KTM RC8 Repair Manual

REPAIR MANUAL 2009
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
1190 RC8 R EU/UK

1190 RC8 R AUS
1190 RC8 R FR
1190 RC8 R JP
Article no. 3206077en
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
Only use ORGINAL KTM SPARE PARTS.

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 manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified
here. It is assumed that the repair work will be performed by a fully trained mechanic.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, 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 special equipment that does not form part of the regular scope of delivery.
2009 by KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved
Reproduction, even in part, 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: TV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS
CONTENTS
Servicing the shock absorber ..........................................

Removing the spring ......................................................
Disassembling the damper .............................................
Disassembling the piston rod ..........................................
Checking the damper .....................................................
Assembling the piston rod ..............................................
Assembling the damper..................................................
Bleeding and filling the damper ......................................
Filling the damper with nitrogen .....................................
Installing the spring.......................................................
Removing the heim joint ................................................
Installing the heim joint .................................................
05/EXHAUST ....................................................................
Lambda sensor..............................................................
Lambda sensor heater ....................................................
Removing the exhaust cover completely ...........................
Installing the exhaust cover completely............................
Removing the exhaust system .........................................
Installing the exhaust system..........................................
06/AIR FILTER..................................................................
Removing the air filter ...................................................
Installing the air filter ....................................................
Removing the filter box bottom .......................................
Installing the filter box bottom........................................
07/FUEL TANK, SEAT, TRIM..............................................
Removing the seat .........................................................
Fitting the seat..............................................................
Removing the passenger seat..........................................
Mounting the passenger seat ..........................................
Dismounting the fuel tank ..............................................
Installing the fuel tank ...................................................
Removing the fuel tank guard .........................................
Installing the fuel tank guard..........................................
Checking the fuel pressure .............................................
Checking the fuel pressure during the actuator test...........
08/MASK, FENDER, DECAL ...............................................
Removing the side covers ...............................................
Installing the side covers................................................
Removing the inside cover..............................................
Installing the inside cover ..............................................
09/FRONT WHEEL ............................................................
Removing the front wheel ...............................................
Installing the front wheel................................................
Checking the tire condition.............................................
Checking the tire pressure ..............................................
Checking the front brake discs........................................
10/REAR WHEEL ..............................................................
Removing the rear wheel ................................................
Installing the rear wheel .................................................
Installing the rear wheel - when installing the engine ........
Checking the rear brake disc...........................................
Checking for chain dirt...................................................
Cleaning the chain.........................................................
Checking the chain tension ............................................
Adjusting the chain tension ............................................
Checking rear sprocket / engine sprocket for wear .............
Checking chain wear ......................................................
Checking chain sliding guard ..........................................
Checking rear hub cush drive..........................................
11/WIRING HARNESS, BATTERY .......................................
Electric starter lock control unit ......................................
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
MEANS OF REPRESENTATION ............................................ 6

IMPORTANT NOTES ............................................................ 7
LOCATION OF SERIAL NUMBERS ........................................ 8
Vehicle identification number/type label ............................ 8
Key number .................................................................... 8
Engine number................................................................ 8
Fork part number............................................................. 8
Shock absorber part number............................................. 8
Steering damper part number ........................................... 9
MOTORCYCLE................................................................... 10
Jacking up motorcycle front............................................ 10
Taking front of motorcycle off work stand......................... 10
Jacking up the motorcycle in the middle (screw-in type).... 10
Removing the motorcycle from the work stand (screw-in
type) ............................................................................ 11
Jacking up the motorcycle in the middle (insertable
type) ............................................................................ 12
Removing the motorcycle from the work stand (insertable
type) ............................................................................ 12
Jacking up motorcycle at the rear.................................... 13
Taking the rear from the workstand ................................. 13
Starting ........................................................................ 13
01/FORK, TRIPLE CLAMP.................................................. 15
Adjusting the compression damping of the fork ................ 15
Adjusting the rebound damping of the fork....................... 15
Adjusting the spring preload of the fork ........................... 16
Bleeding fork legs.......................................................... 16
Vehicle level ................................................................. 17
Adjusting front vehicle level............................................ 17
Removing the fork ......................................................... 18
Installing the fork .......................................................... 19
performing a fork service ................................................ 21
Disassembling the fork legs ............................................ 21
Disassembling the outer tubes ........................................ 24
Checking the fork legs.................................................... 25
changing the lower DU bush ........................................... 26
Assembling the outer tubes ............................................ 27
Assembling the fork legs ................................................ 27
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 32
Adjusting basic position of clutch lever............................ 32
Adjusting the steering damper ........................................ 32
Adjusting the handlebar height ....................................... 32
Adjusting the play in the throttle cable ............................ 33
Throttle grip.................................................................. 34
Changing the throttle grip............................................... 34
Adjusting the throttle cable at the throttle valve................ 37
03/FRAME........................................................................ 40
Side stand switch .......................................................... 40
Footrest position............................................................ 40
Adjusting footrest position .............................................. 40
Rear frame position ....................................................... 41
Adjusting the rear frame position .................................... 41
04/SHOCK ABSORBER, SWINGARM................................... 44
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the rebound damping of the shock absorber....... 45
Adjusting the spring preload of the shock absorber ........... 45
Adjusting the vehicle level at the rear .............................. 46
Removing the shock absorber ......................................... 46
Installing the shock absorber .......................................... 47
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CONTENTS
Removing the heat exchanger .......................................
Removing the rear timing chain tensioner ......................
Removing the rear camshaft .........................................
Removing the rear cylinder head ...................................
Removing the rear piston..............................................
Setting the engine to ignition top dead center of the
front cylinder ..............................................................
Removing the front timing chain tensioner .....................
Removing the front camshafts ......................................
Removing the front cylinder head..................................
Removing the front piston ............................................
Removing the generator cover .......................................
Removing the ignition pulse generator ...........................
Removing the torque limiter and idler............................
Removing the rotor ......................................................
Removing the idler and timing chain on the left .............
Removing the oil filter..................................................
Removing the balancer shaft ........................................
Removing the drive wheel of the balancer shaft ..............
Removing the gear position sensor ................................
Removing the left suction pump ...................................
Removing the water pump wheel...................................
Removing the clutch cover ...........................................
Removing the idler and timing chain on the right............
Removing the clutch facing ..........................................
Removing the outer clutch hub .....................................
Removing the primary gear ...........................................
Removing the force pump ............................................
Removing the shift shaft ..............................................
Removing the shift drum locating..................................
Removing the locking lever...........................................
Removing the left engine case ......................................
Removing the crankshaft ..............................................
Removing the middle suction pump ..............................
Removing the transmission shaft...................................
Removing the oil spray tube .........................................
Removing the timing chain rails of the right engine case
section .......................................................................
Removing the timing chain rails of the left engine case
section .......................................................................
30/ENGINE - WORK ON INDIVIDUAL PARTS.....................
Work on the right section of the engine case ..................
Removing the main bearing of the right engine case
section .......................................................................
Selecting the main bearing shells..................................
Installing the right main bearing ...................................
Work on the left section of the engine case ....................
Removing the left main bearing ....................................
Installing the left main bearing .....................................
Changing the conrod bearing ........................................
Work on the clutch cover ..............................................
Changing the step bearing of the crankshaft...................
Checking the radial clearance of the bottom connecting
rod bearing .................................................................
Checking/measuring the cylinder...................................
Checking/measuring the piston .....................................
Checking the piston ring end gap ..................................
Checking the piston/cylinder mounting clearance............
Work on the cylinder head ............................................
Checking the cylinder head ..........................................
Work on the right idler .................................................
Checking the timing assembly ......................................
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Fuel pump relay ............................................................ 88

Removing the battery ..................................................... 88
Installing the battery...................................................... 89
Recharging the battery ................................................... 90
Changing the main fuse ................................................. 91
Changing the fuses of individual power consumers............ 91
13/BRAKE SYSTEM........................................................... 93
Brake linings................................................................. 93
Checking the front brake linings...................................... 93
Changing the front brake linings ..................................... 93
Checking the front brake fluid level ................................. 95
Adding front brake fluid ................................................. 95
Adjusting the basic position of the hand brake lever.......... 96
Checking the rear brake linings ....................................... 96
Changing the rear brake linings....................................... 97
Checking the rear brake fluid level .................................. 99
Adding rear brake fluid .................................................. 99
Adjusting the foot brake pedal stub ............................... 100
Adjusting the foot brake pedal ...................................... 100
Removing the rear brake system.................................... 101
Installing the rear brake system .................................... 101
14/LIGHT SYSTEM, INSTRUMENTS ................................. 102
Immobilizer control unit ............................................... 102
Activating/deactivating ignition key ............................... 102
Activating the ICU ....................................................... 104
Combination instrument - Activation of the
BOOTLOADER mode.................................................... 105
Updating the combination instrument software............... 105
Setting ROAD or RACE mode........................................ 106
Setting the clock with SET CLOCK ................................ 106
Adjusting shift speed RPM1/2 ...................................... 106
Setting the blank time of the LAP button
LAP BLANK T ............................................................. 107
Setting the number of laps SET NUM LAPS ................... 107
Setting the fuel reserve display TRIPF RESET ................ 108
Setting the kilometers/miles SET KM/MILES .................. 108
Setting the temperature unit SET C/F ......................... 109
Switching the external temperature display on/off ........... 109
Resetting service display .............................................. 110
Checking the headlight setting...................................... 110
Adjust the headlight range............................................ 111
Changing the parking light bulb .................................... 111
Changing the low beam bulb......................................... 112
Changing the high beam bulb ....................................... 113
30/ENGINE..................................................................... 115
Removing the engine ................................................... 115
Preparing the engine for installation .............................. 117
Installing the engine .................................................... 117
rear cylinder................................................................ 120
front cylinder .............................................................. 121
30/DISASSEMBLING THE ENGINE................................... 122
Clamping the engine into the engine work stand ............. 122
Removing the engine bracket........................................ 122
Draining the engine oil ................................................. 122
Removing the front valve cover ..................................... 123
Removing the rear valve cover....................................... 123
rear cylinder................................................................ 123
Removing the starter motor .......................................... 124
Removing the oil filler tube .......................................... 124
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CONTENTS
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167
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169
Adjusting the front cylinder control time ........................

Checking the front valve clearance ................................
Adjusting the front valve clearance................................
Installing the front valve cover ......................................
Installing the rear valve cover .......................................
Mounting the engine bracket ........................................
Dismounting the engine from the work stand..................
31/SECONDARY AIR SYSTEM ..........................................
Exhaust air injection ....................................................
32/CLUTCH ....................................................................
Checking fluid level of hydraulic clutch .........................
Correcting fluid level of hydraulic clutch ........................
34/SHIFT MECHANISM ...................................................
Adjusting shift lever stub..............................................
Adjusting shift lever.....................................................
35/WATER PUMP, COOLING SYSTEM ..............................
Checking the coolant level............................................
Checking the antifreeze................................................
Removing the radiator ..................................................
Installing the radiator...................................................
Adding coolant/bleeding the cooling system ...................
Filling the cooling system compensating tank.................
36/CYLINDER HEAD........................................................
Engine coolant temperature sensor cylinder 1 ................
Engine coolant temperature sensor for cylinder 2............
Checking the valve clearance ........................................
Adjusting the rear valve clearance .................................
Adjusting the front valve clearance................................
Checking the rear cylinder control time..........................
Checking the front cylinder control time ........................
Adjusting the rear cylinder control time .........................
Adjusting the front cylinder control time ........................
Removing the rear camshaft .........................................
Installing the rear camshaft ..........................................
Removing the front camshafts ......................................
Installing the front camshafts .......................................
Installing the rear timing chain tensioner .......................
Installing the front timing chain tensioner......................
38/LUBRICATION SYSTEM ..............................................
Oil circuit ...................................................................
Checking the engine oil level ........................................
Changing the engine oil and filter, cleaning the oil
screens.......................................................................
Draining engine oil, cleaning oil screens ........................
Removing the oil filter..................................................
Installing the oil filter ..................................................
Filling up with engine oil..............................................
Adding engine oil ........................................................
Checking the engine oil pressure...................................
Removing the oil jet for the clutch lubrication ................
Checking / cleaning the oil jet for clutch lubrication........
Installing the oil jet for the clutch lubrication.................
39/IGNITION SYSTEM .....................................................
Crankshaft position sensor............................................
Ignition coil ................................................................
41/THROTTLE VALVE BODY.............................................
Throttle position sensor circuit A...................................
Throttle position sensor circuit A - checking in the
"zero" position .............................................................
Adjusting the position of the throttle position sensor in
circuit A .....................................................................
Removing the throttle valve body to adjust .....................
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Preparing the timing chain tensioner for installation .......

Checking the oil pressure regulator valve........................
Checking the oil pumps................................................
Checking the clutch.....................................................
Checking the shift mechanism ......................................
Preassembling the shift shaft........................................
Dismantling the main shaft ..........................................
Dismantling the countershaft........................................
Checking the transmission............................................
Assembling the main shaft ...........................................
Assembling the countershaft.........................................
30/ASSEMBLING THE ENGINE ........................................
Installing the timing chain rails of the left engine case
section .......................................................................
Installing the timing chain rails of the right engine case
section .......................................................................
Installing the oil spray tube ..........................................
Installing the transmission shaft ...................................
Installing the middle suction pump ...............................
Installing the crankshaft...............................................
Installing the left engine case .......................................
Installing the locking lever............................................
Installing the shift drum locating ..................................
Installing the shift shaft ...............................................
Installing the force pump .............................................
Installing the left suction pump ....................................
rear cylinder................................................................
Installing the primary gear............................................
Installing the outer clutch hub......................................
Installing the clutch facing...........................................
Installing the idler and timing chain on the right ............
Installing the clutch cover ............................................
Installing the water pump wheel ...................................
Installing the gear position sensor .................................
Installing the drive wheel of the balancer shaft...............
Installing the balancer shaft .........................................
Installing the idler and timing chain on the left ..............
Installing the oil filter ..................................................
Installing the rotor .......................................................
Installing the torque limiter and idler ............................
Installing the ignition pulse generator............................
Installing the generator cover........................................
Installing the oil drain plug...........................................
Installing the rear piston ..............................................
Installing the rear cylinder head....................................
Installing the rear camshaft ..........................................
Installing the rear timing chain tensioner .......................
front cylinder ..............................................................
Installing the front piston .............................................
Installing the front cylinder head...................................
Installing the front camshafts .......................................
Installing the front timing chain tensioner......................
Installing the heat exchanger ........................................
Installing the oil filler tube ...........................................
Installing the starter motor ...........................................
Checking the rear cylinder control time..........................
Adjusting the rear cylinder control time .........................
Checking the rear valve clearance .................................
Adjusting the rear valve clearance .................................
Checking the front cylinder control time ........................
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CONTENTS
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Injector cylinder 2 connector DQ...................................

ICU antenna connector DV ...........................................
Fuel pump relay connector EB ......................................
ICU antenna connector EL............................................
Connector EQ..............................................................
Connector ER..............................................................
Connector ES ..............................................................
Connector ET ..............................................................
Combination instrument connector EV ...........................
Exhaust air injection valve, connector FE .......................
Fuel pump relay ..........................................................
CAN bus terminating resistor ........................................
TECHNICAL DATA - ENGINE ............................................
Capacity - engine oil ....................................................
Capacity - coolant........................................................
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE .........................................................................
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........
TECHNICAL DATA - CHASSIS ..........................................
Lighting equipment .....................................................
Capacity - fuel.............................................................
TECHNICAL DATA - FORK................................................
TECHNICAL DATA - SHOCK ABSORBER ...........................
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......
CLEANING/CONSERVATION.............................................
Cleaning motorcycle ....................................................
Conservation for winter operation ..................................
STORAGE .......................................................................
Storage.......................................................................
Putting into operation after storage ...............................
SERVICE SCHEDULE.......................................................
Important service tasks to be carried out by an
authorized KTM-RC8 workshop. ....................................
Important service tasks to be carried out by an
authorized KTM-RC8 workshop. (as additional job) .........
WIRING DIAGRAM ..........................................................
1 of 3.........................................................................
2 of 3.........................................................................
3 of 3.........................................................................
OPERATING SUBSTANCES ..............................................
AUXILIARY SUBSTANCES................................................
SPECIAL TOOLS..............................................................
STANDARDS...................................................................
INDEX ............................................................................
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Reinstalling the throttle valve body when the

adjustments have been made........................................
Throttle position sensor circuit B...................................
Manifold absolute pressure sensor.................................
Connecting the vacuum hand pump to the manifold
absolute pressure sensor ..............................................
Ambient air pressure sensor..........................................
Injector ......................................................................
Rollover sensor............................................................
EFI control unit ...........................................................
Requesting the EFI control unit activation code..............
Coding the EFI control unit...........................................
Flashing the EFI control unit ........................................
IMMOBILIZER BLINK CODE.............................................
ENGINE CONTROL TROUBLE CODE .................................
CONNECTOR OVERVIEW..................................................
Motor drive circuit A connector AE ................................
Connector AI ...............................................................
Crankshaft position sensor connector AL........................
Clutch switch, connector AL .........................................
Throttle position sensor circuit A, connector AM .............
Throttle position sensor circuit B, connector AM.............
Gear position sensor, connector AM...............................
Fuel pump connector AM .............................................
Wheel speed sensor, connector AM ...............................
Connector AO..............................................................
Diagnostic connection plug AP......................................
Rollover sensor connector AP........................................
Throttle position sensor circuit A, connector AR..............
Throttle position sensor circuit B, connector AR .............
Fuel pump connector AR..............................................
Side stand switch, connector AR...................................
Ignition coil cylinder 1 connector AS .............................
Ignition coil cylinder 2 connector AS .............................
CAN bus terminating resistor connector AT ....................
Crankshaft position sensor, connector AT.......................
Clutch switch connector AT ..........................................
Engine coolant temperature sensor cylinder 1 connector
AX..............................................................................
Throttle stepper motor circuit B, connector CA ...............
Lambda sensor cylinder 1, connector CA .......................
Lambda sensor cylinder 2, connector CA .......................
Lambda sensor cylinder 1, connector CE .......................
Lambda sensor cylinder 2, connector CE .......................
Secondary air valve connector CK..................................
Connector CM .............................................................
Connector CO..............................................................
Connector CP ..............................................................
Connector CQ..............................................................
Connector CU..............................................................
Fuel evaporation valve connector DF..............................
Secondary air valve connector DF..................................
Electric starter lock control unit, connector DN ..............
Immobilizer control unit, connector DN .........................
Electric starter lock control unit, connector DO...............
Immobilizer control unit, connector DO..........................
Ambient air pressure sensor connector DP .....................
Manifold absolute pressure sensor cylinder 1,
connector DP ..............................................................
Manifold absolute pressure sensor cylinder 2
connector DP ..............................................................
Injector cylinder 1 connector DQ...................................
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MEANS OF REPRESENTATION
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).
Identifies a page reference (more information is provided on the specified page).
Formats used
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The typographical formats used in this document are explained below.

Specific name
Identifies a proprietary name.
Name
Identifies a protected name.
Brand
Identifies a brand available on the open market.
IMPORTANT NOTES
Warranty
The work described in the service schedule must be carried out exclusively in an authorized KTM-RC8 workshop and confirmed in the
service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
Materials
The fuels, lubricants and other materials named in this repair manual must be used according to specifications.
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.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring mounter (59029019000)
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.
If thread lock (e.g. Loctite) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize sources of danger and may therefore be injured.
Grades of risks
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.
Repair manual
Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and service your motorcycle.
This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.
LOCATION OF SERIAL NUMBERS
Vehicle identification number/type label

3.1
The vehicle identification number is stamped on the frame behind the steering head
on the right.
The type label is on the frame above the vehicle identification number.
100654-10
Key number
3.2
P
a
87 rt
7- Sh
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56 co
86 m
The key number Code 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.
Use the orange programming key to activate and deactivate the black ignition
key. Keep the orange programming key in a safe place: it must only be used for
learning and programming functions.
700222-01
Engine number
3.3
The engine number is stamped on the right side of the engine.
100655-10
Fork part number

3.4
The fork part number is stamped on the inner side of the fork stub.
100656-10
Shock absorber part number

3.5
The shock absorber part number is stamped on the upper part of the shock absorber
above the adjusting ring towards the rear.
100657-10
LOCATION OF SERIAL NUMBERS

Steering damper part number
3.6
The steering damper part number is stamped on the top of the steering damper.
P
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100658-10
MOTORCYCLE
10
Jacking up motorcycle front

4.1
Note
Danger of damageThe parked vehicle can roll away or fall over.
Always place the vehicle on a firm and even surface.
Jack up the motorcycle at the rear. (
Move the handlebar to the straight-ahead position. Align the work stand at the front
with the adapters to the fork legs.
Front work stand (61029055300) (
p. 13)
p. 443)
Info
Always jack up the rear of the motorcycle first.
Jack up the motorcycle at the front.
P
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100679-10
Taking front of motorcycle off work stand

4.2
Note
Secure the motorcycle against falling over.
Remove the work stand from the front.
Jacking up the motorcycle in the middle (screw-in type)

4.3
Note
Remove screw .
Remove screws . Take off the footrest bracket.
Unplug connector of the brake light switch. Remove cable binder .
200598-01
200599-01
Remove screw . Hang the brake fluid reservoir to the side.
Remove screws . Hang the footrest bracket to the side.
MOTORCYCLE
11
Screw the holder of the special tool all the way into the lower drill holes of the
footrest brackets. Select the required height and width of the work stand.
Work stand (62529055000) (
p. 447)
Jack up the motorcycle.
Info
P
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Check that the work stand is seated correctly.
200600-01
Removing the motorcycle from the work stand (screw-in type)

4.4
Note
Remove the motorcycle from the work stand and rest it on the side stand.
Unscrew the holder of the special tool from the drill holes in the footrest brackets.
Remove the work stand.
Work stand (62529055000) (
p. 447)
200600-01
Position the footrest bracket. Mount and tighten screws .
Guideline
Screw, front footrest
bracket
M8
25 Nm
(18.4 lbf ft)
Loctite 243
Position the brake fluid reservoir. Mount and tighten screw .

Guideline
Screw, brake fluid reservoir of rear brake
200599-11
M5
5 Nm
(3.7 lbf ft)
Loctite 243
Plug in connector of the brake light switch. Secure the cable with cable
binder .
MOTORCYCLE
12

Guideline
bracket
M8
25 Nm
(18.4 lbf ft)
Loctite 243
Position the shift rod. Mount and tighten screw .

Guideline
Screw, shift rod
M6
12 Nm
(8.9 lbf ft)
Loctite 243
200598-11
Jacking up the motorcycle in the middle (insertable type)

4.5
Note
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Let the work stand engage in the opening of the swingarm pivot with the plastic
sleeve. Select the required height and width of the work stand.
Work stand (62529055000) (
p. 447)
Jack up the motorcycle.
Info
Check that the work stand is seated correctly.
200597-01
Removing the motorcycle from the work stand (insertable type)

4.6
Note
MOTORCYCLE
13
Remove the motorcycle from the work stand and rest it on the side stand.
Remove the work stand.

p. 447)
P
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Work stand (62529055000) (
200597-01
Jacking up motorcycle at the rear

4.7
Note
Insert the work stand adapter in the rear of the work stand.
Work stand adapter (61029055120) (
Work stand rear (61029055100) (
p. 442)
p. 442)
Stand the motorcycle upright, align the work stand to the link fork and the
adapters, and jack up the motorcycle.
100680-10
Taking the rear from the workstand

4.8
Note
Secure the motorcycle against falling over.
Remove the work stand from the rear and lean the vehicle on the side stand.
Starting
4.9
Danger
Danger of poisoningExhaust gases are poisonous and can 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 a closed
space without an effective exhaust extraction system.
Caution
Danger of accidentsIf 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.
MOTORCYCLE
14
Note
Engine failureHigh 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.
Press the emergency OFF switch into the position
Switch on the ignition by turning the black programming key to the position ON
.
.
After you switch on the ignition, you can hear the fuel pump working for about
two seconds. The function test of the combination instrument is run at the
same time.
Shift into neutral.

The green idling speed indicator lamp N lights up.
Press the electric starter button
Info
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Do not press the electric starter button until the function test of the combination instrument is finished.
When starting the engine, DO NOT apply the throttle. If you apply the throttle
during the starting procedure, the engine management shuts off the injectors and the engine will not start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds
before trying again.
This motorcycle is equipped with a safety start system. You can only start
the engine if the transmission is in neutral or if the clutch is pulled when a
gear is engaged. If the side stand is folded down and you shift into gear and
release the clutch, the engine stops.
100677-10
Take the weight off the side stand and swing it upwards with your foot as far as it
will go.
01/FORK, TRIPLE CLAMP
15
Adjusting the compression damping of the fork

5.1
Info
The hydraulic compression damping determines the fork suspension behavior.
An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or
when the load shifts very fast. It gives the rider good feedback about the road conditions.
Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
P
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Compression damping
100682-10
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting the rebound damping of the fork

5.2
Info
The hydraulic rebound damping determines the fork rebound behavior.

An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to
the zero position.
Turn adjusting screws clockwise to the stop.
Info
The adjusting screws are located at the top end of the fork legs.
Adjust both fork legs to the same setting.
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Info
Turn clockwise to increase suspension damping; turn counterclockwise to

reduce damping.
100683-10
16
Adjusting the spring preload of the fork

5.3
Info
Spring preload determines the initial fork position.
The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and
thus ensures a compromise between maneuverability and stability.
Turn adjusting screws clockwise to the stop.
Info
The adjustment screws are located at the top end of the fork legs.
Adjust both fork legs to the same setting.
Turn back counterclockwise by the number of turns according to the fork type.
Guideline
P
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99 a
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Spring preload - Preload Adjuster

Comfort
5 turns
Standard
5 turns
Sport
3 turns
Full payload
3 turns
Info
Turn clockwise to increase preload, turn counterclockwise to reduce spring

preload.
Changing the spring preload has no influence on the rebound damping
although the adjustment screws turn during the adjustment work. However,
you should also adjust the rebound damping when you alter the spring
preload.
100683-11
Bleeding fork legs

5.4
Lean the motorcycle on the side stand.
Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
Mount and tighten bleeder screws.
Info
Perform this action on both fork legs.
100684-10
17
Vehicle level
5.5
Warning
Danger of accidentsModifications to the suspension settings can seriously alter
the vehicle's ride behavior.
Following modifications, ride slowly at first to get the feel of the new ride
behavior.
The vehicle level can be adjusted at the front by means of the fork leg clamp and at
the rear by the eccentric shaft.
The fork legs can be clamped at three positions in the triple clamps.
0 mm (0 in)
Upper triple clamp flush

with 1st ring of fork legs
2.5 mm (0.098 in)

with 2nd ring of fork legs
(standard)
5 mm (0.2 in)
P
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with upper edge of fork legs
100693-01
The infinitely variable frame height setting can be adjusted by turning the eccentric
shaft.
Frame height difference
HIGH - LOW
12 mm (0.47 in)
Maximum adjustment range

between HIGH - LOW
180
Adjusting front vehicle level

5.6
Warning
Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior.
Following modifications, ride slowly at first to get the feel of the new ride behavior.
Loosen screws on the lower triple clamp.
Loosen screw on the upper triple clamp.
Loosen screw of the handlebar stub.
Info
Loosen the screws far enough to prevent damage to the lacquer when the
fork legs are moved.
Make the adjustments first on one fork leg and then on the other. When the
screws of both fork legs are loosened, the vehicle sags toward the front.
100694-10
Align the fork leg in the desired position by means of the fork rings.
Guideline
100695-01
Upper triple clamp flush with upper

edge of fork legs
0 mm (0 in)
Upper triple clamp flush with 1st ring

of fork legs
2.5 mm (0.098 in)
Upper triple clamp flush with 2nd ring

of fork legs (standard)
5 mm (0.2 in)
Info
The standard adjustment is the setting that provides the best vehicle handling. When the fork is compressed, the suspension setting changes, causing the vehicle to become more stable but also more difficult to handle.
18
Tighten screw .
Guideline
Screw, top triple clamp
M8
17 Nm
(12.5 lbf ft)
M8
15 Nm
(11.1 lbf ft)
M8
20 Nm
(14.8 lbf ft)
Tighten screws .
Guideline
Screw, bottom triple clamp
100694-11
Tighten screw .
Guideline
Screw, handlebar stub
Repeat the adjustment on the other fork leg.
P
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Info
The vehicle level setting on both fork legs must be identical.
Removing the fork

5.7
Jack up the motorcycle in the middle (insertable type). (
Clamp down the rear of the vehicle.
Remove the screws from both brake calipers.
Press back the brake linings with a light lateral tilting of the brake calipers on the
brake disc. Pull the brake caliper carefully back from the brake discs and hang it to
the side.
p. 12)
Info
Do not pull the hand brake lever when the brake calipers are removed.
100719-10
Loosen screws and .
Unscrew screw about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidentsReduced braking efficiency caused by damaged brake

discs.
201056-10
201057-10
Always lay the wheel down in such a way that the brake discs are not
damaged.
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Remove the screws on both sides of the fender . Take off the fender.
19
Remove screws . Hang the wheel speed sensor to the side.
Unscrew screws of the triple clamps and handlebar stubs. Remove the fork legs
downward.
P
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87 rt
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99 a
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86 m
201058-10
201059-10
Installing the fork

5.8
Warning
Slide the fork legs into the triple clamps and handlebar stubs.
Align the fork leg in the desired position by means of the fork rings.
Guideline
100695-01
Upper triple clamp flush with upper

edge of fork legs
0 mm (0 in)
Upper triple clamp flush with 1st ring

of fork legs
2.5 mm (0.098 in)
Upper triple clamp flush with 2nd ring

of fork legs (standard)
5 mm (0.2 in)
Info
The standard adjustment is the setting that provides the best vehicle handling. When the fork is compressed, the suspension setting changes, causing the vehicle to become more stable but also more difficult to handle.
Tighten screws of the triple clamps and handlebar stubs.
Guideline
M8
17 Nm
(12.5 lbf ft)
M8
15 Nm
(11.1 lbf ft)
M8
20 Nm
(14.8 lbf ft)
201059-11
Position the wheel speed sensor. Mount and tighten screws .

Guideline
Screw, wheel speed sensor
201058-11
M4
2 Nm
(1.5 lbf ft)
Loctite 243
20
Position the fender. Mount and tighten screws .

Guideline
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
201057-11
Clean and grease the shaft seal rings and mating surfaces of the spacers.
p. 438)
P
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99 a
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86 m
Long-life grease (
100781-11
Insert the wide spacer on the left-hand side (when looking in the direction of
travel).
Info
The arrow indicates the direction of rotation of the front wheel.
Insert the narrow spacer on the right-hand side (when viewed in the direction of
travel).
100780-11
Warning
Danger of accidentsReduced braking efficiency due to oil or grease on the

brake discs.
201060-10
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
Clean screw and the wheel spindle.
Lift the front wheel into the fork, position it, and insert the wheel spindle.
Mount and tighten screw .

Guideline
Bolt, front axle
M25x1.5
45 Nm
(33.2 lbf ft)
Position the brake calipers and check that the brake linings are seated correctly.
Mount screws on both brake calipers but do not tighten yet.
Operate the hand brake lever repeatedly until the brake lining presses up against
the brake disc and there is a pressure point. Fix the hand brake lever in the activated position.
Tighten screws on both brake calipers.
The brake calipers align themselves.

Guideline
100719-12
Screw, front brake caliper
M10x1.25
45 Nm
(33.2 lbf ft)
Release the fixation of the hand brake lever.
Release the rear of the vehicle.
Remove the motorcycle from the work stand (insertable type). (
Loctite 243
p. 12)
21
Pull the front brake and compress the fork powerfully a few times.
Tighten screws .
The fork legs straighten.

Guideline
Fork end pinch bolts
M8
15 Nm
(11.1 lbf ft)
100782-11
performing a fork service

5.9
Info
P
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7- Sh
99 a
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56 co
86 m
These operations are the same on both fork legs.

Condition
The fork legs have been removed.
Disassemble the fork legs. (
p. 21)
Disassemble the outer tubes. (
Change the lower DU bush. (
Check the fork legs. (
Assemble the outer tubes. (
Assemble the fork legs. (
p. 24)
p. 26)
p. 25)
p. 27)
p. 27)
201097-01
Disassembling the fork legs

5.10
Info
Condition
The fork legs have been removed.
200605-10
Determine and note down the current setting of rebound damping and compression damping .
Completely open the adjusting elements of the rebound and compression damping.
Determine and note down the current setting of spring preload .
Completely open the adjusting elements of the spring preload.
22
Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) (
p. 451)
200606-10
Release Preload Adjuster .

Key (T524) (
p. 450)
Info
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The Preload Adjuster cannot be removed yet.
Unclamp the fork leg. Slide the outer tube down.
Clamp aluminum tube with the special tool.
200607-10
p. 450)
200608-10
Pull up Preload Adjuster . Mount the special tool on the hexagonal piece.
Open-end wrench (T14032) (
p. 450)
200609-10
200610-10
Hold the hexagonal piece in place with the special tool. Release Preload Adjuster
and remove it with preload spacers .
23
Remove adjusting tube .
Screw special tool onto the piston rod and pull it up.
200611-10
Gripping tool (T14026S1) (
p. 449)
Remove the special tool from the hexagonal piece.

p. 450)
P
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7- Sh
99 a
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56 co
86 m
Release special tool .
p. 449)
200612-10
Unclamp the fork leg and clamp it with the axle clamp.
Pull out pin of the special tool.
Pull collar bushing off of aluminum tube . Slide the aluminum tube over the
special tool.
Unscrew the special tool.
Remove the collar bushing.
Remove spring .
Unclamp the fork leg.
200613-10
Info
Hold the fork leg by the axle clamp.
200614-10
Drain the fork oil.
Info
Pull out the piston rod and push back in a number of times to empty the
cartridge.
200615-10
Pull outer tube off of inner tube .
24
Clamp the fork leg with the axle clamp.
Remove screws .
Unscrew screws of the cartridge and remove with the seal ring.
200616-10
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Place a drain pan underneath.
200617-10
Remove the cartridge.
200618-10
Disassembling the outer tubes

5.11
Info
These operations are the same on both outer tubes.
Disassemble the fork legs. (
Clamp the outer tube in the area of the lower triple clamp.
200619-10
Remove dust boot .
p. 21)
p. 451)
25
Remove lock ring .
Remove seal ring .
P
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99 a
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200620-10
200621-10
Remove support ring .
200622-10
Checking the fork legs

5.12
Condition
The fork legs must be disassembled.
Check the inner tube and axle clamp for damage.
If there is damage:
Change the inner tube.
200629-10
Measure the outside diameter at several locations on the inner tube.

Outside diameter of inner tube
If the measured value is less than the specified value:
200630-10
42.975 43.005 mm (1.69193

1.69311 in)
26
Measure the run-out of the inner tube.

0.20 mm ( 0.0079 in)
Run-out of inner tube
If the measured value is greater than the specified value:
200631-10
Check the outer tube for damage.
If there is damage:
Change the outer tube.
P
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87 rt
7- Sh
99 a
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56 co
86 m
200632-10
Check the surface of the upper DU bush.
If the bronze-colored layer under the sliding layer is visible:
Change the outer tube.
Check the surface of the lower DU bush.
If the bronze-colored layer under the sliding layer is visible:
Change the lower DU bush. (
p. 26)
200665-10
Check the spring length.

Guideline
Spring length with preload spacer(s)
405 mm (15.94 in)
If the measured value is less than the specified value:
Reduce the thickness of the preload spacer.
Increase the thickness of the preload spacer.
200666-10
changing the lower DU bush

5.13
Disassemble the outer tubes. (
Heat the outer tube in the area of the lower DU bush.
p. 24)
Guideline
50 C (122 F)
200664-10
Remove DU bush .
Press the new DU bush all the way in.
p. 27)
27
Assembling the outer tubes

5.14
Info
These operations are the same on both outer tubes.
Check the fork legs. (
Clamp the outer tube in the area of the lower triple clamp.
p. 25)

Insert support ring .
P
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87 rt
7- Sh
99 a
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56 co
86 m
p. 451)
200622-11
Lubricate seal ring and mount it with the open side facing downward.
Lubricant (T511) (
p. 438)
200621-11
Mount lock ring .
The lock ring engages audibly.
200620-11
Lubricate and mount dust boot .

Lubricant (T511) (
p. 438)
200619-11
Assembling the fork legs

5.15
Info
p. 27)
28
Slide the cartridge into the inner tube with spring seat and the preload bush.
Clamp the fork leg with the axle clamp.
200618-11
Guideline
M12x1
P
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7- Sh
99 a
r
9- k.
56 co
86 m
Screw, cartridge
25 Nm
(18.4 lbf ft)
200626-10
Lubricate and mount screws of the axle clamp but do not tighten.
Lubricant (T152) (
p. 438)
200616-11
Vertically clamp the fork leg with the axle clamp.
Slide outer tube onto inner tube .
Position the spring in the inner tube.
200615-11
200623-10
29
Slide on collar bushing .
Slide adjusting tube into the piston rod.
Install the special tool.
200624-10
p. 449)
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The special tool must be used to prevent the adjusting tube from being
raised, which would cause oil to enter into the piston rod.
Add fork oil.
Fork oil per fork

leg
200627-10
520 ml
(17.58 fl. oz.)
Fork oil (SAE 5) (
p. 437)
Info
Pull out the piston rod and push back in a number of times to bleed the cartridge.
Slide on aluminum tube . Mount collar bushing .
Mount pin of special tool .
200625-10
Clamp the fork leg at the aluminum tube with the special tool.
p. 449)
p. 450)
Pull up special tool and mount special tool onto the hexagonal piece.
200612-11
p. 450)
30
Unscrew the special tool from the piston rod.

Lubricate the thread of the piston rod.

Lubricant (T159) (
p. 438)
Lubricate the upper edge of the piston rod.

Lubricant (T158) (
p. 449)
p. 438)
Mount Preload Adjuster with preload spacer .
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The Preload Adjuster must reach the stop before the piston rod begins turning 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.
Counter with the special tool and tighten the Preload Adjuster.
Guideline
Preload Adjuster on piston rod
M12x1
200628-10
25 Nm
(18.4 lbf ft)
p. 450)
Pull up Preload Adjuster and remove the special tool from the hexagonal piece.
p. 450)
200609-11
Unclamp the fork leg. Slide the outer tube up and clamp in the area of the lower
triple clamp.
p. 451)
200606-10
Lubricate the O-ring of the Preload Adjuster .

Lubricant (T511) (
p. 438)
Screw on the Preload Adjuster and tighten.

Guideline
Preload Adjuster on outer tube

Key (T524) (
M46x1
50 Nm
(36.9 lbf ft)
p. 450)
200607-11
Alternative 1
Turn the adjusting screw of compression damping and the adjusting screw of
rebound damping all the way clockwise.
200605-11
Turn back counterclockwise by the number of clicks corresponding to the fork

leg type.
31
Guideline
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Compression damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Turn the adjusting screw of spring preload all the way clockwise.
Turn back counterclockwise by the number of turns according to the fork type.
P
a
87 rt
7- Sh
99 a
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9- k.
56 co
86 m
Guideline

Comfort
5 turns
Standard
5 turns
Sport
3 turns
Full payload
3 turns
Alternative 2
Warning
Danger of accidentsModifications to the chassis can seriously alter the

vehicle's handling characteristics.
Extreme modifications to the adjustment of the spring elements can

cause a serious deterioration in the handling characteristics and
overload some components.
Make settings within the recommended range only.
Following modifications, ride slowly at first to get the feel of the new
handling characteristics.
Return the adjusting screws to the position determined when the unit was disassembled.
02/HANDLEBAR, CONTROLS AND INSTRUMENTS
32
Adjusting basic position of clutch lever

6.1
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
Info
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
100751-10
Adjusting the steering damper

6.2
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Info
The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load.
In contrast to other damping elements, the steering damper is adjusted with the damping element open.
Turn the adjusting screw counterclockwise towards "" as far as the last perceptible click.
Adjust the steering damper according to your riding style and the road conditions
by turning the adjust screw clockwise towards "+".
Guideline
Steering damper adjustment range
1 32 clicks
Recommended range for use
1 20 clicks
Standard
1 click
100692-10
Info
Do not change the adjustment of the steering damper during the journey!
After adjusting the steering damper, check the steering for smooth operation, making sure that the handlebar can be moved from extreme left to
extreme right without a tendency to lock.
Adjusting the handlebar height

6.3
Info
The handlebar stub position must be identical on the left and right of the vehicle.
Adjusting the high position of the handlebar stubs:

Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
Remove screw .
100756-10
Remove distance sleeve .
All cables routed under the upper triple clamp must now be routed under the
handlebar stub.
Push the handlebar stub carefully up to the upper triple clamp.
Position the distance sleeve above the triple clamp.
Mount and tighten the screw.

Guideline
Remaining frame bolts
100757-10
M5
5 Nm (3.7 lbf ft)
33
Tighten the screw.

Guideline
M8
Repeat the adjustments on the other handlebar stub.
Move the handlebar to and fro over the entire steering range.
If the cables restrict the freedom of movement of the steering:
100759-01
20 Nm
(14.8 lbf ft)
Correct the cable routing.
Adjusting the low position of the handlebar stubs:

Loosen screw .
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
100759-10
Remove screw with distance sleeve .
Carefully shift the handlebar stub by the length of the distance sleeve.
Guideline
Long distance sleeve
15 mm (0.59 in)
Lay all cables between the upper triple clamp and the handlebar stub.
Position the distance sleeves.
Mount and tighten the screw.

Guideline
100760-10
M5
5 Nm (3.7 lbf ft)
M8
20 Nm
(14.8 lbf ft)
Tighten the screw.

Guideline
Repeat the adjustments on the other handlebar stub.
Move the handlebar to and fro over the entire steering range.
If the cables restrict the freedom of movement of the steering:
100761-01
Correct the cable routing.
Adjusting the play in the throttle cable

6.4
Move the handlebar to the straight-ahead position.
Throttle position sensor circuit A - check in the "zero" position. (
p. 219)
Info
It is imperative to use the KTM diagnostics tool for this.
100754-10
Push back protective cover .
Loosen counter nut .
Set the play in the throttle cable by turning adjusting screw .

Guideline
Throttle cable play
Tighten counter nut .
Mount the protective cover.
3 5 mm (0.12 0.2 in)
34
Throttle grip
6.5
The installed throttle grip twists opens uniformly (linear) over the entire range of the
throttle valve.
The throttle grip supplied does not open the throttle valves as widely at the same
turning angle lower down the rev range. This makes the throttle response in the lower
rev range less aggressive and can fed in more progressively.
By installing the corresponding throttle grip the throttle response can be set to suit
your personal riding style / according to the operating requirements.
100783-10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The throttle grips can be distinguished by the markings stamped into the inner face.
The installed throttle grip has the marking 3081.
The supplied throttle grip has the marking 5209.
Info
Resetting the throttle cable play is necessary after replacement has been carried
out. It is imperative to use the KTM diagnostics tool for this.
100784-10
Changing the throttle grip

6.6
Loosen screw .
Take off handlebar weight .
Unscrew screw .
301446-10
301447-10
301448-10
Remove screw .
Remove the spacer.
Loosen screw .
Turn the handlebar all the way to the right.
Turn the handlebar stub to the left.
Remove the throttle grip.
Push back protective cover .
35
301449-10
Unscrew lock nut .

Screw adjusting screw all the way in.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301450-10
Remove screws .
Take off cover .
Detach the throttle cables.
Remove the throttle grip.
301451-10
301452-10
Throttle grip with code 3081:

Check that angle piece of the throttle cable (closer) is seated correctly.
Guideline
Distance
If the specified value is not reached:
301455-10
9 11 mm (0.35 0.43 in)
Adjust the throttle cable at the throttle valve. (
Position the throttle grip.
Attach the throttle cables.
p. 37)
36
Throttle grip with code 5209:

Check that angle piece of the throttle cable (closer) is seated correctly.
Guideline
Distance
9 11 mm (0.35 0.43 in)
Adjust the throttle cable at the throttle valve. (
Position the throttle grip.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 37)
301455-10
Open the throttle to the point where there is no play in the throttle cable.
Guideline
Marking of the throttle grip must be aligned with the bottom edge of
the housing.
The marking is not aligned:
Correct the play in the throttle cable using barrel adjuster .
301462-10
Grease the front and rear parts of the cover.

Long-life grease (
p. 438)
Position cover .
Mount screws but do not tighten them yet.
Turn the handlebar all the way to the right.
Turn the handlebar stub to the left.
Slide on the throttle grip.
301456-10
301449-10
37
Align the handlebar stub.
Position the distance sleeves.
Mount screw but do not tighten them yet.
Tighten screw .
Guideline
301448-10
M8
20 Nm
(14.8 lbf ft)
M5
5 Nm (3.7 lbf ft)
M5
5 Nm (3.7 lbf ft)
Tighten screw .
Guideline
Fully tighten screws .

Guideline
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301447-10
Mount handlebar weight .
Tighten screw .
Guideline
M6
Adjust the play in the throttle cable. (
p. 33)
301446-10
Adjusting the throttle cable at the throttle valve

6.7
Dismount the fuel tank. (
Remove the air filter. (
Unscrew lock nuts .
Unscrew barrel adjuster .
Detach the throttle cables.
Detach throttle cable wire (closer) and remove it.
p. 70)
p. 67)
301457-10
301458-10
10 Nm (7.4 lbf ft)
38
Unscrew lock nut .
Screw in angle piece until it is seated correctly.

Guideline
9 11 mm (0.35 0.43 in)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Distance
301459-10
Route the throttle cable so it is not under tension.
Attach throttle cable wire (closer).
Mount barrel adjuster .
Mount lock nuts but do not tighten them yet.
Connect the KTM diagnostics tool.
Select the model.
301458-10
301457-10
Select "ECU Diagnosis".
Mark the "Engine management EFI LC8 RC8" control unit.
Press "Continue".
Select "Adjustment".
"Please enter the password:"
Press "Continue".
Select "Throttle position sensor circuit A adjustment".
Press "Continue".
Info
The motor drive moves the throttle valve in circuit A to the zero setting.
Adjust the throttle cable play at the throttle grip using barrel adjusters .
Guideline
Throttle cable play
301461-10
3 5 mm (0.12 0.2 in)
Tighten lock nuts .
Complete the adjustment by pressing the "Quit" button.
Ensure that rubber grommets are seated correctly.
Install the air filter. (
Install the fuel tank. (
p. 67)
p. 71)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301460-10
39
03/FRAME
40
Side stand switch

7.1
Installation location
The side stand switch is fitted to the side stand.
Side stand switch, connector AR (
p. 394) pin assignment
Side stand signal

"SSTAND SW"
Retracted
Side stand signal

"SSTAND SW"
Extended
Side stand voltage "Side stand AD"
900040-60
Retracted
1.5 3.2 V
Extended
4.0 5.0 V
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Footrest position
7.2
The adjustable footrest system enables an individual setting of the footrest height and
an individual adjustment of the controls.
The lower footrest position enables a more comfortable knee angle, the upper footrest
position a sporting sitting position and more forward-leaning freedom for use in racing.
100699-10
Adjusting footrest position

7.3
Info
The footrest position must be identical on the left and the right.
Remove screws .
100713-10
Position the footrest bracket with spacers and screws.
Guideline
Standard
Lower position
Info
The adjustable footrest bracket enables a more comfortable lower footrest

position or a sporting upper footrest position.
100700-10
Mount and tighten screws.

Guideline
bracket
100701-01
M8
25 Nm
(18.4 lbf ft)
Loctite 243
03/FRAME
41
Repeat adjustment work on the footrest bracket on the other side.
Adjust the shift lever. (
Adjust the foot brake pedal. (
p. 192)
p. 100)
100702-01
Rear frame position

7.4
The frame rear height can be set to two different positions, enabling ergonomic adjustment of the seat height.
805 mm (31.69 in)
Seat height
825 mm (32.48 in)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Seat height (standard)
400439-10
Adjusting the rear frame position

7.5
Warning
Remove the seat. (
Remove screws with the bushings.
p. 70)
100762-10
Setting a higher seat position:

Remove screw with washer on the left and right sides of the vehicle.
Push the rear end down until the drill holes of the frame are level with the
lower front drill holes of the rear.
Mount the screw and washer on the left and right sides of the vehicle, but do
not tighten.
100763-10
100764-01
03/FRAME
42
Push the rear end up until the drill holes of the frame are level with the lower
rear drill holes of the rear.
Mount the screw and washer on the left and right sides of the vehicle, and
tighten.
Guideline
Screw, subframe
M8
20 Nm
(14.8 lbf ft)
Loctite 243
100765-10
Tighten screw on the left and right sides of the vehicle.

Guideline
M8
20 Nm
(14.8 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, subframe
Loctite 243
100766-10
Setting a lower seat position:

Push the rear end down until the drill holes of the frame are level with the
upper rear drill holes of the rear.
Mount the screw and washer on the left and right sides of the vehicle, but do
not tighten.
Push the rear end up until the drill holes of the frame are level with the upper
front drill holes of the rear.
Mount the screw and washer on the left and right sides of the vehicle, and
tighten.
100763-11
100765-11
Guideline
Screw, subframe
M8
20 Nm
(14.8 lbf ft)
Loctite 243
100764-01
Tighten screw on the left and right sides of the vehicle.

Guideline
Screw, subframe
100765-12
M8
20 Nm
(14.8 lbf ft)
Loctite 243
03/FRAME
43
When you screw in the rear left fixing screw, the plug-in cable binder is pushed
out of the thread. To reposition the cable of the lambda sensor, fix the plug-in
cable binder in the remaining free drill hole.
Info
Check the cable routing. The cable of the lambda sensor should not be taut.
100767-10
Position bushings .
Mount and tighten screws .
Guideline
Fit the seat. (
p. 70)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
M6
100768-10
10 Nm (7.4 lbf ft)
04/SHOCK ABSORBER, SWINGARM
44
Adjusting the low-speed compression damping of the shock absorber

8.1
Danger
Danger of accidentsDisassembly of pressurized parts can lead to injury.
The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
Turn adjusting screw clockwise with a screwdriver up to the last perceptible

click.
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Do not loosen nut !
Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
Compression damping, low-speed
100686-10
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Adjusting the high-speed compression damping of the shock absorber

8.2
Danger
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
Turn adjusting screw clockwise with an open-ended spanner until it stops.
Info
Do not loosen nut !
Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed

100687-10
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Full payload
1 turn
Info
45
Adjusting the rebound damping of the shock absorber

8.3
Danger
Turn adjusting screw clockwise up to the last perceptible click.

absorber type.
Guideline
Rebound damping
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
10 clicks
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Comfort
100688-10
Info
Turn clockwise to increase damping; turn counterclockwise to reduce suspension damping.
Adjusting the spring preload of the shock absorber

8.4
Warning
Info
The spring preload defines the initial situation of the spring process on the shock absorber.
The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and
thus ensures a compromise between maneuverability and stability.
Take the weight off the rear wheel and swingarm.
Info
The spring preload can be adjusted correctly only if the rear wheel and the
swingarm are fully relieved of weight.
Loosen screw two turns, but do not remove.
Turn the adjusting ring counterclockwise with the wrench from the tool kit until the
spring is no longer under tension.
100689-10
Hook wrench (69012022000)

Extension (60012060000)
Turn the adjusting ring clockwise and tension it to the specified value.
Guideline
Spring preload
100690-01
Comfort
6 mm (0.24 in)
Standard
6 mm (0.24 in)
Sport
8 mm (0.31 in)
Full payload
8 mm (0.31 in)
Info
Turn clockwise to increase preload, turn counterclockwise to reduce spring
preload.
46
Tighten screw .
Guideline
M5
5 Nm (3.7 lbf ft)
100689-11
Adjusting the vehicle level at the rear

8.5
Warning
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Loosen screw but do not remove it.
Turn eccentric shaft to the desired position using the tool from the tool set.
100696-10
Guideline
Standard
LOW
Maximum adjustment range between

HIGH - LOW
180
Open end wrench SW 38 (69012021000)
Info
100697-10
The chassis height can be adjusted in both directions.
Tighten screw .
Guideline
Screw, clamp, eccentric shaft of

deflector
M8
18 Nm
(13.3 lbf ft)
100698-10
Removing the shock absorber

8.6
200602-10
Jack up the motorcycle in the middle (insertable type). (
Remove the lower screw of the shock absorber.
p. 12)
47
Remove screw .
Remove upper screw of the shock absorber.
Remove nut . Pull out the pin of bell crank on the frame. Remove the bell
crank.
Remove the shock absorber toward the rear right.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200603-10
200604-01
Installing the shock absorber

8.7
Fit the shock absorber from the rear left.
Position bell crank . Mount the pin and nut of the bell crank on the frame.
Tighten the nut.
200604-01
Guideline
Nut of bell crank on frame
M14x1.5
100 Nm
(73.8 lbf ft)

Guideline
Screw, shock absorber
M10
45 Nm
(33.2 lbf ft)
Loctite 243
M10
45 Nm
(33.2 lbf ft)
Loctite 243
M10
45 Nm
(33.2 lbf ft)
Loctite 243
200603-11

Guideline
Screw, connecting lever,

shock absorber deflector

Guideline
200602-11
Remove the motorcycle from the work stand (insertable type). (
p. 12)
48
Servicing the shock absorber

8.8
Condition
The shock absorber has been removed.
Remove the spring. (
p. 48)
Disassemble the damper. (
Disassemble the piston rod. (
Check the damper. (
Assemble the piston rod. (
p. 49)
p. 50)
p. 51)
Assemble the damper. (
Install the spring. (
p. 52)
p. 53)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 59)
201094-01
Removing the spring

8.9
Condition
Clamp the shock absorber into the vice with soft jaws.
Measure and note the spring length while the spring is under tension.
Loosen screw .
Turn the adjusting ring until the spring is no longer under tension.
Hook wrench (T106S) (
200561-01
200562-01
Remove spring retainer .
Remove the spring.
p. 448)
49
Disassembling the damper

8.10
Remove the spring. (
Determine and note down the current setting of the rebound and compression
damping.
Remove rubber cap of the reservoir.
Remove adjusting ring .
Slowly open screw .
p. 48)
200563-10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The nitrogen pressure dissipates.
200564-10
Remove locking cap .
Push in seal ring retainer . Remove lock ring .
200565-10
Info
Do not scratch the inside surface.
200566-10
Remove screw . Let the oil drain.
Remove the piston rod. Drain the remaining oil.
200567-10
200568-10
Remove compression damping adjuster . Remove the spring, sleeve and piston.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
50
200569-10
Disassembling the piston rod

8.11
Disassemble the damper. (
Clamp the piston rod into a vise with the heim joint.
Remove nut .
Remove supporting plate and rebound shim stack together with piston .
p. 49)
200570-10
Info
Slip the rebound shim stack onto a screwdriver and set the shims down
together.
200571-10
Remove compression shim stack with supporting plate .
Info
Slip the compression shim stack onto a screwdriver and set the shims down
together.
200572-10
51
Remove seal ring retainer .
Remove locking cap and rubber buffer .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200573-10
200574-10
Checking the damper

8.12
Condition
The damper has been disassembled.
Measure the inside diameter at both ends and in the middle of the damper cartridge.
Damper cartridge
Minimum diameter
If there is damage or wear:
Change the damper cartridge.
Check the damper cartridge for damage and wear.
300601-10
46.10 mm (1.815 in)
Change the damper cartridge.
Measure the diameter of the piston rod.

Piston rod
Diameter
13.95 mm ( 0.5492 in)
Change the piston rod.
Measure the run-out of the piston rod.

Piston rod
300554-10
Run-out
Check the piston rod for damage and wear.
0.06 mm ( 0.0024 in)
52
Check the heim joint for damage and wear.

Change the heim joint.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
300460-01
Assembling the piston rod

8.13
Clamp the piston rod into a vise with the heim joint.
Mount rubber buffer plug and locking cap .
Position special tool on the piston rod.
200574-11
Mounting sleeve (T313) (
p. 450)
Grease the seal ring and slide seal ring retainer onto the piston rod.
Lubricant (T625) (
p. 439)
Remove the special tool.
Mount supporting plate with the rounded side facing downward.
Mount compression shim stack with the smaller shims at the bottom.
Grind the piston on both sides on a surface plate with 1200 grade sand paper.
Clean the piston.
Mount the piston.
200575-10
200572-11
Info
The piston is identical on both sides.
200576-10
53
Mount rebound shim stack with the smaller shims at the top.
Mount supporting plate .
Mount and tighten nut .
200571-11
Guideline
M8
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Nut, piston rod
30 Nm
(22.1 lbf ft)
200570-11
Assembling the damper

8.14
Assemble the piston rod. (
Place the spring and sleeve onto the compression damping adjuster. Mount the piston.
Mount and tighten compression damping adjuster .
p. 52)
Guideline
Compression damping adjuster
M26x1
30 Nm
(22.1 lbf ft)
M10x1
14 Nm
(10.3 lbf ft)
200586-01

Guideline
Screw, filling port
200567-11
54
Fill the damper cartridge about half full.

Shock absorber oil (SAE 2.5) (50180342S1) (
p. 437)
200587-01
Lubricate O-ring of the seal ring retainer.

Lubricant (T158) (
Carefully mount the piston rod.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 438)
200568-11
Mount seal ring retainer and slide it under the ring groove.
Mount lock ring .
Info
Do not scratch the inside surface.
Pull out the piston rod until the seal ring retainer rests against the lock ring.
Mount locking cap of the damper cartridge.
200566-11
Bleed and fill the damper. (
Fill the damper with nitrogen. (
Mount rubber cap of the reservoir.
Mount adjusting ring and turn it all the way down.
p. 55)
p. 58)
200588-01
The collar faces the spring.
200563-11
Alternative 1
Turn adjusting screw clockwise with a screwdriver to the last perceptible
click.

absorber type.
Guideline
200596-01
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
55
Turn adjusting screw clockwise as far as it will go using an open end 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 to the last perceptible click.

absorber type.
Guideline
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
10 clicks
Alternative 2
Warning


Turn adjusting screws , and to the position noted down when the unit
was disassembled.
Install the spring. (
p. 59)
Bleeding and filling the damper

8.15
Info
Before working with the vacuum pump, carefully read the operating manual included with the vacuum pump.
Remove the filling port screw.
Mount adapter on the damper.
Info
Hand-tighten only without using a tool.
200590-01
Connect adapter to connector of the vacuum pump.
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 located at the highest position.
The piston rod moves in and out during filling; do not immobilize it by holding it with your hand.
56
Position the control lever as shown in the photo.

Control lever External tank is set to Closed, Damper is set to Vacuum and
Oil reservoir is set to Vacuum.
Activate On/Off switch .

The suction process begins.
Pressure gauge drops to the required value.
< 0 bar
200271-10
Vacuum gauge drops to the required value.

4 mbar
Determine distance between the floating piston and reservoir hole with the special tool.
p. 449)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Depth micrometer (T107S) (
The floating piston is positioned all the way at the bottom.
200591-01
When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.

0 bar
200267-10
When the pressure gauge reaches the required value, turn control lever Damper
to Pressure.
Guideline
0 bar
Oil is pumped into the damper.

3 bar
200268-10
to Vacuum.
Guideline
3 bar
The pressure gauge drops to the required value.

0 bar
200269-10
When the pressure gauge reaches the required value, turn control lever Oil reservoir to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.
8 mbar
200270-10
57
When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize Pressure.
Guideline
8 mbar
0 bar
200267-10
to Pressure.
Guideline
0 bar
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Oil is pumped into the damper.

3 bar
200268-10
to Vacuum.
Guideline
3 bar

0 bar
When the pressure gauge reaches the required value, activate the On/Off switch.
Guideline
200269-10
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) (
200592-01
p. 449)
Push the floating piston into the reservoir to the distance described above using the
special tool.
Info
When the piston rod is fully extended, the floating piston must be at precisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.
58
Remove adapter from connector of the vacuum pump.
Info
Hold the damper so that the filling port is at the highest location.
Remove the adapter.

Guideline
M10x1
14 Nm
(10.3 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, filling port
200593-01
Filling the damper with nitrogen

8.16
Fix the special tool in the vise.
Nitrogen filling tool (T170S1) (
p. 450)
Screw in screw by approx. 2 turns but do not tighten.
Info
The piston rod is fully extended.
200594-01
Connect the special tool to the pressure regulator of the filling cylinder.
Filling gas - nitrogen
Adjust the pressure regulator.

Guideline
Gas pressure
10 bar (145 psi)
Position the damper in the special tool.
The hexagonal part of tap handle engages in the hexagon socket of the filling port screw.
200595-01
Open spigot .
Fill the damper for at least 15 seconds.

Guideline
Gas pressure
10 bar (145 psi)
Info
Watch the pressure regulator dial.

Ensure that the damper is filled to the specified pressure.
Close the filling port screw with tap handle .
Close the spigot and take the damper out of the special tool.
Tighten the filling port screw.

Guideline
Screw, filling port, reservoir
M5
3.5 Nm
(2.58 lbf ft)
59
Installing the spring

8.17
Clamp the damper into the vice with soft jaws.
Measure the overall spring length without a load.
Position the spring.

Guideline
Spring rate
Medium (standard)
95 N/mm (542 lb/in)
Mount spring retainer .

The open end is opposite to the end of the spring.
200562-11
Alternative 1
Tension the spring by turning the adjusting ring to the prescribed value.
Guideline
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Spring preload
Comfort
6 mm (0.24 in)
Standard
6 mm (0.24 in)
Sport
8 mm (0.31 in)
Full payload
8 mm (0.31 in)
p. 448)
Alternative 2
Warning


Adjust the spring to the value determined when it was removed by turning the
adjusting ring.
p. 448)
Tighten screw .
Guideline
Screw, adjusting ring, shock absorber
200561-11
Removing the heim joint

8.18
Info
The operations are the same for the upper and lower heim joints.
Condition
M6
5 Nm (3.7 lbf ft)
60
Clamp the shock absorber into the vice with soft jaws.
Remove collar bushing of the heim joint with a drift.
Turn the shock absorber around and remove collar bushing of the heim joint with
a drift.
Remove seal rings on both sides.
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200577-10
200578-10
Remove lock rings on both sides.
Place special tool underneath and push out the heim joint with special tool .
200579-10
Pressing tool (T1207S) (
p. 449)
200580-10
Installing the heim joint

8.19
Info
The operations are the same for the upper and lower heim joints.
Place special tool underneath and push the heim joint to the middle using special tool .
Pressing tool (T1206) (
Pressing tool (T129) (
200581-10
p. 449)
p. 449)
61
Mount lock rings on both sides.
Mount and grease seal rings on both sides.
200579-11
p. 438)
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Lubricant (T158) (
200578-11
200582-10
Push in both collar bushings of the heim joint.
05/EXHAUST
62
Lambda sensor
9.1
The lambda sensor for cylinder 1 is installed in the rear exhaust manifold.
The lambda sensor for cylinder 2 is installed in the front exhaust manifold.
900007-61
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Component description
In principle, the lambda sensor consists of a ceramic body that is coated with a
platinum layer on each side. The platinum layer functions like an electrode. The
outer layer comes into contact with the exhaust gas and the inner layer with
ambient air . At a certain temperature, the ceramic body becomes electrically
conductive and a voltage is generated when there is a difference in the oxygen content of the ambient air and the exhaust gas . The greater the difference in oxygen
content, the greater the voltage.
900008-10
Lambda sensor for cylinder 1, connector CE (


Function description
All lambda (O) sensors are open to the atmosphere, which has an oxygen content (O) of approximately twenty one percent. The exhaust gas of a gasoline engine
contains up to two percent oxygen. The sensor output voltage is dependent on the
oxygen content in the exhaust gas stream. This means that when the exhaust gas
contains just two percent oxygen, the engine is running "lean" and the sensor generates a low voltage. When the exhaust gas contains almost zero percent oxygen,
the engine is running "rich" and the sensor generates a high voltage.
Lambda sensor
900009-01
Voltage range within

the closed loop range
"HEGO1AD"
0.2 0.8 V
Voltage range within

the closed loop range
"HEGO2AD"
0.2 0.8 V
Lambda sensor heater

9.2
The lambda sensor heater for cylinder 1 is integrated into the lambda sensor for
cylinder 1, which is installed in the rear exhaust manifold.
900007-61
The lambda sensor heater for cylinder 2 is integrated into the lambda sensor for
cylinder 2, which is installed in the front exhaust manifold.
The lambda sensor is heated internally by a ceramic heating element, so that independent of the exhaust gas temperature the temperature of the lambda sensor is
kept constant. The connections of the heating element are completely isolated from
the sensor signal voltage.


Description of function
The lambda sensor heater is supplied with battery voltage by the power relay. After
the engine is started, the EFI control unit switches the ground signal on/off to the
lambda sensor heater. In order to control the lambda sensor heater, the signal control is modulated.
The lambda sensor heater is controlled at a modulation frequency T of 100 Hz. The
smaller the duty cycle t is set for the control, the greater is the supply voltage of
the lambda sensor heater.
900046-60
05/EXHAUST
63
11.7 14.3
Resistance at: 20 C
(68 F)
Removing the exhaust cover completely

9.3
Remove the side covers. (
p. 75)
Remove screws .
Remove screws on both sides.
Take off exhaust cover completely.
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200532-10
Installing the exhaust cover completely

9.4
Position the exhaust cover.
Guideline
M5
5 Nm (3.7 lbf ft)
Mount and tighten screws on both sides.

Guideline
Install the side covers. (
M5
p. 75)
200532-11
Removing the exhaust system

9.5
Info
The radiator has only been removed to illustrate the procedure more clearly.
Remove the exhaust cover completely. (
Remove the seat. (
p. 70)
p. 63)
5 Nm (3.7 lbf ft)
05/EXHAUST
64
Unplug connector of the lambda sensor (2nd cylinder). Open the cable binder.
Unplug connector of the lambda sensor (1st cylinder).
P
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200513-10
200514-10
Remove screw . Slide the clamp upward.
Remove screw . Slide the clamp upward.
Remove screws with the washers. Take off the main silencer.
200515-10
200516-10
5
0
5
0
5
0
200517-01
05/EXHAUST
65
Remove nuts . Remove the manifold at the front with the seals.
Remove nuts . Remove the manifold at the rear with the seals.
P
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200518-10
200519-10
Installing the exhaust system

9.6
Info
The radiator has only been removed to illustrate the procedure more clearly.
Position the manifold at the front with the seals. Mount nuts but do not tighten
them yet.
Position the manifold at the rear with the seals. Mount nuts but do not tighten
them yet.
200518-11
200519-11
05/EXHAUST
66
Position the main silencer. Mount and tighten screws with the washers.
Guideline
M8
25 Nm
(18.4 lbf ft)
3
0
P
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3
0
3
0
200517-02
Position the clamp. Mount and tighten screw .

Guideline
Screw, exhaust clamp
M6
8 Nm (5.9 lbf ft)
M8
30 Nm
(22.1 lbf ft)
Tighten nuts .
Guideline
Remaining chassis nuts
200515-11
Position the clamp. Mount and tighten screw .

Guideline
M6
8 Nm (5.9 lbf ft)
M8
30 Nm
(22.1 lbf ft)
Tighten nuts .
Guideline
200516-11
Plug in connector of the lambda sensor (2nd cylinder). Secure the cable with
the cable binders.
Plug in connector of the lambda sensor (1st cylinder).
200513-11
200514-11
Fit the seat. (
Install the exhaust cover completely. (
p. 70)
p. 63)
06/AIR FILTER
67
Removing the air filter

10.1
Note
Engine failureUnfiltered intake air has a negative effect on the service life of the engine.
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Remove screws .
Slide back clamp . Pull off the engine breather hose and take off the clamp.
Take off the filter box top.
p. 70)
Info
P
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7- Sh
99 a
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9- k.
56 co
86 m
Watch out for the engine breather hose.
200496-10
Remove air filter .
Clean the air filter box.
Position air filter .
Position the filter box top with the engine breather hose. Mount clamp with the
engine breather hose.
Tighten screws .
Unplug the connector of the manifold absolute pressure sensor .
Take the manifold absolute pressure sensor out of the holder but do not detach the
vacuum hoses.
Disconnect plug-in connector .
Take plug-in connector out of the holding bracket.
200497-10
Installing the air filter

10.2
200497-11
p. 71)
200496-11
Removing the filter box bottom

10.3
200498-10
p. 67)
06/AIR FILTER
68
Remove screws . Take off the retaining plates and holding brackets.
Remove screw . Remove the cover.
Loosen hose clamps .
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200499-10
200500-10
Loosen the spring-loaded band-type clamp using the special tool. Pull off the
fuel hose.
Pliers for spring-loaded band-type clamp (60029057100) (
p. 442)
Pull up the throttle valve body and remove connector with the seal.
Pull the throttle cables out of the filter box bottom with guide piece .
Raise the throttle valve body at the front and fix it on the handlebar.
Remove rubber sleeves .
Raise the filter box bottom and pull off drain hoses .
Detach the connector of the intake air temperature sensor.
Remove snorkel seals .
Raise the filter box bottom at the front and fix it on the handlebar.
Detach the filter box bottom from the handlebar. Mount drain hoses . Plug in the
connector of the intake air temperature sensor.
Position the filter box bottom.
Mount snorkel seals .
200501-10
200502-10
200503-10
Installing the filter box bottom

10.4
200503-11
06/AIR FILTER
69
Mount rubber sleeves . Position and tighten the lower hose clamps.
Guideline
Hose clip, intake flange
M4
1.5 Nm
(1.11 lbf ft)
200502-11
Detach the throttle valve body from the handlebar. Mount connector with the
seal.
Connect the fuel hose. Mount the spring-loaded band-type clamp using the special tool.
P
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7- Sh
99 a
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9- k.
56 co
86 m
p. 442)
Info
The fuel hose must have a minimum distance of 4 mm to the throttle linkage in all operating positions.
Position the throttle cables with guide piece .
Slide the throttle valve body into the rubber sleeves.
Position and tighten upper hose clamps .
200501-11
Guideline
M4
1.5 Nm
(1.11 lbf ft)
200500-11
Mount the cover. Mount and tighten screw .
Position the retaining plates and holding brackets. Mount and tighten screws .
Fix plug-in connector with the holding bracket.
200499-11
200498-11
Connect plug-in connector .
Mount manifold absolute pressure sensor and plug in the connector.
p. 67)
07/FUEL TANK, SEAT, TRIM
70
Removing the seat

11.1
Insert the ignition key in the seat lock and turn it clockwise.
Raise the rear of the seat, push it towards the rear, and remove it upwards.
Position the recesses of the seat to the lugs on the frame, lower the rear end and
simultaneously push it forward.
100669-10
Fitting the seat
P
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11.2
Lock the seat by turning the ignition key in the seat lock.
Remove the ignition key from the seat lock.
Finally, check that the seat is correctly mounted.
Remove the seat. (
100730-10
Removing the passenger seat

11.3
p. 70)
Activate the release lever .
Take off the passenger seat toward the top.
100731-10
Mounting the passenger seat

11.4
Warning
Danger of accidentsThe passenger seat can come loose from the anchoring
if it is not mounted correctly.
100732-01
After mounting the passenger seat, check that it is locked correctly by

pulling up on the supporting strap. There should be no play in the
unlocking lever.
Position the passenger seat in the space provided.
Press down the passenger seat until it clicks into place.
Finally, check that the passenger seat is correctly mounted.
Dismounting the fuel tank

11.5
Danger
Fire hazardFuel is highly flammable.
Never fill up 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.
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
71
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Remove the seat. (
Remove screws of the steering damper.
Remove the steering damper.
p. 70)
P
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99 a
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9- k.
56 co
86 m
200488-10
Remove screws .
Press on metal plate and disconnect the fuel hose connection.
200489-10
Info
Remaining fuel may run out of the fuel hose.
Disconnect electric plug-in connector of the fuel pump.
Raise the front of the fuel tank.
Disconnect plug-in connector of the fuel level indicator.
200490-10
Detach overflow hoses .
Take off the fuel tank.
200491-10
Installing the fuel tank

11.6
Danger
72
Warning
Position the fuel tank and raise it at the front.

Connect overflow hoses .
Connect plug-in connector of the fuel level indicator.
Lower the front of the fuel tank.
P
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7- Sh
99 a
r
9- k.
56 co
86 m
200491-11
Connect fuel hose connector with the new O-ring.
Connect electric plug-in connector of the fuel pump.
200490-10
Guideline
M6
10 Nm (7.4 lbf ft)
M6
10 Nm (7.4 lbf ft)
200489-11
Position the steering damper.

Guideline

Guideline
Screw, steering damper

fixing bracket on triple
clamp
200488-11
Fit the seat. (
Removing the fuel tank guard

11.7
Info
The operations are the same on the left and right sides.
p. 70)
M8
10 Nm
(7.4 lbf ft)
Loctite 243
73
Remove screw .
Take off the fuel tank guard.
500246-10
Installing the fuel tank guard

11.8
Info
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The operations are the same on the left and right sides.
Position the fuel tank guard.

Guideline
Screw, fuel tank guard
M5x17
3 Nm (2.2 lbf ft)
Info
Note the screw length!
500246-10
Checking the fuel pressure

11.9
Press down the metal plate and disconnect the fuel hose connection .
200559-01
Pressure testing tool (61029094000) (
p. 443)
Danger
200560-01
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an
effective exhaust extraction system.
Start the engine.
Check the fuel pressure.

Fuel pressure
For any load
3.3 3.7 bar (48 54 psi)
The specifications have not been met:
Change the fuel filter.
Check that the fuel lines are free of blockages.
Change the fuel pump.
Switch off the engine.
74
Warning
Danger of burnsSome 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.
Connect the fuel hose connection.
Checking the fuel pressure during the actuator test

11.10
Danger
P
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7- Sh
99 a
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56 co
86 m
Warning
Press down the metal plate and disconnect the fuel hose connection .
Info
Remaining fuel may run out of the fuel hose.
200559-01
p. 443)
Start the "Fuel pump relay operation" actuator test.
Check the fuel pressure.

Fuel pressure
When the fuel pump is active
200560-01
3.3 3.7 bar (48 54 psi)
Change the fuel filter.
Check that the fuel lines are free of blockages.
Change the fuel pump.
End the "Fuel pump relay operation" actuator test by pressing the "Quit" button.
Connect the fuel hose connection.
08/MASK, FENDER, DECAL
75
Removing the side covers

12.1
Remove side covers on both sides.
Info
Watch out for the projections on the inside cover.
200492-10
Installing the side covers

12.2
Position side covers on both sides.
P
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7- Sh
99 a
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56 co
86 m
Info
Watch out for the projections on the inside cover.
Mount and tighten screws on both sides.

Guideline
M5
5 Nm (3.7 lbf ft)
200492-11
Removing the inside cover

12.3
Switch off all power consumers and the engine.
Remove the seat. (
Disconnect the negative (minus) cable of the battery.
Remove expanding rivet .
Disconnect the plug-in connectors from generator and ignition pulse generator .
Unscrew ground wire from the frame.
Remove screw .
Remove screws .
Take off the left inside cover.
p. 70)
p. 75)
200493-10
200494-10
200537-10
08/MASK, FENDER, DECAL
76
Remove screw .
Remove the screws of the EFI control unit . Unplug and remove the EFI control
unit.
Unplug the control unit of the electric starter lock .
Remove the overflow hose. Take off the right inside cover.
200495-12
Installing the inside cover

12.4
Position the right inside cover. Mount and tighten screw .

Position the overflow hose.
Plug in EFI control unit and position it. Mount and tighten the screws.
Plug in the control unit of the electric starter lock .
Position the left inside cover. Mount and tighten screw .
Connect the plug-in connectors to generator and ignition pulse generator .
P
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7- Sh
99 a
r
9- k.
56 co
86 m
200495-11
Screw ground wire onto the frame.
Guideline
M6
200494-11
200537-11
200493-11
Mount expanding rivets .
Connect the negative (minus) cable of the battery.
Fit the seat. (
p. 70)
p. 75)
10 Nm (7.4 lbf ft)
09/FRONT WHEEL
77
Removing the front wheel

13.1
Jack up the motorcycle at the front. (
Remove the screws from both brake calipers.
Press back the brake linings with a light lateral tilting of the brake calipers on the
brake disc. Pull the brake calipers carefully back from the brake discs and hang
them to one side.
p. 13)
p. 10)
Info
Do not pull the hand brake lever when the brake calipers are removed.
100719-10
Loosen screws and .
Unscrew screw about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
P
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7- Sh
99 a
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9- k.
56 co
86 m
Warning

discs.
100720-10
damaged.
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Remove spacers .
Clean and grease the shaft seal rings and mating surfaces of the spacers.
100779-10
Installing the front wheel

13.2
Long-life grease (
p. 438)
100781-10
Insert the wide spacer on the left-hand side (when looking in the direction of
travel).
Info
The arrow indicates the direction of rotation of the front wheel.
100780-10
Insert the narrow spacer on the right-hand side (when viewed in the direction of
travel).
09/FRONT WHEEL
78
Warning
Danger of accidentsReduced braking efficiency due to oil or grease on the
brake discs.
100721-10
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
Clean screw and axle .
Lift the front wheel into the fork, position it, and insert the wheel spindle.

Guideline
Bolt, front axle
M25x1.5
45 Nm
(33.2 lbf ft)
Position the brake calipers and check that the brake linings are seated correctly.
Mount screws on both brake calipers but do not tighten yet.
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
100719-11
M10x1.25
45 Nm
(33.2 lbf ft)
Loctite 243
Take the front of the motorcycle off the work stand. (
Take the rear from the work stand. (
Pull the front brake and compress the fork powerfully a few times.
p. 10)
p. 13)
The fork legs straighten.
Guideline
M8
15 Nm
(11.1 lbf ft)
100782-10
Checking the tire condition

13.3
Warning
Danger of accidentsUncontrollable handling characteristic caused by a flat tire.
For your own safety, have damaged tires changed immediately.
Warning
Danger of crashingImpairment of handling characteristic 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 accidentsUncontrollable 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 accidentsReduced 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.
09/FRONT WHEEL
79
Info
The type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle.
Worn tires have a negative effect on handling characteristics, 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
400602-10
If the tread depth is less than the minimum permissible depth:
P
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7- Sh
99 a
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56 co
86 m
2 mm ( 0.08 in)
Change the tires.
Check the age of the tires.
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 manufacture.
KTM recommends that the tires are changed regardless of the actual wear,
at the latest after five years.
If a tire is more than five years old:
Change the tires.
Checking the tire pressure

13.4
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure tool kit comfort and maximum tire service life.
Remove the dust cap.
Check the tire pressure when the tires are cold.

Tire air pressure, Solo
Front
2.5 bar (36 psi)
Rear
2.5 bar (36 psi)
Tire air pressure with passenger / full payload
100729-01
2.5 bar (36 psi)
Rear
2.9 bar (42 psi)
If the tire pressure does not meet specifications:
Front
Correct the tire pressure.
Mount the dust cap.
Info
The rubber seal in the dust cap prevents air leaking out of the tire if the
valve is defective.
09/FRONT WHEEL
80
Checking the front brake discs

13.5
Warning
Danger of accidentsReduced braking efficiency due to worn brake disc(s).
Change the worn brake disc(s) without delay.
Check the thickness of the brake disc in several places to see if it is within the
specified wear tolerance .
Info
Wear reduces the thickness of the brake discs in area of the brake discs.
Brake discs - wear limit
4.5 mm (0.177 in)
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Front
100135-10
If the brake disc thickness is less than the specified value:
Change the brake discs.
Check the brake discs for damage, cracking and deformation.
If the brake discs exhibit damage, cracking or deformation:
10/REAR WHEEL
81
Removing the rear wheel

14.1
p. 13)
Remove nut .
Remove chain adjuster .
Remove the axle .
Push the rear wheel as far forward as possible and then remove the chain from the
rear sprocket.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100722-10
Warning

discs.
100723-01
damaged.
Take the rear wheel out of the swingarm carefully without damaging the rim or
brake disc.
Info
Do not operate the foot brake when the rear wheel is removed.
Installing the rear wheel

14.2
Warning
Danger of accidentsReduced braking efficiency due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsNo braking effect when operating the rear brake.
After installing the rear wheel, always operate the foot brake until the pressure point is reached.
Check the rear hub cush drive. (
Remove spacer . Clean and grease the mating surfaces of the spacers and the
shaft seal rings.
Long-life grease (
p. 86)
p. 438)
Install the spacer.
Clean the thread of the axle and nut.
Clean the mating surfaces of the brake caliper frame and swingarm.
Push the brake caliper frame completely to the rear.
Position the rear wheel, and place the brake caliper frame between the rim and the
brake disc.
Slide the brake caliper onto the brake disc.
Position the rear wheel on the mating surfaces in the swingarm.
100724-10
100725-10
10/REAR WHEEL
82
Push the rear wheel as far forward as possible and place the chain on the rear
sprocket.
Pull the rear wheel back and insert the axle.
Place the chain adjuster on the tensioning screw.
100726-01
Position the chain adjuster and place it on the tensioning screw.
Tighten nut .
Guideline
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
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 .
Nut, rear wheel spindle
100727-10
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Operate the foot brake lever repeatedly until the brake linings press up against the
brake disc and there is a pressure point.
Check the chain tension. (
p. 13)
p. 84)
Installing the rear wheel - when installing the engine

14.3
Warning
Warning
Danger of accidentsNo braking effect when operating the rear brake.
After installing the rear wheel, always operate the foot brake until the pressure point is reached.
Remove spacer . Clean and grease the mating surfaces of the spacers and the
shaft seal rings.
Long-life grease (
p. 438)
Install the spacer.
Clean the thread of the wheel spindle and nut.
Clean the contact areas of the brake caliper support and swingarm.
Push the brake caliper support completely to the rear.
Position the rear wheel, and position the brake caliper support between the rim and
the brake disc.
Position the brake caliper on the brake disc.
Position the rear wheel on the bearing surfaces in the swingarm.
100724-10
100725-10
10/REAR WHEEL
83
Push the rear wheel forward as far as possible and place the chain on the rear
sprocket.
Pull the rear wheel back and push in the wheel spindle.
Place chain adjuster on the tensioning screw.
Position chain adjuster and place it on the tensioning screw.
100726-01
Tighten nut .
Guideline
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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 reference marks .
100727-10
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.
p. 84)
Checking the rear brake disc

14.4
Warning
Danger of accidentsReduced braking efficiency due to worn brake disc(s).
Change the worn brake disc(s) without delay.
Check the thickness of the brake disc in several places to see if it conforms to measurement .
Info
Wear reduces the thickness of the brake disc in area of the brake disc.
Brake disc - wear limit

Rear
400480-10
If the brake disc thickness is less than the specified value:
4.5 mm (0.177 in)
Change the brake disc.
Check the brake disc for damage, cracking and deformation.
If damage, cracks or deformation are visible on the brake disc:
Checking for chain dirt

14.5
Check the chain for loose dirt.
If the chain is very dirty:
400678-01
Clean the chain. (
p. 84)
10/REAR WHEEL
84
Cleaning the chain

14.6
Warning
Danger of accidentsOil or grease on the tires reduces their grip.
Remove oil and grease with a suitable cleaning material.
Warning
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
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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. 438)
After drying, apply chain spray.

Chain lube for road use (
p. 438)
Checking the chain tension

14.7
Warning
Danger of accidentsDanger caused by incorrect chain tension.
If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may
snap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the engine
sprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension and
adjust if necessary.
Lean the motorcycle on the side stand.
Shift into neutral.
In the area in front of where the chain passes through the link fork, push the chain
upward and measure chain tension .
Info
The lower chain section must be taut.

Chain wear is not always even, so you should repeat this measurement at
different chain positions.
700322-01
Chain tension
15 20 mm (0.59 0.79 in)
If the chain tension does not meet specifications:
Adjust the chain tension. (
p. 85)
10/REAR WHEEL
85
Adjusting the chain tension

14.8
Warning
Danger of accidentsDanger caused by incorrect chain tension.
If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may
snap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the engine
sprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension and
adjust if necessary.
p. 84)
Loosen nut .
Loosen nuts .
Adjust chain tension by turning the adjustment screws on the left and right.
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Guideline
Chain tension
15 20 mm (0.59 0.79 in)
Turn the adjusting screws on the left and right so that the markings on the left
and right chain adjuster are in the same position in relation to the reference
marks . The rear wheel is then correctly aligned.
Info
The lower chain section must be taut.

Chain wear is not always even, so you should check the setting at different
chain positions.
Tighten nuts .
Make sure that the chain adjusters are on the adjusting screws .
Tighten nut .
Guideline
100709-10
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Info
The wide adjustment range of the chain adjuster (35mm / 1.38") allows different secondary transmission ratios to be used with the same chain length.
The chain adjusters can be turned through 180.
Checking rear sprocket / engine sprocket for wear

14.9
Check the rear sprocket / engine sprocket for wear.
If the rear sprocket / engine sprocket are worn:
Change the rear sprocket / engine sprocket, chain and chain sliding guard.
Info
The rear sprocket, engine sprocket, chain and chain sliding guard
should always be changed together.
100132-10
10/REAR WHEEL
86
Checking chain wear

14.10
Shift the transmission to neutral.

Pull the lower chain section with specified weight .
Guideline
Weight, chain wear measurement
15 kg (33 lb.)
Measure the 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
chain section
If distance is greater than the specified measurement:
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272 mm (10.71 in)
Change the rear sprocket / engine sprocket, chain and chain sliding guard.
Info
New chains wear out faster on old, worn sprockets.

For safety reasons, the chain has no chain joint.
700303-01
Checking chain sliding guard

14.11
Check the chain sliding guard for wear at the opening.
If the rivets of the chain are no longer visible at the lower edge of the
opening of the chain sliding guard:
Change the chain sliding guard.
100710-10
Checking rear hub cush drive

14.12
Info
The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out
during operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged.
Remove the rear wheel. (
Remove the rear sprocket carrier.
Check the rear hub for damage and wear.
If the rear hub cush drive is damaged or worn:
p. 81)
Change the shock absorber.
Position the rear sprocket carrier.
Info
100728-01
A set of bolts and shock absorbers should have as little free play as possible
to increase the service life of the shock absorbers.
10/REAR WHEEL
87
Install the rear wheel. (
p. 81)
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11/WIRING HARNESS, BATTERY
88
Electric starter lock control unit

15.1
The electric starter lock control unit is located behind the right-hand side cover.
Electric starter lock control unit, connector DO (
900013-01
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900015-10
The electric starter lock control unit prevents the engine from starting during the initialization phase of the EFI system . The
electric starter lock control unit controls the grounding of the auxiliary starter relay . The signal wire sends a signal to the EFI
control unit; the electric starter lock control unit then recognizes that the initialization process has ended and enables the starting
process. The electric starter lock control unit utilizes the signal control wire to send a start permission status signal to the EFI
control unit.
Fuel pump relay

15.2
Pin overview
Control circuit power supply
Control wire
Fuel pump power supply
Working circuit power supply
600852-10
Removing the battery

15.3
Warning
Risk of injuryBattery 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 the battery away from sparks or open flames. Charge only in well-ventilated areas.
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.
Caution
Danger of accidentsIf 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.
Remove the seat. (
p. 70)
89
Disconnect negative (minus) cable of the battery.
Remove the cover of the positive terminal.
Disconnect the positive (plus) cable of the battery.
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100734-10
100735-10
Remove screws .
Removing the securing bracket .
Pull the battery up and out of the battery rack.
Position the battery in the battery rack.
100736-10
Installing the battery

15.4
Info
The terminals of the battery must face the rear of the vehicle.
Position the bracket .
100737-10
Guideline
M6
Reconnect the positive (plus) cable of the battery.
Position cover of the positive terminal.
Reconnect the negative (minus) cable of the battery.
Fit the seat. (
Set the clock with SET CLOCK. (
100738-10
100734-11
p. 70)
p. 106)
10 Nm (7.4 lbf ft)
90
Recharging the battery

15.5
Warning
Risk of injuryBattery 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 the battery away from sparks or open flames. Charge only in well-ventilated areas.
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 hazardBattery parts and acid are harmful to the environment.
Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
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Warning
Info
Even when there is no load on the battery, it discharges steadily.

The charge state and the type of charge 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, i.e., the acid level does not have to be checked.
Remove the seat. (
Disconnect the negative (minus) cable of the battery to avoid damage to the motorcycle's electronics.
Connect the battery charger to the battery. Switch on the battery charger.
p. 70)
Battery charger (58429074000)
You can also use the battery charger to test the rest potential and start potential of
the battery, and to test the generator. With this device, you cannot overcharge the
battery.
Info
Never remove lid .

Charge the battery at no more than 10% of the capacity specified on the
battery housing .
Switch off the charger after charging. Disconnect the battery.

Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
100151-10
Fit the seat. (
p. 70)
p. 106)
3 months
91
Changing the main fuse

15.6
Warning
Fire hazardThe electrical system can be overloaded by the use of incorrect fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle. The main fuse is under the seat.
Remove the seat. (
Remove protection covers .
Remove the faulty main fuse .
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p. 70)
Info
A reserve fuse is located in the starter relay.
Install a new main fuse.
Fuse (58011109130) (
p. 411)
Tip
Place the spare fuse in the starter relay so that it is available if needed.
Attach the protection covers .
Fit the seat. (
p. 70)
p. 106)
100739-10
Changing the fuses of individual power consumers

15.7
Warning
Fire hazardThe electrical system can be overloaded by the use of incorrect fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
100740-10
Remove the seat. (
Open fuse box cover .
p. 70)
92
Check the fuses.
Info
A defective fuse can be identified by the burned-out fuse wire .
Remove the faulty fuse.

Guideline
Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system
(optional)
100741-10
Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 3 - 10A - horn, brake light
Fuse 4 - 10A - radiator fan
Fuse 5 - 10A - fuel pump
Fuse 6 - 10A - ignition/fuel injection
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Fuse 7 - not used
Fuse 8 - 10A - for supplementary equipment (standard accessories)

Fuse 9 - 10A - for supplementary equipment (accessories connected to the ignition switch)
Fuse 10 - not used
Fuse SPARE - 10A/15A - spare fuses
Use spare fuses with the correct rating only.

Fuse (75011088010) (
p. 411)
Fuse (75011088015) (
p. 411)
Tip
Replace the spare fuse in the fuse box so that it is available if needed.
Close the fuse box cover.
Fit the seat. (
p. 70)
13/BRAKE SYSTEM
93
Brake linings
16.1
The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of
the brake linings are entered in the homologation documents.
Info
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction
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 original license.
The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Checking the front brake linings

16.2
Warning
P
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7- Sh
99 a
r
9- k.
56 co
86 m
Danger of accidentsReduced braking efficiency caused by worn brake linings.
Change worn brake linings immediately.
Note
Danger of accidentsReduced 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 rendered unserviceable. Check the brake linings regularly.
Check all brake linings on both brake calipers to ensure they have minimum thickness .
Minimum thickness
If the minimum thickness is less than specified:
Change the front brake linings. (
p. 93)
Check all brake linings on both brake calipers for damage and cracking.
100715-10
1 mm ( 0.04 in)
If damage or wear is encountered:
Change the front brake linings. (
p. 93)
Changing the front brake linings

16.3
Warning
Skin irritationBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsReduced braking efficiency due to old brake fluid.
Change the brake fluid of the front and rear brakes according to the service schedule.
Warning
Warning
Danger of accidentsReduced 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 construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
13/BRAKE SYSTEM
94
Info
Never user 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 is corrosive and will damage painted surfaces.
Use only clean brake fluid from a sealed container!
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove the screws.

Remove cover with membrane .
Press the brake piston back into the basic position and ensure that brake fluid does
not overflow out of the brake fluid reservoir, sucking it away if necessary.
P
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7- Sh
99 a
r
9- k.
56 co
86 m
100714-10
Remove screws .
301496-10
Push the brake linings away from piston and remove them.
Clean the brake caliper.
Position retaining bracket .
Slip in the brake linings and press them toward piston .
301497-10
301498-10
Info
Always change the brake linings in pairs and on both sides.
301499-10
13/BRAKE SYSTEM
95
Position the brake caliper. Mount the screws but do not tighten them yet.
Repeat the operation on the opposite side.

Guideline
301496-10
M10x1.25
Add brake fluid to the MAX level.

Brake fluid DOT 4 / DOT 5.1 (
Loctite 243
p. 436)
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86 m
45 Nm
(33.2 lbf ft)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
Checking the front brake fluid level

16.4
Warning
Danger of accidentsFailure 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
Check the brake fluid level in the brake fluid reservoir .
If the brake fluid is below the MIN marking:
Add front brake fluid. (
p. 95)
100712-10
Adding front brake fluid

16.5
Warning
Warning
Warning
13/BRAKE SYSTEM
96
Warning
Info
brake fluid.
Loosen screw.
Remove cover with membrane .
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7- Sh
99 a
r
9- k.
56 co
86 m
p. 436)
Position the cover with the membrane. Mount and tighten the screws.
Info
100714-10
Adjusting the basic position of the hand brake lever

16.6
Pull the brake lever forwards.
Adjust the basic setting of the hand brake lever to your hand size by turning adjusting wheel .
Info
Do not make any adjustments while riding!
100711-10
Checking the rear brake linings

16.7
Warning
Danger of accidentsReduced braking efficiency caused by worn brake linings.
Change worn brake linings immediately.
Note
Danger of accidentsReduced 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 rendered unserviceable. Check the brake linings regularly.
Check the brake linings for minimum thickness .

Minimum thickness
If the minimum thickness is less than specified:
Change the rear brake linings. (
p. 97)
Check the brake linings for damage and cracking.
If damage or wear is encountered:
100718-10
1 mm ( 0.04 in)
Change the rear brake linings. (
p. 97)
13/BRAKE SYSTEM
97
Changing the rear brake linings

16.8
Warning
Warning
Warning
P
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7- Sh
99 a
r
9- k.
56 co
86 m
Warning
Danger of accidentsReduced 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 construction 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 original 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 cover with membrane .
Press the brake piston back into the basic position and ensure that brake fluid does
not overflow out of the brake fluid reservoir, sucking it away if necessary.
100717-10
301491-10
Remove screws .
Remove the brake caliper and pull the brake line out of the holder.
13/BRAKE SYSTEM
98
Remove locking clip .
Remove bolt .
P
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99 a
r
9- k.
56 co
86 m
301492-10
301493-10
Remove brake linings .
Remove spring .
Clean the brake caliper.
Position brake linings and spring .
Mount bolt .
Mount locking clip .
Position the brake caliper.
301494-10
301495-10
301492-10

Guideline
Screw of rear brake caliper
301491-10
M8
22 Nm
(16.2 lbf ft)
Loctite 243
Attach the brake line to the holder.
Operate the foot brake lever repeatedly until the brake linings press up against the
brake disc and there is a pressure point.
Correct the brake fluid level to the MAX marking.

p. 436)
13/BRAKE SYSTEM
99
Refit screw with membrane.
Info
Checking the rear brake fluid level

16.9
Warning
Warning
P
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7- Sh
99 a
r
9- k.
56 co
86 m
Check the brake fluid level of the brake fluid reservoir.
If the fluid level reaches the MIN mark :
Add rear brake fluid. (
p. 99)
100716-10
Adding rear brake fluid

16.10
Warning
Warning
Warning
Warning
Info
brake fluid.
13/BRAKE SYSTEM
100
Remove screw cover with membrane .

p. 436)
Info
100717-10
Adjusting the foot brake pedal stub

16.11
Remove the screw with the foot brake pedal stub.

Position the foot brake pedal stub with the screw in one of the holes according
to the desired lever length.
P
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7- Sh
99 a
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9- k.
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86 m
Guideline
Standard
Central hole
Tighten screw.
Guideline
Bolt, foot brake pedal stub
M6
10 Nm
(7.4 lbf ft)
Loctite 243
100706-10
Adjusting the foot brake pedal

16.12
Use the tool to press in the anti-rotation lock , then turn the piston rod .
Info
The range of adjustment is limited.
Remove the tool.
The spring tension on the anti-rotation lock is released and the hex nut is
locked.
100707-10
Check the foot brake pedal setting.
Info
Position of the foot brake lever may vary considerably, depending on the
setting.
100708-10
13/BRAKE SYSTEM
101
Removing the rear brake system

16.13
Remove the rear wheel. (
Unplug the brake light switch. Remove the cable clip.
Remove screw .
p. 81)
200525-10
Remove screw . Take off the brake caliper with the brake caliper support.
Take the brake line out of the guide. Completely remove the brake system.
P
a
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7- Sh
99 a
r
9- k.
56 co
86 m
200526-10
Installing the rear brake system

16.14
Position the brake system. Position the brake line in the guide.
Position the brake caliper. Mount and tighten screw .

Guideline
M6
10 Nm (7.4 lbf ft)
200526-11
Guideline
Screw, rear footrest bracket
M8
25 Nm
(18.4 lbf ft)
Position the brake fluid reservoir. Mount and tighten screw .

Guideline
Screw, brake fluid reservoir of rear brake
200525-11
M5
5 Nm
(3.7 lbf ft)
Plug in the brake light switch. Mount the cable clip.
Install the rear wheel. (
p. 81)
Loctite 243
14/LIGHT SYSTEM, INSTRUMENTS
102
Immobilizer control unit

17.1
The ICU is located under the ignition lock.
Imobilizer control unit, connector DN ( p. 399) pin assignment
Imobilizer control unit, antenna coil, connector DV ( p. 401) pin assignment
900039-60
The purpose of the imobilizer control unit is to protect against unauthorized persons
using the vehicle. It is intended to make starting and riding the vehicle impossible
without proper access authorization (code) or other suitable legitimization. It uses an
electronic immobilizer that makes use of a coding procedure to disable or enable the
use of several systems, such as the starting system, fuel supply system, or the ignition
system. This is carried out via the EFI control unit.
Unlocked
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Imobilizer control unit

starter OK " ICUSTR"
Info
The engine may be started.

starter OK " ICUSTR"
Locked
Info
The engine cannot be started.

authentication "ICUINIT"
Initialization in progress...

authentication "ICUINIT"
Initialization complete OK
Activating/deactivating ignition key

17.2
Info
The orange programming key must only be used for activating and deactivating!
Loss of a black ignition key (second black ignition key available):

If a black ignition key is lost or replaced, the black ignition keys must be individually activated/deactivated using the orange programming key. This will also prevent
the vehicle from being operated without authorization with the lost black ignition
key.
The following procedure deactivates all activated black ignition keys that are not
included in the procedure.
100749-01
Insert the orange programming key in the ignition lock.
Switch on the ignition by turning the orange programming key to the ON position .
EFI warning lamp
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
lights up.
Switch off the ignition by turning the orange programming key to the OFF position .
Pull out the orange programming key.
Insert the black ignition key in the ignition lock.
Switch on the ignition by turning the black programming key to

the position ON .
EFI warning lamp

switches on again.
lights up, switches off briefly, and
Switch off the ignition by turning the black programming key to

the position OFF .
Remove the black ignition key.
103
EFI warning lamp

flashes according to the number of functioning black ignition keys including the orange programming key. In this case, twice.

The lost black ignition key is deactivated.
The existing black ignition key is reactivated.
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Loss of both black ignition keys (no black ignition key available):
This procedure is important to prevent misuse of the lost black ignition key.
EFI warning lamp
lights up.
EFI warning lamp

flashes according to the number of functioning black ignition keys including the orange programming key. In this case once, since all black ignition
keys are deactivated.
All black ignition keys are deactivated.
Order a new black ignition key according to the key number on the KEYCODECARD and activate it.
Activating ignition key:

You can activate or deactivate up to four black ignition keys. Only the black ignition keys programmed during an activation procedure are valid. All black ignition
keys not programmed during the activation procedure are invalid, but can be reprogrammed in a further activation procedure.
EFI warning lamp
lights up.
Insert the black ignition key in the ignition lock.
Switch on the ignition by turning the black programming key to

the position ON .
EFI warning lamp

switches on again.
104
Switch off the ignition by turning the black programming key to

the position OFF .
Remove the black ignition key.
To activate further ignition keys, repeat the last 4 steps with the respective
ignition key.
EFI warning lamp

flashes according to the number of functioning black ignition keys including the orange programming key.
P
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7- Sh
99 a
r
9- k.
56 co
86 m
All black ignition keys are activated included in this job sequence are activated.
Activating the ICU

17.3
Info
To program the new imobilizer control unit, the two black ignition keys are needed.
Install the new imobilizer control unit.
Insert the supplied orange programming key into the ignition lock.
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
Insert the first black ignition key into the ignition lock.
The immobilizer
on again.
Switch off the ignition by turning the black programming key to the position OFF
Pull out the first black ignition key.
Insert the second black ignition key into the ignition lock.
The immobilizer
on again.
indicator lamp lights up, switches off briefly, and switches
EFI warning lamp
900039-60
lights up.
EFI warning lamp
100749-01
indicator lamp lights up, switches off briefly, and switches
Connect the diagnostic tool.
Start diagnostic software.
Select the model.
Press "Continue".
Select "Coding".
Press "Continue".
Select "Teach-in immobilizer control unit".
105
Press "Continue".
Read the information page in the KTM diagnostics tool then using "Continue" programm the ICU.
Carry out the start procedure. (
.
.
p. 13)
Guideline
The start procedure was successful.
Delete trouble code.
Combination instrument - Activation of the BOOTLOADER mode

17.4
Press the button MODEand keep it depressed.

Press the button MODEand keep it depressed.
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
.
.
BOOTLOADER mode appears in the combination instrument.
Release MODE button.
400661-10
Updating the combination instrument software

17.5
Condition
The ignition is on.
The diagnostic tool is connected and running.
Activate the combination instrument - BOOTLOADER mode. (
Select the model.
Select "DCL".
Select "Connect".
p. 105)
In the DCL window, "ECU OK" appears in the right-hand lower part of the
screen.
In the DCL window, "ECU NOT OK" appears in the right-hand lower part of the
screen.
400687-60
Check the connection between XC_1 Scan Box and the diagnostics connector on the vehicle and repeat the procedure.
In the DCL window, "ECU NOT OK" appears in the right-hand lower part of the
screen.
Activate the combination instrument - BOOTLOADER mode. (
p. 105)
In the DCL window, "XC_1 Scan Box not found" appears in the right-hand lower
part of the screen.
Check KTM diagnostic tool connection to XC_1 Scan Box and repeat the
procedure.
Press button
under "Select flash file".
A selection window opens.
Select the current file with suffix .kfw and highlight it.
Info
Select the correct file for the vehicle type.
Press "Open".
Press "Transfer".
The software status is updated.
106
Setting ROAD or RACE mode

17.6
Condition
The ignition is on.
The motorcycle is stationary.
Press the button
Press the MODE button briefly.
and the button
for 3 - 5 seconds.
The mode set is shown in the info display.
Select ROAD mode or RACE mode with the
Press the button

the info display.
button or the
button.
The settings are stored and the display changes to the SETUP menu.
P
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7- Sh
99 a
r
9- k.
56 co
86 m
400475-01
briefly and repeatedly until the symbol
shows EXIT SETUP in
Setting the clock with SET CLOCK

17.7
Condition
The ignition is on.
Press the button
and the button
Press the button
once until the symbol
for 3 - 5 seconds.
shows SET CLOCK in the info display.
The hour is shown.
Set the hour with the
Set the minutes with the
Press the button

the info display.
button or the
button.
The minutes are shown.
400455-01
button or the
button.
The settings are stored and the display changes to the SETUP menu.
shows EXIT SETUP in
Adjusting shift speed RPM1/2

17.8
Condition
The ignition is on.
Press the button
and the button
Press the button

info display.
twice until the symbol
for 3 - 5 seconds.
appears in front of SETTINGS in the
RPM1 and RPM2 appear in the info display.

The engine speed after RPM1 flashes.
Info
400460-01
The engine speed can be set at intervals of 50.

RPM1 is the engine speed above which the shift warning light starts to flash.
Set the engine speed with the button
or the button
The engine speed after RPM2 flashes.
Info
RPM2 is the engine speed above which the shift warning light lights up constantly. If RPM1 = RPM2, the shift warning light lights up constantly when
you reach the engine speed set.
107
Set the engine speed with the button
or the button
The settings are stored and the display changes to the SETTING menu.
Info
At delivery, RPM1 is set to 10000 and RPM2 to 10500.
Press the button

info display.
Press the button

the info display.
shows BACK... in the
shows EXIT SETUP in
Setting the blank time of the LAP button LAP BLANK T
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
17.9
Condition
The ignition is on.
Press the button
and the button
Press the button

info display.
Press the button
for 3 - 5 seconds.
shows LAP BLANK T in the info display.
LAP BLANK T. appears in the info display.
Info
400461-01
At delivery, LAP BLANK T. is set to 1 second.
Tip
With LAP BLANK T., you can prevent the lap from being timed too short. This
may happen if you accidentally press the LAP button twice in a row.
Set the blank time of the LAP button with the
button or the
button.
Info
LAP BLANK T. can be set between 1 and 200.
The settings are stored and the display changes to the SETTINGS menu.
Press the button

info display.
Press the button

the info display.
shows EXIT SETUP in
Setting the number of laps SET NUM LAPS

17.10
Condition
The ignition is on.
Press the button
and the button
Press the button

info display.
Press the button

play.
for 3 - 5 seconds.
is on SET NUM LAPS in the info dis-
TOTAL LAPS appears in the info display with the number of laps.
400462-01
108
Info
When delivered, the number of TOTAL LAPS is set to 99 laps.
Set the number of laps with the
button or the
button.
Info
You can set TOTAL LAPS to between 1 and 99 laps.
Press the button

info display.
Press the button

the info display.
shows EXIT SETUP in
P
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99 a
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56 co
86 m
Setting the fuel reserve display TRIPF RESET

17.11
Condition
The ignition is on.
Press the button
and the button
Press the button

info display.
Press the button

display.
for 3 - 5 seconds.
three times until the symbol
shows TRIP F RESET in the info
TRIPF RESET appears in the info display with the reaction time.
400463-01
Info
At delivery, TRIPF RESET is set to 300 seconds.
Set the reaction time of the fuel reserve display with the
button or the
button.
Info
You can set the TRIPF RESET to between 10 and 1000 seconds in steps of
10.
Press the button

info display.
Press the button

the info display.
Setting the kilometers/miles SET KM/MILES

17.12
Info
Making a country-specific setting.
Condition
The ignition is on.
shows EXIT SETUP in
109
Press the button
and the button
Press the button
Select the unit with the
Press the button

info display.
Press the button

the info display.
for 3 - 5 seconds.
shows UNITS in the info display.
The selected unit appears on the left of the display.

button.
The settings are stored and the display changes to the UNITS menu.
P
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87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400464-01
button or the
shows EXIT SETUP in
Setting the temperature unit SET C/F

17.13
Condition
The ignition is on.
Press the button
and the button
Press the button
Press the button
Select the unit with the
for 3 - 5 seconds.
shows UNITS in the info display.
shows SET C/F in the info display.
The selected unit appears on the left of the display.
400465-01
button or the
button.
The settings are stored and the display changes to the UNITS menu.
Press the button

info display.
Press the button

the info display.
shows EXIT SETUP in
Switching the external temperature display on/off

17.14
Condition
The ignition is on.
Press the button
and the button
Press the button

play.
four times until the symbol
Press the button

play.
You can switch the external temperature display on/off with the
button.
for 3 - 5 seconds.
shows OPTIONS in the info dis-
shows OPTION OUTTEMP in the info dis-
You see ENABLED or DISABLED in the info display.

400466-01
button or the
The settings are stored and the display changes to the OPTIONS menu.
Press the button

info display.
Press the button

the info display.
shows EXIT SETUP in
110
Resetting service display

17.15
Condition
The ignition is on.
Press the button
and button
Press the button

info display.
Press the button
and button
Press the button

SERVICE RESET.
repeatedly until the symbol
for 3-5 seconds.

for 3-5 seconds.

appears in front of
P
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99 a
r
9- k.
56 co
86 m
SERVICE RESET appears in the info display.

ARE YOU SURE? flashes.
Press the button
Press the button
The menu is closed.

.
NEXT SERVICE AFTER is displayed.
400486-01
Adjust the distance to the next service using the button
and the button
The menu is closed.
400485-01
Checking the headlight setting

17.16
0
A
On a light-colored wall behind a horizontal area, make a mark as high as the center
of the low beam headlight.
Make another mark at a distance of under the first mark.

Guideline
B
0
Distance
5 cm (2 in)
Position the motorcycle at a distance of away from the wall. The rider, with luggage and passenger if applicable, now mounts the motorcycle.
Guideline
400420-10
Distance
5 m (16 ft)
Switch on the low beam. Check the headlight setting.
The light-dark boundary must lie exactly on the lower mark when the motorcycle
is ready to operate with the rider mounted along with any luggage and a passenger if applicable.
If the boundary between light and dark does not meet specifications:
Adjust the headlight range. (
p. 111)
111
Adjust the headlight range

17.17
Check the headlight setting. (
Adjust the beam distance of the headlight by turning screw .
p. 110)
Guideline
For a motorcycle with rider, and with luggage and a passenger if applicable, the
light/dark boundary must be exactly on the lower mark (applied in: Checking
headlight adjustment).
Info
Turn clockwise to increase the light range, turn counterclockwise to reduce
the light range.
If you have a payload, you may have to correct the headlight range.
100748-10
Changing the parking light bulb
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
17.18
Note
Damage to reflectorReduced luminance.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Clean the bulb and keep it free of grease
before mounting.
Remove screws . Remove the cover.
Release the latch .
Remove the lamp cover .
Pull the parking light carefully out of the holder.
Remove the light bulb.
Position a new light bulb in the holder.
100745-10
100746-10
Parking light (W5W/ base W2.1x9.5d) (
100747-10
p. 411)
Carefully position the holder with the bulb in the holder in the headlight.
112
Position the lug of the lamp cover in the notch. Engage the latch.
Check that the lighting is functioning properly.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400422-12
Position the cover.
Info
Check for correct positioning and freedom of movement of the brake lines.

Guideline
M6
10 Nm (7.4 lbf ft)
100745-12
Changing the low beam bulb

17.19
Note
before mounting.
Fold up the combination instrument. Pull the lug out of the rubber retainer .
Remove the rubber retainer.
Release the latch .
100742-10
100743-10
113
Push off the retaining clamp on both sides, squeeze and fold to the side.
Remove headlight bulb .
Position the new headlight bulb in the headlight housing.
700295-01
Low beam / high beam (H7 / base PX26d) (
p. 411)
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Insert the headlight bulb so that the lug is positioned in the cut-out.
Position the retaining clamp.
Position the plug-in connector.
Position the lug of the lamp cover in the notch. Engage the latch .
Position the rubber holder .
Fold down the combination instrument. Position the lug in the rubber retainer.
700296-01
400422-10
100744-10
Changing the high beam bulb

17.20
Note
before mounting.
Remove screws . Remove the cover.
Release the latch .
114
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100745-10
100746-10
Push off the retaining clamp on both sides, squeeze and fold to the side.
Remove headlight bulb.
Position the new headlight bulb in the headlight housing.

Low beam / high beam (H7 / base PX26d) (
p. 411)
Info
Insert the headlight bulb so that the lug is positioned in the cut-out.
700299-01
Position the retaining clamp.
Position the plug-in connector.
Position the lug of the lamp cover in the notch. Engage the latch.
Position the cover.
400422-11
Info
Check for correct positioning and freedom of movement of the brake lines.

Guideline
100745-11
M6
10 Nm (7.4 lbf ft)
30/ENGINE
115
Removing the engine

18.1
Remove the inside cover. (
p. 13)
p. 70)
p. 75)
Remove the filter box bottom. (
Remove the radiator. (
Remove rear screw of the starter motor.
Remove the screw of ground connector .
Remove the screws of SLS cover . Take off the SLS cover.
p. 67)
p. 67)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 195)
200509-10
Push back protective cover . Unscrew the electrical connection from the starter
motor. Remove the cable.
Unplug the connector of oil pressure sensor .
Unplug the connector of the coolant temperature sensor .
Remove the screws of SLS cover . Take off the SLS cover.
Remove cable protector .
200510-10
200511-10
Unplug connectors of the gear position sensor and of the side stand switch.
Remove the exhaust system. (
Unplug the connectors of ignition coils .
p. 63)
200512-10
200520-10
30/ENGINE
116
Remove screws . Remove the slave cylinder with the spacer and sleeves.
Remove screws . Take off the engine sprocket cover.
Shift into first gear.
200521-10
Info
The purpose is to loosen the nut of the engine sprocket.
Remove screws . Remove the chain securing guide with the spacer.
Remove screws . Remove the side stand bracket.
Remove screw with the washers. Take off the shift shaft deflection.
Remove screws . Take off the horn holder.
Remove the rear brake system. (
Position the floor jack under the engine and screw it on using the special tool.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200522-10
200523-10
p. 101)
200524-10
Floor jack attachment (61229055000) (
p. 447)
Fix the front wheel. Secure the motorcycle against falling over with belts. Remove
the work stand from the rear.
Remove the nut of the engine sprocket with the lock washer. Take off the engine
sprocket.
200527-10
200528-10
30/ENGINE
117
Remove nut . Pull out the pin of the bell crank on the frame.
Remove the nut of the swingarm pivot. Pull out the swingarm pivot.
Take off the swingarm with the shock absorber.
Have an assistant hold the rear of the motorcycle. Remove the securing belts.
200529-10
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Make sure not to misplace the washers.
Lower the engine. Raise the rear of the motorcycle. Pull out the engine from the
side.
Mount the special tool on the frame.
200530-10
Frame support (61229050000) (
p. 446)
Remove both radiator hoses. Remove the vacuum and vent hoses.
Position both radiator hoses. Position and tighten the hose clamps.
Position the hose fixation. Mount and tighten screw .
Preparing the engine for installation

18.2
Guideline
Remaining engine screws
M6
10 Nm (7.4 lbf ft)
Connect the vacuum hoses of manifold absolute pressure sensor .
Position the vent hoses as shown in the figure.
200531-10
Installing the engine

18.3
Prepare the engine for installation. (
Raise the engine onto the special tool and screw it in place.
p. 117)

Frame support (61229050000) (
200530-11
p. 447)
p. 446)
Raise the rear of the motorcycle. Position the engine in the frame.
Mount screws with the washers on both sides but do not tighten them yet.
Secure the motorcycle against falling over with belts.
30/ENGINE
118
Position the swingarm with the shock absorber.
Info
Do not forget the chain.
Center the swingarm.

Centering pin (61229051000) (
p. 446)
Mount the swingarm pivot. Mount and tighten the nut.

Guideline
200529-01
Nut, swingarm pivot
M19x1.5
130 Nm
(95.9 lbf ft)
Thread greased
Tighten screws .
Guideline
M10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, engine bearer
45 Nm
(33.2 lbf ft)
Mount the pin of the bell crank on the frame. Mount and tighten the nut.
Guideline
M14x1.5
Mount the rear work stand.
Remove the securing belts.
Remove the floor jack with the special tool.

100 Nm
(73.8 lbf ft)
p. 447)
Install the rear brake system. (
Mount the engine sprocket with the lock washer.
Mount and tighten the nut.
p. 101)
200527-10
Guideline
Nut of engine sprocket
M20x1.5
100 Nm
(73.8 lbf ft)
Secure the nut with the lock washer.
Position the horn holder. Mount and tighten screws .
Loctite 243
200528-10
Guideline
200524-11
M6
10 Nm (7.4 lbf ft)
30/ENGINE
119

Guideline
bracket
M8
25 Nm
(18.4 lbf ft)
Loctite 243
Position the shift shaft deflection. Mount and tighten screw with the washers.
Guideline
Screw, shift shaft deflector M6
on shift shaft
200523-11
18 Nm
(13.3 lbf ft)
Loctite 243
Position the side stand bracket. Mount and tighten screws .

Guideline
Screw, side stand bracket
25 Nm
(18.4 lbf ft)
Loctite 243
Position the chain securing guide with the spacer. Mount and tighten screws .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
M8
Guideline
Screw, shift shaft deflector M6

on chain securing guide
10 Nm
(7.4 lbf ft)
Loctite 243
10 Nm
(7.4 lbf ft)
M6
200522-11
Mount the slave cylinder with the spacer and sleeves. Mount and tighten screws .
Guideline
M6
10 Nm (7.4 lbf ft)
Mount the engine sprocket cover. Mount and tighten screws .
Guideline
M6
10 Nm (7.4 lbf ft)
200521-11
Plug in the connector of ignition coils .
Install the exhaust system. (
Plug in connector of the gear position sensor and of the side stand switch.
Mount cable protector .
p. 65)
200520-11
200512-11
30/ENGINE
120
Position SLS cover . Mount and tighten the screws.

Guideline
M6
10 Nm (7.4 lbf ft)
200511-11
Plug in the connector of engine coolant temperature sensor .
Plug in the connector of oil pressure sensor .
Position the cable. Screw on the electrical connection on the starter motor. Mount
protective cover .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200510-11
Position SLS cover . Mount and tighten the screws.

Guideline
M6
10 Nm (7.4 lbf ft)
Mount and tighten the screw of ground connection .
Guideline
M6
Mount and tighten rear screw of the starter motor.

Guideline
200509-11
Screw, starter motor
M6
Install the filter box bottom. (
p. 71)
Install the radiator. (
p. 195)
p. 67)
p. 13)
Fill up with engine oil. (
Take a short test ride.
Read out the trouble code memory using the KTM diagnostics tool.
Check the engine for leakage.
Check the engine oil level. (
Check the cooling system for leaks.
Check the coolant level. (
p. 212)
p. 209)
p. 194)
Condition
The valve cover has been removed.
200539-11
10 Nm (7.4 lbf ft)
p. 68)
Setting the engine to ignition top dead center of the rear cylinder
18.4
10 Nm (7.4 lbf ft)
Remove screw of the generator cover.
30/ENGINE
121
Turn the crankshaft counterclockwise until markings are flush with the edge of
the cylinder head.
Remove screw .
Look through the hole to check that the position notch of the crankshaft is visible.
Screw in special tool .
301441-10
p. 444)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Engine blocking screw (61229015000) (
200540-11
Setting the engine to ignition top dead center of the front cylinder
18.5
Condition
The engine is positioned at ignition top dead center of the rear cylinder.
Loosen special tool by several turns.
p. 444)
200544-10
301442-10
Continue turning the crankshaft counterclockwise until markings are flush with
the edge of the cylinder head.
Screw special tool back in.
30/DISASSEMBLING THE ENGINE
122
Clamping the engine into the engine work stand

19.1
Mount special tool on engine work stand .

Engine work stand (61229001000) (
Engine holder (61229002000) (
p. 443)
p. 443)
Mount the engine on special tool .
Info
Have an assistant help you or use a crane.
301339-10
Removing the engine bracket

19.2
Remove screws .
Remove screw and take off the engine bracket.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301345-10
Remove screws .
Remove screw and take off the engine bracket.
Remove oil drain plug with the magnet, O-rings and oil screen.
Completely drain the engine oil.
301346-10
Draining the engine oil

19.3
200480-10
123
Removing the front valve cover

19.4
Remove ignition coil .
Remove screws . Take off the valve cover with the valve cover seal.
Remove the spark plug using the special tool.

Spark plug wrench (75029172000) (
p. 448)
301336-10
Removing the rear valve cover

19.5
Remove ignition coil .

Remove screws . Take off the valve cover with the valve cover seal.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 448)
301337-10
19.6
Remove screw of the generator cover.
Turn the crankshaft counterclockwise until markings of the rear camshafts are
flush with the edge of the cylinder head.
Remove screw .
Look through the hole to check that the position notch of the crankshaft is visible.
301338-10
301341-10
301340-10
p. 444)

Removing the starter motor
19.7
Remove screw . Take off the starter motor.
301348-10
Removing the oil filler tube

19.8
Remove screws .
Remove the oil filler tube with the O-ring.
Remove screws of heat exchanger .
Remove the heat exchanger.
Remove O-rings and sleeves .
Remove seal .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301349-10
Removing the heat exchanger

19.9
301350-10
301366-10
Removing the rear timing chain tensioner

19.10
301351-10
Remove screw with O-ring .
Pull out timing chain tensioner .
124
125
Removing the rear camshaft

19.11
Remove spark plug shaft insert .
Loosen and remove screws from the outside to the inside.
Info
The cams should not activate the valves.
Remove the camshaft bearing bridge.
Raise the camshaft at the rear and take the timing chain off of the rear sprocket.
Remove the camshaft.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301352-10
301353-10
Removing the rear cylinder head

19.12
Remove nuts with the washers.
Alternately loosen screws and remove them.
Take off the cylinder head. Remove the cylinder head gasket.
Push the cylinder up.
301357-10
Removing the rear piston

19.13
Info
Push the cylinder up until the piston pin can be removed.

Make sure that the two pins remain in place.
301354-10
Remove piston pin retainer .
Remove the piston pin.
Remove the cylinder with the piston.
Push the piston upward out of the cylinder.
Info
If no additional work needs to be performed on the cylinder and piston, the
piston can remain in the cylinder.
301355-10
Take off the cylinder base gasket.
126
19.14
Loosen special tool by several turns.

p. 444)
Keep the timing chain tensioned.
Continue turning the crankshaft counterclockwise until markings of the front

camshafts are flush with the edge of the cylinder head.
Screw special tool back in.
301358-10
Removing the front timing chain tensioner

19.15
Remove screw with O-ring .

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301359-10
Removing the front camshafts

19.16
Info
Remove nuts with the washers.
Alternately loosen screws and remove them.
Take off the cylinder head. Remove the cylinder head gasket.
301360-10
301361-10
Removing the front cylinder head

19.17
301362-10
127
Removing the front piston

19.18
Push the cylinder up.
Info
Push the cylinder up until the piston pin can be removed.
Make sure that the two pins remain in place.
301363-10
Remove piston pin retainer .
Remove the piston pin.
Remove the cylinder with the piston.
Push the piston upward out of the cylinder.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Info
If no additional work needs to be performed on the cylinder and piston, the

piston can remain in the cylinder.
301364-10
Take off the cylinder base gasket.
Remove screws .
Screw in special tool and pull off the generator cover.
Removing the generator cover

19.19
301392-10
Extractor (61229010000) (
p. 444)
Info
Gently strike the generator cover with a rubber mallet to prevent strain.
Take off the generator cover seal. Take off the dowels.
Remove the screws of ignition pulse generator .
Pull cable support sleeve out of the engine case. Take off the ignition pulse generator.
301393-10
Removing the ignition pulse generator

19.20
200346-10
128
Removing the torque limiter and idler

19.21
Take off torque limiter .
Remove idler with the washers and needle bearing.
Info
The idler has one disk at the front and one at the rear; the front washer usually sticks to the generator cover.
200347-10
Removing the rotor

19.22
Remove the screws and take off freewheel holder .

Loosen and remove screw of the rotor.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Info
The crankshaft must be blocked.
301396-10
Screw the special tool into the crankshaft.

Pressure piece (61229008000) (
Mount special tool on the rotor, apply counterpressure, and pull off the rotor by
screwing in the screw.
Extractor (58429009000) (
p. 440)
Remove the special tools.
Take free-wheel-gear from rotor .
200349-10
200350-10
Removing the idler and timing chain on the left

19.23
200353-10
p. 444)
Take off idler with washer .
129
Remove the timing chain, needle bearing and the washer lying behind it.
Info
If the timing chain is to be used again, note the direction of travel and the
cylinder on which it was used.
200354-10
Removing the oil filter

19.24
Remove screws . Take off oil filter cover with the O-ring.
Pull oil filter out of the oil filter housing.

p. 440)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Circlip pliers reverse (51012011000) (
301390-10
Removing the balancer shaft

19.25
Remove balancer shaft with washer .
Mount the needle bearing and the rear washer.
301391-10
Removing the drive wheel of the balancer shaft

19.26
Remove the drive wheel of balancer shaft using special tools , and .
Puller, 2-arm (78029033100) (
p. 448)
p. 445)
Arms for extractor 78029033100 (61229017000) (
200358-10
p. 445)

Removing the gear position sensor
19.27
Remove the screws. Remove gear position sensor with the O-ring.
Remove contact pin and the contact spring.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301398-10
301399-10
Removing the left suction pump

19.28
Remove screws .
Screw fitting screws into the oil pump cover.
Pull off the oil pump cover by screwing in the screw.
301400-10
301401-10
Remove oil pump cover .
Remove seal .
130

Remove external rotor and internal rotor .
Remove pin .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301402-10
Removing the water pump wheel

19.29
Remove screws .
Take off the water pump cover.
301394-10
Remove dowels .
Remove screw . Take off the water pump wheel with the washer below it.
Loosen the screws of outer clutch cover .
200398-10
Removing the clutch cover

19.30
200399-10
Remove screws .
Take off the clutch cover.
131
132
Take off dowels . Remove the clutch cover seal.
Remove check valve .
200401-10
Removing the idler and timing chain on the right

19.31
Remove idler .
Take off the timing chain.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Info
If the timing chain is to be used again, note the direction of travel and the
cylinder on which it was used.
200403-10
Removing the clutch facing

19.32
Loosen screws of pressure cap in a crisscross pattern and remove them

together with the spring retainers and the clutch springs.
Take off pressure cap .
Take off push rod .
Remove clutch discs , the support ring and the pretension ring.
Insert special tool into inner clutch hub and outer clutch hub .
200405-10
200406-10
Removing the outer clutch hub

19.33
Clutch holder (61229003000) (
200408-10
p. 443)
Loosen nut and remove it with the washer.
Remove components and of the clutch pressure booster.
133
Remove outer clutch hub with washer .
Remove needle bearing and washer .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301403-10
301404-10
Removing the primary gear

19.34
Loosen nut of primary gear and remove it together with the washer.
Info
Left-handed thread!
Make sure that the crankshaft is blocked.
200412-10
Remove the primary gear with special tools , and .

Puller, 2-arm (78029033100) (
p. 448)
p. 445)
Arms for extractor 78029033100 (61229017000) (
p. 445)
301409-10
Removing the force pump

19.35
301410-10
Remove lock washer and washer . Take off oil pump gear .
Remove pin and washer .
Remove screws .
Remove the oil pump cover.
Remove external rotor and internal rotor .
Remove pin .
134
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301411-10
301412-10
Removing the shift shaft

19.36
Push sliding plate away from the shift drum locating . Remove shift shaft
with the washer.
Remove screw .
Press locking lever away from shift drum locating and take off the shift drum
locating.
Release the locking lever.
301413-10
Removing the shift drum locating

19.37
301414-10
135
Removing the locking lever

19.38
Remove screw .
Take off locking lever with the sleeve and spring.
301415-10
Removing the left engine case
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
19.39
200421-10
Remove screws and .
Swing the left section of the engine case upward. Remove screw .
Loosen the left section of the engine case by striking it lightly with a plastic hammer and remove it.
Remove dowels .
Remove seal .
301422-10
Removing the crankshaft

19.40
301423-10
Remove the crankshaft.
p. 444)

Removing the middle suction pump
19.41
Take off oil pump shaft with internal rotor .
Remove internal rotor and pin from the oil pump shaft .
Remove external rotor .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200425-10
200426-10
Removing the transmission shaft

19.42
Remove shift rails .
Swing shift forks to one side.
200427-10
Info
Make sure not to misplace shift rollers .
Remove shift drum .
Remove shift forks .
200428-10
Info
Make sure not to misplace the shift rollers.
200429-10
136
Place the engine in an upright position.
Remove lock ring and the stop disk.
Pull both transmission shafts out of the bearing seats together.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200430-10
200431-10
Removing the oil spray tube

19.43
Remove oil spray tube . Remove O-rings .
200432-10
Removing the timing chain rails of the right engine case section
19.44
Remove screw . Remove timing chain guide rail .
Remove screw . Remove timing chain tensioning rail .
200434-01
Removing the timing chain rails of the left engine case section
19.45
200447-10
Remove screw . Remove timing chain guide rail .
Remove screw . Remove timing chain tensioning rail .
137
30/ENGINE - WORK ON INDIVIDUAL PARTS
138
Work on the right section of the engine case

20.1
Remove studs .
Remove jet .
Remove oil jets .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200442-10
200440-10
Remove bearing retainers .
Remove the dowels.
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)
200441-10
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.
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
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
After the engine case section has cooled, check that the bearings are firmly seated.
139
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 bearing retainers .

Guideline
Screw, bearing retainer
M5
6 Nm
(4.4 lbf ft)
Loctite 243
M6x0.75
4 Nm
(3 lbf ft)
Loctite 243
Mount and tighten jet .

Guideline
Jet 140
Mount and tighten oil jets .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Oil jet
Mount the dowels.
Mount studs .
M6x0.75
4 Nm
(3 lbf ft)
Loctite 243
200440-10
Guideline
Stud, chain shaft
M6
Blow compressed air through all oil holes and check that they are clear.
200442-10
Removing the main bearing of the right engine case section

20.2
Remove the screws and take off bearing shell bracket .
Mark face of the main bearing shells as shown in the figure.
200435-10
200436-10
8 Nm (5.9 lbf ft)
Place the engine case section on special tool .

Press sleeve (61229045000) (
140
p. 446)
Place special tool with the smaller diameter on the bearing shells and press from
the inside to the outside.
p. 446)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Press drift/press sleeve (61229044000) (
200437-10
Selecting the main bearing shells

20.3
New crankshaft
Select the new bearing shells according to color marking .
Info
Color marking refers to the conrod bearing.
Used crankshaft
Measure both pivot points and select the new bearing shells accordingly.
Guideline
Crankshaft - main bearing diameter
200451-10
Yellow
53.965 53.975 mm (2.1246

2.125 in)
Blue
53.976 53.985 mm (2.12504

2.12539 in)
Red
53.986 53.995 mm (2.12543

2.12578 in)
Installing the right main bearing

20.4
Select the main bearing shells. (
Center the new main bearing shells using special tool .
p. 140)
p. 446)
200439-10
Place the inside of the engine case section on special tool .

Press sleeve (61229045000) (
p. 446)
Align the face of the new bearing shell with the marking made when it was disassembled.
Press the bearing shells with the stepped side of special tool through press
sleeve from the outside to the inside, all the way to the stop.
200438-10
p. 446)
141
Position bearing shell bracket . Mount and tighten the screws.

Guideline
M5
6 Nm
(4.4 lbf ft)
Loctite 243
200435-11
Work on the left section of the engine case

20.5
Remove studs .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200448-10
Remove screw .
Remove oil jets .
200449-10
Remove shaft seal rings .
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.
Info
200450-10
Any bearings that remain in the engine case section must be removed using
a suitable tool.
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.
142
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 ring; otherwise, the bearings 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 oil jets .

Guideline
M6x0.75
4 Nm
(3 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Oil jet
Loctite 243
Mount oil jet .

Guideline
Oil jet for clutch lubrication
M6x0.75
4 Nm (3 lbf ft)
M10x1
15 Nm
(11.1 lbf ft)

Guideline
Plug, clutch lubrication
200449-11
Press in shaft seal rings until they are flush.
Press in the shaft seal ring of push rod .

Press drift (61229013000) (
p. 444)
200450-11
Mount studs .
Guideline
Stud, chain shaft
200442-10
M6
8 Nm (5.9 lbf ft)
Blow compressed air through all oil holes and check that they are clear.
143
Removing the left main bearing

20.6
Remove the screws and take off bearing shell bracket .
Mark joint of the main bearing shells as shown in the figure.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200443-10
200444-10
Place the engine case section on special tool .

Press sleeve (61229045000) (
p. 446)
Place special tool with the smaller diameter on the bearing shells and press from
the inside to the outside.
p. 446)
200445-10
Installing the left main bearing

20.7
Select the main bearing shells. (
Center the new main bearing shells using special tool .
p. 140)
p. 446)
200439-10
Place the inside of the engine case section on special tool .

Press sleeve (61229045000) (
p. 446)
Align the face of the new bearing shell with the marking made when it was disassembled.
Press the bearing shells with the stepped side of special tool through press
sleeve from the outside to the inside, all the way to the stop.
200446-10
p. 446)
144
Position bearing shell bracket . Mount and tighten the screws.

Guideline
M5
6 Nm
(4.4 lbf ft)
Loctite 243
200443-11
Changing the conrod bearing

20.8
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Perform the operation on both connecting rods.
Clamp each connecting rod separately using soft jaws.
Remove screws .
Multi-tooth wrench socket 10 mm; " drive (60029075000) (
p. 442)
Take off the bearing cap and connecting rod. Remove the bearing shells.
Info
Mark the connecting rod bearing cap and connecting rod to ensure that
each connecting rod bearing cap will be mounted on the same connecting
rod.
301424-10
New crankshaft
Select the new bearing shells according to color marking .
Info
Color marking refers to the crankshaft bearing.
200453-10
Used crankshaft
Measure the crank pin diameter and select the new bearing shells accordingly.
Guideline
Crankshaft - crank pin diameter
200485-10
Yellow
41.978 41.989 mm (1.65267

1.65311 in)
Blue
41.990 42.000 mm (1.65315

1.65354 in)
Red
42.001 42.011 mm (1.65358

1.65397 in)
Check the radial clearance of the bottom connecting rod bearing. (
p. 147)
145
Oil the bearing shells.
Position the connecting rod bearing cap according to the markings made when they
were disassembled. Mount the new connecting rod screws and tighten them using
the special tool.
Guideline
Screw, conrod bearing
M10x1
Step 1
25 Nm
(18.4 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
90
Multi-tooth wrench socket 10 mm; " drive (60029075000) (

p. 441)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Graduated disc (60029010000) (
p. 442)
Info
The connecting rod bearing shells are laterally offset in the connecting rod
to allow room for radius of the crankshaft. If installed incorrectly, the
bearing shells will press against the radius and block the connecting rod.
301425-10
Work on the clutch cover

20.9
Remove water pump cover .
Remove outer shaft seal ring .
Remove lock ring .
Remove inner shaft seal ring .
Press bearing out of the clutch cover from the outside to the inside, using a suitable tool.
Press in new bearing from the inside to the outside, all the way to the stop,
using a suitable tool.
Change the step bearing of the crankshaft. (
Press in inner shaft seal ring fully, with the open side flush and facing inwards.
Mount lock ring .
200456-10
200457-10
p. 146)
200458-10
200457-10
146
Press in outer shaft seal ring fully, with the open side flush and facing outwards.
Insert water pump cover .
200456-10
Changing the step bearing of the crankshaft

20.10
Mark the position of the bearing joint .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200459-10
Pull out the step bearing shells using the special tool.
Bearing puller (15112017000) (
p. 440)
Insert for bearing puller (60029018000) (
p. 441)
200460-10
Center the new main bearing shells using the special tool.
Step bearing tool (60029046028) (
p. 442)
200461-10
Support the clutch cover directly under the step bearing. Press in the step bearing
shells using the special tool until they are flush.
Step bearing tool (60029046028) (
200462-10
p. 442)
147
Checking the radial clearance of the bottom connecting rod bearing

20.11
Info
Perform the operation on both connecting rods.
Position the bearing shells. Insert the Plastigauge measuring strips offset by 90
from the bearing joint.
Plastigauge measuring strips (60029012000) (
p. 441)
Position the connecting rod bearing cap. Mount and tighten the screws.
Guideline
M10x1
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Step 1
25 Nm
(18.4 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
90
Info
Do not twist the connecting rod.
200455-10
Remove the connecting rod bearing cap again. Compare the Plastigauge measuring
strip with the specifications on the packaging.
Guideline
Connecting rod - radial clearance of lower conrod bearing

New condition
0.030 0.060 mm (0.00118

0.00236 in)
Wear limit
0.080 mm (0.00315 in)
Info
The width of the Plastigauge measuring strips indicates the bearing play.
Clean the parts.
Check the cylinder bearing surface for damage.
Checking/measuring the cylinder

20.12
If the cylinder bearing surface is damaged:
Change the cylinder and piston.
Measure the cylinder diameter at several places on the contact surface in the
and axes using a micrometer to check for oval wear.
Guideline
Cylinder - bore diameter

Size I
105.000 105.012 mm (4.13385

4.13432 in)
Size II
105.012 105.025 mm (4.13432

4.13483 in)
200472-10
200474-10
The cylinder size is labeled on the side of the cylinder.
148
Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) (
p. 441)
Cylinder/cylinder head - sealing area

distortion
0.05 mm ( 0.002 in)
If the measured value does not equal the specified value:
Change the cylinder.
400376-10
Checking/measuring the piston

20.13
Check the piston bearing surface for damage.
If the piston bearing surface is damaged:

Change the piston and, if necessary, the cylinder.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
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
Use an old piston ring to clean the piston ring groove.
301418-10
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.
Use the special tool to measure clearance of the piston rings in the piston ring
groove.
Guideline
A
0
A
0
Piston ring - groove clearance
A
0
400484-10
Oil scraper ring
0.180 mm ( 0.00709 in)
Change the piston and piston rings.
Check/measure the cylinder. (
p. 147)
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:
p. 441)
If clearance is larger than the specified value:
0
A
0.150 mm ( 0.00591 in)
Check the piston pin for discoloration or signs of wear.
0
A
0.105 mm ( 0.00413 in)
Second ring (lower compression

ring)
Feeler gauge (59029041100) (
First ring (rectangular ring)
Change the connecting rod and the piston pin.
Measure the piston on the piston skirt.

Guideline
Piston - diameter
200475-10
Size I
104.955 104.985 mm (4.13208

4.13326 in)
Size II
104.965 104.995 mm (4.13247

4.13365 in)
Under the edge at right angles to the

piston pin
6 mm (0.24 in)
149
Piston size is marked on the piston head.
Remove the piston ring from the piston.
Place the piston ring in the cylinder and align it with the piston.
301419-10
Checking the piston ring end gap

20.14
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Under the upper edge of the cylinder
10 mm (0.39 in)
Measure the end gap with special tool .
Guideline
0.5 mm ( 0.02 in)
Piston ring end gap
200477-10
Feeler gauge (59029041100) (
If the end gap is more than the specified value:
p. 147)
If the cylinder wear is within the tolerance range:
p. 441)
Change the piston ring.
Mount the piston ring with the marking facing toward the piston head.
Checking the piston/cylinder mounting clearance

20.15
Check/measure the piston. (
The smallest piston/cylinder mounting clearance is the result of the smallest cylinder 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.
p. 147)
p. 148)
Guideline
Piston/cylinder - mounting clearance

New condition
0.015 0.057 mm (0.00059 0.00224 in)
Wear limit
0.150 mm (0.00591 in)
Work on the cylinder head

20.16
Info
The following operations apply to both cylinder heads.
Remove oil pressure switch .
Info
This only applies to the front cylinder head!
200466-10
Remove engine coolant temperature sensor .
Remove screw .
Remove vacuum connection .
Remove O-rings .
150
Remove plugs with the O-ring.
Pull out cam lever axle with a suitable M5 screw and remove the cam lever.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200467-10
Remove shims and label the installation position.
Tension the valve spring with a special tool.
200468-10
Valve spring mounter (59029019000) (
p. 440)
Valve spring mounting device (78029060000) (
p. 448)
Remove valve keys and release tension on the valve spring.
Remove valve spring retainer , valve spring, valve stem seals and valve spring
supports .
200469-10
Info
9
bm
bl
bk
200470-01
Place the valve into a box according to the installation position and label the
box.
Check the cylinder head. (
Mount valve spring supports and new valve stem seals .
Mount valve spring and valve spring retainer .
p. 152)
The tight winding of the valve spring is at the bottom.
151
Tension the valve spring with a special tool.

Valve spring mounter (59029019000) (
p. 440)
Valve spring mounting device (78029060000) (
p. 448)
Mount valve keys . Release the tension on the valve spring.
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.
200469-10
Place shims into the valve spring retainer according to the installation position.
Position the cam lever and mount cam lever axles .
Mount plugs with new O-rings.
200468-10
Guideline
Plug, cam lever axis
M10x1
15 Nm
(11.1 lbf ft)
M10x1
10 Nm (7.4 lbf ft)
200467-11
Mount oil pressure sensor .

Guideline
Oil pressure sensor
Info
This only applies to the front cylinder head!
200466-10
Mount engine coolant temperature sensor .

Guideline
Coolant temperature sensor
M12x1.5
12 Nm (8.9 lbf ft)
152
Mount screw .
Guideline
Plug, vacuum connection
M6
5 Nm
(3.7 lbf ft)
Loctite 243
M6
5 Nm
(3.7 lbf ft)
Loctite 243
Mount vacuum connection .

Guideline
Vacuum connection
Mount and grease O-rings .
Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
Checking the cylinder head

20.17
If there is wear or tearing:
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Change the cylinder head.
Check the valve guides using the special tool.

Limit plug gauge (59029026006) (
p. 440)
Valve guide - diameter
200470-10
6.004 6.016 mm (0.23638

0.23685 in)
Wear limit
6.050 mm (0.23819 in)
If the special tool is easy to insert into the valve guide:
New condition
Change the valve guide and valve.
Check sealing seat of the valves.

Valve - sealing seat width
0
A
1.0 mm (0.039 in)
Intake: Wear limit
1.7 mm (0.067 in)
Exhaust: New condition
1.0 mm (0.039 in)
Exhaust: Wear limit
2.0 mm (0.079 in)
400373-10
Intake: New condition
Machine the valve seat.
Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) (
p. 441)
Cylinder/cylinder head - sealing area

distortion
400376-10
Change the cylinder head with the camshaft bearing bridge.
Check valve for damage and wear.
Change the cylinder head.
Check the pivot points of the camshafts in the cylinder head and in the camshaft
bearing bridge for damage and wear.
0.05 mm ( 0.002 in)
Change the valve.
Check the valve for run-out.

Valve - run-out
200471-10
On the valve stem
0.05 mm ( 0.002 in)
On the valve plate: New condition
0.016 mm ( 0.00063 in)
On the valve plate: Wear limit
0.030 mm ( 0.00118 in)
153
Change the valve.
Check the valve stem diameter.

Valve - valve stem diameter
Intake
5.965 5.980 mm (0.23484

0.23543 in)
Change the valve.
Check valve spring for damage and wear.
Change the valve spring.
Measure the valve spring lengths.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
5.893 5.970 mm (0.23201

0.23504 in)
Exhaust
Valve spring - length
Change the cam lever.
Check cam lever axle for damage and wear.
Change the cam lever axle.
Check valve spring support for damage and wear.
Change the valve springs.
41.2 mm (1.622 in)
Check cam lever for damage and wear.
42.0 mm (1.654 in)
Wear limit
New condition
Change the valve spring seat.
Check valve spring retainer for damage and wear.
Change the valve spring retainer.
Work on the right idler

20.18
Remove bushing .
Remove O-ring .
Remove inner bearing races and .

Extractor (61229020000) (
200465-10
p. 445)
Push on new bearing inner races and .
Mount the new O-ring .
Mount the new bushing .
154
Checking the timing assembly

20.19
2
0
3
60
Check idler for damage and wear.
1
0
4
Clean all parts well.
3 0
0
4
4
0
1
0
Change the timing chain guide rail.
Check camshaft for damage and wear.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Change the timing chain tensioning rail.
Check timing chain guide rail for damage and wear.
Change the idler.
Check timing chain tensioning rail for damage and wear.
Change the camshaft.
If the cam surface is damaged, check the oil supply to the camshaft and
cam lever.
Measure the cam height.

Guideline
301420-01
Camshaft - cam height
38.59 38.69 mm (1.5193

1.5232 in)
Change the camshaft.
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:
Exhaust
Check timing chain for damage and wear.
39.34 39.44 mm (1.5488

1.5528 in)
If cam wear is outside of the tolerance range:
Intake
Change the timing chain.
Check guide rail for damage and wear.
Change the guide rail.
Preparing the timing chain tensioner for installation

20.20
Fully compress the timing chain tensioner.
Info
This requires considerable force since the oil has to be pressed out.
Without pressure, the timing chain tensioner expands fully.
200171-10
Place two spacing washers 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 spacers
2 2.5 mm (0.08 0.098 in)
Release the timing chain tensioner.

The latching system locks and the piston stops moving.
200172-10
End position of piston after latching
3 mm (0.12 in)
155
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.
Checking the oil pressure regulator valve

20.21
Remove supporting plate and spring .

Measure the length of spring .
Oil pressure regulator valve - minimum
spring length
40.5 mm (1.594 in)
If the measured length is less than the specified value:
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Check control piston for damage and wear.
301419-01
Change the spring.
Change the control piston.
Check the control piston hole in oil pump cover for damage and wear.
Change the oil pump cover.
Oil control piston and spring well and mount them.
Mount supporting plate .
Checking the oil pumps

20.22
Info
The following operations apply to all three oil pumps.
Check the clearance between internal rotor and external rotor and between
the external rotor and the engine case.
Oil pumps
200464-10
Clearance between external rotor

and engine case
0.20 0.40 mm (0.0079

0.0157 in)
Clearance between external rotor

and internal rotor
0.10 0.25 mm (0.0039

0.0098 in)
Axial clearance
0.04 0.25 mm (0.0016

0.0098 in)
If the clearance exceeds the specifications:
Change the oil pump and, if necessary, the engine case.
156
Checking the clutch

20.23
4
0
5
0
3
0
8
0
0
9
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
7
0
bm
6
0
0
1 0
2
Change the push rod.
Place push rod on a level surface and check it for run-out.
If there is run-out:
Change the push rod.
Check axial bearing for damage and wear.
Change the axial bearing.
Check the length of clutch springs .

Clutch spring - length
Change all clutch springs.
Check the contact surface of pressure cap for damage and wear.
33.00 34.00 mm (1.2992 1.3386 in)
If the clutch spring length is less than the specified value:
b0o
bo
Change the pressure cap.
Check the contact surfaces of the clutch facing discs in outer clutch hub for wear.
Outer clutch hub - contact surface of clutch facing discs
Wear limit
Change the clutch facing discs and the outer clutch hub.
Check needle bearing for damage and wear.
0.5 mm (0.02 in)
If the contact surface is very worn:
bn
Check pressure piece for damage and wear.
bk bl
Change the needle bearing.
Check the intermediate clutch discs for damage and wear.
If the intermediate clutch discs are not level and have pittings:
301421-01
157
Change all intermediate clutch discs.
Check the thickness of intermediate clutch discs .

Intermediate disk - thickness
1.95 2.05 mm (0.0768 0.0807 in)
Wear limit
1.85 mm (0.0728 in)
If the intermediate clutch discs do not meet specifications:
New condition
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
2.92 3.08 mm (0.115 0.1213 in)
Wear limit
2.85 mm (0.1122 in)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
If the clutch facing discs do not meet specifications:
New condition
Change all clutch facing discs.
Check pretension ring and support ring for damage and wear.
Change the pretension ring and support ring.
Check inner clutch hub for damage and wear.
Change the inner clutch hub.
Check the components of clutch pressure booster for damage and wear.
Change all components of the clutch pressure booster.
Check the springs of outer clutch hub for damage and wear.
If there is damage, wear or play in the direction of rotation:
Change the outer clutch hub.
Checking the shift mechanism

20.24
Check shift forks at leaf for wear.

Shift fork
0
1
3
0
5
0
0
4
0
A
1
0
5
E 7
D
C0
2
B
0
0
4
301418-01
0.70 mm (0.0276 in)
Change the shift fork and the idler/fixed gear pair.
Change the shift drum.
If the shift drum is not seated correctly:

Change the shift drum and/or the grooved ball bearing.
Check grooved ball bearing for stiffness and wear.
If the grooved ball bearings do not move freely or are worn:
Clearance in the sliding gear

groove: Wear limit
Check the seat of the shift drum in grooved ball bearings .
0.35 0.55 mm (0.0138

0.0217 in)
If the shift groove is worn:
3
0
Clearance in the sliding gear

groove: New condition
Check shift grooves of shift drum for wear.
4.85 4.95 mm (0.1909

0.1949 in)
Thickness at leaf
Change the grooved ball bearing.
Check shift drums for ovality, surface damage and cracking.
If the shift drum is oval, or shows signs of surface damage or cracks:
If the spring is broken or worn:
If there is run-out:
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.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Change the shift rail.
Check shift rails for scoring, signs of corrosion and stiffness in the shift fork.
Change the spring of the shift rail.
Check the shift rails on a flat surface for run-out.
Change the shift drum.
Check springs of the shift rails for damage and wear.
158
If deep notches are present:
Check guide pin for looseness and wear.
If the guide pin is loose and/or worn:
Preassembling the shift shaft

20.25
5
0
Fix the short end of the shift shaft in a vise.

Guideline
1
0
2
0
6
0
Use soft jaws.
30
0
4
200175-01
Mount sliding plate with the guide pin facing down and attach the guide pin to
the shift quadrant.
Mount preload 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 .
Mount stop disk .
Dismantling the main shaft

20.26
0
9
bbl
b0k
0l bk
6
0
0 0
5
4
0 0
8
7
3
0
0
2
1
0
200460-01
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
159
Remove stop disk and second-gear fixed gear .
Remove the sixth-gear idler gear .
Remove needle bearing and stop disk .
Remove the third/fourth-gear sliding gear .
Remove lock ring .
Remove stop disk and the fifth-gear idler gear .
Remove needle bearing .
Remove needle bearing using a suitable tool.
Info
It only needs to be removed if worn.
Dismantling the countershaft
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
20.27
2
0
30
0
4 0
5
1
0
b0l bm
bl
b0mbn
b0n bo
b0o
60
0
8
7 0
b0p bq
bp
b0q br
b0r
9
0
b0k
bk
b0s
bs
200462-01
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Remove stop disk and the first-gear idler gear .
Remove the fifth-gear sliding gear and lock ring .
Remove stop disk and the fourth-gear idler gear .
Remove needle bearing and the third-gear idler gear .
Remove lock ring and the sixth-gear sliding gear .
Remove lock ring and stop disk .
Remove the second-gear idler gear and needle bearing .
160
Checking the transmission

20.28
2
0
4
60
0
1 0
0
5
7
0
6
0
8
0
4
0
1
0
6
0
10
0
4
60
0
70
5
1
0
70
0
5
7 0
0
4 0
6
1
0
5
0
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
6
0
60
0
4
10
6
0
3
0
200461-01
Check needle bearing for damage and wear.
Check the pivot points of main shaft and countershaft for damage and wear.
If the fixed gear does not move easily:
Change the fixed gear or the main shaft.
Check fixed gears for smooth operation in the profile of countershaft .
If the fixed gear does not move easily:
Change the idler/fixed gear pair.
Check fixed gears for smooth operation in the profile of main shaft .
Check the tooth profiles of fixed gears for damage and wear.
Check the tooth faces of idler gears and fixed gears for damage and wear.
Check the shift dogs of idler gears and fixed gears for damage and wear.
Change the main shaft and/or countershaft.
Check the pivot points of idler gears 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 fixed gear or the countershaft.
Check stop disks for damage and wear.
Change the stop disk.
Use new lock rings in every repair job.
Check needle bushing for damage and wear.
161
Assembling the main shaft

20.29
Info
Use new lock rings and new stop disks with every repair.
Oil all parts carefully before assembling.
Check the transmission. (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 160)
3
0
1 0
0
2
6
0
7 0
0
8
4 0
0
5
9
0
b0k
b0l
200460-02
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
If removed, mount a new needle bushing using a suitable tool.
Mount needle bearing and put on the fifth-gear idler gear with the shifting claws facing upward.
Mount stop disk and a new lock ring .
Mount the third/fourth-gear sliding gear with the small gear wheel facing upward.
Mount stop disk and needle bearing .
Put on the sixth-gear idler gear with the shifting claws facing downward.
Mount the second-gear fixed gear with the collar facing downward and mount stop disk .
Finally, check all gear wheels for smooth operation.
1 0
2
0
6
0
7
0 0
8
0 0
4
5
9
0
0
bk
Assembling the countershaft

20.30
0
3
Info
Use new lock rings and new stop disks with every repair.
Oil all parts carefully before assembling.
Check the transmission. (
p. 160)
bl

bbr
0r
b0q bp
bq
b0p bo
b0o
b0s
bs
6 0
0
5
40
0
3 0
2
b0k
bk
9
0
1
0
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
80
0
7
b0n bm
bn
b0l
b0m bl
162
200462-02
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Mount needle bearing and the second-gear idler gear on the countershaft with the protruding collar facing downward.
Mount the sixth-gear sliding gear with the shift groove facing upward.
Mount a new lock ring and stop disk .
Mount needle bearing and the third-gear idler gear with the collar facing upward.
Mount needle bearing and the fourth-gear idler gear with the collar facing downward.
Mount the fifth-gear sliding gear with the shift groove facing downward and stop disk .
Mount needle bearing , first-gear idler gear with the groove facing downward and stop disk .
Finally, check all gear wheels for smooth operation.
30/ASSEMBLING THE ENGINE
163
Installing the timing chain rails of the left engine case section
21.1
Position timing chain guide rail . Mount and tighten screw .

Guideline
Screw, timing chain guide
rail
M8
15 Nm
(11.1 lbf ft)
Loctite 243
Info
Ensure that there is no thread locking material at the collar of the screw;
otherwise, the timing chain guide rail could lock and break.
200447-11
Position timing chain tensioning rail . Mount and tighten screw .

Guideline
M8
15 Nm
(11.1 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, timing chain tensioning rail
Loctite 243
Info
otherwise, the timing chain tension rail could lock and break.
Check both timing chain rails for freedom of motion.
Installing the timing chain rails of the right engine case section
21.2
Position timing chain guide rail . Mount and tighten screw .

Guideline
Screw, timing chain guide

rail
M8
15 Nm
(11.1 lbf ft)
Loctite 243
Info
otherwise, the timing chain guide rail could lock and break.
200434-10
Position timing chain tensioning rail . Mount and tighten screw .

Guideline
M8
15 Nm
(11.1 lbf ft)
Loctite 243
Info
otherwise, the timing chain tension rail could lock and break.
Check both timing chain rails for freedom of motion.
164
Installing the oil spray tube

21.3
Mount new O-rings on oil spray tube .
Mount the oil spray tube.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Pin must engage in recess .
200433-01
Installing the transmission shaft

21.4
Clamp the right section of the engine case.

Engine work stand (61229001000) (
Engine holder (61229002000) (
p. 443)
p. 443)
Assemble the two transmission shafts and slide them into the bearing seats
together.
Mount stop disk and lock ring of the countershaft.
Tilt the engine.
Mount shift forks with shift rollers .
200431-10
200430-11
Info
Use a small amount of grease to fix the shift rollers to the shift forks.
200429-11
165
Swing shift forks to one side.
Info
Watch out for the shift rollers .
Insert shift drum into the bearing seat.
Let the shift forks engage in the shift grooves.
Mount shift rails with the pressure springs.
200428-11
Info
Use a small amount of grease to fix the pressure springs in the shift rails.
Check the transmission for smooth operation.
Mount external rotor with the marking facing downward.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200427-11
Installing the middle suction pump

21.5
The marking is not visible after mounting.
Mount pin into the third hole of oil pump shaft after shaft keyway .
Slide internal rotor over the pin.
Mount oil pump shaft with internal rotor .
200426-11
Marking of the internal rotor is visible after mounting while that of the external rotor is not.
Oil the parts.
Slide the crankshaft into the bearing seat.
200425-11
Installing the crankshaft

21.6
Info
Position the connecting rod as shown in the photo.
301423-10
166
Installing the left engine case

21.7
Mount dowels .
Mount gasket .
Check that dowel is correctly seated.
Degrease the sealing area and coat thinly with sealant.
301422-11
Loctite 5910
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Info
Only coat the sealing area around the outside (see figure).
400481-01
200421-11
Attach the left engine case, using a plastic hammer if necessary to seat it properly.
Info
Do not tighten the engine case sections using the screws.

Guideline
Screw, engine case
M8
18 Nm (13.3 lbf ft)
M6x60
10 Nm (7.4 lbf ft)
M6x80
10 Nm (7.4 lbf ft)
M6x90
10 Nm (7.4 lbf ft)

Guideline
Screw, engine case

Guideline
Screw, engine case

Guideline
Screw, engine case
167
Info
Screws must always be replaced with new screws.
Mount screw .
Installing the locking lever

21.8
Position locking lever with sleeve and spring .

Guideline
M6
10 Nm
(7.4 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, locking lever
Loctite 243
200420-11
Installing the shift drum locating

21.9
Press locking lever down and position shift drum locating .
Info
The flat surfaces of the shift drum locating are not symmetric.
Release the locking lever.
301417-10
Guideline
Screw, shift drum locating
M6
10 Nm
(7.4 lbf ft)
301414-11
Installing the shift shaft

21.10
301413-11
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.
Loctite 243
168
Installing the force pump

21.11
Mount pin .
Info
Ensure that pins are seated correctly.
Mount internal rotor and external rotor .

Oil the parts.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301416-10
Position the oil pump cover. Mount and tighten screws .

Guideline
Screw, oil pump cover
M6
10 Nm
(7.4 lbf ft)
Mount washer and pin .
Mount oil pump gear wheel , washer and lock washer .
301411-11
301410-11
Loctite 243
169
Installing the left suction pump

21.12
Mount pin .
Mount internal rotor and external rotor .

Oil the parts.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301405-10
Insert new gasket into the oil pump cover.
Position oil pump cover . Mount and tighten screws .

Guideline
M6
10 Nm
(7.4 lbf ft)
Turn the oil pump gear wheel and check the oil pumps for smooth operation.
301406-10
21.13
Set the crankshaft to top dead center of the rear cylinder.
The position notch of the crankshaft is visible in the hole.
301382-10
Loctite 243
p. 444)
170
Installing the primary gear

21.14
Ensure that the spring washer is seated properly.
Mount primary gear .
Mount the washer and nut and tighten the nut.

Guideline
Nut, primary gear
M33LHx1.5
130 Nm
(95.9 lbf ft)
Loctite 243
200412-11
Installing the outer clutch hub

21.15
Mount washer and needle bearing .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301404-11
Mount outer clutch hub and washer .
Info
Turn the outer clutch hub and oil pump gear wheel back and forth slightly
to help them mesh more easily.
301403-11
Position inner clutch hub in outer clutch hub .
Place the outer component of the clutch pressure booster into the inner clutch
hub.
Mount inner component of the clutch pressure booster.
Projections engage in recesses .
Markings and are adjacent to each other.
200411-10
171
Insert special tool .

Clutch holder (61229003000) (
p. 443)
Mount the washer and nut and tighten the nut.

Guideline
Nut, inner clutch hub
M22x1.5
130 Nm
(95.9 lbf ft)
Loctite 243
200408-11
Installing the clutch facing

21.16
Mount support ring and pretension ring .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The pretension ring rests on the inside of the support ring, with the outside
facing away from the support ring.
200407-10
Oil the clutch facing discs well.
Mount clutch facing disc with the larger inside diameter.
Alternately mount nine intermediate discs and eight identical clutch facing
discs .
Mount the outermost clutch facing disc with the wider elements offset by one
contact .
200408-01
200406-11
Mount push rod .
Attach pressure cap , mount all screws with spring washers and springs, and
tighten them in a crisscross pattern.
Guideline
Screw, clutch spring
200405-11
M6
12 Nm
(8.9 lbf ft)
Loctite 243
172
Installing the idler and timing chain on the right

21.17
Position timing chain according to the direction of travel.
Place the timing chain over the toothing of idler . Align markings and .
Slide on the idler.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200404-10
Installing the clutch cover

21.18
Mount dowels and the clutch cover seal.
Mount check valve .
Slide special tool onto the water pump shaft.
200401-11
Mounting sleeve (61229005000) (
p. 444)
200402-10
Mount the clutch cover. Mount and tighten screws and .
Guideline
Screw, clutch cover
200399-11
M6
10 Nm (7.4 lbf ft)
173
Installing the water pump wheel

21.19
Mount the washer and water pump wheel.

Guideline
Screw, water pump wheel
Mount dowels .
Replace the seal.
Mount the water pump cover.
M6
10 Nm
(7.4 lbf ft)
Loctite 243
200398-11

Guideline
M6
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, water pump cover
10 Nm (7.4 lbf ft)
301394-11
Installing the gear position sensor

21.20
Mount the contact springs and contact bolt .
The contact bolts are mounted with the flat side forward; the rounded sides
face the sensor.
301399-11
Mount gear position sensor with the O-ring. Mount and tighten the screws.
Guideline
Screw, gear sensor
M5
3 Nm
(2.2 lbf ft)
Loctite 243
301398-11
Installing the drive wheel of the balancer shaft

21.21
Heat the drive wheel of the balancer shaft.

Guideline
200 C (392 F)
Ensure that the spring washer is seated properly. Mount the drive wheel of the balancer shaft with the beveled edge facing forward.
Pressure bell (61229016000) (
p. 445)
The markings are visible after mounting.

200400-10
174
Installing the balancer shaft

21.22
Mount the rear washer and needle bearing.
Mount balancer shaft .

Markings and are aligned.
Mount washer .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200357-10
Installing the idler and timing chain on the left

21.23
Mount the rear washer.
Position timing chain in the engine case in accordance with the direction of
travel.
Place timing chain over the toothing of the idler.
Slide on idler .
Mount the needle bearing.
Mount washer .
301445-10
Markings and are aligned.
200355-10
175
Installing the oil filter

21.24
Tilt the engine sideways and fill the oil filter housing to about full with engine
oil.
Insert oil filter .
Lubricate the O-ring of oil filter cover . Mount the oil filter cover.

Guideline
M5
6 Nm (4.4 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301395-10
Installing the rotor

21.25
Turn the free-wheel-gear counterclockwise and mount it in rotor .
200351-10
Ensure that spring washer is seated properly.
Mount the rotor.
Thoroughly clean the oil jet of the rotor screw and blow it out with compressed air.
Mount and tighten rotor screw .
200352-10
Guideline
Rotor screw
M12x1.5
90 Nm
(66.4 lbf ft)
Position freewheel holder . Mount and tighten the screws.

Guideline
200348-11
Screw, freewheel holder
M6
10 Nm
(7.4 lbf ft)
Loctite 243
176
Installing the torque limiter and idler

21.26
Mount the rear washer, needle bearing, idler and front washer.
Mount torque limiter with the rear washer.
200347-11
Installing the ignition pulse generator

21.27
Position the ignition pulse generator .

Mount and tighten the screws.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Screw, pulse generator
200346-10
M5
10 Nm
(7.4 lbf ft)
Loctite 243
Position the cable, thinly coat cable support sleeve with the sealing compound
and insert it in the engine case.
Loctite 5910
Check the distance between the ignition pulse generator and rotor.
Guideline
Crankshaft position sensor/rotor - gap
0.70 mm (0.0276 in)
Installing the generator cover

21.28
Mount the new generator cover seal and dowels.
Position the generator cover.
Guideline
M6
10 Nm (7.4 lbf ft)
301392-10
Installing the oil drain plug

21.29
Mount the new O-rings.
Mount and tighten oil drain plug with the magnet, O-rings and oil screen.
Guideline
Oil drain plug
200480-10
M20x1.5
20 Nm
(14.8 lbf ft)
177
Installing the rear piston

21.30
Shift the joint of the piston rings by 120.
Place the oiled piston on the cylinder. Tighten the piston rings using the special
tool.
Piston ring mounting tool (60029015000) (
p. 441)
200329-10
Using a hammer, lightly strike the special tool from above until it is flush with the
cylinder.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The special tool must squeeze the piston rings together well and lie flush
against the cylinder.
200330-10
Carefully tap the piston into the cylinder using the hammer shaft.
The piston rings should not become caught; otherwise, they may be damaged.
200331-10
Position the new cylinder base gasket .
Ensure that piston marking faces the outfeed side.
Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
200339-10
301365-10
301367-10
178
Position the new piston pin retainer.
Info
For clarity, the following steps are illustrated using a disassembled piston.
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.
Piston pin lock ring insert (75029035000) (
Ensure that the piston pin retainer is correctly seated on both sides.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 447)
200084-10
Remove the cloth.
Keep the timing chain tensioned. Push the cylinder down carefully and let the
dowel pins engage.
Mount the new cylinder head gasket.
Position the cylinder head and mount and tighten the new cylinder head screws .
301354-10
Installing the rear cylinder head

21.31
Guideline
Cylinder head screw
M11x1.5
Tightening
sequence:
Using a crisscross pattern
Step 1
15 Nm
(11.1 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
90
Step 4
90
301369-10
lubricated with
engine oil
Mount and tighten nuts with the washers.

Guideline
Nut, cylinder head
M6
10 Nm (7.4 lbf ft)
179
Installing the rear camshaft

21.32
Pull up the timing chain and insert intake camshaft .
Info
The intake camshaft is labeled with eh.
Place the timing chain over the rear sprocket of the intake camshaft.
Ensure that bleeder is seated correctly.
Position exhaust camshaft .
Marking is aligned.
Info
The exhaust camshaft is labeled with ah.
Place the timing chain over the rear sprocket and position the camshaft in the
bearing seat.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Marking is aligned.
301370-10
Thoroughly clean all oil jets and blow them out with compressed air.
Position the camshaft bearing bridge.
Mount screws and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing support
M6
10 Nm (7.4 lbf ft)
M8
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm
(13.3 lbf ft)
301371-10
Grease the O-rings and mount spark plug shaft insert .
Installing the rear timing chain tensioner

21.33
After it has been positioned in the installation location, insert timing chain tensioner with a new O-ring.
Mount and tighten plug with the new seal ring .

Guideline
Plug, timing-chain tensioner
M24x1.5
25 Nm
(18.4 lbf ft)
301372-10
Remove screw and use the special tool to push the timing chain tensioner
toward the timing chain.
Release device for timing chain tensioner (61229021000) (
p. 445)
The timing chain tensioner unlocks.

Guideline
Screw, timing chain tensioner release
301373-10
M10x1
10 Nm (7.4 lbf ft)
180
21.34
Remove special tool .
Keep the timing chain tensioned.
Turn the crankshaft counterclockwise by the specified value.

Guideline
1 turn
301382-10
Turn the crankshaft counterclockwise by the specified value .

Guideline
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
75
The position notch of the crankshaft is visible in the hole.
p. 444)
200333-10
Installing the front piston

21.35
Shift the joint of the piston rings by 120.
Place the oiled piston on the cylinder. Tighten the piston rings using the special
tool.
Piston ring mounting tool (60029015000) (
p. 441)
200329-10
Using a hammer, lightly strike the special tool from above until it is flush with the
cylinder.
The special tool must squeeze the piston rings together well and lie flush
against the cylinder.
200330-10
Carefully knock the piston into the cylinder using the hammer shaft.
The piston rings should not become caught; otherwise, they may be damaged.
200331-10
181
Position the new cylinder base gasket .
Ensure that piston marking faces the outfeed side.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301383-10
301365-10
Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
Position the new piston pin retainer.
301374-10
Info
For clarity, the following steps are illustrated using a disassembled piston.
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.
Piston pin lock ring insert (75029035000) (
200084-10
p. 447)
Ensure that the piston pin retainer is correctly seated on both sides.
182
Remove the cloth.
Keep the timing chain tensioned. Push the cylinder down carefully and let the
dowel pins engage.
Mount the new cylinder head gasket.
301375-10
Installing the front cylinder head

21.36
Mount the cylinder head. Mount and tighten the new cylinder head screws .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Cylinder head screw
M11x1.5
Tightening
sequence:
Step 1
15 Nm
(11.1 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
90
Step 4
90
301376-10
lubricated with
engine oil
Mount and tighten nuts with the washers.
Guideline
Nut, cylinder head
M6
10 Nm (7.4 lbf ft)
Installing the front camshafts

21.37
Info
The intake camshaft is labeled with ev.
Marking is aligned.
Info
The exhaust camshaft is labeled with av.
bearing seat.
Marking is aligned.
301377-10
183
Thoroughly clean all oil jets and blow them out with compressed air.
Guideline
M6
10 Nm (7.4 lbf ft)
M8
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm
(13.3 lbf ft)
301378-10
Grease the O-rings and mount spark plug shaft insert .
Installing the front timing chain tensioner

21.38
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Mount and tighten plug with the new seal ring .

Guideline
M24x1.5
25 Nm
(18.4 lbf ft)
301379-10
p. 445)
The timing chain tensioner is unlocked.
Guideline
M10x1
10 Nm (7.4 lbf ft)
M6
10 Nm (7.4 lbf ft)
M8
15 Nm
(11.1 lbf ft)
301380-10
Installing the heat exchanger

21.39
Oil and mount O-rings .
Mount sleeves .
Mount gasket .
Position the heat exchanger.
301366-11
Guideline

Guideline
Screw, heat exchanger
301350-11
184
Installing the oil filler tube

21.40
Mount the oil filler tube with the O-ring.

Guideline
M6
10 Nm (7.4 lbf ft)
301349-10
Installing the starter motor

21.41
Grease O-ring . Mount the starter motor.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Long-life grease (
p. 438)
301384-10
Mount and tighten screw with the ground wire.

Guideline
M6
10 Nm (7.4 lbf ft)
301348-11
Checking the rear cylinder control time

21.42
Check the markings of the camshaft.
Info
The markings are shown with the camshafts removed for purposes of illustration.
Align center marking of the camshaft with marking of the camshaft gear.
If the markings do not align:
301389-10
Adjust the rear cylinder control time. (
p. 184)
Adjusting the rear cylinder control time

21.43

301343-10
p. 444)
185
Turn the engine one crankshaft turn in a counterclockwise direction.
Remove screws .
Mount the new screws but do not tighten them yet.
Mount special tool .
Marking faces outward and is flush with the edge of the cylinder head.
301342-10
Marking is aligned and flush with the edge of the cylinder head.
p. 444)
Remove screws .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301344-10
Adjustment gauge, control time, cylinder 1 (69129130000) (
p. 447)

Guideline
Screw, special tool
M6
3 Nm (2.2 lbf ft)
M6
13 Nm (9.6 lbf ft)

Guideline
301464-10
Camshaft drive sprocket bolt
Remove screws .
p. 447)
p. 444)
Guideline
M6
13 Nm (9.6 lbf ft)
301342-10
Checking the rear valve clearance

21.44
301382-10
Crank the engine several times.
Set the engine to ignition top dead center of the rear cylinder. (
p. 123)
186
On all valves, check the valve clearance between the camshaft and cam lever.
Guideline
Valve clearance
Exhaust at: 20 C (68 F)
0.25 0.30 mm (0.0098

0.0118 in)
Intake at: 20 C (68 F)
0.10 0.15 mm (0.0039

0.0059 in)
Feeler gauge (59029041100) (
301385-10
p. 441)
If valve clearance does not meet specifications:
Adjust the rear valve clearance. (
p. 186)
Adjusting the rear valve clearance

21.45
Remove the rear timing chain tensioner. (
p. 124)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Remove the rear camshaft. (
Swing up cam lever .
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.
Install the rear camshaft. (
p. 125)
p. 179)
Install the rear timing chain tensioner. (
Check the rear valve clearance. (
p. 179)
p. 185)
301386-10
Checking the front cylinder control time

21.46
p. 444)
Set the engine to ignition top dead center of the front cylinder. (
p. 126)
301343-10
Info
301389-10
p. 184)
Adjusting the front cylinder control time

21.47

301343-10
p. 444)
187
Remove screws .
301342-10
p. 444)
Remove screws .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301344-10
p. 447)

Guideline
Screw, special tool
M6
3 Nm (2.2 lbf ft)
M6
13 Nm (9.6 lbf ft)

Guideline
301463-10
Remove screws .
p. 447)


Guideline
M6
13 Nm (9.6 lbf ft)
301342-10
Checking the front valve clearance

21.48
Condition
The engine is positioned at ignition top dead center of the front cylinder
Guideline
Valve clearance
0.25 0.30 mm (0.0098

0.0118 in)
0.10 0.15 mm (0.0039

0.0059 in)
Feeler gauge (59029041100) (
301388-10
p. 441)
Adjust the front valve clearance. (
p. 188)
188
Adjusting the front valve clearance

21.49
Remove the front timing chain tensioner. (
Remove the front camshafts. (
Swing up cam lever .
p. 126)
p. 126)
Correct the shims as indicated by the results of the valve clearance check.
Insert suitable shims.
Install the front camshafts. (
Install the front timing chain tensioner. (
Check the front valve clearance. (
Mount and tighten the screw of generator cover .
p. 182)
p. 183)
p. 187)
301387-10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Screw in generator cover
M24x1.5
8 Nm (5.9 lbf ft)
301338-11
Remove special tool . Mount and tighten screw .
Guideline
Plug, crankshaft retainer
M8
15 Nm
(11.1 lbf ft)
301340-11
Installing the front valve cover

21.50
Position the valve cover seal.
Put the valve cover in place with the seal. Mount and tighten screws .
Guideline
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
Info
The front valve cover is not equipped with a connector for the engine vent.
301336-11
Mount and tighten the spark plug using a special tool.

Mount ignition coil .
p. 448)
Installing the rear valve cover

21.51
Put the valve cover in place with the seal. Mount and tighten screws .
Guideline
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
Info
The rear valve cover is equipped with a connector for the engine vent.
301337-11

p. 448)
189
Mount ignition coil .
Position the engine bracket.
Mount and tighten screws and .
Mounting the engine bracket

21.52
Guideline
Screw, engine console
M8
20 Nm
(14.8 lbf ft)
Loctite 243
301345-10
Position the engine bracket.
Mount and tighten screws and .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
M8
20 Nm
(14.8 lbf ft)
301346-10
Dismounting the engine from the work stand

21.53
Remove the screw connections.
Dismount the engine from the work stand.
Info
Have an assistant help you or use a crane.
301334-10
Loctite 243
31/SECONDARY AIR SYSTEM
190
Exhaust air injection

22.1
The exhaust air injection valve is located under the air filter box.
Exhaust air injection valve, connector FE (
The exhaust air injection valve injects purified fresh air into the exhaust port to
improve exhaust emissions as long as closed loop control is not yet active.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
900012-60
32/CLUTCH
191
Checking fluid level of hydraulic clutch

23.1
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.
Check the fluid level.

The fluid level must be between the MIN and MAX markings.
If the coolant level does not meet specifications:

Correct the fluid level of the hydraulic clutch. (
p. 191)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100752-01
Correcting fluid level of hydraulic clutch

23.2
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 screw cover with membrane.
Correct the fuel level.

Guideline
The fluid level must be between the MIN and MAX markings.
Hydraulic fluid (15) (
100753-01
p. 437)
34/SHIFT MECHANISM
192
Adjusting shift lever stub

24.1
Remove the screw with the shift lever stub.
Position the shift lever stub with the screw in one of the holes according to the
desired lever length.
Guideline
Standard
Central hole
Tighten screw.
Guideline
M6
10 Nm
(7.4 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, shift lever stub
Loctite 243
100703-10
Adjusting shift lever

24.2
Info
The footrest system offers many ways of adjusting the shift lever to your riding style and requirements.
Remove screws and take off the shift rod.
The length of the shift rod can be adjusted by means of the screw thread.
Guideline
Shift rod
Loosen the counter nuts .
Adjust the shift shaft.
115 130 mm (4.53 5.12 in)
Info
Make the same adjustments on both sides.

After the counter nuts have been tightened, the bearings of the shift shaft
must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells.
At least 5 screw threads must be screwed into the seating.
100704-10
Tighten the counter nuts.
34/SHIFT MECHANISM
193
Guideline
A
0
B
0
The shift rod can be mounted both on the shift lever variably at an upper or lower
position, and on the reverse gear change of the shift shaft in two different positions.
Standard
Shift lever: lower drill hole,

shift shaft: lower drill hole
Shift power low, long shift travel
Shift lever: lower drill hole,

shift shaft: upper drill hole
Shift power high, short shift travel
Shift lever: upper drill hole,

shift shaft: lower drill hole
Position the shift rod.
Tighten the screws.

Guideline
M6
12 Nm
(8.9 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, shift rod
0
C
Loctite 243
400479-10
The position of the shift lever can be greatly varied, depending on the length of the
shift rod and the drill holes selected. As seen from the footrest, there is either a
high position of the shift lever or a low position of the shift lever .
Info
If you turn the reverse shift shaft 2 teeth on the serration of the shift shaft,
you can adjust the footrest system optimally for the upper footrest position.
After adjusting the shift lever, check its operation. There must be a minimum distance between the moving parts of the shift lever and other parts of the vehicle.
Guideline
Minimum clearance
100705-10
5 mm (0.2 in)
35/WATER PUMP, COOLING SYSTEM
194
Checking the coolant level

25.1
Warning
Scalding hazardDuring motorcycle operation, the coolant gets very hot and is under pressure.
Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the
engine and cooling system cool down first. If you get scalded, immediately flush the affected areas with lukewarm water.
Condition
The engine is cold.
The radiator is completely full.
Rest the motorcycle on its side stand on a horizontal surface.
Check the coolant level in the compensating tank.

The coolant level must be between MIN and MAX.
If there is no coolant in the compensating tank:
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100750-01
Info
Do not operate the motorcycle!
Add coolant/bleed the cooling system. (
p. 196)
If the coolant level in the compensating tank does not meet specifications,
but the tank is not empty:
Fill the cooling system compensating tank. (
p. 197)
Checking the antifreeze

25.2
Warning
Warning
Danger of poisoningCoolants are poisonous and a health hazard.
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
Condition
The engine is cold.
Rest the motorcycle on its side stand on a horizontal surface.
Remove the right side covers.
Remove plug from the compensating tank and radiator cap .
Check the coolant antifreeze.
25 45 C (13 49 F)
If the coolant antifreeze does not meet specifications:
Correct the coolant antifreeze.
Add coolant to the specified level.

Guideline
The radiator must be completely filled.
200535-11
Replace the compensating tank cap and the radiator cap.
Install the right side covers.
195
Removing the radiator

25.3
Remove the exhaust cover completely. (
Remove the inside cover. (
Remove the drain plug of water pump and of radiator . Completely drain the
coolant.
Mount and tighten the drain plug of water pump and radiator .
p. 63)
p. 75)
Guideline
M6
10 Nm (7.4 lbf ft)
200505-10
Loosen the hose clamps. Detach radiator hoses .

Push back the cover. Unplug the connector of thermoswitch .
Unplug connector of the radiator fan.
Unplug the connector of ignition pulse generator .
Unplug the connector of horn .
Loosen hose clamps . Remove the radiator hose.
Remove screw .
Remove screw . Take off the radiator.
Position the radiator. Mount and tighten screw .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200504-10
200506-10
200507-10
Installing the radiator

25.4
Guideline
200507-11
M6
10 Nm (7.4 lbf ft)
196

Guideline
M6
10 Nm (7.4 lbf ft)
Mount the radiator hose. Position and tighten hose clamps .
Mount radiator hoses . Position and tighten the hose clamps.
Plug in the connector of thermoswitch . Mount the cover.
Plug in connector of the radiator fan.
Plug in the connector of ignition pulse generator .
Plug in the connector of horn .
Add coolant/bleed the cooling system. (
Install the inside cover. (
Install the exhaust cover completely. (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200506-11
200504-11
p. 196)
p. 76)
p. 63)
Adding coolant/bleeding the cooling system

25.5
Warning
Condition
The side cover has been removed.
Position the vehicle as shown and secure it against rolling. Height difference
must be reached.
Guideline
Height difference
50 cm (19.7 in)
400494-10
Remove radiator cap and bleeder screw of the radiator.
Remove bleeder screw of the cylinder heads.
Add coolant until it exits from the vent hole without bubbles.
200534-10
Coolant
2.60 l (2.75 qt.)
Coolant (
p. 436)
Coolant (mixed ready to use)

( p. 436)
Mount and tighten the bleeder screws with the seal rings.
Guideline
200536-10
M6
10 Nm (7.4 lbf ft)
M6
10 Nm (7.4 lbf ft)
197
Completely fill the radiator with coolant and close it with radiator cap .
Position the vehicle on a level surface.
Remove the cap of the compensating tank.
Add coolant to the compensating tank until the coolant reaches the specified level.
Guideline
Mount the cap of the compensating tank.
200535-10
Filling the cooling system compensating tank

25.6
Warning
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Warning
Note
Engine damageImpaired cooling efficiency due to air trapped in the cooling system.
After draining coolant and refilling the cooling system, the motorcycle must be raised at the front according to the model type.
This is the only way of ensuring that the cooling system is filled without air bubbles.
Remove the cap of the compensating tank.
Top up with coolant until the specified coolant level is reached.
p. 194)
Guideline
Alternative 1
Coolant (
p. 436)
Alternative 2
100750-10
Coolant (mixed ready to use) (
p. 436)
Mount the cap of the compensating tank.
36/CYLINDER HEAD
198
Engine coolant temperature sensor cylinder 1

26.1
The engine coolant temperature sensor for cylinder 1 is located on the left-hand
side of the rear cylinder head.
900017-01
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The engine coolant temperature sensor is a negative temperature coefficient thermistor (NTC resistor). Resistance falls when the temperature increases in an NTC
resistor; the "nil" value, however, is never reached. When the temperature decreases
the resistance increases; however, the "infinite" value is never reached.
400539-60
Pin overview
Signal wire
Sensor ground
The signal from engine coolant temperature sensor for cylinder 1 is transmitted to
the EFI control unit.
Engine coolant temperature sensor
600853-10
Resistance at: 30 C
(22 F)
22.86 27.94 k
Resistance at: 20 C
(4 F)
13.50 16.50 k
Resistance at: 10 C
(14 F)
8.24 10.08 k
Resistance at: 0 C
(32 F)
5.17 6.31 k
Resistance at: 10 C
(50 F)
3.33 4.07 k
Resistance at: 20 C
(68 F)
2.21 2.70 k
Resistance at: 30 C
(86 F)
1.49 1.83 k
Resistance at: 40 C
(104 F)
1.04 1.27 k
Resistance at: 50 C
(122 F)
730 892
Resistance at: 60 C
(140 F)
526 642
Resistance at: 70 C
(158 F)
385 471
Resistance at: 80 C
(176 F)
286 350
Resistance at: 90 C
(194 F)
216 264
Resistance at: 100 C

(212 F)
165 202

(230 F)
128 156
36/CYLINDER HEAD
199
(248 F)
100 122
Engine coolant temperature sensor for cylinder 2

26.2
The engine coolant temperature sensor for cylinder 2 is located on the right-hand
side of the front cylinder head.
900018-01
P
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7- Sh
99 a
r
9- k.
56 co
86 m
The coolant temperature sensor is an NTC thermistor. In NTC thermistors the
resistance decreases with increasing temperature; however, the "nil" value is never
reached. When the temperature decreases the resistance increases; however, the
"infinite" value is never reached.
400539-60
Pin overview
Signal wire
Sensor ground
The signal from engine coolant temperature sensor for cylinder 2 is transmitted to
the combination instrument.
600853-10
Resistance at: 30 C
(22 F)
22.86 27.94 k
Resistance at: 20 C
(4 F)
13.50 16.50 k
Resistance at: 10 C
(14 F)
8.24 10.08 k
Resistance at: 0 C
(32 F)
5.17 6.31 k
Resistance at: 10 C
(50 F)
3.33 4.07 k
Resistance at: 20 C
(68 F)
2.21 2.70 k
Resistance at: 30 C
(86 F)
1.49 1.83 k
Resistance at: 40 C
(104 F)
1.04 1.27 k
Resistance at: 50 C
(122 F)
730 892
Resistance at: 60 C
(140 F)
526 642
Resistance at: 70 C
(158 F)
385 471
Resistance at: 80 C
(176 F)
286 350
Resistance at: 90 C
(194 F)
216 264

(212 F)
165 202
36/CYLINDER HEAD
200
(230 F)
128 156

(248 F)
100 122
Checking the valve clearance

26.3
Detach connector of the ignition coil.
Remove the ignition coil.
Remove screws and take off the valve cover.
p. 67)
p. 75)
p. 448)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Repeat these steps on the second cylinder.
p. 120)
200538-10
Guideline
Valve clearance
0.25 0.30 mm (0.0098

0.0118 in)
0.10 0.15 mm (0.0039

0.0059 in)
Feeler gauge (59029041100) (
301434-10
p. 441)
Adjust the rear valve clearance. (
p. 201)
p. 121)
Guideline
Valve clearance
0.25 0.30 mm (0.0098

0.0118 in)
0.10 0.15 mm (0.0039

0.0059 in)
Feeler gauge (59029041100) (
301435-10
p. 441)
Adjust the front valve clearance. (
p. 202)
36/CYLINDER HEAD
201
Crank the engine several times. Check the valve clearance and correct it if necessary.
Remove special tool and screw in and tighten screw .

Guideline
M8
15 Nm
(11.1 lbf ft)
200540-10
Mount and tighten the screw of generator cover .

Guideline
M24x1.5
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
8 Nm (5.9 lbf ft)
200539-10

p. 448)
Info
The rear valve cover is equipped with a connector for the engine vent.
The front valve cover is not equipped with a connector for the engine vent.
Position the valve cover with the seal. Mount and tighten screws .
Guideline
Screw, valve cover
M6
Mount the ignition coil.
Attach connector of the ignition coil.
Repeat these steps on the second cylinder.
Install the filter box bottom. (
Remove the rear camshaft. (
Raise cam lever on the outside.
10 Nm (7.4 lbf ft)
p. 68)
p. 75)
200538-10
Adjusting the rear valve clearance

26.4
200546-10
p. 205)
Correct and insert the shims as indicated by the results of the valve clearance
check.
Install the rear camshaft. (
p. 205)
36/CYLINDER HEAD
202
Adjusting the front valve clearance

26.5
Remove the front camshafts. (
Raise cam lever on the outside.
Correct and insert the shims as indicated by the results of the valve clearance
check.
Install the front camshafts. (
p. 206)
p. 206)
200552-10
Checking the rear cylinder control time

26.6
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
Info
Removal is not necessary.
301389-10
p. 203)
Checking the front cylinder control time

26.7
Condition
p. 444)
Set the engine to the ignition top dead center of the front cylinder and screw in
special tool .
301343-10
Info
301389-10
p. 203)
36/CYLINDER HEAD
203
Adjusting the rear cylinder control time

26.8

p. 120)
p. 444)
Info
For purposes of illustration, the following operations are shown with the
engine deinstalled.
301343-10

Remove screws .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301342-10
p. 444)
Remove screws .
301344-10
p. 447)

Guideline
Screw, special tool
M6
3 Nm (2.2 lbf ft)
M6
13 Nm (9.6 lbf ft)

Guideline
301464-10
Remove screws .
p. 447)
p. 444)
Guideline
301342-10
M6
13 Nm (9.6 lbf ft)
36/CYLINDER HEAD
204
Adjusting the front cylinder control time

26.9

p. 121)
p. 444)
Info
For purposes of illustration, the following operations are shown with the
engine deinstalled.
301343-10

Remove screws .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301342-10
p. 444)
Remove screws .
301344-10
p. 447)

Guideline
Screw, special tool
M6
3 Nm (2.2 lbf ft)
M6
13 Nm (9.6 lbf ft)

Guideline
301463-10
Remove screws .
p. 447)
p. 444)
Guideline
301342-10
M6
13 Nm (9.6 lbf ft)
36/CYLINDER HEAD
205
Removing the rear camshaft

26.10
Condition
The engine is positioned at ignition top dead center of the rear cylinder
Remove screw with the O-ring.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200549-10
Info
301436-10
Installing the rear camshaft

26.11
Info
The intake camshaft is labeled with eh.
Ensure that bleeder is seated correctly.
Info
The exhaust camshaft is labeled with ah.
bearing seat.
Markings must be flush with the edge of the cylinder head.
Guideline
301438-10
Screw, camshaft bearing

support
M6
10 Nm
(7.4 lbf ft)

support
M8
Step 1
10 Nm
(7.4 lbf ft)
Step 2
18 Nm
(13.3 lbf ft)

support
M8
Step 1
8.5 Nm
(6.27 lbf ft)
Step 2
14.5 Nm
(10.7 lbf ft)
Only applies when

using:
Hex key bit
(61229025000)
( p. 446)
Hex key bit (61229025000) (
p. 446)
Grease the O-rings and mount the spark plug shaft insert.
Install the rear timing chain tensioner. (
p. 207)
36/CYLINDER HEAD
206
Removing the front camshafts

26.12
Condition
The engine is positioned at ignition top dead center of the front cylinder
Remove screw with the O-ring.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200550-10
Info
301439-10
Installing the front camshafts

26.13
Info
The intake camshaft is labeled with ev.
Info
The exhaust camshaft is labeled with av.
bearing seat.
Markings must be flush with the edge of the cylinder head.
Guideline
301440-10

support
M6
10 Nm
(7.4 lbf ft)

support
M8
Step 1
10 Nm
(7.4 lbf ft)
Step 2
18 Nm
(13.3 lbf ft)

support
M8
Step 1
8.5 Nm
(6.27 lbf ft)
Step 2
14.5 Nm
(10.7 lbf ft)
Only applies when

using:
Hex key bit
(61229025000)
( p. 446)
Hex key bit (61229025000) (
p. 446)
Grease the O-rings and mount the spark plug shaft insert.
Install the front timing chain tensioner. (
p. 207)
36/CYLINDER HEAD
207
Installing the rear timing chain tensioner

26.14
Prepare the timing chain tensioner for installation. (
Mount and tighten plug with a new seal ring.
p. 154)
Guideline
M24x1.5
25 Nm
(18.4 lbf ft)
200549-11
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 445)
The timing chain tensioner unlocks.
Guideline
M10x1
10 Nm (7.4 lbf ft)
200554-10
Installing the front timing chain tensioner

26.15
Prepare the timing chain tensioner for installation. (
Mount and tighten plug with a new seal ring.
p. 154)
Guideline
M24x1.5
25 Nm
(18.4 lbf ft)
200550-11
p. 445)
The timing chain tensioner is unlocked.
Guideline
200555-10
M10x1
10 Nm (7.4 lbf ft)
38/LUBRICATION SYSTEM
208
Oil circuit
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
27.1
Oil circuit of middle suction pump

1
2
3
4
Oil screen of oil drain plug in gearbox

Middle suction pump
Heat exchanger
Oil exit in oil tank
Oil circuit of left suction pump

5
6
7
Crankcase
Left suction pump
Lubricating slots in gearbox
Oil circuit of force pump

8
9
10
11
12
13
Oil screen of oil drain plug in oil tank

Force pump
Oil pressure regulator valve

Oil filter
Crankshaft
Oil jet for generator cooling
14
Timing chain tensioner
15
Camshaft lubrication/oil jets for valve gear lubrication
16
Oil jets for piston cooling
17
Oil spray tube
18
19
Clutch
400492-60
209
Checking the engine oil level

27.2
Info
The engine oil level must be checked at normal engine operating temperature.
Stand the motorcycle upright on a horizontal surface.
Remove oil dipstick . Check the engine oil level in the measurement range.
Info
After switching off the engine, wait one minute before checking the level.
The engine oil level must be in the middle of the measurement range of the
oil dipstick.
If the engine oil level is not at the specified level:
Add engine oil. (
p. 213)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100769-10
Replace the oil dipstick.
Changing the engine oil and filter, cleaning the oil screens
27.3
Drain the engine oil and clean the oil screens. (
Fill up with engine oil. (
p. 209)
p. 212)
500281-01
Draining engine oil, cleaning oil screens

27.4
Warning
Danger of scaldingEngine oil and gear oil get very hot when the motocycle is driven.
Wear suitable protective clothing and protective gloves. If you get scalded, immediately flush the affected areas with lukewarm water.
Warning
Info
Drain the engine oil only when the engine is warm.
210
Remove screws .
Take off the left exhaust cover .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100771-10
Stand the motorcycle on its side stand on a horizontal surface.
Place a suitable container under the engine.
Remove oil drain plug with the magnet, O-rings and oil screen.
Remove the oil filter. (
Thoroughly clean the magnet and oil screen of the oil drain plug.
Mount and tighten the oil drain plugs with the magnet, O-rings and oil screen.
p. 211)
100772-10
100773-10
Guideline
Oil drain plug
100772-11
Install the oil filter. (
M20x1.5
p. 212)
20 Nm
(14.8 lbf ft)
211
Position the left exhaust cover .

Guideline
M5
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
5 Nm (3.7 lbf ft)
100771-10
Removing the oil filter

27.5
Warning
Warning
Remove screws . Take off oil filter cover with the O-ring.
Pull oil filter out of the oil filter housing.
100774-10
100775-10
p. 440)
Clean the parts and the sealing area thoroughly.
212
Installing the oil filter

27.6
Insert oil filter .
Lubricate the O-ring of the oil filter cover. Mount oil filter cover .

Guideline
M5
6 Nm (4.4 lbf ft)
100776-10
Filling up with engine oil

27.7
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
The oil must be topped up in two steps.

Engine oil
100777-10
External temperature: 0 C
( 32 F)
Engine oil
(SAE 10W/50)
( p. 436)
External temperature: < 0 C

(< 32 F)
Engine oil
(SAE 5W/40)
( p. 436)
Remove the dipstick and top up the engine oil.

Engine oil (1st
quantity)
3.60 l (3.8 qt.)
3.00 l (3.17 qt.)
( 32 F)
Engine oil
(SAE 10W/50)
( p. 436)

(< 32 F)
Engine oil
(SAE 5W/40)
( p. 436)
Replace the oil dipstick .
Danger
Start the engine and check that it is oil-tight.
Remove the dipstick and pour in the remaining engine oil.

Engine oil (2nd
quantity)
0.60 l (0.63 qt.)
( 32 F)
Engine oil
(SAE 10W/50)
( p. 436)

(< 32 F)
Engine oil
(SAE 5W/40)
( p. 436)
Replace the oil dipstick .
Danger
p. 209)
213
Adding engine oil

27.8
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
Remove the dipstick and add engine oil.
p. 209)
Condition
External temperature: 0 C ( 32 F)
Engine oil (SAE 10W/50) (
p. 436)
Condition
External temperature: < 0 C (< 32 F)
p. 436)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Engine oil (SAE 5W/40) (

100777-10
Info
For optimal performance of the engine oil, do not mix different types of
engine oil.
If appropriate, change the engine oil.
Replace oil dipstick .
Danger
p. 209)
Checking the engine oil pressure

27.9
Warning
Warning
p. 13)
214
Remove screws .
Take off the left exhaust cover .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
100771-10
Remove screws . Take off the oil filter cover with the O-ring.
Remove oil filter .
p. 440)
200557-10
Position the special tool with the O-ring. Mount and tighten the screws.
Guideline
M5
Oil pressure testing adapter (75029094000) (
p. 448)
Connect the pressure testing tool to the special tool without the t-plate.
200558-10
6 Nm (4.4 lbf ft)
p. 443)
p. 209)
Danger
Start the engine and let it warm up.
Check the engine oil pressure.

Engine oil pressure
215
1.3 2.3 bar (19 33 psi)
Coolant temperature: 70 C
( 158 F)
Engine speed: 5,000 rpm
3.0 4.0 bar (44 58 psi)
Coolant temperature: 70 C
( 158 F)
Check the oil pumps for wear. Check that all oil holes are free of blockages.
Switch off the engine.
Warning
Danger of burnsSome 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.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Remove the special tools.
Insert the new oil filter.
Lubricate the O-ring of the oil filter cover. Mount the oil filter cover.

Guideline
Position the left exhaust cover .
M5
6 Nm (4.4 lbf ft)
M5
5 Nm (3.7 lbf ft)
Guideline
p. 209)
100771-10
Removing the oil jet for the clutch lubrication

27.10
301426-10
Remove screws .
Take off the engine sprocket cover.
p. 13)
216
Remove plug .
Remove oil jet .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301427-10
301429-11
Checking / cleaning the oil jet for clutch lubrication

27.11
Remove the oil jet for the clutch lubrication. (
Check the oil jet for clutch lubrication is not blocked.
If the oil jet is blocked:
p. 215)
Clean the oil jet and change as necessary.
Install the oil jet for the clutch lubrication. (
p. 216)
301428-10
Installing the oil jet for the clutch lubrication

27.12
Mount and tighten oil jet .

Guideline
M6x0.75
4 Nm (3 lbf ft)
M10x1
15 Nm
(11.1 lbf ft)
301429-10
Mount and tighten plugs .
Guideline
301427-10
217
Position the engine sprocket cover.
Guideline
M6
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
301426-11
10 Nm (7.4 lbf ft)
39/IGNITION SYSTEM
218
Crankshaft position sensor

28.1
The crankshaft position sensor is located below the generator cover on the left-hand
side of the engine.
900001-01
The crankshaft position sensor consists of a permanent magnet and an induction
coil with a soft iron core. The counter part to the crankshaft position sensor is a
trigger wheel whose 22 teeth are evenly spaced, but one of the teeth has a wider
gap. The trigger wheel is installed on the generator rotor which is attached to the
crankshaft. There is a small air gap between the crankshaft position sensor and the
toothed wheel.
Crankshaft position sensor, connector AT (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Magnetic flow through the induction coil depends on whether a gap or a tooth is
opposite the crankshaft position sensor. A tooth focuses the magnetic leakage flux
of the permanent magnet while a gap weakens the magnetic flux. When the rotor
(and trigger wheel) starts to turn, the teeth pass the sensor, thus altering the magnetic field strength. The alteration of the magnetic field created in the induction
coil generates an alternating voltage. The number of pulses per second is equivalent to the rotor speed. The larger gap between the teeth on the trigger wheel is
intended so that the EFI control unit can identify the position of the crankshaft.
The gap cannot be altered.
900010-01
Crankshaft position sensor/rotor - gap
0.70 mm (0.0276 in)

Resistance at: 20 C
(68 F)
80 120
Ignition coil
28.2
The ignition coil for cylinder 1 is located on the rear cylinder head.
The ignition coil for cylinder 2 is located on the front cylinder head.
900022-61
Pin overview
Control wire
System voltage
Ignition coil
600851-10
Primary winding resistance at: 20 C (68 F)
1.105 1.495
Secondary winding
resistance at: 20 C
(68 F)
16.2 10.8 k
41/THROTTLE VALVE BODY
219
Throttle position sensor circuit A

29.1
Throttle position sensor circuit A, is located on the throttle valve body for cylinder
2, on the right-hand side of the engine.
900019-60
The throttle position sensor has a linear characteristic line and works like a variable
resistor.
As shown in the diagram, the output voltage correlates to a throttle position.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Throttle position sensor circuit A, connector AM (
900020-10
The output voltage of the throttle position sensor is dependent on the opening
angle of the throttle valve and is sent via the signal wire to determine the throttle
valve position.
Throttle position sensor circuit A voltage "(THAD)"
0.56 4.20 V
Throttle position sensor circuit A, signal "ATP"
0 100 %
Throttle position sensor circuit A - checking in the "zero" position

29.2
Condition
The ignition is on.
400687-60
Select the model.
Press "Continue".
Press "Continue".
Press "Continue".
Read the information page on the KTM diagnostics tool and using "Continue" start
the calibration process.
Info
The motor drive moves the throttle valve in circuit A to the "zero" position
(throttle valve fully closed position).

In "zero" position
0.56 0.64 V
If the displayed value does not correspond to the nominal value:
Adjust the position of the throttle position sensor in circuit A. (
p. 220)
220
Adjusting the position of the throttle position sensor in circuit A

29.3
Condition
The ignition is on.
Remove the throttle valve body to adjust. (
p. 221)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400680-10
Select the model.
Press "Continue".
Press "Continue".
Press "Continue".
Read the information page on the KTM diagnostics tool and using "Continue" start the calibration process.
Info
The motor drive moves the throttle valve in circuit A to the "zero" position (throttle valve fully closed position).

In "zero" position
0.56 0.64 V
Loosen screw .
Turn the throttle position sensor to adjust it to the specified value.

Guideline
In "zero" position
Tighten screw .
Open and close the throttle grip fully ten times.
Check the voltage again and readjust if necessary.
0.56 0.64 V
Reinstall the throttle valve body when the adjustments have been made. (
p. 222)
221
Removing the throttle valve body to adjust

29.4
Unplug the connector of the manifold absolute pressure sensor .
Take the manifold absolute pressure sensor out of the holder but do not detach the
vacuum hoses.
Take plug-in connector out of the holding bracket.
p. 67)
200498-10
Remove screws . Take off the retaining plates and holding brackets.
Remove screw . Remove the cover.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200499-10
Loosen hose clamps .
Loosen the spring-loaded band-type clamp using the special tool. Pull off the
fuel hose.
200500-10
200501-10
p. 442)
Pull up the throttle valve body and remove connector with the seal.
Pull the throttle cables out of the filter box bottom with guide piece .
Remove the throttle valve body.
222
Reinstalling the throttle valve body when the adjustments have been made
29.5
Mount connector with the seal.
Connect the fuel hose. Mount the spring-loaded band-type clamp using the special tool.
p. 442)
Info
The fuel hose must have a minimum distance of 4 mm to the throttle linkage in all operating positions.
Position the throttle cables with guide piece .
Slide the throttle valve body into the rubber sleeves.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200501-11
Position and tighten upper hose clamps .

Guideline
M4
1.5 Nm
(1.11 lbf ft)
200500-11
Mount the cover. Mount and tighten screw .
Position the retaining plates and holding brackets. Mount and tighten screws .
Fix plug-in connector with the holding bracket.
200499-11
200498-11
Connect plug-in connector .
Mount manifold absolute pressure sensor and plug in the connector.
p. 67)
223
Throttle position sensor circuit B

29.6
Throttle position sensor circuit B is located on the throttle valve body for cylinder 1
on the right-hand side of the engine.
900025-60
The throttle position sensor has a linear characteristic line and works like a variable
resistor.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
As shown in the diagram, the voltage can be correlated to a throttle position.
Throttle position sensor circuit B, connector AR (
900047-10
The EFI control unit utilizes the signal from the throttle position sensor in circuit B
to set the opening angle of the second throttle valve. The second throttle valve
enables smoother power delivery from the engine and it is used as part of the electronic power control (EPC).
Position 2. Throttle
valve "2ndTHAngle"
0 100 %
Throttle position sensor circuit B, voltage "TAPAD"
0.156 4.824 V
Manifold absolute pressure sensor

29.7
The manifold absolute pressure sensor cylinder 1 is located on the right-hand
rear side of the air filter box and is connected to the induction manifold by a hose.
The manifold absolute pressure sensor cylinder 2 is located on the front righthand rear side of the air filter box and is connected to the induction manifold by a
hose.
900003-61
The processing electronics and a measuring cell are located in the housing of the
manifold absolute pressure sensor. In the measuring cell a diaphragm encloses a
reference pressure chamber. When the shape of the diaphragm is altered by exterior pressure, the conductivity of the measuring resistors is altered and thus the
measured voltage. The measured voltage is prepared by the processing electronics
and sent on to the EFI control unit.
Pin overview
System voltage
Sensor ground
Signal wire
400659-10
The output voltage of the manifold absolute pressure sensor depends on the manifold pressure and is sent via the signal wire. The voltage signal drops when pressure decreases. This means that when the throttle valve is closed with resulting low
manifold pressure (due to the suction effect of the engine), a low voltage signal is
emitted from the manifold absolute pressure sensor. When the throttle valve is fully
open, the manifold pressure is roughly equal to the ambient air pressure and the
voltage signal is high.
600725-10
Manifold absolute pressure sensor cylinder 1, voltage "PM1AD"

at: 350 mbar (5.08 psi)
1.62 1.68 V
224
at: 400 mbar (5.8 psi)
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar

(12.33 psi)
3.12 3.18 V
at: 900 mbar

(13.05 psi)
3.27 3.33 V
at: 950 mbar

(13.78 psi)
3.42 3.48 V
at: 1,000 mbar

(14.5 psi)
3.57 3.63 V
at: 1,050 mbar

(15.23 psi)
3.72 3.78 V
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar

(12.33 psi)
3.12 3.18 V
at: 900 mbar

(13.05 psi)
3.27 3.33 V
at: 950 mbar

(13.78 psi)
3.42 3.48 V
at: 1,000 mbar

(14.5 psi)
3.57 3.63 V
at: 1,050 mbar

(15.23 psi)
3.72 3.78 V
Connecting the vacuum hand pump to the manifold absolute pressure sensor
29.8
p. 67)
Connecting to the manifold absolute pressure sensor cylinder 1:

Pull off vacuum hose .
Connect the vacuum hand pump to the vacuum hose of the manifold absolute
pressure sensor cylinder 1.
600856-10
Connecting to the manifold absolute pressure sensor cylinder 2:

Pull off vacuum hose .
600856-11
Connect the vacuum hand pump to the vacuum hose of the manifold absolute
pressure sensor cylinder 2.
225
Ambient air pressure sensor

29.9
The ambient air pressure sensor is located on the right-hand side of the frame.
The processing electronics and a measuring cell are located in the housing of the
ambient air pressure sensor. In the measuring cell a diaphragm encloses a reference pressure chamber. When the shape of the diaphragm is altered by external
pressure, the conductivity of the measuring resistors is altered and thus the measured voltage. The measured voltage is prepared by the processing electronics and
sent on to the EFI control unit.
900006-60
Pin overview
System voltage
Sensor ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
1
3
Signal wire
400659-10
The output voltage of the ambient air pressure sensor depends on the ambient air
pressure and is sent via the signal wire. The voltage signal rises when ambient air
pressure increases.
Ambient air pressure sensor voltage "PAAD"
600725-10
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar

(12.33 psi)
3.12 3.18 V
at: 900 mbar

(13.05 psi)
3.27 3.33 V
at: 950 mbar

(13.78 psi)
3.42 3.48 V
at: 1,000 mbar

(14.5 psi)
3.57 3.63 V
at: 1,050 mbar

(15.23 psi)
3.72 3.78 V
Injector
29.10
Injector cylinder 1 is located on the rear throttle valve body.
Injector cylinder 2 is located on the front throttle valve body.
900027-61
The injector consists of a solenoid, a spring loaded plunger, a needle valve and a
filter. When current flows through the coil in the solenoid, a magnetic field is generated which attracts the plunger, overcoming the spring force; this lifts the needle valve off its seat. Fuel is discharged through eight holes and forms two conical
jets. When the current is switched off, the magnetic field collapses and the spring
closes the needle valve. The filter keeps any contamination out of the holes.
Pin overview
400598-10
Control wire
System voltage
226
The injector is supplied with battery voltage by the power relay. The EFI control
unit calculates the amount of fuel required and grounds the injector via the amplification stage in the EFI control unit. The longer the injector is connected to ground,
the greater the amount of fuel injected.
Injector
Resistance at: 20 C
(68 F)
10.5 13.0
Rollover sensor
29.11
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The rollover sensor is located on the base of the air filter box.
900002-60
Rollover sensor construction
900004-10
Pendulum with a magnet
Circuit board with a Hall sensor
Housing
Spacer
Retainer for the connector seal
Connector seal
Normal position, left-hand corner
Normal position, right-hand corner
The sensor makes use of the Hall effect. A pendulum with a magnet attached is
fitted in the rollover sensor. The pendulum passes a Hall element. The evaluation
electronics of the rollover sensor calculates the Hall voltage and activates the signal
voltage.
Pin overview
400660-10
Sensor ground
Signal wire
System voltage
The rollover sensor is connected in series to a sensing resistor (on feed side and
ground side) located in the EFI control unit. The evaluation electronics of the
rollover sensor switches the signal voltage, depending on the inclination of the
vehicle, via a resistor to voltage or to ground. Using the voltage value from the
signal wire, the EFI control unit can determine the inclination of the vehicle.
Rollover sensor
Voltage (Rollover AD)
"no fall detected"
0.4 1.4 V
Voltage (Rollover AD)

"fall detected"
3.7 4.1 V
227
EFI control unit

29.12
The EFI control unit is located behind the right-hand side cover.
Info
When an EFI control unit from the spare parts warehouse is initially
programmed, it is given an identity. This means that when writing to the EFI
control unit, e.g., using the flash container KM690EU0802001 (1190 RC8
series), the EFI control unit is defined as a 690 version, and can from then on
only be used on 690 models (specifically installed control unit).
After programming is complete, the VIN must be entered into the EFI control
unit using the "Coding" function!
900038-60
Connector CO (
Connector AO (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Requesting the EFI control unit activation code

29.13
Condition
An exchanged EFI control unit is connected.
The ignition is on.
The "ECU Flashing" process is complete.
400687-60
Select the model.
Press "Continue".
Select "Coding".
Press "Continue".
Select "Change VIN - New identity".
Press "Continue".
the coding process.
Overwrite the entry under the "Please enter VIN:" heading.
Press "Continue".
Select "Code form".
Press "Print".
The protocol is being printed out.
Fill out the protocol and send to "diagnostic@ktm.com".
Coding the EFI control unit

29.14
Condition
The ignition is on.
400687-60
Request the EFI control unit activation code. (
Select the model.
p. 227)
Press "Continue".
Select "Coding".
Press "Continue".
Select "Change VIN - New identity".
Press "Continue".
the coding process.
228
Overwrite the entry under the "Please enter VIN:" heading.
Press "Continue".
Select "Code entry".
"Please enter the Code"
Press "Continue".
Switch to the main menu.
Select "Show identification".
Compare the old VIN to the new VIN.
The new VIN is written to the EFI control unit.
The new VIN is shown.
Flashing the EFI control unit

29.15
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
400687-60
Select the model.
Press "Continue".
Select "ECU Flashing".
Press "Continue".
Read the safety information and set up the required conditions.
Confirm the instruction by clicking on "OK".
Press "Select file" and select the new mapping.
Info
"The BLZ file and the exhaust system must match!"
Press the "ECU flash process" button.
Read the safety notice and confirm with "OK".

The new mapping is loaded.
IMMOBILIZER BLINK CODE
229
Blink code of immobilizer indicator lamp

12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short
Possible cause
Ignition keys (all) have not been activated (
p. 229)
Ignition keys (all) have not been activated

Activate/deactivate the ignition key. (
p. 102)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
230

Possible cause
ICU antenna - value not plausible (
p. 230)
ICU antenna - coil antenna has an open (

Last measure if none of the documented causes leads to elimination of the fault
p. 230)
Change the immobilizer control unit.
ICU antenna - value not plausible

Condition
The imobilizer control unit antenna coil is disconnected. (
p. 102)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
ICU antenna - checking the resistance
Measure the resistance between the specified points.

ICU antenna connector EL pin 1 ICU antenna connector EL pin 2
13.917 15.383
ICU antenna
If the specifications have not been met:
If the specifications have been met:
400685-10
Change the ICU antenna.
Check the next possible cause:

ICU antenna - coil antenna has an open (
p. 230)
ICU antenna - coil antenna has an open
Condition
The immobilizer control unit is disconnected. ( p. 102)
The imobilizer control unit antenna coil is connected. ( p. 102)
ICU antenna - checking the coil antenna for opens

Immobilizer control unit, connector DO pin 1 Immobilizer control unit,
connector DO pin 2
13.917 15.383
ICU antenna
400657-10
Check connector DO pin 1 and pin 2.
Check connector DV (
Check the cable from connector DO pin 1 to connector DV (

opens.
p. 401) pin 1 for
Check the cable from connector DO pin 2 to connector DV (

opens.
p. 401) pin 2 for
Disconnect connector DV ( p. 401) of the ICU antenna. Check the cables

from connector DO pin 1 and pin 2 to connector DV pin 1 and pin 2 for mutual
short circuits.
p. 401) pin 1 and pin 2.
231

Possible cause
Malfunction in transponder of black ignition key (
p. 231)
Malfunction in transponder of black ignition key
Use spare black ignition key.
Order a new black ignition key according to the key number on the KEYCODECARD.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 102)
232

Possible cause
Ignition key has not been activated (
p. 232)
Ignition key has not been activated

p. 102)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
233

Possible cause
Malfunction, encryption, immobilizer control unit to black ignition key (
p. 233)
p. 102)
Malfunction, encryption, immobilizer control unit to black ignition key
Use the black ignition key belonging to the vehicle.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Activate/deactivate the ignition key. ( p. 102)
234

Possible cause
Immobilizer control unit not activated (
p. 234)
Immobilizer control unit not activated

Activate the ICU. (
p. 104)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
235

Possible cause
Malfunction, encryption query from EFI control unit to immobilizer control unit (
Malfunction, encryption query from EFI control unit to immobilizer control unit
Flash the EFI control unit. (
p. 228)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 235)
236

Possible cause
Malfunction in CAN bus communication (
p. 236)
Malfunction in CAN bus communication

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
237

60 Immobilizer indicator lamp flashes 6x short
Possible cause
EPROM malfunction (
p. 237)
EPROM malfunction
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
ENGINE CONTROL TROUBLE CODE
238
Blink code EFI warning

lamp (MIL)
45 EFI warning lamp (MIL) flashes 4x long, 5x short
Display on diagnostic tool
P0031
"Lambda sensor heater cylinder 1, sensor 1"
"Short circuit to ground or open circuit"
Error level condition
Circuit fault: 3 s
Function check
Checking the lambda sensor heater cylinder 1 (
Possible cause
Lambda sensor heater cylinder 1 - value not plausible (
p. 238)
p. 238)
Lambda sensor heater cylinder 1 - the power supply is faulty (
p. 239)
Lambda sensor heater cylinder 1 - the control wire has an open (
p. 239)
Lambda sensor heater cylinder 1 - the control wire has a short circuit to sensor ground (
p. 240)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31)
( p. 240)
Contact customer service.
Checking the lambda sensor heater cylinder 1

Condition
The ignition is on.
The diagnostics tool is connected and active.
Select the model.
Press "Continue".
Select "Actuator Test".
Press "Continue".
Select "Lambda sensor heater cylinder 1".
Press "Continue".
In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test start
5V
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test end
0.5 V
If the displayed value corresponds to the nominal value:
Take a test ride.

p. 238)
Lambda sensor heater cylinder 1 - value not plausible

Condition
The ignition is off.
Lambda sensor for cylinder 1 is disconnected. (
p. 62)
239
Lambda sensor heater cylinder 1 - check the resistance

Lambda sensor cylinder 1, connector CE pin 1 Lambda sensor cylinder 1,
connector CE pin 2
11.7 14.3
Resistance at: 20 C (68 F)
400647-10
Replace the lambda sensor cylinder 1.

Lambda sensor heater cylinder 1 - the power supply is faulty
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
EFI control unit is connected. ( p. 227)
p. 62)
400646-10
400658-10
Lambda sensor heater cylinder 1 - check the power supply
Measure the voltage between the specified points.

Lambda sensor cylinder 1, connector CA pin 1 Measuring point Ground ()
Info
When taking measurements, the measurement locations must be loaded with a 12V/21W bulb.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
Check connector CA pin 1.
Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.

Lambda sensor heater cylinder 1 - the control wire has an open

Condition
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
p. 239)
p. 239)
240
600850-12
400646-10
Lambda sensor heater cylinder 1 - check the control wire for opens
Break out box CO pin 33 Lambda sensor cylinder 1, connector CA pin 2

0.6
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Check EFI control unit connector CO (
Check the cable from EFI control unit connector CO (
p. 397) pin 33 and connector CA pin 2.
p. 397) pin 33 to connector CA pin 2 for opens.

p. 240)
Lambda sensor heater cylinder 1 - the control wire has a short circuit to sensor ground
Condition
600850-11
600850-12
Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to sensor ground

Break Out Box AO pin 7 Break out box CO pin 33
Resistance

sensor ground.
p. 397) pin 33 to connector CA (
p. 396) pin 2 for a short circuit to

Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31) (
p. 240)
Condition
241
600850-12
400658-10
Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to ground (terminal 31)
Break out box CO pin 33 Measuring point Ground ()

Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

ground (terminal 31).
242

lamp (MIL)
P0032
"Input signal too high"
Circuit fault: 3 s
Function check
Possible cause
p. 242)
p. 242)
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
( p. 243)
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 243)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Press "Continue".
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test start
5V
Lambda sensor
0.5 V
Lambda sensor cylinder 1 voltage "HEGO1AD" at test end
Take a test ride.

p. 242)

Condition
p. 62)
Lambda sensor heater cylinder 1 - check the resistance

connector CE pin 2
400647-10
11.7 14.3
243

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus
(terminal 30) ( p. 243)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Lambda sensor heater cylinder 1 - checking the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 243)
Condition
600850-12
600850-11
Lambda sensor heater cylinder 1 - check the signal wire for a short circuit to ignition plus (terminal 15).

Break out box CO pin 33 Break Out Box AO pin 20
Resistance

ignition plus (terminal 15).

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
244
245

lamp (MIL)
P0051
Circuit fault: 3 s
Function check
Possible cause
p. 245)
p. 245)
p. 246)
p. 246)
p. 247)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
( p. 247)

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Press "Continue".
Lambda sensor
Lambda sensor cylinder 2 voltage "HEGO2AD" at the test

start
5V
Lambda sensor

end
0.5 V
Take a test ride.

p. 245)

Condition
p. 62)
246
Lambda sensor heater cylinder 2 - check the resistance.

connector CE pin 2
11.7 14.3
400647-10
Change the lambda sensor cylinder 2.

Lambda sensor heater cylinder 2 - the power supply is faulty
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
p. 62)
400646-10
400658-10
Lambda sensor heater cylinder 2 - checking the power supply

Lambda sensor cylinder 2, connector CA pin 1 Measuring point Ground ()
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
Check connector CA pin 1.
Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.

Lambda sensor heater cylinder 2 - the control wire has an open

Condition
p. 246)
p. 246)
247
600850-12
400646-10
Lambda sensor heater cylinder 2 - checking the control wire for opens
Break out box CO pin 15 Lambda sensor cylinder 2, connector CA pin 2

0.6
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

p. 247)
Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor ground
Condition
600850-11
600850-12
Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to sensor ground

Break Out Box AO pin 7 Break out box CO pin 15
Resistance

sensor ground.

Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31) (
p. 247)
Condition
248
600850-12
400658-10
Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to ground (terminal 31)

Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

249

lamp (MIL)
P0052
Circuit fault: 3 s
Function check
Possible cause
p. 249)
p. 249)
( p. 250)
( p. 250)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Press "Continue".
Lambda sensor

start
5V
Lambda sensor

end
0.5 V
Take a test ride.

p. 249)

Condition
p. 62)
250
Lambda sensor heater cylinder 2 - check the resistance.

connector CE pin 2
11.7 14.3
400647-10

Lambda sensor heater cylinder 2 - the signal wire has a short circuit to plus
(terminal 30) ( p. 250)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Lambda sensor heater cylinder 2 - checking the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

Lambda sensor heater cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 250)
Condition
600850-12
600850-11
Lambda sensor heater cylinder 2 - check the signal wire for a short circuit to ignition plus (terminal 15).


Resistance

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
251
252

lamp (MIL)
09 EFI warning lamp (MIL) flashes 9x short
P0107
"Manifold absolute pressure sensor cylinder 1"
"Input signal too low"
Manifold absolute pressure sensor cylinder 1, voltage "PM1AD": 0.508 V

Time: 1 s
Substitute value: 700 mbar (10.15 psi)
Function check
Manifold absolute pressure sensor cylinder 1 - checking the voltage (
Possible cause
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground
( p. 253)
p. 252)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31) ( p. 253)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Manifold absolute pressure sensor cylinder 1 - the power supply is interrupted (
p. 253)
Replace the manifold absolute pressure sensor cylinder 1.
Manifold absolute pressure sensor cylinder 1 - checking the voltage

Condition
The ignition is on.
The engine is switched off.
Select the model.
Press "Continue".
Select "Measured Values".
Highlight "Fuel management general".
Press "Continue".
Highlight "Manifold absolute pressure sensor cylinder 1 voltage" and deselect the other parameters with "Select live data".
at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.
If the displayed value is below the nominal value:

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground (
p. 253)
253
Condition
Manifold absolute pressure sensor cylinder 1 is disconnected. (
p. 223)
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to
sensor ground

Manifold absolute pressure sensor cylinder 1, connector DP pin 2 Manifold absolute pressure sensor cylinder 1, connector DP pin 3
Resistance
Check the cable from connector DP pin 3 to the EFI control unit connector AO
( p. 392) pin 3 for a short circuit to sensor ground.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400590-10

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
Condition
p. 223)
400590-10
400658-10
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31)

Manifold absolute pressure sensor cylinder 1, connector DP pin 3 Measuring point Ground ()
Resistance
Check the cable from connector DP pin 1 to EFI control unit connector AO (
minal 31).
p. 392) pin 3 for a short circuit to ground (ter-

p. 253)
Manifold absolute pressure sensor cylinder 1 - the power supply is interrupted

Condition
The ignition is on.
p. 223)
254
400590-10
400658-10
Manifold absolute pressure sensor cylinder 1 - checking the power supply

Manifold absolute pressure sensor cylinder 1, connector DP pin 1 Measuring point Ground ()
Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
4.9 5.1 V
Check connector DP pin 1.
Check the cable from connector DP pin 1 to the next node in the wiring harness for opens.
255

lamp (MIL)
P0108

Time: 1 s
Function check
Possible cause
Manifold absolute pressure sensor cylinder 1 - the signal wire has an open (
p. 255)
Manifold absolute pressure sensor cylinder 1 - the ground wire has an open (
p. 256)
p. 256)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 257)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus
(terminal 15) ( p. 257)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to the sensor
power supply ( p. 257)

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.
If the displayed value is above the nominal value:

p. 256)
256
Manifold absolute pressure sensor cylinder 1 - the signal wire has an open
p. 223)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400590-10
Manifold absolute pressure sensor cylinder 1 - check the signal wire for opens
Break Out Box AO pin 3 Manifold absolute pressure sensor cylinder 1, connector DP pin 3
0.6
Resistance
Check EFI control unit connector AO (
Check the cable from EFI control unit connector AO (
p. 392) pin 3 and connector DP pin 3.
p. 392) pin 3 to connector DP pin 3 for opens.

p. 256)
Manifold absolute pressure sensor cylinder 1 - the ground wire has an open
Condition
p. 223)
600850-11
400590-10
Manifold absolute pressure sensor cylinder 1 - check the ground wire for opens

Break Out Box AO pin 7 Manifold absolute pressure sensor cylinder 1, connector DP pin 2
0.6
Resistance


Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) (
p. 257)
257
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
p. 223)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400658-10
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30)
Break Out Box AO pin 3 Measuring point Ground ()

Voltage
< 0.1 V

plus (terminal 30).
p. 392) pin 3 to connector DP (

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 257)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
p. 223)
ignition plus (terminal 15)

Break Out Box AO pin 3 Break Out Box AO pin 20
Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 3 to connector DP ( p. 400) pin 3 for a short circuit to ignition plus (terminal 15).

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply ( p. 257)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
Condition
p. 223)
258
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to the
sensor power supply

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 3 to connector DP ( p. 400) pin 3 for a short circuit to the sensor power supply.

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
259

lamp (MIL)
P0112
"Intake air temperature sensor"
Intake air temperature sensor "TAAD": 0.156 V

Time: 3 s
Substitute value: 25 C (77 F)
Function check
Intake air temperature sensor - checking the voltage (
Possible cause
Intake air temperature sensor - value not plausible (
p. 259)
p. 259)
Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)
( p. 260)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Intake air temperature sensor - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Intake air temperature sensor voltage (TAAD)" and deselect the other parameters with "Select live data".
Intake air temperature sensor "TAAD"
0.157 4.843 V
Take a test ride.

p. 259)
Intake air temperature sensor - value not plausible
Condition
Intake air temperature sensor - check the resistance

Intake air temperature sensor
600850-11
18.80 k
2.942 k
1.136 k
0.1553 k

Intake air temperature sensor - the signal wire has a short circuit to sensor
ground ( p. 260)
260
Replace the intake air temperature sensor.

Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31) ( p. 260)
Intake air temperature sensor - the signal wire has a short circuit to sensor ground
Condition
The intake air temperature sensor is disconnected.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Intake air temperature sensor - check the signal wire for a short circuit to sensor ground

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM ( p. 397) pin 2 for a short circuit to sensor ground.
Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-11
400658-10
Intake air temperature sensor - check the signal wire for a short circuit to ground (terminal 31)

Resistance

p. 392) pin 22 to connector CM (
261

lamp (MIL)
P0113
"Intake air temperature sensor"
Intake air temperature sensor "TAAD": 4.844 V

Time: 3 s
Function check
Intake air temperature sensor - checking the voltage (
Possible cause
Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) (
p. 261)
p. 261)
Intake air temperature sensor - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 262)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Intake air temperature sensor - the signal wire has a short circuit to the sensor power supply
( p. 262)
Intake air temperature sensor - the signal wire has an open (
p. 263)
Intake air temperature sensor - the ground wire has an open (

p. 263)
p. 264)
Intake air temperature sensor - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Intake air temperature sensor voltage (TAAD)" and deselect the other parameters with "Select live data".
Intake air temperature sensor "TAAD"
0.157 4.843 V
Take a test ride.

Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) (
Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
p. 261)
262
600850-11
400658-10
Intake air temperature sensor - check the signal wire for a short circuit to plus (terminal 30)

0.1 V
Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

plus (terminal 30).
p. 392) pin 22 to connector CM (

Intake air temperature sensor - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 262)
Intake air temperature sensor - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
Intake air temperature sensor - check the signal wire for a short circuit to ignition plus
(terminal 15)

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM ( p. 397) pin 2 for a short circuit to ignition plus (terminal 15).

Intake air temperature sensor - the signal wire has a short circuit to the sensor
Intake air temperature sensor - the signal wire has a short circuit to the sensor power supply
Condition
Intake air temperature sensor - check the signal wire for a short circuit to the sensor power
supply

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM ( p. 397) pin 2 for a short circuit to the sensor power supply.

Intake air temperature sensor - the signal wire has an open (
p. 263)
263
Intake air temperature sensor - the signal wire has an open

Condition
400650-10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-11
Intake air temperature sensor - check the signal wire for opens
Break Out Box AO pin 22 Connector CM pin 2
0.6
Resistance
p. 392) pin 22 and connector CM pin 2.
p. 392) pin 22 to connector CM pin 2 for opens.

Intake air temperature sensor - the ground wire has an open (
p. 263)
Intake air temperature sensor - the ground wire has an open

Condition
600850-11
400650-10
Intake air temperature sensor - check the ground wire for opens

Break Out Box AO pin 7 Connector CM pin 1
0.6
Resistance
p. 392) pin 7 and connector CM pin 1.

p. 392) pin 7 to connector CM pin 1 for opens.

p. 264)
264
Intake air temperature sensor - value not plausible

Condition
Intake air temperature sensor - check the resistance

Intake air temperature sensor
18.80 k
2.942 k
1.136 k
0.1553 k
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-11
Replace the intake air temperature sensor.

265

lamp (MIL)
P0117
"Engine coolant temperature sensor"
Engine coolant temperature sensor voltage "TWAD": 0.156 V

Time: 3 s
Function check
Engine coolant temperature sensor cylinder 1 - checking the voltage (
Possible cause
Cylinder 1 coolant temperature sensor - value not plausible (
p. 265)
p. 265)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31) ( p. 266)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground
( p. 266)
Engine coolant temperature sensor cylinder 1 - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Engine coolant temperature sensor voltage (TWAD)" and deselect the other parameters with "Select live data".
Engine coolant temperature sensor voltage "TWAD"
0.157 4.843 V
Take a test ride.

p. 265)
Cylinder 1 coolant temperature sensor - value not plausible
Condition
Engine coolant temperature sensor for cylinder 1 is disconnected. (
p. 198)
Cylinder 1 coolant temperature sensor - check the resistance

Engine coolant temperature sensor cylinder 1 pin 1 Engine coolant temperature sensor cylinder 1 pin 2
600853-10
22.86 27.94 k
13.50 16.50 k
8.24 10.08 k
5.17 6.31 k
3.33 4.07 k
2.21 2.70 k
1.49 1.83 k
1.04 1.27 k
730 892
526 642
385 471
286 350
216 264
165 202
128 156
100 122
266
Change the engine coolant temperature sensor cylinder 1.

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31) ( p. 266)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
Condition
p. 198)
600850-11
400658-10
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31)

Resistance

p. 392) pin 9 to connector AX (

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground (
p. 266)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground
Condition
p. 198)
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to
sensor ground

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX ( p. 395) pin 2 for a short circuit to sensor ground.

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
267
268

lamp (MIL)
P0118
"Engine coolant temperature sensor"
Engine coolant temperature sensor voltage "TWAD": 4.844 V

Time: 3 s
Function check
Engine coolant temperature sensor cylinder 1 - checking the voltage (
Possible cause
p. 268)
p. 268)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 269)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus
(terminal 15) ( p. 269)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor
Engine coolant temperature sensor cylinder 1 - the signal wire has an open (
Engine coolant temperature sensor cylinder 1 - the ground wire has an open (
p. 270)
p. 271)
Engine coolant temperature sensor cylinder 1 - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Engine coolant temperature sensor voltage (TWAD)" and deselect the other parameters with "Select live data".
Engine coolant temperature sensor voltage "TWAD"
0.157 4.843 V
Take a test ride.

p. 268)
Cylinder 1 coolant temperature sensor - value not plausible

Condition
p. 198)
Cylinder 1 coolant temperature sensor - check the resistance

Engine coolant temperature sensor cylinder 1 pin 1 Engine coolant temperature sensor cylinder 1 pin 2
600853-10
22.86 27.94 k
13.50 16.50 k
8.24 10.08 k
269
5.17 6.31 k
3.33 4.07 k
2.21 2.70 k
1.49 1.83 k
1.04 1.27 k
730 892
526 642
385 471
286 350
216 264
165 202
128 156
100 122
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Change the engine coolant temperature sensor cylinder 1.

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 269)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
Condition
p. 198)
600850-11
400658-10
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30)

0.1 V
Voltage

plus (terminal 30).
p. 392) pin 9 to connector AX (

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 269)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
p. 198)
270
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX ( p. 395) pin 2 for a short circuit to ignition plus (terminal 15).

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply ( p. 270)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
Condition
p. 198)
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to the
sensor power supply

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX ( p. 395) pin 2 for a short circuit to the sensor power supply.

Engine coolant temperature sensor cylinder 1 - the signal wire has an open
( p. 270)
Engine coolant temperature sensor cylinder 1 - the signal wire has an open
Condition
p. 198)
600850-11
400586-10
Engine coolant temperature sensor cylinder 1 - check the signal wire for opens

Break Out Box AO pin 9 Engine coolant temperature sensor cylinder 1 connector AX pin 2
0.6
Resistance
p. 392) pin 9 and connector AX pin 2.

p. 392) pin 9 to connector AX pin 2 for opens.
271

Engine coolant temperature sensor cylinder 1 - the ground wire has an open (
p. 271)
Engine coolant temperature sensor cylinder 1 - the ground wire has an open
p. 198)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400586-10
Engine coolant temperature sensor cylinder 1 - check the ground wire for opens

Break Out Box AO pin 7 Engine coolant temperature sensor cylinder 1 connector AX pin 1
0.6
Resistance
p. 392) pin 7 and connector AX pin 1.
p. 392) pin 7 to connector AX pin 1 for opens.
272

lamp (MIL)
P0122
"Throttle position sensor circuit A"
Throttle position sensor circuit A voltage "(THAD)": 0.156 V

Time: 3 s
Substitute value: 100 %
Function check
Throttle position sensor circuit A - checking the voltage (
Possible cause
Throttle position sensor circuit A - the power supply is interrupted (
p. 272)
p. 272)
Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31)
( p. 273)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground (
Throttle position sensor circuit A - the signal wire has an open (
p. 274)
Throttle position sensor circuit A - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Throttle position sensor voltage circuit A (THAD)" and deselect the other parameters with "Select live data".
0.56 4.20 V
Take a test ride.

Throttle position sensor circuit A - the power supply is interrupted (
Throttle position sensor circuit A - the power supply is interrupted

Condition
The ignition is on.
Throttle position sensor circuit A is disconnected. (
p. 219)
p. 272)
p. 274)
273
400584-10
400658-10
Throttle position sensor circuit A - check the power supply

Throttle position sensor circuit A, connector AR pin 1 Measuring point Ground ()

Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
4.9 5.1 V
Check connector AR pin 1 and connector CP (
Check the cable from connector AR pin 1 to connector CP (
Check connector CQ (
Check the cable from connector CQ (
p. 398) pin 2.14.
p. 398) pin 2.14 for opens.
p. 398) pin 14 and EFI control unit connector AO (
p. 392) pin 1.
p. 398) pin 14 to EFI control unit connector AO (
p. 392) pin 1 for opens.

Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31) (
p. 273)
Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31)
Condition
Throttle position sensor circuit A is disconnected. ( p. 219)
600850-11
400658-10
Throttle position sensor circuit A - check the signal wire for a short circuit to ground (terminal 31)

Resistance

Check the cable from connector CP (

nal 31).
p. 392) pin 10 to connector CQ (
p. 398) pin 2.6 to connector AR (
p. 393) pin 2 for a short circuit to ground (termi-

Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground (
p. 274)
274
Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground
Condition
Throttle position sensor circuit A - check the signal wire for a short circuit to sensor ground

Resistance
Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for a short circuit to sensor ground.
Check the cable from connector CP ( p. 398) pin 2.6 to connector AR

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-11

Throttle position sensor circuit A - the signal wire has an open (
p. 274)
Throttle position sensor circuit A - the signal wire has an open

Condition
600850-11
400584-10
Throttle position sensor circuit A - check the signal wire for opens

Break Out Box AO pin 10 Throttle position sensor circuit A, connector AR pin 2
0.6
Resistance
Check connector CP (
p. 398) pin 6.
p. 398) pin 2.6 and connector AR pin 2.
p. 392) pin 10 and connector CQ (
p. 398) pin 2.6 to connector AR pin 2 for opens.
275

lamp (MIL)
P0123
"Throttle position sensor circuit A"
Throttle position sensor circuit A voltage "(THAD)": 4.824 V

Time: 3 s
Substitute value: 100 %
Function check
Throttle position sensor circuit A - checking the voltage (
Possible cause
Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)
( p. 275)
p. 275)
Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 276)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Throttle position sensor circuit A - the signal wire has a short circuit to the sensor power supply
( p. 276)
Throttle position sensor circuit A - the ground wire has an open (
p. 277)
Throttle position sensor circuit A - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Throttle position sensor voltage circuit A (THAD)" and deselect the other parameters with "Select live data".
0.56 4.20 V
Take a test ride.

Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30) (
Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)
Condition
p. 275)
276
600850-11
400658-10
Throttle position sensor circuit A - check the signal wire for a short circuit to plus (terminal 30)

0.1 V
Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

plus (terminal 30).

nal 30).
p. 398) pin 2.6 to connector AR (
p. 393) pin 2 for a short circuit to plus (termi-

Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 276)
Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
Throttle position sensor circuit A - check the signal wire for a short circuit to ignition plus
(terminal 15)

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for a short circuit to ignition plus (terminal 15).

( p. 393) pin 2 for a short circuit to ignition plus (terminal 15).

Throttle position sensor circuit A - the signal wire has a short circuit to the sensor power supply ( p. 276)
Throttle position sensor circuit A - the signal wire has a short circuit to the sensor power supply
Condition
Throttle position sensor circuit A - check the signal wire for a short circuit to the sensor
power supply

Resistance
600850-11
277
Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for a short circuit to the sensor power supply.

( p. 393) pin 2 for a short circuit to the sensor power supply.

Throttle position sensor circuit A - the ground wire has an open (
Throttle position sensor circuit A - the ground wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400584-10
Throttle position sensor circuit A - check the ground wire for opens
Break Out Box AO pin 7 Throttle position sensor circuit A, connector AR pin 3
0.6
Resistance
p. 398) pin 2.
p. 398) pin 2.2 and connector AR pin 3.
p. 398) pin 2.2 to connector AR pin 3 for opens.
p. 277)
278

lamp (MIL)
P0130
"Lambda sensor cylinder 1, sensor 1"
"Circuit fault"
Circuit fault: 60 s
Function check
Lambda sensor cylinder 1 - checking the voltage (
Possible cause
Lambda sensor cylinder 1 - value not plausible (
p. 278)
p. 278)
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
( p. 279)
Lambda sensor cylinder 1 - the signal wire has a short circuit to sensor ground (
p. 279)
Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) (
p. 280)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 280)
Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
( p. 280)
Lambda sensor cylinder 1 - the signal wire has an open (
Lambda sensor cylinder 1 - the ground wire has an open (
p. 281)
p. 281)
Lambda sensor cylinder 1 - checking the voltage

Condition
The engine is running at idle speed.
The engine is at operating temperature.
Select the model.
Press "Continue".
Mark "Lambda values".
Press "Continue".
Highlight "Lambda sensor cylinder 1 voltage (HEGO1AD)" and deselect the other parameters with "Select live data".
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD"
0.2 0.8 V
Take a test ride.

p. 278)
Lambda sensor cylinder 1 - value not plausible

Condition
The ignition is on.
Lambda sensor for cylinder 1 is connected. (
p. 62)
279
Lambda sensor cylinder 1 - check the voltage

Lambda sensor connector CECA pin 3 Lambda sensor connector CECA
pin 4
Lambda sensor
Lambda sensor cylinder 1 voltage
"HEGO1AD"
0.2 0.8 V
400686-10

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground
(terminal 31) ( p. 279)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-11
400658-10
Lambda sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31).

Resistance


p. 279)
Lambda sensor cylinder 1 - the signal wire has a short circuit to sensor ground
Condition
Lambda sensor cylinder 1 - check the signal wire for a short circuit to sensor ground.

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA ( p. 396) pin 4 for a short circuit to sensor ground.

Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 280)
280
Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400658-10
Lambda sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30).

Voltage
< 0.1 V

plus (terminal 30).

Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 280)
Condition
Lambda sensor cylinder 1 - check the signal wire for a short circuit to ignition plus
(terminal 15).

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).

Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor
Condition
281
Lambda sensor cylinder 1 - check the signal wire for a short circuit to the sensor power
supply.

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.

Lambda sensor cylinder 1 - the signal wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400646-10
Lambda sensor cylinder 1 - check the signal wire for opens.

Break Out Box AO pin 11 Lambda sensor cylinder 1, connector CA pin 4
0.6
Resistance

p. 281)
Lambda sensor cylinder 1 - the ground wire has an open

Condition
600850-11
400646-10
Lambda sensor cylinder 1 - check the ground wire for opens.

Resistance
0.6
p. 281)

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
282
283

lamp (MIL)
P0150
"Lambda sensor cylinder 2, sensor 1"
"Circuit fault"
Circuit fault: 60 s
Function check
Lambda sensor cylinder 2 - checking the voltage (
Possible cause
p. 283)
p. 283)
Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31) (
p. 284)
p. 284)
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) (
p. 285)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
( p. 285)
( p. 285)
p. 286)
p. 286)
Lambda sensor cylinder 2 - checking the voltage

Condition
Select the model.
Press "Continue".
Mark "Lambda values".
Press "Continue".
Highlight "Lambda sensor cylinder 2 voltage (HEGO2AD)" and deselect the other parameters with "Select live data".
Lambda sensor
Lambda sensor cylinder 2 voltage "HEGO2AD"
0.2 0.8 V
Take a test ride.

p. 283)
Lambda sensor cylinder 2 - value not plausible

Condition
The ignition is on.
Lambda sensor for cylinder 2 is connected. (
p. 62)
284
Lambda sensor cylinder 2 - check the voltage

Lambda sensor connector CECA pin 3 Lambda sensor connector CECA
pin 4
Lambda sensor
Lambda sensor cylinder 2 voltage
"HEGO2AD"
0.2 0.8 V
400686-10

Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31) ( p. 284)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-11
400658-10
Lambda sensor cylinder 2 - check the signal wire for a short circuit to ground (terminal 31).

Resistance


p. 284)
Lambda sensor cylinder 2 - the signal wire has a short circuit to sensor ground
Condition
Lambda sensor cylinder 2 - check the signal wire for a short circuit to sensor ground.

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA ( p. 396) pin 4 for a short circuit to sensor ground.

Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) ( p. 285)
285
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400658-10
Lambda sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30).

Voltage
< 0.1 V

plus (terminal 30).

Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 285)
Condition
Lambda sensor cylinder 2 - check the signal wire for a short circuit to ignition plus
(terminal 15).

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).

Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor
Condition
286
Lambda sensor cylinder 2 - check the signal wire for a short circuit to the sensor power
supply.

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.

Lambda sensor cylinder 2 - the signal wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400646-10
Lambda sensor cylinder 2 - check the signal wire for opens.

0.6
Resistance

p. 286)
Lambda sensor cylinder 2 - the ground wire has an open

Condition
600850-11
400646-10
Lambda sensor cylinder 2 - check the ground wire for opens.

Resistance
0.6
p. 286)

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
287
288

lamp (MIL)
P0201
"Injector cylinder 1"
"Circuit fault"
Circuit fault: 0.5 s
Function check
Injector cylinder 1 - checking the control (
Possible cause
Cylinder 1 injector - value not plausible (
p. 288)
p. 288)
Injector cylinder 1 - there is a power supply fault (
p. 289)
Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30) (
p. 289)
Injector cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15) (
Injector cylinder 1 - the control wire has a short circuit to the sensor power supply (
Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31) (
Injector cylinder 1 - the control wire has a short circuit to sensor ground (
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Injector cylinder 1".
Press "Continue".
Injector
Operating noise
Take a test ride.

Cylinder 1 injector - value not plausible (
p. 288)
Cylinder 1 injector - value not plausible

Condition
Injector cylinder 1 is disconnected. (
p. 225)
Cylinder 1 injector - check the resistance

Injector pin 1 Injector pin 2
Injector
400598-10
10.5 13.0
p. 291)
p. 292)
Injector cylinder 1 - checking the control
p. 290)
p. 291)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Injector cylinder 1 - the control wire has an open. (
p. 290)
289
Replace the injector cylinder 1.

Injector cylinder 1 - there is a power supply fault (
p. 289)
Injector cylinder 1 - there is a power supply fault

p. 225)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
400591-10
400658-10
Injector cylinder 1 - check the power supply

Injector cylinder 1 connector DQ pin 1 Measuring point Ground ()
Info
Check connector DQ pin 1 and connector CP (
Check the cable from connector DQ pin 1 to connector CP (
p. 398) pin 2.13.
p. 398) pin 13 to the next node in the wiring harness for opens.

p. 289)
Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30)
Condition
Injector cylinder 1 is disconnected. ( p. 225)
600850-12
400658-10
Injector cylinder 1 - check the control wire for a short circuit to plus (terminal 30).

Voltage
< 0.1 V

plus (terminal 30).

nal 30).
290
p. 398) pin 2.5 to connector DQ (

p. 290)
Injector cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Injector cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).

Resistance


(terminal 15).
p. 400) pin 2 for a short circuit to ignition plus

p. 290)
Injector cylinder 1 - the control wire has a short circuit to the sensor power supply
Condition
600850-12
600850-11
Injector cylinder 1 - check the control wire for a short circuit to the sensor power supply

Resistance

the sensor power supply.

power supply.
291
p. 400) pin 2 for a short circuit to the sensor

p. 291)
Injector cylinder 1 - the control wire has an open.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400591-10
Injector cylinder 1 - check the control wire for opens

Break out box CO pin 5 Injector cylinder 1 connector DQ pin 2
0.6
Resistance
p. 398) pin 5.
p. 398) pin 2.5 and connector DQ pin 2.
p. 398) pin 2.5 to connector DQ pin 2 for opens.

p. 291)
Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
Injector cylinder 1 - check the control wire for a short circuit to ground (terminal 31).

Resistance


nal 31).
292

p. 292)
Injector cylinder 1 - the control wire has a short circuit to sensor ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Injector cylinder 1 - check the control wire for a short circuit to sensor ground.

Resistance

sensor ground.
p. 400) pin 2 for a short circuit to sensor ground.
293

lamp (MIL)
P0202
"Injector cylinder 2"
"Circuit fault"
Circuit fault: 0.5 s
Function check
Injector cylinder 2 - checking the control (
Possible cause
Injector cylinder 2 - value not plausible (
p. 293)
p. 293)
Injector cylinder 2 - the power supply is faulty (
p. 294)
p. 294)
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Injector cylinder 2".
Press "Continue".
Injector
Operating noise
Take a test ride.

Injector cylinder 2 - value not plausible (
p. 293)
Injector cylinder 2 - value not plausible

Condition
p. 225)
Injector cylinder 2 - check the resistance

Injector pin 1 Injector pin 2
Injector
400598-10
10.5 13.0
p. 296)
p. 297)
Injector cylinder 2 - checking the control
p. 295)
p. 296)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 295)
294
Change the injector cylinder 2.

Injector cylinder 2 - the power supply is faulty (
p. 294)
Injector cylinder 2 - the power supply is faulty

p. 225)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
400591-10
400658-10
Injector cylinder 2 - check the power supply

Injector cylinder 2 connector DQ pin 1 Measuring point Ground ()
Info
Check connector DQ pin 1 and connector CP (
Check the cable from connector DQ pin 1 to connector CP (
p. 398) pin 2.13.

p. 294)
Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
Injector cylinder 2 - check the control wire for a short circuit to plus (terminal 30).

Voltage
< 0.1 V

plus (terminal 30).

nal 30).
295

p. 295)
Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Injector cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).

Resistance


(terminal 15).

p. 295)
Injector cylinder 2 - the control wire has a short circuit to the sensor power supply
Condition
600850-12
600850-11
Injector cylinder 2 - check the control wire for a short circuit to the sensor power supply

Resistance

the sensor power supply.

power supply.
296
p. 401) pin 2 for a short circuit to the sensor

p. 296)
Injector cylinder 2 - the control wire has an open.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400591-10
Injector cylinder 2 - check the control wire for opens

Break out box CO pin 6 Injector cylinder 2 connector DQ pin 2
0.6
Resistance
p. 398) pin 9.
p. 398) pin 2.9 and connector DQ pin 2.
p. 398) pin 2.9 to connector DQ pin 2 for opens.

p. 296)
Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
Injector cylinder 2 - check the control wire for a short circuit to ground (terminal 31).

Resistance


nal 31).
297

p. 297)
Injector cylinder 2 - the control wire has a short circuit to sensor ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Injector cylinder 2 - check the control wire for a short circuit to sensor ground.

Resistance

sensor ground.
298

lamp (MIL)
P0222
"Throttle position sensor circuit B"
Throttle position sensor circuit B, voltage "TAPAD": 0.156 V

Time: 3 s
Function check
Throttle position sensor circuit B - checking the voltage (
Possible cause
Throttle position sensor circuit B - the power supply is interrupted (
p. 298)
p. 298)
Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31)
( p. 299)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground (
Throttle position sensor circuit B - the signal wire has an open (
p. 300)
Throttle position sensor circuit B - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".
Voltage "TAPAD"
0.156 4.824 V
Take a test ride.

Throttle position sensor circuit B - the power supply is interrupted (
Throttle position sensor circuit B - the power supply is interrupted

Condition
The ignition is on.
Throttle position sensor circuit B is disconnected. (
p. 223)
p. 298)
p. 300)
299
400582-10
400658-10
Throttle position sensor circuit B - check the power supply

Throttle position sensor circuit B, connector AM pin 2 Measuring point Ground ()

Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
4.9 5.1 V
Check connector AM pin 2 and connector CP (
Check the cable from connector AM pin 2 to connector CP (
Check connector CQ (
p. 398) pin 2.14.
p. 398) pin 14 and EFI control unit connector AO (
p. 392) pin 1.
p. 398) pin 14 to EFI control unit connector AO (

Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31) (
p. 299)
Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31)
Condition
Throttle position sensor circuit B is disconnected. ( p. 223)
600850-11
400658-10
Throttle position sensor circuit B - check the signal wire for a short circuit to ground (terminal 31)

Resistance


nal 31).
p. 398) pin 2.10 to connector AM (

Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground (
p. 300)
300
Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground
Condition
Throttle position sensor circuit B - check the signal wire for a short circuit to sensor ground

Resistance
Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit to sensor ground.
Check the cable from connector CP ( p. 398) pin 2.10 to connector AM

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-11

Throttle position sensor circuit B - the signal wire has an open (
p. 300)
Throttle position sensor circuit B - the signal wire has an open

Condition
600850-11
400582-10
Throttle position sensor circuit B - check the signal wire for opens

Break Out Box AO pin 2 Throttle position sensor circuit B, connector AM pin 1
0.6
Resistance
p. 398) pin 10.
p. 398) pin 2.10 and connector AM pin 1.
p. 398) pin 2.10 to connector AM pin 1 for opens.
301

lamp (MIL)
P0223
"Throttle position sensor circuit B"
Throttle position sensor circuit B, voltage "TAPAD": 4.824 V

Time: 3 s
Function check
Throttle position sensor circuit B - checking the voltage (
Possible cause
Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30)
( p. 301)
p. 301)
Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 302)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Throttle position sensor circuit B - the signal wire has a short circuit to the sensor power supply
( p. 302)
Throttle position sensor circuit B - the ground wire has an open (
p. 303)
Throttle position sensor circuit B - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".
Voltage "TAPAD"
0.156 4.824 V
Take a test ride.

Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30) (
Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30)
Condition
p. 301)
302
600850-11
400658-10
Throttle position sensor circuit B - check the signal wire for a short circuit to plus (terminal 30)

0.1 V
Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

plus (terminal 30).

nal 30).
p. 398) pin 2.10 to connector AM (

Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 302)
Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
Throttle position sensor circuit B - check the signal wire for a short circuit to ignition plus
(terminal 15)

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit to ignition plus (terminal 15).

( p. 392) pin 1 for a short circuit to ignition plus (terminal 15).

Throttle position sensor circuit B - the signal wire has a short circuit to the sensor power supply ( p. 302)
Throttle position sensor circuit B - the signal wire has a short circuit to the sensor power supply
Condition
Throttle position sensor circuit B - check the signal wire for a short circuit to the sensor
power supply

Resistance
600850-11
303
Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit to the sensor power supply.

( p. 392) pin 1 for a short circuit to the sensor power supply.

Throttle position sensor circuit B - the ground wire has an open (
Throttle position sensor circuit B - the ground wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400582-10
Throttle position sensor circuit B - check the ground wire for opens
Break Out Box AO pin 7 Throttle position sensor circuit B, connector AM pin 3
0.6
Resistance
p. 398) pin 2.
p. 398) pin 2.2 and connector AM pin 3.
p. 398) pin 2.2 to connector AM pin 3 for opens.
p. 303)
304

lamp (MIL)
P0335
"Circuit crankshaft position sensor"
"Circuit fault"
The manifold absolute pressure sensor delivers a normal signal (engine running), while the
crankshaft position sensor does not generate any signal at all.
The engine is switched off: 0.1 s
Function check
Crankshaft position sensor - checking the signal (
p. 304)
Possible cause
Crankshaft position sensor - value not plausible (
p. 304)
Crankshaft position sensor - the signal wire has an open (
p. 305)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)
( p. 305)
Crankshaft position sensor - the signal wires have a short circuit to sensor ground (
p. 306)
Crankshaft position sensor - the signal wires have a short circuit to plus (terminal 30) (
p. 306)
Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15)
( p. 307)
Crankshaft position sensor - the signal wire has a short circuit to the sensor power supply
( p. 307)
Crankshaft position sensor - checking the signal

Condition
The ignition is on.
Select the model.
Press "Continue".
Highlight "electric starter".
Press "Continue".
Highlight "Engine speed (NE)" and deselect the other parameters with "Select live data".
Perform the start procedure.

"Engine speed (NE)"
Starter rpm
Take a test ride.

Crankshaft position sensor - value not plausible (
p. 304)
Crankshaft position sensor - value not plausible

Condition
The crankshaft position sensor is disconnected. (
p. 218)
305
Crankshaft position sensor - check the resistance

Crankshaft position sensor, connector AT pin 1 Crankshaft position sensor,
connector AT pin 2
80 120
400585-10
Replace the crankshaft position sensor.

Crankshaft position sensor - the signal wire has an open (
p. 305)
Crankshaft position sensor - the signal wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The crankshaft position sensor is connected. ( p. 218)
Crankshaft position sensor - check the signal wire for opens

80 120
600850-11
Check connector AL (

nector AL ( p. 391) pin 2 for opens.
p. 392) pin 14 to con-

nector AL ( p. 391) pin 1 for opens.
p. 392) pin 14 and pin 13.
p. 391) pin 2 and connector AL pin 1.

Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31) ( p. 305)
Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)
Condition
600850-11
400658-10
Crankshaft position sensor - check the signal wires for a short circuit to ground (terminal 31)

Resistance
306

p. 392) pin 14 to connector AL (


Crankshaft position sensor - the signal wires have a short circuit to sensor ground (
p. 306)
Crankshaft position sensor - the signal wires have a short circuit to sensor ground
Condition
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Crankshaft position sensor - check the signal wires for a short circuit to sensor ground

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 14 to connector AL ( p. 391) pin 2 for a short circuit to sensor ground.
Check the cable from EFI control unit connector AO ( p. 392) pin 13 to connector AL ( p. 391) pin 1 for a short circuit to sensor ground.

Crankshaft position sensor - the signal wires have a short circuit to plus (terminal 30) ( p. 306)
Crankshaft position sensor - the signal wires have a short circuit to plus (terminal 30)
Condition
600850-11
400658-10
Crankshaft position sensor - check the signal wires for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

plus (terminal 30).

Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15) (
p. 307)
307
Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15)
Condition
Crankshaft position sensor - check the signal wire for a short circuit to ignition plus
(terminal 15)

Resistance

Check the cable from EFI control unit connector AO ( p. 392) pin 14 to connector AL ( p. 391) pin 2 for a short circuit to ignition plus (terminal 15).
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 13 to connector AL ( p. 391) pin 1 for a short circuit to ignition plus (terminal 15).

Crankshaft position sensor - the signal wire has a short circuit to the sensor
Crankshaft position sensor - the signal wire has a short circuit to the sensor power supply
Condition
Crankshaft position sensor - check the signal wire for a short circuit to the sensor power
supply

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 14 to connector AL ( p. 391) pin 2 for a short circuit to the sensor power supply.
Check the cable from EFI control unit connector AO ( p. 392) pin 13 to connector AL ( p. 391) pin 1 for a short circuit to the sensor power supply.
308

lamp (MIL)
P0351
"Ignition coil cylinder 1"
"Circuit fault"
Circuit fault.
Function check
Checking the ignition coil cylinder 1 (
Possible cause
Ignition coil cylinder 1 - value not plausible (
p. 308)
p. 308)
Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31) (
Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground (
p. 309)
p. 309)
Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30) (
p. 310)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)
( p. 310)
Ignition coil cylinder 1 - the control wire has an open (
p. 311)
Ignition coil cylinder 1 - the power supply is interrupted (
p. 312)
Checking the ignition coil cylinder 1
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Ignition cylinder 1".
Press "Continue".
Spark plug
Operating noise
Take a test ride.

p. 308)
Ignition coil cylinder 1 - value not plausible

Condition
Ignition coil cylinder 1 is disconnected. (
p. 218)
309
Ignition coil cylinder 1 - check the resistance

Ignition coil pin 1 Ignition coil pin 2
Ignition coil
Primary winding resistance at: 20 C
(68 F)
600851-10
1.105 1.495
Replace the ignition coil cylinder 1.

Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 309)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31)
Condition
Ignition coil cylinder 1 is disconnected. ( p. 218)
600850-12
400658-10
Ignition coil cylinder 1 - check the control wire for a short circuit to ground (terminal 31).

Resistance

p. 397) pin 29 to connector AS (

p. 309)
Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground
Condition
310
600850-12
600850-11
Ignition coil cylinder 1 - check the control wire for a short circuit to sensor ground.
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

sensor ground.

p. 310)
Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
Ignition coil cylinder 1 - check the control wire for a short circuit to plus (terminal 30).

Voltage
< 0.1 V

plus (terminal 30).

Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15) (
p. 310)
Condition
311
600850-12
600850-11
Ignition coil cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m


p. 311)
Ignition coil cylinder 1 - the control wire has an open

Condition
400644-10
400658-10
Ignition coil cylinder 1 - check the control wire for opens

Ignition coil cylinder 1 connector AS pin 1 Measuring point Ground ()
Info
Establish a secure connection from the battery plus terminal to the break out box CO pin 29.
p. 397) pin 29 and connector AS pin 1.

p. 397) pin 29 to connector AS pin 1 for opens.

p. 312)
312
Ignition coil cylinder 1 - the power supply is interrupted
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
400644-10
400658-10
Ignition coil cylinder 1 - check the power supply

Info
Check connector AS pin 2.
Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.
313

lamp (MIL)
P0352
"Ignition coil cylinder 2"
"Circuit fault"
Circuit fault.
Function check
Checking the ignition coil cylinder 2 (
Possible cause
p. 313)
p. 313)
Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31) (
p. 314)
p. 314)
p. 315)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
( p. 315)
p. 316)
p. 317)
Checking the ignition coil cylinder 2
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Ignition cylinder 2".
Press "Continue".
Spark plug
Operating noise
Take a test ride.

p. 313)
Ignition coil cylinder 2 - value not plausible

Condition
Ignition coil cylinder 2 is disconnected. (
p. 218)
314
Ignition coil cylinder 2 - check the resistance

Ignition coil pin 1 Ignition coil pin 2
Ignition coil
Primary winding resistance at: 20 C
(68 F)
600851-10
1.105 1.495
Change the ignition coil cylinder 2.

Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 314)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
Ignition coil cylinder 2 - check the control wire for a short circuit to ground (terminal 31).

Resistance


p. 314)
Ignition coil cylinder 2 - the control wire has a short circuit to sensor ground
Condition
315
600850-12
600850-11
Ignition coil cylinder 2 - check the control wire for a short circuit to sensor ground.
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

sensor ground.

p. 315)
Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
Ignition coil cylinder 2 - check the control wire for a short circuit to plus (terminal 30).

Voltage
< 0.1 V

plus (terminal 30).

Ignition coil cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15) (
p. 315)
Condition
316
600850-12
600850-11
Ignition coil cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m


p. 316)
Ignition coil cylinder 2 - the control wire has an open

Condition
400644-10
400658-10
Ignition coil cylinder 2 - check the control wire for opens

Info
Establish a protected connection from battery plus to break out box CO pin 26.
p. 397) pin 26 and connector AS pin 1.

p. 397) pin 26 to connector AS pin 1 for opens.

p. 317)
317
Ignition coil cylinder 2 - the power supply is interrupted
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
400644-10
400658-10
Ignition coil cylinder 2 - check the power supply

Info
Check connector AS pin 2.
Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.
318

lamp (MIL)
P0413
"Secondary air valve "
The control unit is active.

Circuit fault: 3 s
Function check
Checking the secondary air valve (
Possible cause
Secondary air valve - value not plausible (
p. 318)
p. 318)
Secondary air valve - the control wire has a short circuit to ground (terminal 31) (
Secondary air valve - the control wire has an open (
Secondary air valve - the power supply is faulty (
p. 320)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Secondary air valve - the control wire has a short circuit to sensor ground (
p. 319)
p. 319)
p. 320)
p. 321)
Checking the secondary air valve
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Exhaust air injection valve SLS on/off".
Press "Continue".
Secondary air valve
Operating noise
Take a test ride.

p. 318)
Secondary air valve - value not plausible
Condition
The exhaust air injection valve is disconnected. (
p. 190)
Secondary air valve - check the resistance

Exhaust air injection valve, connector FE pin 1 Exhaust air injection valve,
connector FE pin 2
Secondary air valve
at: 20 C (68 F)
600854-10
18.0 22.0
319
Change the secondary air valve.

Secondary air valve - the control wire has a short circuit to ground (terminal 31)
( p. 319)
p. 190)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600854-10
400658-10
Secondary air valve - check the control wire for a short circuit to ground (terminal 31)

Exhaust air injection valve, connector FE pin 2 Measuring point Ground ()
Resistance

Secondary air valve - the control wire has an open (
p. 319)
Secondary air valve - the control wire has an open
Condition
The exhaust air injection valve is disconnected. ( p. 190)
600850-12
400648-10
Secondary air valve - check the control wire for opens

Break out box CO pin 13 Secondary air valve connector CK pin 2
0.6
Resistance
p. 397) pin 13 and connector CK pin 2.

p. 397) pin 13 to connector CK pin 2 for opens.

Secondary air valve - the power supply is faulty (
p. 320)
320
Secondary air valve - the power supply is faulty

Condition
The ignition is on.
p. 190)
400658-10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400648-10
Secondary air valve - check the power supply

Secondary air valve connector CK pin 1 Measuring point Ground ()
Info
Check connector CK pin 1.
Check the cable from connector CK pin 1 to the next node in the wiring harness for opens.

p. 320)
Condition
400648-10
400658-10
Secondary air valve - check the control wire for a short circuit to ground (terminal 31)

Secondary air valve connector CK pin 2 Measuring point Ground ()
Resistance

minal 31).
p. 397) pin 13 to connector CK pin 2 for a short circuit to ground (ter-

Secondary air valve - the control wire has a short circuit to sensor ground (
p. 321)
321
Secondary air valve - the control wire has a short circuit to sensor ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Secondary air valve - check the control wire for a short circuit to sensor ground.

Resistance

sensor ground.
p. 397) pin 13 to connector CK (
322

lamp (MIL)
P0414
"Secondary air valve "
Circuit fault: 3 s
Function check
Checking the secondary air valve (
Possible cause
p. 322)
p. 322)
Secondary air valve - the signal wire has a short circuit to plus (terminal 30) (
p. 323)
Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15) (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 323)
Checking the secondary air valve
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Exhaust air injection valve SLS on/off".
Press "Continue".
Secondary air valve
Operating noise
Take a test ride.

p. 322)
Secondary air valve - value not plausible
Condition
p. 190)
Secondary air valve - check the resistance

Exhaust air injection valve, connector FE pin 1 Exhaust air injection valve,
connector FE pin 2
Secondary air valve
at: 20 C (68 F)
600854-10
18.0 22.0

Secondary air valve - the signal wire has a short circuit to plus (terminal 30)
( p. 323)
323
Secondary air valve - the signal wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Secondary air valve - check the signal wire for a short circuit to plus (terminal 30)

0.1 V
Voltage

plus (terminal 30).

Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 323)
Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
600850-12
600850-11
Secondary air valve - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance

324

lamp (MIL)
P0505
"Circuit A of motor drive "
"Circuit fault"
Circuit fault: 3 s
Function check
Motor drive circuit A - checking the control (
Possible cause
Motor drive circuit A phase A - value not plausible (
p. 325)
Motor drive circuit A phase B - value not plausible (
p. 325)
p. 324)
Motor drive circuit A phase A - the signal wire has an open (
p. 325)
Motor drive circuit A phase B - the signal wire has an open (
p. 326)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31)
( p. 326)
Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31)
( p. 327)
Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground (
p. 328)
Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground (
p. 328)
Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30) (
p. 329)
Motor drive circuit A phase B - the signal wire has a short circuit to plus (terminal 30) (
p. 329)
Motor drive circuit A phase A - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 330)
Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 330)
Motor drive circuit A - checking the control

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "motor drive circuit A".
Press "Continue".
Idle speed control
Operating noise
Take a test ride.

Motor drive circuit A phase A - value not plausible (
p. 325)
325
Motor drive circuit A phase A - value not plausible

Condition
Connector CP is disconnected. (
p. 398)
Motor drive circuit A phase A - check the resistance

Connector CP pin 2.12 Connector CP pin 2.16

Motor drive circuit A
7.11 8.68
Phase A at: 20 C (68 F)
Check connector CP pin 2.12 and connector AE (
Check the connector from CP pin 2.12 to connector AE (

opens.

opens.
Disconnect connector CQ ( p. 398) from the throttle valve body. Check the
cable from connector CP pin 2.12 to pin 2.16 for a mutual short circuit.
Change the throttle valve body.
p. 391) pin 2.
p. 391) pin 2 for
p. 391) pin 3.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400651-10
p. 391) pin 3 for

Motor drive circuit A phase B - value not plausible (
p. 325)
Motor drive circuit A phase B - value not plausible
Condition
p. 398)
Motor drive circuit A phase B - check the resistance

Phase B at: 20 C (68 F)
400651-10
7.11 8.68

opens.

opens.
p. 391) pin 4.
p. 391) pin 4 for
p. 391) pin 1.
p. 391) pin 1 for

Motor drive circuit A phase A - the signal wire has an open (
Motor drive circuit A phase A - the signal wire has an open

Condition
Connector CP is connected. ( p. 398)
p. 325)
326
Motor drive circuit A phase A - check the signal wire for opens

Break out box CO pin 7 Break out box CO pin 23

( p. 398) pin 12.

nector CQ ( p. 398) pin 12 for opens.

( p. 398) pin 16.

p. 397) pin 7 and connector CQ


P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-12
7.11 8.68
cable from EFI control unit connector CO ( p. 392) pin 7 to pin 23 for a
mutual short circuit.

Motor drive circuit A phase B - the signal wire has an open (
p. 326)
Motor drive circuit A phase B - the signal wire has an open
Condition
Motor drive circuit A phase B - check the signal wire for opens

600850-12
7.11 8.68

( p. 398) pin 4.


( p. 398) pin 8.




Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31) ( p. 326)
Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31)
Condition
327
600850-12
400658-10
Motor drive circuit A phase A - check the signal wire for a short circuit to ground (terminal 31)
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m


nal 31).


nal 31).
p. 398) pin 2.16 to connector AE (

Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31) (
p. 327)
Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
Motor drive circuit A phase B - check the signal wire for a short circuit to ground (terminal 31)

Resistance


p. 391) pin 1 for a short circuit to ground (terminal 31).

Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground (
p. 328)
328
Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground
Condition
600850-11
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-12
Motor drive circuit A phase A - check the signal wire for a short circuit to sensor ground
Resistance

sensor ground.

sensor ground.

Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground (
p. 328)
Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground
Condition
600850-12
600850-11
Motor drive circuit A phase B - check the signal wire for a short circuit to sensor ground

Resistance

sensor ground.

sensor ground.
329

Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30) (
p. 329)
Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Motor drive circuit A phase A - check the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

nal 30).

plus (terminal 30).

nal 30).

Motor drive circuit A phase B - the signal wire has a short circuit to plus (terminal 30) (
p. 329)
Motor drive circuit A phase B - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
Motor drive circuit A phase B - check the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

plus (terminal 30).
330
p. 391) pin 1 for a short circuit to plus (terminal 30).

Motor drive circuit A phase A - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 330)
Motor drive circuit A phase A - the signal wire has a short circuit to ignition plus (terminal 15)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Motor drive circuit A phase A - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance


(terminal 15).


(terminal 15).

Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 330)
Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
600850-12
600850-11
Motor drive circuit A phase B - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance


p. 391) pin 1 for a short circuit to ignition plus (terminal 15).
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
331
332

lamp (MIL)
P0560
"Power supply"
"Circuit fault"
EFI control unit power supply: 0.977 V

Time: 3 s
EFI control unit power supply: 4.980 V
Time: 3 s
Function check
EFI control unit - checking the power supply (
Possible cause
EFI control unit - the power supply is faulty (
p. 332)
p. 332)
EFI control unit - the ground wire (I) has an open (
p. 333)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
EFI control unit - the ground wire (II) has an open (
p. 333)
Change the ambient air pressure sensor.
EFI control unit - checking the power supply

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Battery voltage (VBAT)" and deselect the other parameters with "Select live data".
Take a test ride.

EFI control unit - the power supply is faulty (
p. 332)
EFI control unit - the power supply is faulty
Condition
The ignition is on.
The break out box is connected to the EFI control unit and the wiring harness.
600850-11
EFI control unit - check the power supply

400658-10
333
Info
Check connector AO (
Check the cable from connector AO (
p. 392) pin 20.


EFI control unit - the ground wire (I) has an open (
p. 333)
EFI control unit - the ground wire (I) has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
600850-12
400658-10
EFI control unit - the ground wire (I) has an open

Break out box CO pin 8 Measuring point Plus (+)
Info
Check connector CO (
Check the cable from connector CO (
p. 397) pin 8.

EFI control unit - the ground wire (II) has an open (
p. 333)
EFI control unit - the ground wire (II) has an open
Condition
The ignition is on.
600850-12
EFI control unit - the ground wire (II) has an open

Break out box CO pin 9 Measuring point Plus (+)
400658-10

Info
Check connector CO (
Check the cable from connector CO (
p. 397) pin 9.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
334
335

lamp (MIL)
P0603
"EPROM"
"Fault"
Read data and write data differ.
Function check
Flashing the EFI control unit (
p. 335)
Change the EFI control unit.
Flashing the EFI control unit
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
400687-60
Select the model.
Press "Continue".
Select "ECU Flashing".
Press "Continue".
Read the safety information and set up the required conditions.
Confirm the instruction by clicking on "OK".
Press "Select file" and select the new mapping.
Info
"The BLZ file and the exhaust system must match!"
Press the "ECU flash process" button.
Read the safety notice and confirm with "OK".

The new mapping is loaded.
Change the EFI control unit.
336

lamp (MIL)
50 EFI warning lamp (MIL) flashes 5x long
P0638
"Throttle position sensor actuator circuit B"
"Circuit fault"
Difference between calculated "2nd throttle target angle (STHTRG)" and actual "2nd throttle current
angle (2ndTHAngle)"
Intake air temperature sensor "TA": > 1 C (> 34 F)
25.5 s
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Difference between calculated "2nd throttle target angle (STHTRG)" and actual "2nd throttle current
angle (2ndTHAngle)"
Intake air temperature sensor "TA": 1 C ( 34 F)
Engine coolant temperature sensor "TW": > 1 C (> 34 F)
25.5 s
Function check
Checking circuit B of the motor drive (
Possible cause
Motor drive circuit B phase A - value not plausible (
p. 337)
Motor drive circuit B phase B - value not plausible (
p. 337)
p. 336)
Motor drive circuit B phase A - the signal wire has an open (
p. 338)
Motor drive circuit B phase B - the signal wire has an open (
p. 338)
Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31)
( p. 339)
Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31)
( p. 339)
Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground (
p. 340)
Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground (
p. 340)
Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30) (
p. 341)
Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30) (
p. 341)
Motor drive circuit B phase A - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 342)
Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 342)
Checking circuit B of the motor drive
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Motor drive circuit B".
Press "Continue".
Voltage "TAPAD"
Take a test ride.
0.156 4.824 V
337

Motor drive circuit B phase A - value not plausible (
p. 337)
Motor drive circuit B phase A - value not plausible

Condition
p. 398)
Motor drive circuit B phase A - check the resistance

Motor drive circuit B
5.85 7.15
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400651-10
Check connector CP pin 2.15 and connector CA (
Check the connector from CP pin 2.15 to connector CA (

opens.

opens.
Disconnect connector CA ( p. 395) from motor drive circuit B. Check the

p. 395) pin 1.
p. 395) pin 1 for
p. 395) pin 3.
p. 395) pin 3 for

Motor drive circuit B phase B - value not plausible (
p. 337)
Motor drive circuit B phase B - value not plausible
Condition
p. 398)
Motor drive circuit B phase B - check the resistance

400651-10
5.85 7.15

opens.

opens.
Disconnect connector CA ( p. 395) from motor drive circuit B. Check the

p. 395) pin 4.
p. 395) pin 4 for
p. 395) pin 2.
p. 395) pin 2 for

Motor drive circuit B phase A - the signal wire has an open (
p. 338)
338
Motor drive circuit B phase A - the signal wire has an open

Condition
Motor drive circuit B phase A - check the signal wire for opens

5.85 7.15

( p. 398) pin 15.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-12


( p. 398) pin 11.

Disconnect connector CQ ( p. 398) from motor drive circuit B. Check the



Motor drive circuit B phase B - the signal wire has an open (
p. 338)
Motor drive circuit B phase B - the signal wire has an open
Condition
Motor drive circuit B phase B - check the signal wire for opens

600850-12
5.85 7.15

( p. 398) pin 3.


( p. 398) pin 7.

Disconnect connector CQ ( p. 398) from motor drive circuit B. Check the




Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31) ( p. 339)
339
Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31)
Condition
400658-10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-12
Motor drive circuit B phase A - check the signal wire for a short circuit to ground (terminal 31)
Resistance


p. 398) pin 2.11 to connector CA (

Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31) (
p. 339)
Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
Motor drive circuit B phase B - check the signal wire for a short circuit to ground (terminal 31)

Resistance


340

Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground (
p. 340)
Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Motor drive circuit B phase A - check the signal wire for a short circuit to sensor ground
Resistance

sensor ground.

sensor ground.

Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground (
p. 340)
Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground
Condition
600850-12
600850-11
Motor drive circuit B phase B - check the signal wire for a short circuit to sensor ground

Resistance

sensor ground.

sensor ground.
341

Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30) (
p. 341)
Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Motor drive circuit B phase A - check the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

plus (terminal 30).

Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30) (
p. 341)
Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
Motor drive circuit B phase B - check the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

plus (terminal 30).
342

Motor drive circuit B phase A - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 342)
Motor drive circuit B phase A - the signal wire has a short circuit to ignition plus (terminal 15)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
Motor drive circuit B phase A - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance



Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 342)
Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
600850-12
600850-11
Motor drive circuit B phase B - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance


P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
343
344

lamp (MIL)
P1105
"Connection leaks"
The ambient air pressure is greater than the pressure at the manifold absolute pressure sensor
cylinder 1
Time: 3 s
Function check
Possible cause
Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty
( p. 345)
p. 344)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head is
faulty ( p. 345)

Condition
The ignition is on.
Connect the vacuum hand pump to the manifold absolute pressure sensor. (
Create a vacuum with the vacuum pump.
Select the model.
Press "Continue".
p. 224)
Press "Continue".
at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.

Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty (
p. 345)
345
Manifold absolute pressure sensor cylinder 1 - check the vacuum hose to the cylinder head for leaks.
Vacuum hose
Is OK.
Change the vacuum hose to the cylinder head.

Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head is faulty (
p. 345)
Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head is faulty
Manifold absolute pressure sensor cylinder 1 - check the vacuum connection at the cylinder head.
Vacuum connection
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Is OK.
Change the vacuum connection at the cylinder head.
346

lamp (MIL)
P1106
"Connection leaks"
The ambient air pressure is greater than the pressure at the manifold absolute pressure sensor
cylinder 2
Time: 3 s
Function check
Possible cause
( p. 347)
p. 346)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head is
faulty ( p. 347)
Change the manifold absolute pressure sensor cylinder 2.

Condition
The ignition is on.
Connect the vacuum hand pump to the manifold absolute pressure sensor. (
Create a vacuum with the vacuum pump.
Select the model.
Press "Continue".
p. 224)
Press "Continue".
at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.

Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty (
p. 347)
347
Manifold absolute pressure sensor cylinder 2 - check the vacuum hose to the cylinder head for leaks.
Vacuum hose
Is OK.
Change the vacuum hose to the cylinder head.

Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head is faulty (
p. 347)
Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head is faulty
Manifold absolute pressure sensor cylinder 2 - check the vacuum connection at the cylinder head.
Vacuum connection
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Is OK.
Change the vacuum connection at the cylinder head.
348

lamp (MIL)
P1107
"Ambient air pressure sensor "
Ambient air pressure sensor voltage "PAAD": 0.508 V

Time: 3 s
Function check
Ambient air pressure sensor - checking the voltage (
Possible cause
Ambient air pressure sensor - the signal wire has a short circuit to sensor ground (
p. 348)
p. 348)
Ambient air pressure sensor - the signal wire has a short circuit to ground (terminal 31)
( p. 349)
p. 349)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Ambient air pressure sensor - the power supply is interrupted (

Ambient air pressure sensor - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Ambient air pressure sensor voltage (PAAD)" and deselect the other parameters with "Select live data".
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.

Ambient air pressure sensor - the signal wire has a short circuit to sensor ground (
p. 348)
Ambient air pressure sensor - the signal wire has a short circuit to sensor ground
Condition
The ambient air pressure sensor is disconnected. (
p. 225)
349
Ambient air pressure sensor - check the signal wire for a short circuit to sensor ground

Ambient air pressure sensor connector DP pin 2 Ambient air pressure sensor connector DP pin 3
Resistance
400590-10

Ambient air pressure sensor - the signal wire has a short circuit to ground (terminal 31) ( p. 349)
Ambient air pressure sensor - the signal wire has a short circuit to ground (terminal 31)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
p. 225)
400590-10
400658-10
Ambient air pressure sensor - check the signal wire for a short circuit to ground (terminal 31)

Ambient air pressure sensor connector DP pin 3 Measuring point Ground ()
Resistance
minal 31).

Ambient air pressure sensor - the power supply is interrupted (
p. 349)
Ambient air pressure sensor - the power supply is interrupted

Condition
The ignition is on.
p. 225)
400590-10
400658-10
Ambient air pressure sensor - check the power supply

Ambient air pressure sensor connector DP pin 1 Measuring point Ground ()
Voltage
4.9 5.1 V
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
350
351

lamp (MIL)
P1108
"Ambient air pressure sensor "
Ambient air pressure sensor voltage "PAAD": 4.961 V

Time: 3 s
Function check
Ambient air pressure sensor - checking the voltage (
Possible cause
Ambient air pressure sensor - the signal wire has an open (
p. 351)
Ambient air pressure sensor - the ground wire has an open (
p. 352)
p. 352)
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) (
p. 353)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supply
( p. 353)
Ambient air pressure sensor - checking the voltage

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Ambient air pressure sensor voltage (PAAD)" and deselect the other parameters with "Select live data".
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.

Ambient air pressure sensor - the signal wire has an open (
p. 352)
352
Ambient air pressure sensor - the signal wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ambient air pressure sensor is disconnected. ( p. 225)
600850-11
400590-10
Ambient air pressure sensor - check the signal wire for opens
Break Out Box AO pin 23 Ambient air pressure sensor connector DP pin 3
0.6
Resistance

Ambient air pressure sensor - the ground wire has an open (
p. 352)
Ambient air pressure sensor - the ground wire has an open

Condition
600850-11
400590-10
Ambient air pressure sensor - check the ground wire for opens

Break Out Box AO pin 7 Ambient air pressure sensor connector DP pin 2
0.6
Resistance


Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) (
p. 353)
353
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400658-10
Ambient air pressure sensor - check the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
Ambient air pressure sensor - check the signal wire for a short circuit to ignition plus
(terminal 15)

Resistance
600850-11

Ambient air pressure sensor - the signal wire has a short circuit to the sensor
Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supply
Condition
p. 223)
354
Ambient air pressure sensor - check the signal wire for a short circuit to the sensor power
supply

Resistance
600850-11

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
355

lamp (MIL)
P1231
"Fuel pump relay"
Circuit fault.
The engine is switched off: 3 s
Function check
Checking the fuel pump relay (
Possible cause
Fuel pump relay - value not plausible (
p. 355)
p. 355)
Fuel pump relay - the control wire has an open (
p. 356)
Fuel pump relay - there is an open in the power supply (
p. 356)
Fuel pump relay - the control wire has a short circuit to ground (terminal 31) (
Checking the fuel pump relay
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Fuel pump relay function test".
Press "Continue".
Fuel pump
Operating noise
Take a test ride.

p. 355)
Fuel pump relay - value not plausible
Condition
The fuel pump relay is disconnected. (
p. 404)
Fuel pump relay - check the resistance

Fuel pump relay pin 1 Fuel pump relay pin 2
Fuel pump relay
600852-10
Replace the fuel pump relay.
72 88
p. 357)
p. 357)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Fuel pump relay - the control wire has a short circuit to sensor ground (
356

Fuel pump relay - the control wire has an open (
p. 356)
Fuel pump relay - the control wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The fuel pump relay is disconnected. ( p. 404)
600850-12
400653-10
Fuel pump relay - check the control wire for opens

Break out box CO pin 2 Fuel pump relay connector EB pin 2
0.6
Resistance
Check connector ET (
Check the cable from connector ET (
p. 397) pin 2 and connector ES (
p. 402) pin 15.
p. 397) pin 2 to connector ES (
p. 402) pin 15 and connector EB (
p. 402) pin 15 to connector EB (

Fuel pump relay - there is an open in the power supply (
p. 356)
Fuel pump relay - there is an open in the power supply

Condition
The ignition is on.
400653-10
400658-10
Fuel pump relay - check the power supply

Fuel pump relay connector EB pin 1 Measuring point Ground ()
Info
Establish a protected connection from battery ground to break out box EB pin 1.
Check connector EB pin 1.
p. 401) pin 2.
357
Check the cable from connector EB pin 1 to the next node in the wiring harness for opens.

Fuel pump relay - the control wire has a short circuit to ground (terminal 31) (
p. 357)
Fuel pump relay - the control wire has a short circuit to ground (terminal 31)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Fuel pump relay - check the control wire for a short circuit to ground (terminal 31)

Resistance


nal 31).

Fuel pump relay - the control wire has a short circuit to sensor ground (
p. 357)
Fuel pump relay - the control wire has a short circuit to sensor ground
Condition
600850-12
600850-11
Fuel pump relay - check the control wire for a short circuit to sensor ground.

Resistance

sensor ground.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
358
359

lamp (MIL)
P1232
"Fuel pump relay"
"Short circuit to plus"
Circuit fault.
The engine is switched off: 3 s
Function check
Checking the fuel pump relay (
Possible cause
p. 359)
p. 359)
Fuel pump relay - the control wire has a short circuit to plus (terminal 30) (
p. 360)
Fuel pump relay - the signal wire has a short circuit to ignition plus (terminal 15) (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 360)
Checking the fuel pump relay
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Select "Fuel pump relay function test".
Press "Continue".
Fuel pump
Operating noise
Take a test ride.

p. 359)
Fuel pump relay - value not plausible
Condition
The fuel pump relay is disconnected. (
p. 404)
Fuel pump relay - check the resistance

Fuel pump relay pin 1 Fuel pump relay pin 2
Fuel pump relay
600852-10
72 88
Replace the fuel pump relay.

Fuel pump relay - the control wire has a short circuit to plus (terminal 30)
( p. 360)
360
Fuel pump relay - the control wire has a short circuit to plus (terminal 30)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400658-10
Fuel pump relay - check the control wire for a short circuit to plus (terminal 30)
0.1 V
Voltage

plus (terminal 30).

(terminal 30).
p. 401) pin 2 for a short circuit to plus

Fuel pump relay - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 360)
Fuel pump relay - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
600850-12
600850-11
Fuel pump relay - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance


minal 15).
p. 401) pin 2 for a short circuit to ignition plus (ter-
361

lamp (MIL)
P1590
"Side stand switch (A/D type)"
"Circuit fault"
Fault present: 3.2 s

Side stand switch voltage: 0.996 V
Function check
Checking the side stand switch (
Possible cause
Side stand switch - the signal wire has a short circuit to sensor ground (
p. 361)
p. 361)
Side stand switch - the signal wire has a short circuit to ground (terminal 31) (
p. 362)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Checking the side stand switch
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Side stand switch (SSTAND AD)" and deselect the other parameters with "Select live data".
Side stand voltage "Side stand AD"
Retracted
1.5 3.2 V
Extended
4.0 5.0 V
Take a test ride.

Side stand switch - the signal wire has a short circuit to sensor ground (
p. 361)
Side stand switch - the signal wire has a short circuit to sensor ground
Condition
The electric starter lock control unit connector is disconnected. (
The side stand switch is disconnected. ( p. 40)
p. 88)
Side stand switch - check the signal wire for a short circuit to sensor ground

Side stand switch, connector AR pin 2 Side stand switch, connector AR
pin 3
Resistance
400584-10

nector AR pin 3 for a short circuit to sensor ground.
362

Side stand switch - the signal wire has a short circuit to ground (terminal 31)
( p. 362)
Side stand switch - the signal wire has a short circuit to ground (terminal 31)
p. 88)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The electric starter lock control unit connector is disconnected. (
The side stand switch is disconnected. ( p. 40)
400584-10
400658-10
Side stand switch - check the signal wire for a short circuit to ground (terminal 31)

Side stand switch, connector AR pin 3 Measuring point Ground ()
Resistance

minal 31).
p. 392) pin 26 to connector AR pin 3 for a short circuit to ground (ter-
363

lamp (MIL)
P1631
"Rollover sensor (A/D type)"
Signal voltage "rollover sensor (A/D type)": 0.352 V

Time: 3 s
Function check
Checking the rollover sensor (
Possible cause
Rollover sensor - there is an open in the power supply (
p. 363)
p. 363)
Rollover sensor - the signal wire has a short circuit to ground (terminal 31) (
Rollover sensor - the signal wire has a short circuit to sensor ground (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Checking the rollover sensor
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Rollover sensor (A/D type)" and deselect the other parameters with "Select live data".
Rollover sensor
Voltage (Rollover AD) "no fall detected"
0.4 1.4 V
Voltage (Rollover AD) "fall detected"
3.7 4.1 V
Take a test ride.

Rollover sensor - there is an open in the power supply (
Rollover sensor - there is an open in the power supply

Condition
The ignition is on.
The rollover sensor is disconnected. ( p. 226)
p. 363)
p. 364)
p. 364)
364
400583-10
400658-10
Rollover sensor - check if there is an open in the power supply

Rollover sensor connector AP pin 6 Measuring point Ground ()

Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
4.9 5.1 V
Check connector AP pin 6.
Check the cable from connector AP pin 6 to the next node in the wiring harness for opens.

Rollover sensor - the signal wire has a short circuit to ground (terminal 31) (
p. 364)
Rollover sensor - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-11
400658-10
Rollover sensor - check the signal wire for a short circuit to ground (terminal 31)

Resistance

p. 392) pin 4 to connector AP (

Rollover sensor - the signal wire has a short circuit to sensor ground (
p. 364)
Rollover sensor - the signal wire has a short circuit to sensor ground
Condition
365
Rollover sensor - check the signal wire for a short circuit to sensor ground

Resistance
Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP ( p. 393) pin 5 for a short circuit to sensor ground.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
600850-11
366

lamp (MIL)
P1632
"Rollover sensor (A/D type)"
Signal voltage "rollover sensor (A/D type)": 1.992 3.008 V

Time: 25.5 s
Signal voltage "rollover sensor (A/D type)": 4.805 V
Time: 25.5 s
Function check
Checking the rollover sensor (
Possible cause
Rollover sensor - the signal wire has a short circuit to plus (terminal 30) (
p. 366)
p. 366)
Rollover sensor - the signal wire has a short circuit to ignition plus (terminal 15) (
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Rollover sensor - the signal wire has a short circuit to the sensor power supply (
Rollover sensor - the signal wire has an open (
p. 368)
Rollover sensor - the ground wire has an open (
p. 368)
Checking the rollover sensor
Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
Highlight "Rollover sensor (A/D type)" and deselect the other parameters with "Select live data".
Rollover sensor
Voltage (Rollover AD) "no fall detected"
0.4 1.4 V
Voltage (Rollover AD) "fall detected"
3.7 4.1 V
Take a test ride.

Rollover sensor - the signal wire has a short circuit to plus (terminal 30) (
Rollover sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
p. 366)
p. 367)
p. 367)
367
600850-11
400658-10
Rollover sensor - check the signal wire for a short circuit to plus (terminal 30)

Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
< 0.1 V

plus (terminal 30).
p. 392) pin 4 to connector AP (

Rollover sensor - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 367)
Rollover sensor - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
Rollover sensor - check the signal wire for a short circuit to ignition plus (terminal 15)

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP ( p. 393) pin 5 for a short circuit to ignition plus (terminal 15).

Rollover sensor - the signal wire has a short circuit to the sensor power supply
( p. 367)
Rollover sensor - the signal wire has a short circuit to the sensor power supply
Condition
Rollover sensor - check the signal wire for a short circuit to the sensor power supply

Resistance
600850-11
Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP ( p. 393) pin 5 for a short circuit to the sensor power supply.

Rollover sensor - the signal wire has an open (
p. 368)
368
Rollover sensor - the signal wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400583-10
Rollover sensor - check the signal wire for opens

Break Out Box AO pin 4 Rollover sensor connector AP pin 5
0.6
Resistance
p. 392) pin 4 and connector AP pin 5.
p. 392) pin 4 to connector AP pin 5 for opens.

Rollover sensor - the ground wire has an open (
p. 368)
Rollover sensor - the ground wire has an open

Condition
600850-11
400583-10
Rollover sensor - check the ground wire for opens

Break Out Box AO pin 7 Rollover sensor connector AP pin 4
0.6
Resistance

369

lamp (MIL)
P1650
"Immobilizer control unit"
"Circuit fault"
Possible cause
The ICU is faulty (
p. 369)
Correct the immobilizer fault.
The ICU is faulty
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
The ignition is on.
Read out the blink code at the immobilizer indicator lamp
Immobilizer indicator lamp
Correct the immobilizer fault.
flashes
370

lamp (MIL)
P1687

Time: 1 s
Function check
Possible cause
( p. 371)
p. 370)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 371)

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground (
p. 371)
371
Condition
p. 223)
sensor ground

Manifold absolute pressure sensor cylinder 2 connector DP pin 2 Manifold
absolute pressure sensor cylinder 2 connector DP pin 3
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400590-10

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)
Condition
p. 223)
400590-10
400658-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to ground (terminal 31)

Manifold absolute pressure sensor cylinder 2 connector DP pin 3 Measuring point Ground ()
Resistance
minal 31).

p. 371)
Manifold absolute pressure sensor cylinder 2 - the power supply is interrupted

Condition
The ignition is on.
p. 223)
372
400590-10
400658-10
Manifold absolute pressure sensor cylinder 2 - checking the power supply

Manifold absolute pressure sensor cylinder 2 connector DP pin 1 Measuring point Ground ()
Voltage
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
4.9 5.1 V
373

lamp (MIL)
P1688

Time: 1 s
Function check
Possible cause
p. 373)
p. 374)
p. 374)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) ( p. 375)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus
(terminal 15) ( p. 375)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensor

Condition
The ignition is on.
Select the model.
Press "Continue".
Press "Continue".
at: 350 mbar (5.08 psi)
1.62 1.68 V
1.77 1.83 V
at: 450 mbar (6.53 psi)
1.92 1.98 V
at: 800 mbar (11.6 psi)
2.97 3.03 V
at: 850 mbar (12.33 psi)
3.12 3.18 V
at: 900 mbar (13.05 psi)
3.27 3.33 V
at: 950 mbar (13.78 psi)
3.42 3.48 V
at: 1,000 mbar (14.5 psi)
3.57 3.63 V
at: 1,050 mbar (15.23 psi)
3.72 3.78 V
Take a test ride.

p. 374)
374
Manifold absolute pressure sensor cylinder 2 - the signal wire has an open
p. 223)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400590-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for opens
Break Out Box AO pin 24 Manifold absolute pressure sensor cylinder 2 connector DP pin 3
0.6
Resistance

p. 374)
Manifold absolute pressure sensor cylinder 2 - the ground wire has an open
Condition
p. 223)
600850-11
400590-10
Manifold absolute pressure sensor cylinder 2 - check the ground wire for opens

Break Out Box AO pin 7 Manifold absolute pressure sensor cylinder 2 connector DP pin 2
0.6
Resistance


Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) (
p. 375)
375
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)
p. 223)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-11
400658-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30)

Voltage
< 0.1 V

plus (terminal 30).

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 375)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
p. 223)

Resistance
600850-11

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply ( p. 375)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply
Condition
p. 223)
376
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to the
sensor power supply

Resistance
600850-11

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
377

lamp (MIL)
1690
"CAN bus communication error"
Circuit fault: 3 s
CAN communication: data format and CAN reply - incorrect data format: 10 s
Possible cause
Combination instrument - the CAN-high wire has an open (

Combination instrument - the CAN-low wire has an open (
p. 377)
p. 378)

Immobilizer control unit - the CAN-low wire has an open (
p. 378)
p. 379)
CAN-high - the signal wire has a short circuit to ground (terminal 31) (
p. 379)
p. 380)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
CAN-low - the signal wire has a short circuit to ground (terminal 31) (
CAN-high - the signal wire has a short circuit to sensor ground (
CAN-low - the signal wire has a short circuit to sensor ground (
p. 381)
p. 381)
CAN bus terminating resistor - the CAN-high wire has an open (

CAN bus terminating resistor - the CAN-low wire has an open (
Connector CU - the CAN-high wire has an open (
Connector CU - the CAN-low wire has an open (
p. 382)
p. 383)
p. 383)
p. 384)
Diagnostics connector - the CAN-high wire has an open (

Diagnostics connector - the CAN-low wire has an open (
p. 384)
p. 385)
CAN-high - the signal wire has a short circuit to plus (terminal 30) (
CAN-low - the signal wire has a short circuit to plus (terminal 30) (
p. 385)
p. 386)
CAN-high - the signal wire has a short circuit to ignition plus (terminal 15) (
CAN-low - the signal wire has a short circuit to ignition plus (terminal 15) (
CAN-high - the signal wire has a short circuit to the sensor power supply (
CAN-low - the signal wire has a short circuit to the sensor power supply (
CAN bus terminating resistor - value not plausible (
p. 389)
Combination instrument - the CAN-high wire has an open

Condition
The diagnostics tool is disconnected.
The CAN bus terminating resistor is disconnected. ( p. 404)
The instrument panel is disconnected.
600850-12
400645-10
Combination instrument - check the CAN-high wire for opens

Break out box CO pin 19 Combination instrument connector EV pin 4
Resistance
0.9
p. 387)
p. 387)
p. 388)
p. 389)
378
p. 397) pin 19 and connector EV pin 4.

p. 397) pin 19 to connector EV pin 4 for opens.

Combination instrument - the CAN-low wire has an open (
p. 378)
Combination instrument - the CAN-low wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400645-10
Combination instrument - check the CAN-low wire for opens

Break out box CO pin 20 Combination instrument connector EV pin 5
0.9
Resistance
p. 397) pin 20 and connector EV pin 5.
p. 397) pin 20 to connector EV pin 5 for opens.

p. 378)
Combination instrument - the CAN-high wire has an open

Condition
600850-12
400657-10
Immobilizer control unit - check the CAN-high wire for opens

Break out box CO pin 19 Immobilizer control unit, connector DO pin 6
Resistance
0.9
379
p. 397) pin 19 and connector DO pin 6.

p. 397) pin 19 to connector DO pin 6 for opens.

Immobilizer control unit - the CAN-low wire has an open (
p. 379)
Immobilizer control unit - the CAN-low wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400657-10
Immobilizer control unit - check the CAN-low wire for opens

Break out box CO pin 20 Immobilizer control unit, connector DO pin 8
0.9
Resistance
p. 397) pin 20 and connector DO pin 8.
p. 397) pin 20 to connector DO pin 8 for opens.

CAN-high - the signal wire has a short circuit to ground (terminal 31) (
p. 379)
CAN-high - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
CAN-high - check the signal wire for a short circuit to ground (terminal 31)

Resistance
380
Check the cable from connector EV (

p. 403) pin 4 to EFI control unit connector CO (
Check the cable from connector DO (

Check the cable from connector AT (

Check the cable from connector AP (

Check the cable from connector CU (


CAN-low - the signal wire has a short circuit to ground (terminal 31) (
p. 380)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
CAN-low - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-12
400658-10
CAN-low - check the signal wire for a short circuit to ground (terminal 31)

Resistance






CAN-high - the signal wire has a short circuit to sensor ground (
p. 381)
381
CAN-high - the signal wire has a short circuit to sensor ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
CAN-high - check the signal wire for a short circuit to sensor ground
Resistance

to sensor ground.
p. 403) pin 4 to the EFI control unit connector CO (
p. 397) pin 19 for a short circuit

to sensor ground.

to sensor ground.

to sensor ground.

cuit to sensor ground.
p. 397) pin 19 for a short cir-

CAN-low - the signal wire has a short circuit to sensor ground (
CAN-low - the signal wire has a short circuit to sensor ground

Condition
p. 381)
382
600850-12
600850-11
CAN-low - check the signal wire for a short circuit to sensor ground
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

to sensor ground.

to sensor ground.

to sensor ground.

to sensor ground.

cuit to sensor ground.

CAN bus terminating resistor - the CAN-high wire has an open (
p. 382)
CAN bus terminating resistor - the CAN-high wire has an open

Condition
600850-12
400585-10
CAN bus terminating resistor - check the CAN-high wire for opens

Break out box CO pin 19 CAN bus terminating resistor connector AT pin 2
0.9
Resistance
p. 397) pin 19 and connector AT pin 2.

p. 397) pin 19 to connector AT pin 2 for opens.

CAN bus terminating resistor - the CAN-low wire has an open (
p. 383)
383
CAN bus terminating resistor - the CAN-low wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400585-10
CAN bus terminating resistor - check the CAN-low wire for opens
Break out box CO pin 20 CAN bus terminating resistor connector AT pin 1
0.9
Resistance
p. 397) pin 20 and connector AT pin 1.
p. 397) pin 20 to connector AT pin 1 for opens.

Connector CU - the CAN-high wire has an open (
p. 383)
Connector CU - the CAN-high wire has an open
Condition
600850-12
400588-10
Connector CU - check the CAN-high wire for opens

Break out box CO pin 19 Connector CU pin 3
0.9
Resistance
p. 397) pin 19 and connector CU pin 3.

p. 397) pin 19 to connector CU pin 3 for opens.

Connector CU - the CAN-low wire has an open (
384
p. 384)
Connector CU - the CAN-low wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400588-10
Connector CU - check the CAN-low wire for opens

Break out box CO pin 20 Connector CU pin 4
0.9
Resistance
p. 397) pin 20 and connector CU pin 4.
p. 397) pin 20 to connector CU pin 4 for opens.

Diagnostics connector - the CAN-high wire has an open (
p. 384)
Diagnostics connector - the CAN-high wire has an open

Condition
600850-12
400583-10
Diagnostics connector - check the CAN-high wire for opens

Break out box CO pin 19 Diagnostic connection plug AP pin 2
Resistance
0.9
385

Diagnostics connector - the CAN-low wire has an open (
p. 385)
Diagnostics connector - the CAN-low wire has an open
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
400583-10
Diagnostics connector - check the CAN-low wire for opens

Break out box CO pin 20 Diagnostic connection plug AP pin 3
0.9
Resistance

CAN-high - the signal wire has a short circuit to plus (terminal 30) (
p. 385)
CAN-high - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
CAN-high - check the signal wire for a short circuit to plus (terminal 30)

Voltage
0.1 V
386

to plus (terminal 30).




cuit to plus (terminal 30).

CAN-low - the signal wire has a short circuit to plus (terminal 30) (
p. 386)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
CAN-low - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-12
400658-10
CAN-low - check the signal wire for a short circuit to plus (terminal 30)

Voltage
0.1 V






CAN-high - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 387)
387
CAN-high - the signal wire has a short circuit to ignition plus (terminal 15)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
CAN-high - check the signal wire for a short circuit to ignition plus (terminal 15)
Resistance






CAN-low - the signal wire has a short circuit to ignition plus (terminal 15) (
p. 387)
CAN-low - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
388
600850-12
600850-11
CAN-low - check the signal wire for a short circuit to ignition plus (terminal 15)
Resistance
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m






CAN-high - the signal wire has a short circuit to the sensor power supply (
p. 388)
CAN-high - the signal wire has a short circuit to the sensor power supply
Condition
600850-12
600850-11
CAN-high - check the signal wire for a short circuit to the sensor power supply

Resistance


389




CAN-low - the signal wire has a short circuit to the sensor power supply (
p. 389)
CAN-low - the signal wire has a short circuit to the sensor power supply
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Condition
600850-12
600850-11
CAN-low - check the signal wire for a short circuit to the sensor power supply

Resistance






CAN bus terminating resistor - value not plausible (
p. 389)
CAN bus terminating resistor - value not plausible

Condition
The CAN bus terminating resistor is disconnected. (
p. 404)
390
CAN bus terminating resistor - check the resistor.

CAN bus terminating resistor pin 1 CAN bus terminating resistor pin 2
CAN bus terminating resistor
600857-10
108 132
Change the CAN bus terminating resistor.

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
CONNECTOR OVERVIEW
391
Motor drive circuit A connector AE

32.1
Pin overview
1
Motor drive circuit A phase BP, control wire
Motor drive circuit A phase AN, control wire
Motor drive circuit A phase AP, control wire
Motor drive circuit A phase BN, control wire
400682-10
Connector AI
32.2
Pin overview
Power supply, main relay, fuel pump input
Power supply, main relay, fuel pump output
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400681-10
Crankshaft position sensor connector AL

32.3
Pin overview
Signal wire
Signal wire
400581-10
Clutch switch, connector AL

32.4
Pin overview
Ground
Signal wire
400581-10
Throttle position sensor circuit A, connector AM

32.5
Pin overview
400582-10
System voltage
Signal wire
Sensor ground
CONNECTOR OVERVIEW
392
Throttle position sensor circuit B, connector AM

32.6
Pin overview
1
Signal wire
Power supply
Sensor ground
400582-10
Gear position sensor, connector AM

32.7
Pin overview
Signal wire 3rd gear
Signal wire 2nd gear
Signal wire, idle
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400582-10
Fuel pump connector AM

32.8
Pin overview
Power supply
Not assigned
Ground
400582-10
Wheel speed sensor, connector AM

32.9
Pin overview
Signal wire
System voltage
Ground
400582-10
Connector AO
32.10
Pin overview
400642-10
Sensor voltage supply
Throttle position sensor circuit B, signal wire
Manifold absolute pressure sensor cylinder 1, signal wire
Rollover sensor, signal wire
Not assigned
Ground (terminal 31)
Sensor ground
Input status, electric starter lock control unit
Engine coolant temperature sensor cylinder 1, signal wire
CONNECTOR OVERVIEW
393
Throttle position sensor circuit A, signal wire
11
Lambda sensor cylinder 1, signal wire
12
Lambda sensor cylinder 2, signal wire
13
Crankshaft position sensor, signal wire
14
Crankshaft position sensor, signal wire
15
3rd gear, signal wire
16
Not assigned
17
K bus wire to KTM diagnostics tool
18
2nd gear, signal wire
19
Neutral switch, signal wire
20
EFI control unit voltage supply (terminal 15)
21
Octane selector
22
Intake air temperature sensor, signal wire
23
Ambient air pressure sensor, signal wire
24
Manifold absolute pressure sensor cylinder 2, signal wire
25
Clutch switch, signal wire
26
Side stand switch, signal wire
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
10
Diagnostic connection plug AP

32.11
Pin overview
System voltage
CAN high
CAN low
K bus signal wire to KTM diagnostics tool
Not assigned
Ground
400583-10
Rollover sensor connector AP

32.12
Pin overview
Not assigned
Not assigned
Not assigned
Sensor ground
Signal wire
System voltage
400583-10
Throttle position sensor circuit A, connector AR

32.13
Pin overview
400584-10
Power supply
Signal wire
Sensor ground
CONNECTOR OVERVIEW
394
Throttle position sensor circuit B, connector AR

32.14
Pin overview
1
Signal wire
System voltage
Sensor ground
400584-10
Fuel pump connector AR

32.15
Pin overview
Power supply
Not assigned
Ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400584-10
Side stand switch, connector AR

32.16
Pin overview
System voltage
Sensor ground
Signal wire
400584-10
Ignition coil cylinder 1 connector AS

32.17
Pin overview
Control wire
System voltage
400644-10
Ignition coil cylinder 2 connector AS

32.18
Pin overview
400644-10
Control wire
System voltage
CONNECTOR OVERVIEW
395
CAN bus terminating resistor connector AT

32.19
Pin overview
1
CAN low
CAN high
400585-10
Crankshaft position sensor, connector AT

32.20
Pin overview
Signal wire
Signal wire
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400585-10
Clutch switch connector AT

32.21
Pin overview
Signal wire
Ground
400585-10
Engine coolant temperature sensor cylinder 1 connector AX

32.22
Pin overview
Sensor ground
Signal wire
400586-10
Throttle stepper motor circuit B, connector CA

32.23
Pin overview
400646-10
Motor drive circuit B phase AP, control wire
Motor drive circuit B phase BP, control wire
Motor drive circuit B phase AN, control wire
Motor drive circuit B phase BN, control wire
CONNECTOR OVERVIEW
396
Lambda sensor cylinder 1, connector CA

32.24
Pin overview
1
Power supply, lambda sensor heater
Lambda sensor heater, control wire
Sensor ground
Signal wire
400646-10
Lambda sensor cylinder 2, connector CA

32.25
Pin overview
Sensor ground
Signal wire
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400646-10
Lambda sensor cylinder 1, connector CE

32.26
Pin overview
Sensor ground
Signal wire
400647-10
Lambda sensor cylinder 2, connector CE

32.27
Pin overview
Sensor ground
Signal wire
400647-10
Secondary air valve connector CK

32.28
Pin overview
400648-10
Power supply
Control wire
CONNECTOR OVERVIEW
397
Connector CM
32.29
Pin overview
1
Sensor ground
Signal wire
400650-10
Connector CO
32.30
Pin overview
Not assigned
Fuel pump relay, control wire
Injector cylinder 1, control wire
10
Not assigned
11
12
13
Exhaust air injection valve, control wire
14
Tachometer signal wire
15
Lambda sensor heater cylinder 2, control wire
16
EFI warning lamp (MIL)
17
Not assigned
18
Not assigned
19
CAN high
20
CAN low
21
22
23
24
Not assigned
25
Not assigned
26
Ignition coil cylinder 2, control wire
27
Not assigned
28
Not assigned
29
Ignition coil cylinder 1, control wire
30
Not assigned
31
Fuel evaporation valve, control wire
32
Control wire status, electric starter lock control unit
33
Lambda sensor heater cylinder 1, control wire
34
K bus wire, combination instrument
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400643-10
CONNECTOR OVERVIEW
398
Connector CP
32.31
Pin overview
Not assigned
2.2
Sensor ground
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400651-10
2.1
2.11
2.12
2.13
2.14
Sensor power supply
2.15
2.16
Connector CQ
32.32
Pin overview
400652-10
Not assigned
Sensor ground
10
11
12
13
14
Sensor power supply
15
16
Connector CU
32.33
Pin overview
400588-10
Not in use
Ground
CAN high
CAN low
CONNECTOR OVERVIEW
399
Fuel evaporation valve connector DF

32.34
Pin overview
1
Power supply
Control wire
400589-10
Secondary air valve connector DF

32.35
Pin overview
Power supply
Control wire
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400589-10
Electric starter lock control unit, connector DN

32.36
Pin overview
600859-10
Power supply
Starter auxiliary relay
Ground
Signal wire status, electric starter lock control unit
Signal wire status, electric starter lock control unit
Immobilizer control unit, connector DN

32.37
Pin overview
600859-10
Coil antenna
Coil antenna
System voltage
System voltage
LED
CAN high
Ground
CAN low
Electric starter lock control unit, connector DO

32.38
Pin overview
400657-10
System voltage
Ground
Control wire status, electric starter lock control unit
EFI control unit, control wire status
CONNECTOR OVERVIEW
400
Immobilizer control unit, connector DO

32.39
Pin overview
400657-10
Coil antenna
Coil antenna
Power supply
Power supply
LED
CAN high
Ground
CAN low
Ambient air pressure sensor connector DP

32.40
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Pin overview
System voltage
Sensor ground
Signal wire
400590-10
Manifold absolute pressure sensor cylinder 1, connector DP

32.41
Pin overview
System voltage
Sensor ground
Signal wire
400590-10
Manifold absolute pressure sensor cylinder 2 connector DP

32.42
Pin overview
System voltage
Sensor ground
Signal wire
400590-10
Injector cylinder 1 connector DQ

32.43
Pin overview
400591-10
Power supply
Control wire
CONNECTOR OVERVIEW
401
Injector cylinder 2 connector DQ

32.44
Pin overview
1
Power supply
Control wire
400591-10
ICU antenna connector DV

32.45
Pin overview
Coil antenna
Coil antenna
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400593-10
Fuel pump relay connector EB

32.46
Pin overview
Control circuit, power supply
Control wire
Component power supply
400653-10
ICU antenna connector EL

32.47
Pin overview
Coil antenna
Coil antenna
400685-10
Connector EQ
32.48
Pin overview
400683-10
Not assigned
LED alarm system (optional), signal wire
Power supply (terminal 15)
CAN high
Not assigned
CONNECTOR OVERVIEW
402
10
CAN low
Connector ER
32.49
Pin overview
Not assigned
CAN high
Not assigned
10
CAN low
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400684-10
Connector ES
32.50
Pin overview
400654-10
Power supply (terminal 15) fuse 3
Brake light switch, control wire
Right turn signal, control wire
Left turn signal, control wire
Not assigned
10
Not assigned
11
Not assigned
12
Not assigned
13
14
15
16
Power supply, main relay, fuel pump
17
18
Power supply, start auxiliary relay, working circuit
Connector ET
32.51
Pin overview
400655-10
Brake light switch, control wire
Right turn signal, control wire
Left turn signal, control wire
Not assigned
10
Not assigned
11
Not assigned
12
Not assigned
13
14
CONNECTOR OVERVIEW
403
15
16
Power supply, main relay, fuel pump
17
18
Power supply, start auxiliary relay, working circuit
Combination instrument connector EV

32.52
Pin overview
Power supply
Power supply
Ground
CAN high
CAN low
Fuel level indicator, signal wire
Wheel speed sensor, signal wire
10
Tachometer, signal wire
11
Sensor power supply
12
Ambient air temperature sensor, signal wire
13
Not assigned
14
Ground
15
Oil pressure sensor, signal wire
16
High beam indicator light
17
18
Ground
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
400645-10
19
20
EFI warning lamp (MIL)
21
LAP button, signal wire
22
MODE button, signal wire
23
Turn signal, signal wire
24
Not assigned
25
Not assigned
26
Not assigned
Exhaust air injection valve, connector FE

32.53
Pin overview
600854-10
System voltage
Control wire
CONNECTOR OVERVIEW
404
Fuel pump relay

32.54
Pin overview
1
Control circuit power supply
Control wire
Fuel pump power supply
600852-10
CAN bus terminating resistor

32.55
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Pin overview
600857-10
CAN low
CAN high
TECHNICAL DATA - ENGINE
405
Design
2-cylinder 4-stroke Otto motor, 75 V arrangement, water-cooled
Displacement
1,195 cm (72.92 cu in)
Stroke
69 mm (2.72 in)
Bore
105 mm (4.13 in)
Compression ratio
13.5:1
Control
DOHC, 4 valves per cylinder, chain-driven

Intake
42 mm (1.65 in)
Exhaust
34 mm (1.34 in)
Valve clearance
0.25 0.30 mm (0.0098 0.0118 in)
0.10 0.15 mm (0.0039 0.0059 in)

Sleeve bearing
Conrod bearing
Sleeve bearing
Piston pin bearing
No bearing bushes - DLC-coated piston pins
Piston
Forged light alloy
Piston ring
1 Upper compression (rectangular) ring, 1 lower compression

ring, 1 oil scraper ring
Engine lubrication
Dry sump lubrication system with three rotor pumps
Primary transmission
40:76
Clutch
Multi-disc clutch in oilbath / hydraulically operated
Transmission
6-speed claw gears
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Crankshaft bearing
Transmission ratio
1st gear
14:36
2nd gear
16:30
3rd gear
20:30
4th gear
21:27
5th gear
23:26
6th gear
25:26
Mixture preparation
Electronically controlled fuel injection
Ignition system
Contactless controlled fully electronic ignition with digital ignition adjustment
Generator
12 V, 390 W
Spark plug
NGK LKAR9BI9
Electrode gap, spark plug
0.8 0.9 mm (0.031 0.035 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Cold start device
Electric starter
Capacity - engine oil

33.1
Engine oil
3.60 l (3.8 qt.)
( 32 F)
Engine oil (SAE 10W/50)

( p. 436)

(< 32 F)

( p. 436)
TECHNICAL DATA - ENGINE
406
Capacity - coolant
33.2
Coolant
2.60 l (2.75 qt.)
Coolant (
p. 436)
p. 436)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Coolant (mixed ready to use) (
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE

Camshaft - cam height
Intake
39.34 39.44 mm (1.5488 1.5528 in)
Exhaust
38.59 38.69 mm (1.5193 1.5232 in)
Camshaft - bearing pin
23.960 23.980 mm (0.94331 0.94409 in)
Camshaft bearing - radial clearance

New condition
0.020 0.061 mm (0.00079 0.0024 in)
Wear limit
0.09 mm (0.0035 in)
Valve guide - diameter

New condition
6.004 6.016 mm (0.23638 0.23685 in)
Wear limit
6.050 mm (0.23819 in)
Valve - sealing seat width

1.0 mm (0.039 in)
Intake: Wear limit
1.7 mm (0.067 in)
Exhaust: New condition
1.0 mm (0.039 in)
Exhaust: Wear limit
2.0 mm (0.079 in)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Intake: New condition
Valve - run-out
On the valve stem
0.05 mm ( 0.002 in)
On the valve plate: New condition
0.016 mm ( 0.00063 in)
On the valve plate: Wear limit
0.030 mm ( 0.00118 in)

Exhaust
5.893 5.970 mm (0.23201 0.23504 in)
Intake
5.965 5.980 mm (0.23484 0.23543 in)
Valve spring - length

New condition
42.0 mm (1.654 in)
Wear limit
41.2 mm (1.622 in)
Cylinder head - bearing hole of camshaft
24.000 24.021 mm (0.94488 0.94571 in)
Cylinder/cylinder head - sealing area distortion
0.05 mm ( 0.002 in)
Cylinder - bore diameter

Size I
105.000 105.012 mm (4.13385 4.13432 in)
Size II
105.012 105.025 mm (4.13432 4.13483 in)
Piston - diameter
Size I
104.955 104.985 mm (4.13208 4.13326 in)
Size II
104.965 104.995 mm (4.13247 4.13365 in)
Piston/cylinder - mounting clearance

New condition
0.015 0.057 mm (0.00059 0.00224 in)
Wear limit
0.150 mm (0.00591 in)
Piston - piston pin hole diameter
20.010 20.020 mm (0.78779 0.78819 in)
Piston ring
Width, first ring (rectangular ring)
1.170 1.200 mm (0.04606 0.04724 in)
Width, second ring (lower compression ring)
1.170 1.200 mm (0.04606 0.04724 in)
Width, oil scraper ring
1.970 2.000 mm (0.07756 0.07874 in)
Piston ring - groove clearance

First ring (rectangular ring)
0.105 mm ( 0.00413 in)
Second ring (lower compression ring)
0.150 mm ( 0.00591 in)
Oil scraper ring
0.180 mm ( 0.00709 in)
Piston ring end gap
0.5 mm ( 0.02 in)
Piston pin - diameter
19.995 20.004 mm (0.7872 0.78756 in)
Connecting rod - diameter of upper conrod eye
20.000 20.013 mm (0.7874 0.78791 in)
Connecting rod - axial clearance of lower conrod bearing

New condition
0.10 0.25 mm (0.0039 0.0098 in)
Wear limit
0.40 mm (0.0157 in)
Connecting rod - radial clearance of lower conrod bearing
407
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE

New condition
0.030 0.060 mm (0.00118 0.00236 in)
Wear limit
0.080 mm (0.00315 in)
Connecting rod - large end width
20.950 21.000 mm (0.8248 0.82677 in)
Crankshaft - axial clearance

New condition
0.15 0.43 mm (0.0059 0.0169 in)
Wear limit
1.00 mm (0.0394 in)
Crankshaft - crank pin width
42.100 42.150 mm (1.65748 1.65945 in)
Crankshaft - crank pin diameter

Yellow
41.978 41.989 mm (1.65267 1.65311 in)
Blue
41.990 42.000 mm (1.65315 1.65354 in)
Red
42.001 42.011 mm (1.65358 1.65397 in)
Crankshaft - main bearing diameter

53.965 53.975 mm (2.1246 2.125 in)
Blue
53.976 53.985 mm (2.12504 2.12539 in)
Red
53.986 53.995 mm (2.12543 2.12578 in)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Yellow
Crankshaft - radial clearance of main bearing

New condition
0.025 0.055 mm (0.00098 0.00217 in)
Wear limit
0.080 mm (0.00315 in)
Crankshaft - step bearing diameter
27.985 28.000 mm (1.10177 1.10236 in)
Crankshaft - radial clearance of step bearing

New condition
0.030 0.070 mm (0.00118 0.00276 in)
Wear limit
0.090 mm (0.00354 in)
Clutch facing disc - thickness

New condition
2.92 3.08 mm (0.115 0.1213 in)
Wear limit
2.85 mm (0.1122 in)
Intermediate disk - thickness

New condition
1.95 2.05 mm (0.0768 0.0807 in)
Wear limit
1.85 mm (0.0728 in)
Clutch discs - thickness of total package

New condition
48.30 49.30 mm (1.9016 1.9409 in)
Wear limit
46.60 mm (1.8346 in)
Clutch spring - length
33.00 34.00 mm (1.2992 1.3386 in)
Outer clutch hub - contact surface of clutch facing discs

Wear limit
Oil pressure regulator valve - minimum spring length
0.5 mm (0.02 in)
40.5 mm (1.594 in)
Oil pumps
Clearance between external rotor and engine case
0.20 0.40 mm (0.0079 0.0157 in)
Clearance between external rotor and internal rotor
0.10 0.25 mm (0.0039 0.0098 in)
Axial clearance
0.04 0.25 mm (0.0016 0.0098 in)
Engine oil pressure
Coolant temperature: 70 C ( 158 F)

1.3 2.3 bar (19 33 psi)
Coolant temperature: 70 C ( 158 F)

3.0 4.0 bar (44 58 psi)
Oil consumption
0.6 l/1.000 km ( 0.6 qt./600 mi)
Shift fork
Thickness at leaf
4.85 4.95 mm (0.1909 0.1949 in)
Clearance in the sliding gear groove: New condition
0.35 0.55 mm (0.0138 0.0217 in)
Clearance in the sliding gear groove: Wear limit
0.70 mm (0.0276 in)
Shift shaft - play in sliding plate/shift quadrant
0.40 0.80 mm (0.0157 0.0315 in)
Sliding gear - width of shift fork groove
5.30 5.40 mm (0.2087 0.2126 in)
Transmission shaft - axial clearance
0.05 0.15 mm (0.002 0.0059 in)
408
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
409
M4
1.5 Nm (1.11 lbf ft)
M5
6 Nm (4.4 lbf ft)
M5
6 Nm (4.4 lbf ft)
Loctite 243
Screw, gear sensor
M5
3 Nm (2.2 lbf ft)
Loctite 243
Screw, pulse generator
M5
10 Nm (7.4 lbf ft)
Loctite 243
M6
13 Nm (9.6 lbf ft)
Freewheel ring bolt
M6
15 Nm (11.1 lbf ft)
Loctite 648
Nut, cylinder head
M6
10 Nm (7.4 lbf ft)
Plug, vacuum connection
M6
5 Nm (3.7 lbf ft)
Loctite 243
M6
10 Nm (7.4 lbf ft)
M6
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
Screw, clutch spring
M6
12 Nm (8.9 lbf ft)
Loctite 243
Screw, coolant connection on cylinder

head
M6
10 Nm (7.4 lbf ft)
Screw, engine case
M6x60
10 Nm (7.4 lbf ft)
Screw, engine case
M6x80
10 Nm (7.4 lbf ft)
Screw, engine case
M6x90
10 Nm (7.4 lbf ft)
Screw, freewheel holder
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, generator cover
M6
10 Nm (7.4 lbf ft)
Screw, locking lever
M6
10 Nm (7.4 lbf ft)
Loctite 243
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, shift lever
M6
10 Nm (7.4 lbf ft)
Loctite 243
M6
10 Nm (7.4 lbf ft)
Screw, stator clamp
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
Screw, water pump wheel
M6
10 Nm (7.4 lbf ft)
Loctite 243
Stud, chain shaft
M6
8 Nm (5.9 lbf ft)
Vacuum connection
M6
5 Nm (3.7 lbf ft)
Loctite 243
Jet 140
M6x0.75
4 Nm (3 lbf ft)
Loctite 243
Oil jet
M6x0.75
4 Nm (3 lbf ft)
Loctite 243
M6x0.75
4 Nm (3 lbf ft)
M8
15 Nm (11.1 lbf ft)
M8
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
M8
Step 1
8.5 Nm (6.27 lbf ft)
Step 2
14.5 Nm (10.7 lbf ft)
Only applies when using:

Hex key bit
(61229025000)
( p. 446)
Screw, engine case
M8
18 Nm (13.3 lbf ft)
M8
20 Nm (14.8 lbf ft)
Loctite 243
Screw, heat exchanger
M8
15 Nm (11.1 lbf ft)
Screw, timing chain guide rail
M8
15 Nm (11.1 lbf ft)
Loctite 243
M8
15 Nm (11.1 lbf ft)
Loctite 243
Stud, exhaust flange
M8
10 Nm (7.4 lbf ft)
Oil pressure sensor
M10x1
10 Nm (7.4 lbf ft)
Plug, cam lever axis
M10x1
15 Nm (11.1 lbf ft)
M10x1
15 Nm (11.1 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
410
M10x1
Step 1
25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90
M10x1
10 Nm (7.4 lbf ft)
Cylinder head screw
M11x1.5
Tightening sequence:
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90
Step 4
90
lubricated with engine oil
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Coolant temperature sensor
M12x1.5
12 Nm (8.9 lbf ft)
Rotor screw
M12x1.5
90 Nm (66.4 lbf ft)
Spark plug
M12x1.5
17 Nm (12.5 lbf ft)
Nut of engine sprocket
M20x1.5
100 Nm (73.8 lbf ft)
Loctite 243
Oil drain plug
M20x1.5
20 Nm (14.8 lbf ft)
Nut, inner clutch hub
M22x1.5
130 Nm (95.9 lbf ft)
Loctite 243
M24x1.5
25 Nm (18.4 lbf ft)
M24x1.5
8 Nm (5.9 lbf ft)
Nut, primary gear
M33LHx1.5
130 Nm (95.9 lbf ft)
Loctite 243
TECHNICAL DATA - CHASSIS
411
Frame
Lattice frame made of chromium molybdenum steel tubing,

powder-coated
Fork
WP Suspension Up Side Down 4354
Shock absorber
WP Suspension 4014 VP
Suspension travel
Front
120 mm (4.72 in)
Rear
120 mm (4.72 in)
Brake system
Front
Twin floating disc with radial mount, 4-piston calipers
Rear
Single non-floating disc with 2 piston brake caliper
Brake discs - diameter

320 mm (12.6 in)
Rear
220 mm (8.66 in)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Front
Brake discs - wear limit
Front
4.5 mm (0.177 in)
Brake disc - wear limit

Rear
4.5 mm (0.177 in)
Tire air pressure, Solo

Front
2.5 bar (36 psi)
Rear
2.5 bar (36 psi)
Tire air pressure with passenger / full payload

Front
2.5 bar (36 psi)
Rear
2.9 bar (42 psi)
Secondary drive
17:37
Chain
5/8 x 5/16 Xring
Steering head angle
66.7
Wheelbase
1,425 mm (56.1 in)
Seat height, unloaded
Lower frame rear position
805 mm (31.69 in)
Upper frame rear position
825 mm (32.48 in)
Ground clearance, unloaded
110 mm (4.33 in)
Weight without fuel approx.
184 kg (406 lb.)
Maximum permissible front axle load
150 kg (331 lb.)
Maximum permissible rear axle load
240 kg (529 lb.)
Maximum permissible total weight
380 kg (838 lb.)
Battery
YTZ14S
Battery voltage: 12 V
Nominal capacity: 11.2 Ah
maintenance-free
Fuse
58011109130
30 A
Fuse
75011088015
15 A
Fuse
75011088010
10 A
Low beam / high beam
H7 / base PX26d
12 V
55 W
Parking light
W5W/ base W2.1x9.5d
12 V
5W
Instrument lights and control lamps
LED
Turn signal
LED
Brake/tail light
LED
License plate lamp
W5W/ base W2.1x9.5d
Lighting equipment
36.1
12 V
5W
TECHNICAL DATA - CHASSIS
412
Front tire
Rear tire
120/70 ZR 17 M/C 58W TL

Pirelli Dragon Supercorsa Pro
190/55 ZR 17 M/C 75W TL

Pirelli Dragon Supercorsa Pro
Additional information is available in the Service section under:

http://www.ktm.com
Capacity - fuel
36.2
Total fuel tank capacity,

approx.
Super unleaded (ROZ 98 / RON 98 / PON 94) (

3.5 l (3.7 qt.)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Fuel reserve, approx.
16.5 l (4.36 US gal)
p. 437)
TECHNICAL DATA - FORK
413
Fork part number
05.18.7E.10
Fork
WP Suspension Up Side Down 4354
Compression damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m

Comfort
5 turns
Standard
5 turns
Sport
3 turns
Full payload
3 turns
Spring length with preload spacer(s)
405 mm (15.94 in)
Spring rate
Medium (standard)
9.5 N/mm (54.2 lb/in)
Air chamber length
+0.79
80+20
10 mm (3.150.39 in)
Fork length
735 mm (28.94 in)
Fork oil per fork leg
520 ml (17.58 fl. oz.)
Fork oil (SAE 5) (
p. 437)
TECHNICAL DATA - SHOCK ABSORBER

Shock absorber part number
17.18.7E.10
Shock absorber
WP Suspension 4014 VP

Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Full payload
1 turn

Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
10 clicks
Spring preload
Comfort
6 mm (0.24 in)
Standard
6 mm (0.24 in)
Sport
8 mm (0.31 in)
Full payload
8 mm (0.31 in)
Spring rate
Medium (standard)
95 N/mm (542 lb/in)
Spring length
160 mm (6.3 in)
Gas pressure
10 bar (145 psi)
Static sag
10 15 mm (0.39 0.59 in)
Riding sag
30 35 mm (1.18 1.38 in)
Inbuilt length
290 mm (11.42 in)
414
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
415
M4
2 Nm (1.5 lbf ft)
Loctite 243
M5
5 Nm (3.7 lbf ft)
Screw, brake fluid reservoir of rear

brake
M5
5 Nm (3.7 lbf ft)
Loctite 243
Screw, brake line holder
M5
5 Nm (3.7 lbf ft)
Screw, chain guard
M5
5 Nm (3.7 lbf ft)
Screw, chain sliding piece
M5
5 Nm (3.7 lbf ft)
Screw, fuel level indicator
M5
3 Nm (2.2 lbf ft)
Screw, fuel tank guard
M5x17
3 Nm (2.2 lbf ft)
Screw, steering damper fixing bracket
M5
5 Nm (3.7 lbf ft)
Loctite 243
Bolt, foot brake pedal stub
M6
10 Nm (7.4 lbf ft)
Loctite 243
M6
15 Nm (11.1 lbf ft)
M6
10 Nm (7.4 lbf ft)
Screw for wheel speed sensor bracket
M6
3 Nm (2.2 lbf ft)
Loctite 243
M6
8 Nm (5.9 lbf ft)
Screw, exhaust heat shield
M6
15 Nm (11.1 lbf ft)
Screw, foot brake cylinder
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, foot brake pedal
M6
15 Nm (11.1 lbf ft)
Loctite 243
Screw, fuel pump
M6
6 Nm (4.4 lbf ft)
Screw, shift lever stub
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, shift rod
M6
12 Nm (8.9 lbf ft)
Loctite 243
Screw, shift shaft deflector on chain

securing guide
M6
10 Nm (7.4 lbf ft)
Loctite 243
Screw, shift shaft deflector on shift

shaft
M6
18 Nm (13.3 lbf ft)
Loctite 243
M8
15 Nm (11.1 lbf ft)
Nut, forked bracket on foot brake pedal
M8
30 Nm (22.1 lbf ft)
Loctite 243
M8
30 Nm (22.1 lbf ft)
M8
25 Nm (18.4 lbf ft)
Screw of rear brake caliper
M8
22 Nm (16.2 lbf ft)
Loctite 243
M8
15 Nm (11.1 lbf ft)
Screw, front brake disc
M8
30 Nm (22.1 lbf ft)
Loctite 243
Screw, front footrest bracket
M8
25 Nm (18.4 lbf ft)
Loctite 243
M8
20 Nm (14.8 lbf ft)
Screw, ignition lock (ratchet screw)
M8
Screw, rear brake disc
M8
30 Nm (22.1 lbf ft)
Loctite 243
Screw, rear footrest bracket
M8
25 Nm (18.4 lbf ft)
Screw, shift lever
M8
25 Nm (18.4 lbf ft)
Loctite 243
Screw, side stand bracket
M8
25 Nm (18.4 lbf ft)
Loctite 243
Screw, spring holder on side stand

bracket
M8
15 Nm (11.1 lbf ft)
Loctite 243
Screw, steering damper clamp on console
M8
20 Nm (14.8 lbf ft)
Loctite 243
Screw, steering damper fixing bracket

on triple clamp
M8
10 Nm (7.4 lbf ft)
Loctite 243
Screw, steering stem
M8
20 Nm (14.8 lbf ft)
Screw, subframe
M8
20 Nm (14.8 lbf ft)
Loctite 243
M8
17 Nm (12.5 lbf ft)
Screw, work stand adapter
M8
25 Nm (18.4 lbf ft)
Loctite 243
M10
50 Nm (36.9 lbf ft)
M10
45 Nm (33.2 lbf ft)
Screw, connecting lever, shock

absorber deflector
M10
45 Nm (33.2 lbf ft)
Loctite 243
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, side stand switch
Loctite 243
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
416
M10
45 Nm (33.2 lbf ft)
M10
45 Nm (33.2 lbf ft)
Loctite 243
Screw, side stand
M10
35 Nm (25.8 lbf ft)
Loctite 243
Rear sprocket bolt
M10x1.25
50 Nm (36.9 lbf ft)
Loctite 243
M10x1.25
45 Nm (33.2 lbf ft)
Loctite 243
M14x1.5
100 Nm (73.8 lbf ft)
Lambda sensor
M18x1.5
45 Nm (33.2 lbf ft)
Nut, swingarm pivot
M19x1.5
130 Nm (95.9 lbf ft)
Thread greased
Screw, seat lock
M22x1.5
8 Nm (5.9 lbf ft)
Bolt, front axle
M25x1.5
45 Nm (33.2 lbf ft)
M25x1.5
90 Nm (66.4 lbf ft)
Thread greased
Screw, steering head
M25x1.5
18 Nm (13.3 lbf ft)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Screw, engine bearer
CLEANING/CONSERVATION
417
Cleaning motorcycle
40.1
Note
Material damageDamage and destruction of components by high-pressure cleaning equipment.
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
Info
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
Before cleaning, seal the exhaust system to prevent water from entering.
Remove loose dirt first with a soft jet of water.
Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush.
Motorcycle cleaner (
p. 439)
Info
Use warm water mixed with a normal commercial engine cleaner and a soft sponge.
If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.
After cleaning the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
Warning
Danger of accidentsReduced braking efficiency due to wet or dirty brakes.
Clean or dry dirty or wet brakes by riding and braking gently.
After cleaning, ride a short distance until operating temperature is reached, and apply the brakes.
Info
The heat causes water to evaporate from inaccessible parts of the engine and brakes.
After the engine has cooled down, lubricate or grease all moving parts and bearings.
Clean the chain. (
Treat bare metal (except for brake discs and the exhaust system) with an anticorrosive.
p. 84)
Cleaning and polishing materials for metal, rubber and plastic (
p. 438)
Treat all painted parts with a mild lacquer care spray.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces (
p. 439)
Oil the ignition/steering lock, tank lock, and seat lock.

Universal oil spray (
p. 439)
Conservation for winter operation

40.2
Info
If you use the motorcycle in the winter, you have to expect salt on the roads. You therefore have to take precautions against the
aggressive road salt.
If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.
Clean the motorcycle. (
Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.
p. 417)
Info
Avoid getting anticorrosive on the brake discs: this would badly affect the braking.
After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.
CLEANING/CONSERVATION
Clean the chain. (
p. 84)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
418
STORAGE
419
Storage
41.1
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.
Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.
Clean the motorcycle. (
Change the engine oil and filter, clean the oil screens. (
Check the antifreeze. (
Check the tire pressure. (
Remove the battery. (
Recharge the battery. (
p. 417)
p. 209)
p. 194)
p. 194)
p. 79)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
p. 88)
p. 90)
Guideline
Storage temperature of battery without direct sunshine.
0 35 C (32 95 F)
The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends jacking up the motorcycle.
Jack up the motorcycle at the front. (
Cover the motorcycle with a porous sheet or blanket.
p. 13)
p. 10)
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.
Putting into operation after storage

41.2
Take the front of the motorcycle off the work stand. (
Recharge the battery. (
p. 13)
p. 90)
Install the battery. (
Fill up with fuel.
Make checks before putting into operation.
Take a test ride.
p. 89)
p. 106)
p. 10)
SERVICE SCHEDULE
420
Important service tasks to be carried out by an authorized KTM-RC8 workshop.

42.1
Engine
Change the engine oil and filter, clean the oil screens. (
Check the valve clearance. (
p. 209)
K10N
K75A
K150A
J1A
J2A
p. 200)
Replace the spark plugs.
Check the engine attachment bolts and other engine bolts accessible from outside to ensure that they are tight.
Check the clutch.
Check / clean the oil jet for clutch lubrication. (

Fuel injection
p. 216)
Read out the status request and fault memory with the KTM diagnostics tool.
Check bellows for tears and leaks, and check the linkage of the
throttle valve spigot for freedom of movement.
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Check the wiring harness of the throttle valve body for damage and
correct routing.
Check hoses of vacuum sensors, SLS hoses and vent hoses for
damage, correct routing and leaks.
Check the fuel hose for damage, correct routing and leaks.
Check the fuel pressure. (
Attachments
Check the water pump for leaks (visual check).
Check radiator fan operation.
Check the exhaust system for leaks and correct fitting and check
that the exhaust brackets are tight.
Check the control cables for damage, smooth operation, kink-free

routing and adjustment.
Check the antifreeze. (
p. 73)
p. 194)
p. 194)
Check the fluid level of the hydraulic clutch. (
p. 191)
Check the air filter and change if necessary. Clean the air filter
box.
Brakes
Drain the drainage hose of the air filter box.
Check cables for damage and kink-free routing.
Check the headlight setting. (
Check that the electrical equipment is functioning properly.
p. 110)
Check the fairing parts for damage and breakage.
Check the fasteners for tightness.
Check the front brake linings. (
p. 93)
Check the rear brake linings. (
p. 96)
Check the front brake discs. (
p. 80)
Check that brake lines are undamaged and free of leaks.
Check the braking.
Check the bolts and guide pins of the brake system for tightness.
Check the operation of the forks and the rear shock absorber, also
check for leaks.
Bleed fork legs. (
Check the steering head bearings and adjust if necessary.
Check the swingarm bearings.
Check the rear brake disc. (
p. 83)
Check the front brake fluid level. (

Check the rear brake fluid level. (
p. 95)
p. 99)
Change brake fluid.
Chassis
p. 16)
Check deflector.
Check the eccentric shaft adjustment.
SERVICE SCHEDULE
421
K10N
K75A
K150A
J1A
J2A
Chassis
Check all bolts to make sure they are tight.
Wheels
Check the tire condition. (
Check the rear sprocket / engine sprocket / chain sliding guard to

ensure that they are tight.
Check the rear sprocket / engine sprocket for wear. (
J2A
J4A
p. 78)
Check the tire pressure. (

Check the chain wear. (
p. 79)
p. 86)

Clean the chain. (
p. 85)
p. 84)
p. 84)
Check chain sliding guard. (
p. 86)
Check wheel bearings for play.

p. 86)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Check the rear hub cush drive. (
K10N: after 1,000 km (621.4 mi)

K75A: every 7,500 km (4,660 mi)
K150A: every 15,000 km (9,320 mi) / after every sporting use
J1A: annually
J2A: every 2 years
Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job)
42.2
K150N
Perform a fork service. (
p. 21)
Perform a shock absorber service. (
K150A
Clean the battery terminals and treat with contact grease.

Change the coolant.
K150N: after 15,000 km (9,320 mi)

K150A: every 15,000 km (9,320 mi) / after every sporting use
K300A: every 30,000 km (18,640 mi)
J1A: annually
J2N: after 2 years
J2A: every 2 years
J4A: every 4 years
J1A
p. 48)
Clean and grease the steering head bearing and sealing elements.
K300A
J2N
62
-S2
-V1
1
3
/3.D1
AI/2
-X1
BK/4
144,153,169,182
83 fuel-A4
/2.E5
/2.B5
/3.B6
BR/4
-X1
EL/2
#702
DV/2
/2.B3
/2.B3
64
EQ/10
-X401
ER/10
93
95
178
/2.B3
flaR-X200
flaL-X200
84
98
-X2
74 ACC1
81 STR-A3
84
83
82
81
74
17
16
15
14
13
ET/18
18
17
16
15
14
13
37
15
32
26
31
35
21
-X403
85
18
/2.B3
ES/18
B+
/3.B2
-X5
GND#1
EB/4
/3.D6
27,28,30,39,46,66
86
147
B+
33,62
152
/3.D6
/3.D6
BS/2
BV/2
4,5,6
-X3
-F1 -F2 -F5 -F6 -F8
10A
15A
10A
10A
10A
AR/3
AM/3
lig-X3
11,12,13
/3.A7
-X4
EB/4
-M1
-X405
16
66
-K1
AF/4
68
71
30
A
-G1
K4-X8
GND#1
68
gn
69
EB/4
/2.B1
/2.C1
/3.E1
/2.C2
29
-K4
46
GND#1
tlig-H1
69
70
EU/4
AF/4
EB/4
-K3
20
28
10
25
38
29
21
39
30
65
13
AU/2
65
12
20
23
19
-M2
31
86
BI/2
64
11
15
-K2
36,37
7,8,9,10,14
14
63
BP/4
DG/4
23
16
27
#Ant-1
82,177
60
#Ant-2
178
61
9 10 11 12 13 14
145
7 8
54,55
-S3
35
175
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
24
-S1
34
-X150
98,152,147
34
146
63
1190 RC8 (R) 2009
33
1
EF/14
57
-A1
177
58
26
BI/2
36
32
24,25
19
AU/2
38
176
175,176,144,153,169,182
61
95
60
422
WIRING DIAGRAM
43.1
1 of 3
-K5
EM/3
EN/3
-N1
-G2
3 P.
Page:1
600859-01
WIRING DIAGRAM
Components
Plug-in connector for alarm system (optional) F12
G1
Battery A7
G2
Generator BC8
K1
Starter relay with main fuse A6
K2
Fuel pump relay F4
K3
Light relay F56
K4
Power relay F6
K5
Start auxiliary relay F7
M1
Starter motor AB6
M2
Fuel pump F5
N1
Voltage regulator/rectifier B8
S1
Ignition/steering lock, ICU antenna A12
S2
S3
V1
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
A1
X150
Emergency OFF switch, electric starter button A23

Seat monitoring switch (optional) F34
Diode A4
Resistance F3
Cable colors
gn
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
19
20
21
23
24
Green
Green
Green
Green
Green
Green
Green
White-red
White-red
White-red
White-red
White-red
White-red
White-red
White-red
White-red
Yellow
Black-yellow
Black-green
Yellow-red
Black-blue
White-orange
25
White-orange
26
Blue-gray
27
Brown
28
Brown
29
Orange
30
Brown
31
Red
32
Yellow-orange
33
Brown
34
Red
35
Green-orange
36
Red-violet
423
WIRING DIAGRAM
Red-violet
38
Blue-red
39
Brown
46
Brown
54
Brown
55
Brown
57
Black
58
Violet
60
White-black
61
Red-violet
62
Brown
63
White-red
64
Blue-red
65
66
68
69
70
71
74
81
82
83
84
85
86
93
95
98
144
145
146
147
152
153
169
175
176
177
178
182
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
37
Yellow-orange
Brown
White-red
White-red
Brown
Yellow
Yellow-red
Green-orange
Red
Blue-gray
Yellow-orange
White-red
Red-violet
Blue-red
Yellow-orange
White-red
Yellow-orange
Green
Black-green
White-red
White-red
Yellow-orange
Yellow-orange
Yellow-orange
Yellow-orange
Red
White-red
Yellow-orange
424
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
WIRING DIAGRAM
425
-Y1
-A2
DN/8
-B1
AR/3
AM/3
-S4
3th
AM/3
AR/3
2nd
117
104
-A3
DO/8
DN/8
216
-X16
228,206
115,204,230
-X15
209
210
216
211
220
224
219
168 CLU-S6
/3.B2
/3.D3
CAN-L
/3.D3
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
2
8
/3.B2
221
225
212
200
215
203
208
223
161 Neu-P1
192
#702 93
-X26
220
-X51
1
7
229
207
217
218
121
244
247
258
248
257
255
249
250
243
253
256
254
251
252
/3.F1
238
-B12
-X303
-B13
AR/3
AM/3
AM/3
-X301
241,243
246
-X302
AE/4
-Y2
FE/2
CK/2
-M4
/3.B2
/3.B2
-Y4
245,244
AR/3
DQ/2
TAC-P1
MIL-P1
-Y3
157
163
AS/2
245
-L2
DQ/2
-L1
AS/2
191
AT/2
221
155,180 CAN-H
163
155,180,217
157
96
184
AL/2
114
5
3
226
204
203
4
2
202
DO/8
3
1
-X17
215
97
CO/34
CP/16
-A4
257
#702
199
AP/6
48
100
207
194
#Ant-2
40
99
122
-X14
107
242
B+
230
96,149
222
211
210
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
213
-X401
50
9
10
123,226,225,199
201
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
AO/26
200
#Ant-1
/1.D3
/1.D3
94
190
DF/2
/1.B2
/1.B2
67
10
/3.E1
-X12
185,90,102,189
AT/2
AL/2
214
-X8
114
198
41,40
47
113
88
-X50
1
42
-X6
44,43
43
EQ/10
/3.B2
GND#2
109,118,129,167,171,181,150
GND-P1
-X11
193,125,205,120,191,106
DP/3
CQ/16
-X300
9 87 6 5 4 321
16 15 14 13 12 11 10
126
ER/10
154
89,101,124,186,201,223,116
212
B
45
124
-L3
219
CA/4
CE/4
AX/2
-M5
3 P.
Page: 2
-B16
255
246
254
109,118,129,167,171,181,213,214,229
198
-X10
-B8
222
-X9
97
GND#1 70
209
/1.B4
208
-X101
188,127,195,183
DP/3
DP/3
206
253
116
-X7
187
249
228
/1.B4
103
248
227
STR-A3 81
227
205
GND#1 46
156,179,218
94
258
148
-B7
113
252
117
-X13
105
241
151
261
147
196
247
106
115
99,151
128
250
107
123
104
251
121
122
105
240
120
150
90
238,239
260
89
256
149
88
100,148,224
/1.E7
CA/4
CE/4
-B5
185
/1.B6
CA/4
CE/4
-B6
186
239
192
146
187
1190 RC8 (R) 2009
103
41
-B4
126
202
fuel-A4
83
125
49
29
127
145
101
102
50
197
128
45
K4-X8 29
L
t
193
/1.E7
1
5
AP/6
-B3
194
42
-B2
195
47
188
46
190
44
196
48
189
2
CM/2
183
184
426
WIRING DIAGRAM
43.2
2 of 3
600860-01
WIRING DIAGRAM
Components
Immobilizer control unit A3
A3
Control unit of electric starter lock A5
A4
EFI control unit F47
B1
Side stand switch A4
B2
Intake air temperature sensor F1
B3
Roll angle sensor F1
B4
Lambda sensor (cylinder 2) F12
B5
Lambda sensor (cylinder 1) F2
B6
Ambient air pressure sensor F23
B7
Pressure sensor, induction manifold (cylinder 2) F3
B8
Pressure sensor, induction manifold (cylinder 1) F3
B12
Throttle position sensor circuit A A7
B13
B16
L1
L2
L3
M4
M5
S4
X50
X51
Y1
Y2
Y3
Y4
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
A2
Throttle position sensor circuit B A8
Coolant temperature sensor (1st cylinder) F8

Ignition coil (cylinder 2) F7
Ignition coil (cylinder 1) F7
Crankshaft position sensor F4

Motor drive circuit A CD8
Motor drive circuit B CD8

Gear position sensor A45
Diagnostics connector A1
CAN bus terminating resistor A2
Fuel evaporation valve (USA version only) A2

Secondary air valve F8
Injection valve (cylinder 2) CD7

Injection valve (cylinder 1) CD7
Cable colors
29
40
41
42
43
44
45
46
47
48
49
50
Orange
Black-blue
Black-blue
Black-blue
White-blue
White-blue
White-blue
Brown
Orange
Light blue
Orange
Black-orange
67
Orange
70
Brown
81
Green-orange
83
Blue-gray
88
Violet
89
Black
90
Blue
94
Light blue
96
Black-blue
97
Black-orange
99
White-blue
100
Orange
427
WIRING DIAGRAM
Black
102
Blue
103
Green-gray
104
Yellow-blue
105
White-yellow
106
Orange
107
White-pink
109
Brown
113
Yellow-brown
114
Gray
115
Black-green
116
Black
117
Red-violet
118
120
121
122
123
124
125
126
127
128
129
145
146
147
148
149
150
151
154
155
156
157
161
163
167
168
171
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
101
Brown
Orange
White-violet
Pink
Blue
Black
Orange
White-orange
Black
Brown-red
Brown
Green
Black-green
White-red
Orange
Black-blue
Brown
White-blue
Brown-violet
Black-blue
White-blue
Black-brown
Black-green
White
Brown
Yellow
Brown
179
White-blue
180
Black-blue
181
Brown
183
Black
184
Red
185
Blue
186
Black
187
Black-blue
188
Black
189
Blue
190
Yellow-red
191
Orange
428
WIRING DIAGRAM
White-brown
193
Orange
194
White-black
195
Black
196
Green-red
197
Brown
198
Brown-violet
199
Blue
200
Red-violet
201
Black
202
Blue-red
203
Black
204
Black-green
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
238
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
192
Orange
Yellow
Pink
Blue-orange
Blue-pink
Black-gray
Yellow-orange
White-red
Brown
Brown
Green
White-green
Black-blue
White-blue
Brown-gray
Yellow-green
Green-orange
Blue-brown
Black
Orange
Blue
Blue
Pink
Yellow
Brown
Black-green
Orange
239
Orange
240
Orange
241
Blue
242
Blue
243
Blue
244
Black
245
Black
246
Black
247
Black
248
Green
249
Gray
250
Violet
429
WIRING DIAGRAM
Violet
252
Blue
253
Yellow
254
Red
255
Gray
256
Black-blue
257
Green-red
258
White
260
Blue-orange
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
251
430
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
WIRING DIAGRAM
431
130,131,138,159,162,129,150,133,132
-X500
B+
152
161
154
261
157
Neu-P1
163
TAC-P1
#702
GND-P1
MIL-P1
CAN-H
155,180
-B11
AY/1
BJ/1
-X20
-M3
BI/2
AU/2
-S9
t
AV/2
DA/4
-X23 CR/1
1
-X24 CR/1
/1.B4
-X21 CR/1
ACC1
18
17
-X403
51
53
56
73
59
22
76
75
78
55,54
57
79
58
ET/18
flaR-X200
flaL-X200
GND#1
ES/18
87
80
/1.E4
/1.E3
/1.E3
-X25
-X22 CR/1
58,59
56,57
55
/1.A5
lig-X3
237
234
236
235
4,5,6
10A
10A
10A
-F3 -F4 -F9
22
-S8
18
CR/1
72
52
2.4 2.3 2.2 2.1
AN/4
2.1
72,174
74
17
CU/4
AL/2
AT/2
-X52
73
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
-X18
/2.B6
108
76,77
174
134
132
141
/1.D3
/2.C3
/2.D7
/2.B6
/2.B3
/2.D7
-X19
91
CAN-L
71,136,137,172
77
87
235
-X201
232
237
54
52,53
51
231
236
AH/2
233
-S10
-H5
119
172
139,160
DB/4
-H4
DI/2
75
-S11
CX/2
CW/2
140
165
162
163
160
159
140
157
119
92
155
153
141,142,158
/2.D6
156,179
AD/12
166
164
261
161
112
158
143
156
154
152
142
144
143
144,153,169,182
BD/12
118
P.light
-X1
HI
BY/4
-H6
-H7
-H8
/1.B3
139
137
138
136
71
LO
-X200
CV/4
AK/2
130
181
-S7
110
AJ/3
CX/2
131
111
tlig-H1
GND#2 109,118,129,167,171,181,150
C_AX/2
164
CX/2
/1.B6
-B15
165
BG/3
CW/2
259
112
166
109
170
108
169
78
173
179
110
CW/2
/2.C3
133
167
135
168
CLU-S6
80,135
180
170,171
AK/2
/2.B7
231
182
1190 RC8 (R) 2009
79,134
91
AR/3
92
7
6
5
4
3
2
2
1
2
1
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
8
2
1
AH/2
CW/2
4
3
2
1
1
EV/26
AL/2
CX/2
AT/2
3
2
1
CX/2
EW/4
2
1
AM/3
CW/2
-S5
-H2
-B14 t
-P1
G
-B10
high
low
pos.
-H1
-H3
-S6
432
WIRING DIAGRAM
43.3
3 of 3
3 P.
Page:3
600861-01
WIRING DIAGRAM
Components
Wheel speed sensor D1
B11
Fuel level indicator A4
B14
Ambient air temperature sensor B1
B15
Engine coolant temperature sensor (2nd cylinder) F3
H1
Low beam, high beam, parking light DE1
H2
Front right flasher B1
H3
Front left flasher E1
H4
Horn F56
H5
Rear right flasher C8
H6
Brake/tail light CD8
H7
License plate lamp D8
H8
Rear left flasher DE8
M3
P1
S5
S6
S7
S8
S9
S10
S11
X21
X22
X23
X24
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
B10
X500
Radiator fan A45
Combination instrument CD1

Front brake light switch A1
Clutch switch F1
Horn switch, light switch, headlamp flasher button, flasher switch F34
Oil pressure sensor A4
Thermoswitch A5
Rear brake light switch B8
MODE/LAP button F5
Plug-in connector for supplementary equipment (terminal 30) A6

Plug-in connector not used A3
Cable colors
4
5
6
17
18
22
51
52
53
54
55
56
Green
Green
Green
Yellow-blue
White-black
Black-red
White-green
Yellow
Yellow
Brown
Brown
Black
57
Black
58
Violet
59
Violet
71
Yellow
72
Yellow-blue
74
Yellow-red
75
Black-red
76
White-green
77
White-green
78
Yellow
79
Black
80
Violet
433
WIRING DIAGRAM
Yellow-blue
91
Yellow-green
92
Black-green
93
Blue-red
108
Black
109
Brown
110
Gray
111
Yellow-blue
112
Green-gray
118
Brown
119
Brown-red
129
Brown
130
Brown
131
132
133
134
135
136
137
138
139
140
141
142
143
144
150
152
153
154
155
156
157
158
159
160
161
162
163
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
87
Brown
Brown
Brown
Black
Violet
Yellow
Yellow
Brown
Blue
Gray
Yellow-green
Yellow-green
Black-orange
Yellow-orange
Brown
White-red
Yellow-orange
Brown-violet
Black-blue
White-blue
Black-brown
Yellow-green
Brown
Blue
Black-green
Brown
White
164
Red
165
Green
166
Blue-orange
167
Brown
168
Yellow
169
Yellow-orange
170
Brown
171
Brown
172
Yellow
173
Yellow
174
Yellow-blue
179
White-blue
434
WIRING DIAGRAM
Black-blue
181
Brown
182
Yellow-orange
231
Brown
232
Brown
233
Brown
234
Brown
235
Violet
236
Black
237
White
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
180
435
OPERATING SUBSTANCES
436
Brake fluid DOT 4 / DOT 5.1

According to
DOT
Guideline
Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex products.
Supplier
Castrol
RESPONSE BRAKE FLUID SUPER DOT 4
Motorex
Brake Fluid DOT 5.1
Coolant
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends Motorex products.
Mixture ratio
Antifreeze protection: 25 45 C (13

49 F)
50 % corrosion inhibitor/antifreeze
50 % distilled water
Coolant (mixed ready to use)
40 C (40 F)
Antifreeze
Supplier
Motorex
Anti Freeze

According to
JASO T903 MA (
SAE (
p. 452)
p. 452) (SAE 10W/50)
Guideline
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex products.
Fully synthetic engine oil
Supplier
Motorex
Power Synt 4T

According to
JASO T903 MA (
SAE (
p. 452)
p. 452) (SAE 5W/40)
Guideline
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex products.
Synthetic engine oil
Supplier
Motorex
Power Synt 4T
OPERATING SUBSTANCES
437
Fork oil (SAE 5)

According to
SAE ( p. 452) (SAE 5)
Guideline
Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex products.
Supplier
Motorex
Racing Fork Oil
Hydraulic fluid (15)

According to
ISO VG (15)
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Guideline
Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the
corresponding properties. KTM recommends Motorex products.
Supplier
Motorex
Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)

According to
SAE ( p. 452) (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 98 / RON 98 / PON 94)

According to
DIN EN 228 (ROZ 98 / RON 98 / PON 94)
AUXILIARY SUBSTANCES
Chain cleaner
Guideline
KTM recommends Motorex products.
Supplier
Motorex
Chain Clean 611
Chain lube for road use

Guideline
Supplier
Motorex
Chain Lube 622 Strong
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Cleaning and polishing materials for metal, rubber and plastic

Guideline
Supplier
Motorex
Protect & Shine 645
Long-life grease
Guideline
Supplier
Motorex
Fett 2000
Lubricant (T511)
Guideline
KTM recommends Lubcon products.
Supplier
Lubcon
Turmsilon GTI 300 P
Lubricant (T152)
Guideline
KTM recommends BelRay products.
Supplier
BelRay
Molylube AntiSeize
Lubricant (T159)
Guideline
KTM recommends BelRay products.
Supplier
BelRay
MC11
Lubricant (T158)
Guideline
KTM recommends Lubcon products.
Supplier
Lubcon
Turmogrease PP 300
438
AUXILIARY SUBSTANCES
Lubricant (T625)
Guideline
KTM recommends Molykote products.
Supplier
Molykote
33 Medium
Motorcycle cleaner
Guideline
Supplier
Motorex
Moto Clean 900
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
Supplier
Motorex
Clean & Polish
Universal oil spray
Guideline
Supplier
Motorex
Joker 440 Universal
439
SPECIAL TOOLS
440
Bearing puller
Art. no.: 15112017000
400037-01
Circlip pliers reverse
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 51012011000
400059-01
Extractor
Art. no.: 58429009000
400073-01
Valve spring mounter
Art. no.: 59029019000
400101-01
Limit plug gauge

Art. no.: 59029026006
400104-01
SPECIAL TOOLS
441
Feeler gauge
Art. no.: 59029041100
35
30
25
20
15
12
5
10
400110-01
Graduated disc
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 60029010000
400120-01
Plastigauge measuring strips
Art. no.: 60029012000
400122-01
Piston ring mounting tool
Art. no.: 60029015000
400123-01
Insert for bearing puller

Art. no.: 60029018000
Feature
23 28 mm (0.91 1.1 in)
400038-01
SPECIAL TOOLS
442
Step bearing tool

Art. no.: 60029046028
400136-01
Pliers for spring-loaded band-type clamp
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 60029057100
400085-01
Multi-tooth wrench socket 10 mm; " drive
Art. no.: 60029075000
400145-01
Work stand rear
Art. no.: 61029055100
500077-01
Work stand adapter

Art. no.: 61029055120
700270-01
SPECIAL TOOLS
443
Front work stand

Art. no.: 61029055300
500078-01
Pressure testing tool
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 61029094000
400149-01
Engine work stand
Art. no.: 61229001000
200306-01
Engine holder
Art. no.: 61229002000
200307-01
Clutch holder
Art. no.: 61229003000
200308-01
SPECIAL TOOLS
444
Mounting sleeve
Art. no.: 61229005000
200309-01
Pressure piece
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 61229008000
200438-01
Extractor
Art. no.: 61229010000
200310-01
Press drift
Art. no.: 61229013000
200311-01
Engine blocking screw

Art. no.: 61229015000
200312-01
SPECIAL TOOLS
445
Pressure bell
Art. no.: 61229016000
200313-01
Arms for extractor 78029033100
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 61229017000
200314-01
Pressure piece
Art. no.: 61229018000
200315-01
Extractor
Art. no.: 61229020000
200316-01
Release device for timing chain tensioner

Art. no.: 61229021000
200317-01
SPECIAL TOOLS
446
Hex key bit

Art. no.: 61229025000
200318-01
Press drift/press sleeve
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 61229044000
200319-01
Press sleeve
Art. no.: 61229045000
200320-01
Frame support
Art. no.: 61229050000
400490-01
Centering pin
Art. no.: 61229051000
400491-01
SPECIAL TOOLS
447
Floor jack attachment

Art. no.: 61229055000
400184-01
Work stand
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 62529055000
400151-01
Adjustment gauge, control time, cylinder 2
Art. no.: 69129030000
301465-10
Adjustment gauge, control time, cylinder 1
Art. no.: 69129130000
301466-10
Piston pin lock ring insert

Art. no.: 75029035000
400160-01
SPECIAL TOOLS
448
Oil pressure testing adapter

Art. no.: 75029094000
400169-01
Spark plug wrench
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: 75029172000
400170-01
Puller, 2-arm
Art. no.: 78029033100
500166-01
Valve spring mounting device
Art. no.: 78029060000
500165-01
Hook wrench
Art. no.: T106S
301085-01
SPECIAL TOOLS
449
Depth micrometer
Art. no.: T107S
300577-10
Pressing tool
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: T1206
200583-10
Pressing tool
Art. no.: T1207S
200585-01
Pressing tool
Art. no.: T129
200584-01
Gripping tool
Art. no.: T14026S1
200639-10
SPECIAL TOOLS
450
Open-end wrench
Art. no.: T14032
200640-10
Nitrogen filling tool
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Art. no.: T170S1
300574-10
Mounting sleeve
Art. no.: T313
300578-10
Key
Art. no.: T524
200641-10
Clamping stand
Art. no.: T526S
200636-10
SPECIAL TOOLS
451
Clamping stand
Art. no.: T612S
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
200638-10
STANDARDS
452
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With 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
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
453
torque limiter and idler, installing . . . . . . . . . . . . . . . 176
transmission shaft, installing . . . . . . . . . . . . . . . . . . 164
water pump wheel, installing . . . . . . . . . . . . . . . . . . 173
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air filter
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Ambient air pressure sensor
. . . . . . . . . . . . . . . . . . . . . . 225
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Blank time of the LAP button LAP BLANK T
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Blink code
engine control . . . . . . . . . . . . . . . . . . . . . . . . . 238-390
immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 229-237
Brake disc of rear brake
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Assembling the engine

balancer shaft, installing . . . . . . . . . . . . . . . . . . . . . 174
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 172
clutch facing, installing . . . . . . . . . . . . . . . . . . . . . . 171
crankshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 165
drive wheel of the balancer shaft, installing . . . . . . . . 173
engine bracket, mounting . . . . . . . . . . . . . . . . . . . . 189
engine, dismounting from work stand . . . . . . . . . . . . 189
force pump, installing . . . . . . . . . . . . . . . . . . . . . . . 168
front camshafts, installing . . . . . . . . . . . . . . . . . . . . 182
front cylinder control time, adjusting . . . . . . . . . . . . . 186
front cylinder control time, checking . . . . . . . . . . . . . 186
front cylinder head, installing . . . . . . . . . . . . . . . . . . 182
front piston, installing . . . . . . . . . . . . . . . . . . . . . . . 180
front timing chain tensioner, installing . . . . . . . . 183, 207
front valve clearance, adjusting . . . . . . . . . . . . . . . . 188
front valve clearance, checking . . . . . . . . . . . . . . . . . 187
front valve cover, installing . . . . . . . . . . . . . . . . . . . 188
gear position sensor, installing . . . . . . . . . . . . . . . . . 173
generator cover, installing . . . . . . . . . . . . . . . . . . . . 176
heat exchanger, installing . . . . . . . . . . . . . . . . . . . . 183
idler and timing chain on the left, installing . . . . . . . . 174
idler and timing chain on the right, installing . . . . . . . 172
ignition pulse generator, installing . . . . . . . . . . . . . . 176
ignition top dead center of the front cylinder, setting . . 180
ignition top dead center of the rear cylinder, setting . . 169
left engine case, installing . . . . . . . . . . . . . . . . . . . . 166
left suction pump, installing . . . . . . . . . . . . . . . . . . 169
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 167
middle suction pump, installing . . . . . . . . . . . . . . . . 165
oil drain plug, installing . . . . . . . . . . . . . . . . . . . . . . 176
oil filler tube, installing . . . . . . . . . . . . . . . . . . . . . . 184
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 175
oil spray tube, installing . . . . . . . . . . . . . . . . . . . . . 164
outer clutch hub, installing . . . . . . . . . . . . . . . . . . . 170
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 170
rear camshaft, installing . . . . . . . . . . . . . . . . . . . . . 179
rear cylinder control time, adjusting . . . . . . . . . . . . . 184
rear cylinder control time, checking . . . . . . . . . . . . . . 184
rear cylinder head, installing . . . . . . . . . . . . . . . . . . 178
rear piston, installing . . . . . . . . . . . . . . . . . . . . . . . 177
rear timing chain tensioner, installing . . . . . . . . 179, 207
rear valve clearance, adjusting . . . . . . . . . . . . . . . . . 186
rear valve clearance, checking . . . . . . . . . . . . . . . . . 185
rear valve cover, installing . . . . . . . . . . . . . . . . . . . . 188
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
shift drum locating, installing . . . . . . . . . . . . . . . . . . 167
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 167
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 184
timing chain rails of the left engine case section, installing 163
timing chain rails of the right engine case section,
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Brake discs, front

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 95
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 95
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
front brake linings, changing . . . . . . . . . . . . . . . . . . .
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . .
rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . .
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . .
93
93
93
97
96
Camshaft, rear
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Camshafts, front
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Chain
checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Chain sliding guard
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Clutch
fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . 191
fluid level, correcting . . . . . . . . . . . . . . . . . . . . . . . 191
Clutch lever
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 32
Combination instrument
activating BOOTLOADER mode . . . . . . . . . . . . . . . . . . 105
updating software . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Connector overview . . . . . . . . . . . . . . . . . . . . . . . . . 391-404
Conservation for winter operation . . . . . . . . . . . . . . . . . . . 417
Control unit of electric starter lock . . . . . . . . . . . . . . . . . . . 88
INDEX
454
Coolant
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Cooling system
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
filling compensating tank . . . . . . . . . . . . . . . . . . . . . 197
. . . . . . . . . . . . . . . . . . . . . . . 218
D
129
131
132
135
122
122
122
133
126
126
127
126
123
130
127
124
128
132
127
126
123
135
130
135
136
124
129
137
132
125
125
125
124
123
128
134
134
124
137
EFI control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

activation code, requesting . . . . . . . . . . . . . . . . . . .
coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228,
227
227
227
335
Engine
ignition top dead center of the front cylinder, setting
ignition top dead center of the rear cylinder, setting
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
preparing for installation . . . . . . . . . . . . . . . . . . .
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
120
117
117
115
.
.
.
.
.
.
.
.
.
.
Engine - Work on individual parts

clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . .
conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
countershaft, assembling . . . . . . . . . . . . . . . . . . . . .
countershaft, dismantling . . . . . . . . . . . . . . . . . . . .
cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . .
cylinder, checking/measuring . . . . . . . . . . . . . . . . . .
left engine case section . . . . . . . . . . . . . . . . . . . . . .
left main bearing, installing . . . . . . . . . . . . . . . . . . .
left main bearing, removing . . . . . . . . . . . . . . . . . . .
main bearing of the right engine case section, removing
main bearing shells, selecting . . . . . . . . . . . . . . . . .
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . .
main shaft, dismantling . . . . . . . . . . . . . . . . . . . . . .
oil pressure regulator valve, checking . . . . . . . . . . . .
oil pumps, checking . . . . . . . . . . . . . . . . . . . . . . . .
piston ring end gap, checking . . . . . . . . . . . . . . . . . .
piston, checking/measuring . . . . . . . . . . . . . . . . . . .
piston/cylinder mounting clearance, checking . . . . . . .
radial clearance of the bottom connecting rod bearing,
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
right engine case section . . . . . . . . . . . . . . . . . . . . .
right idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
right main bearing, installing . . . . . . . . . . . . . . . . . .
shift mechanism, checking . . . . . . . . . . . . . . . . . . .
shift shaft, preassembling . . . . . . . . . . . . . . . . . . . .
step bearing of the crankshaft, changing . . . . . . . . . .
timing assembly, checking . . . . . . . . . . . . . . . . . . . .
timing chain tensioner for installation, preparing . . . . .
transmission, checking . . . . . . . . . . . . . . . . . . . . . .
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Disassembling the engine

balancer shaft, removing . . . . . . . . . . . . . . . . . . . . .
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . .
clutch facing, removing . . . . . . . . . . . . . . . . . . . . . .
crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . .
engine bracket, removing . . . . . . . . . . . . . . . . . . . . .
engine oil, draining . . . . . . . . . . . . . . . . . . . . . . . . .
engine, clamping into engine work stand . . . . . . . . . .
force pump, removing . . . . . . . . . . . . . . . . . . . . . . .
front camshafts, removing . . . . . . . . . . . . . . . . . . . .
front cylinder head, removing . . . . . . . . . . . . . . . . . .
front piston, removing . . . . . . . . . . . . . . . . . . . . . . .
front timing chain tensioner, removing . . . . . . . . . . . .
front valve cover, removing . . . . . . . . . . . . . . . . . . . .
gear position sensor, removing . . . . . . . . . . . . . . . . .
generator cover, removing . . . . . . . . . . . . . . . . . . . .
heat exchanger, removing . . . . . . . . . . . . . . . . . . . .
idler and timing chain on the left, removing . . . . . . . .
idler and timing chain on the right, removing . . . . . . .
ignition pulse generator, removing . . . . . . . . . . . . . . .
ignition top dead center of the front cylinder, setting . .
ignition top dead center of the rear cylinder, setting . .
left engine case, removing . . . . . . . . . . . . . . . . . . . .
left suction pump, removing . . . . . . . . . . . . . . . . . . .
locking lever, removing . . . . . . . . . . . . . . . . . . . . . .
middle suction pump, removing . . . . . . . . . . . . . . . .
oil filler tube, removing . . . . . . . . . . . . . . . . . . . . . .
oil filter, removing . . . . . . . . . . . . . . . . . . . . . . . . .
oil spray tube, removing . . . . . . . . . . . . . . . . . . . . .
outer clutch hub, removing . . . . . . . . . . . . . . . . . . .
rear camshaft, removing . . . . . . . . . . . . . . . . . . . . .
rear cylinder head, removing . . . . . . . . . . . . . . . . . .
rear piston, removing . . . . . . . . . . . . . . . . . . . . . . .
rear timing chain tensioner, removing . . . . . . . . . . . .
rear valve cover, removing . . . . . . . . . . . . . . . . . . . .
rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
shift drum locating, removing . . . . . . . . . . . . . . . . . .
shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . .
starter motor, removing . . . . . . . . . . . . . . . . . . . . . .
timing chain rails of the left engine case section, removing
timing chain rails of the right engine case section, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
transmission shaft, removing . . . . . . . . . . . . . . . . . .
water pump wheel, removing . . . . . . . . . . . . . . . . . .
137
136
131
Dismantling the engine

drive wheel of the balancer shaft, removing . . . . . . . . 129
primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 133
torque limiter and idler, removing . . . . . . . . . . . . . . . 128
145
156
144
161
159
149
152
147
141
143
143
139
140
161
158
155
155
149
148
149
147
138
153
140
157
158
146
154
154
160

cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil
adding .
changing
draining
refilling .
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213
209
209
212
Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Engine oil pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Exhaust air injection valve
. . . . . . . . . . . . . . . . . . . . . . . 190
Exhaust cover
installing completely . . . . . . . . . . . . . . . . . . . . . . . . . 63
INDEX
455
removing completely . . . . . . . . . . . . . . . . . . . . . . . . . 63
Exhaust system
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
External temperature display
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
F
Filter box bottom
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Foot brake pedal
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Headlight adjustment
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
High beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
I
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Ignition key
activating/deactivating . . . . . . . . . . . . . . . . . . . . . . . 102
Immobilizer control unit . . . . . . . . . . . . . . . . . . . . . . . . . 102
activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injector
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Foot brake pedal stub

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Handlebar height
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Footrest position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fork
adjusting rebound . . . . . . . . . .
adjusting the spring preload . . .
compression damping, adjusting
fork legs, bleeding . . . . . . . . .
installing . . . . . . . . . . . . . . . .
removing . . . . . . . . . . . . . . . .
Fork legs
assembling . . . . . . . . . .
checking . . . . . . . . . . . .
disassembling . . . . . . . .
fork service, performing . .
lower DU bush, changing .
outer tubes, assembling . .
outer tubes, disassembling
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15
16
15
16
19
18
27
25
21
21
26
27
24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Inside cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
K
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Kilometers/miles SET KM/MILES
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
L
Lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Lambda sensor heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Low beam bulb

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Lower DU bush
fork legs, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 26
M
Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fork service, performing . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Front cylinder control time

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Manifold absolute pressure sensor . . . . . . . . . . . . . . . . . . 223

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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Fuel pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
checking during the actuator test . . . . . . . . . . . . . . . . 74
Fuel reserve display TRIP F RESET
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Motorcycle
cleaning . . . . . . . . . . . .
jacking up front . . . . . . .
jacking up in the middle .
jacking up rear . . . . . . . .
taking front off work stand
taking rear from work stand
work stand, removing from
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. . 417
. . . 10
10, 12
. . . 13
. . . 10
. . . 13
. 11-12
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Number of laps SET NUM LAPS

setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Fuel tank guard

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Fuse
individual power consumers, changing . . . . . . . . . . . . . 91
H
Hand brake lever
basic position, adjusting
. . . . . . . . . . . . . . . . . . . . . . 96
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
checking / cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 216
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
INDEX
456
Oil screen
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Shift lever stub

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Oil screens
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Shift speed RPM1/2

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Outer tubes
fork legs, assembling . . . . . . . . . . . . . . . . . . . . . . . . 27
fork legs, disassembling . . . . . . . . . . . . . . . . . . . . . . 24
P
Parking light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Passenger seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Putting into operation

after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
RACE mode
setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Radiator
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Rear brake system
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Rear cylinder control time
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Rear frame position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear hub cush drive
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Rear sprocket / engine sprocket
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
installing - when installing the engine . . . . . . . . . . . . . 82
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ROAD mode
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Rollover sensor
S
Shock absorber
adjusting the spring preload . . . . . . . . . . .
bleeding and filling . . . . . . . . . . . . . . . . .
compression damping, high-speed, adjusting
compression damping, low-speed, adjusting
damper, assembling . . . . . . . . . . . . . . . .
damper, checking . . . . . . . . . . . . . . . . . .
damper, disassembling . . . . . . . . . . . . . .
heim joint, installing . . . . . . . . . . . . . . . .
heim joint, removing . . . . . . . . . . . . . . . .
installing . . . . . . . . . . . . . . . . . . . . . . . .
nitrogen, filling damper with . . . . . . . . . .
piston rod, assembling . . . . . . . . . . . . . .
piston rod, disassembling . . . . . . . . . . . .
rebound damping, adjusting . . . . . . . . . . .
removing . . . . . . . . . . . . . . . . . . . . . . . .
servicing . . . . . . . . . . . . . . . . . . . . . . . .
spring, installing . . . . . . . . . . . . . . . . . .
spring, removing . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Seat
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Service interval SERVICE RESET
resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 420-421

Servicing the shock absorber . . . . . . . . . . . . . . . . . . . . . . 48
SET C/F temperature unit
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SET CLOCK
setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Shift lever
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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45
55
44
44
53
51
49
60
59
47
58
52
50
45
46
48
59
48
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 8

Side covers
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Side stand switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering damper
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering damper part number . . . . . . . . . . . . . . . . . . . . . . . . 9
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
T
Technical data
chassis . . . . . . . . . . . . . . .
chassis tightening torques . .
engine . . . . . . . . . . . . . . .
engine - tolerance, wear limits
engine tightening torques . .
fork . . . . . . . . . . . . . . . . .
shock absorber . . . . . . . . . .
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. 411-412
. 415-416
. 405-406
. 407-408
. 409-410
. . . . 413
. . . . 414
Throttle cable at throttle valve

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Throttle position sensor circuit A . . . . . . . . . . . . . . . . . . . 219
adjusting the position . . . . . . . . . . . . . . . . . . . . . . . 220
checking in the "zero" position . . . . . . . . . . . . . . . . . 219
. . . . . . . . . . . . . . . . . . . 223
Throttle valve body

reinstalling when adjustments have been made . . . . . . 222
removing to adjust . . . . . . . . . . . . . . . . . . . . . . . . . 221
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INDEX
457
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Trouble code
engine control
. . . . . . . . . . . . . . . . . . . . . . . . . 238-390
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
V
Valve clearance
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Valve clearance, front
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Valve clearance, rear
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
....................... 8
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
Vehicle identification number
Vehicle level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
front, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
rear, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 422-435
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
*3206077en*
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
3206077en
04/2009
Photo: Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com

KTM RC8 Repair Manual

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KTM RC8 Repair Manual

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REPAIR MANUAL 2009

1190 RC8 R EU/UK

Only use ORGINAL KTM SPARE PARTS.

2009 by KTM-Sportmotorcycle AG, Mattighofen Austria

ISO 9001(12 100 6061)

Servicing the shock absorber ..........................................

MEANS OF REPRESENTATION ............................................ 6

Fuel pump relay ............................................................ 88

Adjusting the front cylinder control time ........................

Preparing the timing chain tensioner for installation .......

Injector cylinder 2 connector DQ...................................

Reinstalling the throttle valve body when the

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

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

The typographical formats used in this document are explained below.

Identifies a proprietary name.

Identifies a protected name.

Identifies a brand available on the open market.

Spare parts, accessories

Pay close attention to the notes/warnings.

LOCATION OF SERIAL NUMBERS

Vehicle identification number/type label

The key number Code number can be found on the KEYCODECARD.

The engine number is stamped on the right side of the engine.

Fork part number

Shock absorber part number

LOCATION OF SERIAL NUMBERS

Jacking up motorcycle front

Always place the vehicle on a firm and even surface.

Jack up the motorcycle at the rear. (

Taking front of motorcycle off work stand

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Secure the motorcycle against falling over.

Remove the work stand from the front.

Jacking up the motorcycle in the middle (screw-in type)

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Remove screws . Take off the footrest bracket.

Unplug connector of the brake light switch. Remove cable binder .

Remove screw . Hang the brake fluid reservoir to the side.

Remove screws . Hang the footrest bracket to the side.

Jack up the motorcycle.

Check that the work stand is seated correctly.

Removing the motorcycle from the work stand (screw-in type)

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Position the footrest bracket. Mount and tighten screws .

Position the brake fluid reservoir. Mount and tighten screw .

Position the footrest bracket. Mount and tighten screws .

Position the shift rod. Mount and tighten screw .

Jacking up the motorcycle in the middle (insertable type)

Jack up the motorcycle.

Check that the work stand is seated correctly.

Removing the motorcycle from the work stand (insertable type)

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Remove the work stand.

Work stand (62529055000) (

Jacking up motorcycle at the rear

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Taking the rear from the workstand

Danger of damageThe parked vehicle can roll away or fall over.