222-10

– Position the engine bearer.

– Mount and tighten screws 3.
Guideline
Screw, engine bearer on frame M10 45 Nm
(33.2 lbf ft)
– Mount and tighten screw 4 with nut.
Guideline
Engine carrying screw M10 45 Nm Loctite® 243™
300221-11
(33.2 lbf ft)
– Tighten the swingarm pivot.
Guideline
Screw, swingarm pivot M12 80 Nm (59 lbf ft)
– Tighten the lower engine bracket.
Guideline
Engine carrying screw M10 45 Nm Loctite® 243™
(33.2 lbf ft)
– Position the hoses of the engine breather, the SLS and the oil return line. Mount
the spring band clamp 5 using the special tool.
Pliers for spring band clamp (60029057100) ( p. 212)

300220-11

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 16 ENGINE 104

– Attach the spark plug connector.

– Plug in the connector of the engine coolant temperature sensor 6.

300219-11

– Reconnect plug-in connections 7 of the gear position sensor, the crankshaft posi-
tion sensor, and the alternator.

300218-11

– Slide the throttle valve body into the rubber sleeves.

– Position and tighten hose clip 8.

300217-11

– Position the electrical connection 9 on the starter motor. Mount and tighten the
screw.
Guideline
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft)
– Position the ground wire on the starter motor. Mount and tighten screw bk.
Guideline
Screw, starter motor M6 10 Nm Loctite® 243™
(7.4 lbf ft)
300216-11

– Insert the clutch push rod.

– Position the clutch slave cylinder.
– Mount and tighten screws bl.
Guideline
Screw, clutch slave cylin- M6x20 10 Nm Loctite® 243™
der (7.4 lbf ft)
Screw, clutch slave cylin- M6x35 10 Nm –
der (7.4 lbf ft)
300214-11
– Mount the engine sprocket with the chain.
– Position the new lock washer and mount nut bm but do not tighten yet.
– Position the rear wheel.
– Mount the chain adjuster and nut.
– Push the rear wheel forward so that the chain adjusters are on the tensioning
screws, and tighten the nut bn.
Guideline
Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)

300215-11

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 16 ENGINE 105

– Have an assistant operate the rear brake.

– Tighten the engine sprocket nut.
Guideline
Nut, engine sprocket M20x1.5 80 Nm Loctite® 243™
(59 lbf ft)
– Secure the nut with lock washer.

300214-12

– Position the rear sprocket cover.

– Mount and tighten screw bp.
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
– Mount and tighten screw bq.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
300213-11
– Position the shift lever.
– Mount and tighten screw br.
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 lbf ft)
– Mount and tighten screws bs.
Guideline
Screw, upper radiator bracket M6 10 Nm (7.4 lbf ft)

300212-11

– Position the radiator hoses. Install the spring band clamps bt.
– Install the manifold. ( p. 53)
– Disconnect the battery. ( p. 80)

300211-11

– Remove the oil filler plug with O-ring ck from the clutch cover and fill up with
engine oil.
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 206)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 206)
– Install and tighten the oil filler plug with O-ring ck.
300802-10

Finishing work
– Fill/bleed the cooling system. ( p. 161)
– Remove the motorcycle from the work stand. ( p. 12)
– Take a short test ride.
– Read out the fault memory using the KTM diagnostics tool.

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 16 ENGINE 106

– Check the engine for leakage.

– Check the engine oil level. ( p. 164)
– Check the coolant level. ( p. 163)

16.3 Engine disassembly

16.3.1 Clamping the engine into the engine assembly stand
– Mount special tool 1 on engine assembly stand 2.
Engine assembly stand (61229001000) ( p. 213)
Support for engine assembly stand (75012001060) ( p. 214)
Holder for engine assembly stand (75012001070) ( p. 214)
– Mount the engine on special tool 1.

Info
Have an assistant help you or use a crane.
300144-10

16.3.2 Draining the engine oil

– Remove the oil drain plug 1 with the magnet and seal ring.
– Remove plug 2 with oil screen and the O-rings.

300002-10

– Remove plug 3 with oil screen 4 and the O-rings.

– Completely drain the engine oil.

300161-10

16.3.3 Removing starter motor

– Remove screws 1. Take off the starter motor.

300001-01

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 16 ENGINE 107

16.3.4 Removing valve cover

– Remove screws 1. Take off the valve cover with the valve cover seal.

300003-10

16.3.5 Removing the alternator cover

– Remove screws 1. Take off the alternator cover.
– Remove dowels.

300004-10

16.3.6 Removing spacer

– Remove the spacer 1 of the countershaft.

302124-10

16.3.7 Removing gear position sensor

– Remove screws. Remove the gear position sensor 1.

302126-10

– Remove O-ring 2.
– Remove contact pin 3 and the contact springs 4.

300007-10

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 16 ENGINE 108

16.3.8 Removing oil filter

– Remove screws. Remove the oil filter cover 1 with the O-ring.
– Pull oil filter 2 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 210)

300009-10

– Remove screws. Remove the oil filter cover 3 with the O-ring.
– Pull oil filter 4 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 210)

300011-10

16.3.9 Removing thermostat

– Remove screws. Take off the thermostat case 1 with the radiator hose.
– Pull out the thermostat 2.

300010-10

16.3.10 Setting engine to ignition top dead center

– Turn the crankshaft counterclockwise until markings 1 of the camshafts are flush
with the marks of the camshaft support plate.

300023-10

– Remove screw 2.

Info
Look through the hole to check that the position hole of the balancer shaft
is visible.

– Screw in special tool 3.

Engine blocking screw (77329010000) ( p. 218)

300024-10

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 16 ENGINE 109

16.3.11 Removing water pump wheel

– Remove screws 1. Take off the water pump cover.

300012-10

– Remove screw 2. Take off the water pump wheel 3.

– Take off the water pump cover seal.

Info
Do not lose the centering pins.

300013-10

– Remove the shaped washer 4.

300014-10

16.3.12 Removing clutch cover

– Remove screws 1. Take off the clutch cover.
– Take off the dowels. Remove the clutch cover seal.

300015-10

16.3.13 Removing spacer and spring

– Remove the spacer 1 and spring 2 of the shift shaft.

300154-10

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 16 ENGINE 110

16.3.14 Removing spark plug

– Remove the spark plug using the special tool 1.
Spark plug wrench (75029172000) ( p. 218)

300016-10

16.3.15 Removing timing chain tensioner

– Remove screw 1. Take off the seal ring.
– Pull out timing chain tensioner 2.

300017-10

16.3.16 Removing camshafts

– Remove screw 1. Take off the camshaft support plate 2.

300019-10

– Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft
gear. Remove the camshaft.

300020-10

16.3.17 Removing cylinder head

– Remove screws 1.
– Alternately loosen screws 2 and remove them.
– Take off the cylinder head.

300029-10

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 16 ENGINE 111

16.3.18 Removing piston

– Take off the cylinder head gasket 1.
– Remove screw 2.
– Push the cylinder upward.

Info
Push the cylinder upward only far enough to allow removal of the piston pin.
Ensure that the two grooved pins remain in place.

300030-10

– Remove piston pin retainer 3.

– Remove the piston pin.
– Take off the cylinder with the piston.
– Push the piston upward out of the cylinder.

Info
If no other work is required on the cylinder and the piston, you can leave the
piston in the cylinder.

300031-10 – Take off the cylinder base gasket.

Info
Ensure that the two grooved pins remain in place.

16.3.19 Removing rotor

– Remove special tool 1.
Engine blocking screw (77329010000) ( p. 218)

300044-10

– Use the special tool to hold the rotor tight.

Holding spanner (75029091000) ( p. 217)
– Loosen the nut 1 of the rotor and remove it with the tab washer.

Info
The crankshaft must not be blocked.

300040-10

– Install the special tool 2 on the rotor. Hold it tight using the special tool and pull
off the rotor by turning the screw in.
Extractor (58429009000) ( p. 210)
– Remove the special tool.

302120-10

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 16 ENGINE 112

16.3.20 Removing timing chain rails

– Remove screws 1.
– Pull the timing chain guide rails 2 out of the timing chain securing guide 3.

Info
The support bushing is plugged through the timing chain guide rails into the
timing chain securing guide.

– Remove the timing chain guide rails upward out of the timing chain shaft.

300045-10

– Hold the timing chain securing guide tight and pull the timing chain tensioning
rail 4 out of the timing chain securing guide.
– Remove the timing chain tensioning rail upward out of the timing chain shaft.
– Remove the timing chain securing guide 3.

300046-10

16.3.21 Removing timing chain and timing chain sprocket

– Slip out timing chain 1.

Info
Mark the direction of travel.

– Take off lock ring.

300148-10

– Pull of the timing chain sprocket with the special tool 2.

Extractor (59029033000) ( p. 211)

300149-10

16.3.22 Removing crankshaft position sensor

– Remove the screws of crankshaft position sensor 1.
– Pull cable support sleeve 2 out of the engine case. Take off the crankshaft posi-
tion sensor.

300151-10

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 16 ENGINE 113

16.3.23 Removing clutch cage

– Clamp the antihopping clutch with special tool 1.
Assembly screws (75029033000) ( p. 214)

Info
Apply the special tool with the hand only, do not use another tool.

300051-10

– Loosen the screws 2 diagonally and remove them with their spring retainers and
clutch springs.
– Remove the pressure cap 3.

300052-10

– Remove the pressure piece 4.

– Bend up the lock washer 5.

300053-10

– Hold the clutch cage using the special tool and remove the nut 6 of the inner
clutch hub.
Gear segment (75029081000) ( p. 217)

Info
Make sure that the crankshaft is not blocked.

– Remove the nut 7 of the primary gear.

300054-10 Info
Left-handed thread!

– Take off the stepped washer and remove the half-washers 8.

– Take off the clutch cage.

302125-10

– Remove needle bearing 9 and supporting plate bk.

300056-10

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 16 ENGINE 114

16.3.24 Removing primary gear

– Plug the special tool into the crankshaft.
Protection cover (75029090000) ( p. 217)
– Screw the special tool 1 on to the primary gear 2.
Extractor (75029021000) ( p. 214)
– Hold it using the special tool and pull off the primary gear by turning the screw in.
– Remove the special tools.

300062-10

16.3.25 Removing starter drive

– Remove the lock ring of the starter idler gear 1 and the torque limiter 2.
– Take off the starter idler gear 1 with the washers.
– Remove the torque limiter 2 with the washers and needle bearing.

300064-10

– Take off the free-wheel gear 3.

– Remove the woodruff key 4 and both needle bearings 5.

300065-10

16.3.26 Removing shift shaft

– Push sliding plate 1 away from the shift drum locating 2. Remove shift shaft 3
with the washer.

300066-10

16.3.27 Removing shift drum locating

– Remove screw 1.
– Press locking lever 2 away from shift drum locating 3 and take off the shift drum
locating.
– Release the locking lever.

300067-10

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 16 ENGINE 115

16.3.28 Removing locking lever

– Remove screw 1.
– Take off locking lever 2 with the sleeve and spring.

300069-10

16.3.29 Removing oil pumps

– Remove the lock washers 1 and normal washers 2 from both oil pumps.
– Take off the oil pump toothed wheels 3.

300070-10

– Remove the pins 4 and washers 5.

– Remove screws. Take off the oil pump cover 6.

300071-10

– Remove both oil pump shafts 7 with internal rotors 8.

– Take the external rotors out of the engine case.

300072-10

16.3.30 Removing left engine case

– Remove screws 1.
– Swing the left section of the engine case up and remove the nut or screw of the
engine fixing arm.

300075-10

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 16 ENGINE 116

– Install the special tool 2 with suitable screws.

Extractor (75029048000) ( p. 216)

Info
Use the 750 drill hole.

– Pull off the section of the engine case.

Info
300076-10
Do not tension the section of the engine case.
The balancer shaft and the main shaft have a stop disk, these usually stick
to the bearing.

– Take off the left section of the engine case.

– Remove the special tool.
– Remove dowels.
– Remove O-ring 3.

300077-10

16.3.31 Removing crankshaft and balancer shaft

– Remove the crankshaft 1 and the balancer shaft 2.

300078-10

16.3.32 Removing transmission shafts

– Remove the shift rail 1.

300079-10

– Swing shift forks 2 to one side.

– Remove shift drum 3.

300080-10

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 16 ENGINE 117

– Remove shift forks 2.

Info
Ensure that the pins remain in place.

300081-10

– Remove the lock ring 4 and the stop disk.

300082-10

– Pull both transmission shafts 5 out of the bearing seats together.

Info
The stop disk of the countershaft usually sticks to the bearing.

– Take the O-ring off the countershaft 6.

300083-10

16.4 Work on individual parts

16.4.1 Work on the right section of the engine case
– Remove oil jet 1.
– Remove bearing locks of the main shaft bearing 3, of the countershaft bearing 4,
and of the shift drum bearing 5.
– Remove any sealing mass remnants and clean the engine case section thoroughly.
– Pull the dowels out of the housing.
– Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
300094-10
– Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.

Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.

– Remove oil jet 2.

– Remove the cover plate 6 for the oil return line.
– Press out the shaft seal ring 7 of the crankshaft from the inside to the outside.
– Remove the shaft seal rings 8 of the water pump.
– Press in the shaft seal ring 7 of the crankshaft from the outside to the inside with
the open side facing in.

Info
300095-10
The shaft seal ring must be flush on the outside.

– Press in the shaft seal rings of the water pump with the open side facing out so
that it is flush.

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 16 ENGINE 118

– Warm the engine case section again.

Guideline
150 °C (302 °F)
– Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing from the inside to
the outside, all the way to the stop or so it is flush.

Info
The shift shaft bearing 9 must be pressed in from the outside to the inside
until it is flush.
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer bearing race; otherwise, the bear-
300096-10
ings will be damaged when they are pressed in.

– After the engine case section has cooled, check that the bearings are firmly seated.

Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.

– Position all bearing locks. Mount and tighten the screws.

Guideline
Locking screw for bearing M5 6 Nm Loctite® 243™
(4.4 lbf ft)
– Mount and tighten the oil jet 1.
Guideline
Oil jet, piston cooling M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
– Mount and tighten the oil jet 2.
Guideline
Oil nozzle for conrod bear- M4 2 Nm Loctite® 243™
ing lubrication (1.5 lbf ft)
– Blow compressed air through all oil channels and check that they are clear.
– Position the cover plate 6. Mount and tighten the screws.
Guideline
Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft)
– Reinstall the dowels.

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 16 ENGINE 119

16.4.2 Work on the left section of the engine case

– Remove all dowels.
– Remove oil jet 1.
– Remove the shaft seal ring of countershaft 2 and shift shaft 3.

Info
The shaft seal ring 4 of the crankshaft cannot be removed before the
crankshaft bearing.

– Screw off the membrane support plate 5 and remove it together with
membrane 6.
– Remove screw A with the washer.

302590-10

– Remove screw plug 7 and take pressure spring 8 with piston valve 9 out of the
drill hole.
– Remove any sealing mass remnants and clean the engine case section thoroughly.
– Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
– Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
300160-10
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.

– Press out the shaft seal ring of the crankshaft from the outside to the inside.
– Press in the shaft seal ring of the crankshaft from the inside to the outside with the
open side facing out.

Info
The shaft seal ring must be flush on the outside.

– Warm the engine case section again.

Guideline
150 °C (302 °F)
– Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing all the way to the
stop or so that it is flush.

Info
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer bearing race; otherwise, the bear-
ings will be damaged when they are pressed in.

– After the engine case section has cooled, check that the bearings are firmly seated.

Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.

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 16 ENGINE 120

– Mount and tighten screw A with the washer.

Guideline
Locking screw for bearing M5 6 Nm Loctite® 243™
(4.4 lbf ft)
– Press in the shaft seal ring of countershaft 2 and shift shaft 3 with the open side
facing inwards so that it is flush.
– Mount and tighten the oil jet 1.
Guideline
Oil jet, piston cooling M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
– Mount the dowels.
– Blow compressed air through all oil channels and check that they are clear.
– Measure the spring length of the oil pressure regulator valve.
Oil pressure regulator valve - minimum 25.36 mm (0.9984 in)
spring length
» If the measured value does not equal the specified value:
– Change the spring.
– Check the piston valve for damage and wear.
» If there is damage or wear:
200155-10
– Replace the piston valve.

– Lubricate piston valve 9 and mount it with pressure spring 8. Mount and tighten
screw plug 7 with the new seal ring.
Guideline
Oil pressure regulator valve plug M12x1.5 20 Nm
(14.8 lbf ft)
– Position the membrane support plate 5 with membrane 6. Mount and tighten the
screws.
Guideline
300093-10 Screw, membrane fixation M3 2.5 Nm Loctite® 243™
(1.84 lbf ft)

Info
The membrane support plate is curved and must point away from the mem-
brane.
An incorrectly installed membrane support plate results in loss of perfor-
mance and increased oil consumption or leaks.
Do not apply thread locker between the membrane and the membrane sup-
port plate since this would impair their function.

16.4.3 Work on the clutch cover

– Remove the shaft seal ring 1 of the crankshaft.
– Press in a new shaft seal ring with the open side facing inward until it stops.

Info
Support the clutch cover sufficiently when pressing in.

– Blow compressed air through the oil channel and check that it is clear.

300097-10

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 16 ENGINE 121

16.4.4 Removing crankshaft bearing inner ring

– Fix the crankshaft with special tools 1 and 2 in the vise.
Upper part, pressing-out tool (75029047050) ( p. 216)
Under part, pressing-out tool (75029047051) ( p. 216)

300135-10

– Heat the special tool 3.

Guideline
150 °C (302 °F)

Tool for inner bearing race (58429037043) ( p. 211)

– Push the heated special tool 3 on to the inner bearing race, press them hard
together, and pull them together off the crankshaft.
– Take off the compensation shim.
300136-10 – Repeat the operation on the opposite side.

16.4.5 Removing balancer shaft drive wheel

Preparatory work
– Remove the crankshaft bearing inner ring. ( p. 121)
Main work
– Screw in 2 M6 screws 1 in the threads. Tighten the two screws evenly to pull the
drive wheel 2 off the crankshaft.

300133-10

16.4.6 Changing the connecting rod, conrod bearing, and crank pin
Preparatory work
– Remove the crankshaft bearing inner ring. ( p. 121)
– Remove the drive wheel of the balancer shaft. ( p. 121)
Main work
– Position the crankshaft with the special tool 1 in the press.
Under part, pressing-out tool (75029047051) ( p. 216)
– Position the special tool 2 between the crankwebs.
Upper part, pressing-out tool (75029047050) ( p. 216)
– Press the crank pin with the push-out drift of the special tool out of the upper
crankweb.
300137-10 Pressing device for crankshaft, complete (75029047000) ( p. 215)

Info
Hold the lower crankweb.

– Take off the connecting rod and bearing.

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 16 ENGINE 122

– Press the crank pin out of the crankweb.

300138-10

– Press in the new crank pin 3 as far as possible.

Info
The crank pin must be pressed in so that oil channel A is aligned with oil
channel B.
If the oil channels are not correctly aligned, the conrod bearing will not be
supplied with oil.

– Blow compressed air through the oil channel to check that it is clear.

300140-10

– Install the bearing 4 and the connecting rod 5.

Info
Thoroughly lubricate the bearing.

300141-10

– Position special tool 6 on the press.

Pressing device for crankshaft, complete (75029047000) ( p. 215)
– Place the crankweb in with the connecting rod and the bearing. Position the second
crankweb.

300142-10

– Position the special tool 7 with the heel at the bottom.

Pressing device for crankshaft, complete (75029047000) ( p. 215)
– Press the upper crankweb in as far as possible.

Info
The press mandrel must be applied above the crank pin.

– Take the crankshaft out of the special tool, and check the connecting rod for free-
dom of movement.
300139-10

– Measure the axial clearance between the connecting rod and the crankwebs using
the special tool 8.
Feeler gauge (59029041100) ( p. 212)

Connecting rod - axial clearance of 0.40… 0.60 mm (0.0157…

lower conrod bearing 0.0236 in)
» If the specified value is not met:
– Correct until it complies with the specified value.
300143-10

Finishing work
– Check the crankshaft run-out at the bearing pin. ( p. 123)
– Install the drive wheel of the balancer shaft. ( p. 123)

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 16 ENGINE 123

– Install the crankshaft bearing inner ring. ( p. 123)

– Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 124)

16.4.7 Checking crankshaft run-out at bearing pin

– Position the crankshaft on a roller block.
– Rotate the crankshaft slowly.
– Check the crankshaft run-out at both bearing pins.
Crankshaft run-out at bearing pin ≤ 0.10 mm (≤ 0.0039 in)
» If the crankshaft run-out at the bearing pin is greater than the specified value:
– Align the crankshaft.

300132-10

16.4.8 Installing balancer shaft drive wheel

Main work
– Fix the crankshaft with special tools 1 and 2 in the vise.
Upper part, pressing-out tool (75029047050) ( p. 216)
Under part, pressing-out tool (75029047051) ( p. 216)
– Warm the drive wheel.
Guideline
100 °C (212 °F)
300145-10

– Place the drive wheel on the crankshaft.

The dowel of the crankshaft must fit in the drill hole 4.
The side of the drive wheel with the punch mark 3 must be visible after
assembly, and the side with the bevel 2 must be in contact with the
crankweb.

300159-10

Finishing work
– Install the crankshaft bearing inner ring. ( p. 123)
– Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 124)

16.4.9 Installing crankshaft bearing inner ring

Main work
– Fix the crankshaft with special tools 1 and 2 in the vise.
Upper part, pressing-out tool (75029047050) ( p. 216)
Under part, pressing-out tool (75029047051) ( p. 216)
– Push on the compensation shim.
– Heat the special tool. Install the inner bearing race.
Guideline
300134-10 120 °C (248 °F)

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 16 ENGINE 124

– Repeat the operation on the opposite side.

– Make sure that the new inner bearing race is installed flush.

Info
After changing the crankshaft bearing and the conrod bearing, measure the
axial play of the crankshaft.

Finishing work
– Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 124)

16.4.10 Measuring axial clearance of crankshaft and balancer shaft

– Insert the crankshaft and balancer shaft in the right engine casing.

Info
Do not forget the dowels.

– Mount the left engine casing.

– Mount and tighten the screws.
Guideline
Screw, engine case M6 10 Nm (7.4 lbf ft)
300126-10
– Mount the dial gauge support on the engine case and measure and note the axial
clearance of the crankshaft.
Guideline
Crankshaft - axial clearance 0.15… 0.25 mm (0.0059…
0.0098 in)
» If the measured value does not equal the specified value:
– Remove the crankshaft.
– Remove the crankshaft bearing inner ring. ( p. 121)
– Calculate the thickness of the compensation shims.
– Add or remove compensation shims equally on both sides.

Info
If the axial clearance is too small, remove compensation shims.
If the axial clearance is too large, add compensation shims.

– Install the crankshaft bearing inner ring. ( p. 123)

– Mount the dial gauge support on the engine case and measure and note the axial
clearance of the balancer shaft.
Guideline
Balancer shaft axial clearance 0.05… 0.20 mm (0.002… 0.0079 in)
» If the measured value does not equal the specified value:
– Remove the balancer shaft.
– Calculate the thickness of the compensation shims.
– Add compensation shims to the ignition side only.
300164-10

Info
If the axial clearance is too small, remove compensation shims.
If the axial clearance is too large, add compensation shims.

16.4.11 Cylinder - Nikasil® coating

Nikasil® is a surface protection layer for a coating method developed by the Mahle
company. The name is derived from the two materials used in this method - a layer of
nickel, in which silicon carbide (a particularly hard substance) is embedded.
The most important advantages of the Nikasil® coating are the excellent heat conduc-
tivity resulting in better performance, less wear, and low cylinder weight.

302591-10

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 16 ENGINE 125

16.4.12 Checking/measuring the cylinder

– Check the O-ring of the chain adjuster for damage and wear.
» If there is damage or wear:
– Replace the O-ring.
– Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
– Change the cylinder and piston.
– Measure the cylinder diameter at several places in the X and Y axes using a
micrometer to check for oval wear.
300102-10
– To determine the size, measure the cylinder at a distance B from the top edge of
the cylinder.
Guideline
Distance B 55 mm (2.17 in)
Cylinder - bore diameter
Size I 102.000… 102.012 mm (4.01574…
4.01621 in)
Size II 102.013… 102.025 mm (4.01625…
4.01672 in)
– The cylinder size 1 is marked on the side of the cylinder.

300103-10

– Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) ( p. 212)

Cylinder/cylinder head - sealing area ≤ 0.10 mm (≤ 0.0039 in)

distortion
» If the measured value does not equal the specified value:
– Change the cylinder.
400376-10

16.4.13 Checking/measuring the piston

– Use the special tool to measure clearance A of the piston rings in the piston ring
groove.
Guideline
Piston ring - groove clearance ≤ 0.08 mm (≤ 0.0031 in)
A
0
0
A Feeler gauge (59029041100) ( p. 212)

0
A » If clearance A is larger than the specified value:
– Change the piston and piston rings.
400484-10 – Check/measure the cylinder. ( p. 125)
– Check the piston bearing surface for damage.
» If the piston bearing surface is damaged:
– Change the piston and, if necessary, the cylinder.
– Check that the piston rings can move easily in the piston ring grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.

Tip
300099-10 Use an old piston ring to clean the piston ring groove.

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 16 ENGINE 126

– Check the piston rings for damage.

» If the piston ring is damaged:
– Change the piston ring.

Info
Mount the piston ring with the marking facing upward.

– Check the piston pin for discoloration or signs of wear.

» If the piston pin has strong discoloration/signs of wear:
– Change the piston pin.
– Insert the piston pin into the connecting rod and check the bearing for play.
» If the piston pin bearing has too much play:
– Change the connecting rod and the piston pin.
– Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance B.
Guideline
Distance B 31.5 mm (1.24 in)
Piston - diameter
Size I 101.955… 101.965 mm (4.01397…
4.01436 in)
Size II 101.965… 101.975 mm (4.01436…
301758-10 4.01476 in)

Info
Piston size 1 is marked on the piston head.

16.4.14 Checking piston ring end gap

– Remove the piston ring from the piston.
– Place the piston ring in the cylinder and align it with the piston.
Guideline
Under the upper edge of the cylinder 10 mm (0.39 in)
– Measure the end gap with a feeler gauge A.
Guideline
Piston ring end gap
300098-10 Compression rings ≤ 0.80 mm (≤ 0.0315 in)
Oil scraper ring ≤ 1.00 mm (≤ 0.0394 in)
» If the end gap is more than the specified value:
– Check/measure the cylinder. ( p. 125)
» If the cylinder wear is within the tolerance range:
– Change the piston ring.
– Mount the piston ring with the marking facing toward the piston head.

16.4.15 Checking piston/cylinder mounting clearance

– Check/measure the cylinder. ( p. 125)
– Check/measure the piston. ( p. 125)
– The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam-
eter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston
diameter.
Guideline
Piston/cylinder - mounting clearance
New condition 0.035… 0.060 mm (0.00138… 0.00236 in)
Wear limit 0.10 mm (0.0039 in)

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 16 ENGINE 127

16.4.16 Checking oil pumps for wear

Info
The oil pump wear check shown here is on the suction pump but it applies to all oil pumps.

– Use a feeler gauge 1 to measure the play between the external rotor and the
engine case as well as between the external rotor and the internal rotor.
Oil pump
Clearance between external rotor ≤ 0.20 mm (≤ 0.0079 in)
and engine case
Clearance between external rotor ≤ 0.20 mm (≤ 0.0079 in)
and internal rotor
Axial clearance 0.04… 0.08 mm (0.0016…
300106-10 0.0031 in)
» If the measured value does not meet specifications:
– Change the oil pump and, if necessary, the engine case.

16.4.17 Replacing autodecompressor

– Take the lock ring 1 off the autodecompression shaft and dispose of it.

300107-10

– Pull the autodecompression shaft 2 from the camshaft.

300108-10

– Disconnect the autodecompression spring. Loosen the screw 3 and remove it

together with the autodecompression spring and the autodecompression weight 4.

300109-10

– When assembling, first connect the autodecompression spring and then insert the
screw through the autodecompression weight.
The arm of the autodecompression spring 5 is long enough to pass right
through the autodecompression weight.
– Position the autodecompression weight. Mount and tighten screw 3. Reconnect
the autodecompression spring.
Guideline
Screw, autodecompression M6 3… 4 Nm Loctite® 243™
(2.2…
300110-10
3 lbf ft)

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 16 ENGINE 128

– Mount the autodecompression shaft in the camshaft. Install a new lock ring.
– Check the functioning.
» If the autodecompression spring does not completely retract the autodecom-
pression shaft:
– Replace the autodecompression spring.

16.4.18 Preparing timing chain tensioner for installation

– Fully compress the timing chain tensioner.

Info
This requires considerable force since the oil has to be pressed out.

– Release the timing chain tensioner.

Without pressure, the timing chain tensioner expands fully.

200171-10

– Place two compensating disks or similar aids next to the piston of the timing chain
tensioner. This should ensure that when pushed down, the piston does not fully
withdraw.
Guideline
Thickness of the compensating disks 2… 2.5 mm (0.08… 0.098 in)
– Release the timing chain tensioner.
The latching system locks and the piston stops moving.
End position of piston after latching 3 mm (0.12 in)
200172-10

Info
This position is necessary for installation.
If the timing chain tensioner is now pressed in once more (while it is
installed) and then pulled out no more than halfway (preventing it from
coming out fully), the latching system locks and the timing chain tensioner
can no longer be compacted; this function is necessary to ensure sufficient
tension of the timing chain, even at low oil pressure.

16.4.19 Checking timing assembly

– Clean all parts well.
1
0 5
0 – Check the timing chain gear / timing chain sprocket 1 for damage and wear.
» If there is damage or wear:
– Replace the timing chain gear / timing chain sprocket.
02 – Check timing chain tensioning rail 2 for damage and wear.
» If there is damage or wear:
0
3 – Change the timing chain tensioning rail.
– Check timing chain guide rail 3 for damage and wear.
» If there is damage or wear:
– Change the timing chain guide rail.
– Check timing chain securing guide 4 for damage and wear.
» If there is damage or wear:
– Replace the timing chain securing guide.
– Check timing chain 5 for damage and wear.
4
0 1
0 » If there is damage or wear:
– Change the timing chain.
– Check that the timing chain links move easily. Let the timing chain hang down
300113-01
freely.
» If the chain links no longer straighten out:
– Change the timing chain.

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 16 ENGINE 129

16.4.20 Removing rocker arm

– Remove screws 1.

300113-10

– Screw a suitable screw 3 into the rocker arm shafts 2. Pull out the rocker arm
shafts.
– Take off the rocker arm 4.

300114-10

16.4.21 Changing camshaft bearing

Preparatory work
– Remove the rocker arm. ( p. 129)
Main work
– Clamp the cylinder head.
Clamping plate (75029050000) ( p. 216)
– Remove the large camshaft bearing using the special tool 1.
Push-out drift (75029051000) ( p. 216)

300226-10

– Remove the small camshaft bearing using special tool 2.

Insert for bearing puller (15112018100) ( p. 210)
Bearing puller (15112017000) ( p. 210)

300228-10

– Press in the small camshaft bearing as far as possible using the special tool 3.
Push-in drift (75029044020) ( p. 215)

300229-10

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 16 ENGINE 130

– Press in the large camshaft bearing as far as possible using the special tool 4.
Push-in drift (75029044010) ( p. 215)

300230-10

Finishing work
– Install the rocker arm. ( p. 133)

16.4.22 Removing valves

– Take shims 1 out of the valve spring retainers and lay them to one side according
to their normal built-in position.

300115-10

– Pretension the valve springs using the special tool.

Valve spring compressor (59029019000) ( p. 211)
Valve spring mounting device (78029060000) ( p. 218)
– Remove valve keys and release tension on the valve springs.
– Remove spring retainers and spring.
– Pull the valve down and out of the valve guide, remove the valve stem seal and
valve spring retainer.
300116-10

– Mark the valves according to their normal built-in position.

Info
Place the valves into a box according to the installation position and label
the box.

300117-10

16.4.23 Checking valves

– Check the run-out at the valve plate.
Valve - run-out
On the valve plate ≤ 0.05 mm (≤ 0.002 in)
» If the measured value does not equal the specified value:
– Change the valve.

200193-10

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 16 ENGINE 131

– Check the sealing seat A on the valve.

Valve - sealing seat width
Intake 1.60 mm (0.063 in)

0
A Valve - sealing seat width
Exhaust 2.00 mm (0.0787 in)
» If the sealing area is not in the center of the valve seat or deviates from the
specified value:
400373-10
– Machine the valve seat.

16.4.24 Checking valve springs

– Check the valve springs for fractures and wear (visual check).
» If the valve spring is fractured or worn:
– Change the valve spring.
– Measure the valve spring lengths.
Valve spring
Minimum length (without valve 42.3 mm (1.665 in)
spring cap)

300118-10 » If the measured value does not equal the specified value:
– Change the valve spring.

16.4.25 Checking valve spring retainer

– Check the valve spring retainer for fractures and wear (visual check).
» If the valve spring retainer is fractured or worn:
– Change the valve spring retainer.
– Measure the thickness of the valve spring retainer.
Valve spring cap - thickness 2.4… 2.5 mm (0.094… 0.098 in)
» If the measured value does not equal the specified value:
– Change the valve spring retainer.
300162-10

16.4.26 Checking cylinder head

– Check the valve guides using the special tool 1.
Limit plug gauge (59029026006) ( p. 211)
» If the special tool is easy to insert into the valve guide:
– Change the valve guide and valve.
– Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
» If there is wear or tearing:
300119-10
– Change the cylinder head.

– Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) ( p. 212)

Cylinder/cylinder head - sealing area ≤ 0.10 mm (≤ 0.0039 in)

distortion
» If the measured value does not equal the specified value:
– Change the cylinder head.
400375-10

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 16 ENGINE 132

– Check sealing seat A of the valves.

Valve - sealing seat width
Intake 1.60 mm (0.063 in)

0
A Valve - sealing seat width
Exhaust 2.00 mm (0.0787 in)
» If the measured value does not equal the specified value:
– Machine the valve seat.
400373-10
– Blow compressed air through all oil channels and check that they are clear.

16.4.27 Installing valves

– Position the valve spring cap 1. Install new valve stem seals 2.
– Mount valves 3 according to their normal built-in position.
– Install the valve springs 4 and the spring retainers.

5
0
4
0
2
0 1
0
0
3
0

300118-01

– Pretension the valve springs using the special tool.

Valve spring compressor (59029019000) ( p. 211)
Valve spring mounting device (78029060000) ( p. 218)

300116-11

– Mount valve keys.

Info
When mounting the valve keys, check that they are seated correctly; prefer-
ably, fix the valve keys to the valve with a little grease.

– Place shims 5 into the valve spring retainers according to the installation position.

300115-11

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 16 ENGINE 133

16.4.28 Installing rocker arm

– Position the rocker arm 1 and push in the rocker arm shafts 2.

Info
Make sure that the tapped hole of the rocker arm shaft is positioned facing
outwards.
The small drill hole and the flat surface must point upwards.

300114-11

– Install and tighten the screws 3 of the rocker arm shafts.

Guideline
Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft)

300113-11

16.4.29 Disassembling the antihopping clutch

– Clamp the clutch 1 in a vise.

Info
Use soft jaws.

– Carefully loosen and gradually remove the special tool 2.

300120-10

– Take the clutch out of the vise and lay it on a clean workbench with the outer
clutch hub 5 facing down.
– Take the inner clutch hub 3 and release springs 4 out of the outer clutch hub 5.

300121-10

– Take off the clutch facing discs 6 from the inner clutch hub.
– Remove pretension ring 7 and support ring 8.
– Clean all parts well.
– Check the clutch. ( p. 133)

300122-10

16.4.30 Checking the clutch

Preparatory work
– Disassemble the antihopping clutch. ( p. 133)

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 16 ENGINE 134

4
0 bk
0
5
0

2
0 b0l
bl 6 0
0 9
1
0
3
0 bbo
0o
b0n
bn b0m
bm
0
7 8
0

300123-01

Main work
– Check pressure piece 1 for damage and wear.
» If there is damage or wear:
– Replace the pressure piece.
– Check axial bearing 2 for damage and wear.
» If there is damage or wear:
– Change the axial bearing.
– Place push rod 3 on a level surface and check it for run-out.
» If there is run-out:
– Change the push rod.
– Check the length of clutch springs 4.
Clutch spring - length 31.5… 33.5 mm (1.24… 1.319 in)
» If the clutch spring length is less than the specified value:
– Change all clutch springs.
– Check the contact surface of pressure cap 5 for damage and wear.
» If there is damage or wear:
– Change the pressure cap.
– Check the contact surfaces of the clutch facing discs in the outer clutch hub 6 for wear.
Clutch basket - contact surface of clutch facing discs ≤ 0.5 mm (≤ 0.02 in)
» If the contact surface is very worn:
– Change the clutch facing discs and the outer clutch hub.
– Check needle bearing 7 and supporting plate 8 for damage and wear.
» If there is damage or wear:
– Replace the needle bearing and supporting plate.
– Check the intermediate clutch discs 9 for damage and wear.
» If the intermediate clutch discs are not even or are pitted:
– Change all intermediate clutch discs.

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 16 ENGINE 135

– Check clutch facing discs bk for discoloration and scoring.

» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs bk.
Clutch facing disc - thickness ≥ 2.5 mm (≥ 0.098 in)
» If the clutch facing disc does not meet specifications:
– Change all clutch facing discs.
– Check stepped washer bl for damage and wear.
» If there is damage or wear:
– Replace the stepped washer.
– Check half washers bm for damage and wear.
» If there is damage or wear:
– Replace the half washers.
– Check inner clutch hub bn for damage and wear.
» If there is damage or wear:
– Replace the inner clutch hub.
– Check the outer clutch hub bo for damage and wear.
» If there is damage or wear:
– Replace the outer clutch hub.

Finishing work
– Preassemble the antihopping clutch. ( p. 135)

16.4.31 Preassembling the antihopping clutch

– Thoroughly oil the clutch facing discs.
– Push the support ring 1 and the pretension ring 2 on to the outer clutch hub.

Info
The pretension ring must be installed so that it is flush with the inner
edge A on the support ring.

300123-10

– Position the trimmed clutch facing disc with the recess for the pretension ring on
the outer clutch hub.
– Beginning with the coated intermediate clutch disc, position all further clutch fac-
ing discs and intermediate clutch discs alternately.
– Position the release springs 3.

300124-10

– Push on the outer clutch hub 4 and pay attention to the markings.
The arrow 6 of the outer clutch hub must point to the notch 5 of the inner
clutch hub.
– Push the two clutch hubs firmly together and have an assistant screw in the special
tool.
Assembly screws (75029033000) ( p. 214)

Info
300125-10 Apply the special tool with the hand only, do not use another tool.
Apply the special tool only firmly enough so that the clutch facing discs
can still be turned against each other since they still have to be aligned for
mounting in the clutch basket.

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 16 ENGINE 136

16.4.32 Checking shift mechanism

– Check the shift forks 1 (see A) for damage and wear (visual check).

0
A » If there is damage or wear:
– Change the shift fork and gear wheel pair.
0
1 4 0
0 1 – Check shift grooves B of shift drum 2 for wear.
D
0 4
0 » If the shift groove is worn:
6
0 1
0 – Change the shift roller.
–
C0E Check the seat of the shift drum in the bearings 3.
0 5
0 » If the shift roller is not seated correctly:
– Replace the shift drum and/or the bearing.
– Check bearing 3 for stiffness and wear.
» If the bearings do not move freely or are worn:
– Replace the bearings.
0
2 – Check the needle bushing 4 for stiffness and wear.
0
3 » If the needle bushing does not move freely or is worn:
B
0 – Replace the needle bushing.
0
3 – Check the shift rail 5 on a flat surface for run-out.
» If there is run-out:
300120-01
– Change the shift rail.
– Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
– Change the shift rail.
– Check sliding plate 6 in contact areas C for wear.
» If the sliding plate is worn:
– Change the sliding plate.
– Check return surface D on the sliding plate for wear.
» If deep notches are present:
– Change the sliding plate.
– Check guide pin E for looseness and wear.
» If the guide pin is loose and/or worn:
– Change the sliding plate.
– Preassemble the shift shaft. ( p. 136)
– Check the clearance F between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift 0.40… 0.80 mm (0.0157…
quadrant 0.0315 in)

F
0 » If the measured value does not equal the specified value:
– Change the sliding plate.

0
300122-01

16.4.33 Preassembling shift shaft

– Fix the short end of the shift shaft in a vise.
5 Guideline
Use soft jaws.

13
0 – Mount sliding plate 1 with the guide pin facing down and attach the guide pin to
2 –
the shift quadrant.
Mount preload spring 2.
– Push on spring guide 3, push return spring 4 over the spring guide with the offset
46 end facing upward and lift the offset end over abutment bolt 5.
300154-01
– Mount stop disk 6.

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 16 ENGINE 137

16.4.34 Disassembling the main shaft

bl bk
9
8

7 6
5 1
3 4
2 301980-01

– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
– Remove stop disk 1 and second-gear fixed gear 2.
– Remove the sixth-gear idler gear 3.
– Remove the split needle bearing 4 and stop disk 5.
– Remove lock ring 6.
– Remove the third/fourth-gear sliding gear 7.
– Remove lock ring 8.
– Remove stop disk 9 and fifth-gear idler gear bk.
– Remove bearing bush bl.

16.4.35 Dismantling countershaft

2
4
1 6
3 8
5 bk bl
7
bm bq
bn 9
bo bp
br bs

300128-01

– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws

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 16 ENGINE 138

– Remove stop disk 1 and first-gear idler gear 2.

– Remove needle bearing 3 and stop disk 4.
– Remove fifth-gear sliding gear 5 and lock ring 6.
– Remove stop disk 7 and third-gear idler gear 9.
– Remove needle bearing 8 and the fourth-gear idler gear bl.
– Remove needle bearing bk and stop disk bm.
– Remove lock ring bn and sixth-gear sliding gear bo.
– Remove lock ring bp and stop disk bq.
– Remove the second-gear idler gear br and bearing bush bs.

16.4.36 Checking the transmission

Condition
The transmission has been disassembled.

0
4
9
1
0
0
5
2
7
6
0 0
4
1
0
0
7
6 6
5
0
0
8
7 7
6
0
8
7
7
6
0 0
8
7
7
6
0
40
01 0
7
6
8
7
0 7
6
0
5
0 7
6
0
8
7
0
40
14
0
1
0 3
5
0
4
0
9
1
0 305511-01

– Check needle bearing 1 for damage and wear.

» If there is damage or wear:
– Change the needle bearing.
– Check the pivot points of main shaft 2 and countershaft 3 for damage and wear.
» If there is damage or wear:
– Change the main shaft and/or countershaft.
– Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
» If there is damage or wear:
– Change the main shaft and/or countershaft.
– Check the pivot points of idler gears 4 for damage and wear.
» If there is damage or wear:
– Change the gear wheel pair.
– Check the shift dogs of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
» If there is damage or wear:
– Change the gear wheel pair.
– Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
» If there is damage or wear:
– Change the gear wheel pair.
– Check the tooth profiles of sliding gears 5 for damage and wear.
» If there is damage or wear:
– Change the gear wheel pair.
– Check sliding gears 5 for smooth operation in the profile of main shaft 2.

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 16 ENGINE 139

» If the sliding gear does not move easily:

– Change the sliding gear or the main shaft.
– Check sliding gears 5 for smooth operation in the profile of countershaft 3.
» If the fixed gear does not move easily:
– Change the sliding gear or the countershaft.
– Check stop disks 7 for damage and wear.
» If there is damage or wear:
– Change the stop disk.
– Use new lock rings 8 in every repair job.
– Check bearing bushes 9 for damage and wear.
» If there is damage or wear:
– Change the bearing bush.

16.4.37 Assembling the main shaft

Info
Use new lock rings in every repair job.

Preparatory work
– Oil all parts carefully before assembling.
– Check the transmission. ( p. 138)
Main work

1 2
3
4

5 6
7 bl
9 8
bk 301980-02

– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Lubricate and mount bearing bush 1.
Long-life grease ( p. 208)
– Push on the fifth-gear idler gear 2 with the shift dogs facing upward.
– Mount stop disk 3 and lock ring 4.
– Push on the third/fourth-gear sliding gear 5 with the small gear wheel facing downward and mount lock ring 6.
– Push on stop disk 7 and split needle bearing 8.
– Push on the sixth-gear idler gear 9 with the shift dogs facing downward.
– Push on the second-gear fixed gear bk with the collar facing downward and mount stop disk bl.
– Finally, check all gear wheels for smooth operation.

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 16 ENGINE 140

16.4.38 Assembling countershaft

Info
Use new lock rings in every repair job.

Preparatory work
– Oil all parts carefully before assembling.
– Check the transmission. ( p. 138)
Main work

bq
bn
br 8
bp bk
bo 8 9
bm
7 3
6 bl
5 4
2 1

300128-02

– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Lubricate and mount bearing bush 1.
Long-life grease ( p. 208)
– Mount second-gear idler gear 2 on the countershaft with the protruding collar facing downward.
– Mount stop disk 3 and lock ring 4.
– Mount the sixth-gear sliding gear 5 with the shift groove facing upward.
– Mount lock ring 6 and stop disk 7.
– Mount needle bearing 8 and the fourth-gear idler gear 9 with the collar facing upward.
– Mount needle bearing bk and the third-gear idler gear bl with the collar facing downward.
– Mount stop disk bm and lock ring bn.
– Mount the fifth-gear sliding gear bo with the shift groove facing downward and stop disk bp.
– Mount needle bearing bq, first-gear idler gear br with the recess facing downward, and stop disk bs.
– Finally, check all gear wheels for smooth operation.

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 16 ENGINE 141

16.4.39 Checking the starter drive

5
6

1
2

4 3

300129-01

– Check the teeth and seating of the starter idler gear 1 for damage and wear.
» If there is damage or wear:
– Replace the starter idler gear and/or needle bushing.
– Check the teeth and seating of the torque limiter 2 for damage and wear.
» If there is damage or wear:
– Replace the torque limiter and/or needle bushing.
– Check freewheel gear 3 and bearing when removed for damage and wear.
» If there is damage or wear:
– Replace the freewheel gear and/or the bearing.
– Check freewheel 4 when removed for damage and wear.
» If there is damage or wear:
– Replace the freewheel.
– Check the toothing of the starter motor 5 for damage and wear.
» If there is damage or wear:
– Replace the starter motor.
– Clamp the minus (negative) cable of a 12 Volt power supply to the starter motor housing. Briefly connect the plus (positive) cable
of the power supply to the starter motor connection.
» If the starter motor does not turn when you close the power circuit:
– Replace the starter motor.
– Replace the O-ring 6 of the starter motor.

16.4.40 Removing freewheel

– Extract the lock ring 1 from the groove using suitable pliers.

300127-10

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 16 ENGINE 142

– Compress the expansion ring 2 and remove it, using suitable pliers.
– Take the freewheel 3 out of the primary gear.

300128-10

16.4.41 Checking freewheel

– Insert the freewheel gear 1 in the primary gear 2, turning the primary gear clock-
wise; do not twist!
– Check the locking action of the freewheel gear 1.
» If the primary gear does not turn clockwise or if it does not lock counterclock-
wise:
– Remove the freewheel. ( p. 141)
– Turn the freewheel 180°.
– Install the freewheel. ( p. 142)
300131-10

16.4.42 Installing freewheel

– Lubricate all parts thoroughly.
– Push the freewheel 1 into the primary gear.

Info
Note the direction of rotation.

300129-10

– Install the expansion ring 2.

300128-11

– Make sure that all lugs of the expansion ring locate in the slits A of the freewheel.

Info
If necessary, use a screwdriver to ease them in.

300130-10

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 16 ENGINE 143

– Insert the lock ring 3 into the groove with suitable pliers and check that it is
seated correctly.

300127-11

16.5 Engine assembly

16.5.1 Installing transmission shafts
– Clamp the right section of the engine case.
Holder for engine assembly stand (75012001070) ( p. 214)
Support for engine assembly stand (75012001060) ( p. 214)
Engine assembly stand (61229001000) ( p. 213)
– Make sure that both stop disks 1 are installed.
– Mount the inner bearing race 2 on the countershaft.

300087-10

– Lubricate all bearings.

– Assemble the two transmission shafts and slide them into the bearing seats
together.

300088-10

– Mount the upper shift fork 3, the middle shift fork 4, and the lower shift fork 5.

Info
For the assembly of the middle shift fork 4, the sliding gear of the
third/fourth gear must be lifted.

300089-10

– Insert shift drum 6 into the bearing seat.

– Hang the shift forks into the shift drum.

300090-10

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 16 ENGINE 144

– Install the shift rail 7.

– Check the transmission for smooth operation.

300079-11

– Install the shim 8 and lock ring of the countershaft.

300082-11

16.5.2 Installing crankshaft and balancer shaft

– Mount the special tool 1 on the alternator side of the crankshaft.
Mounting sleeve (75029080000) ( p. 217)
– Mount the special tool 2 on the balancer shaft.
Mounting sleeve (58529005000) ( p. 211)

300085-10

– Push the crankshaft into the bearing seat and take off the special tool.
– Grease the shaft seal rings of the balancer shaft.
– Push the balancer shaft 3 into the bearing seat and take off the special tool.
Align marks A and B.
– Mount stop disk 4.

300165-10

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 16 ENGINE 145

16.5.3 Installing left engine case

– Mount the dowels.
– Mount the O-ring 1.
– Degrease the sealing area. Apply the sealing compound to the left engine case half.
Loctite® 5910

300077-11

– Put on the left engine case half. If necessary, tap lightly with a rubber mallet and
turn the transmission shafts.

Info
Do not tighten the engine case sections using the screws.

– Install the screws 2 and tighten them diagonally.

Guideline
Screw, engine case M6 10 Nm (7.4 lbf ft)
300075-11
Info
Install the screw in the oil filter housing with a new copper washer.

16.5.4 Installing oil pumps

– Install pins and internal rotors on both oil pump shafts.
– Mount external rotors in the engine case.
The marking is not visible after mounting.
– Mount the oil pump shafts 1 with internal rotors 2.
– Oil the parts.

300073-10

– Position both oil pump covers 3. Mount and tighten the screws.
Guideline
Screw, oil pump cover M5 6 Nm Loctite® 243™
(4.4 lbf ft)
– Install washers 4 and pins 5.

300071-11

– Mount the oil pump gears 6, washers 7 and lock washers 8.

300070-11

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 16 ENGINE 146

16.5.5 Installing locking lever

– Position locking lever 1 with sleeve and spring 2.
– Mount and tighten screw 3.
Guideline
Screw, locking lever M6 10 Nm Loctite® 243™
(7.4 lbf ft)

300069-11

16.5.6 Installing shift drum locating

– Press locking lever 1 down and position shift drum locating.

Info
The flat surfaces A of the shift drum locating are not symmetric.

300068-10

– Release the locking lever.

– Mount and tighten screw 2.
Guideline
Screw, shift drum locating M6 10 Nm Loctite® 243™
(7.4 lbf ft)

300067-11

16.5.7 Installing shift shaft

– Slide shift shaft 1 with the washer into the bearing seat.
– Push sliding plate 2 away from the shift drum locating 3. Insert the shift shaft all
the way.
– Let the sliding plate engage in the shift drum locating.
– Shift through the transmission.

300066-11

16.5.8 Installing starter drive

– Install the two needle bearings 1 and the woodruff key 2.
– Push on the freewheel gear 3.

300065-11

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 16 ENGINE 147

– Push on the starter idler gear 4 with washer. Mount lock ring.
– Push on the needle bearing and torque limiter 5 with washer. Mount lock ring.

300064-11

16.5.9 Installing primary gear

– Ensure that the spring washer is seated properly.
– Mount primary gear 1.

Info
Turn freewheel gear backwards and forwards to ease meshing.

300063-10

16.5.10 Installing clutch cage

– Install supporting plate 1 and needle bearing 2.

300057-10

– Install the clutch cage 3.

Info
Turn the clutch basket and oil pump gear wheels backwards and forwards
slightly to help them mesh more easily.

– Mount the half washers with the sharp edge facing outward.

Info
Grease the half washers to ease assembly.
300058-10

– Position stepped washer with the recesses toward the half washers.
– Insert the clutch package 4 in the clutch cage.

Info
If necessary, turn the main shaft a little to ease access.
Make sure that the upper clutch facing disc is offset by one notch.

302123-10

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 16 ENGINE 148

– Position a new lock washer and install the nut 5.

– Lock the clutch basket and primary gear using the special tool and tighten the nut.
Guideline
Nut, inner clutch hub M20x1.5 100 Nm Loctite® 243™
(73.8 lbf ft)

Gear segment (75029081000) ( p. 217)

Info
302121-10
Make sure that the crankshaft is not blocked.

– Secure the nut with the lock washer 6.

– Lock the clutch basket and primary gear using the special tool.
Gear segment (75029081000) ( p. 217)
– Mount and tighten the nut 7.
Guideline
Nut, primary gear M20LHx1.5 90 Nm Loctite® 243™
(66.4 lbf ft)

302122-10

– Insert the pressure piece 8.

300061-10

– Place the pressure cap on.

– Install and tighten the screws 9 with the spring retainers and clutch springs.
Guideline
Screw, clutch spring M5 6 Nm (4.4 lbf ft)
– Remove the special tool.

300052-11

16.5.11 Installing crankshaft position sensor

– Position the crankshaft position sensor 1.
– Mount screws but do not tighten them yet.
Guideline
Screw, ignition pulse gen- M6 10 Nm Loctite® 243™
erator (7.4 lbf ft)
– Position the cable and push the cable support sleeve 2 into the engine case.

300151-10

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 16 ENGINE 149

16.5.12 Installing timing chain and timing chain sprocket

– Heat the timing chain sprocket and push it immediately on to the crankshaft.
Guideline
100 °C (212 °F)
– Mount lock ring 1.

300150-10

– Thread the timing chain 2 in and lay it over the timing chain sprocket.

Info
If the timing chain is not new, pay attention to the direction of travel.

300148-11

16.5.13 Installing timing chain rails

– Position the timing chain securing guide 1.

Info
The cable of the crankshaft position sensor must be laid in the cable chan-
nel of the timing chain securing guide.

– Thread in the timing chain tensioning rail 2 from above. Insert the support bush-
ing into the timing chain securing guide.

300046-11

– Thread in the timing chain guide rail 3 from above. Insert the support bushing into
the timing chain securing guide.
– Mount and tighten screws 4.
Guideline
Screw, timing chain guide M6 10 Nm Loctite® 243™
rail (7.4 lbf ft)
Screw, timing chain ten- M6 10 Nm Loctite® 243™
sioning rail (7.4 lbf ft)
300045-11
Info
Ensure that there is no thread locking material at the collar of the screw;
otherwise, the timing chain tension rail could lock and break.

– Check both timing chain rails for freedom of motion.

16.5.14 Installing rotor

– Ensure that the spring washer 1 is seated properly.
– Degrease the cone of the crankshaft and the rotor.
– Mount the rotor.

Info
Make sure that the crankshaft is not blocked.

– Use the special tool to hold the rotor tight.

Holding spanner (75029091000) ( p. 217)
300042-10

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 16 ENGINE 150

– Mount the tab washer and the nut 2. Tighten nut.

Guideline
Rotor nut M18x1.5 100 Nm
(73.8 lbf ft)

300043-10

16.5.15 Adjusting crankshaft position sensor distance

– Adjust the distance between the crankshaft position sensor 1 and the conductive
element of the rotor using the special tool 2.
Guideline
Crankshaft position sensor/rotor - 0.70 mm (0.0276 in)
distance

Feeler gauge (59029041100) ( p. 212)

– Fully tighten screws 3.
300048-10 Guideline
Screw, ignition pulse gen- M6 10 Nm Loctite® 243™
erator (7.4 lbf ft)

16.5.16 Setting engine to top dead center

– Set the crankshaft to top dead center and lock it with the special tool 1.
Engine blocking screw (77329010000) ( p. 218)

300025-10

16.5.17 Installing piston

– Shift the joint of the piston rings by 120°.
– Push the oiled piston into the special tool.
Piston assembly ring (75029015102) ( p. 214)

300032-10

– Position the piston on the cylinder using the special tool.

– Push the piston carefully into the cylinder from above.
The piston rings should not become caught; otherwise, they may be damaged.

300033-10

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 16 ENGINE 151

– Ensure that piston marking 1 faces the outfeed side.

300035-10

– Apply a thin layer of sealing compound in area A.

Loctite® 5910
– Place the cylinder base gasket on.

Info
Make sure the grooved pins are seated correctly.

300034-10

– Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.

Info
For clarity, the following steps are illustrated using a disassembled piston.

300036-10

– Position the piston pin retainer.

400366-10

– Insert the special tool and firmly press it toward the piston.
– Turn the special tool counterclockwise, thereby pressing the piston pin retainer into
the groove.
Insertion for piston ring lock (75029035000) ( p. 215)
– Make sure that the piston pin retainer is seated correctly on both sides.

300038-10

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 16 ENGINE 152

– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let the
grooved pins engage.

300039-10

16.5.18 Installing cylinder head

– Put on the cylinder head gasket.

Info
Make sure the grooved pins are seated correctly.

– Mount the cylinder head. Mount and tighten cylinder head screw 1 with the wash-
ers.
Guideline
Cylinder head screw M10 Tightening Lubricated with
300029-11 sequence: engine oil
Tighten diag-
onally, begin-
ning with the
rear screw on
the timing
chain shaft.
Step 1
15 Nm
(11.1 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
45 Nm
(33.2 lbf ft)
Step 4
60 Nm
(44.3 lbf ft)

Info
Always use new cylinder head screws.

– Mount and tighten screws 2.

Guideline
Screw, cylinder head M6 10 Nm Loctite® 243™
(7.4 lbf ft)

16.5.19 Installing camshafts

– Lay the timing chain over the camshaft. Push the timing chain into the bearing
seats. The middle drill hole of the camshaft 1 and the drill hole of the cylinder
head 2 must be aligned.

Info
Make sure that the crankshaft is at top dead center.

300163-10

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 16 ENGINE 153

– Position the camshaft support plate 3. Mount and tighten screw 4.

Guideline
Screw, camshaft support M6 10 Nm Loctite® 243™
plate (7.4 lbf ft)

300022-10

16.5.20 Installing timing chain tensioner

– Insert the timing chain tensioner 1.
– Mount and tighten plug 2 with the new seal ring.
Guideline
Plug, timing chain tensioner M20x1.5 25 Nm
(18.4 lbf ft)

300017-11

– Remove screw 3 and use the special tool to push the timing chain tensioner
toward the timing chain.
Release device for timing chain tensioner (77329051000) ( p. 218)
The timing chain tensioner unlocks.
– Mount and tighten screw 3.
Guideline
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft)
sioner
300018-10

16.5.21 Checking valve clearance

– Remove special tool 1.
– Crank the engine several times.
– Set the engine to ignition top dead center. ( p. 108)

300044-10

– Check the valve clearance on all valves between the valve and the rocker arm using
the special tool 2.
Guideline
Valve play, cold 0.07… 0.13 mm (0.0028…
0.0051 in)

Feeler gauge (59029041100) ( p. 212)

» If valve clearance does not meet specifications:
300155-10 – Adjust the valve clearance. ( p. 154)

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 16 ENGINE 154

– Remove the special tool.

Engine blocking screw (77329010000) ( p. 218)
– Mount and tighten screw 3 with the washer.
Guideline
Screw plug, crankshaft clamp M8 20 Nm
(14.8 lbf ft)

306140-10

16.5.22 Adjusting valve clearance

– Remove screws 1.

Info
Make sure that the crankshaft is at top dead center.

300156-10

– Screw suitable screws 2 into the rocker arm shafts 3. Pull out the rocker arm
shafts.
– Take off the rocker arm.

300157-10

– Remove shims 4 and set them down according to the installation position.
– Correct the shims as indicated by the results of the valve clearance check.
– Insert suitable shims.
– Position the rocker arms and push in the rocker arm shafts.

Info
Make sure that the tapped hole of the rocker arm shaft is positioned facing
outwards.
The small drill hole and the flat surface must point upwards.
300158-10

– Install and tighten the screws 5 of the rocker arm shafts.

Guideline
Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft)
– Check the valve clearance. ( p. 153)

300156-11

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 16 ENGINE 155

16.5.23 Installing spark plug

– Mount and tighten the spark plug 1 using the special tool.
Guideline
Spark plug M12x1.25 17 Nm
(12.5 lbf ft)

Spark plug wrench (75029172000) ( p. 218)

300016-11

16.5.24 Installing spacer and spring

– Install the spacer 1 and spring 2 of the shift shaft.

300154-10

16.5.25 Installing clutch cover

– Mount the dowels. Put on the clutch cover seal.
– Position the clutch cover. Mount and tighten screws 1.
Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)

300015-11

16.5.26 Mounting water pump cover

– Push on the shaped washer 1.

300014-11

– Attach the water pump wheel 2. Mount and tighten screw 3

Guideline
Screw, water pump wheel M6 10 Nm Loctite® 243™
(7.4 lbf ft)
– Lay on the water pump cover seal 4.

300013-12

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 16 ENGINE 156

– Put on the water pump cover 5. Mount and tighten screws.

Guideline
Screw, water pump cover M6 10 Nm (7.4 lbf ft)

300012-12

16.5.27 Installing thermostat

– Position the thermostat 1 with the gasket.
The drill hole A must face upward.
– Install the thermostat case 2 with the radiator hose.
– Mount and tighten the screws.
Guideline
Screw, thermostat housing M6 10 Nm Loctite® 243™
(7.4 lbf ft)

300010-11

16.5.28 Installing the oil filter

– Insert the oil filter 1.
– Lubricate the O-ring of the oil filter cover. Install the oil filter cover 2.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)

300009-11

– Insert the oil filter 3.

– Lubricate the O-ring of the oil filter cover. Install the oil filter cover 4.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)

300011-11

16.5.29 Installing gear position sensor

– Mount the contact springs 1 and contact bolt 2.
The contact bolts are mounted with the flat side forward; the pointed sides
face the sensor.
– Position O-ring 3.

300007-11

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 16 ENGINE 157

– Install the gear position sensor 4.

– Position the ground wire 5.
– Mount and tighten the screws.
Guideline
Screw, gear sensor M5 5 Nm Loctite® 243™
(3.7 lbf ft)

302126-11

16.5.30 Installing the spacer

– Grease spacer 1 in area A and O-ring 2 before mounting.
Long-life grease ( p. 208)
– Position the O-ring in the recess of the spacer.

302140-10

– Grease the shaft seal ring.

Long-life grease ( p. 208)
– Slide the spacer with the O-ring onto the countershaft with a twisting motion.
The recess with the O-ring faces inward.
The shaft seal ring rests against the spacer along its entire circumference.

302124-10

16.5.31 Installing oil screens

– Push the oil screen with O-rings on to a pin wrench. Push the pin wrench through
the opening into the drill hole of the opposite engine case wall and push the oil
screen as far as possible into the engine case.

300152-10

– Mount the oil drain plug 1 with the magnet and a new seal ring and tighten it.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
– Mount and tighten screw plug 2 with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
300008-10

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 16 ENGINE 158

– Position the oil screen 3 with O-rings.

– Mount and tighten screw plug 4 with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)

300161-11

16.5.32 Installing alternator cover

– Apply sealing compound lightly in the area of the cable sleeve.
– Install the dowel 1. Put on the alternator cover seal.

300005-10

– Position the alternator cover.

– Mount and tighten screws 2.
Guideline
Screw in alternator cover M6 10 Nm (7.4 lbf ft)
– Mount and tighten screw 3.
Guideline
Screw, alternator cover M6 10 Nm Loctite® 243™
(chain shaft through-hole) (7.4 lbf ft)
300004-11

– Remove special tool 4.

Engine blocking screw (77329010000) ( p. 218)
– Mount and tighten screw 5.
Guideline
Screw plug, crankshaft clamp M8 20 Nm
(14.8 lbf ft)

300024-11

16.5.33 Installing starter motor

– Grease O-ring. Mount the starter motor.
Long-life grease ( p. 208)
– Mount and tighten screws 1.
Guideline
Screw, starter motor M6 10 Nm Loctite® 243™
(7.4 lbf ft)

300001-01

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 16 ENGINE 159

16.5.34 Installing valve cover

– Put the valve cover in place with the seal. Mount and tighten screws 1.
Guideline
Screw, valve cover M6 10 Nm (7.4 lbf ft)

300003-10

16.5.35 Removing the engine from the engine assembly stand

– Remove the screw 1 or the nut 2.
– Remove the engine from the engine assembly stand.

Info
Have an assistant help you or use a crane.

300144-11

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 17 CLUTCH 160

17.1 Checking/rectifying the fluid level of the hydraulic clutch

Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Check the fluid level.
Fluid level under top level of container 4 mm (0.16 in)
» If the level of the coolant does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 207)
100281-10
– Position the cover with the membrane. Mount and tighten the screws.

17.2 Changing the hydraulic clutch fluid

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Bleed syringe (50329050000) ( p. 210)
Hydraulic fluid (15) ( p. 207)
– On the clutch slave cylinder, remove bleeder screw 5 and mount bleeding
syringe 4.
– Inject the liquid into the system until it escapes from hole 6 of the master cylinder
without bubbles.
– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below top edge of container 4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
202086-10

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 18 WATER PUMP, COOLING SYSTEM 161

18.1 Draining the coolant

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme-
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal-
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.

– Stand the motorcycle upright.

– Place a suitable container under the engine.
– Remove screw 1. Remove the radiator cap.
– Completely drain the coolant.
– Mount screw 1 with a new seal ring and tighten it.
Guideline
Plug, drain hole of water pump M10x1 15 Nm
(11.1 lbf ft)
600616-10

18.2 Filling/bleeding the cooling system

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme-
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal-
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.

– Stand the motorcycle on its side stand on a horizontal surface.

– Remove radiator cap 1.

600618-10

– Refill the coolant.

Alternative 1
Coolant ( p. 206)
Alternative 2
Coolant (mixed ready to use) ( p. 206)
– Fill the radiator completely with coolant. Mount radiator cap 1.

600619-10

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 18 WATER PUMP, COOLING SYSTEM 162

– Remove the cap from compensating tank 2 and add coolant to the level shown in
the figure.
– Mount the cap of the compensating tank.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
B01293-11 effective exhaust extraction system.

– Start the engine and run it until the 5th bar of the temperature indicator lights up.
– Switch off the engine and allow it to cool down.
– After the engine has cooled down, check the coolant level in the radiator and in the
compensating tank again and add more coolant if necessary.
– Check the coolant level. ( p. 163)

18.3 Checking the antifreeze and coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme-
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal-
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.

Condition
Engine is cold.
– Stand the motorcycle on its side stand on a horizontal surface.
– Remove the cap of compensating tank 1.
– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the antifreeze of the coolant.
– Check the coolant level in the compensating tank.
B01293-10 The coolant level must be within the range shown in the figure.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 206)
Alternative 2
Coolant (mixed ready to use) ( p. 206)
– Mount the cap of the compensating tank.
– Screw off the radiator cap 2.
– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the antifreeze of the coolant.
– Check the coolant level in the radiator.
The radiator must be completely filled.
100284-10

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 18 WATER PUMP, COOLING SYSTEM 163

» If the coolant level does not meet specifications:

– Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 206)
Alternative 2
Coolant (mixed ready to use) ( p. 206)
– Mount the radiator cap.

18.4 Checking the coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme-
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal-
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.

Condition
Engine is cold.
– Stand the motorcycle on its side stand on a horizontal surface.
– Check the coolant level in the compensating tank 1.
The coolant level must be within the range shown in the figure.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 206)
B01293-10 Alternative 2
Coolant (mixed ready to use) ( p. 206)
– Screw off the radiator cap 2 and check the coolant level in the radiator.
The radiator must be completely filled.
» If the coolant level does not meet specifications:
– Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 206)
Alternative 2
100284-10
Coolant (mixed ready to use) ( p. 206)
– Mount the radiator cap.

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 19 LUBRICATION SYSTEM 164

19.1 Oil circuit

400500-60

Oil circuit of force pump

1 Oil screen
2 Force pump
3 Oil filter
4 Oil pressure regulator valve
5 Timing chain tensioner
6 Rocker arm shaft
7 Transmission
8 Clutch
9 Oil jet for piston cooling
10 Oil filter
11 Oil nozzle for conrod bearing lubrication
Oil circuit of suction pump
12 Oil screen
13 Suction pump
7 Transmission

19.2 Checking the engine oil level

Info
The engine oil level must be checked when the engine is warm.

Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.

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 19 LUBRICATION SYSTEM 165

Main work
– Check the engine oil level.

Info
After switching off the engine, wait one minute before checking the level.

The engine oil must be between the lower and upper edge of the oil level viewer.
» If the engine oil level is not at the specified level:

600602-01
– Add the engine oil. ( p. 169)

19.3 Checking the engine oil pressure

Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Main work
– Remove screw 1.

302039-10

– Position the banjo bolt with the connector and sealing rings. Mount and tighten the
banjo bolt.
Guideline
Banjo bolt M10x1 8 Nm (5.9 lbf ft)

Oil pressure adapter (77329006000) ( p. 218)

– Connect the pressure tester to the special tool without the T-plate.
Pressure testing tool (61029094000) ( p. 213)
302040-10
– Check the engine oil level. ( p. 164)

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and let it run warm.

– Check the engine oil pressure.
Engine oil pressure
Coolant temperature: ≥ 70 °C ≥ 0.4 bar (≥ 6 psi)
(≥ 158 °F)
Engine speed: 1,500 rpm
Coolant temperature: ≥ 70 °C ≥ 1.5 bar (≥ 22 psi)
(≥ 158 °F)
Engine speed: 5,000 rpm
» If the specification is not reached:

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 19 LUBRICATION SYSTEM 166

– Change the oil filter. Check oil pumps for wear. Check that all oil holes are
clear.
– Switch off the engine.

Warning
Danger of burns Some vehicle components get very hot when the machine
is driven.
– Wear appropriate protective clothing and safety gloves. In case of burns,
rinse immediately with lukewarm water.

– Remove the special tools.

– Mount and tighten screw 1.
Guideline
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft)
sioner
Finishing work
– Check the engine oil level. ( p. 164)

19.4 Changing the engine oil and filter, cleaning the oil screens
– Drain the engine oil. ( p. 166)
– Remove the oil filter. ( p. 167)
– Clean the oil screens. ( p. 168)
– Install the oil filter. ( p. 167)
– Fill up with engine oil. ( p. 169)

601022-10

19.5 Draining the engine oil

Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
Drain the engine oil only when the engine is warm.

– Place a suitable container under the engine.

– Remove the oil drain plug 1 with the magnet and seal ring.
– Completely drain the engine oil.

100200-10

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 19 LUBRICATION SYSTEM 167

– Thoroughly clean the oil drain plug with a magnet.

– Mount the oil drain plug with the magnet and seal ring and tighten it.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)

100201-01

19.6 Removing the oil filter

Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Preparatory work
– Place a suitable container under the engine.
Main work
– Remove screws 1. Remove the oil filter cover 2 with the O-ring.
– Pull oil filter 3 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 210)

100202-10

– Remove screws 4. Take off the oil filter cover 5 with the O-ring.
– Pull oil filter 6 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 210)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.

100203-10

19.7 Installing the oil filter

– Insert oil filters 1 and 2.
– Oil the O-rings of the oil filter covers. Mount oil filter covers 3 and 4.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)

100204-10

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 19 LUBRICATION SYSTEM 168

19.8 Cleaning the oil screens

Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Preparatory work
– Place a suitable container under the engine.
Main work
– Remove plug 1 with oil screen 2 and the O-rings.

100205-10

– Remove plug 3 with oil screen 4 and the O-rings.

– Completely drain the remaining engine oil.
– Thoroughly clean the parts and sealing area.

100206-10

– Position oil screen 2 with the O-rings.

– Mount and tighten screw plug 1 with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)

100207-10

– Position oil screen 4 with the O-rings.

– Mount and tighten screw plug 3 with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)

100208-10

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 19 LUBRICATION SYSTEM 169

19.9 Filling up with engine oil

Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.

Main work
– Remove filler plug with O-ring 1 from the clutch cover and add engine oil.
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 206)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 206)
– Refit plug with O-ring 1 and tighten it.
100209-10
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and check that it is oil-tight.

Finishing work
– Check the engine oil level. ( p. 164)

19.10 Adding engine oil

Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.

Main work
– Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with
engine oil.
Engine oil (SAE 10W/60) (00062010035) ( p. 206)
Engine oil (SAE 10W/50) ( p. 206)

Info
For optimal performance of the engine oil, do not mix different types of
100209-10
engine oil.
If appropriate, change the engine oil.

– Install and tighten the oil filler plug 1 with the O-ring.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and check that it is oil-tight.

Finishing work
– Check the engine oil level. ( p. 164)

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 20 IGNITION SYSTEM 170

20.1 Alternator - checking the stator winding

Condition
The stator is disconnected.
Preparatory work
– Remove the seat. ( p. 59)
– Take off the side cover. ( p. 60)
Main work
Stator winding, measurement I - check the resistance
– Measure the resistance between the specified points.
Stator, connector EN pin 1 – Stator, connector EN pin 2

Alternator
Resistance of stator winding at: ≤1Ω
20 °C (68 °F)
» If the displayed value is not equal to the setpoint value:
600894-10
– Replace the stator.
Stator winding, measurement II - check the resistance
– Measure the resistance between the specified points.
Stator, connector EN pin 1 – Stator, connector EN pin 3

Alternator
Resistance of stator winding at: ≤1Ω
20 °C (68 °F)
» If the displayed value is not equal to the setpoint value:
– Replace the stator.

600894-10 601014-10

Stator winding - check for a short circuit to ground (terminal 31)

– Measure the resistance between the specified points.
Stator, connector EN pin 1 – Measuring point Ground (−)

Resistance ∞Ω
» If the displayed value is not equal to the setpoint value:
– Replace the stator.

20.2 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.
– Measure the resistance between the specified points.
Measuring point 1 – Measuring point 2

Spark plug connector

Resistance at: 20 °C (68 °F) 4.3… 5.7 kΩ
» If the specification is not reached:
– Change the spark plug connector.

600893-10

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 20 IGNITION SYSTEM 171

20.3 Ignition coil - checking the secondary winding

Condition
Ignition coil cylinder 1 is disconnected.
Spark plug connector cylinder 1 has been removed.
Preparatory work
– Remove the seat. ( p. 59)
– Remove the fuel tank.
Main work
Ignition coil cylinder 1 - check the secondary winding resistance
– Measure the resistance between the specified points.
Ignition coil pin 2 (+) – Ignition coil pin 3

Ignition coil
Resistance of secondary winding 10.4… 15.6 kΩ
at: 20 °C (68 °F)
» If the displayed value is not equal to the setpoint value:
600739-13
– Replace the ignition coil.

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 21 TECHNICAL DATA 172

21.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 654 cm³ (39.91 cu in)
Stroke 80 mm (3.15 in)
Bore 102 mm (4.02 in)
Compression ratio 11.8:1
Control OHC, 4 valves controlled via rocker arm, chain drive
Valve diameter, intake 40 mm (1.57 in)
Valve diameter, exhaust 34 mm (1.34 in)
Valve play, cold 0.07… 0.13 mm (0.0028… 0.0051 in)
Crankshaft bearing 2 roller bearings
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication Semi-dry sump lubrication with two rotor pumps
Primary transmission 36:79
Clutch APTC™ antihopping clutch in oil bath/hydraulically operated
Gearbox 6-gears, claw-shifted
Transmission ratio
1st gear 14:35
2nd gear 16:28
3rd gear 21:28
4th gear 21:23
5th gear 23:22
6th gear 23:20
Mixture preparation Electronic fuel injection
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Alternator 12 V, 224 W
Spark plug NGK LKAR 8AI - 9
Spark plug electrode gap 0.9 mm (0.035 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Idle speed
Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,550… 1,650 rpm
Starting aid Electric starter, automatic decompressor

21.2 Engine tolerance, wear limits

Camshafts - diameter, bearing pin
Next to exhaust cam ≥ 39.95 mm (≥ 1.5728 in)
Next to inlet cam ≥ 17.96 mm (≥ 0.7071 in)
Valve spring
Minimum length (without valve spring cap) 42.3 mm (1.665 in)
Valve spring cap - thickness 2.4… 2.5 mm (0.094… 0.098 in)
Valve - valve stem diameter
Exhaust ≥ 5.93 mm (≥ 0.2335 in)
Intake ≥ 5.93 mm (≥ 0.2335 in)
Valve guide - diameter
New condition 6.004… 6.016 mm (0.23638… 0.23685 in)
Wear limit 6.050 mm (0.23819 in)
Valve - sealing seat width
Intake 1.60 mm (0.063 in)

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 21 TECHNICAL DATA 173

Exhaust 2.00 mm (0.0787 in)

Valve - run-out
On the valve plate ≤ 0.05 mm (≤ 0.002 in)
On the valve stem ≤ 0.05 mm (≤ 0.002 in)
Cylinder/cylinder head - sealing area distortion ≤ 0.10 mm (≤ 0.0039 in)
Cylinder - bore diameter
Size I 102.000… 102.012 mm (4.01574… 4.01621 in)
Size II 102.013… 102.025 mm (4.01625… 4.01672 in)
Piston - diameter
Size I 101.955… 101.965 mm (4.01397… 4.01436 in)
Size II 101.965… 101.975 mm (4.01436… 4.01476 in)
Piston/cylinder - mounting clearance
New condition 0.035… 0.060 mm (0.00138… 0.00236 in)
Wear limit 0.10 mm (0.0039 in)
Piston ring - groove clearance ≤ 0.08 mm (≤ 0.0031 in)
Piston ring end gap
Compression rings ≤ 0.80 mm (≤ 0.0315 in)
Oil scraper ring ≤ 1.00 mm (≤ 0.0394 in)
Piston - piston pin hole diameter 20.010… 20.020 mm (0.78779… 0.78819 in)
Piston pin - diameter 19.995… 20.004 mm (0.7872… 0.78756 in)
Connecting rod - axial clearance of lower conrod bearing 0.40… 0.60 mm (0.0157… 0.0236 in)
Connecting rod - radial clearance of lower conrod bearing 0.05 mm (0.002 in)
Crankshaft - axial clearance 0.15… 0.25 mm (0.0059… 0.0098 in)
Crankshaft run-out at bearing pin ≤ 0.10 mm (≤ 0.0039 in)
Balancer shaft axial clearance 0.05… 0.20 mm (0.002… 0.0079 in)
Clutch facing disc - thickness ≥ 2.5 mm (≥ 0.098 in)
Intermediate disk - thickness ≥ 1.35 mm (≥ 0.0531 in)
Clutch spring - length 31.5… 33.5 mm (1.24… 1.319 in)
Clutch basket - contact surface of clutch facing discs ≤ 0.5 mm (≤ 0.02 in)
Oil pressure regulator valve - minimum spring length 25.36 mm (0.9984 in)
Oil pump
Clearance between external rotor and engine case ≤ 0.20 mm (≤ 0.0079 in)
Clearance between external rotor and internal rotor ≤ 0.20 mm (≤ 0.0079 in)
Axial clearance 0.04… 0.08 mm (0.0016… 0.0031 in)
Engine oil pressure
Coolant temperature: ≥ 70 °C (≥ 158 °F) ≥ 0.4 bar (≥ 6 psi)
Engine speed: 1,500 rpm
Coolant temperature: ≥ 70 °C (≥ 158 °F) ≥ 1.5 bar (≥ 22 psi)
Engine speed: 5,000 rpm
Main shaft axial clearance 0.10… 0.40 mm (0.0039… 0.0157 in)
Transmission shaft run-out ≤ 0.025 mm (≤ 0.00098 in)
Shift shaft - play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in)
Fuel pressure
Under every load condition 3.3… 3.7 bar (48… 54 psi)
Engine oil consumption
After the vehicle is run-in ≤ 0.7 l/1.000 km (≤ 0.7 qt./600 mi)

Info
The oil consumption depends on the riding style and on
the operating conditions.

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 21 TECHNICAL DATA 174

21.3 Engine tightening torques

Screw, membrane fixation M3 2.5 Nm (1.84 lbf ft) Loctite® 243™
Hose clamp, intake flange M4 2.5 Nm (1.84 lbf ft) –
Oil nozzle for conrod bearing lubrica- M4 2 Nm (1.5 lbf ft) Loctite® 243™
tion
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, breather cover on valve cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, clutch spring M5 6 Nm (4.4 lbf ft) –
Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft) –
Screw, gear sensor M5 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw in alternator cover M6 10 Nm (7.4 lbf ft) –
Screw, alternator cover (chain shaft M6 10 Nm (7.4 lbf ft) Loctite® 243™
through-hole)
Screw, autodecompression M6 3… 4 Nm (2.2… 3 lbf ft) Loctite® 243™
Screw, axial lock of camshaft M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, camshaft support plate M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6x20 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch slave cylinder M6x35 10 Nm (7.4 lbf ft) –
Screw, cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, cylinder head M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, ignition pulse generator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, stator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, thermostat housing M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain guide rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™
Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft) Loctite® 243™
Screw plug, crankshaft clamp M8 20 Nm (14.8 lbf ft) –
Stud, exhaust flange M8 10 Nm (7.4 lbf ft) Loctite® 243™
Cylinder head screw M10 Tightening sequence: Lubricated with engine oil
Tighten diagonally, begin-
ning with the rear screw on
the timing chain shaft.
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
45 Nm (33.2 lbf ft)
Step 4
60 Nm (44.3 lbf ft)
Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) –

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 21 TECHNICAL DATA 175

Screw plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite® 243™
Screw plug, oil channel, for oil radiator M10x1 15 Nm (11.1 lbf ft) –
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) –
sioner
Spark plug M12x1.25 17 Nm (12.5 lbf ft) –
Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) –
head
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) –
Screw plug, oil channel M14x1.5 15 Nm (11.1 lbf ft) Loctite® 243™
Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite® 243™
Rotor nut M18x1.5 100 Nm (73.8 lbf ft) –
Nut, engine sprocket M20x1.5 80 Nm (59 lbf ft) Loctite® 243™
Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite® 243™
Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M20x1.5 25 Nm (18.4 lbf ft) –
Plug, oil thermostat M24x1.5 15 Nm (11.1 lbf ft) –
Screw in alternator cover M24x1.5 8 Nm (5.9 lbf ft) –

21.4 Capacities
21.4.1 Engine oil
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 206)
Alternative engine oil Engine oil (SAE 10W/50)
( p. 206)

21.4.2 Coolant
Coolant 1.20 l (1.27 qt.) Coolant ( p. 206)
Coolant (mixed ready to use) ( p. 206)

21.4.3 Fuel
Total fuel tank capacity, 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 207)
approx.

Fuel reserve, approx. 2.5 l (2.6 qt.)

21.5 Chassis
Frame Lattice frame made of chrome molybdenum steel tubing,
powder-coated
Fork WP Suspension Up Side Down 4860 ROMA
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Suspension travel
Front 275 mm (10.83 in)
Rear 265 mm (10.43 in)
Brake system
Front Disc brake with radially screwed four-piston brake caliper, float-
ing brake disc
Rear Disc brake with single-piston brake caliper, floating
Brake discs - diameter
Front 320 mm (12.6 in)
Rear 240 mm (9.45 in)
Brake discs - wear limit

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 21 TECHNICAL DATA 176

Front 4.0 mm (0.157 in)

Rear 4.5 mm (0.177 in)
Tire air pressure, solo
Front 2.0 bar (29 psi)
Rear 2.0 bar (29 psi)
Tire air pressure with passenger / fully loaded
Front 2.0 bar (29 psi)
Rear 2.2 bar (32 psi)
Secondary drive ratio 16:42
Chain 5/8 x 1/4” X‑ring
Steering head angle 63°
Wheelbase 1,480±15 mm (58.27±0.59 in)
Seat height unloaded 910 mm (35.83 in)
Ground clearance unloaded 290 mm (11.42 in)
Weight without fuel, approx. 139.5 kg (307.5 lb.)
Maximum permissible front axle load 150 kg (331 lb.)
Maximum permissible rear axle load 200 kg (441 lb.)
Maximum permissible overall weight 350 kg (772 lb.)

21.6 Electrical system

Battery YTZ10S Battery voltage: 12 V
Nominal capacity: 8.6 Ah
maintenance-free
Fuse 58011109130 30 A
Fuse 75011088015 15 A
Fuse 75011088010 10 A
Headlight H4 / socket P43t 12 V
60/55 W
Parking light W5W / socket W2.1x9.5d 12 V
5W
Instrument lights and indicator lamps LED
Turn signal RY10W / socket BAU15s 12 V
10 W
Brake/tail light LED
License plate lamp W5W / socket W2.1x9.5d 12 V
5W

21.7 Tires
Front tires Rear tires
120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL
Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro
Additional information is available in the Service section under:
http://www.ktm.com

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 21 TECHNICAL DATA 177

21.8 Fork
Fork part number 14.18.7K.12
Fork WP Suspension Up Side Down 4860 ROMA
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Rebound damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
Spring length with preload spacer(s) 480 mm (18.9 in)
Spring rate
Soft 5.0 N/mm (28.6 lb/in)
Medium (standard) 5.2 N/mm (29.7 lb/in)
Hard 5.4 N/mm (30.8 lb/in)
Air chamber length 100±20 mm (3.94±0.79 in)
Fork length 915 mm (36.02 in)

Fork oil per fork leg 634 ml (21.44 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 207)

21.9 Shock absorber

Shock absorber part number 15.18.7E.12
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Compression damping, high-speed
Comfort 1.5 turns
Standard 1 turn
Sport 0.5 turn
Full payload 0.5 turn
Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Spring preload 18 mm (0.71 in)
Spring rate
Soft 80 N/mm (457 lb/in)
Medium (standard) 85 N/mm (485 lb/in)
Hard 90 N/mm (514 lb/in)
Spring length 220 mm (8.66 in)
Gas pressure 10 bar (145 psi)
Static sag 20 mm (0.79 in)
Riding sag 70… 80 mm (2.76… 3.15 in)
Fitted length 400 mm (15.75 in)

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 21 TECHNICAL DATA 178

Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 207)

21.10 Chassis tightening torques

Screw, chain guard EJOT 2 Nm (1.5 lbf ft) –
Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) –
Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) –
Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) –
Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) –
Fitting, side stand switch M4 2 Nm (1.5 lbf ft) –
Screw, fuel hose clamp on fuel tank M4 2 Nm (1.5 lbf ft) –
Screw, wheel speed sensor M4 1 Nm (0.7 lbf ft) Loctite® 243™
Spoke nipple, front wheel M4.5 3… 6 Nm (2.2… 4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 3… 6 Nm (2.2… 4.4 lbf ft) –
Bolt, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite® 243™
Remaining screws, chassis M5 4 Nm (3 lbf ft) –
Screw, brake line holder on swingarm M5 4 Nm (3 lbf ft) –
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft) –
Screw, electrical holder M5 3 Nm (2.2 lbf ft) –
Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) Loctite® 243™
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft) –
Screw, fuel pump M5 4 Nm (3 lbf ft) –
Screw, fuel tank closure flange M5 2.5 Nm (1.84 lbf ft) –
Screw, headlight mask M5 5 Nm (3.7 lbf ft) –
Screw, pressure regulator M5 4 Nm (3 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws on fuel tank M6 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw connection, foot brake cylinder M6 10 Nm (7.4 lbf ft) –
Screw, air filter box top M6 2 Nm (1.5 lbf ft) –
Screw, ball joint of push rod on foot M6 10 Nm (7.4 lbf ft) Loctite® 243™
brake cylinder
Screw, brake fluid reservoir of rear M6 5 Nm (3.7 lbf ft) –
brake
Screw, chain guard M6 2 Nm (1.5 lbf ft) Loctite® 243™
Screw, chain guide M6 8 Nm (5.9 lbf ft) –
Screw, chain sliding guard M6 8 Nm (5.9 lbf ft) Loctite® 243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, ignition lock M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, lower radiator bracket M6 8 Nm (5.9 lbf ft) –
Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, radiator guard M6 8 Nm (5.9 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, seat lock M6 5 Nm (3.7 lbf ft) –
Screw, side cover M6 5 Nm (3.7 lbf ft) –
Screw, upper radiator bracket M6 10 Nm (7.4 lbf ft) –
Screw, voltage regulator M6 8 Nm (5.9 lbf ft) –
Nut, manifold on cylinder head M8 20 Nm (14.8 lbf ft) Copper paste
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 2701
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –

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 21 TECHNICAL DATA 179

Screw, connection lever on frame M8 30 Nm (22.1 lbf ft) Loctite® 243™

Screw, foot brake lever M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) –
Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) –
Screw, fuel tank, bottom M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, fuel tank, top M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, handrail M8 20 Nm (14.8 lbf ft) –
Screw, heel protector M8x12 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, license plate holder, top M8 20 Nm (14.8 lbf ft) –
Screw, main silencer clamp M8 12 Nm (8.9 lbf ft) Copper paste
Screw, main silencer holder M8 25 Nm (18.4 lbf ft) –
Screw, main silencer holder on fuel M8 25 Nm (18.4 lbf ft) –
tank
Screw, rear footrest bracket M8x16 25 Nm (18.4 lbf ft) –
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, spring holder on side stand M8 25 Nm (18.4 lbf ft) Loctite® 243™
bracket
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, engine bearer on frame M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite® 243™
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, swingarm pivot M12 80 Nm (59 lbf ft) –
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Copper paste
Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) –
Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft) –
Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite® 243™
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) –

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 22 CLEANING/PROTECTIVE TREATMENT 180

22.1 Cleaning the motorcycle

Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
– When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors,
cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component.
Excessive pressure can cause malfunctions or destroy these parts.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

– Seal the exhaust system to keep water out.

– First remove coarse dirt particles with a gentle spray of water.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a
brush.
Motorcycle cleaner ( p. 209)

Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
401061-01 Never apply motorcycle cleaner to the dry vehicle; always rinse with water
first.
If the vehicle was operated in road salt, clean it with cold water. Warm
water enhances the corrosive effects of salt.

– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Remove the plug from the exhaust system.

Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake
system.
– Clean or dry a dirty or wet brake system by riding and braking gently.

– After cleaning, ride a short distance until the engine reaches operating tempera-
ture.

Info
The heat produced causes water at inaccessible locations in the engine and
brake system to evaporate.

– Push back the protection covers of the handlebar controls to allow any water that
has penetrated to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Clean the chain. ( p. 77)
– Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 208)
– Treat all painted parts with a mild paint polish.
High-luster polish for paint ( p. 208)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care agent.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
surfaces ( p. 209)
– Lubricate the ignition/steering lock.
Universal oil spray ( p. 209)

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 22 CLEANING/PROTECTIVE TREATMENT 181

22.2 Checks and maintenance steps for winter operation

Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres-
sive road salt.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of
salt.

– Clean the motorcycle. ( p. 180)

– Clean the brake system.

Info
After EVERY trip on salted roads, thoroughly wash the brake calipers and
brake linings with cold water and dry carefully. This should be done after
the parts are cooled down and while they are installed.
After use on salted roads, clean the motorcycle thoroughly with cold water
and dry it properly.
401060-01
– Treat the engine, the swingarm, and all other bare or galvanized parts (except brake
discs) with a wax-based anti-corrosion substance.

Info
To prevent serious reduction of the braking efficiency, make sure no anti-
corrosion substance gets on to the brake discs.

– Clean the chain. ( p. 77)

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 23 STORAGE 182

23.1 Storage

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.

Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– Clean the motorcycle. ( p. 180)

– Change the engine oil and filter, clean the oil screens. ( p. 166)
– Check the antifreeze and coolant level. ( p. 162)
– When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive ( p. 208)
– Ride the motorcycle until the low fuel warning lamp lights up and the display
changes to TRIP F so that you can fill up with fresh fuel when you take the
401058-01
motorcycle back into service.
– Check the tire air pressure. ( p. 68)
– Remove the battery. ( p. 79)
– Recharge the battery. ( p. 80)
Guideline
Storage temperature of battery without 0… 35 °C (32… 95 °F)
direct sunshine
– Store the vehicle in a dry location that is not subject to large fluctuations in tem-
perature.

Info
KTM recommends jacking up the motorcycle.

– Raise the motorcycle with the rear wheel stand. ( p. 10)

– Raise the motorcycle with the front wheel stand. ( p. 10)
– Cover the motorcycle with a tarp or cover that is permeable to air.

Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot
warm up properly, the water vapor produced during combustion condenses
and causes valves and exhaust system to rust.

23.2 Preparing for use after storage

– Take the motorcycle off of the front wheel stand. ( p. 10)
– Take the motorcycle off of the rear wheel stand. ( p. 10)
– Recharge the battery. ( p. 80)
– Install the battery. ( p. 79)
– Set the clock. ( p. 94)
– Refuel.
– Perform checks and vehicle care when preparing for use.
– Take a test ride.
401059-01

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 24 SERVICE SCHEDULE 183

24.1 Service schedule

Every 30,000 km (18,641 mi) or every 4 years
Every 15,000 km (9,321 mi) or every 2 years
Every 7,500 km (4,660 mi) or annually
Once after 1,000 km (621.4 mi)
Check that the electrical equipment is functioning correctly. ○ ●
Read out the fault memory using the KTM diagnostics tool. ○ ●
Check the measured service values with the KTM diagnostics tool. ●
Change the engine oil and filter, clean the oil screens. ( p. 166) ○ ●
Check the front brake linings. ( p. 85) ○ ●
Check the rear brake linings. ( p. 88) ○ ●
Check the brake discs. ( p. 69) ○ ●
Check the brake lines for damage and leakage. ○ ●
Check the rear brake fluid level. ( p. 91) ○ ●
Check the free travel of the foot brake lever. ( p. 90) ○ ●
Lubricate the linkage of the rear wheel suspension. ●
Check that the shock absorber and fork are leak tight. If necessary and depending on use, service the fork and ○ ●
shock absorber.
Check the swingarm bearing. ●
Check the wheel bearing for play. ●
Check the tire condition. ( p. 68) ○ ●
Check the tire air pressure. ( p. 68) ○ ●
Check the spoke tension. ( p. 69) ○ ●
Check for rim run-out. ○ ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 75) ●
Check the chain tension. ( p. 74) ○ ●
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. ○ ●
Clean the dust boots of the fork legs. ( p. 15) ●
Check the front brake fluid level. ( p. 86) ○ ●
Bleed the fork legs. ( p. 14) ●
Check the steering head bearing play. ( p. 27) ○ ●
Change the spark plug. ● ●
Check the valve clearance. ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect rout- ● ●
ing.
Check the antifreeze and coolant level. ( p. 162) ○ ●
Check the cables for damage and routing without sharp bends. ●
Check that the throttle cables are undamaged, routed without sharp bends and set correctly. ○ ●
Change the air filter. Clean the air filter box. ●
Check the fuel pressure. ●
Check the CO adjustment with the KTM diagnostics tool. ●
Check/rectify the fluid level of the hydraulic clutch. ( p. 160) ●
Check the screws and nuts for tightness. ○ ●
Change the coolant. ●
Change the front brake fluid. ( p. 88) ● ●
Change the rear brake fluid. ( p. 92) ● ●
Check the clutch. ● ●
Check the headlight setting. ( p. 96) ○ ●
Check that the radiator fan is functioning properly. ○ ●
Final check: Check the vehicle for roadworthiness and take a test ride. ○ ●
Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ●
Make the service entry in KTM DEALER.NET and in the service record. ○ ●

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 24 SERVICE SCHEDULE 184

○ One-time interval
● Periodic interval

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 185

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 186

1 2 3 4 5 6 7 8

401215-01
-A11
/2.A7
A A
43
DS/44
43
-X18

gn
B B
wh-rd a /2.B1
bl-rd b /2.C1
wh-rd

wh-rd

wh-rd
wh-rd

wh-rd
bl-rd

bl-rd
bl

bl

bl

bl

C -X12 C
-X13 AU/2 -X19 -X9

2
1
AF/4 EB/4 FJ/2

4
2

2
1

1
BI/2

1
1

1
2
2

2
4
-M10 -K10 -G10 -T20 -G20 -K11 -F9
3
30A

1 1
2 2

10A
M
U 3 3 G
CR/1 CR/1

1
EM/3

EN/3
-X292 -X291
3

3
4

1
AF/4 EB/4 FJ/2

1
2
3

3
4

D -X13 -X19 -X9 D

rd-bu

rd-bu

ye-rd

ye-rd
gn
gn

gn
br

br
bl
-X302 -X301
WIRING DIAGRAM

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E E
Page 01 of 10

br c /2.F1
F F
690 Enduro 08/09/10
25.1 110
/
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 187

Components:
A11 EFI control unit
F9 Fuse
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
K11 Start auxiliary relay
M10 Starter motor
T20 Voltage regulator
X291 Connector for accessory ground (terminal 31) ACC 1 (not assigned)
X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)

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 188

1 2 3 4 5 6 7 8

401216-01
-A12 -P10 -A11
/7.A6 /3.A3 /1.A5
A /7.A3 A
15
18

8
1

1
DT/36 ED/32 ED/32 ED/32 DS/44 DS/44
1

1
18

8
15

-X21 -X63 -X63 -X63 -X18 -X18

wh-rd

wh-bl
ye-rd

ye-rd
br-gr
br
B B
gn d /3.B1
/1.B8 a wh-rd
/1.C8 b bl-rd e /7.C1

wh-rd

wh-rd

wh-rd
wh-bl

ye-rd
bl-rd

rd

rd

rd
C -X37 -X41 C
BR/4 BY/4 -X1 -X14 -X15
4

4
1

FJ/2 EB/4 EB/4

4
2

2
1
BK/4 CV/4
1

1
2
4

2
3

4
-S23 -S11 -F1 -K12 -K30

10A
AP/6
1
6

-X295
BK/4 CV/4

3
4
2
3

3
2

1
1
FJ/2 EB/4 EB/4

1
2

3
4
D BR/4 BY/4 -X1 -X14 -X15 D
2

3
-X37 -X41

wh-rd

wh-rd
ye-rd

ye-rd

ye-rd

ye-rd

ye-rd
br-gr

gn
br

br

br

br
WIRING DIAGRAM

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E E
Page 02 of 10

/1.F8 c br br c /3.F1
F F
690 Enduro 08/09/10
25.2 2/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 189

Components:
A11 EFI control unit
A12 EPT control unit
F1 Fuse
K12 Light relay
K30 Power relay
P10 Combination instrument
S11 Ignition/steering lock
S23 Emergency OFF switch, electric starter button
X295 Diagnostics connector

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 190

1 2 3 4 5 6 7 8

401217-01
-P10
/2.A3
A /5.A1 A
8

ED/32
8

-X63
bu

B B
/2.B8 d gn gn d /6.B1
gn

gn
bu

bu
gn

bu
gn

bu

bu

gn
gr

gr

br
C -X34 C
-X7 -X24 AC/6 -X23 -X61 -X6
3

6
4

FJ/2 FF/1 BW/3 DI/2 FJ/2

2

2
1

1
BC/6 -X29 -X28
1

1
3

6
4
2

2
-F7 -P15 -S29 BP/4 -E13 -P35 DG/4 -F6

3
4
2
1
/5.C1 LO HI
15A

10A
DG/4 BP/4

1
2

3
4
-X28 -X29
BC/6

3
2

2
5
2
1

1
1
FJ/2 FF/1 BW/3 DI/2 FJ/2
1

1
2
3
D -X7 -X25 AC/6 -X23 -X61 -X6 D

5
-X34
ye-bu

ye-bu
bu
gn
ye

ye

ye
br

br

br

br

br
WIRING DIAGRAM

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E E
Page 03 of 10

ye-bu f /4.F1
ye g /4.F1
/2.F8 c br br c /4.F1
F F
690 Enduro 08/09/10
25.3 3/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 191

Components:
E13 Low beam, high beam
F6 Fuse
F7 Fuse
P10 Combination instrument
P15 Horn
P35 Parking light
S29 High beam/low beam switch, horn button, turn signal switch

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 192

1 2 3 4 5 6 7 8

401218-01
A A
B B
wh-gn

wh-gn

wh-gn
wh

wh
ye

C -X32 -X22 -X27 -X26 C

AJ/3 BV/2 -X58 AH/2 AH/2
2

2
1

DI/2
2

BG/3 BS/2 AK/2 AK/2

1

1
2

2
2

-P36 -E60 -B77 -B76

P
BG/3 BS/2 AK/2 AK/2
3

1
DI/2
1
D AJ/3 BV/2 -X58 AH/2 AH/2 D

1
2
3

-X32 -X22 -X27 -X26

ye-bu

ye-bu
br

br

br
WIRING DIAGRAM

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E E
Page 04 of 10

/3.F8 f ye-bu ye-bu f /5.F1

/3.F8 g ye
/3.F8 c br br c /5.F1
F F
690 Enduro 08/09/10
25.4 4/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 193

Components:
B76 Front brake light switch
B77 Brake light switch, rear
E60 License plate lamp
P36 Brake/tail light

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 194

1 2 3 4 5 6 7 8

401219-01
-P10
/3.A3
A /7.A1 A
10
9

ED/32
10
9

-X63
pu
bl

B B
bl-or
pu

pu

pu
br

br

br
bl

bl

bl
C -X30 -X31 -X47 -X46 C
BT/3 -X20 CX/2 CX/2 CX/2 CX/2
3
2

2
1

1
AH/2
2

BG/3 CW/2 CW/2 -X60 CW/2 CW/2

1
2

2
3

2
-S29 -K20 -P42 -P41 BY/4 -P45 -P46 -X59

2
/3.C3 G CV/4

3
4
LR
CV/4

2
-X59 BY/4

3
4
BG/3 CW/2 CW/2 CW/2 CW/2 -X60

2
1
1

1
AH/2

1
D BT/3 -X20 CX/2 CX/2 CX/2 CX/2 D
1

1
2

2
-X17 -X30 -X31 -X47 -X46

ye-bu
bl-or

pu

pu
br

br

br

bl

bl
WIRING DIAGRAM

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E E
Page 05 of 10

/4.F8 f ye-bu
/4.F8 c br br c /6.F1
F F
690 Enduro 08/09/10
25.5 5/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 195

Components:
K20 Turn signal relay
P10 Combination instrument
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S29 High beam/low beam switch, horn button, turn signal switch

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 196

1 2 3 4 5 6 7 8

401220-01
A A
B B
/3.B8 d gn
gn

gn

bl

bl
C -X10 C
-X8 -X5 AU/2 -X33

1
FJ/2 FJ/2 AV/2
2

1
BI/2

1
2

2
-F8 -F5 -M14 -B33
10A

10A
CR/1 CR/1 M
1

t°
-X294 -X293
BI/2

2
2
1

1
FJ/2 FJ/2 AV/2
1

2
D -X8 -X5 AU/2 -X33 D

2
-X10

wh-bl

wh-bl
bl-rd

bl-rd

br

br
WIRING DIAGRAM

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E E
Page 06 of 10

/5.F8 c br br c /7.F1
F F
690 Enduro 08/09/10
25.6 6/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 197

Components:
B33 Temperature switch for radiator fan
F5 Fuse
F8 Fuse
M14 Radiator fan
X293 Connector for accessory ground (terminal 31) ACC 2 (not assigned)
X294 Connector for accessory plus (terminal 15) ACC 2 (not assigned)

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 25 WIRING DIAGRAM 198

25.7 Page 07 of 10

A
F

B
/2.C8 e
/6.F8 c

/8.A7
/5.A1
-P10
ye-rd
br
1

1
br-pu br-pu 24 24

ED/32
-X63
-X300
br-pu
br-pu
2

2
br
690 SMC 08/09/10/11
690 Enduro 08/09/10

-F2

/2.A7
/8.A1
-A11
1 10A 2
or 1 2 ye-rd
FJ/2

FJ/2
-X2

-X2
br-pu 3 3
6 6
3

3
or or

DS/44
-M13

-X18
bl-bu 2 2 1 1 bu-gr bu-gr 16 16
M
DV/2

DV/2
-X38

-X38
bl-rd 27 27
wh-br 39 39
gn-or 21 21
wh-bu 28 28
bl-bu 5 5

DS/44
-X18
-F4
4

4
1 10A 2
bl-bu 1 2 ye-rd
FJ/2

FJ/2
-X4

-X4
5

5
-F3

/2.A1
-A12
6

6
1 10A 2
bu-or 1 2 ye-rd
FJ/2

FJ/2
-X3

-X3

bl-bu 11 11
wh-bu 12 12
gn-or 17 17
wh-br 20 20
4 bl-rd bl-rd 10 10
-X295
AP/6

br-pu 8 8

19 19
7

bu-or
br br 35 35
br br 36 36
DT/36
-X21
-M60

1 1 rd rd 30 30
2 2 gn gn 29 29
3 3 bl bl 24 24
M

4 4 bu-br bu-br 31 31
5 5 wh-gn wh-gn 14 14
6 6 wh-rd wh-rd 16 16
7 7 wh-or wh-or 15 15
8 8 bu bu 13 13
8

8
br
or

FK/8

DR/8

DT/36
-X39

-X21
h /8.F1
c /10.F1
7/10

401221-01
A
F

B
D

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 25 WIRING DIAGRAM 199

Components:
A11 EFI control unit
A12 EPT control unit
F2 Fuse
F3 Fuse
F4 Fuse
M13 Fuel pump
M60 Motor drive
P10 Combination instrument
X295 Diagnostics connector

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 200

1 2 3 4 5 6 7 8

401222-01
-A11 -P10
/7.A3 /7.A1
A /9.A1 /9.A7 A
17

18

12

25

23
42
22

40
41

3
4
2
DS/44 DS/44 DS/44 DS/44 DS/44 DS/44 ED/32 ED/32
41
18

12
42

3
17

25

23
22

4
40
-X18 -X18 -X18 -X18 -X18 -X63 -X63
wh-pu

wh-bu

wh-bu
gn-rd

bu-br
rd-gr
bl-or

bl-gr

bl-or
lbu

or
bl
B B

wh-pu

gn-rd

bu-br
rd-gr
bl-or

bl-gr

bl-or
lbu
C -X45 -X62 C
-X40 -X42 -X43 -X48 FS/4 CY/3

4
2

2
1
DF/2 DW/2 DQ/2 FM/1
2

1
DY/4 CZ/3

1
1

2
4
2

-M20 -M21 -M51 -R51 -B51 -B70

L
t°
DY/4 CZ/3
2

3
1

1
DF/2 DW/2 DQ/2 FL/1
1

1
2

2
D -X40 -X42 -X43 -X44 FS/4 CY/3 D

1
3

3
-X45 -X62
or

or

or

or

or

or

or
bl

bl
WIRING DIAGRAM

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E E
Page 08 of 10

bl i /9.E1
/7.F8 h or
F F
690 Enduro 08/09/10
25.8 8/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 201

Components:
A11 EFI control unit
B51 Lambda sensor (cylinder 1)
B70 Front wheel speed sensor
M20 Fuel evaporation valve (USA version only)
M21 Secondary air valve
M51 Injector (cylinder 1)
P10 Combination instrument
R51 Ignition coil (cylinder 1)

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 202

1 2 3 4 5 6 7 8

401223-01
-A11 -P10
/8.A1 /8.A7
A /10.A1 /10.A7 A
15

13

10
26

34

11

32
31

11
4

DS/44 DS/44 DS/44 DS/44 DS/44 DS/44 DS/44 ED/32

11

31

11
32
15

13

10
26
4

34

-X18 -X18 -X18 -X18 -X18 -X18 -X18 -X63

wh-pk
ye-gn

ye-or

ye-br

bl-gn

bl-gn
bu

pk

rd

gr
B B
wh-pk
ye-gn

ye-or

ye-br

bl-gn
pk

rd

gr
C -X49 -X50 C
AR/3 -X51 -X16 -X35 -X36 AM/3
3

3
2
1
AP/6 CM/2 FT/3 FT/3
5

2
AM/3 AR/3

1
1

2
3

3
2

2
5

-B30 -B26 -B12 -B31 -B10 -B34

2nd
3rd
t°

N
AM/3
3

3
6
4
2

1
1

AP/6 CM/2 FT/3 FT/3

1
3

3
6
4

D AR/3 -X51 -X16 -X35 -X36 D

1

-X49
bu

bu

bu

bu

bu
bl

bl

bl

bl

bl
WIRING DIAGRAM

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E E
bu j /10.E1
Page 09 of 10

/8.E8 i bl bl i /10.E1
F F
690 SMC 2011
25.9 9 /10
25
1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 203

Components:
A11 EFI control unit
B10 Throttle position sensor circuit A
B12 Intake air temperature sensor
B26 Rollover sensor
B30 Side stand switch
B31 Accelerator position sensor
B34 Gear position sensor
P10 Combination instrument

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 204

1 2 3 4 5 6 7 8

401224-01
-A11 -P10
/9.A1 /9.A7
A A
14

35

20

23

24

33

36
38

12
44

7
5
2

DS/44 DS/44 DS/44 DS/44 DS/44 DS/44 ED/32 ED/32

7
12
2

5
14

20

23

24
35

33

36
38
44

-X18 -X18 -X18 -X18 -X18 -X18 -X63 -X63

wh-ye

ye-bu
gn-gr

bu-or

br-rd
bl-ye
bl-br

wh

wh
pu

ye

br
br

B B
wh-ye

ye-bu
gn-gr

bu-or

br-rd
bl-ye
bl-br
pu

ye

C -X54 -X52 -X56 C

-X53 -X11 AL/2 AL/2 -X55 -X57 AT/2
2

2
1

1
DP/3 DX/3 DV/2 EC/3
3

3
2

1
AT/2 AT/2 AL/2

1
1

1
2

2
2
3

3
-B13 -B41 -B38 -B37 -S55 -B21 t° t° -B32
R R
p p
AT/2 AL/2
3
2

2
1

1
DP/3 DX/3 DV/2 EC/3
1

1
2

2
3

D -X53 -X11 AL/2 -X55 -X57 AT/2 D

2
-X54 -X56
bu

bu

br

br
br

br

br
bl

bl

bl
WIRING DIAGRAM

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E E
/9.E8 j bu
Page 10 of 10

/9.E8 i bl
/7.F8 c br
F F
690 Enduro 08/09/10
25.10 10/10
25

690 SMC 08/09/10/11

1 2 3 4 5 6 7 8
 25 WIRING DIAGRAM 205

Components:
A11 EFI control unit
B13 Ambient air pressure sensor
B21 Engine coolant temperature sensor (cylinder 1)
B32 Fuel level indicator
B37 Crankshaft position sensor
B38 Clutch switch
B41 Manifold absolute pressure sensor (cylinder 1)
P10 Combination instrument
S55 Map‑Select Switch
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
lbu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow

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 26 SUBSTANCES 206

Brake fluid DOT 4 / DOT 5.1

According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1

Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
−49 °F) 50 % distilled water

Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
– COOLANT G48

Engine oil (SAE 10W/60) (00062010035)

According to
– JASO T903 MA ( p. 222)
– SAE ( p. 222) (SAE 10W/60)
– KTM LC4 2007+
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Cross Power 4T

Engine oil (SAE 10W/50)

According to
– JASO T903 MA ( p. 222)
– SAE ( p. 222) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Fully synthetic engine oil
Supplier
Motorex®
– Power Synt 4T

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 26 SUBSTANCES 207

Fork oil (SAE 4) (48601166S1)

According to
– SAE ( p. 222) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.

Hydraulic fluid (15)

According to
– ISO VG (15)
Guideline
– Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Hydraulic Fluid 75

Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 222) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.

Super unleaded (ROZ 95/RON 95/PON 91)

According to
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.

Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

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 27 AUXILIARY SUBSTANCES 208

Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean

Chain lube for road use

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chainlube Road

Cleaning and preserving materials for metal, rubber and plastic

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Protect & Shine

Fuel additive
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Fuel Stabilizer

High-luster polish for paint

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Polish

Long-life grease
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Bike Grease 2000

Lubricant (T511)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmsilon® GTI 300 P

Lubricant (T158)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmogrease® PP 300

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 27 AUXILIARY SUBSTANCES 209

Lubricant (T152)
Guideline
– KTM recommends Bel‑Ray® products.
Supplier
Bel‑Ray®
– Molylube® Anti‑Seize

Lubricant (T159)
Guideline
– KTM recommends Bel‑Ray® products.
Supplier
Bel‑Ray®
– MC‑11®

Lubricant (T625)
Guideline
– KTM recommends Molykote® products.
Supplier
Molykote®
– 33 Medium

Motorcycle cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Clean 900

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Clean & Polish

Universal oil spray

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Joker 440 Synthetic

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 28 SPECIAL TOOLS 210

Bearing puller
Art. no.: 15112017000

400037-01

Insert for bearing puller

Art. no.: 15112018100
Feature
18… 23 mm (0.71… 0.91 in)

400125-01

Bleed syringe
Art. no.: 50329050000

400058-01

Circlip pliers reverse

Art. no.: 51012011000

400059-01

Extractor
Art. no.: 58429009000

400073-01

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 28 SPECIAL TOOLS 211

Tool for inner bearing race

Art. no.: 58429037043

400082-01

Mounting sleeve
Art. no.: 58529005000

400095-01

Valve spring compressor

Art. no.: 59029019000

400101-01

Limit plug gauge

Art. no.: 59029026006

400104-01

Extractor
Art. no.: 59029033000

400105-01

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 28 SPECIAL TOOLS 212

Feeler gauge
Art. no.: 59029041100

35
30
25

20

15

12
10
5

400110-01

Hose clamp pliers

Art. no.: 60029057000

400142-01

Pliers for spring band clamp

Art. no.: 60029057100

400085-01

Adapter
Art. no.: 61029055110

500079-01

Front wheel stand

Art. no.: 61029055300

500078-01

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 28 SPECIAL TOOLS 213

Rear wheel stand

Art. no.: 61029055400

500077-01

Testing hose
Art. no.: 61029093000

201314-01

Pressure testing tool

Art. no.: 61029094000

400149-01

Engine assembly stand

Art. no.: 61229001000

200306-01

Work stand
Art. no.: 62529055000

400151-01

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 28 SPECIAL TOOLS 214

Support for engine assembly stand

Art. no.: 75012001060

400153-01

Holder for engine assembly stand

Art. no.: 75012001070

400154-01

Piston assembly ring

Art. no.: 75029015102

400156-01

Extractor
Art. no.: 75029021000

400157-01

Assembly screws
Art. no.: 75029033000

400158-01

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 28 SPECIAL TOOLS 215

Insertion for piston ring lock

Art. no.: 75029035000

400160-01

Work stand adapter

Art. no.: 75029036000

400161-01

Push-in drift
Art. no.: 75029044010

500163-01

Push-in drift
Art. no.: 75029044020

500162-01

Pressing device for crankshaft, complete

Art. no.: 75029047000

400185-01

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 28 SPECIAL TOOLS 216

Upper part, pressing-out tool

Art. no.: 75029047050

400186-01

Under part, pressing-out tool

Art. no.: 75029047051

400187-01

Extractor
Art. no.: 75029048000

400162-01

Clamping plate
Art. no.: 75029050000

400163-01

Push-out drift
Art. no.: 75029051000

400164-01

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 28 SPECIAL TOOLS 217

Floor jack attachment

Art. no.: 75029055000

400184-01

Mounting sleeve
Art. no.: 75029080000

400165-01

Gear segment
Art. no.: 75029081000

400068-01

Protection cover
Art. no.: 75029090000

400167-01

Holding spanner
Art. no.: 75029091000

400168-01

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 28 SPECIAL TOOLS 218

Spark plug wrench

Art. no.: 75029172000

400170-01

Oil pressure adapter

Art. no.: 77329006000

400176-01

Engine blocking screw

Art. no.: 77329010000

400177-01

Release device for timing chain tensioner

Art. no.: 77329051000

400181-01

Valve spring mounting device

Art. no.: 78029060000

500165-01

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 28 SPECIAL TOOLS 219

Hook wrench
Art. no.: T106S

301085-01

Depth micrometer
Art. no.: T107S

300577-10

Pin
Art. no.: T120

201235-10

Pressing tool
Art. no.: T1206

200583-10

Pressing tool
Art. no.: T1207S

200585-01

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 28 SPECIAL TOOLS 220

Vacuum pump
Art. no.: T1240S

200273-10

Pressing tool
Art. no.: T129

200584-01

Protecting sleeve
Art. no.: T1401

200635-10

Gripping tool
Art. no.: T14026S1

200639-10

Assembly tool
Art. no.: T1402S

200634-10

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 28 SPECIAL TOOLS 221

Open-end wrench
Art. no.: T14032

200640-10

Clamping stand
Art. no.: T1403S

200637-10

Mounting sleeve
Art. no.: T1515

300569-10

Nitrogen filling tool

Art. no.: T170S1

300574-10

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 29 STANDARDS 222

JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.

SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.

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 INDEX 223

front brake, removing . . . . . . . . . . . . . . . . . . . . . . . . 72

INDEX

A rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . . . 74

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . . . 73
Air filter Brake discs
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Brake fluid
Air filter box front brake, adding . .. . . . . . . . . . . . . . . . . . . . . . . . 87
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 88
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 rear brake, adding . .. . . . . . . . . . . . . . . . . . . . . . . . 92
Alternator rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 92
stator winding, checking . . . . . . . . . . . . . . . . . . . . . 170 Brake fluid level
Antifreeze front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 86
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 91

Assembling the engine Brake linings

alternator cover, installing . . . . . . . . . . . . . . . . . . . . 158 front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 85
camshafts, installing . . . . . . . . . . . . . . . . . . . . . . . . 152 front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 85
clutch cage, installing . . . . . . . . . . . . . . . . . . . . . . . 147 rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 89
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 155 rear brake, checking .. . . . . . . . . . . . . . . . . . . . . . . . 88
crankshaft and balancer shaft, installing . . . . . . . . . . 144 C
crankshaft position sensor distance, adjusting . . . . . . 150
Capacity
crankshaft position sensor, installing . . . . . . . . . . . . . 148
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
cylinder head, installing . . . . . . . . . . . . . . . . . . . . . 152
engine oil . . . . . . . . . . . . . . . . . . . . . . . 105, 169, 175
engine, setting to top dead center . . . . . . . . . . . . . . . 150
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
gear position sensor, installing . . . . . . . . . . . . . . . . . 156
left engine case, installing . . . . . . . . . . . . . . . . . . . . 145 Chain
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 146 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 156 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
oil pumps, installing . . . . . . . . . . . . . . . . . . . . . . . . 145 Chain guide
oil screens, installing . . . . . . . . . . . . . . . . . . . . . . . 157 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
piston, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 150 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 147 Chain tension
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
shift drum locating, installing . . . . . . . . . . . . . . . . . . 146 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 146
Changing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . 99
spacer and spring, installing . . . . . . . . . . . . . . . . . . 155
spacer, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Charging voltage
spark plug, installing . . . . . . . . . . . . . . . . . . . . . . . . 155 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
starter drive, installing . . . . . . . . . . . . . . . . . . . . . . 146 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 158 Clutch
taking engine off universal mounting rack . . . . . . . . . 159 checking/correcting fluid level . . . . . . . . . . . . . . . . . 160
thermostat, installing . . . . . . . . . . . . . . . . . . . . . . . 156 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
timing chain and timing chain sprocket, installing . . . . 149
Combination instrument
timing chain rails, installing . . . . . . . . . . . . . . . . . . . 149
clock, setting . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 94
timing chain tensioner, installing . . . . . . . . . . . . . . . 153
kilometers or miles, setting . . ... . . . . . . . . . . . . . . . 94
transmission shafts, installing . . . . . . . . . . . . . . . . . 143
TRIP 1 display, setting/resetting .. . . . . . . . . . . . . . . . 94
valve clearance, adjusting . . . . . . . . . . . . . . . . . . . . 154
TRIP 2 display, setting/resetting .. . . . . . . . . . . . . . . . 94
valve clearance, checking . . . . . . . . . . . . . . . . . . . . 153
wheel circumference, setting . ... . . . . . . . . . . . . . . . 95
valve cover, installing . . . . . . . . . . . . . . . . . . . . . . . 159
water pump cover, mounting . . . . . . . . . . . . . . . . . . 155 Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coolant level
B checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162-163
Battery Cooling system
connecting . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . . . 124
fitting . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
recharging . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 D
removing . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Disassembling the engine
Brake disc alternator cover, removing . . . . . . . . . . . . . . . . . . . . 107
front brake, installing . . . . . . . . . . . . . . . . . . . . . . . . 72 camshafts, removing . . . . . . . . . . . . . . . . . . . . . . . . 110

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 INDEX 224

clutch cage, removing . . . . . . . . . . . . . . . . . . . . . . . 113 piston ring end gap, checking . . . . . . . . . . . . . . . . . . 126
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 109 piston, checking/measuring . . . . . . . . . . . . . . . . . . . 125
crankshaft and balancer shaft, removing . . . . . . . . . . 116 piston/cylinder mounting clearance, checking . . . . . . . 126
crankshaft position sensor, removing . . . . . . . . . . . . . 112 right engine case section . . . . . . . . . . . . . . . . . . . . . 117
cylinder head, removing . . . . . . . . . . . . . . . . . . . . . . 110 rocker arm, installing . . . . . . . . . . . . . . . . . . . . . . . 133
engine oil, draining . . . . . . . . . . . . . . . . . . . . . . . . . 106 rocker arm, removing . . . . . . . . . . . . . . . . . . . . . . . 129
engine, setting to ignition top dead center . . . . . . . . . 108 shift mechanism, checking . . . . . . . . . . . . . . . . . . . 136
gear position sensor, removing . . . . . . . . . . . . . . . . . 107 shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . 136
left engine case, removing . . . . . . . . . . . . . . . . . . . . 115 starter drive, checking . . . . . . . . . . . . . . . . . . . . . . . 141
locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 115 timing assembly, checking . . . . . . . . . . . . . . . . . . . . 128
oil filter, removing . . . . . . . . . . . . . . . . . . . . . . . . . 108 timing chain tensioner, preparing for installation . . . . . 128
oil pumps, removing . . . . . . . . . . . . . . . . . . . . . . . . 115 transmission, checking . . . . . . . . . . . . . . . . . . . . . . 138
piston, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 valve spring retainer, checking . . . . . . . . . . . . . . . . . 131
primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 114 valve springs, checking . . . . . . . . . . . . . . . . . . . . . . 131
rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 valves, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
shift drum locating, removing . . . . . . . . . . . . . . . . . . 114 valves, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 114 valves, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
spacer and spring, removing . . . . . . . . . . . . . . . . . . . 109 Engine characteristic
spacer, removing . . . . . . . . . . . . . . . . . . . . . . . . . . 107 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
spark plug, removing . . . . . . . . . . . . . . . . . . . . . . . . 110
Engine disassembly
starter drive, removing . . . . . . . . . . . . . . . . . . . . . . . 114
engine, clamping into the engine assembly stand . . . . 106
starter motor, removing . . . . . . . . . . . . . . . . . . . . . . 106
thermostat, removing . . . . . . . . . . . . . . . . . . . . . . . 108 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
timing chain and timing chain sprocket, removing . . . . 112 Engine oil
timing chain rails, removing . . . . . . . . . . . . . . . . . . . 112 adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
timing chain tensioner, removing . . . . . . . . . . . . . . . 110 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
transmission shafts, removing . . . . . . . . . . . . . . . . . 116 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
valve cover, removing . . . . . . . . . . . . . . . . . . . . . . . 107 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
water pump wheel, removing . . . . . . . . . . . . . . . . . . 109 Engine oil level
E checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Engine Engine oil pressure

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Engine sprocket
Engine - Work on individual parts checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
antihopping clutch, disassembling . . . . . . . . . . . . . . 133 F
antihopping clutch, preassembling . . . . . . . . . . . . . . 135 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
autodecompressor . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Filler cap
axial clearance of crankshaft and balancer shaft,
measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
balancer shaft drive wheel, installing . . . . . . . . . . . . . 123 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
balancer shaft drive wheel, removing . . . . . . . . . . . . . 121 Foot brake lever
camshaft bearing, changing . . . . . . . . . . . . . . . . . . . 129 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 91
clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 90
clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Fork
connecting rod, conrod bearing and crank pin, changing 121 adjusting compression damping . . . . . . . . . . . . . . . . . 14
countershaft, assembling . . . . . . . . . . . . . . . . . . . . . 140 adjusting rebound . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
countershaft, dismantling . . . . . . . . . . . . . . . . . . . . 137 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 15
crankshaft bearing inner ring, installing . . . . . . . . . . . 123 fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 14
crankshaft bearing inner ring, removing . . . . . . . . . . . 121
Fork legs
crankshaft run-out at bearing pin, checking . . . . . . . . 123
assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . 124
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . 131
disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
cylinder, checking/measuring . . . . . . . . . . . . . . . . . . 125
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
freewheel, checking . . . . . . . . . . . . . . . . . . . . . . . . 142
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
freewheel, installing . . . . . . . . . . . . . . . . . . . . . . . . 142
servicing the fork . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
freewheel, removing . . . . . . . . . . . . . . . . . . . . . . . . 141
left engine case section . . . . . . . . . . . . . . . . . . . . . . 119 Fork part number ............................... 8
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 139 Fork protector
main shaft, disassembling . . . . . . . . . . . . . . . . . . . . 137 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
oil pumps for wear, checking . . . . . . . . . . . . . . . . . . 127 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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 INDEX 225

Fork service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Oil screens

Front wheel cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 P
Fuel filter
Parking light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 64
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fuel pressure
Play in throttle cable
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuse checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
of individual power consumer, changing . . . . . . . . . . . . 82
Preparing for use
H after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Hand brake lever R
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 86
Rear hub rubber dampers
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rear sprocket
Headlight checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
light range, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 96
Rear wheel
Headlight bulb, changing . . . . . . . . . . . . . . . . . . . . . . . . . 98 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Headlight mask with headlight removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Riding sag
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Headlight setting, checking . . . . . . . . . . . . . . . . . . . . . . . . 96 Rim run-out
I checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Ignition coil S
secondary winding, checking . . . . . . . . . . . . . . . . . . 171 Seat
K mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 183-184
M
Servicing the shock absorber . . . . . . . . . . . . . . . . . . . . . . 38
Main fuse
Shock absorber
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
adjusting rebound damping . . . . . . . . . . . . . . . . . . . . 33
Main silencer compression damping, high-speed, adjusting . . . . . . . . 32
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 compression damping, low-speed, adjusting . . . . . . . . . 32
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 damper, assembling . . . . . . . . . . . . . . . . . . . . . . . . . 45
Manifold damper, bleeding and filling . . . . . . . . . . . . . . . . . . . 47
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 damper, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 damper, dismantling . . . . . . . . . . . . . . . . . . . . . . . . . 39
Motorcycle damper, filling with nitrogen . . . . . . . . . . . . . . . . . . . 49
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 heim joint, installing . . . . . . . . . . . . . . . . . . . . . . . . . 43
raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 11 heim joint, removing . . . . . . . . . . . . . . . . . . . . . . . . . 42
raising with the front wheel stand . . . . . . . . . . . . . . . . 10 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
raising with the rear wheel stand . . . . . . . . . . . . . . . . . 10 piston rod, assembling . . . . . . . . . . . . . . . . . . . . . . . 44
raising with work stand . . . . . . . . . . . . . . . . . . . . . . . 11 piston rod, disassembling . . . . . . . . . . . . . . . . . . . . . 40
removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 11 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
removing from work stand . . . . . . . . . . . . . . . . . . . . . 12 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 34
taking off of the front wheel stand . . . . . . . . . . . . . . . . 10 shock absorber, servicing . . . . . . . . . . . . . . . . . . . . . . 38
taking off of the rear wheel stand . . . . . . . . . . . . . . . . 10 spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 34
spring, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
O
spring, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil filter Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 9
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Side cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil screen
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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 INDEX 226

Spark plug connector

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Starting procedure
for making checks . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 178
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 176
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
engine tightening torques . . . . . . . . . . . . . . . . . . . . 174
engine tolerance, wear limits . . . . . . . . . . . . . . . . . . 172
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . 181
Wiring diagram . . ........................ 186-205
page 01 of 10 ........................ . . . . 186
page 02 of 10 ........................ . . . . 188
page 03 of 10 ........................ . . . . 190
page 04 of 10 ........................ . . . . 192
page 05 of 10 ........................ . . . . 194
page 06 of 10 ........................ . . . . 196
page 07 of 10 ........................ . . . . 198
page 08 of 10 ........................ . . . . 200
page 09 of 10 ........................ . . . . 202
page 10 of 10 ........................ . . . . 204
Work rules ................................... 6

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 *3206122en*
3206122en

10/2012

KTM-Sportmotorcycle AG
5230 Mattighofen/Austria Photo: Mitterbauer/KTM
http://www.ktm.com

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