2014 690 SMC R Eu

REPAIR MANUAL 2014
690 SMC R EU
690 SMC R AU/GB
Art. no. 3206193en
INTRODUCTION 1
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this 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 the 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 delivery.
© 2014 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
TABLE OF CONTENTS 2
8.5 Checking the static sag of the shock absorber .... 34

TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5

1.1 Symbols used ................................................... 5 8.6 Checking the riding sag of the shock absorber.... 35
1.2 Formats used.................................................... 5 8.7 Adjusting the spring preload of the shock
2 SAFETY ADVICE........................................................... 6 absorber......................................................... 35
2.1 Repair Manual .................................................. 6 8.8 Adjusting the riding sag ................................... 36
2.2 Safety advice.................................................... 6 8.9 Removing the shock absorber ........................... 36
2.3 Degrees of risk and symbols ............................... 6 8.10 Installing the shock absorber............................ 37
2.4 Work rules........................................................ 6 8.11 Servicing the shock absorber............................ 39
3 IMPORTANT INFORMATION ......................................... 7 8.12 Removing the spring........................................ 39
3.1 Guarantee, warranty .......................................... 7 8.13 Dismantling the damper .................................. 40
3.2 Operating and auxiliary substances ..................... 7 8.14 Disassembling the piston rod ........................... 41
3.3 Spare parts, accessories .................................... 7 8.15 Checking the damper ...................................... 42
3.4 Figures ............................................................ 7 8.16 Removing the heim joint.................................. 43
4 SERIAL NUMBERS ...................................................... 8 8.17 Installing the heim joint................................... 44
4.1 Chassis number ................................................ 8 8.18 Assembling the piston rod................................ 45
4.2 Type label ........................................................ 8 8.19 Assembling the damper ................................... 46
4.3 Engine number ................................................. 8 8.20 Bleeding and filling the damper ....................... 48
4.4 Key number...................................................... 8 8.21 Filling the damper with nitrogen ....................... 50
4.5 Fork part number .............................................. 8 8.22 Installing the spring ........................................ 51
4.6 Shock absorber part number .............................. 9 9 EXHAUST .................................................................. 53
5 MOTORCYCLE ........................................................... 10 9.1 Removing the manifold.................................... 53
5.1 Raising the motorcycle with the rear wheel 9.2 Installing the manifold .................................... 54
stand ............................................................. 10 9.3 Removing the main silencer ............................. 55
5.2 Taking the motorcycle off of the rear wheel 9.4 Installing the main silencer.............................. 56
stand ............................................................. 10 10 AIR FILTER ............................................................... 57
5.3 Raising the motorcycle with the front wheel 10.1 Removing the air filter ..................................... 57
stand ............................................................. 10 10.2 Installing the air filter...................................... 57
5.4 Taking the motorcycle off of the front wheel 10.3 Removing the air filter box ............................... 57
stand ............................................................. 11 10.4 Installing the air filter box................................ 59
5.5 Raising the motorcycle with a lift stand............. 11 11 FUEL TANK, SEAT, TRIM ........................................... 61
5.6 Removing the motorcycle from the lift stand...... 11 11.1 Opening the filler cap...................................... 61
5.7 Raising the motorcycle with the work stand ....... 11 11.2 Closing filler cap............................................. 61
5.8 Removing the motorcycle from the work stand ... 12 11.3 Removing the seat .......................................... 61
5.9 Starting.......................................................... 12 11.4 Mounting the seat ........................................... 62
5.10 Starting the motorcycle to make checks ............ 13 11.5 Taking off the side cover.................................. 62
6 FORK, TRIPLE CLAMP ............................................... 14 11.6 Mounting the side cover................................... 62
6.1 Adjusting the compression damping of the 11.7 Checking the fuel pressure............................... 62
fork ............................................................... 14
11.8 Changing the fuel filter.................................... 64
6.2 Adjusting the rebound damping of the fork ........ 14
11.9 Changing the fuel pump .................................. 67
6.3 Bleeding the fork legs...................................... 15
12 WHEELS ................................................................... 70
6.4 Cleaning the dust boots of the fork legs............. 15
12.1 Checking the tire air pressure........................... 70
6.5 Removing the fork protector ............................. 15
12.2 Checking the tire condition .............................. 70
6.6 Installing the fork protector.............................. 16
12.3 Checking the brake discs ................................. 71
6.7 Removing fork legs.......................................... 16
12.4 Checking the spoke tension.............................. 71
6.8 Installing the fork legs ..................................... 17
12.5 Checking the rim run-out ................................. 72
6.9 Disassembling the fork legs.............................. 18
12.6 Front wheel .................................................... 72
6.10 Checking the fork legs ..................................... 21
12.6.1 Removing front wheel.................................. 72
6.11 Assembling the fork legs.................................. 22
12.6.2 Installing the front wheel ............................. 73
6.12 Checking the steering head bearing play............ 26
12.6.3 Removing the brake disc of the front brake.... 74
6.13 Adjusting the steering head bearing play ........... 26
12.6.4 Installing the brake disc of the front brake .... 74
7 HANDLEBAR, CONTROLS........................................... 28
12.7 Rear wheel ..................................................... 74
7.1 Handlebar position.......................................... 28
12.7.1 Removing rear wheel ................................... 74
7.2 Adjusting the handlebar position ...................... 28
12.7.2 Installing the rear wheel .............................. 75
7.3 Changing the throttle grip ................................ 28
12.7.3 Removing the brake disc of the rear brake ..... 76
8 SHOCK ABSORBER, SWINGARM ................................ 33
12.7.4 Installing the brake disc of the rear brake...... 76
8.1 Adjusting the high-speed compression
12.7.5 Checking the chain tension.......................... 77
damping of the shock absorber......................... 33
12.7.6 Adjusting the chain tension ......................... 77
8.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 33 12.7.7 Adjusting chain guide.................................. 78
8.3 Adjusting the rebound damping of the shock 12.7.8 Checking the chain, rear sprocket, engine
absorber......................................................... 34 sprocket, and chain guide............................ 78
8.4 Measuring the unloaded rear wheel sag ............. 34 12.7.9 Cleaning the chain ...................................... 80
12.7.10 Checking the rear hub rubber dampers.......... 80
TABLE OF CONTENTS 3
13 WIRING HARNESS, BATTERY..................................... 82 16.3.14 Removing the cylinder head ....................... 115
13.1 Removing the battery ...................................... 82 16.3.15 Removing the piston ................................. 115
13.2 Installing the battery ....................................... 82 16.3.16 Removing the water pump impeller............. 116
13.3 Disconnecting the battery ................................ 83 16.3.17 Removing the rotor.................................... 116
13.4 Connecting the battery .................................... 83 16.3.18 Removing the timing chain rails ................. 117
13.5 Recharging the battery .................................... 83 16.3.19 Removing the timing chain and timing
13.6 Checking the charging voltage .......................... 84 chain sprocket .......................................... 117
13.7 Checking the quiescent current ........................ 85 16.3.20 Removing the ignition pulse generator ........ 118
13.8 Changing the main fuse ................................... 85 16.3.21 Removing the clutch cover......................... 118
13.9 Changing fuses of individual power 16.3.22 Removing the spacer and spring................. 118
consumers...................................................... 86 16.3.23 Removing the clutch basket ....................... 119
13.10 Adjusting the engine characteristic ................... 87 16.3.24 Removing the primary gear ........................ 120
14 BRAKE SYSTEM ........................................................ 89 16.3.25 Removing the starter drive ......................... 120
14.1 Checking the front brake linings ....................... 89 16.3.26 Removing shift shaft ................................. 121
14.2 Changing the brake linings of the front brake..... 89 16.3.27 Removing shift drum locating..................... 121
14.3 Adjusting the basic position of the hand brake 16.3.28 Removing locking lever.............................. 122
lever .............................................................. 90 16.3.29 Removing the oil pumps ............................ 122
14.4 Checking brake fluid level of front brake ........... 90 16.3.30 Removing the left engine case.................... 123
14.5 Adding front brake fluid................................... 91 16.3.31 Removing the crankshaft and balancer
14.6 Changing the front brake fluid .......................... 92 shaft........................................................ 124
14.7 Checking the rear brake linings ........................ 93 16.3.32 Removing the transmission shafts............... 124
14.8 Changing the rear brake linings ........................ 93 16.4 Work on individual parts ................................ 125
14.9 Checking the free travel of foot brake lever ........ 95 16.4.1 Work on the right section of the engine
14.10 Adjusting the basic position of the foot brake case ........................................................ 125
lever .............................................................. 95 16.4.2 Work on the left section of the engine
14.11 Checking rear brake fluid level ......................... 95 case ........................................................ 126
14.12 Adding rear brake fluid .................................... 96 16.4.3 Work on the clutch cover ........................... 128
14.13 Changing the rear brake fluid ........................... 97 16.4.4 Removing crankshaft bearing inner ring ...... 128
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 99 16.4.5 Removing balancer shaft drive wheel .......... 128
15.1 Combination instrument .................................. 99 16.4.6 Changing the connecting rod, conrod
15.1.1 Setting kilometers or miles .......................... 99 bearing, and crank pin .............................. 128
15.1.2 Setting the clock ........................................ 99 16.4.7 Checking crankshaft run-out at bearing
pin .......................................................... 130
15.1.3 Setting/resetting display TRIP 1 ................... 99
16.4.8 Installing balancer shaft drive wheel ........... 130
15.1.4 Setting/resetting display TRIP 2 ................... 99
16.4.9 Installing crankshaft bearing inner ring ....... 131
15.1.5 Setting the wheel circumference ................ 100
16.4.10 Measuring axial clearance of crankshaft
15.2 Checking the headlight setting ....................... 101
and balancer shaft .................................... 131
15.3 Adjusting the headlight range......................... 101
16.4.11 Cylinder - Nikasil® coating ......................... 132
15.4 Removing the headlight mask with the
16.4.12 Checking/measuring the cylinder ................ 132
headlight...................................................... 101
16.4.13 Checking/measuring the piston................... 133
15.5 Installing the headlight mask with the
headlight...................................................... 102 16.4.14 Checking piston ring end gap ..................... 134
15.6 Changing the parking light bulb...................... 102 16.4.15 Determining the piston/cylinder mounting
clearance ................................................. 134
15.7 Changing the headlight bulb .......................... 103
16.4.16 Checking the oil pumps for wear................. 134
15.8 Changing the turn signal bulb ........................ 104
16.4.17 Replacing autodecompressor...................... 135
16 ENGINE .................................................................. 105
16.4.18 Preparing timing chain tensioner for
16.1 Removing the engine..................................... 105
installation ............................................... 136
16.2 Installing the engine...................................... 107
16.4.19 Checking the timing assembly.................... 137
16.3 Disassembling the engine .............................. 111
16.4.20 Removing the rocker arm ........................... 138
16.3.1 Clamping the engine into the engine
16.4.21 Changing the camshaft bearing .................. 138
assembly stand......................................... 111
16.4.22 Removing the valves.................................. 139
16.3.2 Draining the engine oil .............................. 111
16.4.23 Checking the valves .................................. 140
16.3.3 Removing the starter motor........................ 112
16.4.24 Checking valve springs .............................. 140
16.3.4 Removing the valve cover........................... 112
16.4.25 Checking valve spring retainer.................... 140
16.3.5 Removing the alternator cover .................... 112
16.4.26 Checking the cylinder head........................ 140
16.3.6 Removing the spacer................................. 112
16.4.27 Installing the valves .................................. 141
16.3.7 Removing the gear position sensor.............. 113
16.4.28 Installing the rocker arm............................ 142
16.3.8 Removing the oil filter ............................... 113
16.4.29 Disassembling the antihopping clutch......... 142
16.3.9 Removing the thermostat........................... 113
16.4.30 Checking the clutch .................................. 143
16.3.10 Setting engine to ignition top dead center ... 113
16.4.31 Preassembling the antihopping clutch......... 144
16.3.11 Removing the spark plugs.......................... 114
16.4.32 Checking the shift mechanism ................... 145
16.3.12 Removing the timing chain tensioner .......... 114
16.4.33 Preassembling the shift shaft ..................... 146
16.3.13 Removing the camshafts............................ 114
16.4.34 Disassembling the main shaft .................... 147
TABLE OF CONTENTS 4
16.4.35 Disassembling the countershaft.................. 148 20.3 Checking the engine oil pressure .................... 182
16.4.36 Checking the transmission ......................... 148 20.4 Changing the engine oil and filter, cleaning
16.4.37 Assembling the main shaft......................... 150 the oil screens .............................................. 183
16.4.38 Assembling the countershaft ...................... 151 20.5 Draining the engine oil .................................. 183
16.4.39 Checking the starter drive .......................... 152 20.6 Removing the oil filter ................................... 184
16.4.40 Checking freewheel ................................... 153 20.7 Installing the oil filter.................................... 184
16.4.41 Removing freewheel .................................. 153 20.8 Cleaning the oil screens................................. 185
16.4.42 Installing freewheel................................... 153 20.9 Filling up with engine oil ............................... 186
16.5 Assembling the engine .................................. 154 20.10 Adding engine oil .......................................... 186
16.5.1 Installing the transmission shafts ............... 154 21 IGNITION ................................................................ 187
16.5.2 Installing crankshaft and balancer shaft ...... 155 21.1 Alternator - checking the stator winding .......... 187
16.5.3 Installing the left engine case .................... 156 21.2 Checking the spark plug connector ................. 187
16.5.4 Installing the oil pumps............................. 157 21.3 Ignition coil – checking the secondary
16.5.5 Installing locking lever .............................. 158 winding........................................................ 188
16.5.6 Installing shift drum locating ..................... 158 22 THROTTLE VALVE BODY .......................................... 189
16.5.7 Installing shift shaft .................................. 158 22.1 Performing the initialization run ..................... 189
16.5.8 Installing the starter drive.......................... 158 23 TECHNICAL DATA.................................................... 190
16.5.9 Installing the primary gear ......................... 159 23.1 Engine ......................................................... 190
16.5.10 Installing the clutch basket........................ 159 23.2 Engine tolerance, wear limits ......................... 190
16.5.11 Installing the spacer and spring.................. 161 23.3 Engine tightening torques .............................. 192
16.5.12 Installing the clutch cover ......................... 161 23.4 Capacities .................................................... 193
16.5.13 Installing the ignition pulse generator ......... 162 23.4.1 Engine oil ................................................ 193
16.5.14 Installing timing chain and timing chain 23.4.2 Coolant .................................................... 193
sprocket................................................... 162 23.4.3 Fuel ........................................................ 193
16.5.15 Installing the timing chain rails .................. 162 23.5 Chassis ........................................................ 194
16.5.16 Installing the rotor .................................... 163 23.6 Electrical system........................................... 194
16.5.17 Adjusting crankshaft position sensor 23.7 Tires ............................................................ 195
distance................................................... 163 23.8 Fork............................................................. 195
16.5.18 Setting engine to top dead center ............... 164 23.9 Shock absorber ............................................. 195
16.5.19 Mounting the water pump cover ................. 164 23.10 Chassis tightening torques ............................. 196
16.5.20 Installing piston........................................ 164 24 CLEANING/PROTECTIVE TREATMENT....................... 198
16.5.21 Installing the cylinder head........................ 166 24.1 Cleaning the motorcycle ................................ 198
16.5.22 Installing the camshafts ............................ 167 24.2 Checks and maintenance steps for winter
16.5.23 Installing timing chain tensioner ................ 167 operation...................................................... 199
16.5.24 Checking valve clearance........................... 168 25 STORAGE ................................................................ 200
16.5.25 Adjusting the valve clearance ..................... 169 25.1 Storage ........................................................ 200
16.5.26 Installing the spark plugs........................... 170 25.2 Preparing for use after storage........................ 200
16.5.27 Installing the thermostat............................ 170 26 SERVICE SCHEDULE ............................................... 201
16.5.28 Installing the oil filter................................ 170 26.1 Service schedule........................................... 201
16.5.29 Installing the gear position sensor .............. 171 27 WIRING DIAGRAM ................................................... 202
16.5.30 Installing the spacer.................................. 171 27.1 Page 01 of 11 .............................................. 202
16.5.31 Installing the alternator cover..................... 171 27.2 Page 02 of 11 .............................................. 204
16.5.32 Installing oil screens ................................. 172 27.3 Page 03 of 11 .............................................. 206
16.5.33 Installing the starter motor......................... 172 27.4 Page 04 of 11 .............................................. 208
16.5.34 Installing the valve cover ........................... 173 27.5 Page 05 of 11 .............................................. 210
16.5.35 Removing the engine from the engine 27.6 Page 06 of 11 .............................................. 212
assembly stand......................................... 173 27.7 Page 07 of 11 .............................................. 214
17 CLUTCH .................................................................. 174 27.8 Page 08 of 11 .............................................. 216
17.1 Checking/rectifying the fluid level of the 27.9 Page 09 of 11 .............................................. 218
hydraulic clutch............................................ 174 27.10 Page 10 of 11 .............................................. 220
17.2 Changing the hydraulic clutch fluid ................ 174 27.11 Page 11 of 11 .............................................. 222
18 SHIFT MECHANISM................................................. 175 28 SUBSTANCES ......................................................... 224
18.1 Changing the gear position sensor................... 175 29 AUXILIARY SUBSTANCES ........................................ 226
18.2 Programming the gear position sensor ............. 177 30 SPECIAL TOOLS ...................................................... 228
19 WATER PUMP, COOLING SYSTEM ............................ 178 31 STANDARDS ........................................................... 241
19.1 Draining the coolant ...................................... 178 INDEX ............................................................................ 242
19.2 Filling/bleeding the cooling system ................. 178
19.3 Checking the antifreeze and coolant level ........ 179
19.4 Checking the coolant level ............................. 180
20 LUBRICATION SYSTEM............................................ 181
20.1 Oil circuit..................................................... 181
20.2 Checking the engine oil level.......................... 181
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.

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.
3 IMPORTANT INFORMATION 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.
4 SERIAL NUMBERS 8
4.1 Chassis number

The chassis number  is stamped on the steering head on the right.
401945-10
4.2 Type label

The type label  is located on the right side of the frame.
101973-10
4.3 Engine number

The engine number  is stamped on the left side of the engine under the engine
sprocket.
401949-10
4.4 Key number

The key number  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  is stamped on the inner side of the fork stub.
401947-10
4 SERIAL NUMBERS 9
4.6 Shock absorber part number

The shock absorber part number  is on the left of the shock absorber.
402025-10
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. 231)
Rear wheel stand (61029055400) ( p. 231)
– Position the motorcycle upright, align the stand and raise the motorcycle.
101984-10
5.2 Taking the motorcycle off of the rear wheel stand
Note
– Secure the motorcycle against falling over.

– Remove the rear wheel stand and lean the vehicle on the side stand.
401943-10
5.3 Raising the motorcycle with the front wheel stand
Note
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. 231)
Info
Always raise the rear of the motorcycle first.
– Raise the front of the motorcycle.

101985-01
5 MOTORCYCLE 11
5.4 Taking the motorcycle off of the front wheel stand
Note

– Remove the front wheel stand.
5.5 Raising the motorcycle with a lift stand
Note
– Stand the motorcycle upright on a level surface.

– Raise the motorcycle in the area of the footrest bracket.
401942-01
5.6 Removing the motorcycle from the lift stand
Note
– Remove the motorcycle from the lift stand and rest it on its side stand.
– Remove the lift stand.
401943-10
5.7 Raising the motorcycle with the work stand
Note
– Mount the special tool on the footrest.

Work stand adapter (75029036000) ( p. 234)
300579-10
5 MOTORCYCLE 12
– Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 232)
300201-10
5.8 Removing the motorcycle from the work stand
Note

– 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.
5 MOTORCYCLE 13
– 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.
The ABS warning lamp lights up and goes back out after starting off.
– Shift gear to neutral.
The green idling speed indicator lamp N lights up.
B00782-10 – Press the electric starter button .
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.
Switching off ABS
KTM recommends riding with ABS at all times. However, situations may arise in
which ABS is not advantageous.
Condition
Vehicle stationary, engine running.
– Press the  button for 3 - 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
401426-11
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 .

– Switch on the ignition.
– Press the electric starter button .
Info
Do not open the throttle.
B00782-10
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 the white adjusting screw  all the way clockwise.

Info
Adjusting screw  is located at the upper end of the left fork leg.
The compression damping is located in the left fork leg COMP (white adjust-
ing screw). The rebound damping is located in the right fork leg REB (red
adjusting screw).
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
101981-10 Guideline
Compression damping
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 the red adjusting screw  all the way clockwise.

Info
Adjusting screw  is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg REB (red adjusting
screw). The compression damping is located in the left fork leg COMP (white
adjusting screw).
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
101982-10 Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Info
ing.
6.3 Bleeding the fork legs

Preparatory work
– Lean the motorcycle on the side stand.
Main work
– Loosen bleeder screw .
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.
601879-10
6.4 Cleaning the dust boots of the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 11)
– Remove the fork protector. ( p. 15)
Main work
– Push dust boots  on both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind the dust boots 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 inside fork tube of both fork legs.
Universal oil spray ( p. 227)
– Push the dust boots back into their normal position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 16)
– Remove the motorcycle from the lift stand. ( p. 11)
6.5 Removing the fork protector

– Remove screws  and take off clamp.
– Remove screws  on left fork leg. Remove the fork protector.
– Remove the screws on the right fork leg. Remove the fork protector.
101986-10
6.6 Installing the fork protector

– Position the fork protection on the left fork leg. Mount and tighten screws .
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  .
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
101986-11
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 screw  and pull wheel speed sensor  out of the hole.
– Remove screws  and spacers .
– 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.
101995-10
– Loosen screw  and screws .

– Unscrew screw  about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
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.
G00827-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove screws  and the clamp. Take the brake line and wiring harness out of
the holder.
G00828-10
– Remove screws . Take off the fork protector.
G00832-10
– Loosen the screws  of the triple clamp. Remove the fork legs from the bottom.
G00829-10
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  on both sides.

G00829-11 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 .
Guideline
G00832-11
– Position the brake line, wiring harness and clamp.

– Mount and tighten screws .
G00828-11
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  and the wheel spindle.

– Position the front wheel and insert the wheel spindle.
G00830-11 The brake linings are correctly positioned.
– Mount and tighten screw .
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  with spacers  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.
– Tighten screws .
Guideline
Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
G00831-10
(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 .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
G00827-11
6.9 Disassembling the fork legs
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.
– Note down the current state of the rebound  and compression damping .
– Note down the current spring preload .
– Completely open the adjusters of the rebound damping, compression damping, and
spring preload.
202305-10
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 240)
– Remove adjuster .
202307-10
– Release Preload Adjuster .

Pin wrench (T103) ( p. 237)
Info
The Preload Adjuster cannot be removed yet.
202308-10
– Drain the fork oil.
202309-10
– Clamp the fork leg with the axle clamp.
Info
Use soft jaws.
– Slide the outer tube down.

– Pull the spring downwards. Mount the special tool on the hexagonal part.
Open-end wrench (T14032) ( p. 239)
202310-10
Info
Preload spacers  should be above the special tool.
– Clamp the special tool in the vise. Release Preload Adjuster .
202311-10
–  with preload spacers .

Remove Preload Adjuster
– Remove adjusting tube .
202312-10
– Pull the spring downwards. Remove the special tool.

– Remove the spring.
202313-10
– Clamp the fork leg with the axle clamp.

Guideline
Use soft jaws.
– Remove screw  of the cartridge.
Info
Place a container underneath to catch any oil that may run out.
202314-10
– Remove the cartridge.
202315-10
– Remove dust boot .
202115-13
– Remove lock ring .

Info
The lock ring has a beveled end where a screwdriver can be applied.
202005-12
– Heat up the outer tube in area  of the lower sliding bushing.

Guideline
50 °C (122 °F)
– Pull the outer tube from the inner tube with a jerk.
Info
The lower sliding bushing  must be pulled from its bearing seat.
202016-12
– Remove the upper sliding bushing .

Info
Without using a tool, carefully pull the stack apart by hand.
– Take off the lower sliding bushing .

– Take off support ring .
– Take off seal ring .
202104-12 – Take off lock ring .
– Take off dust boot .
– Unclamp the fork leg.
6.10 Checking the fork legs

Condition
Fork disassembled.
– Check the inner tube and axle clamp for damage.
» If there is damage:
– Change the inner tube.
202134-10
– Measure the outside diameter at several locations on the inner tube.

Outside diameter of inner tube 47.975… 48.005 mm (1.88878…
1.88996 in)
» If the measured value is less than the specified value:
200684-10
– 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:
200685-10
– Check the outer tube for damage.

» If there is damage:
– Change the outer tube.
202112-10
– Check the surface of the sliding bushings.

» If the bronze-colored layer  under the sliding layer  is visible:
– Replace the sliding bushings.
200665-10
– Check the spring length.

Guideline
Spring length with preload spacer(s) 463 mm (18.23 in)
– Reduce the thickness of the preload spacers.
» If the measured value is less than the specified value:
– Increase the thickness of the preload spacers.
202135-10
6.11 Assembling the fork legs
Info
These operations are the same on both fork legs.
Preparatory work
– Check the fork legs. ( p. 21)
Main work
– Clamp the inner tube with the axle clamp.
– Install the special tool.
Protecting sleeve (T1401) ( p. 239)
– Grease and push on dust boot .
Lubricant (T511) ( p. 226)
200669-10 Info
Always replace the dust boot, lock ring, seal ring, and support ring.
Install the dust boot with the sealing lip and spring expander facing down-
ward.
– Push on lock ring .

– Grease and push on seal ring .
Info
Sealing lip downward, open side upward.
– Push on support ring .

– Sand the edges of the sliding bushings with 600-grain sandpaper, then clean and
grease them.
Fork oil (SAE 4) (48601166S1) ( p. 225)
200670-10
– .
Push on the lower sliding bushing
– Mount the upper sliding bushing .
Info
Without using a tool, carefully pull the stack apart by hand.
200671-10
– Heat up the outer tube in area  of the lower sliding bushing.

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.
Mounting tool (T14040S) ( p. 240)
– Push the sliding bushing all the way into the outer tube.
201324-10
– Position the support ring.

– Hold the seal ring with the shorter side of the special tool.
Mounting tool (T14040S) ( p. 240)
– Push the seal ring and support ring all the way into the outer tube.
201325-10
– Mount lock ring .

Info
The lock ring must engage audibly.
200656-13
– Install dust boot .
200655-13
– Assemble related individual components accordingly.
Info
Compression damping side: cartridge with additional oil holes , white
adjuster, axle clamp marked L.
Rebound damping side: cartridge without additional oil holes, red adjuster,
axle clamp marked R.
202316-10
– Mount cartridge.
202315-10
– Mount and tighten screw  of the cartridge.

Guideline
Screw, cartridge M12x1 25 Nm
(18.4 lbf ft)
202314-11
– Mount special tool on the cartridge; remove pin  of the special tool.
Gripping tool (T14026S1) ( p. 239)
– Pull out the piston rod. Mount the spring. Mount the pin again.
– Pull up cartridge with special tool. Pull the spring downward and slide the special
tool onto the hexagonal piece.
Open-end wrench (T14032) ( p. 239)
202317-10
Gripping tool (T14026S1) ( p. 239)
– Clamp the special tool in the vise.
– Mount adjusting tube .
The adjusting tube protrudes 5 mm (0.197 in) from the cartridge and can be
pressed in against the resistance of the spring.
The adjusting tube protrudes more than 7 mm (0.275 in) from the cartridge
and cannot be pressed in against the resistance of the spring.
– Lubricate the thread of the piston rod.
202318-10
– Lubricate the upper edge of the piston rod.
– Screw the Preload Adjuster  with the preload spacers onto the piston rod.
Info
The Preload Adjuster must reach the stop before the piston rod begins turn-
ing as well. If the piston rod thread is stiff, the rod must be held to prevent
it from turning. If the Preload Adjuster is not screwed in all the way, the
rebound adjustment will not function properly.
– Tighten Preload Adjuster .

Guideline
Nut, piston rod on screw cover M12x1 25 Nm
(18.4 lbf ft)
– Release the special tool. Pull the spring downwards. Remove the special tool.
202319-10
– Clamp the fork vertically.

– Add fork oil.
Fork oil per fork 625 ml Fork oil (SAE 4) (48601166S1)
leg (21.13 fl. oz.) ( p. 225)
202320-10
– Push the outer tube upward.

– Clamp the fork in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 240)
– Lubricate the O-ring of the Preload Adjuster.
– Screw on the Preload Adjuster and tighten.
Guideline
202321-10
Screw cover on outer tube M47x1.5 40 Nm
(29.5 lbf ft)
Pin wrench (T103) ( p. 237)

– Mount adjuster ; mount and tighten the screw.
Guideline
Adapter M4x0.5 1.5 Nm
(1.11 lbf ft)
Info
Compression damping side: white adjuster, axle clamp marked L.
Rebound damping side: red adjuster, axle clamp marked R.
202322-10
Alternative 1
– Turn the adjusting screw of rebound damping 
and the adjusting screw of
compression damping 
clockwise as far as possible.
– Turn back counterclockwise by the number of clicks corresponding to the fork
leg type.
Guideline
Rebound damping
Comfort 20 clicks
202323-10 Standard 15 clicks
Sport 10 clicks
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
– Turn spring preload  clockwise all the way.
– Turn back counterclockwise by the number of turns corresponding to the fork
leg type.
Guideline
Spring preload - Preload Adjuster
Comfort 2 turns
Standard 5 turns
Sport 5 turns
Full payload 8 turns
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.
– Return the adjusting screws to the position determined when the unit was dis-
assembled.
6.12 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
– 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
– 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. 26)
– 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. 26)
– Check the steering head bearing and change if necessary.
Finishing work
– Release the rear of the vehicle.
6.13 Adjusting the steering head bearing play

Preparatory work
– 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 . Remove screw .
– Loosen and retighten screw .
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 .
G00790-10 Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Mount and tighten screw .
Guideline
Screw, steering stem M8 20 Nm
(14.8 lbf ft)
Finishing work
– Check the steering head bearing play. ( p. 26)
– Release the rear of the vehicle.
7 HANDLEBAR, CONTROLS 28
7.1 Handlebar position

In the upper triple clamp, there are 2 drill holes separated by a distance of .
Hole distance  15 mm (0.59 in)
The drill holes on the handlebar holder are centered and separated by a distance
of 
.
Hole distance  3.5 mm (0.138 in)
The handlebar can be mounted in 4 different positions. In this way, the handlebar can
be mounted in the position that is most comfortable for the rider.
601874-10
7.2 Adjusting the handlebar position

– Remove the four screws . Remove the handlebar clamps. Take off the handlebar
and set it aside.
Info
Cover the motorcycle and attachments to protect them from damage.
Do not kink the cables and lines.
– Remove the two screws . Take off the handlebar holder.

– Move the handlebar holder to the desired position. Mount and tighten the two
601875-10 screws  .
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)
Info
Position the handlebar holders evenly on the left and right.
– Position the handlebar.
Info
Ensure that the cables and lines are routed correctly.
– Position the handlebar clamps. Mount and evenly tighten the four screws .
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
7.3 Changing the throttle grip

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 101)
– Remove the seat. ( p. 61)
Main work
– Remove the cable binder.
G00778-10
– Remove screws . Take off the side cover.
G00779-10
G00781-10
– Remove screw .
– Push the trim aside.
G00780-10
– Disconnect plug-in connector .

– Expose the cable of the accelerator position sensor.
G00782-10
– Remove screws .
– Take the combination instrument up out of the holder and hang to the side.
G00783-10
– Loosen screw .
G00784-10
– Remove screws .
– Take off the handlebar guard.
G00785-10
– Remove screws .
G00786-10
– Pull throttle grip  and accelerator position sensor  from the handlebar.
G00787-10
–  and accelerator position sensor  on the handlebar.

Position throttle grip
Catch  engages in driver .
G00788-10
– Mount and tighten screws .

Guideline
Screw, throttle grip M5 3.5 Nm
(2.58 lbf ft)
Catch  engages in recess .
G00789-10
– Position the handlebar guard.

– Mount and tighten screws .
Guideline
G00785-10
– Tighten screw .
G00784-10
– Connect plug-in connector .

– Route the wiring harness of the accelerator position sensor without tension.
G00782-10
– Secure the cable with the cable binders.
G00781-10
– Position the combination instrument in the holder.

– Mount and tighten screws .
Guideline
Remaining screws, chassis M4 4 Nm (3 lbf ft)
G00783-10

Guideline
G00780-10
– Position the side cover.

– Mount and tighten screws .
Guideline
G00779-10
– Secure the cable with the cable binder.
G00778-10
Finishing work
– Install the headlight mask with the headlight. ( p. 102)
– Check the headlight setting. ( p. 101)
– Reset the control unit engine electronics KHRS.
– Program the gear position sensor. ( p. 177)
– Mount the seat. ( p. 62)
8 SHOCK ABSORBER, SWINGARM 33
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 takes effect during the fast compression of the shock absorber.
– Turn adjusting screw  clockwise all the way using a socket wrench.
Info
Do not loosen fitting !
– Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
101983-11
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Info
ing.
8.2 Adjusting the low-speed compression damping of the shock absorber
Caution
Info
The low-speed setting takes effect during the slow to normal compression of the shock absorber.
– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible

click.
Info
Do not loosen fitting !
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
101983-10 Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Full load capacity 15 clicks
Info
ing.
8.3 Adjusting the rebound damping of the shock absorber
Caution
– Turn adjusting screw  clockwise up to the last perceptible click.

absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
601891-10
Info
ing.
8.4 Measuring the unloaded rear wheel sag

Preparatory work
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 .
400988-10
Finishing work
8.5 Checking the static sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 34)
– 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 .
Info
The static sag is the difference between measurements  and .
– Check the static sag.
Static sag 20… 25 mm (0.79… 0.98 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( p. 35)
B
0
400989-10
8.6 Checking the riding sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 34)
– 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 .
Info
The riding sag is the difference between measurements  and .
– Check the riding sag.
Riding sag 70… 80 mm (2.76… 3.15 in)
C
0 » If the riding sag differs from the specified measurement:
– Adjust the riding sag. ( p. 36)
400990-10
8.7 Adjusting the spring preload of the shock absorber
Caution
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Preparatory work
– Take off the side cover. ( p. 62)
– Remove the shock absorber. ( p. 36)
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen retaining ring .
– Turn adjusting ring  until the spring is no longer under tension.
Hook wrench (T106S) ( p. 238)
– Measure the overall spring length without a load.
– Tension the spring by turning adjusting ring  to the prescribed value.
Guideline
201271-11 Spring preload 20 mm (0.79 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
– Tighten retaining ring .

Finishing work
– Install the shock absorber. ( p. 37)
– Mount the side cover. ( p. 62)
8.8 Adjusting the riding sag

Preparatory work
– Remove the shock absorber. ( p. 36)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Medium (standard) 80 N/mm (457 lb/in)
Hard 85 N/mm (485 lb/in)
Info
201352-10 The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber. ( p. 37)
– Check the static sag of the shock absorber. ( p. 34)
– Adjust the rebound damping of the shock absorber. ( p. 34)
8.9 Removing the shock absorber

Preparatory work
Main work
– Remove screws .
– Take off grab handle .
G00821-10
– Remove screws .
G00816-13
– Lift the rear fairing.

– Remove screws .
G00742-13
– Remove screws .
G00818-11
– Loosen screw.
– Remove screw .
– Remove screw .
G00825-11
– Fold the rear upward.

– Take out shock absorber  toward the top.
G00824-10
8.10 Installing the shock absorber

Main work
– Fold the rear upward and maneuver in shock absorber  from above.
– Fold the rear down and position the shock absorber.
G00824-11
– Mount screw  but do not tighten yet.

– Mount and tighten screw .
Guideline
Screw, bottom shock M10 45 Nm Loctite® 243™
absorber (33.2 lbf ft)
– Tighten screw .
Guideline
Screw, top shock absorber M10 45 Nm Loctite® 243™
(33.2 lbf ft)
G00825-10

Guideline
Screw, fuel tank, bottom M8 25 Nm Loctite® 243™
(18.4 lbf ft)
G00818-12

– Mount and tighten screws .
Guideline
Screw, main silencer holder on fuel M8 25 Nm
tank (18.4 lbf ft)
G00742-15

Guideline
Screw, side cover M6 5 Nm (3.7 lbf ft)
G00816-14
– Position grab handle .

– Mount and tighten screws .
Guideline
Screw, handrail M8 20 Nm
(14.8 lbf ft)
G00821-11
Finishing work

8.11 Servicing the shock absorber
Caution
Condition
The shock absorber has been removed.
– Remove the spring. ( p. 39)
– Dismantle the damper. ( p. 40)
– Disassemble the piston rod. ( p. 41)
– Check the damper. ( p. 42)
– Remove the heim joint. ( p. 43)
– Install the heim joint. ( p. 44)
– Assemble the piston rod. ( p. 45)
– Assemble the damper. ( p. 46)
– Install the spring. ( p. 51)
201289-01
8.12 Removing the spring

Condition
– Clamp the shock absorber in the vise using soft jaws for protection.
– Measure and note spring length in preloaded state.
– Loosen retaining ring  and the adjusting ring with the special tool.
– Turn the retaining ring and adjusting ring until the spring is fully relieved of ten-
sion.
201271-10
– Remove spring retainer .

– Take off spring  with the retaining ring and adjusting ring .
201272-10
8.13 Dismantling the damper

Preparatory work
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  of the reservoir.
– Open screw  slowly.
The pressurized nitrogen escapes.
201273-10
– Clamp the damper in the vise using soft jaws.

– Remove locking cap .
201274-10
– Press in seal ring retainer . Remove lock ring .

Info
Do not scratch the inner surface.
201276-10
– Remove screw . Drain the oil.
201277-10
– Remove the piston rod. Drain the remaining oil.
201278-10
– Remove compression adjuster . Remove the spring, sleeve, and piston.
201279-10
8.14 Disassembling the piston rod

Preparatory work
– Dismantle the damper. ( p. 40)
Main work
– Clamp the piston rod with the heim joint in a vise.
– Remove nut .
300540-10
– Remove supporting plate  and rebound shim stack  together with piston .
Info
Thread the rebound shim set on a screwdriver and set the parts down
together.
300541-10
– Remove compression shim stack  with supporting plate .

Info
Thread the compression shim stack on a screwdriver and set the parts down
together.
200572-11
– Remove seal ring retainer .
300542-10
– Remove locking cap  and rubber buffer .
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)
– 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)
– Check the piston rod for damage and wear.
» If there is damage or wear:
– Check the heim joint for damage and wear.

– Change the heim joint.
300460-01
8.16 Removing the heim joint

Condition
– Clamp the shock absorber in the vise using soft jaws for protection.
– Remove collar bushing  of the heim joint.
Pin (T120) ( p. 238)
– Turn over the shock absorber and remove collar bushing  of the heim joint.
Pin (T120) ( p. 238)
200577-10
– Remove seal rings  on both sides.
200578-10
– Remove lock rings  on both sides.
200579-10
– Place special tool  underneath and press out the heim joint with special
tool .
Pressing tool (T1207S) ( p. 238)
200580-10
8.17 Installing the heim joint

– Place special tool  underneath and press in the heim joint as far as the center
using special tool .
Pressing tool (T1206) ( p. 238)
Pressing tool (T129) ( p. 239)
200581-10
– Mount lock rings  on both sides.
200579-11
– Mount seal rings  on both sides and grease them.

200578-11
– Press in both collar sleeves  of the heim joint.
200582-10
8.18 Assembling the piston rod

Preparatory work
Main work
– Clamp the piston rod with the heim joint in a vise.
Guideline
Use soft jaws.
– Mount rubber buffer  and locking cap .
300543-11
– Position special tool  on the piston rod.

Mounting sleeve (T1515) ( p. 240)
– Grease the seal ring and push seal ring retainer  on to the piston rod.
300548-10
– Mount supporting plate with the rounded side facing downward.

– Mount the compression shim stack  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  Piston from above
View  Piston from below
201270-10
– Mount the rebound shim stack  with the smaller shims facing upward.
– Install supporting plate .
300541-11
– Mount and tighten nut .

Guideline
Piston rod nut M12x1 40 Nm
(29.5 lbf ft)
300540-11
8.19 Assembling the damper

Preparatory work
– Assemble the piston rod. ( p. 45)
Main work
– Push the spring and sleeve onto the compression adjuster. Mount the piston.
– Mount and tighten compression adjuster .
Guideline
Compression adjuster M26x1 30 Nm
(22.1 lbf ft)
201279-11

Guideline
Filling port screw M10x1 14 Nm
(10.3 lbf ft)
201277-11

– Fill the damper cartridge about half full.
Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 225)
201288-10
– Grease O-ring  of the seal ring retainer.

– Mount the piston rod carefully.
201278-11
– Install the seal ring bearer  and push it under the ring groove.
– Mount lock ring .
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  of the damper cartridge.

– Bleed and fill the damper. ( p. 48)
– Fill the damper with nitrogen. ( p. 50)
201275-10
Alternative 1
– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible
click.
absorber type.
Guideline
Compression damping, low-speed
Comfort 25 clicks
201287-10 Standard 20 clicks
Sport 15 clicks
– Turn adjusting screw  all the way clockwise using a socket wrench.
– Turn back counterclockwise the number of turns corresponding to the shock
absorber type.
Guideline
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
– Turn adjusting screw  clockwise up to the last perceptible click.
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Alternative 2
Warning
new ride behavior.
– Turn adjusting screws ,  and  to the position determined during disas-

sembly.
Finishing work
– Install the spring. ( p. 51)
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  on the damper.
Info
Tighten only hand-tight, without the use of tools.
– Connect the adapter  to connector  of the vacuum pump.

Vacuum pump (T1240S) ( p. 239)
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.

 control lever is on Closed, Damper  on Vacuum,
The External tank
 on Vacuum.
and Oil reservoir
– Operate the On/Off switch .
The vacuum pump process starts.
Pressure gauge  falls to the specified value.
< 0 bar
200271-10 The vacuum gauge  falls to the specified value.
4 mbar
– Measure distance  between the floating piston and reservoir hole with the spe-
cial tool.
Depth micrometer (T107S) ( p. 238)
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 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 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
3 bar
200268-10
– When the pressure gauge reaches the specified value, turn the Damper  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  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 to Equalize Pressure.
Guideline
4 mbar
0 bar
200267-10
– When the pressure gauge reaches the specified value, turn the Damper control
lever to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
3 bar
200268-10
– When the pressure gauge reaches the specified value, turn the Damper  control
lever to Vacuum.
Guideline
3 bar
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 
to the end of the special tool by the specified value (distance 
minus specified value).
Guideline
10 mm
Depth micrometer (T107S) ( p. 238)

– 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 adapter  from connection  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 .
Guideline
201283-10
Filling port screw M10x1 14 Nm
(10.3 lbf ft)
8.21 Filling the damper with nitrogen

– Screw in screw  by approx. 2 rotations but do not tighten.
Info
The piston rod is fully extended.
201282-10
– Clamp special tool in the vise.

Nitrogen filling tool (T170S1) ( p. 240)
– 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  engages in the hexagon socket of the
filling port screw.
– Open filler tap .
– Fill the damper for at least 15 seconds.
Guideline
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 .

– Close spigot  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

– Install retaining ring  and turn it down as far as possible.
The collar points to the adjusting ring.
– Mount adjusting ring  and turn it down as far as possible.
The collar points to the spring.
– Measure the overall spring length without a load.
– Mount spring .
201272-11 Guideline
Spring rate
– Mount spring retainer .
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 20 mm (0.79 in)
201271-11
Alternative 2
Warning
new ride behavior.
– Tension the spring to the amount measured during dismantling by turning

adjusting ring .
– Tighten lock nut  and the adjusting ring.
9 EXHAUST 53
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
Main work
– Remove cable binders .
– Push the cable to the right. Disconnect plug-in connector  of the lambda sensor.
– Feed out the cable of the lambda sensor.
G00811-10
– Remove the exhaust heat shield.
G00812-10
– Remove nuts  of the manifold.

Info
Do not misplace the spacer.
G00813-10
– Loosen screw .
G00814-10
– Remove screw .
– Take off the manifold.
G00815-10
9 EXHAUST 54
9.2 Installing the manifold

Main work
– Position the manifold with the seals.
– Position the spacer.
– Mount and tighten nuts  with the gasket.
Guideline
Nut, manifold on cylinder M8 25 Nm Copper paste
head (18.4 lbf ft)
G00813-11
– Position the screw clamp.

Guideline
Screw, main silencer M8 12 Nm Copper paste
clamp (8.9 lbf ft)
G00814-11

Guideline
Screw, exhaust clamp M8 12 Nm Copper paste
(8.9 lbf ft)
G00815-12
– Connect plug-in connector 

of the lambda sensor. Route the wiring harness with-
out tension and secure it with cable binders .
G00811-11
– Position the exhaust heat guard.

Guideline
Screw, exhaust heat shield M5 8 Nm Loctite® 243™
(5.9 lbf ft)
G00812-11
Finishing work
9 EXHAUST 55
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.
Preparatory work
Main work
– Remove the exhaust heat guard.
G00812-12
– Loosen screw .
G00814-11
– Remove grab handle .
G00821-12
G00816-10
– Remove screws .
– Remove the main silencer.
G00817-10
9 EXHAUST 56
9.4 Installing the main silencer

Main work
– Position the main silencer.
– Mount and tighten screw .
Guideline
Screw, main silencer holder M8 25 Nm
(18.4 lbf ft)
G00817-11

Guideline
Screw, main silencer M8 12 Nm Copper paste
clamp (8.9 lbf ft)
G00814-11
– Position the exhaust heat guard.

Guideline
Screw, exhaust heat shield M5 8 Nm Loctite® 243™
(5.9 lbf ft)
G00812-13

Guideline
Rear fairing screw M6 5 Nm (3.7 lbf ft)
G00816-11
– Position grab handle .

Guideline
Screw, handrail M8 20 Nm
(14.8 lbf ft)
G00821-13
Finishing work
10 AIR FILTER 57
10.1 Removing the air filter

Preparatory work
Main work
– Remove screws . Take off air filter box top .
601882-10
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the
engine.
– Never operate the vehicle without an air filter as dust and dirt will enter the
engine and lead to increased wear.
– Remove air filter .

601880-10
10.2 Installing the air filter

Main work
– Clean the air filter box.
– Mount air filter .
Info
The air filter must lie flush against the air filter box along the entire sealing
surface  .
If the air filter is not correctly mounted, dust and dirt can enter the engine
and cause damage.
601881-10
–  into the front of the air filter box and swing down.
Hook air filter box top
Guideline
Screw, air filter box top M6 2 Nm (1.5 lbf ft)
601882-11
Finishing work
10.3 Removing the air filter box

Preparatory work
10 AIR FILTER 58
Main work
– Take off the voltage regulator and hang it to the side in a de-energized state.
G00792-10
– Remove screws .
G00793-10
G00794-10
– Loosen hose clip .
G00795-10
– Detach vent hose .
G00796-10
– Remove battery cover .
G00797-10
10 AIR FILTER 59
– Take off control unit  and hang to the side.
G00798-10

– Disconnect connector  of the intake air temperature sensor.
– Raise the air filter box at the rear.
– Take off the air filter box.
G00799-10
10.4 Installing the air filter box

Main work
– Position the air filter box.
– Plug in connector  of the intake air temperature sensor and secure with the
cable binder.
G00799-11
– Position control unit .
G00798-11
– Mount battery cover .
G00797-11
– Route vent hose  without bends and mount.
G00796-11
10 AIR FILTER 60
– Mount and tighten hose clip .
G00795-11

Guideline
G00794-11

Guideline
G00793-11
– Position the voltage regulator.

– Mount and tighten screws .
Guideline
G00792-11
Finishing work
11 FUEL TANK, SEAT, TRIM 61
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
– Lift the cover of filler cap  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.
101975-10
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.
101976-01
11.3 Removing the seat

– Pull on strap  and raise the rear of the seat at the same time.
– Pull back the seat and lift it off.
101977-10
11.4 Mounting the seat
101988-10
– Hook slot of the seat onto screw , press the rear downward and at the same time push it forward.
– Push locking pin  into lock housing  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.
11.5 Taking off the side cover

Preparatory work
Main work
– Pull off the side cover in area  and take off from above.
– Repeat the operation on the opposite side.
G00791-11
11.6 Mounting the side cover

Main work
– Attach the side cover in area
 and engage it in area .
Guideline
G00791-10
Finishing work
11.7 Checking the fuel pressure
Danger
Warning
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.
– Press on the metal plate and disconnect the fuel hose connection .
Info
Remaining fuel may run out of the fuel hose.
302037-10
– Mount special tool .

3
0 Pressure testing tool (61029094000) ( p. 232)
– Mount special tool  with nozzle code 0,60.
Testing hose (61029093000) ( p. 231)
– Insert the hose end in a fuel canister.
2
0 Guideline
400926-10
Minimum fuel canister capacity 10 l (2.6 US gal)
– 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)
– Open the filler cap. ( p. 61)
– 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)
– Check that the fuel line is clear.
– Change the fuel filter. ( p. 64)
– Change the fuel pump. ( p. 67)
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
Warning
Warning
Preparatory work
– Remove the air filter box. ( p. 57)
– Disconnect the battery. ( p. 83)
– Drain the fuel from the fuel tank into a suitable container.
Main work
G00816-12

G00817-12
– Remove screw  on both sides.

– Swing the rear end upward and secure it.
G00818-10
– Remove screws  and the splash protector.
G00819-10
– Pull out the fuel pump.
S00113-10
– Disconnect both fuel hose connections .

– Unplug connector . Remove the fuel pump.
G00820-10
– Remove hose clamps .

– Remove fuel filter.
– Mount the new fuel filter.
Arrow points away from the fuel pump.
– Mount hose clamps .
Hose clamp pliers (60029057000) ( p. 230)
202049-10
– Press locking mechanism  on both sides.

– Pull off the fuel pump housing.
202050-10
– Change fuel screen .

– Mount the fuel pump housing.
202051-10
– Connect both fuel hose connections .

– Attach connector .
G00820-10
– Position the fuel pump.

Guideline
Screw, fuel pump M5 4 Nm (3 lbf ft)
S00113-10
– Position the splash protector. Mount and tighten screws .

Guideline
G00819-10
– Position the rear end.

– Mount and tighten screw  on both sides.
Guideline
(18.4 lbf ft)
G00818-10

– Mount and tighten screws .
Guideline
tank (18.4 lbf ft)
G00817-12

Guideline
G00816-12
Finishing work
– Install the air filter box. ( p. 59)

– Set the clock. ( p. 99)
11.9 Changing the fuel pump
Danger
Warning
Warning
Preparatory work
– Drain the fuel from the fuel tank into a suitable container.
Main work
G00816-12

G00817-12
– Remove screw  on both sides.

– Swing the rear end upward and secure it.
G00818-10
– Remove screws  and the splash protector.
G00819-10
– Pull out the fuel pump.
S00113-10
– Disconnect both fuel hose connections .

– Disconnect plug-in connector . Disconnect the fuel pump.
– Connect the new fuel pump, attaching both fuel hose connections .
– Connect plug-in connector .
G00820-10
– Position the fuel pump.

Guideline
Screw, fuel pump M5 4 Nm (3 lbf ft)
S00113-10
– Position the splash protector. Mount and tighten screws .

Guideline
G00819-10
– Position the rear end.

– Mount and tighten screw  on both sides.
Guideline
(18.4 lbf ft)
G00818-10

Guideline
tank (18.4 lbf ft)
G00817-12

Guideline
G00816-12
Finishing work
12 WHEELS 70
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

400695-01
» 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:
– Check the age of the tires.
12 WHEELS 71
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:

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 . 
Info
Wear reduces the thickness of the brake disc at the contact surface  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.
12 WHEELS 72
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)
– 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 front wheel stand. ( p. 10)
Main work
– Remove screw  and pull wheel speed sensor  out of the hole.
– Remove screws  and spacers .
– 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.
101995-10
– Loosen screw  and screws .

– Unscrew screw  about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
discs.
damaged.
101996-10
12 WHEELS 73
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove spacers .
101998-10
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 .
Long-life grease ( p. 226)
– Insert the spacers.
101998-11
– Clean and grease the thread of the wheel spindle and screw .
– Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount
and tighten screw  .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
101997-10 – Insert wheel speed sensor  into the hole. Mount and tighten screw .
Guideline
– Position the brake caliper and check that the brake linings are seated correctly.
– Position spacers . Mount screws  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.
– Tighten screws .
Guideline
Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
– Remove the fixation of the hand brake lever.
12 WHEELS 74
– Take the motorcycle off of the front wheel stand. ( p. 11)

– Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
– Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
101999-10
Finishing work
– Take the motorcycle off of the rear wheel stand. ( p. 10)
12.6.3 Removing the brake disc of the front brake

Preparatory work
– Remove front wheel. ( p. 72)
Main work
– Remove screws . Take off the brake disc with the ABS sensor wheel.
402044-10
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 ABS sensor wheel.
The lettering on the ABS sensor wheel is located on the outside.
Guideline
Screw, front brake disc M6 14 Nm Loctite® 243™
(10.3 lbf ft)
402044-10
Finishing work
– Install the front wheel. ( p. 73)
12.7 Rear wheel

12.7.1 Removing rear wheel
Preparatory work
Main work
– Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
– Remove screw and pull wheel speed sensor  out of the hole.
– Remove nut . Remove chain adjuster .
102000-10
12 WHEELS 75
– Pull out wheel spindle  to the point where the chain adjuster is no longer in con-
tact with the adjusting screw.
– Push the rear wheel forwards as far as possible and take the chain off the rear
sprocket.
– Pull out the wheel spindle.
Warning
discs.
102001-01
damaged.
– Take the rear wheel out of the swing arm.
Info
Do not operate the foot brake when the rear wheel is removed.
12.7.2 Installing the rear wheel
Warning
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. 80)
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Replace the wheel bearing.
– Remove bushing 
. Clean and grease the roll surfaces of the bushing and the
shaft seal ring . 
– Mount the bushing.
102002-10 – Clean and grease the threads of the wheel spindle and nut .
– Mount the rubber damper and rear sprocket carrier in the rear wheel.
– Position the rear wheel.
The brake linings are correctly positioned.
12 WHEELS 76
– Push the rear wheel forward as far as possible and lay the chain on the rear
sprocket.
– Mount the wheel spindle, chain adjuster , and nut .
Guideline
In order for the rear wheel to be correctly aligned, the markings on the left and
right chain adjusters must be in the same position relative to the reference
marks .
Info
Mount the left and right chain adjusters  in the same position.
– Tighten nut .
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.
– Insert wheel speed sensor  into the hole. Mount and tighten screw .
102003-10
Guideline
– Check the chain tension.
Finishing work
12.7.3 Removing the brake disc of the rear brake

Preparatory work
– Remove the rear wheel. ( p. 74)
Main work
– Remove screws . Take off the brake disc with the ABS sensor wheel.
402046-10
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 ABS sensor wheel.
The lettering on the ABS sensor wheel is located on the outside.
Guideline
Screw, rear brake disc M6 14 Nm Loctite® 243™
(10.3 lbf ft)
402046-10
Finishing work
– Install the rear wheel. ( p. 75)
12 WHEELS 77
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.

– Push the chain upward at a distance  from the chain sliding guard and deter-
mine the chain tension 
.
Info
The upper chain section  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. 77)
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. 77)
12 WHEELS 78
Main work
– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning adjusting screws  on the left and right.
Guideline
Chain tension 5 mm (0.2 in)
Turn the left and right adjusting screws  so that the markings on the left
and right chain adjusters  are in the same position relative to the reference
marks  . 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 .
– Make sure that the chain adjusters  are installed correctly on adjusting
screws . 
101989-10
– Tighten nut .
Guideline
(66.4 lbf ft)
12.7.7 Adjusting chain guide

– Remove screws  and . Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
–  in hole . Position the chain guide.
Insert nut
– Mount and tighten screws  and .
Guideline
Screw, chain guide M6 8 Nm (5.9 lbf ft)
Condition
Number of teeth: ≥ 45 teeth
–  in hole . Position the chain guide.
Insert nut
– Mount and tighten screws  and .
Guideline
Screw, chain guide M6 8 Nm (5.9 lbf ft)
S00080-10
12.7.8 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
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
12 WHEELS 79
– Pull on the upper section of the chain with the specified weight .
Guideline
Weight of chain wear measurement 15 kg (33 lb.)
0
A – Measure distance  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  at the longest 272 mm (10.71 in)

chain section
» If the distance  is greater than the specified measurement:
– Replace the chain.
B
0 Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
1 2 3 16 17 18 New chains wear out faster on old, worn sprockets.
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
12 WHEELS 80
– 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)
601884-01
Finishing work
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
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. 226)
– After drying, apply chain spray.
Chain lube for road use ( p. 226)
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
– Remove the rear wheel. ( p. 74)
12 WHEELS 81
Main work
– Check bearing .
» If the bearing is damaged or worn:
– Replace the bearings.
– Check rubber dampers  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.
102004-10
– Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert
the wheel spindle in the hub.
– To check play , 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)

102005-10
» If play  is larger than the specified value:
– Change all rubber dampers in the rear hub.
Finishing work
– Install the rear wheel. ( p. 75)
13 WIRING HARNESS, BATTERY 82
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
Main work
– Remove battery cover .
– Pull the EFI control unit  off of the holder and set it to one side.
B01974-10
– Disconnect negative cable  of the battery.

– Take off the positive terminal cover  and disconnect the positive cable from the
battery.
– Pull retaining bracket  of the battery forward and remove it.
– Lift the battery up and out.
Info
B01975-10 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
– Insert the battery into the battery compartment with the terminals facing rearward.
Battery (YTZ10S) ( p. 194)
– Position retaining bracket  and mount and tighten screws .
Guideline
– Position the positive cable and mount and tighten the screw.
B01975-11 Guideline
– Position positive terminal cover .
– Position negative cable  and mount and tighten the screw.
Guideline
– Position EFI control unit .

– Mount battery cover .
B01976-10
Finishing work
13.3 Disconnecting the battery

Preparatory work
Main work
– Disconnect the negative (minus) cable  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.
G00800-10
13.4 Connecting the battery

Main work
– Reconnect minus cable .
G00800-10
Finishing work
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.
– 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
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
– Remove the battery. ( p. 82)
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  .
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing .
– 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. 82)
13.6 Checking the charging voltage

Condition
The battery must be fully functional and completely charged.
Preparatory work
Main work
– Remove the battery cover.
–  off of the holder and set it to one side.
Pull the EFI control unit
– Take off terminal cover .
– Start the motorcycle to make checks. ( p. 13)
G00801-10
– 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-
G00802-10 ness.
– Check the stator winding of the alternator. ( p. 187)
» If the displayed value is greater than the specified value:
– Change the voltage regulator.
– Position terminal cover.
– Mount EFI control unit .
– Mount the battery cover.
G00801-10
Finishing work
13.7 Checking the quiescent current

Preparatory work
Main work
– Remove the battery cover.
– Disconnect the negative (minus) cable of the battery.
– Measure the current between battery ground (−) and the negative cable.
Info
The value of the open-circuit current only applies to vehicles in the original
state, without additional power consumers.
309519-10 Maximum open-circuit current < 1.0 mA

– Disconnect the voltage regulator from the wiring harness and take the mea-
surement again.
– Mount the battery cover.
Finishing work
13.8 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
Main work
– Remove protection covers .
102006-10
– Remove a defective main fuse  with needle nose pliers.

Info
A defective fuse is indicated by a burned-out fuse wire .
A reserve fuse  is located in the starter relay.
– Install a new main fuse.

Fuse (58011109130) ( p. 194)
102007-10
Info
Insert a new replacement fuse into the starter relay to have it available when
needed.
– Check the functioning of the electrical equipment.

– Mount the protection covers.
Finishing work
13.9 Changing fuses of individual power consumers
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
Main work
– Open fuse box cover .
102012-10
– Remove the defective fuse.

Guideline
Fuse 1 - 10 A - ignition, combination instrument, clock, EFI control unit
Fuse 2 - 10 A - ignition, combination instrument, EFI control unit
Fuse 3 - 10 A - fuel pump
Fuse 4 - 10 A - radiator fan
Fuse 5 - 10 A - horn, brake light, turn signal
Fuse 6 - 15 A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 7 - 10 A - for auxiliary equipment (permanent positive)
Fuse 8 - 10 A - for supplementary equipment (accessories connected with igni-
tion switch)
Fuse 9 - 10 A - ABS
Fuse 10 - not used
Fuse SPARE - 10 A/15 A - spare fuses
Info
102008-10
A defective fuse is indicated by a burned-out fuse wire .
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. 194)
Fuse (75011088015) ( p. 194)
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
13.10 Adjusting the engine characteristic

Preparatory work
– Switch off the ignition by turning the ignition key to position OFF .
Main work
– Pull the Map‑Select switch and holder  upward off of the retaining bracket.
– Pull the Map‑Select switch out of the holder.
102019-10
– Turn the adjusting wheel until the desired digit is next to marking .
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.
Advanced – homologated performance with extremely direct responsive-
ness.
601802-10 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.
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
14 BRAKE SYSTEM 89
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 .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:

– Change the brake linings of the front brake. ( p. 89)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the brake linings of the front brake. ( p. 89)
101990-10
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.
– 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
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
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.
14 BRAKE SYSTEM 90
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove cover with membrane .
– Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
G00807-10
–  and pull out pin .

Push the spring hanger forward from spring
– Remove springs . Remove brake linings .
– Clean the brake caliper.
– Insert new brake linings . Position springs  and mount pins .
Info
The spring hanger of springs  must be positioned upward.
400421-10
– Add brake fluid to level .

Guideline
Level  5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 224)

– Position the cover with the membrane. Mount and tighten the screws.
Info
G00806-11 Clean up overflowed or spilt brake fluid immediately with water.
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 .
Info
Pull the hand brake lever forward and turn the adjusting wheel.
Do not make any adjustments while riding!
B01955-10
14.4 Checking brake fluid level of front brake
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
14 BRAKE SYSTEM 91
– Check the brake fluid level in the viewer.
» If the brake fluid has dropped below marking :
– Add front brake fluid. ( p. 91)
102010-10
14.5 Adding front brake fluid
Warning
Warning
Warning
Warning
Info
brake fluid.
Preparatory work
– Check the front brake linings. ( p. 89)
Main work
– Remove cover  with membrane .
– Add brake fluid to level .
Guideline
Measurement of  5 mm (0.2 in)

102011-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
14 BRAKE SYSTEM 92
14.6 Changing the front brake fluid
Warning
Warning
Info
– Cover the painted parts.
– Remove screws.
– Remove cover  with membrane.
– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 229)
G00803-10 Brake fluid DOT 4 / DOT 5.1 ( p. 224)
– Mount bleeder cover .

Bleeder cover (00029013010) ( p. 228)
– Connect the bleeding device.
Bleeding device (00029013100) ( p. 228)
G00804-10
– Open shut-off valve .

Info
Follow the operating instructions of the bleeding device.
– Ensure that the inflation pressure is correctly set at pressure gauge . If neces-
sary, adjust the inflation pressure at pressure regulator  .
Guideline
Inflation pressure 2… 2.5 bar (29… 36 psi)
201494-10
– Pull off protection cap  of the brake caliper bleeder screw. Connect the hose of
the bleeder bottle.
– Open bleeder screw  by approx. one half turn.
Info
Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
G00805-10
– Tighten the bleeder screw.
– Close shut-off valve .
14 BRAKE SYSTEM 93
– Open the bleeder screw again until brake fluid stops emerging.
Info
This prevents overfilling of the brake fluid reservoir.
– Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro-
tection cap.
– Disconnect the bleeding device. Remove the bleeder cover.
– Correct the brake fluid level.
Guideline
Add brake fluid to level . 5 mm (0.2 in)

Info
G00806-10 Clean up overflowed or spilt brake fluid immediately with water.
– Check the hand brake lever for a firm pressure point.
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.
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:

– Change the rear brake linings. ( p. 93)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the rear brake linings. ( p. 93)
101994-10
14.8 Changing the rear brake linings
Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally.
Warning
Warning
Warning
14 BRAKE SYSTEM 94
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
Info
brake fluid.
– Stand the vehicle upright.

– Remove screw cap  with membrane .
– 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.
101993-10
– Remove cotter pin , remove pin  toward the left by striking it, and remove
the brake linings.
– Clean brake caliper and brake caliper support.
100288-10
– Check that leaf spring  in the brake caliper and sliding plate  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.
– Mount the screw cap with the membrane.
Info
100289-01 Clean up overflowed or spilt brake fluid immediately with water.
14 BRAKE SYSTEM 95
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 . 
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.
402027-10
» If the free travel does not meet specifications:
– Adjust the basic position of the foot brake lever. ( p. 95)
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  on foot brake cylinder .

– To adjust the basic position of the foot brake lever individually, loosen nut  and
turn screw 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  so that the foot brake lever has the necessary free
travel. Hold screws  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. 95)
– Tighten nut .
101991-10
14.11 Checking rear brake fluid level
Warning
Warning
14 BRAKE SYSTEM 96

– Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN marking :
– Add rear brake fluid. ( p. 96)
101992-10
14.12 Adding rear brake fluid
Warning
Warning
Warning
Warning
Info
brake fluid.
Preparatory work
– Check the rear brake linings. ( p. 93)
Main work
– Remove screw cap  with the washer and membrane .
– Add brake fluid to the MAX mark.
– Mount the screw cap with the washer and membrane.
Info
101993-10
14 BRAKE SYSTEM 97
14.13 Changing the rear brake fluid
Warning
Warning
Info
– Cover the painted parts.

– Take off screw cap  with the washer and membrane.
– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 229)
G00808-10
– Mount bleeder cover .

Bleeder cover (00029013004) ( p. 228)
– Connect the bleeding device.
G00809-10
– Open shut-off valve .

Info
Follow the operating instructions of the bleeding device.
– Ensure that the inflation pressure is correctly set at pressure gauge . If neces-
sary, adjust the inflation pressure at pressure regulator  .
Guideline
Inflation pressure 2… 2.5 bar (29… 36 psi)
201494-11
– Pull off protection cap  of the bleeder screw. Connect the hose of the bleeder
bottle.
– Open bleeder screw  by approx. one-half turn.
Info
Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
G00810-10
– Tighten the bleeder screw.
– Close shut-off valve .
14 BRAKE SYSTEM 98
– Open the bleeder screw again until brake fluid stops emerging.
Info
This prevents overfilling of the brake fluid reservoir.
– Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro-
tection cap.
– Disconnect the bleeding device. Remove the bleeder cover.
– Add brake fluid to the MAX mark .
– Mount the screw cap with the washer and membrane.
Info
G00808-11
15 LIGHTING SYSTEM, INSTRUMENTS 99
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.
– 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.
401444-01
15.1.2 Setting the clock

Condition
– 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.
The time is set.
401444-01
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.

– 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.
401445-01
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.

– 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.
401446-01
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
Preparatory work
Main work
– Unplug connector ED from the combination instrument.
– Unlock pin 18  and remove it from connector ED.
– Plug connector ED into the combination instrument.
– 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  .
Reducing the wheel circumference
– Press the SET button 
.
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.
202058-10
– Connect pin 18 to connector ED.
– Plug connector ED into the combination instrument.
Finishing work
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  under the first mark.
Guideline
Distance  5 cm (2 in)
– Position the vehicle vertically at a distance  in front of the wall.

Guideline
400726-10 Distance  5 m (16 ft)
– 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. 101)
15.3 Adjusting the headlight range

Preparatory work
Main work
– Turn adjusting screw  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
102024-10
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
Main work
– Cover the fender with a cloth to protect it from damage.
– Remove screws  on both sides.
– Tip the headlight mask forward.
102025-10
– Disconnect the connectors of turn signals  and headlight .

– Remove the headlight mask.
102026-10
15.5 Installing the headlight mask with the headlight

Main work
– Connect the connectors of headlight  and turn signal lights .
– Check lighting function.
102026-11
– Remove the cloth from the fender and position the headlight mask.
Holding lugs  reach into the headlight mask.
102027-10
– Position groove  on counterpiece .
102028-10
– Position brake line guides . Mount and tighten screws .

Guideline
Screw, headlight mask M5 5 Nm (3.7 lbf ft)
102025-11
Finishing work
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
Main work
– Remove protection cap .
600610-12
– Pull bulb socket  out of the reflector.

– Pull parking light bulb  out of the bulb socket.
– Insert a new parking light bulb in the bulb socket.
Parking light (W5W / socket W2.1x9.5d) ( p. 194)
– Insert the bulb socket in the reflector.
– Insert the protection cap.
600612-10
Finishing work
15.7 Changing the headlight bulb
Note
before mounting.
Preparatory work
Main work
– Pull off connector .
– Take off protection cap  of the headlight bulb.
600610-10
– Detach spring bar .

– Remove headlight bulb .
– Insert a new headlight bulb into the headlight housing.
Headlight (H4 / socket P43t) ( p. 194)
– Fix the headlight bulb in the headlight using the spring bar.
– Mount the protection cap. Attach the connector.
600611-10
Finishing work
15.8 Changing the turn signal bulb
Note
before mounting.
Main work
– Remove the screw on the rear of the turn signal housing.
– Carefully swing turn signal glass  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. 194)
– 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.
16 ENGINE 105
16.1 Removing the engine

Preparatory work
– Remove the manifold. ( p. 53)
– Drain the coolant. ( p. 178)
Main work
– Loosen the spring band clamp  using the special tool. Detach the radiator hoses.
Pliers for spring band clamp (60029057100) ( p. 231)
G00833-10
G00834-10
– Take off the engine sprocket cover.
– Remove screw .
– Take off the shift lever.
G00835-10
– Bend up lock washer .

– Have an assistant operate the rear brake.
– Remove the nut of the engine sprocket with the lock washer.
G00836-10
– Remove nut . 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 does not need to be fully removed.
G00837-10
16 ENGINE 106
– Take off the engine sprocket.

– Remove screws .
– Remove cable binder .
– Take off the clutch slave cylinder with the gasket and hang it to the side.
Info
Do not kink the clutch line.
Do not activate the clutch lever if the clutch slave cylinder has been
removed.
G00838-10 – Take off the clutch push rod.

– Pull back the protection cap. Remove nut .
– Remove screw .
G00839-10
– Loosen hose clip .

– Pull off the throttle valve body from the rear.
G00840-10
– Disconnect plug-in connector  of the gear position sensor, crankshaft position

sensor, and alternator.
G00841-10
– Detach the spark plug connectors.

– Unplug the connector of the engine coolant temperature sensor .
G00842-10
– Loosen the spring band clamps  using the special tool.

G00843-10
16 ENGINE 107
– Detach connector  of the oil pressure sensor. Remove screw .

– Release connection . Remove the line with the oil pressure sensor.
G00844-10
– Remove screws . Remove the engine bearer.
G00845-10
– Position the floor jack under the engine and fix it using the special tool.
Floor jack attachment (75029055000) ( p. 235)
G00846-10
– Remove nut  and screw  of the lower engine bracket.
G00847-10
– Lower the engine.
Info
You should have an assistant for this step.
Make sure that the motorcycle is sufficiently secured against falling over.
Protect the frame and attachments from damage.
G00848-10
16.2 Installing the engine

Preparatory work
– Raise the engine onto the special tool and fix it.
16 ENGINE 108
Main work
– Position the engine in the frame.
G00848-10
– Mount swingarm pivot.

– Mount the screw of swingarm pivot  but do not tighten yet.
– Mount screw connection  of the lower engine attachment but do not tighten yet.
Info
You should have an assistant for this step.
Make sure that the motorcycle is sufficiently secured against falling over.
Protect the frame and attachments from damage.
G00847-11
– Remove the floor jack with the special tool.

G00846-10
– Position the engine bearer.

Guideline
Screw, engine bearer on frame M10 45 Nm
(33.2 lbf ft)
– Mount and tighten fitting .
Guideline
G00845-11 Engine carrying screw M10 45 Nm Loctite® 243™
(33.2 lbf ft)
– Tighten the screw of swingarm pivot .
Guideline
Screw, swingarm pivot M12 80 Nm (59 lbf ft)
– Tighten fitting  of the lower engine bracket.
Guideline
Engine carrying screw M10 45 Nm Loctite® 243™
(33.2 lbf ft)
– Position the line with the oil pressure sensor. Mount and tighten connection .
Guideline
Oil pressure sensor line M10x1 10 Nm (7.4 lbf ft)
– Position the clamp of the oil line. Mount and tighten screw . Plug in the connec-
tor.
Guideline
G00844-11
16 ENGINE 109
– Position the hoses of the engine breather, the SAS, and the oil return line. Mount
the spring band clamp  using the special tool.
G00843-11
– Attach the spark plug connectors.

– Plug in the connector of the engine coolant temperature sensor .
G00842-11
– Connect plug-in connectors  of the gear position sensor, crankshaft position sen-
sor, and alternator.
G00841-11
– Position the throttle valve body.

– Position and tighten hose clip .
G00840-11
– Position the electrical connection  on the starter motor. Mount and tighten
screw. Mount the protection cap.
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 .
Guideline
Screw, starter motor M6x20 10 Nm Loctite® 243™
(7.4 lbf ft)
G00839-11
– Insert the clutch push rod.

– Position the clutch slave cylinder.
– Mount and tighten screws .
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)
G00838-11
– Secure the cable with cable binders .
16 ENGINE 110
– Mount the engine sprocket with the chain.

– Position the new lock washer and mount nut 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 rest against the tensioning
screws, and tighten nut .
Guideline
G00837-11 (66.4 lbf ft)
– Have an assistant operate the rear brake.
– Tighten nut.
Guideline
Nut, engine sprocket M20x1.5 80 Nm Loctite® 243™
(59 lbf ft)
– Secure the nut with lock washer .
G00836-11
– Position the engine sprocket cover.

– Mount and tighten screw .
Guideline
(18.4 lbf ft)
– Mount and tighten screw .
Guideline
G00835-11 Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the shift lever.
– Mount and tighten screw .
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 lbf ft)
– Mount and tighten screw .
Guideline
Screw, upper radiator bracket M6 10 Nm (7.4 lbf ft)
G00834-11
– Position the radiator hoses. Mount the spring band clamps .
– Install the manifold. ( p. 54)
G00833-11
16 ENGINE 111
– Remove the oil filler plug  with the O-ring 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. 224)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 224)
– Mount and tighten the filler plug with O-ring .
G00910-10
Finishing work
– Fill/bleed the cooling system. ( p. 178)
– Perform the initialization run. ( p. 189)
– Take a short test ride.
– Read out the fault memory using the KTM diagnostics tool.
– Check the engine for leakage.
– Check the engine oil level. ( p. 181)
– Check the coolant level. ( p. 180)
16.3 Disassembling the engine

16.3.1 Clamping the engine into the engine assembly stand
– Mount special tool  on engine assembly stand .
Engine assembly stand (61229001000) ( p. 232)
Support for engine assembly stand (75012001060) ( p. 232)
Holder for engine assembly stand (75012001070) ( p. 232)
– Mount the engine on special tool .
Info
Have an assistant help you or use a crane.
305506-10
16.3.2 Draining the engine oil

– Remove the oil drain plug  with the magnet and seal ring.
– Remove plug  with oil screen and the O-rings.
305508-10
– Remove plug  with oil screen  and the O-rings.

– Completely drain the engine oil.
305509-10
16 ENGINE 112
16.3.3 Removing the starter motor

– Remove oil throttle .
– Take off the starter motor.
305512-10
16.3.4 Removing the valve cover

– Take off the valve cover with the valve cover seal.
305517-10
16.3.5 Removing the alternator cover

– Take off the alternator cover.
305518-10
– Take off alternator cover gasket  and remove dowels .
305520-10
16.3.6 Removing the spacer

– Remove spacer .
305521-10
16 ENGINE 113
16.3.7 Removing the gear position sensor

– Remove screws  with the washers.
– Remove gear position sensor  with the O-ring.
201959-11
16.3.8 Removing the oil filter

– Take off the oil filter cover with the O-ring.
– Remove oil filter .
Circlip pliers reverse (51012011000) ( p. 229)
305526-10
– Take off the oil filter cover with the O-ring.
– Remove oil filter .
305549-10
16.3.9 Removing the thermostat

– Take off the thermostat case.
– Remove thermostat .
305528-10
16.3.10 Setting engine to ignition top dead center

– Turn the crankshaft counterclockwise until markings  of the camshafts are flush
with the marks of the camshaft support plate.
305531-10
16 ENGINE 114
Info
Look through the hole to check that the position hole of the balancer shaft
is visible.
– Screw in special tool .

Engine blocking screw (77329010000) ( p. 237)
305532-10
16.3.11 Removing the spark plugs

– Remove spark plugs  and .
Spark plug wrench (75029172000) ( p. 236)
305516-10
16.3.12 Removing the timing chain tensioner

– Remove screw  with the seal ring.
– Remove timing chain tensioner .
305539-10
16.3.13 Removing the camshafts

– Remove screw .
– Take off the camshaft support plate .
305542-10
– Pull the camshaft out of the bearing seats.

– Take the timing chain off the camshaft gear.
– Remove the camshaft.
305543-10
16 ENGINE 115
16.3.14 Removing the cylinder head

305544-10
– Loosen screws  diagonally and remove them.

– Take off the cylinder head.
305545-10
16.3.15 Removing the piston

– Take off the cylinder head gasket .
– 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.
305546-10
– Remove piston pin retainer .

– 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.
305551-10
– Take off the cylinder base gasket .

Info
Ensure that the two grooved pins remain in place.
305552-10
16 ENGINE 116
16.3.16 Removing the water pump impeller

– Remove screws . Take off the water pump cover.
305556-10
– Remove water pump impeller .
– Take off the water pump cover seal.
Info
Ensure the locating pins remain in place.
305557-10
– Remove formed washer .
305558-10
16.3.17 Removing the rotor

– Remove special tool .
305560-10
– Hold the rotor with special tool .

Holding spanner (75029091000) ( p. 236)
Info
Make sure that the crankshaft is not blocked.
– Remove nut  and the locking edge washer.

305561-10
16 ENGINE 117
– Mount the special tool  on the rotor.

Extractor (58429009000) ( p. 229)
– Hold it tight using the special tool and pull off the rotor by turning the screw in.
305562-10
16.3.18 Removing the timing chain rails

– Pull the timing chain guide rails  out of the timing chain securing guide .
Info
The support bushing is plugged into the timing chain securing guide
through the timing chain guide rails.
– Remove the timing chain guide rails upward out of the timing chain shaft.
305565-10
– Hold the timing chain securing guide tight and pull the timing chain tensioning
rail 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.
305566-10
16.3.19 Removing the timing chain and timing chain sprocket

– Slip out timing chain .
Info
If the timing chain will be used again, mark the direction of travel.
305569-10
– Take off lock ring .
305570-10
16 ENGINE 118
– Pull off the timing chain sprocket with special tool .

Extractor (59029033000) ( p. 230)
305571-10
16.3.20 Removing the ignition pulse generator

– Pull cable sleeve  out of the engine case.
– Remove the ignition pulse generator.
305572-10
16.3.21 Removing the clutch cover

– Take off the clutch cover.
305573-10
– Remove the clutch cover gasket .

– Take off dowels  .
305574-10
16.3.22 Removing the spacer and spring

– Remove spacer  and spring .
305575-10
16 ENGINE 119
16.3.23 Removing the clutch basket

– Clamp the antihopping clutch with special tool .
Assembly screws (75029033000) ( p. 233)
Info
Apply the special tool with the hand only, do not use another tool.
305576-10
– Loosen screws  diagonally and remove them with their spring retainers and
clutch springs.
– Remove pressure cap .
305577-10
– Remove pressure piece .

– Bend open lock washer .
305578-10
– Hold the clutch basket with special tool .

Gear segment (75029081000) ( p. 236)
Info
– Remove nut .
– Remove the lock washer.
305579-10 – Remove nut .
Info
Left-handed thread!

Gear segment (75029081000) ( p. 236)
– Take out the antihopping clutch.
305580-10
16 ENGINE 120
– Remove stepped washer .
305581-10
– Remove half washers .

– Take off the clutch basket .
305582-10
– Remove needle bearing  and supporting plate .
305583-10
16.3.24 Removing the primary gear

– Position special tool .
Protection cover (75029090000) ( p. 236)
– Mount special tool .
Extractor (75029021000) ( p. 233)
– Hold it using the special tool and pull off the primary gear by turning the screw in.
– Remove the special tools.
305585-10
16.3.25 Removing the starter drive

– Remove lock ring .
– Take off the starter idler gear  with the washers.
305614-10
16 ENGINE 121
– Remove lock ring .

– Remove torque limiter  with the washers and needle bearing.
305615-10
– Take off freewheel gear .
305616-10
– Remove woodruff key  and both needle bearings .
305617-10
16.3.26 Removing shift shaft

– Push sliding plate 
away from the shift drum locating . Remove shift
shaft with the washer.
305618-10
16.3.27 Removing shift drum locating

– Press locking lever  away from shift drum locating  and take off the shift
drum locating.
– Release the locking lever.
305619-10
16 ENGINE 122
16.3.28 Removing locking lever

– Take off locking lever  with the sleeve and spring.
305622-10
16.3.29 Removing the oil pumps

– Remove lock washers  and normal washers  from both oil pumps.
– Take off the oil pump gear wheels .
305624-10
– Remove pins  and washers.
305625-10
– Take off the oil pump cover.
305626-10
– Remove oil pump shaft  with the internal rotors.

– Remove external rotor .
305627-10
16 ENGINE 123
– Remove screws .
– Take off the oil pump cover.
305628-10
– Remove oil pump shaft  with the internal rotors.

– Remove external rotor .
305629-10
16.3.30 Removing the left engine case

– Swing the left section of the engine case up and remove the nut or screw of the
engine fixing arm.
305632-10
– Install special tool  with suitable screws.

Extractor (75029048000) ( p. 235)
Info
Use the 750 drill hole.
– Pull off the section of the engine case.
Info
305633-10
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 dowels .
– Remove O-ring .
305634-10
16 ENGINE 124
16.3.31 Removing the crankshaft and balancer shaft

– Remove balancer shaft  and crankshaft .
305637-10
16.3.32 Removing the transmission shafts

– Remove shift rail .
305638-10
–  to one side.
Swing shift forks
– Remove shift drum .
305639-10
– Remove shift forks .

Info
Ensure that the pins remain in place.
305640-10
– Remove lock ring  and the stop disk.
305641-10
16 ENGINE 125
– Remove transmission shafts .

Info
The stop disk of the countershaft usually sticks to the bearing.
– Take off the O-ring of countershaft .
305642-10
16.4 Work on individual parts

16.4.1 Work on the right section of the engine case
– Remove oil jet .
– Remove bearing locks of the main shaft bearing , of the countershaft
bearing 
, and of the shift drum bearing .
– 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)
305649-10
– 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 .

– Remove the cover plate  for the oil return line.
– Press out the shaft seal ring  of the crankshaft from the inside to the outside.
– Remove the shaft seal rings  of the water pump.
– Press in the shaft seal ring  of the crankshaft from the outside to the inside with
the open side facing in.
Info
305650-10 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.
– 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  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-
305651-10
ings will be damaged when they are pressed in.
– After the engine case section has cooled, check that the bearings are firmly seated.
16 ENGINE 126
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 .
Guideline
Oil jet, piston cooling M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
– Mount and tighten the oil jet .
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 . Mount and tighten the screws.
Guideline
Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft)
– Reinstall the dowels.
16.4.2 Work on the left section of the engine case

– Remove all dowels.
– Remove oil jet .
– Remove the shaft seal ring of countershaft  and shift shaft .
Info
The shaft seal ring  of the crankshaft cannot be removed before the
crankshaft bearing.
– Screw off the membrane support plate  and remove it together with
membrane . 
– Remove screw  with the washer.
305646-10
– Remove screw plug  and take pressure spring  with piston valve  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.
305647-10
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
16 ENGINE 127
– 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.
– Mount and tighten screw  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  and shift shaft  with the open
side facing inwards so that it is flush.
– Mount and tighten the oil jet .
Guideline
Oil jet, piston cooling M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
– Mount the dowels.
– 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.
305602-10
– Replace the piston valve.
– Lubricate piston valve 

and mount it with pressure spring . Mount and
tighten screw plug 
with the new seal ring.
Guideline
Oil pressure regulator valve plug M12x1.5 20 Nm
(14.8 lbf ft)
– Position the membrane support plate  with membrane . Mount and tighten
the screws.
Guideline
305648-10
Screw, membrane fixation M3 2 Nm Loctite® 243™
(1.5 lbf ft)
16 ENGINE 128
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  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.
305662-10
16.4.4 Removing crankshaft bearing inner ring

– Fix the crankshaft with special tools  and  in the vise.
Upper part, pressing-out tool (75029047050) ( p. 234)
Under part, pressing-out tool (75029047051) ( p. 235)
302145-10
– Heat the special tool .

Guideline
150 °C (302 °F)
Tool for inner bearing race (58429037043) ( p. 229)

– Push the heated special tool  on to the inner bearing race, press them hard
together, and pull them together off the crankshaft.
– Take off the compensation shim.
302146-10 – Repeat the operation on the opposite side.
16.4.5 Removing balancer shaft drive wheel

Preparatory work
– Remove the crankshaft bearing inner ring. ( p. 128)
Main work
– Screw in 2 M6 screws 
in the threads. Tighten the two screws evenly to pull the
drive wheel 
off the crankshaft.
302147-10
16.4.6 Changing the connecting rod, conrod bearing, and crank pin
Preparatory work
– Remove the drive wheel of the balancer shaft. ( p. 128)
16 ENGINE 129
Main work
– Position the crankshaft with special tool  in the press.
– Position special tool  between the crankwebs.
– Press the crank pin out of the upper crankweb with the push-out drift of the special
tool.
302151-10
Pressing device for crankshaft, complete (75029047000) ( p. 234)
Info
Hold the lower crankweb.
– Take off the connecting rod and bearing.

– Press the crank pin out of the crankweb.
300138-10
– Press in the new crank pin  as far as possible.

Info
The crank pin must be pressed in so that oil channel  is aligned with oil
channel  .
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.
305653-10
– Mount bearing  and connecting rod .

Info
Thoroughly lubricate the bearing.
305654-10
– Position special tool  on the press.

– Place the crankweb in with the connecting rod and the bearing. Position the second
crankweb.
300142-10
16 ENGINE 130
– Position special tool  with the heel at the bottom.

– 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-
302152-10 dom of movement.
– Measure axial play  between the connecting rod and the crankwebs using the
special tool.
Feeler gauge (59029041100) ( p. 230)
Connecting rod - axial clearance of 0.30… 0.60 mm (0.0118…

lower conrod bearing 0.0236 in)
– Correct until it complies with the specified value.
305655-10
Finishing work
– Check the crankshaft run-out at the bearing pin. ( p. 130)
– Install the drive wheel of the balancer shaft. ( p. 130)
– Install the crankshaft bearing inner ring. ( p. 131)
– Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 131)
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
– Warm the drive wheel.
Guideline
100 °C (212 °F)
302148-10
16 ENGINE 131
– Place the drive wheel on the crankshaft.

The dowel of the crankshaft must fit in the drill hole .
The side of the drive wheel with the punch mark 
must be visible after
assembly, and the side with the bevel  must be in contact with the
crankweb.
300159-10
Finishing work
16.4.9 Installing crankshaft bearing inner ring

Main work
– Push on the compensation shim.
– Heat the special tool. Install the inner bearing race.
Guideline
302150-10 120 °C (248 °F)
– 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
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)
16 ENGINE 132

– Remove the crankshaft.
– 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.

– 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)
– 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.
305656-10
16.4.12 Checking/measuring the cylinder

– Check the O-ring of the chain adjuster for damage and wear.
– Change 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  and  axes using a
micrometer to check for oval wear.
305591-10
– To determine the size, measure the cylinder at a distance  from the top edge of
the cylinder.
Guideline
Distance  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)
16 ENGINE 133
– The cylinder size  is marked on the side of the cylinder.
305588-10
– Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) ( p. 230)
Cylinder/cylinder head - sealing area ≤ 0.10 mm (≤ 0.0039 in)

distortion
– Change the cylinder.
305589-10
16.4.13 Checking/measuring the piston

– Use the special tool to measure play  of the piston rings in the piston ring
groove.
Guideline
Piston ring - groove clearance ≤ 0.08 mm (≤ 0.0031 in)
Feeler gauge (59029041100) ( p. 230)

» If play  is greater than the specified value:
– Change the piston and piston rings.
305604-10 – Check/measure the cylinder. ( p. 132)
– 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
305645-10 Use an old piston ring to clean the piston ring groove.
– 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.
16 ENGINE 134
– Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance . 
Guideline
Distance  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…
305603-10 4.01476 in)
Info
Piston size  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 .
Guideline
Piston ring end gap
305590-10 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. 132)
» 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 Determining the piston/cylinder mounting clearance

– Check/measure the cylinder. ( p. 132)
– Check/measure the piston. ( p. 133)
– The smallest piston/cylinder mounting clearance is the result of the smallest cylin-
der bore diameter minus the largest piston diameter. 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
305645-10 New condition 0.035… 0.060 mm (0.00138…
0.00236 in)
Wear limit 0.10 mm (0.0039 in)
16.4.16 Checking the 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 

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…
305663-10 0.0031 in)
16 ENGINE 135
» If the measured value does not meet specifications:

– Change the oil pump and, if necessary, the engine case.
305661-10
– Check the internal rotor and external rotor of oil pumps  for damage and wear.
– Change the oil pumps.
– Check oil pump shafts  for damage and wear.
– Change the oil pump shaft.
– Check both oil pump covers for damage and wear.
– Change the oil pump cover.
16.4.17 Replacing autodecompressor

– Take the lock ring  off the autodecompression shaft and dispose of it.
300107-10
– Pull the autodecompression shaft  from the camshaft.
300108-10
16 ENGINE 136
– Disconnect the autodecompression spring. Loosen the screw 

and remove it
together with the autodecompression spring and the autodecompression weight .
300109-10
– When assembling, first connect the autodecompression spring and then insert the
screw through the autodecompression weight.
The arm of the autodecompression spring  is long enough to pass right
through the autodecompression weight.
– Position the autodecompression weight. Mount and tighten screw . Reconnect
the autodecompression spring.
Guideline
Screw, autodecompression M6 3… 4 Nm Loctite® 243™
300110-10 (2.2…
3 lbf ft)
– 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 ENGINE 137
16.4.19 Checking the timing assembly
305601-10
– Clean all parts well.

– Check timing chain gear  for damage and wear.
– Change the timing chain gear/timing chain sprocket.
– Check timing chain tensioning rail  for damage and wear.
– Change the timing chain tensioning rail.
– Check timing chain guide rail  for damage and wear.
– Change the timing chain guide rail.
– Check timing chain securing guide  for damage and wear.
– Change the timing chain securing guide.
– Check timing chain  for damage and wear.
– Change the timing chain.
– Check that the timing chain links move easily. Let the timing chain hang down freely.
» If the chain links no longer straighten out:
– Change the timing chain.
– Check timing chain sprocket  for damage and wear.
– Change the timing chain gear/timing chain sprocket.
16 ENGINE 138
16.4.20 Removing the rocker arm

– Take shims  out of the valve spring retainers and lay them to one side according
to their normal built-in position.
305664-10
305665-10
– Screw a suitable screw  into the rocker arm shafts . Pull out the rocker arm
shafts.
– Take off rocker arm .
305666-10
16.4.21 Changing the camshaft bearing

Preparatory work
– Remove the rocker arm. ( p. 138)
Main work
– Mount the cylinder head on the special tool.
Clamping plate (75029050000) ( p. 235)
305668-10
– Remove the large camshaft bearing using special tool .

Push-out drift (75029051000) ( p. 235)
Info
Brace the back of the special tool with a suitable tool .
305669-10
16 ENGINE 139
– Remove the small camshaft bearing using special tool .

Insert for bearing puller (15112018100) ( p. 228)
Bearing puller (15112017000) ( p. 228)
305670-10
– Press in the small camshaft bearing as far as possible using special tool .
Push-in drift (75029044020) ( p. 234)
305671-10
– Press in the large camshaft bearing as far as possible using special tool .
Push-in drift (75029044010) ( p. 234)
305672-10
Finishing work
– Install the rocker arm. ( p. 142)
16.4.22 Removing the valves

– Pretension the valve springs using the special tool.
Valve spring compressor (59029019000) ( p. 230)
Valve spring mounting device (78029060000) ( p. 237)
– Remove the valve keys and release the tension on the valve springs.
– Remove the spring retainer and spring.
– Pull the valve down and out of the valve guide, and remove the valve stem seal and
valve spring seat.
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 ENGINE 140
16.4.23 Checking the valves

– Check the run-out at the valve plate.
Valve - run-out
On the valve plate ≤ 0.05 mm (≤ 0.002 in)
– Change the valve.
305605-10
– Check sealing seat  on the valve.

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

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:
302809-10
– 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)
305593-10 » 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)
– Change the valve spring retainer.
305594-10
16.4.26 Checking the cylinder head

– Check valve guides  with the special tool.
Limit plug gauge (59029026006) ( p. 230)
» 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
cracking.
» If there is damage or cracking:
305595-10 – Change the cylinder head.
16 ENGINE 141
– Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) ( p. 230)
Cylinder/cylinder head - sealing area ≤ 0.10 mm (≤ 0.0039 in)

distortion
– Change the cylinder head.
305592-10
– Check sealing seat  of the valves.


– Machine the valve seat.
302808-10
16.4.27 Installing the valves

– Position the valve spring seat . Mount the new valve stem seals .
– Mount valves  according to their normal built-in position.
– Mount valve springs  and the spring retainers.
305596-10
– Pretension the valve springs using the special tool.

Valve spring compressor (59029019000) ( p. 230)
Valve spring mounting device (78029060000) ( p. 237)
– Mount the 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.
300116-11
16 ENGINE 142
16.4.28 Installing the rocker arm

– Position rocker arm  and push in the rocker arm shafts .
Info
Make sure that the tapped hole of the rocker arm shaft is facing outward.
The small drill hole  and the flat surface must face upward.
– Remove screw .
305667-10

Guideline
Screw, rocker arm shaft M6x30 12 Nm (8.9 lbf ft)
305665-11
– Place shims  into the valve spring retainers according to their normal built-in
position.
305664-11
16.4.29 Disassembling the antihopping clutch

– Clamp the clutch  in a vise.
Info
Use soft jaws.
– Carefully loosen and gradually remove the special tool .
300120-10
16 ENGINE 143
– Take the clutch out of the vise and lay it on a clean workbench with the outer
clutch hub  facing down.
– Take the inner clutch hub  and release springs  out of the outer clutch
hub  .
300121-10
–  from the inner clutch hub.

Take off the clutch facing discs
– Remove pretension ring  and support ring .
– Clean all parts well.
– Check the clutch. ( p. 143)
300122-10
16.4.30 Checking the clutch

Preparatory work
– Disassemble the antihopping clutch. ( p. 142)
305657-10
Main work
– Check pressure piece  for damage and wear.
– Change the pressure piece.
– Check axial bearing  for damage and wear.
– Change the axial bearing.
16 ENGINE 144
– Place push rod  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 .
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  for damage and wear.
– Change the pressure cap.
– Check the contact surfaces of the clutch facing discs in the clutch basket  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 clutch basket.
– Check needle bearing  and supporting plate  for damage and wear.
– Change the needle bearing and supporting plate.
– Check the intermediate clutch discs  for damage and wear.
» If the intermediate clutch discs are not even or are pitted:
– Change all intermediate clutch discs.
– Check clutch facing discs  for discoloration and scoring.
» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs .
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  for damage and wear.
– Change the stepped washer.
– Check half washers  for damage and wear.
– Change the half washers.
– Check inner clutch hub  for damage and wear.
– Change the inner clutch hub.
– Check the outer clutch hub  for damage and wear.
– Change the outer clutch hub.
Finishing work
– Preassemble the antihopping clutch. ( p. 144)
16.4.31 Preassembling the antihopping clutch

– Thoroughly oil the clutch facing discs.
– Push the support ring  and the pretension ring  on to the outer clutch hub.
Info
The pretension ring must be installed so that it is flush with the inner
edge  on the support ring.
300123-10
16 ENGINE 145
– 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 .
300124-10
– Push on the outer clutch hub  and pay attention to the markings.
The arrow  of the outer clutch hub must point to the notch  of the inner
clutch hub.
– Push the two clutch hubs firmly together and have an assistant screw in the special
tool.
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.
16.4.32 Checking the shift mechanism
305597-10
– Check shift forks  (see ) for damage and wear (visual check).
– Change the shift fork and gear wheel pair.
– Check shift grooves  of shift drum  for wear.
» If the shift groove is worn:
– Change the shift drum.
16 ENGINE 146
– Check the seat of the shift drum in bearings .

» If the shift drum is not seated correctly:
– Change the shift drum and/or the bearing.
– Check bearing  for stiffness and wear.
» If the bearings do not move freely or are worn:
– Change the bearings.
– Check needle bushing  for stiffness and wear.
» If the needle bushing does not move freely or is worn:
– Change the needle bushing.
– Check shift rail  on a flat surface for run-out.
» If there is run-out:
– 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  in contact areas  for wear.
» If the sliding plate is worn:
– Change the sliding plate.
– Check return surface  on the sliding plate for wear.
» If deep notches are present:
– Check guide pin  for looseness and wear.
» If the guide pin is loose and/or worn:
– Preassemble the shift shaft. ( p. 146)
– Check play  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)
305598-10
16.4.33 Preassembling the shift shaft

– Fix the short end of the shift shaft in a vise.
Guideline
Use soft jaws.
– Mount sliding plate  with the guide pin facing down and attach the guide pin to
the shift quadrant.
– Mount pressure spring .
– Push on spring guide , push return spring  over the spring guide with the
offset end facing upward and lift the offset end over abutment bolt .
305599-10
– Mount stop disk .
16 ENGINE 147
16.4.34 Disassembling the main shaft
306232-10
– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
– Remove stop disk  and second-gear fixed gear .
– Remove the sixth-gear idler gear .
– Remove the split needle bearing  and stop disk .
– Remove lock ring .
Info
Open the lock ring with a screwdriver and twist it off the transmission shaft with pliers.
– Remove the third/fourth-gear sliding gear .

– Remove lock ring.
– Remove stop disk and fifth-gear idler gear .
– Remove bearing bush .
16 ENGINE 148
16.4.35 Disassembling the countershaft
306233-10
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Remove stop disk  and first-gear idler gear .
– Remove needle bearing  and stop disk .
– Remove fifth-gear sliding gear  and lock ring .
Info
Open the lock ring with a screwdriver and twist it off the transmission shaft with pliers.
– Remove stop disk  and third-gear idler gear .

– Remove needle bearing  and the fourth-gear idler gear .
– Remove needle bearing  and stop disk .
– Remove lock ring  and sixth-gear sliding gear .
– Remove lock ring  and stop disk .
– Remove the second-gear idler gear  and bearing bush .
16.4.36 Checking the transmission

Condition
The transmission has been disassembled.
16 ENGINE 149
305674-10
– Check needle bearings  for damage and wear.

– Change the needle bearing.
– Check the pivot points of main shaft  and countershaft  for damage and wear.
– Change the main shaft and/or countershaft.
– Check the tooth profiles of main shaft  and countershaft  for damage and wear.
– Change the main shaft and/or countershaft.
– Check the pivot points of idler gears  for damage and wear.
– Change the gear wheel pair.
– Check the shift dogs of idler gears , sliding gears , and fixed gear  for damage and wear.
– Check the tooth faces of idler gears , sliding gears , and fixed gear  for damage and wear.
– Check the tooth profiles of sliding gears  for damage and wear.
– Check sliding gears  for smooth operation in the profile of main shaft .
» If the sliding gear does not move easily:
– Change the sliding gear or the main shaft.
– Check sliding gears  for smooth operation in the profile of countershaft .
» If the fixed gear does not move easily:
– Change the sliding gear or the countershaft.
16 ENGINE 150
– Check stop disks  for damage and wear.

– Change the stop disk.
– Use new lock rings in every repair job.
– Check bearing bush  for damage and wear.
– Change the bearing bush.
16.4.37 Assembling the main shaft
Info
Use new lock rings in every repair job.
Preparatory work
– Lubricate all parts carefully before assembling.
– Check the transmission. ( p. 148)
306234-10
Main work
– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Lubricate and mount bearing bush .
– Push on the fifth-gear idler gear  with the shift dogs facing upward.
– Mount stop disk  .
– Position special tool  on the transmission shaft.
Mounting tool for lock ring (75029005000) ( p. 233)
– Position lock ring  on special tool  and push down with sleeve .
The lock ring engages in the groove of the transmission shaft.
16 ENGINE 151
– Push on the third/fourth-gear sliding gear  with the small gear wheel facing downward.
– Position lock ring  on special tool  and push down with sleeve .
– Push on stop disk and split needle bearing .
–  with the shift dogs facing downward.
Push on the sixth-gear idler gear
– Push on the second-gear fixed gear  with the collar facing downward and mount stop disk .
– Finally, check all gear wheels for smooth operation.
16.4.38 Assembling the countershaft
Info
Use new lock rings in every repair job.
Preparatory work
– Lubricate all parts carefully before assembling.
– Check the transmission. ( p. 148)
306235-10
Main work
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Mount bearing bush  and the second-gear idler gear  on the countershaft with the protruding collar facing downward.
– Mount stop disk .
– Position lock ring  on special tool  and push down with sleeve .
16 ENGINE 152
– Mount the sixth-gear sliding gear  with the shift groove facing upward.
– Position lock ring  on special tool  and push down with sleeve .
– Mount stop disk .
– Mount needle bearing  and the fourth-gear idler gear  with the collar facing upward.
– Mount needle bearing  and the third-gear idler gear  with the collar facing downward.
– Mount stop disk .
– Position lock ring  on special tool  and push down with sleeve .
–  with the shift groove facing downward and stop disk .
Mount the fifth-gear sliding gear
– Mount needle bearing , first-gear idler gear  with the recess facing downward and stop disk .
– Finally, check all gear wheels for smooth operation.
16.4.39 Checking the starter drive
305600-10
– Check the teeth and seating of the starter idler gear  for damage and wear.
– Change the starter idler gear and/or needle bushing.
– Check the teeth and seating of torque limiter  for damage and wear.
– Change the torque limiter and/or needle bearing.
– Check freewheel gear  and bearing when removed for damage and wear.
16 ENGINE 153
– Change the freewheel gear and/or the bearing.

– Check freewheel  when removed for damage and wear.
– Change the freewheel.
– Check the toothing of starter motor  for damage and wear.
– Change the starter motor.
– Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Briefly connect the positive cable of the
power supply to the starter motor connection.
» If the starter motor does not turn when the circuit is closed:
– Change the starter motor.
– Change O-ring  of the starter motor.
16.4.40 Checking freewheel
– Insert the freewheel gear  in the primary gear , turning the primary gear
clockwise; do not twist!
– Check the locking action of the freewheel gear .
» If the primary gear does not turn clockwise or if it does not lock counterclock-
wise:
– Remove the freewheel. ( p. 153)
– Turn the freewheel 180°.
– Install the freewheel. ( p. 153)
300131-10
16.4.41 Removing freewheel

– Extract the lock ring  from the groove using suitable pliers.
300127-10
– Compress the expansion ring  and remove it, using suitable pliers.
– Take the freewheel  out of the primary gear.
300128-10
16.4.42 Installing freewheel

– Lubricate all parts thoroughly.
– Push the freewheel  into the primary gear.
Info
Note the direction of rotation.
300129-10
16 ENGINE 154
– Install the expansion ring .
300128-11
– Make sure that all lugs of the expansion ring locate in the slits  of the freewheel.
Info
If necessary, use a screwdriver to ease them in.
300130-10
– Insert the lock ring  into the groove with suitable pliers and check that it is
seated correctly.
300127-11
16.5 Assembling the engine

16.5.1 Installing the transmission shafts
– Clamp the right section of the engine case.
Holder for engine assembly stand (75012001070) ( p. 232)
Support for engine assembly stand (75012001060) ( p. 232)
Engine assembly stand (61229001000) ( p. 232)
– Make sure that both stop disks are installed.
– Mount the inner bearing race  on the countershaft.
305652-10
– Oil all bearings.

– Assemble the two transmission shafts and slide them into the bearing seats
together.
305642-11
16 ENGINE 155
– Mount the upper shift fork , the middle shift fork , and the lower shift
fork  .
Info
For easier assembly of the middle shift fork , lift the sliding gear of the
third/fourth gear.
305643-10
– Insert shift drum  into the bearing seat.

– Hang the shift forks into the shift drum.
305639-11
– Mount shift rail .

– Check the transmission for smooth operation.
305638-11
– Mount the washer and lock ring .
305641-11
16.5.2 Installing crankshaft and balancer shaft

– Mount the special tool  on the alternator side of the crankshaft.
Mounting sleeve (75029080000) ( p. 236)
– Mount the special tool  on the balancer shaft.
Mounting sleeve (58529005000) ( p. 229)
302136-10
16 ENGINE 156
– Push the crankshaft into the bearing seat and take off the special tool.
– Grease the shaft seal rings of the balancer shaft.
–  into the bearing seat and take off the special tool.
Push the balancer shaft
Align marks  and .
– Mount stop disk .
305644-10
16.5.3 Installing the left engine case

– Mount the dowels.
– Mount O-ring .
– Degrease the sealing area. Apply the sealing compound to the left section of the
engine case.
Loctite® 5910
305635-10
– Put on the left section of the engine case. If necessary, tap lightly with a rubber
mallet and turn the transmission shafts.
Info
Do not tighten the engine case sections using the screws.
– Mount screw  but do not tighten it yet.

Guideline
Screw, engine case M6x80 10 Nm (7.4 lbf ft)
305636-10
– Mount screw  but do not tighten it yet.
Guideline
– Mount screws  but do not tighten yet.
Guideline
– Mount screw  with washer but do not tighten it yet.
Guideline
Info
Mount the screw with a new copper washer.
– Tighten all screws in a crisscross pattern.

Guideline
Screw, engine case M6 10 Nm (7.4 lbf ft)
16 ENGINE 157
16.5.4 Installing the oil pumps

– Mount the pin and internal rotor on the oil pump shaft.
– Position the external rotor in the engine case.
The marking is not visible after mounting.
– Mount the oil pump shaft  with internal rotor .
– Oil the parts.
305630-10
– Position the oil pump cover.

Guideline
Screw, oil pump cover M5 6 Nm Loctite® 243™
(4.4 lbf ft)
305628-11
– Mount the pin and internal rotor on the oil pump shaft.
– Position the external rotor in the engine case.
The marking is not visible after mounting.
– Mount the oil pump shaft  with internal rotor .
– Oil the parts.
305631-10
– Position the oil pump cover.

Guideline
Screw, oil pump cover, top M5 6 Nm Loctite® 243™
(4.4 lbf ft)
Guideline
305626-11 Screw, oil pump cover, M6 10 Nm Loctite® 243™
bottom (7.4 lbf ft)
– Mount washers and pins .
305625-11
– Mount the oil pump gear wheels , washers  and lock washers .
305624-11
16 ENGINE 158
16.5.5 Installing locking lever

–  with sleeve and spring .
Position locking lever
Guideline
Screw, locking lever M6x20 10 Nm Loctite® 243™
(7.4 lbf ft)
305623-10
16.5.6 Installing shift drum locating

– Press locking lever  down and position shift drum locating.
Info
The flat surfaces  of the shift drum locating are not symmetric.
305620-10
– Release the locking lever.

Guideline
Screw, shift drum locating M6x30 10 Nm Loctite® 243™
(7.4 lbf ft)
305621-10
16.5.7 Installing shift shaft

– Slide shift shaft with the washer into the bearing seat.
– Push sliding plate  away from the shift drum locating . Insert the shift shaft
all the way.
– Let the sliding plate engage in the shift drum locating.
– Shift through the transmission.
305618-11
16.5.8 Installing the starter drive

– Mount the two needle bearings  and the woodruff key .
305617-11
16 ENGINE 159
– Position freewheel gear .
305616-11
– Mount the needle bearing and torque limiter  with the washer.
– Mount lock ring .
305615-11
– Mount the starter idler gear  with the washer.

– Mount lock ring .
305614-11
16.5.9 Installing the primary gear

– Ensure that the woodruff key is seated properly.
– Mount primary gear .
Info
Turn freewheel gear  backwards and forwards to ease meshing.
305586-10
16.5.10 Installing the clutch basket

– Mount supporting plate  and needle bearing .
305583-11
16 ENGINE 160
– Mount clutch basket .

Info
Turn the clutch basket and oil pump gear wheels backwards and forwards
slightly to help them mesh more easily.
– Mount half washers  with the sharp edge facing outward.

Info
305582-11 Grease the half washers to ease assembly.
– Position stepped washer  with the recesses toward the half washers.
305581-11
– Insert the antihopping clutch in the clutch basket.

The uppermost clutch facing disc is offset by one tooth.
Info
If necessary, turn the main shaft a little to ease access.
305580-10
– Mount the new lock washer  with nut .

– Lock the clutch basket and primary gear using 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. 236)
305584-10
Info
– Secure the nut with the lock washer.

– Mount and tighten nut .
Guideline
Nut, primary gear M20LHx1.5 90 Nm Loctite® 243™
(66.4 lbf ft)
Gear segment (75029081000) ( p. 236)
– Mount pressure piece .
305578-11
16 ENGINE 161
– Position pressure cap .

– Mount and tighten screws  with the spring retainers and clutch springs.
Guideline
Screw, clutch spring M5x25 6 Nm (4.4 lbf ft)
Info
Ensure that all clutch springs have a blue color coding.
305577-11
– Remove special tool .

305576-11
16.5.11 Installing the spacer and spring

– Position spacer  and spring .
305575-10
16.5.12 Installing the clutch cover

– Mount dowels  and position the clutch cover gasket .
305574-11
– Position the clutch cover.

– Mount screws  but do not tighten yet.
Guideline
Screw, clutch cover M6x30 10 Nm (7.4 lbf ft)
– Mount screw  but do not tighten it yet.
Guideline
305587-10 – Mount screws  and tighten all screws in a crisscross pattern.
Guideline
16 ENGINE 162
16.5.13 Installing the ignition pulse generator

– Position the ignition pulse generator.
– Mount screws  but do not tighten yet.
Guideline
Screw, crankshaft position M6x16 10 Nm Loctite® 243™
sensor (7.4 lbf ft)
– Position the cable and position cable sleeve  in the engine case.
305572-10
16.5.14 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 .
305570-11
– Thread the timing chain  in and lay it over the timing chain sprocket.
Info
If the timing chain is not new, pay attention to the direction of travel.
305569-11
16.5.15 Installing the timing chain rails

– Position the timing chain securing guide .
The ignition pulse generator cable is routed in the cable duct of the timing
chain securing guide.
305567-10
– Position the timing chain tensioning rail  from above.

– Insert the support bushing into the timing chain securing guide.
305566-11
16 ENGINE 163
– Position the timing chain guide rail  from above.

– Insert the support bushing into the timing chain securing guide.
Guideline
Screw, timing chain guide M6x30 10 Nm Loctite® 243™
rail (7.4 lbf ft)
Screw, timing chain ten- M6x30 10 Nm Loctite® 243™
sioning rail (7.4 lbf ft)
305568-10
Info
Ensure that there is no thread locking material at the collar of the screw;
otherwise, the timing chain tensioning rail could lock and break.
– Check both timing chain rails for freedom of movement.
16.5.16 Installing the rotor

– Ensure that woodruff key  is seated properly.
– Degrease the cone of the crankshaft and rotor.
– Mount the rotor.
Info
305563-10
– Hold the rotor with special tool .

Holding spanner (75029091000) ( p. 236)
– Mount and tighten nut  with the locking edge washer.
Guideline
Rotor nut M18x1.5 100 Nm
(73.8 lbf ft)
305561-10
16.5.17 Adjusting crankshaft position sensor distance

– Adjust the distance between the crankshaft position sensor  and the conductive
element of the rotor using the special tool .
Guideline
Crankshaft position sensor/rotor - 0.70 mm (0.0276 in)
distance
Feeler gauge (59029041100) ( p. 230)

– Fully tighten screws .
305564-10 Guideline
Screw, crankshaft position M6x16 10 Nm Loctite® 243™
sensor (7.4 lbf ft)
16 ENGINE 164
16.5.18 Setting engine to top dead center

– Set the crankshaft to top dead center and lock it with the special tool .
305560-10
16.5.19 Mounting the water pump cover

– Mount form washer .
305558-11
– Mount water pump impeller.

Guideline
Screw, water pump M6x15 10 Nm Loctite® 243™
impeller (7.4 lbf ft)
– Lay on the water pump cover seal .
305559-10
– Position the water pump cover.

Guideline
Screw, water pump cover M6x30 10 Nm (7.4 lbf ft)
305556-11
16.5.20 Installing piston

– Shift the joint of the piston rings by 120°.
– Push the oiled piston into the special tool.
Piston assembly ring (75029015102) ( p. 233)
302600-10
16 ENGINE 165
– 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.
302601-10
– Ensure that piston marking  faces the outfeed side.
302599-10
– Apply a thin layer of sealing compound in area .

Loctite® 5910
– Place the cylinder base gasket on.
Info
Make sure the grooved pins are seated correctly.
305553-10
– 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.
305554-10
– Position the piston pin retainer.
400366-10
16 ENGINE 166
– 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. 233)
– Make sure that the piston pin retainer is seated correctly on both sides.
300038-10
– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let the
grooved pins engage.
305555-10
16.5.21 Installing the cylinder head

– Put on the cylinder head gasket.
Info
Make sure the grooved pins are seated correctly.
– Mount the cylinder head.

– Mount and tighten screws  with the washers.
Guideline
Cylinder head screw M10 Tightening Lubricated with
305545-11
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.

Guideline
Cylinder head screw M6x25 10 Nm Loctite® 243™
(7.4 lbf ft)
305544-11
16 ENGINE 167
16.5.22 Installing the camshafts

– Lay the timing chain over the camshaft. Push the camshaft into the bearing seats.
The crankshaft is at top dead center.
The middle drill hole of camshaft  and the drill hole of cylinder head 
are aligned.
305548-10
– Position the camshaft support plate . Mount and tighten screw .

Guideline
Screw, camshaft support M6x12 10 Nm Loctite® 243™
plate (7.4 lbf ft)
Marking  of the camshaft is aligned with the marking of the camshaft sup-
port plate.
305547-10
16.5.23 Installing timing chain tensioner

– Insert the timing chain tensioner .
– Mount and tighten plug  with the new seal ring.
Guideline
Plug, timing chain tensioner M20x1.5 25 Nm
(18.4 lbf ft)
305540-10
16 ENGINE 168
– Remove screw and use the special tool to push the timing chain tensioner
toward the timing chain.
Release device for timing chain tensioner (77329051000) ( p. 237)
The timing chain tensioner unlocks.
Guideline
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft)
sioner
305541-10
16.5.24 Checking valve clearance

– Remove special tool .
– Crank the engine several times.
– Set the engine to ignition top dead center. ( p. 113)
305533-10
– Check the valve clearance on all valves between the valve and the rocker arm using
the special tool 
.
Guideline
Valve play, cold 0.07… 0.13 mm (0.0028…
0.0051 in)
Feeler gauge (59029041100) ( p. 230)

» If valve clearance does not meet specifications:
305534-10 – Adjust the valve clearance. ( p. 169)

– Mount and tighten screw  with the washer.
Guideline
Screw plug, crankshaft clamp M8 20 Nm
(14.8 lbf ft)
306140-10
16 ENGINE 169
16.5.25 Adjusting the valve clearance

Info
Make sure that the crankshaft is at top dead center.
305535-10
– Screw suitable screws  into the rocker arm shafts .

– Remove the rocker arm shafts and take off the rocker arm.
305536-10
– Remove shims  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.
305538-10
– Position the rocker arms and mount the rocker arm shafts.
The tapped hole of the rocker arm shaft faces outward.
Drill hole  and the flat surface face upward.
305537-10

Guideline
Guideline
– Check the valve clearance. ( p. 168)
305535-11
16 ENGINE 170
16.5.26 Installing the spark plugs

– Mount and tighten spark plug  using the special tool.
Guideline
Spark plug inside M12x1.25 18 Nm
(13.3 lbf ft)

– Mount and tighten spark plug  using the special tool.
Guideline
305516-10
Spark plug outside M10x1 11 Nm (8.1 lbf ft)
16.5.27 Installing the thermostat

– Position thermostat  with the gasket.
Drill hole  must face upward.
305529-10
– Position the thermostat case.

Guideline
Screw, thermostat case M6x20 10 Nm Loctite® 243™
(7.4 lbf ft)
305530-10
16.5.28 Installing the oil filter

– Insert oil filter .
– Oil the O-ring of the oil filter cover and mount it with the oil filter cover.
Guideline
Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft)
305527-10
– Insert oil filter .

– Oil the O-ring of the oil filter cover and mount it with the oil filter cover.
Guideline
305550-10
16 ENGINE 171
16.5.29 Installing the gear position sensor

– Mount gear position sensor with the O-ring.
Pin  engages in drill hole .
201958-10
– Mount and tighten screws  with the washers.

Guideline
Screw, gear position sen- M5x16 5 Nm Loctite® 243™
sor (3.7 lbf ft)
201959-10
16.5.30 Installing the spacer

– Grease spacer  in area  and O-ring  before mounting.
– Position the O-ring in the recess of the spacer.
302140-10
– Grease the shaft seal ring.

– 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.
305521-10
16.5.31 Installing the alternator cover

– Apply sealing compound lightly in the area of the cable sleeve.
– Mount dowel  and position the alternator cover gasket .
305520-11
16 ENGINE 172
– Position the alternator cover.

Guideline
Screw, alternator cover M6x25 10 Nm (7.4 lbf ft)
Guideline
Screw, alternator cover M6x30 10 Nm (7.4 lbf ft)
305519-10 – Mount and tighten screw .
Guideline
Screw, alternator cover M6x25 10 Nm Loctite® 243™
(chain shaft through-hole) (7.4 lbf ft)
16.5.32 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.
305510-10
– Mount the oil drain plug  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  with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
305508-10
–  with O-rings.
Position the oil screen
– Mount and tighten screw plug  with the O-ring.
Guideline
(11.1 lbf ft)
305511-10
16.5.33 Installing the starter motor

– Grease the O-ring and mount the starter motor.
– Mount and tighten oil throttle .
Guideline
Screw, starter motor with M6 10 Nm Loctite® 243™
oil throttle (7.4 lbf ft)
305513-10
16 ENGINE 173
16.5.34 Installing the valve cover

– Position the valve cover with the gasket.
Guideline
Screw, valve cover M6 10 Nm (7.4 lbf ft)
305517-10
16.5.35 Removing the engine from the engine assembly stand

– Remove the engine from the engine assembly stand.
Info
Have an assistant help you or use a motorized hoist.
305506-11
17 CLUTCH 174
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.
– 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. 225)
B01956-10
17.2 Changing the hydraulic clutch fluid
Warning
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Fill bleeding syringe  with the appropriate hydraulic fluid.
Bleed syringe (50329050000) ( p. 229)
Hydraulic fluid (15) ( p. 225)
– On the clutch slave cylinder, remove bleeder screw  and mount bleeding
syringe .
– Inject the liquid into the system until it escapes from hole  of the master cylin-
der 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)
202086-10
18 SHIFT MECHANISM 175
18.1 Changing the gear position sensor

Preparatory work
Main work
– Remove screw . Take off the engine sprocket cover.
G00772-10
– Remove cable binder .
G00773-10
– Disconnect plug-in connector .
G00774-10
– Remove cable binder .

– Expose the cable.
G00775-10
– Take off the gear position sensor.
G00776-10
– Lubricate O-ring  of the new gear position sensor.

– Position the gear position sensor.
Pin  engages in drill hole .
G00777-10

Guideline
Screw, gear position sen- M5x16 5 Nm Loctite® 243™
sor (3.7 lbf ft)
G00776-10
– Secure the wiring harness with cable binder .
G00775-10
– Connect plug-in connector .

– Route the cable without tension.
G00774-10
– Secure the connector with cable binder .
G00773-10
– Position the engine sprocket cover.

Guideline
– Mount and tighten screw .
Guideline
G00772-11 (18.4 lbf ft)
Finishing work
– Program the gear position sensor. ( p. 177)
18.2 Programming the gear position sensor

Condition
The diagnostics tool is connected and running.
Preparatory work
– Reset the control unit engine electronics KHRS.
Main work
– Execute "Engine electronics" > "Functions" > "Program the gear position sensor".
– Switch to the main menu.
– Switch the ignition off and on again.
The green idling speed indicator lamp N lights up.
19 WATER PUMP, COOLING SYSTEM 178
19.1 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 . Take off the radiator cap.
– Completely drain the coolant.
– Mount screw  with a new seal ring and tighten it.
Guideline
Plug, drain hole of water pump M10x1 15 Nm
(11.1 lbf ft)
102016-10
19.2 Filling/bleeding the cooling system
Warning
children.
– Stand the motorcycle on its side stand on a horizontal surface.

– Remove radiator cap .
102015-11
– Refill the coolant.

Alternative 1
Coolant ( p. 224)
Alternative 2
Coolant (mixed ready to use) ( p. 224)
– Fill the radiator completely with coolant. Mount radiator cap .
102017-10
– Remove the cap from compensating tank  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
102018-10 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. 180)
19.3 Checking the antifreeze and coolant level
Warning
Warning
children.
Condition
Engine is cold.
– Remove the cap of compensating tank .
– 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.
102014-10
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. 224)
Alternative 2
– Mount the cap of the compensating tank.
– Screw off the radiator cap .
– 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.
102015-10

– Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 224)
Alternative 2
– Mount the radiator cap.
19.4 Checking the coolant level
Warning
Warning
children.
Condition
Engine is cold.
– Check the coolant level in the compensating tank .
The coolant level must be within the range shown in the figure.
– Correct the coolant level.
Alternative 1
Coolant ( p. 224)
102014-10
Alternative 2
– Screw off the radiator cap  and check the coolant level in the radiator.
The radiator must be completely filled.
– Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 224)
Alternative 2
102015-10
– Mount the radiator cap.
20 LUBRICATION SYSTEM 181
20.1 Oil circuit
402053-60
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
20.2 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.
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:
C00182-10
– Add the engine oil. ( p. 186)
20.3 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
Main work
S00101-10
– 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. 237)

– Connect the pressure tester to the special tool without the T-plate.
Pressure testing tool (61029094000) ( p. 232)
S00102-10
Danger
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)
– Change the oil filter. Check the 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.

Guideline
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft)
sioner
Finishing work
20.4 Changing the engine oil and filter, cleaning the oil screens
– Drain the engine oil. ( p. 183)
– Remove the oil filter. ( p. 184)
– Clean the oil screens. ( p. 185)
– Install the oil filter. ( p. 184)
– Fill up with engine oil. ( p. 186)
601022-10
20.5 Draining the engine oil
Warning
Warning
Info
Drain the engine oil only when the engine is warm.

– Remove the oil drain plug  with the magnet and seal ring.
100200-10
– 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
20.6 Removing the oil filter
Warning
Warning
Preparatory work
Main work
– Remove screws . Remove the oil filter cover  with the O-ring.
– Pull oil filter  out of the oil filter housing.
102020-10
– Remove screws . Take off the oil filter cover  with the O-ring.
– Pull oil filter  out of the oil filter housing.
– Thoroughly clean the parts and sealing area.
102021-10
20.7 Installing the oil filter

– Insert oil filters  and .
– Oil the O-rings of the oil filter covers. Mount oil filter covers  and .
– Mount and tighten the screws.
Guideline
102022-10
20.8 Cleaning the oil screens
Warning
Warning
Preparatory work
Main work
– Remove screw plug  with oil screen  and the O-rings.
100205-10
– Remove screw plug  with oil screen  and the O-rings.

– Completely drain the remaining engine oil.
– Thoroughly clean the parts and sealing area.
100206-10
–  with the O-rings.

Position oil screen
– Mount and tighten screw plug  with the O-ring.
Guideline
(11.1 lbf ft)
100207-10
–  with the O-rings.

Position oil screen
– Mount and tighten screw plug  with the O-ring.
Guideline
(11.1 lbf ft)
100208-10
20.9 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  from the clutch cover and add engine oil.
1
0 Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 224)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 224)
– Refit plug with O-ring  and tighten it.
401955-10
Danger
– Start the engine and check that it is oil-tight.

Finishing work
20.10 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  with the O-ring from the clutch cover and fill up with
1
0 engine oil.
Engine oil (SAE 10W/60) (00062010035) ( p. 224)
Engine oil (SAE 10W/50) ( p. 224)
Info
For optimal performance of the engine oil, do not mix different types of
401955-10 engine oil.
If appropriate, change the engine oil.
– Install and tighten the oil filler plug  with the O-ring.
Danger
– Start the engine and check that it is oil-tight.

Finishing work
21 IGNITION 187
21.1 Alternator - checking the stator winding

Condition
The stator is disconnected.
Preparatory work
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
Stator, connector EN pin 1 – Stator, connector EN pin 3
Alternator
Resistance of stator winding at: ≤1Ω
20 °C (68 °F)
600894-10 G00802-10
Stator winding - check for a short circuit to ground (terminal 31)

Stator, connector EN pin 1 – Measuring point Ground (−)
Resistance ∞Ω
21.2 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.
Measuring point 1 – Measuring point 2
Spark plug connector

Resistance at: 20 °C (68 °F) 4.3… 5.7 kΩ
– Change the spark plug connector.
600893-10
21 IGNITION 188
21.3 Ignition coil – checking the secondary winding

Condition
Ignition coil cylinder 1 is disconnected.
Spark plug connector cylinder 1 has been removed.
Preparatory work
Main work
Ignition coil cylinder 1 – check the secondary winding resistance
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 does not correspond to the nominal value:
600739-13
– Change the ignition coil.
22 THROTTLE VALVE BODY 189
22.1 Performing the initialization run

Condition
The diagnostics tool is connected and running.
– Execute "Engine electronics" > "Functions" > "Delete adaptation values".
The adaptation values are deleted.
– Switch off ignition.
– Disconnect the diagnostics tool.
Danger
401897-01
– Start the engine without activating the throttle grip.

Guideline
Coolant temperature < 25 °C (< 77 °F)
– Let the engine idle for at least 10 minutes (600 seconds).
Info
Do not activate the throttle grip during the initialization process.
– Switch off the ignition after 10 minutes (600 seconds).
Info
If initialization is not completed or if the initialization process was inter-
rupted, the entire process must be restarted.
23 TECHNICAL DATA 190
23.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 690 cm³ (42.11 cu in)
Stroke 84.5 mm (3.327 in)
Bore 102 mm (4.02 in)
Compression ratio 12.6:1
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 Piston pin with DLC coating
Pistons Forged light alloy
Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication Semi-dry sump lubrication system with two rotor pumps
Primary transmission 36:79
Clutch APTC™ antihopping clutch in oil bath/hydraulically operated
Transmission 6-gear, 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
Inside spark plug NGK LKAR8BI-9
Outside spark plug NGK LMAR7A-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
23.2 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)

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)
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 0.30… 0.60 mm (0.0118… 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)
Coolant temperature: ≥ 70 °C (≥ 158 °F) ≥ 1.5 bar (≥ 22 psi)
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.
23.3 Engine tightening torques

Screw, membrane fixation M3 2 Nm (1.5 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™
Remaining screws, engine M5 6 Nm (4.4 lbf ft) –
Screw, breather cover on valve cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, clutch spring M5x25 6 Nm (4.4 lbf ft) –
Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft) –
Screw, gear position sensor M5x16 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) –
Screw, oil pump cover, top M5 6 Nm (4.4 lbf ft) Loctite® 243™
Cylinder head screw M6x25 10 Nm (7.4 lbf ft) Loctite® 243™
Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite® 243™
Remaining screws, engine M6 10 Nm (7.4 lbf ft) –
Screw, alternator cover M6x25 10 Nm (7.4 lbf ft) –
Screw, alternator cover (chain shaft M6x25 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, 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, crankshaft position sensor M6x16 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, ignition coil M6 10 Nm (7.4 lbf ft) –
Screw, locking lever M6x20 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, oil pump cover, bottom M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, rocker arm shaft M6x30 12 Nm (8.9 lbf ft) –
Screw, shift drum locating M6x30 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, starter motor M6x20 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, stator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, thermostat case M6x20 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain guide rail M6x30 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6x30 10 Nm (7.4 lbf ft) –
Screw, water pump impeller M6x15 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)
Oil line for oil pressure sensor M10x1 10 Nm (7.4 lbf ft) –
Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) –
Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) –
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 outside M10x1 11 Nm (8.1 lbf ft) –
Spark plug inside M12x1.25 18 Nm (13.3 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) –
23.4 Capacities
23.4.1 Engine oil
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 224)
Alternative engine oil Engine oil (SAE 10W/50)
( p. 224)
23.4.2 Coolant
Coolant 1.20 l (1.27 qt.) Coolant ( p. 224)
23.4.3 Fuel
Total fuel tank capacity, 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 225)
approx.
Fuel reserve, approx. 2.5 l (2.6 qt.)

23.5 Chassis
Frame Lattice frame made of chrome molybdenum steel tubing,
powder-coated
Fork WP Suspension 4860 ROTA SPLIT
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Suspension travel
Front 215 mm (8.46 in)
Rear 250 mm (9.84 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
Front 4.0 mm (0.157 in)
Rear 4.5 mm (0.177 in)
Tire air pressure, solo
Tire air pressure with passenger / fully loaded
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 890 mm (35.04 in)
Ground clearance unloaded 270 mm (10.63 in)
Weight without fuel, approx. 144 kg (317 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.)
23.6 Electrical system

Battery YTZ10S Battery voltage: 12 V
Nominal capacity: 8.6 Ah
maintenance-free
Fuse 58011109130 30 A
Fuse 58011109125 25 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
23.7 Tires
Front tires Rear tires
120/70 R 17 M/C 58H TL 160/60 R 17 M/C 69H TL
Continental Conti Attack SM Continental Conti Attack SM
Additional information is available in the Service section under:
http://www.ktm.com
23.8 Fork
Fork part number 14.18.8N.25
Fork WP Suspension 4860 ROTA SPLIT
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring length with preload spacer(s) 463 mm (18.23 in)
Spring rate
Medium (standard) 5.3 N/mm (30.3 lb/in)
Air chamber length 110+20
−30 mm (4.33−1.18 in)
+0.79
Fork length 895 mm (35.24 in)
Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 225)
23.9 Shock absorber

Shock absorber part number 15.18.7L.12
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring preload 20 mm (0.79 in)
Spring rate
Spring length 220 mm (8.66 in)
Static sag 20… 25 mm (0.79… 0.98 in)

Riding sag 70… 80 mm (2.76… 3.15 in)
Fitted length 395 mm (15.55 in)
Shock absorber fluid Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 225)
23.10 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 cover on spoiler EJOT 1 Nm (0.7 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) –
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 nuts, chassis M5 4 Nm (3 lbf ft) –
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 hose clamp on fuel tank M5 5 Nm (3.7 lbf ft) –
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) –
Screw, throttle grip M5 3.5 Nm (2.58 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, ABS control unit M6 5 Nm (3.7 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, fan hood M6 4 Nm (3 lbf ft) –
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) –

Screw, wheel speed sensor M6 6 Nm (4.4 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 2701™
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
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™
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™
Banjo bolt, brake line M10x1 20 Nm (14.8 lbf ft) –
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) –
24 CLEANING/PROTECTIVE TREATMENT 198
24.1 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
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. 226)
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. 80)
– Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Preserving materials for paints, metal and rubber ( p. 227)
– Treat all painted parts with a mild paint polish.
Perfect Finish and high gloss polish for paints ( p. 226)
Info
Do not polish parts that were matte when delivered as this would strongly
impair the material quality.
24 CLEANING/PROTECTIVE TREATMENT 199
– Treat all plastic parts and powder-coated parts with a mild cleaning and care agent.
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
( p. 227)
– Lubricate the ignition/steering lock.
Universal oil spray ( p. 227)
24.2 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. 198)

– 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. 80)

25 STORAGE 200
25.1 Storage
Warning
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.
– When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive ( p. 226)
– Refuel.
– Clean the motorcycle. ( p. 198)
– Change the engine oil and filter, clean the oil screens. ( p. 183)
– Check the antifreeze and coolant level. ( p. 179)
401058-01
– Check the tire air pressure. ( p. 70)
– Remove the battery. ( p. 82)
– Recharge the battery. ( p. 83)
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.

– 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.
25.2 Preparing for use after storage

– Take the motorcycle off of the front wheel stand. ( p. 11)
– Recharge the battery. ( p. 83)
– Install the battery. ( p. 82)
– Perform checks and vehicle care when preparing for use.
– Take a test ride.
401059-01
26 SERVICE SCHEDULE 201
26.1 Service schedule

Every 20,000 km (12,428 mi) or every 2 years
Every 10,000 km (6,214 mi) or annually or after every sporting use
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. 183) ○ ● ●
Check the front brake linings. ( p. 89) ○ ● ●
Check the rear brake linings. ( p. 93) ○ ● ●
Check the brake discs. ( p. 71) ○ ● ●
Check the brake lines for damage and leakage. ○ ● ●
Check the rear brake fluid level. ( p. 95) ○ ● ●
Check the free travel of the foot brake lever. ( p. 95) ○ ● ●
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. 70) ○ ● ●
Check the tire air pressure. ( p. 70) ○ ● ●
Check the spoke tension. ( p. 71) ○ ● ●
Check for rim run-out. ○ ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 78) ● ●
Check the chain tension. ( p. 77) ○ ● ●
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 brake fluid level of the front brake. ( p. 90) ○ ● ●
Bleed the fork legs. ( p. 15) ● ●
Check the steering head bearing play. ( p. 26) ○ ● ●
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 routing. ●
Check the antifreeze and coolant level. ( p. 179) ○ ● ●
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. 174) ● ●
Check the screws and nuts for tightness. ○ ● ●
Change the rear brake fluid. ( p. 97) ●
Change the rear brake fluid. ( p. 97) ●
Check the clutch. ●
Check the headlight setting. ( p. 101) ○ ● ●
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. ○ ● ●
○ One-time interval
● Periodic interval
202
1 2 3 4 5
G00401-01
6 7 8
-A11
/2.A6
A A
30
GF/48
30
-X1
gn
B B
wh-rd , wh-rd , wh-rd a /2.B1
bl-rd b /2.C1
bl , rd , rd
rd , rd
wh-rd
wh-rd
wh-rd
wh-rd
wh-rd
bl-rd
bl-rd
bl
bl
bl
C -X11 C
-X12 AU/2 -X19 -X119
2
1
AF/4
2
EB/4 FJ/2
1
2
3
1
BI/2
1
1
2
2
start relais
-M10 -K10 -G10 -T20 -G20 -K11 -F7
3
30A
1 1
1 1 2 2
10A
M
U
Oese/1
G
Oese/1
-X74
-X75
B A 3 3 CR/1 CR/1
1
EM/3
EN/3
-X292 -X291
4
3
1
AF/4 EB/4 FJ/2
1
4
4
D -X12 -X19 -X119 D
rd-bu
rd-bu
ye-rd
ye-rd
gn
gn
gn
gn
br
bl
br
-X 30 2 -X 301
WIRING DIAGRAM
E E
Page 01 of 11
c /11.F1
d /2.F1
F F
690 SMC R 2014
27.1
111
/
27 1 2 3 4 5 6 7 8
27 WIRING DIAGRAM 203
Components:
A11 EFI control unit
F7 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)
204
G00402-01
1 2 3 4 5 6 7
-P10 -A11
/3.A3 /1.A4
/7.A1 A
A
46
29
17
3
1
ED/32 GF/48 GF/48
46
29
3
1
-X2 -X1 -X1
bu-gr
wh-bl
ye-rd
wh-or
B
B
gn e /3.B1
/1.B8 a wh-rd , wh-rd , wh-rd
bl-rd bl-ye f /7.C1
/1.C8 b
bu-gr
wh-rd
wh-bl
ye-rd
wh-rd
wh-rd
bl-rd
rd
rd
rd
C -X17 -X50 C
-X121 BY/4 -X14 -X15 -X120 -X38
4
AZ/4
4
1
FJ/2 DV/2
2
EB/4
1
2
4
EB/4
4
FJ/2
1
CV/4
2
2
4
BK/4
4
2
4
2
1
-S23 -F1 -S11 -K12 -K30 -F3 -M13

/7.D3
10A
10A
M
AP/6
1
-X295
2
1
3
1
3
CV/4
1
3
1
1
BK/4
2
EB/4 EB/4 FJ/2 DV/2
2
1
FJ/2
3
3
1
-X15 -X120 -X38 D
D AZ/4 -X121 BY/4 -X14
3
3
2
-X17 -X50
bl-bu
bl-bu
wh-or
bl-ye
wh-or
ye-rd
ye-rd
ye-rd
gn
br
br
WIRING DIAGRAM
E
E
Page 02 of 11
br , br br , br , br , br d /3.F1
/1.F8 d
F
F
690 SMC R 2014
27.2
2/11
27 1 2 3 4 5 6 7 8
Components:
F1 Fuse
F3 Fuse
K12 Light relay
K30 Power relay
M13 Fuel pump
P10 Combination instrument
S11 Ignition/steering lock
S23 Emergency OFF switch, electric starter button
X295 Diagnostics connector
206
1 2 3 4
G00403-01
5 6 7 8
-P10
/2.A3
A /5.A3 A
8
ED/32
8
-X2
bu
B B
228
/2.B8 e gn gn , gn , gn e /6.B1
229
gn
gn
bu
gn
bu
gn
bu
gn
bu
gr
bu
gr
br
C -X22 C
-X122 -X126 -X24 AC/6 -X64 -X66
4
3
6
226 231
FJ/2 FJ/2 CR/1
2
BW/3 DI/2
2
1
3
230
1
BC/6
1
1
1
2
4
6
2
3
-F5 -F6 -P15 -S24 -X61 -E13 -P35 -X62
/5.C3 BP/4 DG/4
2
3
1
4
HI LO
10A
15A
DG/4 BP/4
1
2
3
4
-X62 -X61
2
1
2
1
2
5
1
FJ/2 FJ/2 CR/1 BW/3 DI/2
1
2
D -X122 -X126 -X25 AC/6 -X64 -X66 D
5
-X22
br , br
ye-bu
ye-bu
ye
bu
gn
ye
br
br
ye
br
br
WIRING DIAGRAM
E E
Page 03 of 11
ye g /4.E1
ye-bu , ye-bu , ye-bu h /4.F1
/2.F8 d br , br , br , br br , br , br , br , br , br d /4.F1
F F
690 SMC R 2014
27.3
3/11
27 1 2 3 4 5 6 7 8
Components:
E13 Low beam, high beam
F5 Fuse
F6 Fuse
P15 Horn
P35 Parking light
S24 Light switch, horn button, headlight flasher switch, turn signal switch
208
7 8
G00404-01
1 2 3 4 5 6
A A
B B
wh-gn
wh-gn
wh-gn
wh-gn
wh-gn
wh
wh
wh
br
br
C -X27 -X26 -X132 -X63 C
AJ/3 CW/2
1
AH/2
1
AH/2
2
2
AK/2 AK/2 -X34 BG/3 CX/2
1
1
2
2
2
-B77 -B76 BG/3 -P36 -E60
2
3
1
P
AJ/3
1
2
3
-X32
BG/3 CX/2
2
3
AK/2 1 AK/2
1
D AJ/3 CW/2 D
AH/2 AH/2
2
1
3
1
-X27 -X26 -X132 -X63
wh-gn
wh-gn
ye-bu
ye-bu
wh
wh
br
br
ye
br
br
WIRING DIAGRAM
E E
Page 04 of 11
/3.E8 g ye
/3.F8 h ye-bu , ye-bu , ye-bu ye-bu h /5.F1
/3.F8 d br , br , br , br , br , br br , br , br , br , br , br , br d /5.F1
F F
690 SMC R 2014
27.4
4/11
27 1 2 3 4 5 6 7 8
Components:
B76 Front brake light switch
B77 Rear brake light switch
E60 License plate lamp
P36 Brake/tail light
210
6 7 8
G00405-01
1 2 3 4 5
-P10
/3.A3
A /8.A6 A
10
9
ED/32
9
10
-X2
pu
bl
B B
pu
pu
pu
bl
bl
bl -X23 -X30 -X31 -X58 -X65
C C
-X29 BT/3 CX/2 CX/2 CX/2 CX/2
1
1
2
1
3
1
IE/2
1
CW/2 CW/2 CW/2 CW/2
1
1
1
1
1
2
3
-K20 -S24 -P42 -P41 -X71 -P46 -P45
/3.C3 CV/4
4
3
G LR
FR/4
2
3
4
-X70 CW/2 CW/2
2
CW/2
2
CW/2
2
2
2
1
IE/2
2
D -X29 BT/3 CX/2 CX/2 CX/2 CX/2 D
2
1
2
2
2
-X23 -X30 -X31 -X58 -X65
ye-bu
ye-or
ye-or
pu
br
br
br
br
br
br
bl
WIRING DIAGRAM
E E
Page 05 of 11
/4.F8 h ye-bu
/4.F8 d d /6.F1
F F
690 SMC R 2014
27.5
5/11
27 1 2 3 4 5 6 7 8
Components:
K20 Turn signal relay
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S24 Light switch, horn button, headlight flasher switch, turn signal switch
212
1 2 3 4 5 6 7 8
G00406-01
A A
B B
/3.B8 e gn e /11.B1
gn
gn
bl
bl
C -X110 C
-X129 -X128 ID/2 -X33
1
FJ/2 FJ/2 AV/2
2
2
2
BI/2
2
2
2
-F8 -F4 -M14 -B33
10A
10A
CR/1 CR/1 M
1
1
t°
-X294 -X293
BI/2
1
1
1
FJ/2 FJ/2 AV/2
1
1
1
D -X129 -X128 ID/2 -X33 D
2
-X110
wh-bl
wh-bl
bl-rd
bl-rd
br
br
WIRING DIAGRAM
E E
Page 06 of 11
/5.F8 d d /10.F1
F F
690 SMC R 2014
27.6
6/11
27 1 2 3 4 5 6 7 8
Components:
B33 Radiator fan temperature switch
F4 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)
27.7 Page 07 of 11
F
B
D
A
/2.C8 f
bl-ye
1
1
-F2
1 10A 2
1 2
/2.A6
or bl-ye
/8.A1
-A11
FJ/2
FJ/2
-X127
-X127
or or 4 4
-X1
GF/48
2
2
-M60
1 1 gn-or gn-or 17 17
2 2 2 2
M
bu-gn bu-gn
4 4 wh-or wh-or 21 21
690 SMC R 2014
6 6 ye-or ye-or 5 5
3 3 bl-pk bl-pk 38 38
5 5 bu-pk bu-pk 19 19
-X36
GH/6
-X1
GF/48
3
3
/2.D1
-B80
3 3 bu-pk
2 2 bl-pk
1 1 gn-pk gn-pk 22 22
4 4 pu-gn pu-gn 6 6
5 5 bl-pu bl-pu 37 37
6 6 bu-pu bu-pu 18 18
BH/6
-X35
-X1
GF/48
AP/6
4
4
-R51/1
or 2 2 1 1 wh-pu wh-pu 15 15
5
5
-X16
-X16
-X1
GF/48
AS/2
AS/2
-R51/2
or 2 2 1 1 ye-pu ye-pu 16 16
IA/2
IA/2
-X103
-X103
-X1
GF/48
6
6
-M20
or 1 1 2 2 bl-or bl-or 45 45
DF/2
DF/2
-X40
-X40
-X1
GF/48
7
7
-M51
or 2 2 1 1 bl-gr bl-gr 13 13
DQ/2
DQ/2
-X43
-X43
-X1
GF/48
or , or
8
8
i /8.F1
7/11
G00407-01
F
B
C
D
A
Components:
B80 Accelerator position sensor
F2 Fuse
M20 Fuel evaporation valve
M51 Injector cylinder 1
M60 Motor drive
R51/1 Ignition coil 1, (cylinder 1)
R51/2 Ignition coil 2, (cylinder 1)
216
1 2 3 4 5 6 7 8
G00408-01
-A11 -P10
/7.A1 /5.A3
A /9.A1 /9.A6 A
44
24
26
23
11
14
20
19
23
7
2
5
GF/48 GF/48 GF/48 GF/48 GF/48 ED/32 ED/32 ED/32 ED/32
11
44
24
26
23
2
5
14
20
19
23
-X1 -X1 -X1 -X1 -X1 -X2 -X2 -X2 -X2
gn-rd
rd-pu
gn-gr
gn-rd
bu-br
ye-br
bl-ye
bl-br
lbu
ye
rd
or
B B
gn-rd
br-pu
br-pu
rd-pu
gn-rd
bu-br
ye-br
bl-ye
bl-br
lbu
ye
C -X45 -X54 rd -X69 C

CU/4 AL/2 -X37 -X55 -X57 IJ/3
2
2
4
2
3
1
CM/2 DV/2 EC/3
3
1
1
DY/4 AT/2 CZ/3
1
1
1
2
2
4
2
3
3
-B51 -B38 -B12 -S55 -B21 t° t° -B35 -S37
L t° R
t° P
DY/4 AT/2
2
3
1
1
1
CM/2 DV/2 EC/3 GB/2
2
D CU/4 AL/2 -X37 -X55 -X57 -X68 D
1
1
3
-X45 -X54
br-pu
br-pu
br-pu
br-pu
br-pu
gn-gr
or
rd
rd
or
WIRING DIAGRAM
E E
Page 08 of 11
d /11.E1
/7.F8 i or , or
F F
690 SMC R 2014
27.8
8/11
27 1 2 3 4 5 6 7 8
Components:
B12 Intake air temperature sensor
B21 Engine coolant temperature sensor cylinder 1
B35 Oil pressure sensor
B38 Clutch switch
B51 Lambda sensor (cylinder 1)
S37 Switch
S55 Map‑Select Switch
218
1 2 3 4 5 6 7 8
G00409-01
-A11 -P10
/8.A1 /8.A6
A /10.A2 /10.A6 A
42
41
10
20
39
6
8
9
GF/48 GF/48 GF/48 GF/48 GF/48 GF/48 GF/48 ED/32

41
6
42
8
10
9
20
39
-X1 -X1 -X1 -X1 -X1 -X1 -X1 -X2
br-gn
br-gn
ye-gn
gn-gr
pu
bu
pk
bl
B B
br-gn
ye-gn
gn-gr
pu
bu
pk
bl
C -X49 -X21 C
IB/3 -X51 -X53 -X111 IM/4
4
3
AP/6 DP/3 DX/3
2
3
5
AM/3 DY/4
1
3
4
2
2
3
3
5
-B30 -B26 -B13 -B41 -B34
p p
AM/3 DY/4
2
2
3
4
3
1
6
1
1
2
1
AP/6 DP/3 DX/3
1
1
3
2
4
6
D IB/3 -X51 -X53 -X111 IM/4 D
1
1
2
2
-X49 -X21
bu
bu
bu
bu
bu
bu
bl
bl
bl
bl
bl
bl
WIRING DIAGRAM
E E
Page 09 of 11
F F
690 SMC R 2014
27.9
9/11
27 1 2 3 4 5 6 7 8
Components:
B13 Ambient air pressure sensor
B26 Rollover sensor
B30 Side stand switch
B31 Accelerator position sensor
B41 Manifold absolute pressure sensor cylinder 1
220
1 2 3 4 5 6 7 8
G00410-01
-A11 -P10
/9.A1 /9.A6
A /11.A1 /11.A3 A
11
12
18
28
14
43
32
47
48
36
35
7
4
GF/48 GF/48 GF/48 ED/32 ED/32
11
7
12
18
4
43
32
48
28
14
47
36
35
-X1 -X1 -X1 -X2 -X2
wh-gn
wh-gn
wh-ye
ye-bu
bl-gn
bl-gn
br-rd
wh
wh
br
br
br
br
B B
wh-ye
ye-bu
br-rd
C -X52 -X56 C
AL/2 II/2
2
1
1
AT/2 IK/2
1
1
2
-B37 -B32
R
IK/2
2
D II/2 D
2
-X56
br
br
br
br
br
WIRING DIAGRAM
E E
Page 10 of 11
/6.F8 d br d /11.F1
F F
27.10
690 SMC R 2014
10/11
27 1 2 3 4 5 6 7 8
Components:
B32 Fuel level indicator
B37 Crankshaft position sensor
222
1 2 3 4 5 6 7 8
G00411-01
-A11 -P10 -A30
/10.A2 /10.A6
A A
14
13
12
18
10
15
17
11
15
24
22
33
34
3
9
1
4
8
3
GF/48 ED/32 GE/18 GE/18 GE/18 GE/18 GE/18 GE/18

1
11
1
12
18
2
14
13
9
4
8
10
15
17
3
15
24
22
33
34
-X1 -X2 -X3 -X3 -X3 -X3 -X3 -X3

wh-bu
wh-bu
wh-bl
gn-rd
br-pu
br-pu
bl-bu
bl-bu
bl-ye
bl-ye
bl-gr
bl-or
bl-or
wh
gn
gn
gr
or
or
bl
bl
B B
/6.B8 e gn
wh-bu
wh-bl
gn-rd
br-pu
br-pu
br-pu
br-pu
br-pu
br-pu
bl-bu
bl-gr
wh
gn
gr
or
or
br
br
bl
bl
C -X42 -X39 C
-X125 -X124 -X123 DM/2 DM/2
2
2
1
1
FJ/2 EA/2 EA/2
2
2
2
FI/2 FI/2
1
1
2
2
2
2
2
-F9 -X295 -F21 -F22 -B70 -B71

AP/6
2
3
6
15A
25A
10A
-X303
1
1
1
FJ/2 EA/2 EA/2
1
1
1
D -X125 -X124 -X123 D

-X300
gn-rd
gn-rd
rd
rd
WIRING DIAGRAM
E E
/8.E8 dbr-pu , br-pu , br-pu , br-pu
Page 11 of 11
/1.F8 c rd , rd
/10.F8 d
F F
27.11
690 SMC R 2014
1111
/
27 1 2 3 4 5 6 7 8
Components:
A30 ABS control unit
B70 Front wheel speed sensor
B71 Wheel speed sensor, rear
F9 Fuse
F21 ABS fuse
F22 ABS fuse
X295 Diagnostics connector
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
28 SUBSTANCES 224
Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties.
Recommended supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
– Use only coolant based on ethylene glycol.
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)
Motorex®
– COOLANT M5.0
Engine oil (SAE 10W/60) (00062010035)

– JASO T903 MA ( p. 241)
– SAE ( p. 241) (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-
Synthetic engine oil
Motorex®
– Cross Power 4T
Engine oil (SAE 10W/50)

– JASO T903 MA ( p. 241)
– SAE ( p. 241) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
Fully synthetic engine oil
Motorex®
– Power Synt 4T
28 SUBSTANCES 225
Fork oil (SAE 4) (48601166S1)

– SAE ( p. 241) (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)

– ISO VG (15)
Guideline
– Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre-
Motorex®
– Hydraulic Fluid 75
Shock absorber fluid (SAE 2.5) (50180751S1)

– SAE ( p. 241) (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)

– 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).
29 AUXILIARY SUBSTANCES 226
Chain cleaner
Motorex®
– Chain Clean
Chain lube for road use

Guideline
Motorex®
– Chainlube Road
Fuel additive
Motorex®
– Fuel Stabilizer
Long-life grease
Motorex®
– Bike Grease 2000
Lubricant (T511)
Lubcon®
– Turmsilon® GTI 300 P
Lubricant (T159)
Bel‑Ray®
– MC‑11®
Lubricant (T158)
Lubcon®
– Turmogrease® PP 300
Lubricant (T625)
Molykote®
– 33 Medium
Motorcycle cleaner
Motorex®
– Moto Clean
Perfect Finish and high gloss polish for paints

Motorex®
– Moto Polish & Shine
29 AUXILIARY SUBSTANCES 227
Preserving materials for paints, metal and rubber

Motorex®
– Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Motorex®
– Quick Cleaner
Universal oil spray

Motorex®
– Joker 440 Synthetic
30 SPECIAL TOOLS 228
Bleeder cover
Art. no.: 00029013004
201830-10
Bleeder cover
Art. no.: 00029013010
201606-10
Bleeding device
Art. no.: 00029013100
201491-10
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
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
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
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
Support for engine assembly stand

Art. no.: 75012001060
400153-01
Holder for engine assembly stand

Art. no.: 75012001070
400154-01
Mounting tool for lock ring

Art. no.: 75029005000
305660-10
Piston assembly ring

Art. no.: 75029015102
400156-01
Extractor
Art. no.: 75029021000
400157-01
Assembly screws
Art. no.: 75029033000
400158-01
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
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
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
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
Pin wrench
Art. no.: T103
200734-10
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
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
Open-end wrench
Art. no.: T14032
200640-10
Clamping stand
Art. no.: T1403S
200637-10
Mounting tool
Art. no.: T14040S
200634-10
Mounting sleeve
Art. no.: T1515
300569-10
Nitrogen filling tool

Art. no.: T170S1
300574-10
31 STANDARDS 241
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.
INDEX 242
front brake, removing . . . . . . . . . . . . . . . . . . . . . . . . 74

INDEX
A rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . . . 76

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . . . 76
Air filter Brake discs
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Brake fluid
Air filter box front brake, adding . .. . . . . . . . . . . . . . . . . . . . . . . . 91
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 92
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 rear brake, adding . .. . . . . . . . . . . . . . . . . . . . . . . . 96
Alternator rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 97
stator winding, checking . . . . . . . . . . . . . . . . . . . . . 187 Brake fluid level
Antifreeze checking the brake fluid level of front brake . . . . . . . . . 90
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 95
Assembling the engine Brake linings

alternator cover, installing . . . . . . . . . . . . . . . . . . . . 171 front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 89
camshafts, installing . . . . . . . . . . . . . . . . . . . . . . . . 167 front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 89
clutch basket, installing . . . . . . . . . . . . . . . . . . . . . 159 rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 93
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 161 rear brake, checking .. . . . . . . . . . . . . . . . . . . . . . . . 93
crankshaft and balancer shaft, installing . . . . . . . . . . 155 C
crankshaft position sensor distance, adjusting . . . . . . 163
Capacity
cylinder head, installing . . . . . . . . . . . . . . . . . . . . . 166
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
engine, setting to top dead center . . . . . . . . . . . . . . . 164
engine oil . . . . . . . . . . . . . . . . . . . . . . . 111, 186, 193
gear position sensor, installing . . . . . . . . . . . . . . . . . 171
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
ignition pulse generator, installing . . . . . . . . . . . . . . 162
left engine case, installing . . . . . . . . . . . . . . . . . . . . 156 Chain
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 158 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 170 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
oil pumps, installing . . . . . . . . . . . . . . . . . . . . . . . . 157 Chain guide
oil screens, installing . . . . . . . . . . . . . . . . . . . . . . . 172 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
piston, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 164 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 159 Chain tension
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
shift drum locating, installing . . . . . . . . . . . . . . . . . . 158 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 158
Changing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . 104
spacer and spring, installing . . . . . . . . . . . . . . . . . . 161
spacer, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Charging voltage
spark plugs, installing . . . . . . . . . . . . . . . . . . . . . . . 170 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
starter drive, installing . . . . . . . . . . . . . . . . . . . . . . 158 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 172 Clutch
taking engine off universal mounting rack . . . . . . . . . 173 checking/correcting fluid level . . . . . . . . . . . . . . . . . 174
thermostat, installing . . . . . . . . . . . . . . . . . . . . . . . 170 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
timing chain and timing chain sprocket, installing . . . . 162
Combination instrument
timing chain rails, installing . . . . . . . . . . . . . . . . . . . 162
clock, setting . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 99
timing chain tensioner, installing . . . . . . . . . . . . . . . 167
kilometers or miles, setting . . ... . . . . . . . . . . . . . . . 99
transmission shafts, installing . . . . . . . . . . . . . . . . . 154
TRIP 1 display, setting/resetting .. . . . . . . . . . . . . . . . 99
valve clearance, adjusting . . . . . . . . . . . . . . . . . . . . 169
TRIP 2 display, setting/resetting .. . . . . . . . . . . . . . . . 99
valve clearance, checking . . . . . . . . . . . . . . . . . . . . 168
wheel circumference, setting . ... . . . . . . . . . . . . . . 100
valve cover, installing . . . . . . . . . . . . . . . . . . . . . . . 173
water pump cover, mounting . . . . . . . . . . . . . . . . . . 164 Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coolant level
B checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179-180
Battery Cooling system
connecting . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . . . 132
fitting . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
recharging . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 D
removing . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Disassembling the engine
Brake disc alternator cover, removing . . . . . . . . . . . . . . . . . . . . 112
front brake, installing . . . . . . . . . . . . . . . . . . . . . . . . 74 camshafts, removing . . . . . . . . . . . . . . . . . . . . . . . . 114
INDEX 243
clutch basket, removing . . . . . . . . . . . . . . . . . . . . . . 119 piston ring end gap, checking . . . . . . . . . . . . . . . . . . 134
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 118 piston, checking/measuring . . . . . . . . . . . . . . . . . . . 133
crankshaft and balancer shaft, removing . . . . . . . . . . 124 piston/cylinder mounting clearance, determining . . . . . 134
cylinder head, removing . . . . . . . . . . . . . . . . . . . . . . 115 right engine case section . . . . . . . . . . . . . . . . . . . . . 125
engine oil, draining . . . . . . . . . . . . . . . . . . . . . . . . . 111 rocker arm, installing . . . . . . . . . . . . . . . . . . . . . . . 142
engine, setting to ignition top dead center . . . . . . . . . 113 rocker arm, removing . . . . . . . . . . . . . . . . . . . . . . . 138
gear position sensor, removing . . . . . . . . . . . . . . . . . 113 shift mechanism, checking . . . . . . . . . . . . . . . . . . . 145
ignition pulse generator, removing . . . . . . . . . . . . . . . 118 shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . 146
left engine case, removing . . . . . . . . . . . . . . . . . . . . 123 starter drive, checking . . . . . . . . . . . . . . . . . . . . . . . 152
locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 122 timing assembly, checking . . . . . . . . . . . . . . . . . . . . 137
oil filter, removing . . . . . . . . . . . . . . . . . . . . . . . . . 113 timing chain tensioner, preparing for installation . . . . . 136
oil pumps, removing . . . . . . . . . . . . . . . . . . . . . . . . 122 transmission, checking . . . . . . . . . . . . . . . . . . . . . . 148
piston, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 valve spring retainer, checking . . . . . . . . . . . . . . . . . 140
primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 120 valve springs, checking . . . . . . . . . . . . . . . . . . . . . . 140
rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 valves, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
shift drum locating, removing . . . . . . . . . . . . . . . . . . 121 valves, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 121 valves, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
spacer and spring, removing . . . . . . . . . . . . . . . . . . . 118 Engine characteristic
spacer, removing . . . . . . . . . . . . . . . . . . . . . . . . . . 112 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
spark plugs, removing . . . . . . . . . . . . . . . . . . . . . . . 114
Engine disassembly
starter drive, removing . . . . . . . . . . . . . . . . . . . . . . . 120
engine, clamping into the engine assembly stand . . . . 111
starter motor, removing . . . . . . . . . . . . . . . . . . . . . . 112
thermostat, removing . . . . . . . . . . . . . . . . . . . . . . . 113 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
timing chain and timing chain sprocket, removing . . . . 117 Engine oil
timing chain rails, removing . . . . . . . . . . . . . . . . . . . 117 adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
timing chain tensioner, removing . . . . . . . . . . . . . . . 114 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
transmission shafts, removing . . . . . . . . . . . . . . . . . 124 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
valve cover, removing . . . . . . . . . . . . . . . . . . . . . . . 112 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
water pump impeller, removing . . . . . . . . . . . . . . . . . 116 Engine oil level
E checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Engine Engine oil pressure

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Engine sprocket
Engine - Work on individual parts checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
antihopping clutch, disassembling . . . . . . . . . . . . . . 142 F
antihopping clutch, preassembling . . . . . . . . . . . . . . 144 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
autodecompressor . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Filler cap
axial clearance of crankshaft and balancer shaft,
measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
balancer shaft drive wheel, installing . . . . . . . . . . . . . 130 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
balancer shaft drive wheel, removing . . . . . . . . . . . . . 128 Foot brake lever
camshaft bearing, changing . . . . . . . . . . . . . . . . . . . 138 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 95
clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 95
clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Fork
connecting rod, conrod bearing, and crank pin, changing 128 compression damping, adjusting . . . . . . . . . . . . . . . . . 14
countershaft, assembling . . . . . . . . . . . . . . . . . . . . . 151 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 15
countershaft, disassembling . . . . . . . . . . . . . . . . . . . 148 fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 15
crankshaft bearing inner ring, installing . . . . . . . . . . . 131 rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
crankshaft bearing inner ring, removing . . . . . . . . . . . 128
Fork legs
crankshaft run-out at bearing pin, checking . . . . . . . . 130
assembling . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . 132
checking . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . 140
disassembling .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
cylinder, checking/measuring . . . . . . . . . . . . . . . . . . 132
fitting . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
freewheel, checking . . . . . . . . . . . . . . . . . . . . . . . . 153
removing . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
freewheel, installing . . . . . . . . . . . . . . . . . . . . . . . . 153
freewheel, removing . . . . . . . . . . . . . . . . . . . . . . . . 153 Fork part number ............................... 8
left engine case section . . . . . . . . . . . . . . . . . . . . . . 126 Fork protector
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 150 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
main shaft, disassembling . . . . . . . . . . . . . . . . . . . . 147 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
oil pumps, checking for wear . . . . . . . . . . . . . . . . . . 134
INDEX 244
Front wheel Oil filter

fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Fuel filter removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 67 Oil screens
Fuel pressure cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 185
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuse P
of individual power consumer, changing . . . . . . . . . . . . 86
Parking light bulb
G changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Gear position sensor Preparing for use
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 R
H Rear hub rubber dampers
Hand brake lever checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 90 Rear sprocket
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Rear wheel
Headlight installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
light range, adjusting . . . . . . . . . . . . . . . . . . . . . . . 101 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Headlight bulb, changing . . . . . . . . . . . . . . . . . . . . . . . . 103 Riding sag
Headlight mask with headlight adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Rim run-out
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Headlight setting, checking . . . . . . . . . . . . . . . . . . . . . . . 101 S
I Seat
Ignition coil mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
secondary winding, checking . . . . . . . . . . . . . . . . . . 188 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Initialization run Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

performing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Servicing the shock absorber . . . . . . . . . . . . . . . . . . . . . . 39
K Shock absorber
compression damping, high-speed, adjusting . . . . . . . . 33
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
compression damping, low-speed, adjusting . . . . . . . . . 33
M damper, assembling . . . . . . . . . . . . . . . . . . . . . . . . . 46
Main fuse damper, bleeding and filling . . . . . . . . . . . . . . . . . . . 48
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 damper, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
damper, dismantling . . . . . . . . . . . . . . . . . . . . . . . . . 40
Main silencer
damper, filling with nitrogen . . . . . . . . . . . . . . . . . . . 50
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
heim joint, installing . . . . . . . . . . . . . . . . . . . . . . . . . 44
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
heim joint, removing . . . . . . . . . . . . . . . . . . . . . . . . . 43
Manifold installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 piston rod, assembling . . . . . . . . . . . . . . . . . . . . . . . 45
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 piston rod, disassembling . . . . . . . . . . . . . . . . . . . . . 41
Motorcycle rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 34
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 11 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 35
raising with the front wheel stand . . . . . . . . . . . . . . . . 10 shock absorber, servicing . . . . . . . . . . . . . . . . . . . . . . 39
raising with the rear wheel stand . . . . . . . . . . . . . . . . . 10 spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 35
raising with work stand . . . . . . . . . . . . . . . . . . . . . . . 11 spring, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing from the lift stand . . . . . . . . . . . . . . . . . . . . 11 spring, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
removing from work stand . . . . . . . . . . . . . . . . . . . . . 12 static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 34
taking off of the front wheel stand . . . . . . . . . . . . . . . . 11 Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 9
taking off of the rear wheel stand . . . . . . . . . . . . . . . . 10
Side cover
O mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INDEX 245
Spark plug connector

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Starting procedure
for making checks . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 196
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 194
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
engine tightening torques . . . . . . . . . . . . . . . . . . . . 192
engine tolerance, wear limits . . . . . . . . . . . . . . . . . . 190
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Throttle grip
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . 199
Wiring diagram . . ........................ 202-223
page 01 of 11 ........................ . . . . 202
page 02 of 11 ........................ . . . . 204
page 03 of 11 ........................ . . . . 206
page 04 of 11 ........................ . . . . 208
page 05 of 11 ........................ . . . . 210
page 06 of 11 ........................ . . . . 212
page 07 of 11 ........................ . . . . 214
page 08 of 11 ........................ . . . . 216
page 09 of 11 ........................ . . . . 218
page 10 of 11 ........................ . . . . 220
page 11 of 11 ........................ . . . . 222
Work rules ................................... 6
*3206193en*
3206193en
03/2014
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria Photo: Mitterbauer/KTM
http://www.ktm.com

2014 690 SMC R Eu

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2014 690 SMC R Eu

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REPAIR MANUAL 2014

© 2014 KTM-Sportmotorcycle AG, Mattighofen Austria

ISO 9001(12 100 6061)

8.5 Checking the static sag of the shock absorber .... 34

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

1.1 Symbols used

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

Name® Identifies a protected name.

Brand™ Identifies a trademark.

2.1 Repair Manual

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Work rules

3.1 Guarantee, warranty

3.2 Operating and auxiliary substances

3.3 Spare parts, accessories

4.1 Chassis number

4.2 Type label

4.3 Engine number

4.4 Key number

4.5 Fork part number

4.6 Shock absorber part number

5.1 Raising the motorcycle with the rear wheel stand

5.2 Taking the motorcycle off of the rear wheel stand

– Secure the motorcycle against falling over.

5.3 Raising the motorcycle with the front wheel stand

– Raise the front of the motorcycle.

5.4 Taking the motorcycle off of the front wheel stand

– Secure the motorcycle against falling over.

5.5 Raising the motorcycle with a lift stand

– Stand the motorcycle upright on a level surface.

5.6 Removing the motorcycle from the lift stand

5.7 Raising the motorcycle with the work stand

– Mount the special tool on the footrest.

5.8 Removing the motorcycle from the work stand

– Secure the motorcycle against falling over.

– Remove the special tool.

– Turn the emergency OFF switch to the position .

5.10 Starting the motorcycle to make checks

– Turn the emergency OFF switch to the position .

6.1 Adjusting the compression damping of the fork

– Turn the white adjusting screw  all the way clockwise.

6.2 Adjusting the rebound damping of the fork

– Turn the red adjusting screw  all the way clockwise.

6.3 Bleeding the fork legs

6.4 Cleaning the dust boots of the fork legs

6.5 Removing the fork protector

6.6 Installing the fork protector

6.7 Removing fork legs

– Loosen screw  and screws .

– Remove screws . Take off the fork protector.

6.8 Installing the fork legs