RC8R Workshop Manul 3206077 PDF

REPAIR MANUAL 2009
1190 RC8 R EU/UK

1190 RC8 R AUS
1190 RC8 R FR
1190 RC8 R JP
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Article no. 3206077en
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INTRODUCTION 1
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.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not form part of the regular scope of delivery.
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© 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.
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ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
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to the maximum possible quality of the products.

Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
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CONTENTS 2
Servicing the shock absorber .......................................... 48

CONTENTS
MEANS OF REPRESENTATION ............................................ 6

IMPORTANT NOTES ............................................................ 7 Removing the spring ...................................................... 48
LOCATION OF SERIAL NUMBERS ........................................ 8 Disassembling the damper ............................................. 49
Vehicle identification number/type label ............................ 8 Disassembling the piston rod .......................................... 50
Key number .................................................................... 8 Checking the damper ..................................................... 51
Engine number................................................................ 8 Assembling the piston rod .............................................. 52
Fork part number............................................................. 8 Assembling the damper.................................................. 53
Shock absorber part number............................................. 8 Bleeding and filling the damper ...................................... 55
Steering damper part number ........................................... 9 Filling the damper with nitrogen ..................................... 58
MOTORCYCLE................................................................... 10 Installing the spring....................................................... 59
Jacking up motorcycle front............................................ 10 Removing the heim joint ................................................ 59
Taking front of motorcycle off work stand......................... 10 Installing the heim joint ................................................. 60
Jacking up the motorcycle in the middle (screw-in type).... 10 05/EXHAUST .................................................................... 62
Removing the motorcycle from the work stand (screw-in Lambda sensor.............................................................. 62
type) ............................................................................ 11 Lambda sensor heater .................................................... 62
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Jacking up the motorcycle in the middle (insertable Removing the exhaust cover completely ........................... 63
type) ............................................................................ 12 Installing the exhaust cover completely............................ 63
Removing the motorcycle from the work stand (insertable Removing the exhaust system ......................................... 63
type) ............................................................................ 12 Installing the exhaust system.......................................... 65
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Jacking up motorcycle at the rear.................................... 13 06/AIR FILTER.................................................................. 67
Taking the rear from the workstand ................................. 13 Removing the air filter ................................................... 67
Starting ........................................................................ 13 Installing the air filter .................................................... 67
01/FORK, TRIPLE CLAMP.................................................. 15 Removing the filter box bottom ....................................... 67
Adjusting the compression damping of the fork ................ 15
9- k. Installing the filter box bottom........................................ 68
Adjusting the rebound damping of the fork....................... 15 07/FUEL TANK, SEAT, TRIM.............................................. 70
Adjusting the spring preload of the fork ........................... 16 Removing the seat ......................................................... 70
Bleeding fork legs.......................................................... 16 Fitting the seat.............................................................. 70
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Vehicle level ................................................................. 17 Removing the passenger seat.......................................... 70
Adjusting front vehicle level............................................ 17
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Mounting the passenger seat .......................................... 70

Removing the fork ......................................................... 18 Dismounting the fuel tank .............................................. 70
Installing the fork .......................................................... 19 Installing the fuel tank ................................................... 71
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performing a fork service ................................................ 21 Removing the fuel tank guard ......................................... 72
Disassembling the fork legs ............................................ 21 Installing the fuel tank guard.......................................... 73
Disassembling the outer tubes ........................................ 24 Checking the fuel pressure ............................................. 73
Checking the fork legs.................................................... 25 Checking the fuel pressure during the actuator test........... 74
changing the lower DU bush ........................................... 26
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08/MASK, FENDER, DECAL ............................................... 75

Assembling the outer tubes ............................................ 27 Removing the side covers ............................................... 75
Assembling the fork legs ................................................ 27 Installing the side covers................................................ 75
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 32
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Removing the inside cover.............................................. 75

Adjusting basic position of clutch lever............................ 32 Installing the inside cover .............................................. 76
Adjusting the steering damper ........................................ 32 09/FRONT WHEEL ............................................................ 77
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Adjusting the handlebar height ....................................... 32 Removing the front wheel ............................................... 77
Adjusting the play in the throttle cable ............................ 33 Installing the front wheel................................................ 77
Throttle grip.................................................................. 34 Checking the tire condition............................................. 78
Changing the throttle grip............................................... 34 Checking the tire pressure .............................................. 79
Adjusting the throttle cable at the throttle valve................ 37 Checking the front brake discs........................................ 80
03/FRAME........................................................................ 40 10/REAR WHEEL .............................................................. 81
Side stand switch .......................................................... 40 Removing the rear wheel ................................................ 81
Footrest position............................................................ 40 Installing the rear wheel ................................................. 81
Adjusting footrest position .............................................. 40 Installing the rear wheel - when installing the engine ........ 82
Rear frame position ....................................................... 41 Checking the rear brake disc........................................... 83
Adjusting the rear frame position .................................... 41 Checking for chain dirt................................................... 83
04/SHOCK ABSORBER, SWINGARM................................... 44 Cleaning the chain......................................................... 84
Adjusting the low-speed compression damping of the Checking the chain tension ............................................ 84
shock absorber .............................................................. 44
Adjusting the chain tension ............................................ 85
Adjusting the high-speed compression damping of the
Checking rear sprocket / engine sprocket for wear ............. 85
shock absorber .............................................................. 44
Checking chain wear ...................................................... 86
Adjusting the rebound damping of the shock absorber....... 45
Checking chain sliding guard .......................................... 86
Adjusting the spring preload of the shock absorber ........... 45
Checking rear hub cush drive.......................................... 86
Adjusting the vehicle level at the rear .............................. 46
11/WIRING HARNESS, BATTERY ....................................... 88
Removing the shock absorber ......................................... 46
Electric starter lock control unit ...................................... 88
Installing the shock absorber .......................................... 47
CONTENTS 3
Fuel pump relay ............................................................ 88 Removing the heat exchanger ....................................... 124
Removing the battery ..................................................... 88 Removing the rear timing chain tensioner ...................... 124
Installing the battery...................................................... 89 Removing the rear camshaft ......................................... 125
Recharging the battery ................................................... 90 Removing the rear cylinder head ................................... 125
Changing the main fuse ................................................. 91 Removing the rear piston.............................................. 125
Changing the fuses of individual power consumers............ 91 Setting the engine to ignition top dead center of the
13/BRAKE SYSTEM........................................................... 93 front cylinder .............................................................. 126
Brake linings................................................................. 93 Removing the front timing chain tensioner ..................... 126
Checking the front brake linings...................................... 93 Removing the front camshafts ...................................... 126
Changing the front brake linings ..................................... 93 Removing the front cylinder head.................................. 126
Checking the front brake fluid level ................................. 95 Removing the front piston ............................................ 127
Adding front brake fluid ................................................. 95 Removing the generator cover ....................................... 127
Adjusting the basic position of the hand brake lever.......... 96 Removing the ignition pulse generator ........................... 127
Checking the rear brake linings ....................................... 96 Removing the torque limiter and idler............................ 128
Changing the rear brake linings....................................... 97 Removing the rotor ...................................................... 128
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Checking the rear brake fluid level .................................. 99 Removing the idler and timing chain on the left ............. 128
Adding rear brake fluid .................................................. 99 Removing the oil filter.................................................. 129
Adjusting the foot brake pedal stub ............................... 100 Removing the balancer shaft ........................................ 129
Adjusting the foot brake pedal ...................................... 100 Removing the drive wheel of the balancer shaft .............. 129
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Removing the rear brake system.................................... 101 Removing the gear position sensor ................................ 130
Installing the rear brake system .................................... 101 Removing the left suction pump ................................... 130
14/LIGHT SYSTEM, INSTRUMENTS ................................. 102 Removing the water pump wheel................................... 131
Immobilizer control unit ............................................... 102 Removing the clutch cover ........................................... 131
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Activating/deactivating ignition key ............................... 102 Removing the idler and timing chain on the right............ 132
Activating the ICU ....................................................... 104 Removing the clutch facing .......................................... 132
Combination instrument - Activation of the Removing the outer clutch hub ..................................... 132
BOOTLOADER mode.................................................... 105 Removing the primary gear ........................................... 133
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Updating the combination instrument software............... 105 Removing the force pump ............................................ 133
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Setting ROAD or RACE mode........................................ 106 Removing the shift shaft .............................................. 134
Setting the clock with SET CLOCK ................................ 106 Removing the shift drum locating.................................. 134
Adjusting shift speed RPM1/2 ...................................... 106 Removing the locking lever........................................... 135
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Setting the blank time of the LAP button Removing the left engine case ...................................... 135
LAP BLANK T ............................................................. 107 Removing the crankshaft .............................................. 135
Setting the number of laps SET NUM LAPS ................... 107 Removing the middle suction pump .............................. 136
Setting the fuel reserve display TRIPF RESET ................ 108 Removing the transmission shaft................................... 136
Setting the kilometers/miles SET KM/MILES .................. 108 Removing the oil spray tube ......................................... 137
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Setting the temperature unit SET °C/°F ......................... 109 Removing the timing chain rails of the right engine case
Switching the external temperature display on/off ........... 109 section ....................................................................... 137
Resetting service display .............................................. 110 Removing the timing chain rails of the left engine case
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Checking the headlight setting...................................... 110 section ....................................................................... 137

Adjust the headlight range............................................ 111 30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 138
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Changing the parking light bulb .................................... 111 Work on the right section of the engine case .................. 138
Changing the low beam bulb......................................... 112 Removing the main bearing of the right engine case
Changing the high beam bulb ....................................... 113 section ....................................................................... 139
30/ENGINE..................................................................... 115 Selecting the main bearing shells.................................. 140
Removing the engine ................................................... 115 Installing the right main bearing ................................... 140
Preparing the engine for installation .............................. 117 Work on the left section of the engine case .................... 141
Installing the engine .................................................... 117 Removing the left main bearing .................................... 143
Setting the engine to ignition top dead center of the Installing the left main bearing ..................................... 143
rear cylinder................................................................ 120 Changing the conrod bearing ........................................ 144
Setting the engine to ignition top dead center of the Work on the clutch cover .............................................. 145
front cylinder .............................................................. 121 Changing the step bearing of the crankshaft................... 146
30/DISASSEMBLING THE ENGINE................................... 122 Checking the radial clearance of the bottom connecting
Clamping the engine into the engine work stand ............. 122 rod bearing ................................................................. 147
Removing the engine bracket........................................ 122 Checking/measuring the cylinder................................... 147
Draining the engine oil ................................................. 122 Checking/measuring the piston ..................................... 148
Removing the front valve cover ..................................... 123 Checking the piston ring end gap .................................. 149
Removing the rear valve cover....................................... 123 Checking the piston/cylinder mounting clearance............ 149
Setting the engine to ignition top dead center of the Work on the cylinder head ............................................ 149
rear cylinder................................................................ 123 Checking the cylinder head .......................................... 152
Removing the starter motor .......................................... 124 Work on the right idler ................................................. 153
Removing the oil filler tube .......................................... 124 Checking the timing assembly ...................................... 154
CONTENTS 4
Preparing the timing chain tensioner for installation ....... 154 Adjusting the front cylinder control time ........................ 186
Checking the oil pressure regulator valve........................ 155 Checking the front valve clearance ................................ 187
Checking the oil pumps................................................ 155 Adjusting the front valve clearance................................ 188
Checking the clutch..................................................... 156 Installing the front valve cover ...................................... 188
Checking the shift mechanism ...................................... 157 Installing the rear valve cover ....................................... 188
Preassembling the shift shaft........................................ 158 Mounting the engine bracket ........................................ 189
Dismantling the main shaft .......................................... 158 Dismounting the engine from the work stand.................. 189
Dismantling the countershaft........................................ 159 31/SECONDARY AIR SYSTEM .......................................... 190
Checking the transmission............................................ 160 Exhaust air injection .................................................... 190
Assembling the main shaft ........................................... 161 32/CLUTCH .................................................................... 191
Assembling the countershaft......................................... 161 Checking fluid level of hydraulic clutch ......................... 191
30/ASSEMBLING THE ENGINE ........................................ 163 Correcting fluid level of hydraulic clutch ........................ 191
Installing the timing chain rails of the left engine case 34/SHIFT MECHANISM ................................................... 192
section ....................................................................... 163 Adjusting shift lever stub.............................................. 192
Installing the timing chain rails of the right engine case Adjusting shift lever..................................................... 192
section ....................................................................... 163
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35/WATER PUMP, COOLING SYSTEM .............................. 194
Installing the oil spray tube .......................................... 164 Checking the coolant level............................................ 194
Installing the transmission shaft ................................... 164 Checking the antifreeze................................................ 194
Installing the middle suction pump ............................... 165 Removing the radiator .................................................. 195
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Installing the crankshaft............................................... 165 Installing the radiator................................................... 195
Installing the left engine case ....................................... 166 Adding coolant/bleeding the cooling system ................... 196
Installing the locking lever............................................ 167 Filling the cooling system compensating tank................. 197
Installing the shift drum locating .................................. 167 36/CYLINDER HEAD........................................................ 198
Installing the shift shaft ............................................... 167
9- k. Engine coolant temperature sensor cylinder 1 ................ 198
Installing the force pump ............................................. 168 Engine coolant temperature sensor for cylinder 2............ 199
Installing the left suction pump .................................... 169 Checking the valve clearance ........................................ 200
Setting the engine to ignition top dead center of the Adjusting the rear valve clearance ................................. 201
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rear cylinder................................................................ 169
Adjusting the front valve clearance................................ 202
Installing the primary gear............................................ 170
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Checking the rear cylinder control time.......................... 202

Installing the outer clutch hub...................................... 170
Checking the front cylinder control time ........................ 202
Installing the clutch facing........................................... 171
Adjusting the rear cylinder control time ......................... 203
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Installing the idler and timing chain on the right ............ 172
Adjusting the front cylinder control time ........................ 204
Installing the clutch cover ............................................ 172
Removing the rear camshaft ......................................... 205
Installing the water pump wheel ................................... 173
Installing the rear camshaft .......................................... 205
Installing the gear position sensor ................................. 173
Removing the front camshafts ...................................... 206
Installing the drive wheel of the balancer shaft............... 173
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Installing the front camshafts ....................................... 206

Installing the balancer shaft ......................................... 174
Installing the rear timing chain tensioner ....................... 207
Installing the idler and timing chain on the left .............. 174
Installing the front timing chain tensioner...................... 207
Installing the oil filter .................................................. 175
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38/LUBRICATION SYSTEM .............................................. 208

Installing the rotor ....................................................... 175
Oil circuit ................................................................... 208
Installing the torque limiter and idler ............................ 176
Checking the engine oil level ........................................ 209
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Installing the ignition pulse generator............................ 176

Changing the engine oil and filter, cleaning the oil
Installing the generator cover........................................ 176 screens....................................................................... 209
Installing the oil drain plug........................................... 176 Draining engine oil, cleaning oil screens ........................ 209
Installing the rear piston .............................................. 177 Removing the oil filter.................................................. 211
Installing the rear cylinder head.................................... 178 Installing the oil filter .................................................. 212
Installing the rear camshaft .......................................... 179 Filling up with engine oil.............................................. 212
Installing the rear timing chain tensioner ....................... 179 Adding engine oil ........................................................ 213
Setting the engine to ignition top dead center of the Checking the engine oil pressure................................... 213
front cylinder .............................................................. 180
Removing the oil jet for the clutch lubrication ................ 215
Installing the front piston ............................................. 180
Checking / cleaning the oil jet for clutch lubrication........ 216
Installing the front cylinder head................................... 182
Installing the oil jet for the clutch lubrication................. 216
Installing the front camshafts ....................................... 182
39/IGNITION SYSTEM ..................................................... 218
Installing the front timing chain tensioner...................... 183
Crankshaft position sensor............................................ 218
Installing the heat exchanger ........................................ 183
Ignition coil ................................................................ 218
Installing the oil filler tube ........................................... 184
41/THROTTLE VALVE BODY............................................. 219
Installing the starter motor ........................................... 184
Throttle position sensor circuit A................................... 219
Checking the rear cylinder control time.......................... 184
Throttle position sensor circuit A - checking in the
Adjusting the rear cylinder control time ......................... 184 "zero" position ............................................................. 219
Checking the rear valve clearance ................................. 185 Adjusting the position of the throttle position sensor in
Adjusting the rear valve clearance ................................. 186 circuit A ..................................................................... 220
Checking the front cylinder control time ........................ 186 Removing the throttle valve body to adjust ..................... 221
CONTENTS 5
Reinstalling the throttle valve body when the Injector cylinder 2 connector DQ................................... 401
adjustments have been made........................................ 222 ICU antenna connector DV ........................................... 401
Throttle position sensor circuit B................................... 223 Fuel pump relay connector EB ...................................... 401
Manifold absolute pressure sensor................................. 223 ICU antenna connector EL............................................ 401
Connecting the vacuum hand pump to the manifold Connector EQ.............................................................. 401
absolute pressure sensor .............................................. 224 Connector ER.............................................................. 402
Ambient air pressure sensor.......................................... 225 Connector ES .............................................................. 402
Injector ...................................................................... 225 Connector ET .............................................................. 402
Rollover sensor............................................................ 226 Combination instrument connector EV ........................... 403
EFI control unit ........................................................... 227 Exhaust air injection valve, connector FE ....................... 403
Requesting the EFI control unit activation code.............. 227 Fuel pump relay .......................................................... 404
Coding the EFI control unit........................................... 227 CAN bus terminating resistor ........................................ 404
Flashing the EFI control unit ........................................ 228 TECHNICAL DATA - ENGINE ............................................ 405
IMMOBILIZER BLINK CODE............................................. 229 Capacity - engine oil .................................................... 405
ENGINE CONTROL TROUBLE CODE ................................. 238 Capacity - coolant........................................................ 406
CONNECTOR OVERVIEW.................................................. 391
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TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
Motor drive circuit A connector AE ................................ 391 ENGINE ......................................................................... 407
Connector AI ............................................................... 391 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 409
Crankshaft position sensor connector AL........................ 391 TECHNICAL DATA - CHASSIS .......................................... 411
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Clutch switch, connector AL ......................................... 391 Lighting equipment ..................................................... 411
Throttle position sensor circuit A, connector AM ............. 391 Capacity - fuel............................................................. 412
Throttle position sensor circuit B, connector AM............. 392 TECHNICAL DATA - FORK................................................ 413
Gear position sensor, connector AM............................... 392 TECHNICAL DATA - SHOCK ABSORBER ........................... 414
Fuel pump connector AM ............................................. 392
9- k. TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 415
Wheel speed sensor, connector AM ............................... 392 CLEANING/CONSERVATION............................................. 417
Connector AO.............................................................. 392 Cleaning motorcycle .................................................... 417
Diagnostic connection plug AP...................................... 393 Conservation for winter operation .................................. 417
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Rollover sensor connector AP........................................ 393 STORAGE ....................................................................... 419
Throttle position sensor circuit A, connector AR.............. 393
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Storage....................................................................... 419
Throttle position sensor circuit B, connector AR ............. 394 Putting into operation after storage ............................... 419
Fuel pump connector AR.............................................. 394 SERVICE SCHEDULE....................................................... 420
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Side stand switch, connector AR................................... 394 Important service tasks to be carried out by an
Ignition coil cylinder 1 connector AS ............................. 394 authorized KTM-RC8 workshop. .................................... 420
Ignition coil cylinder 2 connector AS ............................. 394 Important service tasks to be carried out by an
CAN bus terminating resistor connector AT .................... 395 authorized KTM-RC8 workshop. (as additional job) ......... 421
Crankshaft position sensor, connector AT....................... 395 WIRING DIAGRAM .......................................................... 422
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Clutch switch connector AT .......................................... 395 1 of 3......................................................................... 422

Engine coolant temperature sensor cylinder 1 connector 2 of 3......................................................................... 426
AX.............................................................................. 395 3 of 3......................................................................... 432
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Throttle stepper motor circuit B, connector CA ............... 395 OPERATING SUBSTANCES .............................................. 436
Lambda sensor cylinder 1, connector CA ....................... 396 AUXILIARY SUBSTANCES................................................ 438
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Lambda sensor cylinder 2, connector CA ....................... 396 SPECIAL TOOLS.............................................................. 440

Lambda sensor cylinder 1, connector CE ....................... 396 STANDARDS................................................................... 452
Lambda sensor cylinder 2, connector CE ....................... 396 INDEX ............................................................................ 453
Secondary air valve connector CK.................................. 396
Connector CM ............................................................. 397
Connector CO.............................................................. 397
Connector CP .............................................................. 398
Connector CQ.............................................................. 398
Connector CU.............................................................. 398
Fuel evaporation valve connector DF.............................. 399
Secondary air valve connector DF.................................. 399
Electric starter lock control unit, connector DN .............. 399
Immobilizer control unit, connector DN ......................... 399
Electric starter lock control unit, connector DO............... 399
Immobilizer control unit, connector DO.......................... 400
Ambient air pressure sensor connector DP ..................... 400
Manifold absolute pressure sensor cylinder 1,
connector DP .............................................................. 400
Manifold absolute pressure sensor cylinder 2
connector DP .............................................................. 400
Injector cylinder 1 connector DQ................................... 400
MEANS OF REPRESENTATION 6
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
The typographical formats used in this document are explained below.
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Specific name Identifies a proprietary name.
Name® Identifies a protected name.
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Brand™ Identifies a brand available on the open market.
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IMPORTANT NOTES 7
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 manipula-
tion 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.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
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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
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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.
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Following repairs or servicing, the vehicle must be checked for roadworthiness.
Notes/warnings
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Pay close attention to the notes/warnings.
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Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
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ing, you or others may not recognize sources of danger and may therefore be injured.
Grades of risks
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Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
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Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
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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 8
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
The key number Code number  can be found on the KEYCODECARD.
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Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
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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
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Engine number
3.3
The engine number  is stamped on the right side of the engine.

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100655-10
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Fork part number

3.4
The fork part number  is stamped on the inner side of the fork stub.
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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 9
Steering damper part number

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

4.1
Note
Danger of damage The 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. ( p. 13)

– 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. 443)
Info
Always jack up the rear of the motorcycle first.
– Jack up the motorcycle at the front.
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100679-10
Taking front of motorcycle off work stand
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4.2
Note
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– Secure the motorcycle against falling over.
– Remove the work stand from the front.
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Jacking up the motorcycle in the middle (screw-in type)
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4.3
Note
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– Remove screw .
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– Remove screws . Take off the footrest bracket.

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200598-01
– 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.
200599-01
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.
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Check that the work stand is seated correctly.
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Removing the motorcycle from the work stand (screw-in type)

4.4
Note
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– Remove the motorcycle from the work stand and rest it on the side stand.
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– Unscrew the holder of the special tool from the drill holes in the footrest brackets.
Remove the work stand.
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Work stand (62529055000) ( p. 447)

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200600-01
– Position the footrest bracket. Mount and tighten screws .

Guideline
Screw, front footrest M8 25 Nm Loctite® 243™
bracket (18.4 lbf ft)
– Position the brake fluid reservoir. Mount and tighten screw .
Guideline
Screw, brake fluid reser- M5 5 Nm Loctite® 243™
voir of rear brake (3.7 lbf ft)
200599-11
– Plug in connector  of the brake light switch. Secure the cable with cable
binder .
MOTORCYCLE 12
– Position the footrest bracket. Mount and tighten screws .

Guideline
– Position the shift rod. Mount and tighten screw .
Guideline
Screw, shift rod M6 12 Nm Loctite® 243™
(8.9 lbf ft)
200598-11
Jacking up the motorcycle in the middle (insertable type)

4.5
Note
86 m
– 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.
56 co
Work stand (62529055000) ( p. 447)
– Jack up the motorcycle.
Info
9- k.
r
Check that the work stand is seated correctly.
99 a
7- Sh
87 rt
200597-01
Removing the motorcycle from the work stand (insertable type)

a
4.6
Note
P

MOTORCYCLE 13
– Remove the motorcycle from the work stand and rest it on the side stand.
– Remove the work stand.
Work stand (62529055000) ( p. 447)
86 m
56 co
200597-01
Jacking up motorcycle at the rear

4.7
Note
9- k.
r
– Insert the work stand adapter in the rear of the work stand.
99 a
Work stand adapter (61029055120) ( p. 442)

Work stand rear (61029055100) ( p. 442)
7- Sh
– Stand the motorcycle upright, align the work stand to the link fork and the
adapters, and jack up the motorcycle.
87 rt
100680-10
Taking the rear from the workstand

a
4.8
Note
P

– 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 poisoning Exhaust 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 accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
MOTORCYCLE 14
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
– 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
86 m
Do not press the electric starter button until the function test of the combi-
nation 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 injec-
56 co
tors 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
9- k. 100677-10
release the clutch, the engine stops.
– Take the weight off the side stand and swing it upwards with your foot as far as it
will go.
r
99 a
7- Sh
87 rt
a
P
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
Compression damping
86 m
100682-10 Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
56 co
Full payload 5 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
9- k. pension damping.
Adjusting the rebound damping of the fork

5.2
r
Info
99 a
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
7- Sh
the zero position.
– Turn adjusting screws  clockwise to the stop.
Info
87 rt
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.
a
Guideline
Rebound damping
P
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Info
Turn clockwise to increase suspension damping; turn counterclockwise to
reduce damping.
100683-10
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
Spring preload - Preload Adjuster
86 m
Comfort 5 turns
Standard 5 turns
Sport 3 turns
56 co
Full payload 3 turns
Info
Turn clockwise to increase preload, turn counterclockwise to reduce spring
9- k. preload.
Changing the spring preload has no influence on the rebound damping
although the adjustment screws turn during the adjustment work. However,
100683-11 you should also adjust the rebound damping when you alter the spring
r
preload.
99 a
Bleeding fork legs

5.4
7- Sh
– 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.
87 rt
Info
Perform this action on both fork legs.
a
100684-10
P
Vehicle level
5.5
Warning
Danger of accidents Modifications 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.
Upper triple clamp flush 0 mm (0 in)
with upper edge of fork legs
Upper triple clamp flush 2.5 mm (0.098 in)
with 1st ring of fork legs
86 m
Upper triple clamp flush 5 mm (0.2 in)
with 2nd ring of fork legs
(standard)
56 co
The infinitely variable frame height setting can be adjusted by turning the eccentric
shaft.
100693-01
Frame height difference 12 mm (0.47 in)
HIGH - LOW
9- k.
Maximum adjustment range 180°
between HIGH - LOW
r
Adjusting front vehicle level
5.6
99 a
Warning
Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.
7- Sh
– 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.
87 rt
– Loosen screw  of the handlebar stub.
Info
a
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
P
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
Upper triple clamp flush with upper 0 mm (0 in)
edge of fork legs
Upper triple clamp flush with 1st ring 2.5 mm (0.098 in)
of fork legs
Upper triple clamp flush with 2nd ring 5 mm (0.2 in)
of fork legs (standard)
100695-01
Info
The standard adjustment is the setting that provides the best vehicle han-
dling. When the fork is compressed, the suspension setting changes, caus-
ing the vehicle to become more stable but also more difficult to handle.
– Tighten screw .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Tighten screws .
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
100694-11
– Tighten screw .
Guideline
Screw, handlebar stub M8 20 Nm
(14.8 lbf ft)
– Repeat the adjustment on the other fork leg.
86 m
Info
The vehicle level setting on both fork legs must be identical.
56 co
Removing the fork
5.7
– Jack up the motorcycle in the middle (insertable type). ( p. 12)

– Clamp down the rear of the vehicle.
– Remove the screws  from both brake calipers.
9- k.
– 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.
r
Info
99 a
Do not pull the hand brake lever when the brake calipers are removed.
7- Sh
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 .
87 rt
Warning
Danger of accidents Reduced braking efficiency caused by damaged brake
discs.
a
– Always lay the wheel down in such a way that the brake discs are not
damaged.
P
201056-10
– 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.
201057-10
– Remove screws . Hang the wheel speed sensor to the side.
201058-10
– Unscrew screws  of the triple clamps and handlebar stubs. Remove the fork legs
downward.
86 m
56 co
201059-10
Installing the fork

5.8
Warning
9- k.
r
– 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.
99 a
Guideline
Upper triple clamp flush with upper 0 mm (0 in)
7- Sh
edge of fork legs

Upper triple clamp flush with 1st ring 2.5 mm (0.098 in)
of fork legs
Upper triple clamp flush with 2nd ring 5 mm (0.2 in)
87 rt
100695-01 of fork legs (standard)
Info
a
The standard adjustment is the setting that provides the best vehicle han-
dling. When the fork is compressed, the suspension setting changes, caus-
ing the vehicle to become more stable but also more difficult to handle.
P
– Tighten screws  of the triple clamps and handlebar stubs.

Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
(14.8 lbf ft)
201059-11
– Position the wheel speed sensor. Mount and tighten screws .

Guideline
Screw, wheel speed sensor M4 2 Nm Loctite® 243™
(1.5 lbf ft)
201058-11
– 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.
Long-life grease ( p. 438)
86 m
56 co
100781-11
– Insert the wide spacer on the left-hand side  (when looking in the direction of
travel).
Info
9- k. 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).
r
99 a
100780-11
Warning
7- Sh
Danger of accidents Reduced braking efficiency due to oil or grease on the

brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
87 rt
– Clean screw  and the wheel spindle.

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
201060-10 – Mount and tighten screw .
a
Guideline
Bolt, front axle M25x1.5 45 Nm
P
(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 acti-
vated position.
The brake calipers align themselves.
– Tighten screws  on both brake calipers.
Guideline
100719-12 Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(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). ( p. 12)
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws .
Guideline
Fork end pinch bolts M8 15 Nm
(11.1 lbf ft)
100782-11
performing a fork service

5.9
Info
These operations are the same on both fork legs.
86 m
Condition
The fork legs have been removed.
– Disassemble the fork legs. ( p. 21)
56 co
– Disassemble the outer tubes. ( p. 24)
– Change the lower DU bush. ( p. 26)
– Check the fork legs. ( p. 25)
– Assemble the outer tubes. ( p. 27)
9- k.
r
– Assemble the fork legs. ( p. 27)
99 a
7- Sh
87 rt
201097-01
a
Disassembling the fork legs

5.10
Info
P
Condition
The fork legs have been removed.
– Determine and note down the current setting of rebound damping  and compres-
sion 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.
200605-10
– 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
The Preload Adjuster cannot be removed yet.
86 m
– Unclamp the fork leg. Slide the outer tube down.
56 co
200607-10
– Clamp aluminum tube  with the special tool.

9- k. Clamping stand (T526S) ( p. 450)
r
99 a
200608-10
– Pull up Preload Adjuster . Mount the special tool on the hexagonal piece.
7- Sh
Open-end wrench (T14032) ( p. 450)

87 rt
200609-10
a
– Hold the hexagonal piece in place with the special tool. Release Preload Adjuster 
and remove it with preload spacers .
P
200610-10
– Remove adjusting tube .
200611-10
– Screw special tool  onto the piston rod and pull it up.
Gripping tool (T14026S1) ( p. 449)
– Remove the special tool from the hexagonal piece.
86 m
– Release special tool .
56 co
200612-10
– Unclamp the fork leg and clamp it with the axle clamp.
9- k. – Pull out pin  of the special tool.
r
99 a
200613-10
– Pull collar bushing  off of aluminum tube . Slide the aluminum tube over the
special tool.
7- Sh
– Unscrew the special tool.

– Remove the collar bushing.
– Remove spring .
– Unclamp the fork leg.
87 rt
Info
200614-10
Hold the fork leg by the axle clamp.
a
– Drain the fork oil.

P
Info
Pull out the piston rod and push back in a number of times to empty the
cartridge.
– Pull outer tube  off of inner tube .
200615-10
– Clamp the fork leg with the axle clamp.

– Remove screws .
200616-10
– Unscrew screws  of the cartridge and remove with the seal ring.
Info
Place a drain pan underneath.
86 m
56 co
9- k.
r
99 a
200617-10
– Remove the cartridge.

7- Sh
87 rt
a
200618-10
Disassembling the outer tubes

P
5.11
Info
These operations are the same on both outer tubes.
– Disassemble the fork legs. ( p. 21)

– Clamp the outer tube in the area of the lower triple clamp.
– Remove dust boot .
200619-10
– Remove lock ring .
200620-10
– Remove seal ring .
86 m
56 co
200621-10
– Remove support ring .

9- k.
r
99 a
200622-10
Checking the fork legs

7- Sh
5.12
Condition
The fork legs must be disassembled.
– Check the inner tube and axle clamp for damage.
» If there is damage:
87 rt
– Change the inner tube.

a
P
200629-10
– Measure the outside diameter at several locations on the inner tube.

Outside diameter of inner tube 42.975… 43.005 mm (1.69193…
1.69311 in)
» If the measured value is less than the specified value:
200630-10
– Measure the run-out of the inner tube.

Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in)
» If the measured value is greater than the specified value:
200631-10
– Check the outer tube for damage.

» If there is damage:
– Change the outer tube.
86 m
56 co
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.
–
9- k. 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)
r
99 a
200665-10
– Check the spring length.

7- Sh
Guideline
Spring length with preload spacer(s) 405 mm (15.94 in)
– Reduce the thickness of the preload spacer.
87 rt
» If the measured value is less than the specified value:

– Increase the thickness of the preload spacer.
200666-10
a
changing the lower DU bush

P
5.13
– Disassemble the outer tubes. ( p. 24)

– Heat the outer tube in the area of the lower DU bush.
Guideline
50 °C (122 °F)
– Remove DU bush .
– Press the new DU bush all the way in.
200664-10
Assembling the outer tubes

5.14
Info
These operations are the same on both outer tubes.
– Check the fork legs. ( p. 25)

– Clamp the outer tube in the area of the lower triple clamp.
– Insert support ring .
86 m
200622-11
– Lubricate seal ring  and mount it with the open side facing downward.
Lubricant (T511) ( p. 438)
56 co
9- k.
200621-11
– Mount lock ring .

r
The lock ring engages audibly.
99 a
7- Sh
200620-11
87 rt
– Lubricate and mount dust boot .

a
P
200619-11
Assembling the fork legs

5.15
Info

– Slide the cartridge into the inner tube with spring seat  and the preload bush.
200618-11
– Clamp the fork leg with the axle clamp.

– Mount and tighten screw .
Guideline
Screw, cartridge M12x1 25 Nm
(18.4 lbf ft)
86 m
56 co
9- k.
r
99 a
200626-10
– Lubricate and mount screws  of the axle clamp but do not tighten.
7- Sh

87 rt
a
200616-11
– Vertically clamp the fork leg with the axle clamp.

P
– Slide outer tube  onto inner tube .
200615-11
– Position the spring in the inner tube.
200623-10
– Slide on collar bushing .

– Slide adjusting tube  into the piston rod.
200624-10
– Install the special tool.

Info
The special tool must be used to prevent the adjusting tube from being
86 m
raised, which would cause oil to enter into the piston rod.
– Add fork oil.

Fork oil per fork 520 ml Fork oil (SAE 5) ( p. 437)
56 co
200627-10
leg (17.58 fl. oz.)
Info
Pull out the piston rod and push back in a number of times to bleed the car-
tridge.
9- k.
– Slide on aluminum tube . Mount collar bushing .
r
99 a
7- Sh
200625-10
– Mount pin  of special tool .

87 rt

– Clamp the fork leg at the aluminum tube with the special tool.
a

– Pull up special tool  and mount special tool  onto the hexagonal piece.
P
200612-11
– Unscrew the special tool from the piston rod.

– Lubricate the thread of the piston rod.
– Lubricate the upper edge of the piston rod.
– Mount Preload Adjuster  with preload spacer .
Info
The Preload Adjuster must reach the stop before the piston rod begins turn-
ing as well. If the piston rod thread is stiff, the rod must be held to prevent
it from turning. If the Preload Adjuster is not screwed in all the way, the
rebound adjustment will not function properly.
86 m
– Counter with the special tool and tighten the Preload Adjuster.
Guideline
Preload Adjuster on piston rod M12x1 25 Nm
56 co
200628-10 (18.4 lbf ft)

– Pull up Preload Adjuster  and remove the special tool from the hexagonal piece.
9- k.
r
99 a
7- Sh
200609-11
– Unclamp the fork leg. Slide the outer tube up and clamp in the area of the lower
triple clamp.
87 rt
a
200606-10
P
– Lubricate the O-ring of the Preload Adjuster .

– Screw on the Preload Adjuster and tighten.
Guideline
Preload Adjuster on outer tube M46x1 50 Nm
(36.9 lbf ft)
Key (T524) ( p. 450)

200607-11
Alternative 1
– Turn the adjusting screw of compression damping  and the adjusting screw of
rebound damping  all the way clockwise.
– Turn back counterclockwise by the number of clicks corresponding to the fork
leg type.
200605-11
Guideline
Rebound damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Compression damping
Comfort 15 clicks
Standard 10 clicks
Sport 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.
86 m
Guideline
Comfort 5 turns
56 co
Standard 5 turns
Sport 3 turns
Alternative 2
9- k.
Warning
Danger of accidents Modifications to the chassis can seriously alter the
vehicle's handling characteristics.
r
– Extreme modifications to the adjustment of the spring elements can
99 a
cause a serious deterioration in the handling characteristics and

overload some components.
7- Sh
– 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 dis-
assembled.
87 rt
a
P
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.
100751-10
Do not make any adjustments while riding!
Adjusting the steering damper

6.2
Info
86 m
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.
56 co
– Turn the adjusting screw  counterclockwise towards "–" as far as the last percep-
tible click.
– Adjust the steering damper according to your riding style and the road conditions
by turning the adjust screw clockwise towards "+".
9- k. Guideline
Steering damper adjustment range 1… 32 clicks
Recommended range for use 1… 20 clicks
r
Standard 1 click
100692-10
99 a
Info
Do not change the adjustment of the steering damper during the journey!
7- Sh
After adjusting the steering damper, check the steering for smooth oper-
ation, making sure that the handlebar can be moved from extreme left to
extreme right without a tendency to lock.
Adjusting the handlebar height

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

P
– 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 M5 5 Nm (3.7 lbf ft)
100757-10
– Tighten the screw.

Guideline
(14.8 lbf ft)
– 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:
– Correct the cable routing.
100759-01
Adjusting the low position of the handlebar stubs:

Info
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
86 m
56 co
100759-10
– Remove screw  with distance sleeve .

– Carefully shift the handlebar stub by the length of the distance sleeve.
Guideline
9- k. Long distance sleeve 15 mm (0.59 in)
– Lay all cables between the upper triple clamp and the handlebar stub.
– Position the distance sleeves.
r
– Mount and tighten the screw.
Guideline
99 a
100760-10
7- Sh
– Tighten the screw.

Guideline
(14.8 lbf ft)
– Repeat the adjustments on the other handlebar stub.
87 rt
– Move the handlebar to and fro over the entire steering range.
» If the cables restrict the freedom of movement of the steering:
a
– Correct the cable routing.

100761-01
P
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.
– Push back protective cover .

– Loosen counter nut .
– Set the play in the throttle cable by turning adjusting screw .
100754-10
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten counter nut .
– Mount the protective cover.
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
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.
86 m
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.
56 co
100784-10
Changing the throttle grip

6.6
9- k. – Loosen screw .
– Take off handlebar weight .
r
99 a
7- Sh
301446-10
– Unscrew screw .
87 rt
a
P
301447-10
– Remove screw .
– Remove the spacer.
– Loosen screw .
301448-10
– Turn the handlebar all the way to the right.

– Turn the handlebar stub to the left.
– Remove the throttle grip.
301449-10
– Push back protective cover .

– Unscrew lock nut .
– Screw adjusting screw  all the way in.
86 m
56 co
301450-10
– Remove screws .
9- k. – Take off cover .
r
99 a
301451-10
– Detach the throttle cables.

7- Sh
– Remove the throttle grip.

87 rt
301452-10
a
Throttle grip with code 3081:

– Check that angle piece  of the throttle cable (closer) is seated correctly.
P
Guideline
Distance  9… 11 mm (0.35… 0.43 in)
» If the specified value is not reached:
– Adjust the throttle cable at the throttle valve. ( p. 37)
– Position the throttle grip.
– Attach the throttle cables.
301455-10
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. ( p. 37)
– Position the throttle grip.
86 m
56 co
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
9- k. the housing.
» The marking is not aligned:
– Correct the play in the throttle cable using barrel adjuster .
r
99 a
301462-10
– Grease the front and rear parts of the cover.

7- Sh

– Position cover .
– Mount screws  but do not tighten them yet.
87 rt
a
P
301456-10
– Turn the handlebar all the way to the right.

– Turn the handlebar stub to the left.
– Slide on the throttle grip.
301449-10
– Align the handlebar stub.

– Position the distance sleeves.
– Mount screw  but do not tighten them yet.
– Tighten screw .
Guideline
(14.8 lbf ft)
– Tighten screw .
301448-10
Guideline
– Fully tighten screws .
Guideline
86 m
56 co
301447-10
– Mount handlebar weight .

– Tighten screw .
9- k.
Guideline
– Adjust the play in the throttle cable. ( p. 33)
r
99 a
301446-10
7- Sh
Adjusting the throttle cable at the throttle valve

6.7
– Dismount the fuel tank. ( p. 70)

– Remove the air filter. ( p. 67)
87 rt
– Unscrew lock nuts .

– Unscrew barrel adjuster .
– Detach the throttle cables.
a
P
301457-10
– Detach throttle cable wire  (closer) and remove it.
301458-10
– Unscrew lock nut .

– Screw in angle piece  until it is seated correctly.
Guideline
Distance  9… 11 mm (0.35… 0.43 in)
86 m
56 co
301459-10
– Route the throttle cable so it is not under tension.

9- k. – Attach throttle cable wire  (closer).
r
99 a
301458-10

7- Sh
– Mount barrel adjuster .

– Mount lock nuts  but do not tighten them yet.
– Connect the KTM diagnostics tool.
– Select the model.
87 rt
– Select "ECU Diagnosis".

– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
a
301457-10
– Select "Adjustment".
– "Please enter the password:"
P
– Select "Throttle position sensor circuit A adjustment".
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 3… 5 mm (0.12… 0.2 in)
– Tighten lock nuts .
– Complete the adjustment by pressing the "Quit" button.
301461-10
– Ensure that rubber grommets  are seated correctly.

– Install the air filter. ( p. 67)
– Install the fuel tank. ( p. 71)
301460-10
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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 Retracted
"SSTAND SW"
Side stand signal Extended
"SSTAND SW"
Side stand voltage "Side stand AD"
900040-60
Retracted 1.5… 3.2 V
Extended 4.0… 5.0 V
Footrest position
7.2
86 m
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.
56 co
9- k.
100699-10
Adjusting footrest position

r
7.3
Info
99 a
The footrest position must be identical on the left and the right.
7- Sh
– Remove screws .
87 rt
a
100713-10
P
– 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
100701-01
03/FRAME 41
– Repeat adjustment work on the footrest bracket on the other side.

– Adjust the shift lever. ( p. 192)
– Adjust the foot brake pedal. ( p. 100)
100702-01
Rear frame position

7.4
The frame rear height can be set to two different positions, enabling ergonomic adjust-
ment of the seat height.
Seat height  (standard) 805 mm (31.69 in)
86 m
Seat height  825 mm (32.48 in)
56 co
400439-10
Adjusting the rear frame position

7.5
9- k.
Warning
r
99 a
– Remove the seat. ( p. 70)

– Remove screws  with the bushings.
7- Sh
87 rt
a
100762-10
Setting a higher seat position:

P
– 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.
100763-10
– Mount the screw and washer on the left and right sides of the vehicle, but do
not tighten.
100764-01
03/FRAME 42
– Remove screw  with washer on the left and right sides of the vehicle.
– 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 Loctite® 243™
(14.8 lbf ft)
100765-10
– Tighten screw  on the left and right sides of the vehicle.

Guideline
(14.8 lbf ft)
86 m
56 co
100766-10
Setting a lower 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
upper rear drill holes of the rear.
9- k.
– Mount the screw and washer on the left and right sides of the vehicle, but do
not tighten.
r
99 a
100763-11
– Remove screw  with washer on the left and right sides of the vehicle.
7- Sh
– Push the rear end up until the drill holes of the frame are level with the upper
front drill holes of the rear.
87 rt
100765-11
a
– Mount the screw and washer on the left and right sides of the vehicle, and
tighten.
P
Guideline
(14.8 lbf ft)
100764-01
– Tighten screw  on the left and right sides of the vehicle.

Guideline
(14.8 lbf ft)
100765-12
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)
86 m
56 co
100768-10
9- k.
r
99 a
7- Sh
87 rt
a
P
04/SHOCK ABSORBER, SWINGARM 44
Adjusting the low-speed compression damping of the shock absorber

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

click.
Info
Do not loosen nut !
86 m
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
56 co
100686-10 Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
9- k.
Info
r
pension damping.
99 a
Adjusting the high-speed compression damping of the shock absorber

7- Sh
8.2
Danger
87 rt
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
a
– Turn adjusting screw  clockwise with an open-ended spanner until it stops.

P
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
pension damping.
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
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
86 m
100688-10
Info
56 co
Turn clockwise to increase damping; turn counterclockwise to reduce sus-
pension damping.
Adjusting the spring preload of the shock absorber

8.4
9- k.
Warning
r
99 a
Info
The spring preload defines the initial situation of the spring process on the shock absorber.
7- Sh
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.

87 rt
Info
The spring preload can be adjusted correctly only if the rear wheel and the
swingarm are fully relieved of weight.
a
– Loosen screw  two turns, but do not remove.

P
100689-10
– Turn the adjusting ring counterclockwise with the wrench from the tool kit until the
spring is no longer under tension.
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.
– Tighten screw .
Guideline
100689-11
Adjusting the vehicle level at the rear

8.5
Warning
86 m
– Loosen screw  but do not remove it.
56 co
9- k.
100696-10
r
– Turn eccentric shaft  to the desired position using the tool from the tool set.
Guideline
99 a
Standard LOW
Maximum adjustment range between 180°
7- Sh
HIGH - LOW
Open end wrench SW 38 (69012021000)
Info
87 rt
100697-10
The chassis height can be adjusted in both directions.
a
Guideline
Screw, clamp, eccentric shaft of M8 18 Nm
P
deflector (13.3 lbf ft)
100698-10
Removing the shock absorber

8.6
– Jack up the motorcycle in the middle (insertable type). ( p. 12)

– Remove the lower screw  of the shock absorber.
200602-10
– Remove upper screw  of the shock absorber.
– Remove nut . Pull out the pin of bell crank  on the frame. Remove the bell
crank.
200603-10
– Remove the shock absorber toward the rear right.
86 m
56 co
200604-01
Installing the shock absorber

8.7
– Fit the shock absorber from the rear left.

9- k.
r
99 a
7- Sh
200604-01
– Position bell crank . Mount the pin and nut  of the bell crank on the frame.
Tighten the nut.
Guideline
Nut of bell crank on frame M14x1.5 100 Nm
87 rt
(73.8 lbf ft)

– Mount and tighten screw .
Guideline
a
Screw, shock absorber M10 45 Nm Loctite® 243™

200603-11 (33.2 lbf ft)
P
– Mount and tighten screw .

Guideline
Screw, connecting lever, M10 45 Nm Loctite® 243™
shock absorber deflector (33.2 lbf ft)
– Mount and tighten screw .
Guideline
Screw, shock absorber M10 45 Nm Loctite® 243™
(33.2 lbf ft)
– Remove the motorcycle from the work stand (insertable type). ( p. 12)
200602-11
Servicing the shock absorber

8.8
Condition
The shock absorber has been removed.
– Remove the spring. ( p. 48)
– Disassemble the damper. ( p. 49)
– Disassemble the piston rod. ( p. 50)
– Check the damper. ( p. 51)
– Assemble the piston rod. ( p. 52)
– Assemble the damper. ( p. 53)
– Install the spring. ( p. 59)
86 m
56 co 201094-01
9- k.
Removing the spring
8.9
Condition
r
– Clamp the shock absorber into the vice with soft jaws.
99 a
– Measure and note the spring length while the spring is under tension.
7- Sh
– Turn the adjusting ring until the spring is no longer under tension.
Hook wrench (T106S) ( p. 448)
87 rt
a
200561-01
– Remove spring retainer .

P
– Remove the spring.
200562-01
Disassembling the damper

8.10
– Remove the spring. ( p. 48)

– Determine and note down the current setting of the rebound and compression
damping.
– Completely open the adjusting elements of the rebound and compression damping.
– Remove rubber cap  of the reservoir.
– Remove adjusting ring .
200563-10
– Slowly open screw .

The nitrogen pressure dissipates.
86 m
56 co
200564-10
– Remove locking cap .

9- k.
r
99 a
7- Sh
200565-10
– Push in seal ring retainer . Remove lock ring .
Info
Do not scratch the inside surface.
87 rt
a
P
200566-10
– Remove screw . Let the oil drain.
200567-10
– Remove the piston rod. Drain the remaining oil.
200568-10
– Remove compression damping adjuster . Remove the spring, sleeve and piston.
86 m
56 co
200569-10
Disassembling the piston rod

8.11
– Disassemble the damper. ( p. 49)

9- k. – Clamp the piston rod into a vise with the heim joint.
– Remove nut .
r
99 a
7- Sh
200570-10
– Remove supporting plate  and rebound shim stack  together with piston .
Info
87 rt
Slip the rebound shim stack onto a screwdriver and set the shims down
together.
a
P
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
– Remove seal ring retainer .
200573-10
– Remove locking cap  and rubber buffer .
86 m
56 co
200574-10
Checking the damper

8.12
Condition
The damper has been disassembled.
9- k.
– Measure the inside diameter at both ends and in the middle of the damper car-
tridge.
Damper cartridge
r
Minimum diameter 46.10 mm (1.815 in)
99 a

– Change the damper cartridge.
7- Sh
– Check the damper cartridge for damage and wear.

300601-10 » If there is damage or wear:
– Change the damper cartridge.
– Measure the diameter of the piston rod.
87 rt
Piston rod
Diameter ≥ 13.95 mm (≥ 0.5492 in)
a

– Change the piston rod.
–
P
Measure the run-out of the piston rod.

Piston rod
300554-10
Run-out ≤ 0.06 mm (≤ 0.0024 in)
– Check the piston rod for damage and wear.
» If there is damage or wear:
– Check the heim joint for damage and wear.

– Change the heim joint.
86 m
56 co
300460-01
Assembling the piston rod

8.13
– Clamp the piston rod into a vise with the heim joint.
9- k.
r
– Mount rubber buffer plug  and locking cap .
99 a
7- Sh
200574-11
– Position special tool  on the piston rod.

Mounting sleeve (T313) ( p. 450)
– Grease the seal ring and slide seal ring retainer  onto the piston rod.
87 rt

– Remove the special tool.
a
P
200575-10
– Mount supporting plate  with the rounded side facing downward.

– Mount compression shim stack  with the smaller shims at the bottom.
200572-11
– Grind the piston on both sides on a surface plate with 1200 grade sand paper.
– Clean the piston.
– Mount the piston.
Info
The piston is identical on both sides.
200576-10
– Mount rebound shim stack  with the smaller shims at the top.
– Mount supporting plate .
200571-11
– Mount and tighten nut .

Guideline
Nut, piston rod M8 30 Nm
(22.1 lbf ft)
86 m
56 co
200570-11
Assembling the damper

8.14
– Assemble the piston rod. ( p. 52)

– Place the spring and sleeve onto the compression damping adjuster. Mount the pis-
9- k.
ton.
– Mount and tighten compression damping adjuster .
Guideline
r
Compression damping adjuster M26x1 30 Nm
99 a
(22.1 lbf ft)

7- Sh
87 rt
a
P
200586-01

Guideline
Screw, filling port M10x1 14 Nm
(10.3 lbf ft)
200567-11
– 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.

– Carefully mount the piston rod.
86 m
56 co
200568-11
– Mount seal ring retainer  and slide it under the ring groove.
– Mount lock ring .
Info
9- k.
Do not scratch the inside surface.
– Pull out the piston rod until the seal ring retainer rests against the lock ring.
r
99 a
200566-11
– Mount locking cap  of the damper cartridge.

7- Sh
– Bleed and fill the damper. ( p. 55)

– Fill the damper with nitrogen. ( p. 58)
87 rt
200588-01
a
– Mount rubber cap  of the reservoir.

– Mount adjusting ring  and turn it all the way down.
P
The collar faces the spring.
200563-11
Alternative 1
– Turn adjusting screw  clockwise with a screwdriver to the last perceptible
click.
absorber type.
Guideline
Compression damping, low-speed
Comfort 20 clicks
200596-01 Standard 15 clicks
Sport 10 clicks
– 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
Rebound damping
86 m
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
56 co
Alternative 2
Warning
9- k. Danger of accidents Modifications to the chassis can seriously alter the
r
99 a

7- Sh
– Turn adjusting screws ,  and  to the position noted down when the unit
was disassembled.
– Install the spring. ( p. 59)
87 rt
Bleeding and filling the damper

8.15
Info
a
Before working with the vacuum pump, carefully read the operating manual included with the vacuum pump.
Completely open the adjusting elements of the rebound and compression damping.
P
– Remove the filling port screw.

– Mount adapter  on the damper.
Info
Hand-tighten only without using a tool.
– Connect adapter  to connector  of the vacuum pump.

– Clamp the damper with soft jaws or hold it as shown in the photo.
200590-01 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 hold-
ing it with your hand.
– 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 spe-
cial tool.
Depth micrometer (T107S) ( p. 449)
86 m
The floating piston is positioned all the way at the bottom.
56 co
200591-01
– When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir  to Equalize pressure.
9- k. Guideline
4 mbar
The pressure gauge increases to the required value.

r
0 bar
99 a
200267-10
7- Sh
– When the pressure gauge reaches the required value, turn control lever Damper 
to Pressure.
Guideline
0 bar
87 rt
Oil is pumped into the damper.

a
3 bar
200268-10
P
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 reser-
voir  to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.

8 mbar
200270-10
– When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir  to Equalize Pressure.
Guideline
8 mbar

0 bar
200267-10
to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
86 m
3 bar
56 co
200268-10
to Vacuum.
Guideline
3 bar
9- k.
0 bar
r
– When the pressure gauge reaches the required value, activate the On/Off switch.
99 a
200269-10 Guideline
0 bar
7- Sh
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
87 rt
10 mm
Depth micrometer (T107S) ( p. 449)

a
– Push the floating piston into the reservoir to the distance described above using the
special tool.
P
200592-01
Info
When the piston rod is fully extended, the floating piston must be at pre-
cisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.

– 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.

– Mount and tighten screw .
Guideline
Screw, filling port M10x1 14 Nm
(10.3 lbf ft)
86 m
56 co
200593-01
Filling the damper with nitrogen

8.16
– Fix the special tool in the vise.

9- k.
Nitrogen filling tool (T170S1) ( p. 450)
– Screw in screw  by approx. 2 turns but do not tighten.
r
Info
The piston rod is fully extended.
99 a
7- Sh
200594-01
– Connect the special tool to the pressure regulator of the filling cylinder.
Filling gas - nitrogen
– Adjust the pressure regulator.
87 rt
Guideline
Gas pressure 10 bar (145 psi)
a
– Position the damper in the special tool.

The hexagonal part of tap handle  engages in the hexagon socket of the fill-
P
200595-01 ing port screw.

– Open spigot .
– Fill the damper for at least 15 seconds.
Guideline
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)
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 .
200562-11 The open end is opposite to the end of the spring.
Alternative 1
– Tension the spring by turning the adjusting ring to the prescribed value.
Guideline
Spring preload
86 m
Comfort 6 mm (0.24 in)
56 co

Alternative 2
9- k.
Warning
Danger of accidents Modifications to the chassis can seriously alter the
r
99 a

7- Sh
– Adjust the spring to the value determined when it was removed by turning the
adjusting ring.
87 rt

– Tighten screw .
a
Guideline
Screw, adjusting ring, shock absorber M6 5 Nm (3.7 lbf ft)
P
200561-11
Removing the heim joint

8.18
Info
The operations are the same for the upper and lower heim joints.
Condition
– 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.
200577-10
– Remove seal rings  on both sides.
86 m
56 co
200578-10
– Remove lock rings  on both sides.

9- k.
r
99 a
200579-10
– Place special tool  underneath and push out the heim joint with special tool .
7- Sh
Pressing tool (T1207S) ( p. 449)

87 rt
200580-10
a
Installing the heim joint

P
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 spe-
cial tool .
Pressing tool (T1206) ( p. 449)
Pressing tool (T129) ( p. 449)
200581-10
– Mount lock rings  on both sides.
200579-11
– Mount and grease seal rings  on both sides.

86 m
56 co
200578-11
– Push in both collar bushings  of the heim joint.

9- k.
r
99 a
200582-10
7- Sh
87 rt
a
P
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
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
86 m
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 con-
tent of the ambient air and the exhaust gas . The greater the difference in oxygen
content, the greater the voltage.
56 co
Lambda sensor for cylinder 1, connector CE ( p. 396) pin assignment
900008-10 Lambda sensor for cylinder 2, connector CE ( p. 396) pin assignment
Function description
– All lambda (O₂) sensors are open to the atmosphere, which has an oxygen con-
9- k. tent (O₂) 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 gen-
r
erates a low voltage. When the exhaust gas contains almost zero percent oxygen,
the engine is running "rich" and the sensor generates a high voltage.
99 a
Lambda sensor
900009-01
7- Sh
Voltage range within 0.2… 0.8 V

the closed loop range
"HEGO1AD"
Voltage range within 0.2… 0.8 V
the closed loop range
87 rt
"HEGO2AD"
Lambda sensor heater

9.2
a
– The lambda sensor heater for cylinder 1 is integrated into the lambda sensor for
cylinder 1, which is installed in the rear exhaust manifold.
P
– 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 inde-
pendent of the exhaust gas temperature the temperature of the lambda sensor is
kept constant. The connections of the heating element are completely isolated from
900007-61
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 con-
trol is modulated.
The lambda sensor heater is controlled at a modulation frequency T of 100 Hz. The
smaller the duty cycle t₁ is set for the control, the greater is the supply voltage of
the lambda sensor heater.

900046-60
05/EXHAUST 63
Resistance at: 20 °C 11.7… 14.3 Ω

(68 °F)
Removing the exhaust cover completely

9.3
– Remove the side covers. ( p. 75)

– Remove screws  on both sides.
– Take off exhaust cover  completely.
86 m
56 co
9- k.
200532-10
Installing the exhaust cover completely

r
9.4
– Position the exhaust cover.

99 a
– Mount and tighten screws .

Guideline
7- Sh

– Mount and tighten screws  on both sides.
Guideline
87 rt
– Install the side covers. ( p. 75)

a
P
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. ( p. 63)

05/EXHAUST 64
– Unplug connector  of the lambda sensor (2nd cylinder). Open the cable binder.
200513-10
– Unplug connector  of the lambda sensor (1st cylinder).
86 m
56 co
200514-10
– Remove screw . Slide the clamp upward.

9- k.
r
99 a
200515-10
– Remove screw . Slide the clamp upward.

7- Sh
87 rt
200516-10
a
– Remove screws  with the washers. Take off the main silencer.
P
5
0
5
0
5
0
200517-01
05/EXHAUST 65
– Remove nuts . Remove the manifold at the front with the seals.
200518-10
– Remove nuts . Remove the manifold at the rear with the seals.
86 m
56 co
200519-10
Installing the exhaust system

9.6
Info
9- k.
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.
r
99 a
7- Sh
200518-11
87 rt
– Position the manifold at the rear with the seals. Mount nuts  but do not tighten
them yet.
a
P
200519-11
05/EXHAUST 66
– Position the main silencer. Mount and tighten screws  with the washers.
Guideline
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
3
0
3
0
86 m
3
0
56 co
200517-02
– Position the clamp. Mount and tighten screw .

Guideline
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft)
9- k.
– Tighten nuts .
Guideline
Remaining chassis nuts M8 30 Nm
r
(22.1 lbf ft)
99 a
200515-11
– Position the clamp. Mount and tighten screw .

7- Sh
Guideline
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft)
– Tighten nuts .
Guideline
87 rt
Remaining chassis nuts M8 30 Nm

(22.1 lbf ft)
a
200516-11
– Plug in connector  of the lambda sensor (2nd cylinder). Secure the cable with
the cable binders.
P
200513-11
– Plug in connector  of the lambda sensor (1st cylinder).

– Install the exhaust cover completely. ( p. 63)
200514-11
06/AIR FILTER 67
Removing the air filter

10.1
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

– Slide back clamp . Pull off the engine breather hose and take off the clamp.
– Take off the filter box top.
Info
Watch out for the engine breather hose.
86 m
200496-10
– Remove air filter .
56 co
– Clean the air filter box.
9- k.
200497-10
r
99 a
Installing the air filter

10.2
– Position air filter .

7- Sh
87 rt
a
200497-11
– Position the filter box top with the engine breather hose. Mount clamp  with the
engine breather hose.
P
– Tighten screws .
200496-11
Removing the filter box bottom

10.3

– 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.
200498-10
06/AIR FILTER 68
– Remove screws . Take off the retaining plates and holding brackets.
– Remove screw . Remove the cover.
200499-10
– Loosen hose clamps .
86 m
56 co
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)
9- k. – 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.
r
99 a
200501-10
– Remove rubber sleeves .

7- Sh
87 rt
200502-10
a
– Raise the filter box bottom and pull off drain hoses .
– Detach the connector of the intake air temperature sensor.
P
– Remove snorkel seals .

– Raise the filter box bottom at the front and fix it on the handlebar.
200503-10
Installing the filter box bottom

10.4
– 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 .
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 spe-
cial tool.
86 m
Info
The fuel hose must have a minimum distance of 4 mm to the throttle link-
age in all operating positions.
56 co
– Position the throttle cables with guide piece .
9- k. – Slide the throttle valve body into the rubber sleeves.
r
99 a
200501-11
– Position and tighten upper hose clamps .

7- Sh
Guideline
(1.11 lbf ft)
87 rt
a
200500-11
– Mount the cover. Mount and tighten screw .

P
– Position the retaining plates and holding brackets. Mount and tighten screws .
200499-11
– Fix plug-in connector  with the holding bracket.

– Connect plug-in connector .
– Mount manifold absolute pressure sensor  and plug in the connector.
200498-11
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.
100669-10
Fitting the seat

11.2
– Position the recesses of the seat to the lugs on the frame, lower the rear end and
simultaneously push it forward.
86 m
– 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.
56 co 100730-10
9- k.
Removing the passenger seat
11.3

r
– Activate the release lever .
– Take off the passenger seat  toward the top.
99 a
7- Sh
100731-10
87 rt
Mounting the passenger seat

11.4
Warning
a
Danger of accidents The passenger seat can come loose from the anchoring
if it is not mounted correctly.
P
– 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.

100732-01 – 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 hazard Fuel 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.
Warning
Danger of poisoning Fuel 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 immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact 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 screws  of the steering damper.
– Remove the steering damper.
86 m
200488-10
– Remove screws .
56 co
9- k.
r
200489-10
– Press on metal plate  and disconnect the fuel hose connection.

99 a
Info
7- Sh
Remaining fuel may run out of the fuel hose.
– Disconnect electric plug-in connector  of the fuel pump.

87 rt
200490-10
– Raise the front of the fuel tank.

a
– Disconnect plug-in connector  of the fuel level indicator.

– Detach overflow hoses .
P
– Take off the fuel tank.
200491-10
Installing the fuel tank

11.6
Danger
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.
86 m
200491-11
– Connect fuel hose connector  with the new O-ring.

– Connect electric plug-in connector  of the fuel pump.
56 co
9- k.
200490-10
r
– Mount and tighten screws .
Guideline
99 a

7- Sh
87 rt
200489-11
– Position the steering damper.

– Mount and tighten screws .
a
Guideline
P
– Mount and tighten screw .

Guideline
Screw, steering damper M8 10 Nm Loctite® 243™
fixing bracket on triple (7.4 lbf ft)
200488-11
clamp
Removing the fuel tank guard

11.7
Info
The operations are the same on the left and right sides.
– Take off the fuel tank guard.
500246-10
Installing the fuel tank guard

11.8
Info
The operations are the same on the left and right sides.
86 m
– Position the fuel tank guard.
– Mount and tighten screw .
Guideline
56 co
Screw, fuel tank guard M5x17 3 Nm (2.2 lbf ft)
Info
Note the screw length!
9- k.
500246-10
Checking the fuel pressure

r
11.9
– Press down the metal plate and disconnect the fuel hose connection .
99 a
7- Sh
87 rt
200559-01

a
Pressure testing tool (61029094000) ( p. 443)

P
Danger
Danger of poisoning Exhaust gases are poisonous and can result in uncon-
sciousness and/or death.
– When running the engine, always make sure there is sufficient venti-
lation, and do not start or run the engine in a closed space without an
200560-01 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.
Warning
Danger of burns Some vehicle components get very hot when the machine
is driven.
– Wear appropriate protective clothing and safety gloves. In case of burns,
rinse immediately with lukewarm water.

– Connect the fuel hose connection.
Checking the fuel pressure during the actuator test

11.10
Danger
86 m
Warning
56 co
9- k.
– Press down the metal plate and disconnect the fuel hose connection .
Info
r
Remaining fuel may run out of the fuel hose.
99 a
7- Sh
200559-01

87 rt

– Start the "Fuel pump relay operation" actuator test.
a
– Check the fuel pressure.

Fuel pressure
P
When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)
200560-01
– 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 screws  on both sides.

– 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.
86 m
Info
Watch out for the projections on the inside cover.
– Mount and tighten screws  on both sides.
56 co
Guideline
200492-11
9- k.
Removing the inside cover
12.3
– Switch off all power consumers and the engine.

r
– Disconnect the negative (minus) cable of the battery.
99 a

– Remove expanding rivet .
7- Sh
87 rt
a
200493-10
– Disconnect the plug-in connectors from generator  and ignition pulse genera-
P
tor .
– Unscrew ground wire  from the frame.
– Remove screw .
200494-10
– Remove screws .
– Take off the left inside cover.
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.
86 m
– Plug in the control unit of the electric starter lock .
56 co
200495-11
– Position the left inside cover. Mount and tighten screw .

– Connect the plug-in connectors to generator  and ignition pulse generator .
9- k.
– Screw ground wire  onto the frame.
Guideline
r
99 a
7- Sh
200494-11
– Mount and tighten screws .

87 rt
a
200537-11
P
– Mount expanding rivets .

– Connect the negative (minus) cable of the battery.
200493-11
09/FRONT WHEEL 77
Removing the front wheel

13.1

– Jack up the motorcycle at the front. ( p. 10)
– 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.
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
86 m
wheel spindle out of the axle clamp. Remove screw .
Warning
56 co
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.
100720-10
9- k. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove spacers .
r
99 a
7- Sh
100779-10
87 rt
Installing the front wheel

13.2
– Clean and grease the shaft seal rings  and mating surfaces  of the spacers.
a

P
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.
– Insert the narrow spacer on the right-hand side (when viewed in the direction of
travel).
100780-10
09/FRONT WHEEL 78
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
– Clean screw  and axle .

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
100721-10 – 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.
86 m
vated position.
56 co
– Tighten screws  on both brake calipers.
Guideline
(33.2 lbf ft)
9- k.
– Take the front of the motorcycle off the work stand. ( p. 10)
–
r
Take the rear from the work stand. ( p. 13)
– Pull the front brake and compress the fork powerfully a few times.
99 a
The fork legs straighten.

– Fully tighten screws .
7- Sh
Guideline
Fork end pinch bolts M8 15 Nm
(11.1 lbf ft)
87 rt
100782-10
Checking the tire condition

a
13.3
Warning
P
Danger of accidents Uncontrollable handling characteristic caused by a flat tire.

– For your own safety, have damaged tires changed immediately.
Warning
Danger of crashing Impairment 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 accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be
roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not
achieved until the tires have been run in.
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 ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum permissible depth:
86 m
– Check the age of the tires.
Info
56 co
The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits refer
to the week of manufacture and last two digits refer to the year of manufac-
ture.
KTM recommends that the tires are changed regardless of the actual wear,
9- k.
at the latest after five years.
» If a tire is more than five years old:

r
99 a
Checking the tire pressure

13.4
Info
7- Sh
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.

87 rt
– Check the tire pressure when the tires are cold.

Tire air pressure, Solo
Front 2.5 bar (36 psi)
a
Rear 2.5 bar (36 psi)

P
Tire air pressure with passenger / full payload

100729-01
» If the tire pressure does not meet specifications:
– 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 accidents Reduced 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

Front 4.5 mm (0.177 in)
86 m
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:
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
10/REAR WHEEL 81
Removing the rear wheel

14.1

– Remove nut .
– Remove chain adjuster .
– Remove the axle .
100722-10
– Push the rear wheel as far forward as possible and then remove the chain from the
rear sprocket.
86 m
Warning
discs.
–
56 co
Always lay the wheel down in such a way that the brake discs are not
damaged.
100723-01 – Take the rear wheel out of the swingarm carefully without damaging the rim or
brake disc.
9- k.
Info
Do not operate the foot brake when the rear wheel is removed.
r
Installing the rear wheel
14.2
99 a
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
7- Sh
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents No braking effect when operating the rear brake.
87 rt
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.
– Check the rear hub cush drive. ( p. 86)

a
– Remove spacer . Clean and grease the mating surfaces of the spacers and the
shaft seal rings.
P

– Install the spacer.
– Clean the thread of the axle and nut.
– Clean the mating surfaces of the brake caliper frame and swingarm.
100724-10
– 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.
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.
100726-01
– Place the chain adjuster  on the tensioning screw.

– Position the chain adjuster  and place it on the tensioning screw.
– Tighten nut .
Guideline
In order for the rear wheel to be correctly aligned, the markings on the left and
86 m
right chain adjusters must be in the same position relative to the reference
marks .
Nut, rear wheel spindle M25x1.5 90 Nm Thread greased
56 co
100727-10
(66.4 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings press up against the
brake disc and there is a pressure point.
– Take the rear from the work stand. ( p. 13)
9- k. – Check the chain tension. ( p. 84)
Installing the rear wheel - when installing the engine

14.3
r
Warning
99 a
7- Sh
Warning
Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.
87 rt
– Remove spacer . Clean and grease the mating surfaces of the spacers and the
shaft seal rings.
a
– Install the spacer.

– Clean the thread of the wheel spindle and nut.
P
– Clean the contact areas of the brake caliper support and swingarm.
100724-10
– 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.
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.
100726-01
– Place chain adjuster  on the tensioning screw.

– Position chain adjuster  and place it on the tensioning screw.
– Tighten nut .
Guideline
In order for the rear wheel to be correctly aligned, the markings on the left and
86 m
right chain adjusters must be in the same position relative to reference marks .
Nut, rear wheel spindle M25x1.5 90 Nm Thread greased

(66.4 lbf ft)
56 co
100727-10
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.
9- k. – Check the chain tension. ( p. 84)
Checking the rear brake disc

14.4
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
r
– Change the worn brake disc(s) without delay.
99 a
– Check the thickness of the brake disc in several places to see if it conforms to mea-
7- Sh
surement .
Info
Wear reduces the thickness of the brake disc in area  of the brake disc.
87 rt
Brake disc - wear limit

Rear 4.5 mm (0.177 in)
» If the brake disc thickness is less than the specified value:
a
400480-10
– Change the brake disc.
– Check the brake disc for damage, cracking and deformation.
P
» 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:
– Clean the chain. ( p. 84)
400678-01
10/REAR WHEEL 84
Cleaning the chain

14.6
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
86 m
Info
The service life of the chain depends largely on its maintenance.
56 co
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)
9- k.
– After drying, apply chain spray.
Chain lube for road use ( p. 438)
r
Checking the chain tension
14.7
99 a
Warning
Danger of accidents Danger caused by incorrect chain tension.
7- Sh
– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings 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.
87 rt
– Lean the motorcycle on the side stand.

– Shift into neutral.
a
– In the area in front of where the chain passes through the link fork, push the chain
upward and measure chain tension .
P
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 accidents Danger caused by incorrect chain tension.
– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings 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.
– Check the chain tension. ( p. 84)

– Loosen nut .
– Loosen nuts .
– Adjust chain tension by turning the adjustment screws  on the left and right.
Guideline
86 m
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
56 co
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
9- k.
chain positions.
– Tighten nuts .
–
r
Make sure that the chain adjusters  are on the adjusting screws .
– Tighten nut .
99 a
Guideline
100709-10 Nut, rear wheel spindle M25x1.5 90 Nm Thread greased
7- Sh
(66.4 lbf ft)
Info
The wide adjustment range of the chain adjuster (35mm / 1.38") allows dif-
ferent secondary transmission ratios to be used with the same chain length.
87 rt
The chain adjusters  can be turned through 180°.
Checking rear sprocket / engine sprocket for wear

a
14.9
– Check the rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:
P
– 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 272 mm (10.71 in)

chain section
» If distance  is greater than the specified measurement:
86 m
– Change the rear sprocket / engine sprocket, chain and chain sliding guard.
Info
New chains wear out faster on old, worn sprockets.
56 co
For safety reasons, the chain has no chain joint.
700303-01
Checking chain sliding guard

14.11
9- k.
– 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:
r
– Change the chain sliding guard.
99 a
7- Sh
87 rt
a
P
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. ( p. 81)

– Remove the rear sprocket carrier.
– Check the rear hub for damage and wear.
» If the rear hub cush drive is damaged or worn:
– Change the shock absorber.
– Position the rear sprocket carrier.
Info
A set of bolts and shock absorbers should have as little free play as possible
100728-01
to increase the service life of the shock absorbers.
10/REAR WHEEL 87
– Install the rear wheel. ( p. 81)
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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 ( p. 399) pin assignment
900013-01
86 m
56 co
900015-10
– The electric starter lock control unit  prevents the engine from starting during the initialization phase of the EFI system . The
9- k.
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.
r
Fuel pump relay
99 a
15.2
Pin overview
7- Sh
1 Control circuit power supply

2 Control wire
3 Fuel pump power supply
4 Working circuit power supply
87 rt
600852-10
a
Removing the battery

P
15.3
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep 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 accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.

– Disconnect negative (minus) cable  of the battery.
100734-10
– Remove the cover of the positive terminal.

– Disconnect the positive (plus) cable  of the battery.
86 m
56 co
100735-10
– Removing the securing bracket .
– Pull the battery up and out of the battery rack.
9- k.
r
99 a
100736-10
Installing the battery

7- Sh
15.4
– Position the battery in the battery rack.
Info
The terminals of the battery must face the rear of the vehicle.
87 rt
– Position the bracket .

a
100737-10
P
– Mount and tighten screws .

Guideline
– Reconnect the positive (plus)  cable of the battery.
– Position cover of the positive terminal.
100738-10
– Reconnect the negative (minus) cable  of the battery.

– Set the clock with SET CLOCK. ( p. 106)
100734-11
Recharging the battery

15.5
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Avoid contact with battery acid and battery gases.
– Keep 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 hazard Battery 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.
86 m
Warning
56 co
Info
Even when there is no load on the battery, it discharges steadily.
9- k.
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.
r
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
99 a
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
7- Sh

– Disconnect the negative (minus) cable of the battery to avoid damage to the motor-
cycle's electronics.
87 rt
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
a
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
P
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 3 months
motorcycle is not in use
100151-10
Changing the main fuse

15.6
Warning
Fire hazard The 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 protection covers .
– Remove the faulty main fuse .
86 m
Info
A reserve fuse  is located in the starter relay.
56 co
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.
9- k.
– Attach the protection covers .
r
99 a
7- Sh
100739-10
Changing the fuses of individual power consumers

15.7
87 rt
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect fuses.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
a
Info
P
The fuse box containing the fuses of individual power consumers is located under the seat.

– Open fuse box cover .
100740-10
– 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
Fuse 7 - not used
86 m
Fuse 8 - 10A - for supplementary equipment (standard accessories)
Fuse 9 - 10A - for supplementary equipment (accessories connected to the igni-
tion switch)
56 co
Fuse 10 - not used
Fuse SPARE - 10A/15A - spare fuses
– Use spare fuses with the correct rating only.
9- k. Fuse (75011088010) ( p. 411)
Fuse (75011088015) ( p. 411)
Tip
r
Replace the spare fuse in the fuse box so that it is available if needed.
99 a
– Close the fuse box cover.

7- Sh
87 rt
a
P
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 lin-
ings. 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
Danger of accidents Reduced braking efficiency caused by worn brake linings.
86 m
– Change worn brake linings immediately.
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
56 co
– 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 thick-
9- k. ness .
Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
r
– Change the front brake linings. ( p. 93)
99 a
– Check all brake linings on both brake calipers for damage and cracking.
» If damage or wear is encountered:
7- Sh
100715-10
– Change the front brake linings. ( p. 93)
Changing the front brake linings

16.3
Warning
87 rt
Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
a
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
P
Warning
Danger of accidents Reduced 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 accidents Reduced braking efficiency due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
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.
86 m
100714-10
56 co
9- k.
301496-10
– Push the brake linings away from piston  and remove them.
r
– Clean the brake caliper.
99 a
7- Sh
301497-10
87 rt
– Position retaining bracket .

a
P
301498-10
– Slip in the brake linings and press them toward piston .
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.
vated position.
– Tighten screws  on both brake calipers.
Guideline
(33.2 lbf ft)
– Add brake fluid to the MAX level.
Brake fluid DOT 4 / DOT 5.1 ( p. 436)
–
86 m
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
56 co
Checking the front brake fluid level
16.4
Warning
9- k.
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
r
Warning
99 a

7- Sh
– 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)
87 rt
a
100712-10
P
Adding front brake fluid

16.5
Warning
Warning
Warning
13/BRAKE SYSTEM 96
Warning
Info
brake fluid.
– Loosen screw.
– Remove cover  with membrane .
86 m
– Position the cover with the membrane. Mount and tighten the screws.
56 co
Info
100714-10
Adjusting the basic position of the hand brake lever

16.6
9- k.
– Pull the brake lever forwards.
– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing wheel .
r
Info
99 a
Do not make any adjustments while riding!

7- Sh
100711-10
Checking the rear brake linings

16.7
87 rt
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
a
– Change worn brake linings immediately.
Note
P
Danger of accidents Reduced braking efficiency caused by damaged brake discs.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.
– Check the brake linings for minimum thickness .

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

16.8
Warning
Warning
Warning
86 m
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
–
56 co
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
9- k.
r
Info
99 a
brake fluid.
7- Sh
– Stand the vehicle upright.

– Remove screw cover  with membrane .
87 rt
– 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.
a
P
100717-10
– Remove the brake caliper and pull the brake line out of the holder.
301491-10
13/BRAKE SYSTEM 98
– Remove locking clip .
301492-10
– Remove bolt .
86 m
56 co
301493-10
– Remove brake linings .

– Remove spring .
– Clean the brake caliper.
9- k.
r
99 a
301494-10
– Position brake linings  and spring .

7- Sh
– Mount bolt .
87 rt
301495-10
a
– Mount locking clip .

P
301492-10
– Position the brake caliper.

– Mount and tighten screws .
Guideline
Screw of rear brake caliper M8 22 Nm Loctite® 243™
(16.2 lbf ft)
– 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.
301491-10
– Correct the brake fluid level to the MAX marking.
13/BRAKE SYSTEM 99
– Refit screw with membrane.
Info
Checking the rear brake fluid level

16.9
Warning
Warning
86 m
– Check the brake fluid level of the brake fluid reservoir.
56 co
» If the fluid level reaches the MIN mark :
– Add rear brake fluid. ( p. 99)
9- k.
100716-10
r
Adding rear brake fluid
16.10
99 a
Warning
7- Sh
Warning
87 rt
a
Warning
P

Warning
Info
brake fluid.
13/BRAKE SYSTEM 100

– Remove screw cover  with membrane .
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.
86 m
Guideline
Standard Central hole
– Tighten screw.
56 co
Guideline
Bolt, foot brake pedal stub M6 10 Nm Loctite® 243™
9- k. (7.4 lbf ft)
r
99 a
7- Sh
100706-10
Adjusting the foot brake pedal

16.12
– Use the tool to press in the anti-rotation lock , then turn the piston rod .
87 rt
Info
The range of adjustment is limited.
a
– Remove the tool.

The spring tension on the anti-rotation lock is released and the hex nut is
P
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. ( p. 81)

– Unplug the brake light switch. Remove the cable clip.
– Remove screws . Take off the footrest bracket.
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.
86 m
56 co
9- k. 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 .
r
Guideline
99 a
7- Sh
200526-11
– Position the footrest bracket. Mount and tighten screws .

87 rt
Guideline
Screw, rear footrest bracket M8 25 Nm
(18.4 lbf ft)
a
– Position the brake fluid reservoir. Mount and tighten screw .

Guideline
P
Screw, brake fluid reser- M5 5 Nm Loctite® 243™

voir of rear brake (3.7 lbf ft)
200525-11
– Plug in the brake light switch. Mount the cable clip.
– Install the rear wheel. ( p. 81)
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
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
900039-60
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.
Imobilizer control unit Unlocked
starter OK " ICUSTR"
86 m
Info
The engine may be started.
Imobilizer control unit Locked
56 co
starter OK " ICUSTR"
Info
The engine cannot be started.
Imobilizer control unit Initialization in progress...

9- k.
authentication "ICUINIT"
Imobilizer control unit Initialization complete OK
authentication "ICUINIT"
r
Activating/deactivating ignition key
99 a
17.2
Info
7- Sh
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 individu-
ally activated/deactivated using the orange programming key. This will also prevent
87 rt
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
a
included in the procedure.

P
– Insert the orange programming key in the ignition lock.

100749-01 – Switch on the ignition by turning the orange programming key to the ON posi-
tion .
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 posi-
tion .
– 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 .
The immobilizer indicator lamp lights up, switches off briefly, and
switches on again.
– Switch off the ignition by turning the black programming key to
the position OFF .
– Remove the black ignition key.

– Switch on the ignition by turning the orange programming key to the ON posi-
tion .
flashes according to the number of functioning black ignition keys includ-
ing the orange programming key. In this case, twice.
tion .
The lost black ignition key is deactivated.
The existing black ignition key is reactivated.
Loss of both black ignition keys (no black ignition key available):
This procedure is important to prevent misuse of the lost black ignition key.
86 m
tion .
56 co
tion .
9- k.
tion .
r
99 a

ing the orange programming key. In this case once, since all black ignition
keys are deactivated.
7- Sh
tion .
All black ignition keys are deactivated.
87 rt
– Order a new black ignition key according to the key number on the KEYCODE-
CARD and activate it.
Activating ignition key:
a
You can activate or deactivate up to four black ignition keys. Only the black igni-
tion keys programmed during an activation procedure are valid. All black ignition
keys not programmed during the activation procedure are invalid, but can be repro-
P
grammed in a further activation procedure.

tion .
tion .
– Insert the black ignition key in the ignition lock.
– Switch on the ignition by turning the black programming key to
the position ON .
switches on again.
– 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.
tion .
ing the orange programming key.
tion .
86 m
All black ignition keys are activated included in this job sequence are acti-
vated.
56 co
Activating the ICU
17.3
Info
To program the new imobilizer control unit, the two black ignition keys are needed.
9- k.
– Install the new imobilizer control unit.
– Insert the supplied orange programming key into the ignition lock.
r
– Switch on the ignition by turning the orange programming key to the ON position .
99 a
7- Sh
tion .
100749-01
– Insert the first black ignition key into the ignition lock.
–
87 rt
Switch on the ignition by turning the black programming key to the position ON .
The immobilizer indicator lamp lights up, switches off briefly, and switches
a
on again.
– Switch off the ignition by turning the black programming key to the position OFF .
P
– Pull out the first black ignition key.

– Insert the second black ignition key into the ignition lock.
The immobilizer indicator lamp lights up, switches off briefly, and switches
on again.
– Connect the diagnostic tool.
– Start diagnostic software.
– Select "Coding".
900039-60
– Select "Teach-in immobilizer control unit".
– Read the information page in the KTM diagnostics tool then using "Continue" pro-
gramm 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.
86 m
– Press the button MODEand keep it depressed.
BOOTLOADER mode appears in the combination instrument.
– Release MODE button.
56 co
400661-10
Updating the combination instrument software

17.5
9- k.
Condition
The ignition is on.
The diagnostic tool is connected and running.
r
– Activate the combination instrument - BOOTLOADER mode. ( p. 105)
99 a

– Select "DCL".
7- Sh
– Select "Connect".
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.
87 rt
– Check the connection between XC_1 Scan Box and the diagnostics connec-
400687-60 tor on the vehicle and repeat the procedure.
a
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)
P
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.
Setting ROAD or RACE mode

17.6
Condition
The ignition is on.
The motorcycle is stationary.
– Press the button and the button for 3 - 5 seconds.
– Press the MODE button briefly.
The mode set is shown in the info display.
– Select ROAD mode or RACE mode with the button or the button.
The settings are stored and the display changes to the SET‑UP menu.
– Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
400475-01
86 m
Setting the clock with SET CLOCK
17.7
Condition
The ignition is on.
56 co
– Press the button once until the symbol shows SET CLOCK in the info display.
9- k. The hour is shown.
– Set the hour with the button or the button.
r
The minutes are shown.
– Set the minutes with the button or the button.
99 a
400455-01
The settings are stored and the display changes to the SET‑UP menu.
7- Sh
the info display.
87 rt
Adjusting shift speed RPM1/2

17.8
Condition
The ignition is on.
a

P
– Press the button twice until the symbol appears in front of SETTINGS in the
info display.
RPM1 and RPM2 appear in the info display.
The engine speed after RPM1 flashes.
400460-01 Info
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 con-
stantly. If RPM1 = RPM2, the shift warning light lights up constantly when
you reach the engine speed set.
– 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 briefly and repeatedly until the symbol shows BACK... in the
info display.
the info display.
Setting the blank time of the LAP button LAP BLANK T

17.9
86 m
Condition
The ignition is on.
56 co
info display.
– Press the button once until the symbol shows LAP BLANK T in the info display.
9- k.
LAP BLANK T. appears in the info display.
Info
r
400461-01
At delivery, LAP BLANK T. is set to 1 second.
99 a
Tip
7- Sh
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
87 rt
LAP BLANK T. can be set between 1 and 200.

a
The settings are stored and the display changes to the SETTINGS menu.
P
info display.
the info display.
Setting the number of laps SET NUM LAPS

17.10
Condition
The ignition is on.
info display.
– Press the button twice until the symbol is on SET NUM LAPS in the info dis-
play.
TOTAL LAPS appears in the info display with the number of laps.
400462-01
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.

info display.
the info display.
86 m
Setting the fuel reserve display TRIPF RESET

17.11
56 co
Condition
The ignition is on.
9- k.
info display.
– Press the button three times until the symbol shows TRIP F RESET in the info
r
display.
99 a
TRIPF RESET appears in the info display with the reaction time.
400463-01
7- Sh
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
87 rt
You can set the TRIPF RESET to between 10 and 1000 seconds in steps of
10.
a

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

17.12
Info
Making a country-specific setting.
Condition
The ignition is on.

– Press the button three times until the symbol shows UNITS in the info display.
The selected unit appears on the left of the display.
– Select the unit with the button or the button.
The settings are stored and the display changes to the UNITS menu.
400464-01
info display.
the info display.
86 m
Setting the temperature unit SET °C/°F
17.13
Condition
56 co
The ignition is on.
– Press the button three times until the symbol shows UNITS in the info display.
9- k.
– Press the button once until the symbol shows SET °C/°F in the info display.
The selected unit appears on the left of the display.
r
– Select the unit with the button or the button.
99 a

400465-01
The settings are stored and the display changes to the UNITS menu.
7- Sh
info display.
the info display.
87 rt
Switching the external temperature display on/off

a
17.14
Condition
The ignition is on.
P

– Press the button four times until the symbol shows OPTIONS in the info dis-
play.
– Press the button once until the symbol shows OPTION OUTTEMP in the info dis-
play.
You see ENABLED or DISABLED in the info display.
400466-01 – You can switch the external temperature display on/off with the button or the
button.
The settings are stored and the display changes to the OPTIONS menu.
info display.
the info display.
Resetting service display

17.15
Condition
The ignition is on.
– Press the button and button for 3-5 seconds.
info display.
– Press the button and button for 3-5 seconds.
– Press the button repeatedly until the symbol appears in front of
SERVICE RESET.
SERVICE RESET appears in the info display.
86 m
ARE YOU SURE? flashes.
– Press the button .
56 co
The menu is closed.
– Press the button .
NEXT SERVICE AFTER is displayed.
400486-01
9- k. – Adjust the distance to the next service using the button and the button .
The menu is closed.
r
99 a
7- Sh
400485-01
Checking the headlight setting

17.16
87 rt
– On a light-colored wall behind a horizontal area, make a mark as high as the center
0
A –
of the low beam headlight.
Make another mark at a distance of  under the first mark.
a
Guideline
B
0 Distance  5 cm (2 in)
P
– Position the motorcycle at a distance of  away from the wall. The rider, with lug-
gage 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 passen-
ger if applicable.
» If the boundary between light and dark does not meet specifications:
– Adjust the headlight range. ( p. 111)
Adjust the headlight range

17.17
– Check the headlight setting. ( p. 110)

– Adjust the beam distance of the headlight by turning screw .
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.
100748-10
If you have a payload, you may have to correct the headlight range.
Changing the parking light bulb

17.18
86 m
Note
Damage to reflector Reduced 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
56 co
before mounting.

– Remove screws . Remove the cover.
9- k.
r
99 a
7- Sh
100745-10
– Release the latch .

– Remove the lamp cover .
87 rt
a
P
100746-10
– Pull the parking light  carefully out of the holder.

– Remove the light bulb.
– Position a new light bulb in the holder.
Parking light (W5W/ base W2.1x9.5d) ( p. 411)
– Carefully position the holder with the bulb in the holder in the headlight.
100747-10
– Position the lug  of the lamp cover in the notch. Engage the latch.
– Check that the lighting is functioning properly.
86 m
56 co
400422-12
– Position the cover.
Info
Check for correct positioning and freedom of movement of the brake lines.
9- k.
Guideline
r
99 a
100745-12
7- Sh
Changing the low beam bulb

17.19
Note
87 rt
before mounting.

a
– Fold up the combination instrument. Pull the lug  out of the rubber retainer .
– Remove the rubber retainer.
P
100742-10
– Release the latch .

– Remove the lamp cover .
100743-10
– Disconnect plug-in connector .

– Push off the retaining clamp  on both sides, squeeze and fold to the side.
– Remove headlight bulb .
700295-01
– 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.
86 m
– Position the retaining clamp.
– Position the plug-in connector.
56 co
700296-01
– Position the lug  of the lamp cover in the notch. Engage the latch .
9- k. – Check that the lighting is functioning properly.
r
99 a
7- Sh
87 rt
a
400422-10
– Position the rubber holder .

P
– Fold down the combination instrument. Position the lug  in the rubber retainer.
100744-10
Changing the high beam bulb

17.20
Note
before mounting.

– Remove screws . Remove the cover.
100745-10
– Release the latch .

– Remove the lamp cover .
86 m
56 co
100746-10
– Disconnect plug-in connector .

– Push off the retaining clamp  on both sides, squeeze and fold to the side.
– Remove headlight bulb.
–
9- k. Position the new headlight bulb in the headlight housing.
Low beam / high beam (H7 / base PX26d) ( p. 411)
Info
r
Insert the headlight bulb so that the lug is positioned in the cut-out.
99 a
700299-01
– Position the retaining clamp.
– Position the plug-in connector.
7- Sh
– Position the lug  of the lamp cover in the notch. Engage the latch.
– Check that the lighting is functioning properly.
87 rt
a
P
400422-11
– Position the cover.
Info
Check for correct positioning and freedom of movement of the brake lines.
– Mount and tighten screws .

Guideline
100745-11
30/ENGINE 115
Removing the engine

18.1

– Remove the inside cover. ( p. 75)
– Remove the filter box bottom. ( p. 67)
– Remove the radiator. ( p. 195)
– Remove rear screw  of the starter motor.
– Remove the screw of ground connector .
– Remove the screws of SLS cover . Take off the SLS cover.
86 m
200509-10
– Push back protective cover . Unscrew the electrical connection from the starter
56 co
motor. Remove the cable.
– Unplug the connector of oil pressure sensor .
– Unplug the connector of the coolant temperature sensor .
9- k.
r
200510-10
–
99 a
Remove the screws of SLS cover . Take off the SLS cover.
7- Sh
87 rt
200511-10
– Remove cable protector .

a
– Unplug connectors  of the gear position sensor and of the side stand switch.
– Remove the exhaust system. ( p. 63)
P
200512-10
– Unplug the connectors of ignition coils .
200520-10
30/ENGINE 116
– Remove screws . Remove the slave cylinder with the spacer and sleeves.
– Remove screws . Take off the engine sprocket cover.
200521-10
– Shift into first gear.
Info
The purpose is to loosen the nut of the engine sprocket.
– Remove screws . Remove the chain securing guide with the spacer.
86 m
56 co
200522-10
– Remove screws . Remove the side stand bracket.

– Remove screw  with the washers. Take off the shift shaft deflection.
– Remove screws . Take off the footrest bracket.
9- k.
r
99 a
200523-10
– Remove screws . Take off the horn holder.

7- Sh
– Remove the rear brake system. ( p. 101)

87 rt
200524-10
a
– Position the floor jack under the engine and screw it on using the special tool.
P
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.
200527-10
– Remove the nut of the engine sprocket with the lock washer. Take off the engine
sprocket.
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.
200529-10
– Have an assistant hold the rear of the motorcycle. Remove the securing belts.
– Remove screws  on both sides.
Info
Make sure not to misplace the washers.
86 m
– Lower the engine. Raise the rear of the motorcycle. Pull out the engine from the
side.
– Mount the special tool on the frame.
56 co
200530-10
Frame support (61229050000) ( p. 446)
– Remove both radiator hoses. Remove the vacuum and vent hoses.
Preparing the engine for installation

18.2
9- k.
– Position both radiator hoses. Position and tighten the hose clamps.
– Position the hose fixation. Mount and tighten screw .
Guideline
r
Remaining engine screws M6 10 Nm (7.4 lbf ft)
99 a
– Connect the vacuum hoses of manifold absolute pressure sensor .

– Position the vent hoses as shown in the figure.
7- Sh
87 rt
a
P
200531-10
Installing the engine

18.3
– Prepare the engine for installation. ( p. 117)

– Raise the engine onto the special tool and screw it in place.
Frame support (61229050000) ( 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.
200530-11
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.
200529-01 Guideline
Nut, swingarm pivot M19x1.5 130 Nm Thread greased
(95.9 lbf ft)
– Tighten screws .
Guideline
Screw, engine bearer M10 45 Nm
86 m
(33.2 lbf ft)
– Mount the pin of the bell crank on the frame. Mount and tighten the nut.
Guideline
56 co
Nut of bell crank on frame M14x1.5 100 Nm
(73.8 lbf ft)
– Mount the rear work stand.
– Remove the securing belts.
9- k. – Remove the floor jack with the special tool.
– Install the rear brake system. ( p. 101)
r
99 a
7- Sh
200527-10
– Mount the engine sprocket with the lock washer.

– Mount and tighten the nut.
87 rt
Guideline
Nut of engine sprocket M20x1.5 100 Nm Loctite® 243™
(73.8 lbf ft)
a
– Secure the nut with the lock washer.

P
200528-10
– Position the horn holder. Mount and tighten screws .

Guideline
200524-11
30/ENGINE 119
– Position the footrest bracket. Mount and tighten screws .

Guideline
– Position the shift shaft deflection. Mount and tighten screw  with the washers.
Guideline
Screw, shift shaft deflector M6 18 Nm Loctite® 243™
on shift shaft (13.3 lbf ft)
200523-11
– Position the side stand bracket. Mount and tighten screws .
Guideline
Screw, side stand bracket M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Position the chain securing guide with the spacer. Mount and tighten screws .
86 m
Guideline
Screw, shift shaft deflector M6 10 Nm Loctite® 243™
on chain securing guide (7.4 lbf ft)
Remaining chassis screws M6 10 Nm –
56 co
(7.4 lbf ft)
200522-11
9- k.
– Mount the slave cylinder with the spacer and sleeves. Mount and tighten screws .
Guideline
r
– Mount the engine sprocket cover. Mount and tighten screws .
99 a
Guideline
7- Sh
200521-11
– Plug in the connector of ignition coils .

– Install the exhaust system. ( p. 65)
87 rt
a
P
200520-11
– Plug in connector  of the gear position sensor and of the side stand switch.
– Mount cable protector .
200512-11
30/ENGINE 120
– Position SLS cover . Mount and tighten the screws.

Guideline
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 .
86 m
56 co
200510-11
– Position SLS cover . Mount and tighten the screws.

Guideline
9- k. – Mount and tighten the screw of ground connection .
Guideline
r
– Mount and tighten rear screw  of the starter motor.
99 a
200509-11 Guideline
Screw, starter motor M6 10 Nm (7.4 lbf ft)
7- Sh
– Install the filter box bottom. ( p. 68)

– Install the radiator. ( p. 195)
87 rt

– Fill up with engine oil. ( p. 212)
– Take a short test ride.
a
– Read out the trouble code memory using the KTM diagnostics tool.
– Check the engine for leakage.
P
– Check the engine oil level. ( p. 209)

– Check the cooling system for leaks.
– Check the coolant level. ( p. 194)
Setting the engine to ignition top dead center of the rear cylinder
18.4
Condition
The valve cover has been removed.
– Remove screw  of the generator cover.
200539-11
30/ENGINE 121
– Turn the crankshaft counterclockwise until markings  are flush with the edge of
the cylinder head.
301441-10
– Look through the hole to check that the position notch of the crankshaft is visible.
– Screw in special tool .
Engine blocking screw (61229015000) ( p. 444)
86 m
56 co
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.
9- k.
– Loosen special tool  by several turns.
r
99 a
7- Sh
200544-10
– Continue turning the crankshaft counterclockwise until markings  are flush with
the edge of the cylinder head.
87 rt
– Screw special tool  back in.

a
P
301442-10
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) ( p. 443)
Engine holder (61229002000) ( 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 screw  and take off the engine bracket.
86 m
56 co 301345-10
9- k. – Remove screws .
– Remove screw  and take off the engine bracket.
r
99 a
7- Sh
301346-10
Draining the engine oil

19.3
87 rt
– Remove oil drain plug  with the magnet, O-rings and oil screen.
– Completely drain the engine oil.
a
P
200480-10
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.
86 m
56 co 301337-10
9- k.
19.6
– Remove screw  of the generator cover.

r
99 a
7- Sh
301338-10
87 rt
– Turn the crankshaft counterclockwise until markings  of the rear camshafts are
flush with the edge of the cylinder head.
a
P
301341-10
– Look through the hole to check that the position notch of the crankshaft is visible.
– Screw in special tool .
301340-10
Removing the starter motor

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

19.8
– Remove the oil filler tube with the O-ring.
86 m
56 co 301349-10
9- k.
Removing the heat exchanger
19.9
– Remove screws  of heat exchanger .

r
– Remove the heat exchanger.
99 a
7- Sh
301350-10
87 rt
– Remove O-rings  and sleeves .

– Remove seal .
a
P
301366-10
Removing the rear timing chain tensioner

19.10
– Remove screw  with O-ring .

– Pull out timing chain tensioner .
301351-10
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.
301352-10
– Raise the camshaft at the rear and take the timing chain off of the rear sprocket.
Remove the camshaft.
86 m
56 co
301353-10
Removing the rear cylinder head

19.12
9- k. – Remove nuts  with the washers.
– Alternately loosen screws  and remove them.
– Take off the cylinder head. Remove the cylinder head gasket.
r
99 a
7- Sh
301357-10
Removing the rear piston

19.13
87 rt
– Push the cylinder up.
Info
Push the cylinder up until the piston pin can be removed.
a
Make sure that the two pins remain in place.

P
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.

19.14
– Loosen special tool  by several turns.

– 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 .

– Pull out timing chain tensioner .
86 m
56 co 301359-10
9- k.
Removing the front camshafts
19.16
– Remove spark plug shaft insert .

r
– Loosen and remove screws  from the outside to the inside.
99 a
Info
7- Sh
301360-10
87 rt
a
P
301361-10
Removing the front cylinder head

19.17
– Remove nuts  with the washers.

– Alternately loosen screws  and remove them.
– Take off the cylinder head. Remove the cylinder head gasket.
301362-10
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.
86 m
Info
If no additional work needs to be performed on the cylinder and piston, the
56 co
piston can remain in the cylinder.
301364-10 – Take off the cylinder base gasket.
Removing the generator cover

19.19
9- k.
r
99 a
7- Sh
301392-10
– Screw in special tool  and pull off the generator cover.

Extractor (61229010000) ( p. 444)
87 rt
Info
Gently strike the generator cover with a rubber mallet to prevent strain.
a
– Take off the generator cover seal. Take off the dowels.
P
301393-10
Removing the ignition pulse generator

19.20
– Remove the screws of ignition pulse generator .

– Pull cable support sleeve  out of the engine case. Take off the ignition pulse gen-
erator.
200346-10
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 usu-
ally 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.
86 m
Info
The crankshaft must be blocked.
56 co 301396-10
9- k. – Screw the special tool into the crankshaft.
Pressure piece (61229008000) ( p. 444)
– Mount special tool  on the rotor, apply counterpressure, and pull off the rotor by
r
screwing in the screw.
99 a
Extractor (58429009000) ( p. 440)

– Remove the special tools.
7- Sh
200349-10
– Take free-wheel-gear  from rotor .

87 rt
a
P
200350-10
Removing the idler and timing chain on the left

19.23
– Take off idler  with washer .
200353-10
– 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.
Circlip pliers reverse (51012011000) ( p. 440)
86 m
56 co
9- k.
r
99 a
7- Sh
301390-10
Removing the balancer shaft

19.25
– Remove balancer shaft  with washer .

–
87 rt
Mount the needle bearing and the rear washer.

a
P
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)
Pressure piece (61229018000) ( p. 445)
Arms for extractor 78029033100 (61229017000) ( p. 445)
200358-10
Removing the gear position sensor

19.27
– Remove the screws. Remove gear position sensor  with the O-ring.
301398-10
– Remove contact pin  and the contact spring.
86 m
56 co
301399-10
Removing the left suction pump

19.28
9- k.
r
99 a
7- Sh
301400-10
– Screw fitting screws into the oil pump cover.

– Pull off the oil pump cover by screwing in the screw.
87 rt
– Remove oil pump cover .

– Remove seal .
a
P
301401-10
– Remove external rotor  and internal rotor .

– Remove pin .
86 m
56 co
301402-10
Removing the water pump wheel

19.29
9- k.
r
– Take off the water pump cover.
99 a
7- Sh
301394-10
– Remove dowels .
– Remove screw . Take off the water pump wheel with the washer below it.
87 rt
a
P
200398-10
Removing the clutch cover

19.30
– Loosen the screws of outer clutch cover .

– Take off the clutch cover.
200399-10
– 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.
Info
86 m
If the timing chain is to be used again, note the direction of travel and the
cylinder on which it was used.
56 co
200403-10
Removing the clutch facing

19.32
9- k.
– 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 .
r
– Take off push rod .
99 a
7- Sh
200405-10
– Remove clutch discs , the support ring and the pretension ring.
87 rt
a
P
200406-10
Removing the outer clutch hub

19.33
– Insert special tool  into inner clutch hub  and outer clutch hub .
Clutch holder (61229003000) ( p. 443)
– Loosen nut  and remove it with the washer.
– Remove components  and  of the clutch pressure booster.
200408-10
– Remove outer clutch hub  with washer .
301403-10
– Remove needle bearing  and washer .
86 m
56 co
301404-10
Removing the primary gear

19.34
– Loosen nut  of primary gear  and remove it together with the washer.
9- k. Info
Left-handed thread!
Make sure that the crankshaft is blocked.
r
99 a
7- Sh
200412-10
– Remove the primary gear with special tools ,  and .

Puller, 2-arm (78029033100) ( p. 448)
Pressure piece (61229018000) ( p. 445)
87 rt
Arms for extractor 78029033100 (61229017000) ( p. 445)

a
301409-10
P
Removing the force pump

19.35
– Remove lock washer  and washer . Take off oil pump gear .
301410-10
– Remove pin  and washer .

– Remove screws .
– Remove the oil pump cover.
301411-10
– Remove external rotor  and internal rotor .

– Remove pin .
86 m
56 co
9- k.
r
99 a
301412-10
7- Sh
Removing the shift shaft

19.36
– Push sliding plate  away from the shift drum locating . Remove shift shaft 
with the washer.
87 rt
a
P
301413-10
Removing the shift drum locating

19.37
– Press locking lever  away from shift drum locating  and take off the shift drum
locating.
– Release the locking lever.
301414-10
Removing the locking lever

19.38
– Take off locking lever  with the sleeve and spring.
301415-10
Removing the left engine case

19.39
86 m
56 co
9- k.
r
99 a
7- Sh
200421-10
– Remove screws  and .

– Swing the left section of the engine case upward. Remove screw .
87 rt
– Loosen the left section of the engine case by striking it lightly with a plastic hammer and remove it.
– Remove dowels .
a
– Remove seal .
P
301422-10
Removing the crankshaft

19.40

– Remove the crankshaft.
301423-10
Removing the middle suction pump

19.41
– Take off oil pump shaft  with internal rotor .
200425-10
– Remove internal rotor  and pin  from the oil pump shaft .
– Remove external rotor .
86 m
56 co
200426-10
Removing the transmission shaft

19.42
9- k.
r
– Remove shift rails .
99 a
7- Sh
200427-10
– Swing shift forks  to one side.
Info
87 rt
Make sure not to misplace shift rollers .
– Remove shift drum .

a
P
200428-10
– Remove shift forks .
Info
Make sure not to misplace the shift rollers.
200429-10
– Place the engine in an upright position.

– Remove lock ring  and the stop disk.
200430-10
– Pull both transmission shafts out of the bearing seats together.
86 m
56 co
200431-10
Removing the oil spray tube

19.43
– Remove oil spray tube . Remove O-rings .

9- k.
r
99 a
7- Sh
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 .
87 rt
a
P
200434-01
Removing the timing chain rails of the left engine case section
19.45
– Remove screw . Remove timing chain guide rail .

– Remove screw . Remove timing chain tensioning rail .
200447-10
30/ENGINE - WORK ON INDIVIDUAL PARTS 138
Work on the right section of the engine case

20.1
– Remove studs .
200442-10
– Remove jet .
– Remove oil jets .
86 m
56 co
9- k.
r
99 a
7- Sh
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.
87 rt
Guideline
150 °C (302 °F)
a
– Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
200441-10
P
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.
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 Loctite® 243™
(4.4 lbf ft)
– Mount and tighten jet .
Guideline
Jet 140 M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
– Mount and tighten oil jets .
86 m
Guideline
Oil jet M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
56 co
– Mount the dowels.
9- k.
r
99 a
200440-10
– Mount studs .
7- Sh
Guideline
Stud, chain shaft M6 8 Nm (5.9 lbf ft)
– Blow compressed air through all oil holes and check that they are clear.
87 rt
a
200442-10
Removing the main bearing of the right engine case section

P
20.2
– Remove the screws and take off bearing shell bracket .
200435-10
– Mark face  of the main bearing shells as shown in the figure.
200436-10
– 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.
Press drift/press sleeve (61229044000) ( p. 446)
86 m
56 co
200437-10
Selecting the main bearing shells

20.3
New crankshaft
– Select the new bearing shells according to color marking .
9- k.
Info
Color marking  refers to the conrod bearing.
r
Used crankshaft
99 a
– Measure both pivot points and select the new bearing shells accordingly.
Guideline
7- Sh
200451-10 Crankshaft - main bearing diameter

Yellow 53.965… 53.975 mm (2.1246…
2.125 in)
Blue 53.976… 53.985 mm (2.12504…
2.12539 in)
87 rt
Red 53.986… 53.995 mm (2.12543…

2.12578 in)
a
Installing the right main bearing

20.4
– Select the main bearing shells. ( p. 140)

P
– Center the new main bearing shells  using special tool .

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 disas-
sembled.
– 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
– Position bearing shell bracket . Mount and tighten the screws.

Guideline
(4.4 lbf ft)
200435-11
Work on the left section of the engine case

20.5
– Remove studs .
86 m
56 co
200448-10
– Remove oil jets .
9- k.
r
99 a
7- Sh
87 rt
a
P
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.
200450-10 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.
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
Oil jet M6x0.75 4 Nm Loctite® 243™
86 m
(3 lbf ft)
– Mount oil jet .
Guideline
56 co
Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft)
Guideline
Plug, clutch lubrication M10x1 15 Nm
9- k.
(11.1 lbf ft)
r
99 a
7- Sh
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)
87 rt
a
P
200450-11
– Mount studs .
Guideline
Stud, chain shaft M6 8 Nm (5.9 lbf ft)
– Blow compressed air through all oil holes and check that they are clear.
200442-10
Removing the left main bearing

20.6
– Remove the screws and take off bearing shell bracket .
200443-10
– Mark joint  of the main bearing shells as shown in the figure.
86 m
56 co
200444-10
– Place the engine case section on special tool .

Press sleeve (61229045000) ( p. 446)
9- k.
– Place special tool  with the smaller diameter on the bearing shells and press from
the inside to the outside.
r
99 a
200445-10
7- Sh
Installing the left main bearing

20.7
– Select the main bearing shells. ( p. 140)

– Center the new main bearing shells  using special tool .
87 rt

a
P
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 disas-
sembled.
– 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
– Position bearing shell bracket . Mount and tighten the screws.

Guideline
(4.4 lbf ft)
200443-11
Changing the conrod bearing

20.8
Info
Perform the operation on both connecting rods.
86 m
– Clamp each connecting rod separately using soft jaws.
Multi-tooth wrench socket 10 mm; ½" drive (60029075000) ( p. 442)
56 co
– 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
9- k. each connecting rod bearing cap will be mounted on the same connecting
rod.
r
99 a
7- Sh
301424-10
87 rt
New crankshaft
– Select the new bearing shells according to color marking .
Info
a
Color marking  refers to the crankshaft bearing.

P
200453-10
Used crankshaft
– Measure the crank pin diameter and select the new bearing shells accordingly.
Guideline
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)
200485-10 Red 42.001… 42.011 mm (1.65358…
1.65397 in)
– Check the radial clearance of the bottom connecting rod bearing. ( p. 147)
– 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; ½" drive (60029075000) ( p. 442)

Graduated disc (60029010000) ( p. 441)
86 m
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
56 co
301425-10
bearing shells will press against the radius and block the connecting rod.
Work on the clutch cover

20.9
– Remove water pump cover .

9- k.
– Remove outer shaft seal ring .
r
99 a
7- Sh
200456-10
– Remove lock ring .

– Remove inner shaft seal ring .
87 rt
a
P
200457-10
– Press bearing  out of the clutch cover from the outside to the inside, using a suit-
able 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. ( p. 146)
200458-10
– Press in inner shaft seal ring  fully, with the open side flush and facing inwards.
– Mount lock ring .
200457-10
– 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 .
86 m
56 co
200459-10
– Pull out the step bearing shells  using the special tool.
9- k. Bearing puller (15112017000) ( p. 440)
Insert for bearing puller (60029018000) ( p. 441)
r
99 a
7- Sh
200460-10
– Center the new main bearing shells  using the special tool.
Step bearing tool (60029046028) ( p. 442)
87 rt
a
200461-10
P
– 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) ( p. 442)
200462-10
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
Screw, conrod bearing M10x1 Step 1
25 Nm
(18.4 lbf ft)
Step 2
86 m
30 Nm
(22.1 lbf ft)
Step 3
90°
56 co
Info
Do not twist the connecting rod.
– Remove the connecting rod bearing cap again. Compare the Plastigauge measuring
9- k. strip with the specifications on the packaging.
200455-10
Guideline
Connecting rod - radial clearance of lower conrod bearing
r
New condition 0.030… 0.060 mm (0.00118…
0.00236 in)
99 a
Wear limit 0.080 mm (0.00315 in)

7- Sh
Info
The width of the Plastigauge measuring strips indicates the bearing play.
– Clean the parts.

87 rt
Checking/measuring the cylinder

20.12
– Check the cylinder bearing surface for damage.

» If the cylinder bearing surface is damaged:
a
– Change the cylinder and piston.

– Measure the cylinder diameter at several places on the contact surface in the 
P
and  axes using a micrometer to check for oval wear.

Guideline
Cylinder - bore diameter
Size I 105.000… 105.012 mm (4.13385…
200472-10 4.13432 in)
Size II 105.012… 105.025 mm (4.13432…
4.13483 in)
– The cylinder size  is labeled on the side of the cylinder.
200474-10
– 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 ≤ 0.05 mm (≤ 0.002 in)

distortion
» 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.
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.
56 co
Tip
301418-10 Use an old piston ring to clean the piston ring groove.
– Check the piston rings for damage.

9- k. » If the piston ring is damaged:
– Change the piston ring.
Info
r
Mount the piston ring with the marking facing upward.
99 a
– Use the special tool to measure clearance  of the piston rings in the piston ring
groove.
7- Sh
Guideline
Piston ring - groove clearance
A
0 First ring (rectangular ring) ≤ 0.105 mm (≤ 0.00413 in)
A
0 Second ring (lower compression ≤ 0.150 mm (≤ 0.00591 in)
A
0
87 rt
ring)
Oil scraper ring ≤ 0.180 mm (≤ 0.00709 in)
400484-10
Feeler gauge (59029041100) ( p. 441)
a
» If clearance  is larger than the specified value:

P
– Change the piston and piston rings.

– Check/measure the cylinder. ( p. 147)
– Check the piston pin for discoloration or signs of wear.
» If the piston pin has strong discoloration/signs of wear:
– Change the piston pin.
– Insert the piston pin into the connecting rod and check the bearing for play.
» If the piston pin bearing has too much play:
– Change the connecting rod and the piston pin.
– Measure the piston on the piston skirt.
A Guideline
0
A Piston - diameter
Size I 104.955… 104.985 mm (4.13208…
0
A 4.13326 in)
Size II 104.965… 104.995 mm (4.13247…
4.13365 in)
Under the edge at right angles to the 6 mm (0.24 in)
200475-10 piston pin
– Piston size  is marked on the piston head.
301419-10
Checking the piston ring end gap

20.14
– Remove the piston ring from the piston.

– Place the piston ring in the cylinder and align it with the piston.
Guideline
86 m
Under the upper edge of the cylinder 10 mm (0.39 in)
– Measure the end gap with special tool .
Guideline
56 co
Piston ring end gap ≤ 0.5 mm (≤ 0.02 in)
200477-10
Feeler gauge (59029041100) ( p. 441)
» If the end gap is more than the specified value:
9- k. – Check/measure the cylinder. ( p. 147)
» If the cylinder wear is within the tolerance range:
– Change the piston ring.
r
– Mount the piston ring with the marking facing toward the piston head.
99 a
Checking the piston/cylinder mounting clearance

20.15
– Check/measure the cylinder. ( p. 147)

7- Sh
– Check/measure the piston. ( p. 148)

– The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam-
eter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston
diameter.
87 rt
Guideline
Piston/cylinder - mounting clearance
New condition 0.015… 0.057 mm (0.00059… 0.00224 in)
a

P
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!
– Remove engine coolant temperature sensor .

– Remove screw .
– Remove vacuum connection .
– Remove O-rings .
200466-10
– Remove plugs  with the O-ring.

– Pull out cam lever axle  with a suitable M5 screw and remove the cam lever.
86 m
56 co
200467-10
– Remove shims  and label the installation position.

9- k.
r
99 a
200468-10
– Tension the valve spring with a special tool.

7- Sh
Valve spring mounter (59029019000) ( p. 440)

Valve spring mounting device (78029060000) ( p. 448)
– Remove valve keys  and release tension on the valve spring.
87 rt
a
P
200469-10
– Remove valve spring retainer , valve spring, valve stem seals  and valve spring
supports .
Info
9 Place the valve into a box according to the installation position and label the
box.
bk – Check the cylinder head. ( p. 152)

bl – Mount valve spring supports  and new valve stem seals .
bm 200470-01 – Mount valve spring and valve spring retainer .
The tight winding of the valve spring is at the bottom.
– 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
When mounting the valve keys, check that they are seated correctly; prefer-
ably, fix the valve keys to the valve with a little grease.
86 m
56 co
200469-10
– Place shims  into the valve spring retainer according to the installation position.
9- k.
r
99 a
200468-10
– Position the cam lever and mount cam lever axles .

7- Sh
– Mount plugs  with new O-rings.

Guideline
Plug, cam lever axis M10x1 15 Nm
(11.1 lbf ft)
87 rt
a
P
200467-11
– Mount oil pressure sensor .

Guideline
Oil pressure sensor M10x1 10 Nm (7.4 lbf ft)
Info
This only applies to the front cylinder head!
– Mount engine coolant temperature sensor .
200466-10
Guideline
Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft)
– Mount screw .
Guideline
Plug, vacuum connection M6 5 Nm Loctite® 243™
(3.7 lbf ft)
– Mount vacuum connection .
Guideline
Vacuum connection M6 5 Nm Loctite® 243™
(3.7 lbf ft)
– Mount and grease O-rings .
Checking the cylinder head

20.17
– Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
» If there is wear or tearing:
86 m
– Change the cylinder head.
– Check the valve guides using the special tool.
Limit plug gauge (59029026006) ( p. 440)
56 co
Valve guide - diameter
200470-10 New condition 6.004… 6.016 mm (0.23638…
0.23685 in)
9- k. Wear limit 6.050 mm (0.23819 in)
» If the special tool is easy to insert into the valve guide:
– Change the valve guide and valve.
r
– Check sealing seat  of the valves.
99 a
Valve - sealing seat width

Intake: New condition 1.0 mm (0.039 in)
7- Sh
Intake: Wear limit 1.7 mm (0.067 in)

0
A Exhaust: New condition 1.0 mm (0.039 in)
Exhaust: Wear limit 2.0 mm (0.079 in)
87 rt
400373-10 – Machine the valve seat.

– Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
a
Feeler gauge (59029041100) ( p. 441)
Cylinder/cylinder head - sealing area ≤ 0.05 mm (≤ 0.002 in)

P
distortion
– Change the cylinder head.
400376-10 – Check the pivot points of the camshafts in the cylinder head and in the camshaft
bearing bridge for damage and wear.
A » If there is damage or wear:
– Change the cylinder head with the camshaft bearing bridge.
– Check valve  for damage and wear.
– Change the valve.
– Check the valve for run-out.
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)
200471-10 On the valve plate: Wear limit ≤ 0.030 mm (≤ 0.00118 in)

– Check the valve stem diameter.
Valve - valve stem diameter
Exhaust 5.893… 5.970 mm (0.23201…
0.23504 in)
Intake 5.965… 5.980 mm (0.23484…
0.23543 in)
– Check valve spring  for damage and wear.
– Change the valve spring.
– Measure the valve spring lengths.
86 m
Valve spring - length
New condition 42.0 mm (1.654 in)
56 co
– Change the valve springs.
– Check cam lever  for damage and wear.
9- k. » If there is damage or wear:
– Change the cam lever.
– Check cam lever axle  for damage and wear.
r
–
99 a
Change the cam lever axle.

– Check valve spring support  for damage and wear.
7- Sh
– Change the valve spring seat.

– Check valve spring retainer  for damage and wear.
– Change the valve spring retainer.
87 rt
Work on the right idler

20.18
– Remove bushing .
a
– Remove O-ring .
– Remove inner bearing races  and .
P
Extractor (61229020000) ( p. 445)

– Push on new bearing inner races  and .
– Mount the new O-ring .
– Mount the new bushing .
200465-10
Checking the timing assembly

20.19
– Clean all parts well.

2
0 6 – Check idler  for damage and wear.
5 – Change the idler.
– Check timing chain tensioning rail  for damage and wear.
4
0 – Change the timing chain tensioning rail.
3 0
0 4 – Check timing chain guide rail  for damage and wear.
1
0 1
0 » If there is damage or wear:
4 60
3 – Change the timing chain guide rail.
– Check camshaft  for damage and wear.
5
86 m
– Change the camshaft.
–
2 If the cam surface is damaged, check the oil supply to the camshaft and
cam lever.
56 co
– Measure the cam height.
Guideline
301420-01
Camshaft - cam height
Intake 39.34… 39.44 mm (1.5488…
1.5528 in)
9- k.
Exhaust 38.59… 38.69 mm (1.5193…
1.5232 in)
» If cam wear is outside of the tolerance range:
r
– Change the camshaft.
99 a
– Check timing chain  for damage and wear.

7- Sh
– 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:
–
87 rt
Change the timing chain.

– Check guide rail  for damage and wear.
a
– Change the guide rail.
Preparing the timing chain tensioner for installation

P
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.
End position of piston after latching 3 mm (0.12 in)
200172-10
Info
This position is necessary for installation.
If the timing chain tensioner is now pressed in once more (while it is
installed) and then pulled out no more than halfway (preventing it from
coming out fully), the latching system locks and the timing chain tensioner
can no longer be compacted; this function is necessary to ensure sufficient
tension of the timing chain, even at low oil pressure.
Checking the oil pressure regulator valve

20.21
– Remove supporting plate  and spring .

– Measure the length of spring .
4 Oil pressure regulator valve - minimum 40.5 mm (1.594 in)
spring length
2 » If the measured length is less than the specified value:
3
86 m
–
1 –
Change the spring.
Check control piston  for damage and wear.
56 co
301419-01
– Change the control piston.
– Check the control piston hole in oil pump cover  for damage and wear.
– Change the oil pump cover.
9- k.
– Oil control piston  and spring  well and mount them.
– Mount supporting plate .
r
Checking the oil pumps
20.22
99 a
Info
The following operations apply to all three oil pumps.
7- Sh
– Check the clearance between internal rotor  and external rotor  and between
the external rotor and the engine case.
Oil pumps
87 rt
Clearance between external rotor 0.20… 0.40 mm (0.0079…

and engine case 0.0157 in)
Clearance between external rotor 0.10… 0.25 mm (0.0039…
a
and internal rotor 0.0098 in)

Axial clearance 0.04… 0.25 mm (0.0016…
0.0098 in)
P
200464-10
» If the clearance exceeds the specifications:

– Change the oil pump and, if necessary, the engine case.
Checking the clutch

20.23
4
0
3
0
8
0
5
0
0
9
9
86 m
9 bk bl
bn
56 co
7
0
bm
6
0
9- k.
b0o
bo
0
1 0
2
r
301421-01
99 a
– Check pressure piece  for damage and wear.

7- Sh
– 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.
87 rt
– Check axial bearing  for damage and wear.

– Change the axial bearing.
a
– Check the length of clutch springs .

Clutch spring - length 33.00… 34.00 mm (1.2992… 1.3386 in)
P
» If the clutch spring length is less than the specified value:

– Change all clutch springs.
– Check the contact surface of pressure cap  for damage and wear.
– Change the pressure cap.
– Check the contact surfaces of the clutch facing discs in outer clutch hub  for wear.
Outer clutch hub - contact surface of clutch facing discs
» If the contact surface is very worn:
– Change the clutch facing discs and the outer clutch hub.
– Check needle bearing  for damage and wear.
– Change the needle bearing.
– Check the intermediate clutch discs  for damage and wear.
» If the intermediate clutch discs are not level and have pittings:
– Change all intermediate clutch discs.

– Check the thickness of intermediate clutch discs .
Intermediate disk - thickness
» If the intermediate clutch discs do not meet specifications:
– 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
86 m
» If the clutch facing discs do not meet specifications:
– Change all clutch facing discs.
56 co
– 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.
9- k.
– Change the inner clutch hub.
– Check the components of clutch pressure booster  for damage and wear.
r
99 a
– Change all components of the clutch pressure booster.

– Check the springs of outer clutch hub  for damage and wear.
7- Sh
» If there is damage, wear or play in the direction of rotation:

– Change the outer clutch hub.
Checking the shift mechanism

20.24
87 rt
– Check shift forks  at leaf  for wear.

Shift fork
Thickness at leaf 4.85… 4.95 mm (0.1909…
5 0
A
a
0
1 0 0.1949 in)
Clearance in the sliding gear 0.35… 0.55 mm (0.0138…
1
0
P
0
4 groove: New condition
Clearance in the sliding gear
0.0217 in)
0.70 mm (0.0276 in)
6 0
4 groove: Wear limit
5 » If the measured value does not equal the specified value:

E 7 – Change the shift fork and the idler/fixed gear pair.
– Check shift grooves  of shift drum  for wear.
D » If the shift groove is worn:
C0
2 – Change the shift drum.
– Check the seat of the shift drum in grooved ball bearings .
3
0 » If the shift drum is not seated correctly:
B
0 – Change the shift drum and/or the grooved ball bearing.
3
0 – Check grooved ball bearing  for stiffness and wear.
301418-01
» If the grooved ball bearings do not move freely or are worn:
– 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:
– Change the shift drum.

– Check springs  of the shift rails for damage and wear.
» If the spring is broken or worn:
– Change the spring of the shift rail.
– Check the shift rails  on a flat surface for run-out.
» If there is run-out:
– Change the shift rail.
– Check shift rails for scoring, signs of corrosion and stiffness in the shift fork.
» 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.
86 m
» If deep notches are present:
– Check guide pin  for looseness and wear.
56 co
» If the guide pin is loose and/or worn:
Preassembling the shift shaft

20.25
9- k.
– Fix the short end of the shift shaft in a vise.
5
0 Guideline
Use soft jaws.
r
1
0 – Mount sliding plate  with the guide pin facing down and attach the guide pin to
30
0
99 a
the shift quadrant.

4 – Mount preload spring .
7- Sh
– Push on spring guide , push return spring  over the spring guide with the offset
2
0 6
0 end facing upward and lift the offset end over abutment bolt .
200175-01
– Mount stop disk .
Dismantling the main shaft

87 rt
20.26
a
P
bbl
0l bk
b0k 0
9
6
0 0 0
8 7
0 0
5 4 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.
– 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

20.27
86 m
2
0
30
0 4 0
5
56 co
1
0 60
0 7 0
8
b0l bm
bl b0mbn 9
0 b0k
bk
b0n bo
b0o
9- k.
b0p bq
bp b0q br
b0r
b0s
bs
r
99 a
7- Sh
200462-01
– Fix the countershaft in the vise with the geared end facing downward.
87 rt
Guideline
Use soft jaws
–
a
Remove stop disk  and the first-gear idler gear .

– Remove needle bearing  and stop disk .
–
P
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 needle bearing  and stop disk .
– Remove lock ring  and the sixth-gear sliding gear .
– Remove lock ring  and stop disk .
– Remove the second-gear idler gear  and needle bearing .
Checking the transmission

20.28
2
0
60
0 4 10
0 4
60
0705
1 0
0 5
7
0 8
0 60
0104
4
0 5
0
1
0
6
0 1
0
6
0 70
0 5
7 0
0 4 0
6
6
0 1
0
86 m
3
0
6
0
56 co
200461-01
– Check needle bearing  for damage and wear.

9- k.
– Check the pivot points of main shaft  and countershaft  for damage and wear.
r
– Change the main shaft and/or countershaft.
99 a
– Check the tooth profiles of main shaft  and countershaft  for damage and wear.
7- Sh
– Change the main shaft and/or countershaft.

– Check the pivot points of idler gears  for damage and wear.
– Change the idler/fixed gear pair.
87 rt
– Check the shift dogs of idler gears  and fixed gears  for damage and wear.
a
– Check the tooth faces of idler gears  and fixed gears  for damage and wear.
P

– Check the tooth profiles of fixed gears  for damage and wear.
– Check fixed gears  for smooth operation in the profile of main shaft .
» 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 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.
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. 160)
86 m
1 0
0 2 3
0
6
0 4 0
0 5
56 co
7 0
0 8 9
0
b0k
9- k.
b0l
r
99 a
200460-02
– Fix the main shaft in the vise with the geared end facing downward.
7- Sh
Guideline
Use soft jaws
– If removed, mount a new needle bushing  using a suitable tool.
– 1 0
0 2 0
3
Mount needle bearing  and put on the fifth-gear idler gear  with the shifting claws facing upward.
87 rt
–
6
0
Mount stop disk  and a new lock ring .
0 0
4
–
5
Mount the third/fourth-gear sliding gear  with the small gear wheel facing upward.
–
7
0 0
a
Mount stop disk  and needle bearing .

– 8 9
0
Put on the sixth-gear idler gear  with the shifting claws facing downward.
–
P
Mount the second-gear fixed gear  with the collar facing downward and mount stop disk .
– Finally, check all gear wheels for smooth operation. 0
bk
Assembling the countershaft
20.30
bl
Info
Use new lock rings and new stop disks with every repair.
– Oil all parts carefully before assembling.

– Check the transmission. ( p. 160)
bbr
0r
b0q bp
bq b0p bo
b0o
b0s
bs b0n bm
bn b0m bl
b0l
80
0 7 b0k
bk 9
0
6 0
0 5
40
0 3 0
2
1
0
86 m
56 co
200462-02
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
9- k.
– Mount needle bearing  and the second-gear idler gear  on the countershaft with the protruding collar facing downward.
– Mount stop disk  and a new lock ring .
– Mount the sixth-gear sliding gear  with the shift groove facing upward.
r
– Mount a new lock ring  and stop disk .
99 a
– 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.
7- Sh
– Mount stop disk  and a new lock ring .

– 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.
87 rt
a
P
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 M8 15 Nm Loctite® 243™
rail (11.1 lbf ft)
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
Screw, timing chain ten- M8 15 Nm Loctite® 243™
sioning rail (11.1 lbf ft)
86 m
Info
otherwise, the timing chain tension rail could lock and break.
56 co
– 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 .

9- k.
Guideline
Screw, timing chain guide M8 15 Nm Loctite® 243™
rail (11.1 lbf ft)
r
Info
99 a
otherwise, the timing chain guide rail could lock and break.
7- Sh
200434-10 – Position timing chain tensioning rail . Mount and tighten screw .
Guideline
Screw, timing chain ten- M8 15 Nm Loctite® 243™
sioning rail (11.1 lbf ft)
87 rt
Info
otherwise, the timing chain tension rail could lock and break.
a
– Check both timing chain rails for freedom of motion.

P
Installing the oil spray tube

21.3
– Mount new O-rings  on oil spray tube .

– Mount the oil spray tube.
Pin  must engage in recess .
86 m
56 co
200433-01
Installing the transmission shaft

21.4
9- k.
– Clamp the right section of the engine case.
Engine work stand (61229001000) ( p. 443)
Engine holder (61229002000) ( p. 443)
r
– Assemble the two transmission shafts and slide them into the bearing seats
99 a
together.
7- Sh
200431-10
– Mount stop disk  and lock ring  of the countershaft.

87 rt
a
P
200430-11
– Tilt the engine.

– Mount shift forks  with shift rollers .
Info
Use a small amount of grease to fix the shift rollers to the shift forks.
200429-11
– 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.
200428-11
– Mount shift rails  with the pressure springs.
Info
Use a small amount of grease to fix the pressure springs in the shift rails.
– Check the transmission for smooth operation.
86 m
56 co
200427-11
Installing the middle suction pump

21.5
– Mount external rotor  with the marking facing downward.

The marking is not visible after mounting.
9- k.
– Mount pin  into the third hole of oil pump shaft  after shaft keyway .
– Slide internal rotor  over the pin.
r
99 a
7- Sh
200426-11
– Mount oil pump shaft  with internal rotor .

Marking  of the internal rotor is visible after mounting while that of the exter-
nal rotor is not.
– Oil the parts.
87 rt
a
200425-11
P
Installing the crankshaft

21.6
– Slide the crankshaft into the bearing seat.
Info
Position the connecting rod as shown in the photo.
301423-10
Installing the left engine case

21.7
– Mount dowels .
– Mount gasket .
– Check that dowel  is correctly seated.
301422-11
– Degrease the sealing area and coat thinly with sealant.

Loctite® 5910
Info
86 m
Only coat the sealing area around the outside (see figure).
56 co
400481-01
9- k.
r
99 a
7- Sh
87 rt
a
P
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)
– Mount and tighten screws .
Guideline
Screw, engine case M6x60 10 Nm (7.4 lbf ft)
– Mount and tighten screws .
Guideline
Guideline
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
Screw, locking lever M6 10 Nm Loctite® 243™
(7.4 lbf ft)
86 m
200420-11
Installing the shift drum locating

21.9
56 co
– 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.

9- k.
r
301417-10
99 a

Guideline
7- Sh
Screw, shift drum locating M6 10 Nm Loctite® 243™

(7.4 lbf ft)
87 rt
301414-11
a
Installing the shift shaft

21.10
– Slide shift shaft  with the washer into the bearing seat.
P
– 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.
301413-11
Installing the force pump

21.11
– Mount pin .
Info
Ensure that pins  are seated correctly.
– Mount internal rotor  and external rotor .

nal rotor is not.
– Oil the parts.
86 m
56 co
301416-10
– Position the oil pump cover. Mount and tighten screws .

Guideline
9- k.
Screw, oil pump cover M6 10 Nm Loctite® 243™
(7.4 lbf ft)
– Mount washer  and pin .
r
99 a
7- Sh
301411-11
– Mount oil pump gear wheel , washer  and lock washer .
87 rt
a
301410-11
P
Installing the left suction pump

21.12
– Mount pin .
– Mount internal rotor  and external rotor .
nal rotor is not.
– Oil the parts.
86 m
56 co
301405-10
– Insert new gasket  into the oil pump cover.

– Position oil pump cover . Mount and tighten screws .
9- k.
Guideline
Screw, oil pump cover M6 10 Nm Loctite® 243™
(7.4 lbf ft)
r
– Turn the oil pump gear wheel and check the oil pumps for smooth operation.
99 a
7- Sh
87 rt
a
301406-10
P
21.13
– Set the crankshaft to top dead center of the rear cylinder.

The position notch of the crankshaft is visible in the hole.
– Screw in special tool .
301382-10
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 Loctite® 243™
(95.9 lbf ft)
200412-11
Installing the outer clutch hub

21.15
– Mount washer  and needle bearing .
86 m
56 co 301404-11
9- k. – Mount outer clutch hub  and washer .
Info
Turn the outer clutch hub and oil pump gear wheel back and forth slightly
r
to help them mesh more easily.
99 a
7- Sh
301403-11
– Position inner clutch hub  in outer clutch hub .

– Place the outer component  of the clutch pressure booster into the inner clutch
87 rt
hub.
Projections  engage in recesses .
– Mount inner component  of the clutch pressure booster.
a
Markings  and  are adjacent to each other.

P
200411-10
– 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 Loctite® 243™
(95.9 lbf ft)
200408-11
Installing the clutch facing

21.16
– Mount support ring  and pretension ring .

The pretension ring rests on the inside of the support ring, with the outside
facing away from the support ring.
86 m
56 co
9- k.
r
99 a
7- Sh
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 .
87 rt
a
3
P
200408-01
– Mount the outermost clutch facing disc  with the wider elements  offset by one
contact .
4 200406-11
– Mount push rod .

– Attach pressure cap , mount all screws  with spring washers and springs, and
tighten them in a crisscross pattern.
Guideline
3 Screw, clutch spring M6 12 Nm Loctite® 243™
(8.9 lbf ft)
200405-11
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.
86 m
56 co
200404-10
Installing the clutch cover

21.18
9- k.
– Mount dowels  and the clutch cover seal.
– Mount check valve .
r
99 a
7- Sh
200401-11
– Slide special tool  onto the water pump shaft.

Mounting sleeve (61229005000) ( p. 444)
87 rt
a
P
200402-10
– Mount the clutch cover. Mount and tighten screws  and .

Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
200399-11
Installing the water pump wheel

21.19
– Mount the washer and water pump wheel.

– Mount and tighten screw .
Guideline
Screw, water pump wheel M6 10 Nm Loctite® 243™
(7.4 lbf ft)
– Mount dowels .
– Replace the seal.
200398-11
– Mount the water pump cover.

Guideline
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
86 m
56 co
301394-11
Installing the gear position sensor

21.20
9- k. – Mount the contact springs and contact bolt .
The contact bolts are mounted with the flat side forward; the rounded sides
face the sensor.
r
99 a
7- Sh
301399-11
– Mount gear position sensor  with the O-ring. Mount and tighten the screws.
Guideline
87 rt
Screw, gear sensor M5 3 Nm Loctite® 243™

(2.2 lbf ft)
a
P
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 bal-
ancer shaft with the beveled edge facing forward.
Pressure bell (61229016000) ( p. 445)
The markings are visible after mounting.

200400-10
Installing the balancer shaft

21.22
– Mount the rear washer and needle bearing.

– Mount balancer shaft .
Markings  and  are aligned.
– Mount washer .
86 m
56 co
200357-10
Installing the idler and timing chain on the left

21.23
9- k.
– Mount the rear washer.
– Position timing chain  in the engine case in accordance with the direction of
travel.
r
99 a
7- Sh
301445-10
– Place timing chain  over the toothing of the idler.

Markings  and  are aligned.
87 rt
– Slide on idler .
– Mount the needle bearing.
–
a
Mount washer .
P
200355-10
Installing the oil filter

21.24
– Tilt the engine sideways and fill the oil filter housing to about ⅓ full with engine
oil.
– Insert oil filter .
– Lubricate the O-ring of oil filter cover . Mount the oil filter cover.
Guideline
86 m
56 co
301395-10
Installing the rotor

21.25
9- k.
– Turn the free-wheel-gear  counterclockwise and mount it in rotor .
r
99 a
7- Sh
200351-10
– Ensure that spring washer  is seated properly.

– Mount the rotor.
87 rt
a
P
200352-10
– Thoroughly clean the oil jet of the rotor screw and blow it out with compressed air.
– Mount and tighten rotor screw .
Guideline
Rotor screw M12x1.5 90 Nm
(66.4 lbf ft)
– Position freewheel holder . Mount and tighten the screws.
Guideline
Screw, freewheel holder M6 10 Nm Loctite® 243™
200348-11
(7.4 lbf ft)
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.
86 m
Guideline
Screw, pulse generator M5 10 Nm Loctite® 243™
(7.4 lbf ft)
56 co
– Position the cable, thinly coat cable support sleeve  with the sealing compound
and insert it in the engine case.
Loctite® 5910
200346-10
– Check the distance between the ignition pulse generator and rotor.
9- k.
Guideline
Crankshaft position sensor/rotor - gap 0.70 mm (0.0276 in)
r
Installing the generator cover
99 a
21.28
– Mount the new generator cover seal and dowels.

– Position the generator cover.
7- Sh

Guideline
87 rt
301392-10
a
Installing the oil drain plug

21.29
P
– Mount the new O-rings.

– Mount and tighten oil drain plug  with the magnet, O-rings and oil screen.
Guideline
Oil drain plug M20x1.5 20 Nm
(14.8 lbf ft)
200480-10
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.
The special tool must squeeze the piston rings together well and lie flush
against the cylinder.
86 m
56 co
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.
9- k.
r
99 a
200331-10
7- Sh
– Position the new cylinder base gasket .

87 rt
a
200339-10
P
– Ensure that piston marking  faces the outfeed side.
301365-10
– Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
301367-10
– 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) ( p. 447)
– Ensure that the piston pin retainer is correctly seated on both sides.
86 m
56 co
9- k.
200084-10
r
– Remove the cloth.
99 a
– Keep the timing chain tensioned. Push the cylinder down carefully and let the
dowel pins engage.
7- Sh
87 rt
301354-10
Installing the rear cylinder head

a
21.31
– Mount the new cylinder head gasket.

– Position the cylinder head and mount and tighten the new cylinder head screws .
P
Guideline
Cylinder head screw M11x1.5 Tightening lubricated with
sequence: engine oil
Using a criss-
cross pattern
Step 1
15 Nm
301369-10 (11.1 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
90°
Step 4
90°
– Mount and tighten nuts  with the washers.
Guideline
Nut, cylinder head M6 10 Nm (7.4 lbf ft)
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.
Marking  is aligned.
– Ensure that bleeder  is seated correctly.
– Position exhaust camshaft .
Info
The exhaust camshaft is labeled with ah.
– Place the timing chain over the rear sprocket and position the camshaft in the
86 m
bearing seat.
Marking  is aligned.
56 co
301370-10
– Thoroughly clean all oil jets and blow them out with compressed air.
– Position the camshaft bearing bridge.
9- k.
– Mount screws  and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
r
Screw, camshaft bearing support M8 Step 1
99 a
10 Nm (7.4 lbf ft)

Step 2
18 Nm
7- Sh
301371-10
(13.3 lbf ft)
– Grease the O-rings and mount spark plug shaft insert .
Installing the rear timing chain tensioner

21.33
87 rt
– After it has been positioned in the installation location, insert timing chain ten-
sioner  with a new O-ring.
– Mount and tighten plug  with the new seal ring .
a
Guideline
Plug, timing-chain tensioner M24x1.5 25 Nm
P
(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 M10x1 10 Nm (7.4 lbf ft)
301373-10
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
75°
86 m
The position notch of the crankshaft is visible in the hole.
– Screw in special tool .
56 co
200333-10
Installing the front piston

21.35
9- k. – Shift the joint of the piston rings by 120°.
– Place the oiled piston on the cylinder. Tighten the piston rings using the special
tool.
r
Piston ring mounting tool (60029015000) ( p. 441)
99 a
7- Sh
200329-10
– Using a hammer, lightly strike the special tool from above until it is flush with the
cylinder.
87 rt
The special tool must squeeze the piston rings together well and lie flush
against the cylinder.
a
P
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
– Position the new cylinder base gasket .
301383-10
– Ensure that piston marking  faces the outfeed side.
86 m
56 co
301365-10
– Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
9- k.
r
99 a
301374-10
– Position the new piston pin retainer.

7- Sh
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
87 rt
the groove.
Piston pin lock ring insert (75029035000) ( p. 447)
a
– Ensure that the piston pin retainer is correctly seated on both sides.
P
200084-10
– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let the
dowel pins engage.
301375-10
Installing the front cylinder head

21.36
– Mount the new cylinder head gasket.

– Mount the cylinder head. Mount and tighten the new cylinder head screws .
Guideline
86 m
Cylinder head screw M11x1.5 Tightening lubricated with
sequence: engine oil
Using a criss-
cross pattern
56 co
Step 1
15 Nm
301376-10 (11.1 lbf ft)
Step 2
30 Nm
9- k. (22.1 lbf ft)
Step 3
90°
Step 4
r
90°
99 a
– Mount and tighten nuts  with the washers.

Guideline
7- Sh
Nut, cylinder head M6 10 Nm (7.4 lbf ft)
Installing the front camshafts

21.37

87 rt
Info
The intake camshaft is labeled with ev.
a
Marking  is aligned.
P
– Position exhaust camshaft .
Info
The exhaust camshaft is labeled with av.
bearing seat.
Marking  is aligned.
301377-10
– Thoroughly clean all oil jets and blow them out with compressed air.
– Mount screws  and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
Screw, camshaft bearing support M8 Step 1
10 Nm (7.4 lbf ft)
Step 2
301378-10 18 Nm
(13.3 lbf ft)
– Grease the O-rings and mount spark plug shaft insert .
Installing the front timing chain tensioner

21.38
86 m
– Mount and tighten plug  with the new seal ring .
Guideline
56 co
(18.4 lbf ft)
301379-10
9- k.
– Remove screw  and use the special tool to push the timing chain tensioner
r
The timing chain tensioner is unlocked.
99 a

Guideline
7- Sh

301380-10
Installing the heat exchanger

21.39
87 rt
– Oil and mount O-rings .

– Mount sleeves .
– Mount gasket .
a
P
301366-11
– Position the heat exchanger.

– Mount and tighten screws .
Guideline
– Mount and tighten screw .
Guideline
Screw, heat exchanger M8 15 Nm
(11.1 lbf ft)
301350-11
Installing the oil filler tube

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

Guideline
301349-10
Installing the starter motor

21.41
– Grease O-ring . Mount the starter motor.
86 m
56 co 301384-10
9- k. – Mount and tighten screw  with the ground wire.
Guideline
Screw, starter motor M6 10 Nm (7.4 lbf ft)
r
99 a
7- Sh
301348-11
Checking the rear cylinder control time

21.42
87 rt
– Check the markings of the camshaft.
Info
The markings are shown with the camshafts removed for purposes of illus-
a
tration.
P
Align center marking  of the camshaft with marking  of the camshaft gear.
» If the markings do not align:
– Adjust the rear cylinder control time. ( p. 184)
301389-10
Adjusting the rear cylinder control time

21.43

301343-10
– Turn the engine one crankshaft turn in a counterclockwise direction.

Marking  faces outward and is flush with the edge of the cylinder head.
– Mount the new screws  but do not tighten them yet.
301342-10

Marking  is aligned and flush with the edge of the cylinder head.
– Mount special tool .
–
86 m
Remove screws .
56 co
301344-10

Adjustment gauge, control time, cylinder 1 (69129130000) ( p. 447)
9- k.
Guideline
Screw, special tool M6 3 Nm (2.2 lbf ft)
– Fully tighten screws .
r
Guideline
99 a
301464-10
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
7- Sh

87 rt

a

Guideline
P
301342-10
Checking the rear valve clearance

21.44

– Crank the engine several times.
– Set the engine to ignition top dead center of the rear cylinder. ( p. 123)
301382-10
– 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) ( p. 441)

301385-10
» 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)
86 m
– Remove the rear camshaft. ( p. 125)
– Swing up cam lever .
– Remove shims  and set them down according to the installation position.
–
56 co
Correct the shims as indicated by the results of the valve clearance check.
– Insert suitable shims.
– Install the rear camshaft. ( p. 179)
– Install the rear timing chain tensioner. ( p. 179)
– Check the rear valve clearance. ( p. 185)
9- k.
301386-10
r
Checking the front cylinder control time
21.46
–
99 a
Remove special tool .

7- Sh
– Set the engine to ignition top dead center of the front cylinder. ( p. 126)
87 rt
301343-10

a
Info
P
tration.
301389-10
Adjusting the front cylinder control time

21.47

301343-10

301342-10

–
86 m
Remove screws .
56 co
301344-10

9- k.
Guideline
r
Guideline
99 a
301463-10
7- Sh

87 rt

Guideline
a

P
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
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) ( p. 441)

301388-10
– Adjust the front valve clearance. ( p. 188)
Adjusting the front valve clearance

21.49
– Remove the front timing chain tensioner. ( p. 126)

– Remove the front camshafts. ( p. 126)
– Swing up cam lever .
– Correct the shims as indicated by the results of the valve clearance check.
– Insert suitable shims.
– Install the front camshafts. ( p. 182)
– Install the front timing chain tensioner. ( p. 183)
– Check the front valve clearance. ( p. 187)
301387-10
– Mount and tighten the screw of generator cover .

Guideline
86 m
Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft)
56 co 301338-11
9- k.
– Remove special tool . Mount and tighten screw .
Guideline
Plug, crankshaft retainer M8 15 Nm
r
(11.1 lbf ft)
99 a
7- Sh
301340-11
Installing the front valve cover

21.50
87 rt
– Position the valve cover seal.

– Put the valve cover in place with the seal. Mount and tighten screws .
Guideline
a
Screw, valve cover M6 10 Nm (7.4 lbf ft)

P
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 .
Installing the rear valve cover

21.51

– Put the valve cover in place with the seal. Mount and tighten screws .
Guideline
Info
The rear valve cover is equipped with a connector for the engine vent.
301337-11
– Mount ignition coil .
Mounting the engine bracket

21.52
– Position the engine bracket.

– Mount and tighten screws  and .
Guideline
Screw, engine console M8 20 Nm Loctite® 243™
(14.8 lbf ft)
301345-10
– Position the engine bracket.

– Mount and tighten screws  and .
86 m
Guideline
Screw, engine console M8 20 Nm Loctite® 243™
(14.8 lbf ft)
56 co
301346-10
9- k.
Dismounting the engine from the work stand
21.53
– Remove the screw connections.

– Dismount the engine from the work stand.
r
Info
99 a
Have an assistant help you or use a crane.

7- Sh
301334-10
87 rt
a
P
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 ( p. 403) pin assignment
– 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.
900012-60
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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)
86 m
100752-01
Correcting fluid level of hydraulic clutch
56 co
23.2
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
9- k.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screw cover with membrane.
– Correct the fuel level.
r
Guideline
99 a
The fluid level must be between the MIN and MAX markings.
Hydraulic fluid (15) ( p. 437)

7- Sh
100753-01
87 rt
a
P
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
Screw, shift lever stub M6 10 Nm Loctite® 243™
(7.4 lbf ft)
86 m
56 co
100703-10
Adjusting shift lever

24.2
9- k.
Info
The footrest system offers many ways of adjusting the shift lever to your riding style and requirements.
r
– Remove screws  and take off the shift rod.
99 a
– The length of the shift rod can be adjusted by means of the screw thread.
Guideline
7- Sh
Shift rod 115… 130 mm (4.53… 5.12 in)

– Loosen the counter nuts .
– Adjust the shift shaft.
87 rt
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 free-
a
dom of movement in the bearing shells.

At least 5 screw threads must be screwed into the seating.
P
– Tighten the counter nuts.
100704-10
34/SHIFT MECHANISM 193
– 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 posi-
tions.
Guideline
A
0 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
B
0 – Position the shift rod.
– Tighten the screws.
Guideline
Screw, shift rod M6 12 Nm Loctite® 243™
(8.9 lbf ft)
86 m
0
C
56 co
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 .
9- k. 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.
r
– After adjusting the shift lever, check its operation. There must be a minimum dis-
tance between the moving parts of the shift lever and other parts of the vehicle.
99 a
Guideline
Minimum clearance 5 mm (0.2 in)
7- Sh
87 rt
a
100705-10
P
35/WATER PUMP, COOLING SYSTEM 194
Checking the coolant level

25.1
Warning
Scalding hazard During 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:
86 m
– Check the cooling system for leaks.
100750-01
Info
Do not operate the motorcycle!
56 co
– 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:
9- k. – Check the cooling system for leaks.
– Fill the cooling system compensating tank. ( p. 197)
Checking the antifreeze

r
25.2
99 a
Warning
7- Sh
Warning
Danger of poisoning Coolants are poisonous and a health hazard.
87 rt
– 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.
a
Condition
The engine is cold.
P
– 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
200535-11 The radiator must be completely filled.
– Replace the compensating tank cap and the radiator cap.
– Install the right side covers.
Removing the radiator

25.3
– Remove the exhaust cover completely. ( p. 63)

– Remove the inside cover. ( p. 75)
– 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 .
Guideline
200505-10
– Loosen the hose clamps. Detach radiator hoses .

– Push back the cover. Unplug the connector of thermoswitch .
86 m
– Unplug connector  of the radiator fan.
– Unplug the connector of ignition pulse generator .
– Unplug the connector of horn .
56 co 200504-10
9- k.
– Loosen hose clamps . Remove the radiator hose.
– Remove screw .
r
99 a
7- Sh
200506-10
– Remove screw . Take off the radiator.

87 rt
a
P
200507-10
Installing the radiator

25.4
– Position the radiator. Mount and tighten screw .

Guideline
200507-11

Guideline
– Mount the radiator hose. Position and tighten hose clamps .
200506-11
– 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 .
86 m
– Add coolant/bleed the cooling system. ( p. 196)
– Install the inside cover. ( p. 76)
– Install the exhaust cover completely. ( p. 63)
56 co
200504-11
Adding coolant/bleeding the cooling system

25.5
Warning
9- k.
r
99 a
Condition
The side cover has been removed.
7- Sh
– Position the vehicle as shown and secure it against rolling. Height difference 
must be reached.
Guideline
Height difference  50 cm (19.7 in)
87 rt
a
400494-10
– Remove radiator cap  and bleeder screw  of the radiator.

P
200534-10
– Remove bleeder screw  of the cylinder heads.

– Add coolant until it exits from the vent hole without bubbles.
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 Remaining engine screws M6 10 Nm (7.4 lbf ft)
– 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
86 m
Warning
56 co
Note
9- k.
Engine damage Impaired 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.
r
99 a

– Remove the cap  of the compensating tank.
7- Sh
– Top up with coolant until the specified coolant level is reached.

Guideline
Alternative 1
87 rt
Coolant ( p. 436)
100750-10 Alternative 2
Coolant (mixed ready to use) ( p. 436)
a
– Mount the cap of the compensating tank.

P
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
– The engine coolant temperature sensor is a negative temperature coefficient ther-
mistor (NTC resistor). Resistance falls when the temperature increases in an NTC
resistor; the "nil" value, however, is never reached. When the temperature decreases
86 m
the resistance increases; however, the "infinite" value is never reached.
56 co
400539-60
Pin overview
1 Signal wire
9- k.
2 Sensor ground
– The signal from engine coolant temperature sensor for cylinder 1 is transmitted to
r
the EFI control unit.
99 a
Engine coolant temperature sensor

600853-10 Resistance at: −30 °C 22.86… 27.94 kΩ
7- Sh
(−22 °F)
Resistance at: −20 °C 13.50… 16.50 kΩ
(−4 °F)
(14 °F)
87 rt
Resistance at: 0 °C 5.17… 6.31 kΩ

(32 °F)
a
(50 °F)
P
(68 °F)
(86 °F)
(104 °F)
Resistance at: 50 °C 730… 892 Ω
(122 °F)
(140 °F)
(158 °F)
(176 °F)
(194 °F)
(212 °F)
(230 °F)

(248 °F)
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
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.
56 co
9- k. 400539-60
Pin overview
1 Signal wire
r
2 Sensor ground
99 a
– The signal from engine coolant temperature sensor for cylinder 2 is transmitted to
the combination instrument.
7- Sh

600853-10 Resistance at: −30 °C 22.86… 27.94 kΩ
(−22 °F)
87 rt
(−4 °F)
(14 °F)
a

(32 °F)
P

(50 °F)
(68 °F)
(86 °F)
(104 °F)
(122 °F)
(140 °F)
(158 °F)
(176 °F)
(194 °F)
(212 °F)

(230 °F)
(248 °F)
Checking the valve clearance

26.3

– Detach connector  of the ignition coil.
– Remove the ignition coil.
– Remove screws  and take off the valve cover.
86 m
– Repeat these steps on the second cylinder.
56 co
9- k.
r
200538-10
99 a
Guideline
7- Sh
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…
87 rt
0.0059 in)
Feeler gauge (59029041100) ( p. 441)

301434-10
a

– Adjust the rear valve clearance. ( p. 201)
P
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) ( p. 441)

301435-10
– Adjust the front valve clearance. ( p. 202)
– Remove special tool .

– Crank the engine several times. Check the valve clearance and correct it if neces-
sary.
– Remove special tool  and screw in and tighten screw .
Guideline
Plug, crankshaft retainer M8 15 Nm
(11.1 lbf ft)
200540-10
– Mount and tighten the screw of generator cover .

Guideline
Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft)
86 m
56 co
200539-10

9- k.
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.
r
– Position the valve cover with the seal. Mount and tighten screws .
99 a
Guideline
7- Sh
– Mount the ignition coil.

– Attach connector  of the ignition coil.
– Repeat these steps on the second cylinder.
– Install the filter box bottom. ( p. 68)
87 rt

a
200538-10
Adjusting the rear valve clearance

P
26.4
– Remove the rear camshaft. ( p. 205)

– Raise cam lever  on the outside.
– Correct and insert the shims as indicated by the results of the valve clearance
check.
– Install the rear camshaft. ( p. 205)
200546-10
Adjusting the front valve clearance

26.5
– Remove the front camshafts. ( p. 206)

– 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)
200552-10
Checking the rear cylinder control time

26.6
Condition
86 m
Info
56 co
tration.
9- k. Removal is not necessary.
301389-10
r
Checking the front cylinder control time
99 a
26.7
Condition
7- Sh

– Set the engine to the ignition top dead center of the front cylinder and screw in
special tool .
87 rt
a
301343-10
P
Info
tration.
Removal is not necessary.
301389-10
Adjusting the rear cylinder control time

26.8
Info
For purposes of illustration, the following operations are shown with the
engine deinstalled.
301343-10

–
86 m
Remove screws .
56 co
301342-10

9- k.
r
99 a

7- Sh
301344-10

87 rt
Guideline
a

Guideline
P
301464-10
Guideline
301342-10
Adjusting the front cylinder control time

26.9
Info
For purposes of illustration, the following operations are shown with the
engine deinstalled.
301343-10

–
86 m
Remove screws .
56 co
301342-10

9- k.
r
99 a

7- Sh
301344-10

87 rt
Guideline
a

Guideline
P
301463-10
Guideline
301342-10
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.
– Pull out timing chain tensioner .
200549-10
– Remove spark plug shaft insert .

– Loosen and remove screws  from the outside to the inside.
86 m
Info
56 co
301436-10
9- k.
Installing the rear camshaft
26.11

r
Info
99 a
The intake camshaft is labeled with eh.
7- Sh
– Ensure that bleeder  is seated correctly.

– Position exhaust camshaft .
Info
The exhaust camshaft is labeled with ah.
87 rt
bearing seat.
a
Markings  must be flush with the edge of the cylinder head.

P
– Mount screws  and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing M6 10 Nm –
301438-10 support (7.4 lbf ft)
Screw, camshaft bearing M8 Step 1 –
support 10 Nm
(7.4 lbf ft)
Step 2
18 Nm
(13.3 lbf ft)
Screw, camshaft bearing M8 Step 1 Only applies when
support 8.5 Nm using:
(6.27 lbf ft) Hex key bit
Step 2 (61229025000)
14.5 Nm ( p. 446)
(10.7 lbf ft)
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)
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.
– Pull out timing chain tensioner .
200550-10
– Remove spark plug shaft insert .

– Loosen and remove screws  from the outside to the inside.
86 m
Info
56 co
301439-10
9- k.
Installing the front camshafts
26.13

r
Info
99 a
The intake camshaft is labeled with ev.
7- Sh
– Position exhaust camshaft .
Info
The exhaust camshaft is labeled with av.
87 rt
bearing seat.
Markings  must be flush with the edge of the cylinder head.
a

– Mount screws  and tighten them from the outside to the inside.
P
Guideline
Screw, camshaft bearing M6 10 Nm –
support (7.4 lbf ft)
301440-10 Screw, camshaft bearing M8 Step 1 –
support 10 Nm
(7.4 lbf ft)
Step 2
18 Nm
(13.3 lbf ft)
Screw, camshaft bearing M8 Step 1 Only applies when
support 8.5 Nm using:
(6.27 lbf ft) Hex key bit
Step 2 (61229025000)
14.5 Nm ( p. 446)
(10.7 lbf ft)
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)
Installing the rear timing chain tensioner

26.14
– Prepare the timing chain tensioner for installation. ( p. 154)

– Mount and tighten plug  with a new seal ring.
Guideline
(18.4 lbf ft)
200549-11
– Remove screw  and use the special tool to push the timing chain tensioner
86 m
The timing chain tensioner unlocks.
56 co
Guideline
9- k. 200554-10
Installing the front timing chain tensioner

26.15
– Prepare the timing chain tensioner for installation. ( p. 154)

r
– Mount and tighten plug  with a new seal ring.
99 a
Guideline
7- Sh
(18.4 lbf ft)
200550-11
87 rt
– Remove screw  and use the special tool to push the timing chain tensioner
a
The timing chain tensioner is unlocked.

P
Guideline
200555-10
38/LUBRICATION SYSTEM 208
Oil circuit
27.1
86 m
56 co
9- k.
r
400492-60
99 a
Oil circuit of middle suction pump

1 Oil screen of oil drain plug in gearbox
7- Sh
2 Middle suction pump

3 Heat exchanger
4 Oil exit in oil tank
Oil circuit of left suction pump
87 rt
5 Crankcase
6 Left suction pump
a
7 Lubricating slots in gearbox

Oil circuit of force pump
P
8 Oil screen of oil drain plug in oil tank

9 Force pump
10 Oil pressure regulator valve
11 Oil filter
12 Crankshaft
13 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 Oil jet for clutch lubrication
19 Clutch
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)
86 m
100769-10
– Replace the oil dipstick.
Changing the engine oil and filter, cleaning the oil screens
56 co
27.3
– Drain the engine oil and clean the oil screens. ( p. 209)
– Fill up with engine oil. ( p. 212)
9- k.
r
500281-01
99 a
Draining engine oil, cleaning oil screens

7- Sh
27.4
Warning
Danger of scalding Engine 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 luke-
warm water.
87 rt
Warning
a
P
Info
Drain the engine oil only when the engine is warm.
– Take off the left exhaust cover .
86 m
56 co
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.
9- k. – Remove the oil filter. ( p. 211)
r
99 a
100772-10
– Thoroughly clean the magnet  and oil screen  of the oil drain plug.
7- Sh
87 rt
a
100773-10
– Mount and tighten the oil drain plugs with the magnet, O-rings and oil screen.
P
Guideline
Oil drain plug M20x1.5 20 Nm
(14.8 lbf ft)
– Install the oil filter. ( p. 212)
100772-11
– Position the left exhaust cover .

Guideline
86 m
56 co
100771-10
Removing the oil filter

27.5
Warning
9- k.
warm water.
r
Warning
99 a

7- Sh

– Remove screws . Take off oil filter cover  with the O-ring.
87 rt
a
P
100774-10
– Pull oil filter  out of the oil filter housing.

– Clean the parts and the sealing area thoroughly.
100775-10
Installing the oil filter

27.6
– Insert oil filter .

– Lubricate the O-ring of the oil filter cover. Mount oil filter cover .
Guideline
100776-10
Filling up with engine oil

27.7
Info
86 m
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.
56 co
Engine oil 3.60 l (3.8 qt.) External tem- Engine oil
perature: ≥ 0 °C (SAE 10W/50)
(≥ 32 °F) ( p. 436)
External tem- Engine oil
perature: < 0 °C (SAE 5W/40)
9- k. (< 32 °F) ( p. 436)
– Remove the dipstick  and top up the engine oil.
100777-10
Engine oil (1st 3.00 l (3.17 qt.) External tem- Engine oil
r
quantity) perature: ≥ 0 °C (SAE 10W/50)
99 a
(≥ 32 °F) ( p. 436)
7- Sh
(< 32 °F) ( p. 436)

– Replace the oil dipstick .
Danger
87 rt

a
effective exhaust extraction system.
P
– Start the engine and check that it is oil-tight.

– Remove the dipstick  and pour in the remaining engine oil.
Engine oil (2nd 0.60 l (0.63 qt.) External tem- Engine oil
quantity) perature: ≥ 0 °C (SAE 10W/50)
(≥ 32 °F) ( p. 436)
(< 32 °F) ( p. 436)
– Replace the oil dipstick .
Danger

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.
Condition
External temperature: ≥ 0 °C (≥ 32 °F)
Engine oil (SAE 10W/50) ( p. 436)
Condition
External temperature: < 0 °C (< 32 °F)
Engine oil (SAE 5W/40) ( p. 436)
86 m
100777-10
Info
For optimal performance of the engine oil, do not mix different types of
engine oil.
56 co
If appropriate, change the engine oil.
– Replace oil dipstick .
Danger
9- k.
r
99 a

7- Sh
Checking the engine oil pressure

27.9
Warning
87 rt
warm water.
a
Warning
P

– Take off the left exhaust cover .
86 m
56 co
100771-10

– Remove screws . Take off the oil filter cover with the O-ring.
– Remove oil filter .
9- k.
r
99 a
7- Sh
87 rt
a
200557-10
– Position the special tool with the O-ring. Mount and tighten the screws.
P
Guideline
Oil pressure testing adapter (75029094000) ( p. 448)

– Connect the pressure testing tool to the special tool without the t-plate.
200558-10
Danger
– Start the engine and let it warm up.

– Check the engine oil pressure.
Engine oil pressure
Coolant temperature: ≥ 70 °C 1.3… 2.3 bar (19… 33 psi)

(≥ 158 °F)
Engine speed: 1,500 rpm
Coolant temperature: ≥ 70 °C 3.0… 4.0 bar (44… 58 psi)
(≥ 158 °F)
– Check the oil pumps for wear. Check that all oil holes are free of blockages.
– Switch off the engine.
Warning
Danger of burns Some vehicle components get very hot when the machine
is driven.
– Wear appropriate protective clothing and safety gloves. In case of burns,
rinse immediately with lukewarm water.
86 m
– Remove the special tools.
– Insert the new oil filter.
56 co
– Lubricate the O-ring of the oil filter cover. Mount the oil filter cover.
Guideline
9- k. – Position the left exhaust cover .
Guideline
r
99 a

7- Sh
87 rt
a
P
100771-10
Removing the oil jet for the clutch lubrication

27.10
– Take off the engine sprocket cover.
301426-10
– Remove plug .
301427-10
– Remove oil jet .
86 m
56 co
301429-11
Checking / cleaning the oil jet for clutch lubrication

27.11
– Remove the oil jet for the clutch lubrication. ( p. 215)

– Check the oil jet for clutch lubrication is not blocked.
9- k.
» If the oil jet is blocked:
– Clean the oil jet and change as necessary.
– Install the oil jet for the clutch lubrication. ( p. 216)
r
99 a
7- Sh
301428-10
Installing the oil jet for the clutch lubrication

27.12
– Mount and tighten oil jet .

87 rt
Guideline
Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft)
a
P
301429-10
– Mount and tighten plugs .

Guideline
Plug, clutch lubrication M10x1 15 Nm
(11.1 lbf ft)
301427-10
– Position the engine sprocket cover.

Guideline
301426-11
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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.
– 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
900001-01 toothed wheel.
Crankshaft position sensor, connector AT ( p. 395) pin assignment

– 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
86 m
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 mag-
netic field strength. The alteration of the magnetic field created in the induction
coil generates an alternating voltage. The number of pulses per second is equiv-
56 co
alent 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 sen- 0.70 mm (0.0276 in)

9- k.
sor/rotor - gap
r
(68 °F)
99 a
Ignition coil
28.2
7- Sh
– 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.
87 rt
a
900022-61
Pin overview
P
1 Control wire
2 System voltage
Ignition coil
Primary winding resis- 1.105… 1.495 Ω
tance at: 20 °C (68 °F)
Secondary winding 16.2… 10.8 kΩ
resistance at: 20 °C
600851-10
(68 °F)
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.
86 m
Throttle position sensor circuit A, connector AM ( p. 391) pin assignment
– The output voltage of the throttle position sensor is dependent on the opening
56 co
angle of the throttle valve and is sent via the signal wire to determine the throttle
900020-10 valve position.
Throttle position sensor cir- 0.56… 4.20 V

cuit A voltage "(THAD)"
9- k.
Throttle position sensor cir- 0… 100 %
cuit A, signal "ATP"
r
Throttle position sensor circuit A - checking in the "zero" position
29.2
99 a
Condition
The ignition is on.
7- Sh

87 rt
a

400687-60
P
– 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).
Throttle position sensor circuit A voltage "(THAD)"

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)
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)
86 m
56 co
9- k.
400680-10

r
99 a

7- Sh
87 rt
– Read the information page on the KTM diagnostics tool and using "Continue" start the calibration process.
a
Info
The motor drive moves the throttle valve in circuit A to the "zero" position (throttle valve fully closed position).
P

– Turn the throttle position sensor to adjust it to the specified value.
Guideline
– Open and close the throttle grip fully ten times.
– Check the voltage again and readjust if necessary.
– Reinstall the throttle valve body when the adjustments have been made. ( p. 222)
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.
– Disconnect plug-in connector .
– Take plug-in connector  out of the holding bracket.
200498-10
– Remove screws . Take off the retaining plates and holding brackets.
– Remove screw . Remove the cover.
86 m
56 co
200499-10
– Loosen hose clamps .

9- k.
r
99 a
7- Sh
200500-10
– Loosen the spring-loaded band-type clamp  using the special tool. Pull off the
fuel hose.
87 rt
– 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.
a
P
200501-10
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 spe-
cial tool.
Info
The fuel hose must have a minimum distance of 4 mm to the throttle link-
age in all operating positions.
– Position the throttle cables with guide piece .

– Slide the throttle valve body into the rubber sleeves.
86 m
56 co
200501-11
– Position and tighten upper hose clamps .

Guideline
9- k.
(1.11 lbf ft)
r
99 a
7- Sh
200500-11
– Mount the cover. Mount and tighten screw .

– Position the retaining plates and holding brackets. Mount and tighten screws .
87 rt
a
200499-11
P
– Fix plug-in connector  with the holding bracket.

– Connect plug-in connector .
– Mount manifold absolute pressure sensor  and plug in the connector.
200498-11
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.
– As shown in the diagram, the voltage can be correlated to a throttle position.
86 m
Throttle position sensor circuit B, connector AR ( p. 394) pin assignment
– The EFI control unit utilizes the signal from the throttle position sensor in circuit B
56 co
to set the opening angle of the second throttle valve. The second throttle valve
900047-10 enables smoother power delivery from the engine and it is used as part of the elec-
tronic power control (EPC).
Position 2. Throttle 0… 100 %

9- k. valve "2ndTHAngle"
Throttle position sensor cir- 0.156… 4.824 V
cuit B, voltage "TAPAD"
r
Manifold absolute pressure sensor
99 a
29.7
– The manifold absolute pressure sensor cylinder 1  is located on the right-hand
7- Sh
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 right-
hand rear side of the air filter box and is connected to the induction manifold by a
hose.
87 rt
– 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
900003-61 reference pressure chamber. When the shape of the diaphragm is altered by exte-
a
rior 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.
P
Pin overview
1 System voltage
2 Sensor ground
3 Signal wire
400659-10
– The output voltage of the manifold absolute pressure sensor depends on the man-
ifold pressure and is sent via the signal wire. The voltage signal drops when pres-
sure 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.
Manifold absolute pressure sensor cylinder 1, voltage "PM1AD"

600725-10
at: 350 mbar (5.08 psi) 1.62… 1.68 V
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 3.12… 3.18 V
(12.33 psi)
at: 900 mbar 3.27… 3.33 V
(13.05 psi)
at: 950 mbar 3.42… 3.48 V
(13.78 psi)
at: 1,000 mbar 3.57… 3.63 V
(14.5 psi)
at: 1,050 mbar 3.72… 3.78 V
(15.23 psi)
86 m
at: 350 mbar (5.08 psi) 1.62… 1.68 V
at: 400 mbar (5.8 psi) 1.77… 1.83 V
at: 450 mbar (6.53 psi) 1.92… 1.98 V
56 co
at: 800 mbar (11.6 psi) 2.97… 3.03 V
at: 850 mbar 3.12… 3.18 V
(12.33 psi)
at: 900 mbar 3.27… 3.33 V
9- k. (13.05 psi)
at: 950 mbar 3.42… 3.48 V
(13.78 psi)
r
at: 1,000 mbar 3.57… 3.63 V
(14.5 psi)
99 a
at: 1,050 mbar 3.72… 3.78 V

(15.23 psi)
7- Sh
Connecting the vacuum hand pump to the manifold absolute pressure sensor
29.8

Connecting to the manifold absolute pressure sensor cylinder 1:
– Pull off vacuum hose .
87 rt
– Connect the vacuum hand pump to the vacuum hose of the manifold absolute
pressure sensor cylinder 1.
a
P
600856-10
Connecting to the manifold absolute pressure sensor cylinder 2:

– Pull off vacuum hose .
– Connect the vacuum hand pump to the vacuum hose of the manifold absolute
pressure sensor cylinder 2.
600856-11
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 refer-
ence pressure chamber. When the shape of the diaphragm is altered by external
pressure, the conductivity of the measuring resistors is altered and thus the mea-
sured voltage. The measured voltage is prepared by the processing electronics and
sent on to the EFI control unit.
900006-60
Pin overview
1 System voltage
2 Sensor ground
86 m
3 Signal wire
56 co
400659-10
– The output voltage of the ambient air pressure sensor depends on the ambient air
9- k. pressure and is sent via the signal wire. The voltage signal rises when ambient air
pressure increases.
Ambient air pressure sensor voltage "PAAD"

r
at: 800 mbar (11.6 psi) 2.97… 3.03 V
99 a
at: 850 mbar 3.12… 3.18 V

(12.33 psi)
600725-10
at: 900 mbar 3.27… 3.33 V
7- Sh
(13.05 psi)
at: 950 mbar 3.42… 3.48 V
(13.78 psi)
at: 1,000 mbar 3.57… 3.63 V
87 rt
(14.5 psi)
at: 1,050 mbar 3.72… 3.78 V
(15.23 psi)
a
Injector
29.10
P
– Injector cylinder 1  is located on the rear throttle valve body.
Injector cylinder 2  is located on the front throttle valve body.
– 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 gen-
erated which attracts the plunger, overcoming the spring force; this lifts the nee-
dle 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
900027-61 closes the needle valve. The filter keeps any contamination out of the holes.
Pin overview
1 Control wire
2 System voltage
400598-10
– 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 amplifi-
cation 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 10.5… 13.0 Ω
(68 °F)
Rollover sensor
29.11
– The rollover sensor is located on the base of the air filter box.
86 m
56 co
900002-60
Rollover sensor construction

1 Pendulum with a magnet
9- k. 2 Circuit board with a Hall sensor
3 Housing
4 Spacer
r
5 Retainer for the connector seal
6 Connector seal
99 a
900004-10
A Normal position, left-hand corner
B Normal position, right-hand corner
7- Sh
– 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
87 rt
voltage.
Pin overview
4 Sensor ground
a
5 Signal wire
6 System voltage
P
– 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
400660-10 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) 0.4… 1.4 V
"no fall detected"
Voltage (Rollover AD) 3.7… 4.1 V
"fall detected"
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).
900038-60 After programming is complete, the VIN must be entered into the EFI control
unit using the "Coding" function!
– Connector CO ( p. 397) pin assignment

– Connector AO ( p. 392) pin assignment
86 m
Requesting the EFI control unit activation code
29.13
Condition
56 co
An exchanged EFI control unit is connected.
The ignition is on.
The "ECU Flashing" process is complete.
9- k. – Select "ECU Diagnosis".
r
99 a
– Select "Change VIN - New identity".
7- Sh
400687-60
the coding process.
– Overwrite the entry under the "Please enter VIN:" heading.
87 rt
– Select "Code form".
– Press "Print".
a
The protocol is being printed out.

– Fill out the protocol and send to "diagnostic@ktm.com".
P
Coding the EFI control unit

29.14
Condition
The ignition is on.
– Request the EFI control unit activation code. ( p. 227)
– Select "Change VIN - New identity".
400687-60
the coding process.
– Overwrite the entry under the "Please enter VIN:" heading.

– Select "Code entry".
– "Please enter the Code"
The new VIN is written to the EFI control unit.
– Switch to the main menu.
– Select "Show identification".
– Compare the old VIN to the new VIN.
The new VIN is shown.
Flashing the EFI control unit

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

– Read the safety notice and confirm with "OK".
The new mapping is loaded.
87 rt
a
P
IMMOBILIZER BLINK CODE 229
Blink code of immobilizer indi-

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

cator lamp
Possible cause ICU antenna - value not plausible ( p. 230)
ICU antenna - coil antenna has an open ( p. 230)
Last measure if none of the doc- – Change the immobilizer control unit.
umented causes leads to elimi-
nation of the fault
ICU antenna - value not plausible

Condition
The imobilizer control unit antenna coil is disconnected. ( p. 102)
ICU antenna - checking the resistance
– Measure the resistance between the specified points.
86 m
ICU antenna connector EL pin 1 – ICU antenna connector EL pin 2
ICU antenna 13.917… 15.383 Ω

» If the specifications have not been met:
56 co
– Change the ICU antenna.
» If the specifications have been met:
400685-10 – Check the next possible cause:
ICU antenna - coil antenna has an open ( p. 230)
9- k.
ICU antenna - coil antenna has an open
Condition
r
The immobilizer control unit is disconnected. ( p. 102)
The imobilizer control unit antenna coil is connected. ( p. 102)
99 a
ICU antenna - checking the coil antenna for opens

7- Sh
Immobilizer control unit, connector DO pin 1 – Immobilizer control unit,

connector DO pin 2
ICU antenna 13.917… 15.383 Ω
87 rt
– Check connector DO pin 1 and pin 2.

– Check connector DV ( p. 401) pin 1 and pin 2.
400657-10
– Check the cable from connector DO pin 1 to connector DV ( p. 401) pin 1 for
a
opens.
– Check the cable from connector DO pin 2 to connector DV ( p. 401) pin 2 for
opens.
P
– 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.
– Change the immobilizer control unit.

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

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

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

cator lamp
Possible cause Malfunction, encryption, immobilizer control unit to black ignition key ( p. 233)
Last measure if none of the doc- – Activate/deactivate the ignition key. ( p. 102)
nation of the fault
Malfunction, encryption, immobilizer control unit to black ignition key

– Use the black ignition key belonging to the vehicle.
Last measure if none of the documented causes leads to elimination of the fault
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

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

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

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

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

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

cator lamp
60 Immobilizer indicator lamp flashes 6x short
Possible cause E²PROM malfunction ( p. 237)
E²PROM malfunction
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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 ( p. 238)
Possible cause Lambda sensor heater cylinder 1 - value not plausible ( 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)
Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31)
( p. 240)
86 m
Last measure if none of the doc- – Contact customer service.
nation of the fault
56 co
Checking the lambda sensor heater cylinder 1
Condition
The ignition is on.
The diagnostics tool is connected and active.
9- k.
r
99 a
– Select "Actuator Test".

7- Sh
– Select "Lambda sensor heater cylinder 1".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
87 rt
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test start 5V
a
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test end ≤ 0.5 V
P
» If the displayed value corresponds to the nominal value:

– Take a test ride.
– Check the next possible cause:
Lambda sensor heater cylinder 1 - value not plausible ( p. 238)
Lambda sensor heater cylinder 1 - value not plausible

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

Lambda sensor cylinder 1, connector CE pin 1 – Lambda sensor cylinder 1,
connector CE pin 2
Resistance at: 20 °C (68 °F) 11.7… 14.3 Ω
– Replace the lambda sensor cylinder 1.
400647-10
Lambda sensor heater cylinder 1 - the power supply is faulty

Condition
86 m
The ignition is on.
EFI control unit is connected. ( p. 227)
56 co
9- k.
r
400646-10 400658-10
Lambda sensor heater cylinder 1 - check the power supply

99 a
– Measure the voltage between the specified points.

Lambda sensor cylinder 1, connector CA pin 1 – Measuring point Ground (−)
7- Sh
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.
87 rt

– Check connector CA pin 1.
a
– Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.
P

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.
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
Resistance ≤ 0.6 Ω
86 m
– Check EFI control unit connector CO ( p. 397) pin 33 and connector CA pin 2.
– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA pin 2 for opens.
56 co
Lambda sensor heater cylinder 1 - the control wire has a short circuit to sensor ground
9- k.
Condition
r
99 a
7- Sh
87 rt
600850-11 600850-12
Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to sensor ground
a

Break Out Box AO pin 7 – Break out box CO pin 33
P
Resistance ∞Ω
– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA ( p. 396) pin 2 for a short circuit to
sensor ground.
Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 240)
Condition
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 ∞Ω
86 m
ground (terminal 31).
56 co
– Contact customer service.
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Input signal too high"
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)
86 m
nation of the fault
56 co
Condition
The ignition is on.
9- k.
r
–
99 a
"Please enter the password:"

–
7- Sh
Select "Lambda sensor heater cylinder 1".

Lambda sensor
87 rt
Lambda sensor cylinder 1 voltage "HEGO1AD" at test start 5V
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test end ≤ 0.5 V
a

P


Condition
Lambda sensor heater cylinder 1 - check the resistance
connector CE pin 2
400647-10

– Replace the lambda sensor cylinder 1.
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus
(terminal 30) ( p. 243)
Condition
86 m
56 co
600850-12 400658-10
9- k.
Lambda sensor heater cylinder 1 - checking the signal wire for a short circuit to plus (terminal 30)
r
Voltage < 0.1 V
99 a
plus (terminal 30).
7- Sh

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 243)
87 rt
Condition
a

P
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 ∞Ω
ignition plus (terminal 15).

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

lamp (MIL)
( p. 247)
86 m
nation of the fault
56 co
Condition
The ignition is on.
9- k.
r
99 a

7- Sh
– Select "Lambda sensor heater cylinder 2".
87 rt
Lambda sensor
Lambda sensor cylinder 2 voltage "HEGO2AD" at the test 5V
start
a
Lambda sensor
Lambda sensor cylinder 2 voltage "HEGO2AD" at the test ≤ 0.5 V
P
end

Condition
Lambda sensor heater cylinder 2 - check the resistance.

connector CE pin 2
– Change the lambda sensor cylinder 2.
400647-10
Lambda sensor heater cylinder 2 - the power supply is faulty

Condition
86 m
The ignition is on.
56 co
9- k.
r
400646-10 400658-10
Lambda sensor heater cylinder 2 - checking the power supply

99 a

Lambda sensor cylinder 2, connector CA pin 1 – Measuring point Ground (−)
7- Sh
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
87 rt

– Check connector CA pin 1.
a
– Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.
P

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

Condition
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
86 m
– Check EFI control unit connector CO ( p. 397) pin 15 and connector CA pin 2.
– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA pin 2 for opens.
56 co
Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor ground
9- k.
Condition
r
99 a
7- Sh
87 rt
600850-11 600850-12
Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to sensor ground
a

Break Out Box AO pin 7 – Break out box CO pin 15
P
Resistance ∞Ω
sensor ground.
Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 247)
Condition
600850-12 400658-10
Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to ground (terminal 31)
Resistance ∞Ω
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
( p. 250)
( p. 250)
86 m
nation of the fault
56 co
Condition
The ignition is on.
9- k.
r
–
99 a
"Please enter the password:"

–
7- Sh
Select "Lambda sensor heater cylinder 2".

Lambda sensor
87 rt
Lambda sensor cylinder 2 voltage "HEGO2AD" at the test 5V

start
Lambda sensor
a
Lambda sensor cylinder 2 voltage "HEGO2AD" at the test ≤ 0.5 V

end
P


Condition
Lambda sensor heater cylinder 2 - check the resistance.

connector CE pin 2
– Change the lambda sensor cylinder 2.
400647-10
Lambda sensor heater cylinder 2 - the signal wire has a short circuit to plus
(terminal 30) ( p. 250)
86 m
Condition
56 co
9- k.
r
99 a
600850-12 400658-10
Lambda sensor heater cylinder 2 - checking the signal wire for a short circuit to plus (terminal 30)
7- Sh

Voltage < 0.1 V

87 rt
plus (terminal 30).
a

Lambda sensor heater cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 250)
P
Condition
600850-12 600850-11
Lambda sensor heater cylinder 2 - check the signal wire for a short circuit to ignition plus (terminal 15).
Resistance ∞Ω
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
09 EFI warning lamp (MIL) flashes 9x short
"Manifold absolute pressure sensor cylinder 1"
"Input signal too low"
Error level condition 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 ( p. 252)
Possible cause Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground
( p. 253)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ground (termi-
nal 31) ( p. 253)
Manifold absolute pressure sensor cylinder 1 - the power supply is interrupted ( p. 253)
86 m
Last measure if none of the doc- – Replace the manifold absolute pressure sensor cylinder 1.
nation of the fault
56 co
Manifold absolute pressure sensor cylinder 1 - checking the voltage
Condition
The ignition is on.
9- k.
The engine is switched off.
r
99 a
– Select "Measured Values".
7- Sh
– Highlight "Fuel management general".

– Highlight "Manifold absolute pressure sensor cylinder 1 voltage" and deselect the other parameters with "Select live data".
87 rt
at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V
at: 450 mbar (6.53 psi) 1.92… 1.98 V
a
at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V
P
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
» 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)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground
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 – Mani-
fold absolute pressure sensor cylinder 1, connector DP pin 3
Resistance ∞Ω
– Check the cable from connector DP pin 3 to the EFI control unit connector AO
400590-10 ( p. 392) pin 3 for a short circuit to sensor ground.
86 m
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short cir-
cuit to ground (terminal 31) ( p. 253)
56 co
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
Condition
9- k.
r
99 a
7- Sh
400590-10 400658-10
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31)
87 rt

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

Condition
The ignition is on.
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 4.9… 5.1 V

86 m
– Check connector DP pin 1.
– Check the cable from connector DP pin 1 to the next node in the wiring harness for opens.
56 co
– Replace the manifold absolute pressure sensor cylinder 1.
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
Error level condition Manifold absolute pressure sensor cylinder 1, voltage "PM1AD": ≥ 4.922 V
Time: ≥ 1 s
Possible cause Manifold absolute pressure sensor cylinder 1 - the signal wire has an open ( p. 256)
Manifold absolute pressure sensor cylinder 1 - the ground wire has an open ( p. 256)
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 257)
86 m
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)
56 co
nation of the fault
9- k.
Condition
The ignition is on.
r
99 a

7- Sh

–
87 rt
Press "Continue".
a
at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V
P
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
» If the displayed value is above the nominal value:
Manifold absolute pressure sensor cylinder 1 - the signal wire has an open ( p. 256)
Manifold absolute pressure sensor cylinder 1 - the signal wire has an open
Condition
86 m
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
56 co
– Check EFI control unit connector AO ( p. 392) pin 3 and connector DP pin 3.
9- k.
– Check the cable from EFI control unit connector AO ( p. 392) pin 3 to connector DP pin 3 for opens.
r
99 a
Manifold absolute pressure sensor cylinder 1 - the ground wire has an open
Condition
7- Sh

87 rt
a
P
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
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 plus (terminal 30)
Condition
86 m
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 (−)
56 co
Voltage < 0.1 V
– 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
9- k.
plus (terminal 30).
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 257)
r
99 a
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
7- Sh

87 rt
ignition plus (terminal 15)

Break Out Box AO pin 3 – Break Out Box AO pin 20
a
Resistance ∞Ω
P
– Check the cable from EFI control unit connector AO ( p. 392) pin 3 to con-
nector DP ( p. 400) pin 3 for a short circuit to ignition plus (terminal 15).
600850-11
cuit 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
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to the
sensor power supply
Resistance ∞Ω
nector DP ( p. 400) pin 3 for a short circuit to the sensor power supply.
600850-11
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Intake air temperature sensor"
Error level condition 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 ( p. 259)
Possible cause Intake air temperature sensor - value not plausible ( p. 259)
Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)
( p. 260)
86 m
nation of the fault
Intake air temperature sensor - checking the voltage
56 co
Condition
The ignition is on.
–
9- k.
Select "ECU Diagnosis".
r
99 a
– Highlight "Intake air temperature sensor voltage (TAAD)" and deselect the other parameters with "Select live data".
7- Sh
Intake air temperature sensor "TAAD" 0.157… 4.843 V

–
87 rt
Take a test ride.

a

Intake air temperature sensor - value not plausible ( p. 259)
P
Intake air temperature sensor - value not plausible

Condition
Intake air temperature sensor - check the resistance
Intake air temperature sensor

Resistance at: −20 °C (−4 °F) 18.80 kΩ
Resistance at: 20 °C (68 °F) 2.942 kΩ
600850-11
Intake air temperature sensor - the signal wire has a short circuit to sensor
ground ( p. 260)
– Replace the intake air temperature sensor.

Intake air temperature sensor - the signal wire has a short circuit to ground (ter-
minal 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.
Intake air temperature sensor - check the signal wire for a short circuit to sensor ground
86 m
Resistance ∞Ω
56 co
nector CM ( p. 397) pin 2 for a short circuit to sensor ground.
600850-11
9- k. – Contact customer service.
Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)
Condition
r
99 a
7- Sh
87 rt
600850-11 400658-10
a
Intake air temperature sensor - check the signal wire for a short circuit to ground (terminal 31)
P
Resistance ∞Ω
– 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

lamp (MIL)
"Intake air temperature sensor"
Error level condition Intake air temperature sensor "TAAD": ≥ 4.844 V
Time: ≥ 3 s
Function check Intake air temperature sensor - checking the voltage ( p. 261)
Possible cause Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 261)
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 the sensor power supply
( p. 262)
86 m
Intake air temperature sensor - the signal wire has an open ( p. 263)
Intake air temperature sensor - the ground wire has an open ( p. 263)
56 co
nation of the fault
9- k.
Intake air temperature sensor - checking the voltage
Condition
The ignition is on.
r
99 a

7- Sh
87 rt
– 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
a

P

Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 261)
Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-11 400658-10
Intake air temperature sensor - check the signal wire for a short circuit to plus (terminal 30)
Voltage ≤ 0.1 V
86 m
– 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
plus (terminal 30).
56 co
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)
9- k. Condition
r
Intake air temperature sensor - check the signal wire for a short circuit to ignition plus
99 a
(terminal 15)
7- Sh
Resistance ∞Ω
nector CM ( p. 397) pin 2 for a short circuit to ignition plus (terminal 15).
87 rt
600850-11
a
Intake air temperature sensor - the signal wire has a short circuit to the sensor
P
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 ∞Ω
nector CM ( p. 397) pin 2 for a short circuit to the sensor power supply.
600850-11
Intake air temperature sensor - the signal wire has an open ( p. 263)
Intake air temperature sensor - the signal wire has an open

Condition
600850-11 400650-10
86 m
Intake air temperature sensor - check the signal wire for opens
Break Out Box AO pin 22 – Connector CM pin 2
56 co
– Check EFI control unit connector AO ( p. 392) pin 22 and connector CM pin 2.
– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM pin 2 for opens.
9- k.
Intake air temperature sensor - the ground wire has an open ( p. 263)
r
Intake air temperature sensor - the ground wire has an open
99 a
Condition
7- Sh

87 rt
a
P
600850-11 400650-10
Intake air temperature sensor - check the ground wire for opens
Break Out Box AO pin 7 – Connector CM pin 1
– Check EFI control unit connector AO ( p. 392) pin 7 and connector CM pin 1.
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector CM pin 1 for opens.
Intake air temperature sensor - value not plausible

Condition
Intake air temperature sensor - check the resistance
Intake air temperature sensor

Resistance at: −20 °C (−4 °F) 18.80 kΩ
600850-11
86 m
– Replace the intake air temperature sensor.
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Engine coolant temperature sensor"
Error level condition Engine coolant temperature sensor voltage "TWAD": ≤ 0.156 V
Time: ≥ 3 s
Function check Engine coolant temperature sensor cylinder 1 - checking the voltage ( p. 265)
Possible cause Cylinder 1 coolant temperature sensor - value not plausible ( p. 265)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (termi-
nal 31) ( p. 266)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground
( p. 266)
86 m
nation of the fault
56 co
Engine coolant temperature sensor cylinder 1 - checking the voltage
Condition
The ignition is on.
9- k.
r
99 a

7- Sh
– 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
87 rt

a
P

Cylinder 1 coolant temperature sensor - value not plausible ( 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 tem-
perature sensor cylinder 1 pin 2
Resistance at: −30 °C (−22 °F) 22.86… 27.94 kΩ
Resistance at: −10 °C (14 °F) 8.24… 10.08 kΩ
600853-10 Resistance at: 0 °C (32 °F) 5.17… 6.31 kΩ
Resistance at: 10 °C (50 °F) 3.33… 4.07 kΩ

Resistance at: 50 °C (122 °F) 730… 892 Ω
– Change the engine coolant temperature sensor cylinder 1.
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
56 co
Condition
9- k.
Engine coolant temperature sensor for cylinder 1 is disconnected. (
r
p. 198)
99 a
7- Sh
600850-11 400658-10
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31)
87 rt
Resistance ∞Ω
a

– 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
P

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
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to
sensor ground
Resistance ∞Ω
600850-11
nector AX ( p. 395) pin 2 for a short circuit to sensor ground.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Engine coolant temperature sensor"
Error level condition Engine coolant temperature sensor voltage "TWAD": ≥ 4.844 V
Time: ≥ 3 s
Function check Engine coolant temperature sensor cylinder 1 - checking the voltage ( p. 268)
Possible cause Cylinder 1 coolant temperature sensor - value not plausible ( p. 268)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 269)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus
(terminal 15) ( p. 269)
86 m
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 ( p. 270)
56 co
Engine coolant temperature sensor cylinder 1 - the ground wire has an open ( p. 271)
nation of the fault
9- k.
Engine coolant temperature sensor cylinder 1 - checking the voltage
Condition
r
The ignition is on.
99 a

7- Sh

87 rt
– 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
a

–
P
Delete trouble code.

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

Condition
Cylinder 1 coolant temperature sensor - check the resistance
Engine coolant temperature sensor cylinder 1 pin 1 – Engine coolant tem-
perature sensor cylinder 1 pin 2
Resistance at: −10 °C (14 °F) 8.24… 10.08 kΩ
600853-10

86 m
– Change the engine coolant temperature sensor cylinder 1.
56 co
cuit to plus (terminal 30) ( p. 269)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
9- k.
Condition
r
99 a
7- Sh
87 rt
600850-11 400658-10
a
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30)
P
Voltage ≤ 0.1 V
– 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
plus (terminal 30).
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
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to
Resistance ∞Ω
nector AX ( p. 395) pin 2 for a short circuit to ignition plus (terminal 15).
600850-11
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
86 m
Condition
56 co
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to the
sensor power supply
9- k.
Resistance ∞Ω
r
nector AX ( p. 395) pin 2 for a short circuit to the sensor power supply.
99 a
600850-11
7- Sh
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
87 rt
Condition
a

P
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
– Check EFI control unit connector AO ( p. 392) pin 9 and connector AX pin 2.
– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX pin 2 for opens.

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
Condition
86 m
600850-11 400586-10
56 co
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
9- k.
– Check EFI control unit connector AO ( p. 392) pin 7 and connector AX pin 1.
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector AX pin 1 for opens.
r
99 a

7- Sh
87 rt
a
P

lamp (MIL)
"Throttle position sensor circuit A"
Error level condition 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 ( p. 272)
Possible cause Throttle position sensor circuit A - the power supply is interrupted ( p. 272)
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 sensor ground ( p. 274)
86 m
Throttle position sensor circuit A - the signal wire has an open ( p. 274)
nation of the fault
56 co
Throttle position sensor circuit A - checking the voltage
Condition
The ignition is on.
9- k.
r
99 a

7- Sh
– Highlight "Throttle position sensor voltage circuit A (THAD)" and deselect the other parameters with "Select live data".
Throttle position sensor circuit A voltage "(THAD)" 0.56… 4.20 V
87 rt

a
P

Throttle position sensor circuit A - the power supply is interrupted ( p. 272)
Throttle position sensor circuit A - the power supply is interrupted

Condition
The ignition is on.
Throttle position sensor circuit A is disconnected. ( p. 219)
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 (−)

86 m
– Check connector AR pin 1 and connector CP ( p. 398) pin 2.14.
– Check the cable from connector AR pin 1 to connector CP ( p. 398) pin 2.14 for opens.
– Check connector CQ ( p. 398) pin 14 and EFI control unit connector AO ( p. 392) pin 1.
56 co
– Check the cable from connector CQ ( 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)
9- k.
Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31)
Condition
r
99 a

7- Sh
87 rt
a
600850-11 400658-10
Throttle position sensor circuit A - check the signal wire for a short circuit to ground (terminal 31)
P

Resistance ∞Ω
– 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
– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR ( p. 393) pin 2 for a short circuit to ground (termi-
nal 31).
Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground ( p. 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 ∞Ω
nector 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
86 m
600850-11
( p. 393) pin 2 for a short circuit to sensor ground.
56 co
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
9- k.
r
99 a
7- Sh
87 rt
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
a
P

– Check EFI control unit connector AO ( p. 392) pin 10 and connector CQ ( p. 398) pin 6.
– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for opens.
– Check connector CP ( p. 398) pin 2.6 and connector AR pin 2.
– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR pin 2 for opens.

lamp (MIL)
"Throttle position sensor circuit A"
Error level condition 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 ( p. 275)
Possible cause Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)
( p. 275)
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 the sensor power supply
86 m
( p. 276)
Throttle position sensor circuit A - the ground wire has an open ( p. 277)
56 co
nation of the fault
Throttle position sensor circuit A - checking the voltage

Condition
9- k.
The ignition is on.
r
99 a

7- Sh

– Highlight "Throttle position sensor voltage circuit A (THAD)" and deselect the other parameters with "Select live data".
87 rt
Throttle position sensor circuit A voltage "(THAD)" 0.56… 4.20 V

a

P

Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30) ( p. 275)
Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-11 400658-10
Throttle position sensor circuit A - check the signal wire for a short circuit to plus (terminal 30)
Voltage ≤ 0.1 V
86 m
plus (terminal 30).
– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR ( p. 393) pin 2 for a short circuit to plus (termi-
56 co
nal 30).
Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 276)
9- k.
Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
r
99 a

Throttle position sensor circuit A - check the signal wire for a short circuit to ignition plus
7- Sh
(terminal 15)
Resistance ∞Ω
87 rt

nector CQ ( p. 398) pin 6 for a short circuit to ignition plus (terminal 15).
a
600850-11
( p. 393) pin 2 for a short circuit to ignition plus (terminal 15).
P

Throttle position sensor circuit A - the signal wire has a short circuit to the sen-
sor 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 ∞Ω
600850-11
nector 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 ( p. 277)
Throttle position sensor circuit A - the ground wire has an open

Condition
86 m
56 co 600850-11 400584-10
9- k.
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
r
99 a

7- Sh
– Check connector CP ( p. 398) pin 2.2 and connector AR pin 3.
– Check the cable from connector CP ( p. 398) pin 2.2 to connector AR pin 3 for opens.
87 rt

a
P

lamp (MIL)
"Lambda sensor cylinder 1, sensor 1"
"Circuit fault"
Function check Lambda sensor cylinder 1 - checking the voltage ( p. 278)
Possible cause Lambda sensor cylinder 1 - value not plausible ( 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)
Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
86 m
( p. 280)
Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
( p. 280)
56 co
Lambda sensor cylinder 1 - the signal wire has an open ( p. 281)
Lambda sensor cylinder 1 - the ground wire has an open ( p. 281)
nation of the fault
9- k.
Lambda sensor cylinder 1 - checking the voltage
Condition
r
The engine is running at idle speed.
99 a
The engine is at operating temperature.

7- Sh

87 rt
– Mark "Lambda values".

– Highlight "Lambda sensor cylinder 1 voltage (HEGO1AD)" and deselect the other parameters with "Select live data".
a
Lambda sensor
P
Lambda sensor cylinder 1 voltage "HEGO1AD" 0.2… 0.8 V

Lambda sensor cylinder 1 - value not plausible ( p. 278)
Lambda sensor cylinder 1 - value not plausible

Condition
The ignition is on.
Lambda sensor for cylinder 1 is connected. ( p. 62)
Lambda sensor cylinder 1 - check the voltage

Lambda sensor connector CE‑CA pin 3 – Lambda sensor connector CE‑CA
pin 4
Lambda sensor
Lambda sensor cylinder 1 voltage 0.2… 0.8 V
"HEGO1AD"
400686-10 – Replace the lambda sensor cylinder 1.
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground
(terminal 31) ( p. 279)
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
86 m
Condition
56 co
9- k.
r
99 a
600850-11 400658-10
7- Sh
Lambda sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31).
Resistance ∞Ω
87 rt

– 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
a

P
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 ∞Ω
nector CA ( p. 396) pin 4 for a short circuit to sensor ground.
600850-11
Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 280)
Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
Condition
86 m
600850-11 400658-10
Lambda sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30).
56 co
Voltage < 0.1 V
9- k.
plus (terminal 30).
Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 280)
r
99 a
Condition
7- Sh

Lambda sensor cylinder 1 - check the signal wire for a short circuit to ignition plus
87 rt
(terminal 15).
a
Resistance ∞Ω
P
nector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).
600850-11
Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor
Condition
Lambda sensor cylinder 1 - check the signal wire for a short circuit to the sensor power
supply.
Resistance ∞Ω
nector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.
600850-11
Lambda sensor cylinder 1 - the signal wire has an open

Condition
86 m
56 co
9- k.
r
600850-11 400646-10
99 a
Lambda sensor cylinder 1 - check the signal wire for opens.

7- Sh
Break Out Box AO pin 11 – Lambda sensor cylinder 1, connector CA pin 4
– Check EFI control unit connector AO ( p. 392) pin 11 and connector CA pin 4.
87 rt
– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA pin 4 for opens.
a

P
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.


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

lamp (MIL)
"Lambda sensor cylinder 2, sensor 1"
"Circuit fault"
Function check Lambda sensor cylinder 2 - checking the voltage ( p. 283)
Possible cause Lambda sensor cylinder 2 - value not plausible ( p. 283)
Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31) ( p. 284)
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) ( p. 285)
( p. 285)
86 m
( p. 285)
56 co
nation of the fault
9- k.
Lambda sensor cylinder 2 - checking the voltage
Condition
r
99 a

7- Sh

– Mark "Lambda values".
87 rt
– Highlight "Lambda sensor cylinder 2 voltage (HEGO2AD)" and deselect the other parameters with "Select live data".
a
Lambda sensor
Lambda sensor cylinder 2 voltage "HEGO2AD" 0.2… 0.8 V
P

Lambda sensor cylinder 2 - value not plausible ( p. 283)
Lambda sensor cylinder 2 - value not plausible

Condition
The ignition is on.
Lambda sensor for cylinder 2 is connected. ( p. 62)
Lambda sensor cylinder 2 - check the voltage

Lambda sensor connector CE‑CA pin 3 – Lambda sensor connector CE‑CA
pin 4
Lambda sensor
Lambda sensor cylinder 2 voltage 0.2… 0.8 V
"HEGO2AD"
400686-10 – Change the lambda sensor cylinder 2.
Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (termi-
nal 31) ( p. 284)
Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)
86 m
Condition
56 co
9- k.
r
99 a
600850-11 400658-10
7- Sh
Lambda sensor cylinder 2 - check the signal wire for a short circuit to ground (terminal 31).
Resistance ∞Ω
87 rt

a

P
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 ∞Ω
nector CA ( p. 396) pin 4 for a short circuit to sensor ground.
600850-11
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 285)
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)
Condition
86 m
600850-11 400658-10
Lambda sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30).
56 co
Voltage < 0.1 V
9- k.
plus (terminal 30).
Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 285)
r
99 a
Condition
7- Sh

Lambda sensor cylinder 2 - check the signal wire for a short circuit to ignition plus
87 rt
(terminal 15).
a
Resistance ∞Ω
P
nector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).
600850-11
Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor
Condition
Lambda sensor cylinder 2 - check the signal wire for a short circuit to the sensor power
supply.
Resistance ∞Ω
nector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.
600850-11
Lambda sensor cylinder 2 - the signal wire has an open

Condition
86 m
56 co
9- k.
r
600850-11 400646-10
99 a
Lambda sensor cylinder 2 - check the signal wire for opens.

7- Sh
87 rt
a

P
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.


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

lamp (MIL)
"Injector cylinder 1"
"Circuit fault"
Error level condition Circuit fault: ≥ 0.5 s
Function check Injector cylinder 1 - checking the control ( p. 288)
Possible cause Cylinder 1 injector - value not plausible ( 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) ( p. 290)
Injector cylinder 1 - the control wire has a short circuit to the sensor power supply ( p. 290)
Injector cylinder 1 - the control wire has an open. ( p. 291)
86 m
Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 291)
Injector cylinder 1 - the control wire has a short circuit to sensor ground ( p. 292)
56 co
nation of the fault
Injector cylinder 1 - checking the control

9- k.
Condition
The ignition is on.
–
r
Select the model.
99 a

7- Sh

– Select "Injector cylinder 1".
87 rt
Injector Operating noise
a

P

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
– 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

Condition
The ignition is on.
86 m
400591-10 400658-10
56 co
Injector cylinder 1 - check the power supply
Injector cylinder 1 connector DQ pin 1 – Measuring point Ground (−)
Info
9- k.
r
99 a
– Check connector DQ pin 1 and connector CP ( p. 398) pin 2.13.

– Check the cable from connector DQ pin 1 to connector CP ( p. 398) pin 2.13 for opens.
7- Sh
– Check the cable from connector CQ ( p. 398) pin 13 to the next node in the wiring harness for opens.
87 rt
Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30)
Condition
a

P
600850-12 400658-10
Injector cylinder 1 - check the control wire for a short circuit to plus (terminal 30).
Voltage < 0.1 V

– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for a short circuit to
plus (terminal 30).
– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to plus (termi-
nal 30).
Injector cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)
Condition
86 m
56 co
600850-12 600850-11
Injector cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).
9- k.
Resistance ∞Ω
r
99 a

– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to ignition plus
7- Sh
(terminal 15).
87 rt
Injector cylinder 1 - the control wire has a short circuit to the sensor power supply
Condition
a

P
600850-12 600850-11
Injector cylinder 1 - check the control wire for a short circuit to the sensor power supply
Resistance ∞Ω
the sensor power supply.
– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to the sensor
power supply.
Injector cylinder 1 - the control wire has an open.

Condition
86 m
56 co
600850-12 400591-10
Injector cylinder 1 - check the control wire for opens

9- k.
Break out box CO pin 5 – Injector cylinder 1 connector DQ pin 2
r
– Check EFI control unit connector CO ( p. 397) pin 5 and connector CQ ( p. 398) pin 5.
99 a
– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for opens.
– Check connector CP ( p. 398) pin 2.5 and connector DQ pin 2.
7- Sh
– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ pin 2 for opens.
87 rt
Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31)
Condition
a

P

600850-12 400658-10
Injector cylinder 1 - check the control wire for a short circuit to ground (terminal 31).
Resistance ∞Ω
– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to ground (termi-
nal 31).
Injector cylinder 1 - the control wire has a short circuit to sensor ground
Condition
86 m
56 co
600850-12 600850-11
Injector cylinder 1 - check the control wire for a short circuit to sensor ground.
9- k.
Resistance ∞Ω
r
99 a
sensor ground.
– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to sensor ground.
7- Sh

87 rt
a
P

lamp (MIL)
"Injector cylinder 2"
"Circuit fault"
Error level condition Circuit fault: ≥ 0.5 s
Function check Injector cylinder 2 - checking the control ( p. 293)
Possible cause Injector cylinder 2 - value not plausible ( p. 293)
Injector cylinder 2 - the power supply is faulty ( p. 294)
86 m
56 co
nation of the fault
Injector cylinder 2 - checking the control

9- k.
Condition
The ignition is on.
–
r
Select the model.
99 a

7- Sh

– Select "Injector cylinder 2".
87 rt
Injector Operating noise
a

P

Injector cylinder 2 - value not plausible ( p. 293)
Injector cylinder 2 - value not plausible

Condition
Injector cylinder 2 - check the resistance
Injector pin 1 – Injector pin 2
Injector
400598-10
– Change the injector cylinder 2.

Injector cylinder 2 - the power supply is faulty ( p. 294)
Injector cylinder 2 - the power supply is faulty

Condition
The ignition is on.
86 m
400591-10 400658-10
56 co
Injector cylinder 2 - check the power supply
Injector cylinder 2 connector DQ pin 1 – Measuring point Ground (−)
Info
9- k.
r
99 a
– Check connector DQ pin 1 and connector CP ( p. 398) pin 2.13.

– Check the cable from connector DQ pin 1 to connector CP ( p. 398) pin 2.13 for opens.
7- Sh
– Check the cable from connector CQ ( p. 398) pin 13 to the next node in the wiring harness for opens.
87 rt
Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30)
Condition
a

P
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).
– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to plus (termi-
nal 30).
Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)
Condition
86 m
56 co
600850-12 600850-11
Injector cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).
9- k.
Resistance ∞Ω
r
99 a

– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to ignition plus
7- Sh
(terminal 15).
87 rt
Injector cylinder 2 - the control wire has a short circuit to the sensor power supply
Condition
a

P
600850-12 600850-11
Injector cylinder 2 - check the control wire for a short circuit to the sensor power supply
Resistance ∞Ω
the sensor power supply.
– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to the sensor
power supply.
Injector cylinder 2 - the control wire has an open.

Condition
86 m
56 co
600850-12 400591-10
Injector cylinder 2 - check the control wire for opens

9- k.
Break out box CO pin 6 – Injector cylinder 2 connector DQ pin 2
r
– Check EFI control unit connector CO ( p. 397) pin 6 and connector CQ ( p. 398) pin 9.
99 a
– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for opens.
– Check connector CP ( p. 398) pin 2.9 and connector DQ pin 2.
7- Sh
– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ pin 2 for opens.
87 rt
Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31)
Condition
a

P

600850-12 400658-10
Injector cylinder 2 - check the control wire for a short circuit to ground (terminal 31).
Resistance ∞Ω
– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to ground (termi-
nal 31).
Injector cylinder 2 - the control wire has a short circuit to sensor ground
Condition
86 m
56 co
600850-12 600850-11
Injector cylinder 2 - check the control wire for a short circuit to sensor ground.
9- k.
Resistance ∞Ω
r
99 a
sensor ground.
– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to sensor ground.
7- Sh

87 rt
a
P

lamp (MIL)
"Throttle position sensor circuit B"
Error level condition Throttle position sensor circuit B, voltage "TAPAD": ≤ 0.156 V
Time: ≥ 3 s
Function check Throttle position sensor circuit B - checking the voltage ( p. 298)
Possible cause Throttle position sensor circuit B - the power supply is interrupted ( p. 298)
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 sensor ground ( p. 300)
86 m
Throttle position sensor circuit B - the signal wire has an open ( p. 300)
nation of the fault
56 co
Throttle position sensor circuit B - checking the voltage
Condition
The ignition is on.
9- k.
r
99 a

7- Sh
– Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".
Voltage "TAPAD" 0.156… 4.824 V
87 rt

a

P

Throttle position sensor circuit B - the power supply is interrupted ( p. 298)
Throttle position sensor circuit B - the power supply is interrupted

Condition
The ignition is on.
Throttle position sensor circuit B is disconnected. ( p. 223)
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 (−)

86 m
– Check connector AM pin 2 and connector CP ( p. 398) pin 2.14.
– Check the cable from connector AM pin 2 to connector CP ( p. 398) pin 2.14 for opens.
– Check connector CQ ( p. 398) pin 14 and EFI control unit connector AO ( p. 392) pin 1.
56 co
– Check the cable from connector CQ ( p. 398) pin 14 to EFI control unit connector AO ( p. 392) pin 1 for opens.
Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31) ( p. 299)
9- k.
Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31)
Condition
r
99 a

7- Sh
87 rt
a
600850-11 400658-10
Throttle position sensor circuit B - check the signal wire for a short circuit to ground (terminal 31)
P

Resistance ∞Ω
– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM ( p. 392) pin 1 for a short circuit to ground (termi-
nal 31).
Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground ( p. 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 ∞Ω
nector 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
86 m
600850-11
56 co
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
9- k.
r
99 a
7- Sh
87 rt
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
a
P

– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 2.10 for opens.
– Check connector CP ( p. 398) pin 2.10 and connector AM pin 1.
– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM pin 1 for opens.

lamp (MIL)
"Throttle position sensor circuit B"
Error level condition Throttle position sensor circuit B, voltage "TAPAD": ≥ 4.824 V
Time: ≥ 3 s
Function check Throttle position sensor circuit B - checking the voltage ( p. 301)
Possible cause Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30)
( p. 301)
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 the sensor power supply
86 m
( p. 302)
Throttle position sensor circuit B - the ground wire has an open ( p. 303)
56 co
nation of the fault
Throttle position sensor circuit B - checking the voltage

Condition
9- k.
The ignition is on.
r
99 a

7- Sh

– Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".
87 rt

a

P
Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30) ( p. 301)
Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-11 400658-10
Throttle position sensor circuit B - check the signal wire for a short circuit to plus (terminal 30)
Voltage ≤ 0.1 V
86 m
plus (terminal 30).
– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM ( p. 392) pin 1 for a short circuit to plus (termi-
56 co
nal 30).
Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 302)
9- k.
Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
r
99 a

Throttle position sensor circuit B - check the signal wire for a short circuit to ignition plus
7- Sh
(terminal 15)
Resistance ∞Ω
87 rt

nector CQ ( p. 398) pin 10 for a short circuit to ignition plus (terminal 15).
a
600850-11
( p. 392) pin 1 for a short circuit to ignition plus (terminal 15).
P

Throttle position sensor circuit B - the signal wire has a short circuit to the sen-
sor 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 ∞Ω
600850-11
nector 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 ( p. 303)
Throttle position sensor circuit B - the ground wire has an open

Condition
86 m
56 co 600850-11 400582-10
9- k.
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
r
99 a

7- Sh
– Check connector CP ( p. 398) pin 2.2 and connector AM pin 3.
– Check the cable from connector CP ( p. 398) pin 2.2 to connector AM pin 3 for opens.
87 rt

a
P

lamp (MIL)
"Circuit crankshaft position sensor"
"Circuit fault"
Error level condition 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)
Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)
( p. 305)
86 m
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)
56 co
Crankshaft position sensor - the signal wire has a short circuit to the sensor power supply
( p. 307)
9- k.
nation of the fault
Crankshaft position sensor - checking the signal

r
Condition
The ignition is on.
99 a

7- Sh

87 rt
– Highlight "electric starter".

– Highlight "Engine speed (NE)" and deselect the other parameters with "Select live data".
a
– Perform the start procedure.

"Engine speed (NE)" Starter rpm
P

Crankshaft position sensor - value not plausible ( p. 304)
Crankshaft position sensor - value not plausible

Condition
The crankshaft position sensor is disconnected. ( p. 218)
Crankshaft position sensor - check the resistance

Crankshaft position sensor, connector AT pin 1 – Crankshaft position sensor,
connector AT pin 2
– Replace the crankshaft position sensor.
400585-10
Crankshaft position sensor - the signal wire has an open ( p. 305)
Crankshaft position sensor - the signal wire has an open

Condition
86 m
The crankshaft position sensor is connected. ( p. 218)
56 co
Crankshaft position sensor - check the signal wire for opens

9- k.
– Check EFI control unit connector AO ( p. 392) pin 14 and pin 13.
r
600850-11 – Check connector AL ( p. 391) pin 2 and connector AL pin 1.
99 a
nector AL ( p. 391) pin 2 for opens.
7- Sh
nector AL ( p. 391) pin 1 for opens.
Crankshaft position sensor - the signal wires have a short circuit to ground (ter-
87 rt
minal 31) ( p. 305)
Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)
a
Condition
P

600850-11 400658-10
Crankshaft position sensor - check the signal wires for a short circuit to ground (terminal 31)
Resistance ∞Ω
– 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
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
Crankshaft position sensor - check the signal wires for a short circuit to sensor ground
–
86 m
Measure the resistance between the specified points.
Resistance ∞Ω
56 co
nector AL ( p. 391) pin 2 for a short circuit to sensor ground.
600850-11
nector AL ( p. 391) pin 1 for a short circuit to sensor ground.
9- k.
Crankshaft position sensor - the signal wires have a short circuit to plus (termi-
r
nal 30) ( p. 306)
99 a
Crankshaft position sensor - the signal wires have a short circuit to plus (terminal 30)
Condition
7- Sh

87 rt
a
P
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)
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 ∞Ω
nector AL ( p. 391) pin 2 for a short circuit to ignition plus (terminal 15).
86 m
600850-11
nector AL ( p. 391) pin 1 for a short circuit to ignition plus (terminal 15).
56 co
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
9- k.
Condition
r
99 a
Crankshaft position sensor - check the signal wire for a short circuit to the sensor power
supply
–
7- Sh

Resistance ∞Ω
87 rt
nector AL ( p. 391) pin 2 for a short circuit to the sensor power supply.
600850-11
a
nector AL ( p. 391) pin 1 for a short circuit to the sensor power supply.
P


lamp (MIL)
"Ignition coil cylinder 1"
"Circuit fault"
Error level condition Circuit fault.
Function check Checking the ignition coil cylinder 1 ( p. 308)
Possible cause Ignition coil cylinder 1 - value not plausible ( p. 308)
Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 309)
Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground ( p. 309)
Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30) ( p. 310)
Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)
86 m
( 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)
56 co
nation of the fault
Checking the ignition coil cylinder 1

9- k.
Condition
The ignition is on.
r
99 a

7- Sh
– Select "Ignition cylinder 1".
87 rt
a
Spark plug Operating noise

P

Ignition coil cylinder 1 - value not plausible ( p. 308)
Ignition coil cylinder 1 - value not plausible

Condition
Ignition coil cylinder 1 is disconnected. ( p. 218)
Ignition coil cylinder 1 - check the resistance

Ignition coil pin 1 – Ignition coil pin 2
Ignition coil
Primary winding resistance at: 20 °C 1.105… 1.495 Ω
(68 °F)
– Replace the ignition coil cylinder 1.
600851-10
Ignition coil cylinder 1 - the control wire has a short circuit to ground (termi-
nal 31) ( p. 309)
Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31)
86 m
Condition
56 co
9- k.
r
99 a
600850-12 400658-10
Ignition coil cylinder 1 - check the control wire for a short circuit to ground (terminal 31).
7- Sh

Resistance ∞Ω
87 rt
– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS ( p. 394) pin 1 for a short circuit to
a

P
Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground
Condition
600850-12 600850-11
Ignition coil cylinder 1 - check the control wire for a short circuit to sensor ground.
Resistance ∞Ω
86 m
sensor ground.
56 co
Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30)
Condition
9- k.
r
99 a
7- Sh
87 rt
600850-12 400658-10
Ignition coil cylinder 1 - check the control wire for a short circuit to plus (terminal 30).
a

P
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
600850-12 600850-11
Ignition coil cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).
Resistance ∞Ω
86 m
56 co
Ignition coil cylinder 1 - the control wire has an open

Condition
9- k.
r
99 a
7- Sh
87 rt
400644-10 400658-10
Ignition coil cylinder 1 - check the control wire for opens

a

Ignition coil cylinder 1 connector AS pin 1 – Measuring point Ground (−)
P
Info
Establish a secure connection from the battery plus terminal to the break out box CO pin 29.
– Check EFI control unit connector CO ( p. 397) pin 29 and connector AS pin 1.
– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS pin 1 for opens.
Ignition coil cylinder 1 - the power supply is interrupted

Condition
The ignition is on.
86 m
400644-10 400658-10
Ignition coil cylinder 1 - check the power supply

56 co
Info
9- k.
– Check connector AS pin 2.
r
– Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.
99 a

7- Sh
87 rt
a
P

lamp (MIL)
"Ignition coil cylinder 2"
"Circuit fault"
Function check Checking the ignition coil cylinder 2 ( p. 313)
Possible cause Ignition coil cylinder 2 - value not plausible ( p. 313)
Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 314)
86 m
( p. 315)
56 co
nation of the fault
Checking the ignition coil cylinder 2

9- k.
Condition
The ignition is on.
r
99 a

7- Sh
– Select "Ignition cylinder 2".
87 rt
a
Spark plug Operating noise

P

Ignition coil cylinder 2 - value not plausible ( p. 313)
Ignition coil cylinder 2 - value not plausible

Condition
Ignition coil cylinder 2 - check the resistance

Ignition coil pin 1 – Ignition coil pin 2
Ignition coil
Primary winding resistance at: 20 °C 1.105… 1.495 Ω
(68 °F)
– Change the ignition coil cylinder 2.
600851-10
Ignition coil cylinder 2 - the control wire has a short circuit to ground (termi-
nal 31) ( p. 314)
Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31)
86 m
Condition
56 co
9- k.
r
99 a
600850-12 400658-10
Ignition coil cylinder 2 - check the control wire for a short circuit to ground (terminal 31).
7- Sh

Resistance ∞Ω
87 rt
a

P
Ignition coil cylinder 2 - the control wire has a short circuit to sensor ground
Condition
600850-12 600850-11
Ignition coil cylinder 2 - check the control wire for a short circuit to sensor ground.
Resistance ∞Ω
86 m
sensor ground.
56 co
Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30)
Condition
9- k.
r
99 a
7- Sh
87 rt
600850-12 400658-10
Ignition coil cylinder 2 - check the control wire for a short circuit to plus (terminal 30).
a

P
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
600850-12 600850-11
Ignition coil cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).
Resistance ∞Ω
86 m
56 co
Ignition coil cylinder 2 - the control wire has an open

Condition
9- k.
r
99 a
7- Sh
87 rt
400644-10 400658-10
Ignition coil cylinder 2 - check the control wire for opens

a

P
Info
Establish a protected connection from battery plus to break out box CO pin 26.
– Check EFI control unit connector CO ( p. 397) pin 26 and connector AS pin 1.
– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS pin 1 for opens.
Ignition coil cylinder 2 - the power supply is interrupted

Condition
The ignition is on.
86 m
400644-10 400658-10
Ignition coil cylinder 2 - check the power supply

56 co
Info
9- k.
– Check connector AS pin 2.
r
– Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.
99 a

7- Sh
87 rt
a
P

lamp (MIL)
"Secondary air valve "
Error level condition The control unit is active.
Circuit fault: ≥ 3 s
Function check Checking the secondary air valve ( p. 318)
Possible cause Secondary air valve - value not plausible ( p. 318)
Secondary air valve - the control wire has a short circuit to ground (terminal 31) ( p. 319)
Secondary air valve - the control wire has an open ( p. 319)
Secondary air valve - the power supply is faulty ( p. 320)
86 m
Secondary air valve - the control wire has a short circuit to sensor ground ( p. 321)
56 co
nation of the fault
Checking the secondary air valve

Condition
The ignition is on.
9- k.
r
99 a
7- Sh

– Select "Exhaust air injection valve SLS on/off".
87 rt
Secondary air valve Operating noise
a

P
Secondary air valve - value not plausible ( 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) 18.0… 22.0 Ω
600854-10
– Change the secondary air valve.

Secondary air valve - the control wire has a short circuit to ground (terminal 31)
( p. 319)
Condition
86 m
56 co
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 (−)
9- k.
Resistance ∞Ω
r
99 a

Secondary air valve - the control wire has an open ( p. 319)
7- Sh
Secondary air valve - the control wire has an open

Condition
87 rt

a
P
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
– Check EFI control unit connector CO ( p. 397) pin 13 and connector CK pin 2.
– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK pin 2 for opens.
Secondary air valve - the power supply is faulty ( p. 320)
Secondary air valve - the power supply is faulty

Condition
The ignition is on.
400648-10 400658-10
86 m
Secondary air valve - check the power supply
Secondary air valve connector CK pin 1 – Measuring point Ground (−)
56 co
Info
9- k.
– Check connector CK pin 1.
– Check the cable from connector CK pin 1 to the next node in the wiring harness for opens.
r
99 a

7- Sh
Condition
87 rt

a
P
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 ∞Ω
– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK pin 2 for a short circuit to ground (ter-
minal 31).
Secondary air valve - the control wire has a short circuit to sensor ground ( p. 321)
Secondary air valve - the control wire has a short circuit to sensor ground
Condition
86 m
600850-12 600850-11
Secondary air valve - check the control wire for a short circuit to sensor ground.
56 co
Resistance ∞Ω
– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK ( p. 396) pin 2 for a short circuit to
9- k.
sensor ground.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Secondary air valve "
Function check Checking the secondary air valve ( p. 322)
Possible cause Secondary air valve - value not plausible ( 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. 323)
nation of the fault
86 m
Checking the secondary air valve
Condition
56 co
The ignition is on.
9- k.
r
99 a
– Select "Exhaust air injection valve SLS on/off".

7- Sh
Secondary air valve Operating noise
87 rt

a

Secondary air valve - value not plausible ( p. 322)
P
Secondary air valve - value not plausible

Condition
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) 18.0… 22.0 Ω
600854-10
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 plus (terminal 30)
Condition
86 m
600850-12 400658-10
Secondary air valve - check the signal wire for a short circuit to plus (terminal 30)
56 co
Voltage ≤ 0.1 V
9- k.
plus (terminal 30).
Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 323)
r
99 a
Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
7- Sh

87 rt
a
P
600850-12 600850-11
Secondary air valve - check the signal wire for a short circuit to ignition plus (terminal 15)
Resistance ∞Ω

lamp (MIL)
"Circuit A of motor drive "
"Circuit fault"
Function check Motor drive circuit A - checking the control ( p. 324)
Possible cause Motor drive circuit A phase A - value not plausible ( p. 325)
Motor drive circuit A phase B - value not plausible ( p. 325)
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)
Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31)
( p. 326)
86 m
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)
56 co
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)
9- k. ( p. 330)
Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 330)
–
r
Last measure if none of the doc- Contact customer service.
99 a
nation of the fault
Motor drive circuit A - checking the control

7- Sh
Condition
The ignition is on.
87 rt

a

P
– Select "motor drive circuit A".
Idle speed control Operating noise
Motor drive circuit A phase A - value not plausible ( p. 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

Phase A at: 20 °C (68 °F) 7.11… 8.68 Ω
– Check connector CP pin 2.12 and connector AE ( p. 391) pin 2.
400651-10 – Check the connector from CP pin 2.12 to connector AE ( p. 391) pin 2 for
opens.
86 m
– Check the connector from CP pin 2.16 to connector AE ( p. 391) pin 3 for
opens.
– Disconnect connector CQ ( p. 398) from the throttle valve body. Check the
56 co
cable from connector CP pin 2.12 to pin 2.16 for a mutual short circuit.
– Change the throttle valve body.
9- k. Motor drive circuit A phase B - value not plausible ( p. 325)
Motor drive circuit A phase B - value not plausible

r
Condition
99 a

Motor drive circuit A phase B - check the resistance
–
7- Sh


Phase B at: 20 °C (68 °F) 7.11… 8.68 Ω
87 rt

400651-10 – Check the connector from CP pin 2.4 to connector AE ( p. 391) pin 4 for
a
opens.
P
– Check the connector from CP pin 2.8 to connector AE ( p. 391) pin 1 for
opens.
Motor drive circuit A phase A - the signal wire has an open ( p. 325)
Motor drive circuit A phase A - the signal wire has an open

Condition
Connector CP is connected. ( p. 398)
Motor drive circuit A phase A - check the signal wire for opens
Break out box CO pin 7 – Break out box CO pin 23

Phase A at: 20 °C (68 °F) 7.11… 8.68 Ω
– Check EFI control unit connector CO ( p. 397) pin 7 and connector CQ
( p. 398) pin 12.
600850-12
– Check the cable from EFI control unit connector CO ( p. 397) pin 7 to con-
nector CQ ( p. 398) pin 12 for opens.
( p. 398) pin 16.
86 m
cable from EFI control unit connector CO ( p. 392) pin 7 to pin 23 for a
mutual short circuit.
56 co
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

9- k. Condition
r
99 a
Motor drive circuit A phase B - check the signal wire for opens
7- Sh

Phase B at: 20 °C (68 °F) 7.11… 8.68 Ω
87 rt

( p. 398) pin 4.
600850-12
a

( p. 398) pin 8.
P
Motor drive circuit A phase A - the signal wire has a short circuit to ground (ter-
minal 31) ( p. 326)
Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-12 400658-10
Motor drive circuit A phase A - check the signal wire for a short circuit to ground (terminal 31)
Resistance ∞Ω
86 m
– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to ground (termi-
56 co
nal 31).
– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to ground (termi-
nal 31).
9- k.
Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31) ( p. 327)
r
Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31)
99 a
Condition
7- Sh

87 rt
a
P
600850-12 400658-10
Motor drive circuit A phase B - check the signal wire for a short circuit to ground (terminal 31)
Resistance ∞Ω
– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to ground (terminal 31).
– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 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)
Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground
Condition
600850-12 600850-11
86 m
Motor drive circuit A phase A - check the signal wire for a short circuit to sensor ground
56 co
Resistance ∞Ω
sensor ground.
–
9- k.
Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to sensor ground.
sensor ground.
r
– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to sensor ground.
99 a

Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground ( p. 328)
7- Sh
Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground
Condition
87 rt

a
P
600850-12 600850-11
Motor drive circuit A phase B - check the signal wire for a short circuit to sensor ground
Resistance ∞Ω
sensor ground.
– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to sensor ground.
sensor ground.
– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to sensor ground.

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)
Condition
86 m
600850-12 400658-10
56 co
Motor drive circuit A phase A - check the signal wire for a short circuit to plus (terminal 30)
Voltage < 0.1 V

9- k.
plus (terminal 30).
r
– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to plus (termi-
nal 30).
99 a
plus (terminal 30).
7- Sh
– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to plus (termi-
nal 30).
87 rt
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)
a
Condition
P
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).
– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to plus (terminal 30).
plus (terminal 30).
– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 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)
Condition
86 m
56 co
600850-12 600850-11
9- k.
Motor drive circuit A phase A - check the signal wire for a short circuit to ignition plus (terminal 15)
r
Resistance ∞Ω
99 a

7- Sh
– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to ignition plus
(terminal 15).
87 rt
– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to ignition plus
(terminal 15).
a

Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 330)
P
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 ∞Ω

– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to ignition plus (terminal 15).
– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to ignition plus (terminal 15).
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Power supply"
"Circuit fault"
Error level condition 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 ( p. 332)
Possible cause EFI control unit - the power supply is faulty ( p. 332)
EFI control unit - the ground wire (I) has an open ( p. 333)
EFI control unit - the ground wire (II) has an open ( p. 333)
86 m
Last measure if none of the doc- – Change the ambient air pressure sensor.
nation of the fault
56 co
EFI control unit - checking the power supply
Condition
The ignition is on.
9- k.
–
r
Mark the "Engine management EFI LC8 RC8" control unit.
99 a

7- Sh
– Highlight "Battery voltage (VBAT)" and deselect the other parameters with "Select live data".
87 rt

a
P

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 400658-10
EFI control unit - check the power supply

Info
– Check connector AO ( p. 392) pin 20.
– Check the cable from connector AO ( p. 392) pin 20 to the next node in the wiring harness for opens.
EFI control unit - the ground wire (I) has an open ( p. 333)
EFI control unit - the ground wire (I) has an open

Condition
The ignition is on.
86 m
56 co
9- k.
600850-12 400658-10
r
EFI control unit - the ground wire (I) has an open
99 a
Break out box CO pin 8 – Measuring point Plus (+)
Info
7- Sh
87 rt
– Check connector CO ( p. 397) pin 8.

– Check the cable from connector CO ( p. 397) pin 8 to the next node in the wiring harness for opens.
a

EFI control unit - the ground wire (II) has an open ( p. 333)
P
EFI control unit - the ground wire (II) has an open

Condition
The ignition is on.
600850-12 400658-10
EFI control unit - the ground wire (II) has an open

Break out box CO pin 9 – Measuring point Plus (+)
Info
– Check connector CO ( p. 397) pin 9.
– Check the cable from connector CO ( p. 397) pin 9 to the next node in the wiring harness for opens.
– Change the ambient air pressure sensor.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"E²PROM"
"Fault"
Error level condition Read data and write data differ.
Function check Flashing the EFI control unit ( p. 335)
Last measure if none of the doc- – Change the EFI control unit.
nation of the fault
Flashing the EFI control unit

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

– Read the safety notice and confirm with "OK".
The new mapping is loaded.
87 rt
Last measure if none of the documented causes leads to elimination of the fault
– Change the EFI control unit.
a
P

lamp (MIL)
50 EFI warning lamp (MIL) flashes 5x long
"Throttle position sensor actuator circuit B"
"Circuit fault"
Error level condition 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
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
86 m
Function check Checking circuit B of the motor drive ( p. 336)
Possible cause Motor drive circuit B phase A - value not plausible ( p. 337)
Motor drive circuit B phase B - value not plausible ( p. 337)
56 co
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)
9- k. 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)
r
Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30) ( p. 341)
99 a
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)
7- Sh
( p. 342)
Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15)
( p. 342)
87 rt
nation of the fault
Checking circuit B of the motor drive

a
Condition
The ignition is on.
P

– Select "Motor drive circuit B".
Motor drive circuit B phase A - value not plausible ( p. 337)
Motor drive circuit B phase A - value not plausible

Condition
Motor drive circuit B phase A - check the resistance
Motor drive circuit B

Phase A at: 20 °C (68 °F) 5.85… 7.15 Ω
86 m
– Check connector CP pin 2.15 and connector CA ( p. 395) pin 1.
400651-10 – Check the connector from CP pin 2.15 to connector CA ( p. 395) pin 1 for
56 co
opens.
– Check the connector from CP pin 2.11 to connector CA ( p. 395) pin 3 for
opens.
– Disconnect connector CA ( p. 395) from motor drive circuit B. Check the
9- k.
r
99 a
Motor drive circuit B phase B - value not plausible ( p. 337)
Motor drive circuit B phase B - value not plausible

7- Sh
Condition
Motor drive circuit B phase B - check the resistance
–
87 rt


a
Phase B at: 20 °C (68 °F) 5.85… 7.15 Ω

P

400651-10 – Check the connector from CP pin 2.3 to connector CA ( p. 395) pin 4 for
opens.
– Check the connector from CP pin 2.7 to connector CA ( p. 395) pin 2 for
opens.
– Disconnect connector CA ( p. 395) from motor drive circuit B. Check the
Motor drive circuit B phase A - the signal wire has an open ( p. 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

Phase A at: 20 °C (68 °F) 5.85… 7.15 Ω
( p. 398) pin 15.
86 m
600850-12
56 co
( p. 398) pin 11.
– Disconnect connector CQ ( p. 398) from motor drive circuit B. Check the
9- k. mutual short circuit.
r
Motor drive circuit B phase B - the signal wire has an open ( p. 338)
99 a
Motor drive circuit B phase B - the signal wire has an open

Condition
7- Sh

Motor drive circuit B phase B - check the signal wire for opens
87 rt


a
Phase B at: 20 °C (68 °F) 5.85… 7.15 Ω

P

( p. 398) pin 3.
600850-12
( 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 (ter-
minal 31) ( p. 339)
Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31)
Condition
600850-12 400658-10
86 m
Motor drive circuit B phase A - check the signal wire for a short circuit to ground (terminal 31)
56 co
Resistance ∞Ω
–
9- k.
Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to ground (terminal 31).
r
– Check connector CP ( p. 398) pin 2.15 to connector CA ( p. 395) pin 1 for a short circuit to ground (terminal 31).
99 a

Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31) ( p. 339)
7- Sh
Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31)
Condition
87 rt

a
P
600850-12 400658-10
Motor drive circuit B phase B - check the signal wire for a short circuit to ground (terminal 31)
Resistance ∞Ω

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
Condition
86 m
600850-12 600850-11
56 co
Motor drive circuit B phase A - check the signal wire for a short circuit to sensor ground
Resistance ∞Ω
9- k.
sensor ground.
r
– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to sensor ground.
99 a
sensor ground.
7- Sh

Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground ( p. 340)
87 rt
Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground
Condition
a

P
600850-12 600850-11
Motor drive circuit B phase B - check the signal wire for a short circuit to sensor ground
Resistance ∞Ω
sensor ground.
sensor ground.
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)
Condition
86 m
56 co
600850-12 400658-10
Motor drive circuit B phase A - check the signal wire for a short circuit to plus (terminal 30)
–
9- k.
Measure the voltage between the specified points.
Voltage < 0.1 V

r
99 a
plus (terminal 30).
– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to plus (terminal 30).
7- Sh
plus (terminal 30).
87 rt

Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30) ( p. 341)
a
Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30)
Condition
P

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).
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)
Condition
86 m
56 co
9- k.
600850-12 600850-11
Motor drive circuit B phase A - check the signal wire for a short circuit to ignition plus (terminal 15)
r
99 a
Resistance ∞Ω
7- Sh
– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to ignition plus (terminal 15).
87 rt

a

Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 342)
P
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 ∞Ω

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

lamp (MIL)
"Connection leaks"
Error level condition The ambient air pressure is greater than the pressure at the manifold absolute pressure sensor
cylinder 1
Time: ≥ 3 s
Possible cause Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty
( p. 345)
Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head is
faulty ( p. 345)
86 m
nation of the fault
56 co
Condition
The ignition is on.
9- k.
– Connect the vacuum hand pump to the manifold absolute pressure sensor. ( p. 224)
– Create a vacuum with the vacuum pump.
r
99 a

7- Sh
87 rt

at: 350 mbar (5.08 psi) 1.62… 1.68 V
a
at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V
P
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
Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty ( p. 345)
Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty
– 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 Is OK.
86 m
– Change the vacuum connection at the cylinder head.
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Connection leaks"
Error level condition The ambient air pressure is greater than the pressure at the manifold absolute pressure sensor
cylinder 2
Time: ≥ 3 s
Possible cause Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty
( p. 347)
Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head is
faulty ( p. 347)
86 m
Last measure if none of the doc- – Change the manifold absolute pressure sensor cylinder 2.
nation of the fault
56 co
Condition
The ignition is on.
9- k.
– Connect the vacuum hand pump to the manifold absolute pressure sensor. ( p. 224)
– Create a vacuum with the vacuum pump.
r
99 a

7- Sh
87 rt

at: 350 mbar (5.08 psi) 1.62… 1.68 V
a
at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V
P
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
Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty ( p. 347)
Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty
– 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 Is OK.
86 m
– Change the vacuum connection at the cylinder head.
– Change the manifold absolute pressure sensor cylinder 2.
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Ambient air pressure sensor "
Error level condition Ambient air pressure sensor voltage "PAAD": ≤ 0.508 V
Time: ≥ 3 s
Function check Ambient air pressure sensor - checking the voltage ( p. 348)
Possible cause 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 ground (terminal 31)
( p. 349)
Ambient air pressure sensor - the power supply is interrupted ( p. 349)
86 m
nation of the fault
56 co
Ambient air pressure sensor - checking the voltage
Condition
The ignition is on.
9- k.
–
r
Mark the "Engine management EFI LC8 RC8" control unit.
99 a

7- Sh
– 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
87 rt
at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V
a
at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V
P
at: 1,050 mbar (15.23 psi) 3.72… 3.78 V

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)
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 sen-
sor connector DP pin 3
Resistance ∞Ω
400590-10 » If the specifications have been met:
Ambient air pressure sensor - the signal wire has a short circuit to ground (ter-
minal 31) ( p. 349)
Ambient air pressure sensor - the signal wire has a short circuit to ground (terminal 31)
Condition
86 m
56 co
9- k.
r
400590-10 400658-10
99 a
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 (−)
7- Sh
Resistance ∞Ω
87 rt
minal 31).
a
Ambient air pressure sensor - the power supply is interrupted ( p. 349)
Ambient air pressure sensor - the power supply is interrupted

P
Condition
The ignition is on.
400590-10 400658-10
Ambient air pressure sensor - check the power supply

Ambient air pressure sensor connector DP pin 1 – Measuring point Ground (−)


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

lamp (MIL)
"Ambient air pressure sensor "
Error level condition Ambient air pressure sensor voltage "PAAD": ≥ 4.961 V
Time: ≥ 3 s
Function check Ambient air pressure sensor - checking the voltage ( p. 351)
Possible cause Ambient air pressure sensor - the signal wire has an open ( p. 352)
Ambient air pressure sensor - the ground wire has an open ( p. 352)
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15)
86 m
( p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supply
( p. 353)
56 co
nation of the fault
Ambient air pressure sensor - checking the voltage

9- k.
Condition
The ignition is on.
r
99 a

7- Sh
87 rt
– 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
a
at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V
P
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
Ambient air pressure sensor - the signal wire has an open ( p. 352)
Ambient air pressure sensor - the signal wire has an open

Condition
86 m
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
56 co
9- k.
r
Ambient air pressure sensor - the ground wire has an open ( p. 352)
99 a
Ambient air pressure sensor - the ground wire has an open

Condition
7- Sh

87 rt
a
P
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
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
86 m
600850-11 400658-10
Ambient air pressure sensor - check the signal wire for a short circuit to plus (terminal 30)
56 co
Voltage < 0.1 V
9- k.
plus (terminal 30).
Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 353)
r
99 a
Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
7- Sh

Ambient air pressure sensor - check the signal wire for a short circuit to ignition plus
87 rt
(terminal 15)
a
Resistance ∞Ω
P
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
Ambient air pressure sensor - check the signal wire for a short circuit to the sensor power
supply
Resistance ∞Ω
600850-11
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Fuel pump relay"
The engine is switched off: ≥ 3 s
Function check Checking the fuel pump relay ( p. 355)
Possible cause Fuel pump relay - value not plausible ( 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) ( p. 357)
Fuel pump relay - the control wire has a short circuit to sensor ground ( p. 357)
86 m
nation of the fault
56 co
Checking the fuel pump relay
Condition
The ignition is on.
9- k.
r
99 a

7- Sh
– Select "Fuel pump relay function test".
87 rt
Fuel pump Operating noise

a

P

Fuel pump relay - value not plausible ( 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

– Replace the fuel pump relay.

Fuel pump relay - the control wire has an open ( p. 356)
Fuel pump relay - the control wire has an open

Condition
86 m
600850-12 400653-10
56 co
Fuel pump relay - check the control wire for opens
Break out box CO pin 2 – Fuel pump relay connector EB pin 2
9- k.
– Check EFI control unit connector CO ( p. 397) pin 2 and connector ES ( p. 402) pin 15.
– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for opens.
r
– Check connector ET ( p. 402) pin 15 and connector EB ( p. 401) pin 2.
99 a
– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for opens.
7- Sh

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
87 rt
The ignition is on.

a
P
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.
– 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)
Condition
86 m
56 co
600850-12 400658-10
Fuel pump relay - check the control wire for a short circuit to ground (terminal 31)
9- k.
Resistance ∞Ω
r
– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for a short circuit to
99 a
– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to ground (termi-
nal 31).
7- Sh

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
87 rt
Condition
a

P
600850-12 600850-11
Fuel pump relay - check the control wire for a short circuit to sensor ground.
Resistance ∞Ω
sensor ground.
– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to sensor ground.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Fuel pump relay"
"Short circuit to plus"
The engine is switched off: ≥ 3 s
Function check Checking the fuel pump relay ( p. 359)
Possible cause Fuel pump relay - value not plausible ( 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. 360)
86 m
nation of the fault
Checking the fuel pump relay
56 co
Condition
The ignition is on.
9- k.
r
99 a
– Select "Fuel pump relay function test".
7- Sh
Fuel pump Operating noise
87 rt

a

P
Fuel pump relay - value not plausible ( p. 359)
Fuel pump relay - value not plausible

Condition
Fuel pump relay - check the resistance
Fuel pump relay pin 1 – Fuel pump relay pin 2
Fuel pump relay

– Replace the fuel pump relay.
Fuel pump relay - the control wire has a short circuit to plus (terminal 30)
( p. 360)
Fuel pump relay - the control wire has a short circuit to plus (terminal 30)
Condition
86 m
600850-12 400658-10
Fuel pump relay - check the control wire for a short circuit to plus (terminal 30)
56 co
Voltage ≤ 0.1 V
9- k.
plus (terminal 30).
– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to plus
(terminal 30).
r
99 a
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)
7- Sh
Condition
87 rt

a
P
600850-12 600850-11
Fuel pump relay - check the signal wire for a short circuit to ignition plus (terminal 15)
Resistance ∞Ω
– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to ignition plus (ter-
minal 15).

lamp (MIL)
"Side stand switch (A/D type)"
"Circuit fault"
Error level condition Fault present: ≥ 3.2 s
Side stand switch voltage: ≤ 0.996 V
Function check Checking the side stand switch ( p. 361)
Possible cause 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 ground (terminal 31) ( p. 362)
nation of the fault
86 m
Checking the side stand switch
Condition
The ignition is on.
56 co
9- k.
r
99 a
– Highlight "Side stand switch (SSTAND AD)" and deselect the other parameters with "Select live data".
Side stand voltage "Side stand AD"
7- Sh
Retracted 1.5… 3.2 V

Extended 4.0… 5.0 V
87 rt

a

Side stand switch - the signal wire has a short circuit to sensor ground ( p. 361)
P
Side stand switch - the signal wire has a short circuit to sensor ground
Condition
The electric starter lock control unit connector is disconnected. ( p. 88)
The side stand switch is disconnected. ( p. 40)
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 ∞Ω
nector AR pin 3 for a short circuit to sensor ground.

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)
Condition
The electric starter lock control unit connector is disconnected. ( p. 88)
The side stand switch is disconnected. ( p. 40)
86 m
56 co
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 (−)
9- k.
Resistance ∞Ω
r
– Check the cable from EFI control unit connector AO ( p. 392) pin 26 to connector AR pin 3 for a short circuit to ground (ter-
minal 31).
99 a

7- Sh
87 rt
a
P

lamp (MIL)
"Rollover sensor (A/D type)"
Error level condition Signal voltage "rollover sensor (A/D type)": ≤ 0.352 V
Time: ≥ 3 s
Function check Checking the rollover sensor ( p. 363)
Possible cause Rollover sensor - there is an open in the power supply ( p. 363)
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 sensor ground ( p. 364)
86 m
nation of the fault
Checking the rollover sensor
56 co
Condition
The ignition is on.
9- k.
r
99 a
– Highlight "Rollover sensor (A/D type)" and deselect the other parameters with "Select live data".
7- Sh
Rollover sensor
Voltage (Rollover AD) "no fall detected" 0.4… 1.4 V
Voltage (Rollover AD) "fall detected" 3.7… 4.1 V
87 rt

a

P
Rollover sensor - there is an open in the power supply ( p. 363)
Rollover sensor - there is an open in the power supply

Condition
The ignition is on.
The rollover sensor is disconnected. ( p. 226)
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 (−)

86 m
– Check connector AP pin 6.
– Check the cable from connector AP pin 6 to the next node in the wiring harness for opens.
56 co
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)
9- k.
Condition
r
99 a
7- Sh
87 rt
600850-11 400658-10
Rollover sensor - check the signal wire for a short circuit to ground (terminal 31)
a

P
Resistance ∞Ω
– 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
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
Rollover sensor - check the signal wire for a short circuit to sensor ground
Resistance ∞Ω
nector AP ( p. 393) pin 5 for a short circuit to sensor ground.
600850-11
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
"Rollover sensor (A/D type)"
Error level condition 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 ( p. 366)
Possible cause Rollover sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 366)
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 the sensor power supply ( p. 367)
86 m
Rollover sensor - the signal wire has an open ( p. 368)
Rollover sensor - the ground wire has an open ( p. 368)
56 co
nation of the fault
Checking the rollover sensor

Condition
9- k.
The ignition is on.
r
99 a
7- Sh

– Highlight "Rollover sensor (A/D type)" and deselect the other parameters with "Select live data".
Rollover sensor
87 rt
Voltage (Rollover AD) "no fall detected" 0.4… 1.4 V

Voltage (Rollover AD) "fall detected" 3.7… 4.1 V
a

P

Rollover sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 366)
Rollover sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
600850-11 400658-10
Rollover sensor - check the signal wire for a short circuit to plus (terminal 30)
Voltage < 0.1 V

86 m
– 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
plus (terminal 30).
56 co
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)
9- k. Condition
r
Rollover sensor - check the signal wire for a short circuit to ignition plus (terminal 15)
99 a

7- Sh
Resistance ∞Ω
nector AP ( p. 393) pin 5 for a short circuit to ignition plus (terminal 15).
87 rt

600850-11
Rollover sensor - the signal wire has a short circuit to the sensor power supply
a
( p. 367)
P
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 ∞Ω
nector AP ( p. 393) pin 5 for a short circuit to the sensor power supply.
600850-11
Rollover sensor - the signal wire has an open ( p. 368)
Rollover sensor - the signal wire has an open

Condition
86 m
600850-11 400583-10
Rollover sensor - check the signal wire for opens

Break Out Box AO pin 4 – Rollover sensor connector AP pin 5
56 co
– Check EFI control unit connector AO ( p. 392) pin 4 and connector AP pin 5.
9- k.
– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP pin 5 for opens.
r
Rollover sensor - the ground wire has an open ( p. 368)
99 a
Rollover sensor - the ground wire has an open

Condition
7- Sh

87 rt
a
P
600850-11 400583-10
Rollover sensor - check the ground wire for opens

Break Out Box AO pin 7 – Rollover sensor connector AP pin 4
– Check EFI control unit connector AO ( p. 392) pin 7 and connector AP pin 4.
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector AP pin 4 for opens.

lamp (MIL)
"Immobilizer control unit"
"Circuit fault"
Possible cause The ICU is faulty ( p. 369)
Last measure if none of the doc- – Correct the immobilizer fault.
nation of the fault
The ICU is faulty

Condition
The ignition is on.
86 m
– Read out the blink code at the immobilizer indicator lamp .
Immobilizer indicator lamp flashes
56 co
– Correct the immobilizer fault.
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
Error level condition Manifold absolute pressure sensor cylinder 2, voltage "PM2AD": ≤ 0.508 V
Time: ≥ 1 s
Possible cause Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground
( p. 371)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ground (termi-
nal 31) ( p. 371)
86 m
nation of the fault
56 co
Condition
The ignition is on.
9- k.
r
99 a
7- Sh

87 rt
at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V
at: 450 mbar (6.53 psi) 1.92… 1.98 V
a
at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V
P
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
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground ( p. 371)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground
Condition
sensor ground
Manifold absolute pressure sensor cylinder 2 connector DP pin 2 – Manifold
absolute pressure sensor cylinder 2 connector DP pin 3
Resistance ∞Ω
400590-10 ( p. 392) pin 3 for a short circuit to sensor ground.
86 m
56 co
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)
Condition
9- k.
r
99 a
7- Sh
400590-10 400658-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to ground (terminal 31)
87 rt

Manifold absolute pressure sensor cylinder 2 connector DP pin 3 – Measuring point Ground (−)
a
Resistance ∞Ω
P
minal 31).
Manifold absolute pressure sensor cylinder 2 - the power supply is interrupted

Condition
The ignition is on.
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 (−)

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

lamp (MIL)
Error level condition Manifold absolute pressure sensor cylinder 2, voltage "PM2AD": ≥ 4.922 V
Time: ≥ 1 s
Possible cause Manifold absolute pressure sensor cylinder 2 - the signal wire has an open ( p. 374)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 375)
86 m
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
56 co
nation of the fault
9- k.
Condition
The ignition is on.
r
99 a

7- Sh

–
87 rt
Press "Continue".
a
at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V
P
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
Manifold absolute pressure sensor cylinder 2 - the signal wire has an open ( p. 374)
Manifold absolute pressure sensor cylinder 2 - the signal wire has an open
Condition
86 m
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
56 co
9- k.
r
99 a
Manifold absolute pressure sensor cylinder 2 - the ground wire has an open
Condition
7- Sh

87 rt
a
P
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
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 plus (terminal 30)
Condition
86 m
600850-11 400658-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30)
56 co
Voltage < 0.1 V
9- k.
plus (terminal 30).
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 375)
r
99 a
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
7- Sh

87 rt

a
Resistance ∞Ω
P
600850-11
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply
Condition
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to the
sensor power supply
Resistance ∞Ω
600850-11
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

lamp (MIL)
Display on diagnostic tool 1690
"CAN bus communication error"
CAN communication: data format and CAN reply - incorrect data format: ≥ 10 s
Possible cause Combination instrument - the CAN-high wire has an open ( p. 377)
Combination instrument - the CAN-low wire has an open ( p. 378)
Combination instrument - the CAN-high wire has an open ( p. 378)
Immobilizer control unit - the CAN-low wire has an open ( p. 379)
CAN-high - the signal wire has a short circuit to ground (terminal 31) ( p. 379)
CAN-low - the signal wire has a short circuit to ground (terminal 31) ( p. 380)
86 m
CAN-high - the signal wire has a short circuit to sensor ground ( p. 381)
CAN-low - the signal wire has a short circuit to sensor ground ( p. 381)
CAN bus terminating resistor - the CAN-high wire has an open ( p. 382)
56 co
CAN bus terminating resistor - the CAN-low wire has an open ( p. 383)
Connector CU - the CAN-high wire has an open ( p. 383)
Connector CU - the CAN-low wire has an open ( p. 384)
Diagnostics connector - the CAN-high wire has an open ( p. 384)
9- k. Diagnostics connector - the CAN-low wire has an open ( p. 385)
CAN-high - the signal wire has a short circuit to plus (terminal 30) ( p. 385)
CAN-low - the signal wire has a short circuit to plus (terminal 30) ( p. 386)
r
CAN-high - 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) ( p. 387)
99 a
CAN-high - the signal wire has a short circuit to the sensor power supply ( p. 388)
CAN-low - the signal wire has a short circuit to the sensor power supply ( p. 389)
7- Sh
CAN bus terminating resistor - value not plausible ( p. 389)

nation of the fault
87 rt
Combination instrument - the CAN-high wire has an open

Condition
a

The diagnostics tool is disconnected.
P

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

– Check EFI control unit connector CO ( p. 397) pin 19 and connector EV pin 4.
– Check the cable from EFI control unit connector CO ( 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

Condition
86 m
56 co
9- k.
600850-12 400645-10
Combination instrument - check the CAN-low wire for opens

r
Break out box CO pin 20 – Combination instrument connector EV pin 5
99 a
7- Sh

– Check EFI control unit connector CO ( p. 397) pin 20 and connector EV pin 5.
– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector EV pin 5 for opens.
87 rt

Combination instrument - the CAN-high wire has an open ( p. 378)
a
Combination instrument - the CAN-high wire has an open

Condition
P

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

– Check EFI control unit connector CO ( p. 397) pin 19 and connector DO pin 6.
– Check the cable from EFI control unit connector CO ( 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

Condition
86 m
56 co
9- k.
600850-12 400657-10
Immobilizer control unit - check the CAN-low wire for opens

r
Break out box CO pin 20 – Immobilizer control unit, connector DO pin 8
99 a
7- Sh

– Check EFI control unit connector CO ( p. 397) pin 20 and connector DO pin 8.
– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector DO pin 8 for opens.
87 rt

CAN-high - the signal wire has a short circuit to ground (terminal 31) ( p. 379)
a
CAN-high - the signal wire has a short circuit to ground (terminal 31)
Condition
P

600850-12 400658-10
CAN-high - check the signal wire for a short circuit to ground (terminal 31)
Resistance ∞Ω

– Check the cable from connector EV ( p. 403) pin 4 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit to
– Check the cable from connector DO ( p. 400) pin 6 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit to
– Check the cable from connector AT ( p. 395) pin 2 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit to
– Check the cable from connector AP ( p. 393) pin 2 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit to
– Check the cable from connector CU ( p. 398) pin 3 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit to
CAN-low - the signal wire has a short circuit to ground (terminal 31) ( p. 380)
86 m
CAN-low - the signal wire has a short circuit to ground (terminal 31)
Condition
56 co
9- k.
r
99 a
7- Sh
600850-12 400658-10
CAN-low - check the signal wire for a short circuit to ground (terminal 31)
87 rt
Resistance ∞Ω
a

– Check the cable from connector EV ( p. 403) pin 5 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit to
P

– Check the cable from connector DO ( p. 400) pin 8 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit to
– Check the cable from connector AT ( p. 395) pin 1 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit to
– Check the cable from connector AP ( p. 393) pin 3 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit to
– Check the cable from connector CU ( p. 398) pin 4 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit to
CAN-high - the signal wire has a short circuit to sensor ground ( p. 381)
CAN-high - the signal wire has a short circuit to sensor ground

Condition
86 m
600850-12 600850-11
56 co
CAN-high - check the signal wire for a short circuit to sensor ground
Resistance ∞Ω
9- k.
– Check the cable from connector EV ( p. 403) pin 4 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuit
to sensor ground.
r
– Check the cable from connector DO ( p. 400) pin 6 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuit
to sensor ground.
99 a
– Check the cable from connector AT ( p. 395) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuit
to sensor ground.
7- Sh
– Check the cable from connector AP ( p. 393) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuit
to sensor ground.
– Check the cable from connector CU ( p. 398) pin 3 to the EFI control unit connector CO ( p. 397) pin 19 for a short cir-
cuit to sensor ground.
87 rt

CAN-low - the signal wire has a short circuit to sensor ground ( p. 381)
a
CAN-low - the signal wire has a short circuit to sensor ground

Condition
P

600850-12 600850-11
CAN-low - check the signal wire for a short circuit to sensor ground
Resistance ∞Ω
86 m
to sensor ground.
56 co
to sensor ground.
to sensor ground.
to sensor ground.
9- k.
cuit to sensor ground.
r
99 a
CAN bus terminating resistor - the CAN-high wire has an open ( p. 382)
CAN bus terminating resistor - the CAN-high wire has an open

7- Sh
Condition
87 rt

a
P
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
– Check EFI control unit connector CO ( p. 397) pin 19 and connector AT pin 2.
– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector AT pin 2 for opens.
CAN bus terminating resistor - the CAN-low wire has an open ( p. 383)
CAN bus terminating resistor - the CAN-low wire has an open

Condition
86 m
600850-12 400585-10
56 co
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
9- k.
– Check EFI control unit connector CO ( p. 397) pin 20 and connector AT pin 1.
– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector AT pin 1 for opens.
r
99 a

Connector CU - the CAN-high wire has an open ( p. 383)
7- Sh
Connector CU - the CAN-high wire has an open

Condition
87 rt

a

P
600850-12 400588-10
Connector CU - check the CAN-high wire for opens

Break out box CO pin 19 – Connector CU pin 3
– Check EFI control unit connector CO ( p. 397) pin 19 and connector CU pin 3.
– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector CU pin 3 for opens.

Connector CU - the CAN-low wire has an open ( p. 384)
Connector CU - the CAN-low wire has an open

Condition
86 m
56 co
600850-12 400588-10
Connector CU - check the CAN-low wire for opens

9- k.
Break out box CO pin 20 – Connector CU pin 4
r
– Check EFI control unit connector CO ( p. 397) pin 20 and connector CU pin 4.
99 a
– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector CU pin 4 for opens.
7- Sh

Diagnostics connector - the CAN-high wire has an open ( p. 384)
Diagnostics connector - the CAN-high wire has an open

Condition
87 rt

a

P

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
– Check EFI control unit connector CO ( p. 397) pin 19 and connector AP pin 2.
– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector AP pin 2 for opens.
Diagnostics connector - the CAN-low wire has an open ( p. 385)
Diagnostics connector - the CAN-low wire has an open

Condition
86 m
56 co 600850-12 400583-10
9- k.
Diagnostics connector - check the CAN-low wire for opens
Break out box CO pin 20 – Diagnostic connection plug AP pin 3
r
99 a

– Check EFI control unit connector CO ( p. 397) pin 20 and connector AP pin 3.
7- Sh
– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector AP pin 3 for opens.
CAN-high - the signal wire has a short circuit to plus (terminal 30) ( p. 385)
87 rt
CAN-high - the signal wire has a short circuit to plus (terminal 30)
Condition
a

P

600850-12 400658-10
CAN-high - check the signal wire for a short circuit to plus (terminal 30)
Voltage ≤ 0.1 V

to plus (terminal 30).
cuit to plus (terminal 30).
CAN-low - the signal wire has a short circuit to plus (terminal 30) ( p. 386)
86 m
CAN-low - the signal wire has a short circuit to plus (terminal 30)
Condition
56 co
9- k.
r
99 a
7- Sh
600850-12 400658-10
CAN-low - check the signal wire for a short circuit to plus (terminal 30)
87 rt
Voltage ≤ 0.1 V
a

P

CAN-high - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 387)
CAN-high - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
86 m
600850-12 600850-11
56 co
CAN-high - check the signal wire for a short circuit to ignition plus (terminal 15)
Resistance ∞Ω
9- k.
r
99 a
7- Sh
87 rt

CAN-low - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 387)
a
CAN-low - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
P

600850-12 600850-11
CAN-low - check the signal wire for a short circuit to ignition plus (terminal 15)
Resistance ∞Ω
86 m
56 co
9- k.
r
99 a
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
7- Sh
Condition
87 rt

a
P
600850-12 600850-11
CAN-high - check the signal wire for a short circuit to the sensor power supply
Resistance ∞Ω
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
Condition
86 m
56 co
9- k.
r
600850-12 600850-11
99 a
CAN-low - check the signal wire for a short circuit to the sensor power supply
7- Sh
Resistance ∞Ω
87 rt

a
P
CAN bus terminating resistor - value not plausible ( p. 389)
CAN bus terminating resistor - value not plausible

Condition
CAN bus terminating resistor - check the resistor.

CAN bus terminating resistor pin 1 – CAN bus terminating resistor pin 2
CAN bus terminating resistor

– Change the CAN bus terminating resistor.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
CONNECTOR OVERVIEW 391
Motor drive circuit A connector AE

32.1
Pin overview
1 Motor drive circuit A phase BP, control wire
2 Motor drive circuit A phase AN, control wire
3 Motor drive circuit A phase AP, control wire
4 Motor drive circuit A phase BN, control wire
400682-10
Connector AI
32.2
Pin overview
1 Power supply, main relay, fuel pump input
86 m
2 Power supply, main relay, fuel pump output
56 co 400681-10
9- k.
Crankshaft position sensor connector AL
32.3
Pin overview
r
1 Signal wire
2 Signal wire
99 a
7- Sh
400581-10
87 rt
Clutch switch, connector AL

32.4
Pin overview
a
1 Ground
2 Signal wire
P
400581-10
Throttle position sensor circuit A, connector AM

32.5
Pin overview
1 System voltage
2 Signal wire
3 Sensor ground
400582-10
Throttle position sensor circuit B, connector AM

32.6
Pin overview
1 Signal wire
2 Power supply
3 Sensor ground
400582-10
Gear position sensor, connector AM

32.7
Pin overview
1 Signal wire 3rd gear
86 m
2 Signal wire 2nd gear
3 Signal wire, idle
56 co 400582-10
9- k.
Fuel pump connector AM
32.8
Pin overview
r
1 Power supply
2 Not assigned
99 a
3 Ground
7- Sh
400582-10
87 rt
Wheel speed sensor, connector AM

32.9
Pin overview
a
1 Signal wire
2 System voltage
P
3 Ground
400582-10
Connector AO
32.10
Pin overview
1 Sensor voltage supply
2 Throttle position sensor circuit B, signal wire
3 Manifold absolute pressure sensor cylinder 1, signal wire
4 Rollover sensor, signal wire
5 Not assigned
6 Ground (terminal 31)
400642-10
7 Sensor ground
8 Input status, electric starter lock control unit
9 Engine coolant temperature sensor cylinder 1, signal wire
10 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
86 m
23 Ambient air pressure sensor, signal wire
24 Manifold absolute pressure sensor cylinder 2, signal wire
25 Clutch switch, signal wire
56 co
26 Side stand switch, signal wire
Diagnostic connection plug AP

32.11
Pin overview
9- k.
1 System voltage
2 CAN high
3 CAN low
r
4 K bus signal wire to KTM diagnostics tool
99 a
5 Not assigned
6 Ground
7- Sh
400583-10
Rollover sensor connector AP

32.12
Pin overview
87 rt
1 Not assigned
2 Not assigned
3 Not assigned
a
4 Sensor ground
5 Signal wire
P
6 System voltage
400583-10
Throttle position sensor circuit A, connector AR

32.13
Pin overview
1 Power supply
2 Signal wire
3 Sensor ground
400584-10
Throttle position sensor circuit B, connector AR

32.14
Pin overview
1 Signal wire
2 System voltage
3 Sensor ground
400584-10
Fuel pump connector AR

32.15
Pin overview
1 Power supply
86 m
2 Not assigned
3 Ground
56 co 400584-10
9- k.
Side stand switch, connector AR
32.16
Pin overview
r
1 System voltage
2 Sensor ground
99 a
3 Signal wire
7- Sh
400584-10
87 rt
Ignition coil cylinder 1 connector AS

32.17
Pin overview
a
1 Control wire
2 System voltage
P
400644-10
Ignition coil cylinder 2 connector AS

32.18
Pin overview
1 Control wire
2 System voltage
400644-10
CAN bus terminating resistor connector AT

32.19
Pin overview
1 CAN low
2 CAN high
400585-10
Crankshaft position sensor, connector AT

32.20
Pin overview
1 Signal wire
86 m
2 Signal wire
56 co 400585-10
9- k.
Clutch switch connector AT
32.21
Pin overview
r
1 Signal wire
2 Ground
99 a
7- Sh
400585-10
87 rt
Engine coolant temperature sensor cylinder 1 connector AX

32.22
Pin overview
a
1 Sensor ground
2 Signal wire
P
400586-10
Throttle stepper motor circuit B, connector CA

32.23
Pin overview
1 Motor drive circuit B phase AP, control wire
2 Motor drive circuit B phase BP, control wire
3 Motor drive circuit B phase AN, control wire
4 Motor drive circuit B phase BN, control wire
400646-10
Lambda sensor cylinder 1, connector CA

32.24
Pin overview
1 Power supply, lambda sensor heater
2 Lambda sensor heater, control wire
3 Sensor ground
4 Signal wire
400646-10
Lambda sensor cylinder 2, connector CA

32.25
Pin overview
86 m
3 Sensor ground
4 Signal wire
56 co 400646-10
9- k.
Lambda sensor cylinder 1, connector CE
32.26
Pin overview
r
99 a
3 Sensor ground
4 Signal wire
7- Sh
400647-10
87 rt
Lambda sensor cylinder 2, connector CE

32.27
Pin overview
a

P
3 Sensor ground
4 Signal wire
400647-10
Secondary air valve connector CK

32.28
Pin overview
1 Power supply
2 Control wire
400648-10
Connector CM
32.29
Pin overview
1 Sensor ground
2 Signal wire
400650-10
Connector CO
32.30
Pin overview
1 Not assigned
86 m
2 Fuel pump relay, control wire
56 co
5 Injector cylinder 1, control wire
400643-10
9- k.
10 Not assigned
r
99 a
13 Exhaust air injection valve, control wire

14 Tachometer signal wire
7- Sh
15 Lambda sensor heater cylinder 2, control wire

16 EFI warning lamp (MIL)
17 Not assigned
18 Not assigned
87 rt
19 CAN high
20 CAN low
a

P
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
Connector CP
32.31
Pin overview
2.1 Not assigned
2.2 Sensor ground
2.3 Motor drive circuit B phase BN, control wire
2.4 Motor drive circuit A phase BN, control wire
2.5 Injector cylinder 1, control wire
2.6 Throttle position sensor circuit A, signal wire
400651-10
2.7 Motor drive circuit B phase BP, control wire
2.8 Motor drive circuit A phase BP, control wire
2.9 Injector cylinder 2, control wire
2.10 Throttle position sensor circuit B, signal wire
86 m
2.11 Motor drive circuit B phase AN, control wire
2.12 Motor drive circuit A phase AN, control wire
2.13 Intake air temperature sensor, signal wire
56 co
2.14 Sensor power supply
2.15 Motor drive circuit B phase AP, control wire
2.16 Motor drive circuit A phase AP, control wire
Connector CQ
32.32
9- k.
Pin overview
1 Not assigned
r
2 Sensor ground
99 a

7- Sh

6 Throttle position sensor circuit A, signal wire
400652-10
87 rt

10 Throttle position sensor circuit B, signal wire
a

13 Intake air temperature sensor, signal wire
P
14 Sensor power supply

Connector CU
32.33
Pin overview
1 Not in use
2 Ground
3 CAN high
4 CAN low
400588-10
Fuel evaporation valve connector DF

32.34
Pin overview
1 Power supply
2 Control wire
400589-10
Secondary air valve connector DF

32.35
Pin overview
1 Power supply
86 m
2 Control wire
56 co 400589-10
9- k.
Electric starter lock control unit, connector DN
32.36
Pin overview
r
1 Power supply
99 a
3 Starter auxiliary relay

7- Sh
5 Ground
6 Signal wire status, electric starter lock control unit
600859-10
7 Signal wire status, electric starter lock control unit
87 rt
Immobilizer control unit, connector DN

32.37
a
Pin overview
1 Coil antenna
P
2 Coil antenna
3 System voltage
4 System voltage
5 LED
6 CAN high
600859-10
7 Ground
8 CAN low
Electric starter lock control unit, connector DO

32.38
Pin overview
1 System voltage
5 Ground
6 Control wire status, electric starter lock control unit
400657-10
7 EFI control unit, control wire status
Immobilizer control unit, connector DO

32.39
Pin overview
1 Coil antenna
2 Coil antenna
3 Power supply
4 Power supply
5 LED
6 CAN high
400657-10
7 Ground
8 CAN low
Ambient air pressure sensor connector DP

32.40
Pin overview
86 m
1 System voltage
2 Sensor ground
3 Signal wire
56 co
9- k. 400590-10
Manifold absolute pressure sensor cylinder 1, connector DP

32.41
Pin overview
r
1 System voltage
99 a
2 Sensor ground
3 Signal wire
7- Sh
87 rt
400590-10
Manifold absolute pressure sensor cylinder 2 connector DP

32.42
a
Pin overview
1 System voltage
P
2 Sensor ground
3 Signal wire
400590-10
Injector cylinder 1 connector DQ

32.43
Pin overview
1 Power supply
2 Control wire
400591-10
Injector cylinder 2 connector DQ

32.44
Pin overview
1 Power supply
2 Control wire
400591-10
ICU antenna connector DV

32.45
Pin overview
1 Coil antenna
86 m
2 Coil antenna
56 co 400593-10
9- k.
Fuel pump relay connector EB
32.46
Pin overview
r
1 Control circuit, power supply
2 Control wire
99 a
3 Component power supply

7- Sh
400653-10
87 rt
ICU antenna connector EL

32.47
Pin overview
a
1 Coil antenna
2 Coil antenna
P
400685-10
Connector EQ
32.48
Pin overview
1 Not assigned
2 LED alarm system (optional), signal wire
4 Power supply (terminal 15)
5 CAN high
6 Not assigned
400683-10
10 CAN low
Connector ER
32.49
Pin overview
1 Not assigned
5 CAN high
6 Not assigned
400684-10
86 m
10 CAN low
Connector ES
32.50
56 co
Pin overview
1 Power supply (terminal 15) fuse 3
9- k.
5 Brake light switch, control wire
r
400654-10
7 Right turn signal, control wire
99 a
8 Left turn signal, control wire

9 Not assigned
7- Sh
10 Not assigned
11 Not assigned
12 Not assigned
87 rt

16 Power supply, main relay, fuel pump
a

18 Power supply, start auxiliary relay, working circuit
P
Connector ET
32.51
Pin overview
5 Brake light switch, control wire
400655-10
7 Right turn signal, control wire
8 Left turn signal, control wire
9 Not assigned
10 Not assigned
11 Not assigned
12 Not assigned

16 Power supply, main relay, fuel pump
18 Power supply, start auxiliary relay, working circuit
Combination instrument connector EV

32.52
Pin overview
1 Power supply
2 Power supply
3 Ground
4 CAN high
5 CAN low
86 m
400645-10
8 Fuel level indicator, signal wire
9 Wheel speed sensor, signal wire
56 co
10 Tachometer, signal wire
11 Sensor power supply
12 Ambient air temperature sensor, signal wire
13 Not assigned
9- k.
14 Ground
15 Oil pressure sensor, signal wire
16 High beam indicator light
r
99 a
18 Ground
7- Sh
20 EFI warning lamp (MIL)

21 LAP button, signal wire
22 MODE button, signal wire
23 Turn signal, signal wire
87 rt
24 Not assigned
25 Not assigned
26 Not assigned
a
Exhaust air injection valve, connector FE

P
32.53
Pin overview
1 System voltage
2 Control wire
600854-10
Fuel pump relay

32.54
Pin overview
1 Control circuit power supply
2 Control wire
3 Fuel pump power supply
600852-10
CAN bus terminating resistor

32.55
Pin overview
86 m
1 CAN low
2 CAN high
56 co
9- k.
r
600857-10
99 a
7- Sh
87 rt
a
P
TECHNICAL DATA - ENGINE 405
Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled

Displacement 1,195 cm³ (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
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)
Crankshaft bearing Sleeve bearing
86 m
Conrod bearing Sleeve bearing
Piston pin bearing No bearing bushes - DLC-coated piston pins
Piston Forged light alloy
56 co
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
9- k. Multi-disc clutch in oilbath / hydraulically operated
Transmission 6-speed claw gears
Transmission ratio
r
1st gear 14:36
99 a
2nd gear 16:30

3rd gear 20:30
7- Sh
4th gear 21:27

5th gear 23:26
6th gear 25:26
Mixture preparation Electronically controlled fuel injection
87 rt
Ignition system Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Generator 12 V, 390 W
a
Spark plug NGK LKAR9BI9

Electrode gap, spark plug 0.8… 0.9 mm (0.031… 0.035 in)
P
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.) External temperature: ≥ 0 °C Engine oil (SAE 10W/50)
(≥ 32 °F) ( p. 436)
External temperature: < 0 °C Engine oil (SAE 5W/40)
(< 32 °F) ( p. 436)
TECHNICAL DATA - ENGINE 406
Capacity - coolant
33.2
Coolant 2.60 l (2.75 qt.) Coolant ( p. 436)

Coolant (mixed ready to use) ( p. 436)
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 407
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
Valve guide - diameter
Valve - sealing seat width
Intake: New condition 1.0 mm (0.039 in)
Intake: Wear limit 1.7 mm (0.067 in)
86 m
Exhaust: New condition 1.0 mm (0.039 in)
Exhaust: Wear limit 2.0 mm (0.079 in)
Valve - run-out
56 co
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)
9- k.
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
r
New condition 42.0 mm (1.654 in)
99 a

Cylinder head - bearing hole of camshaft 24.000… 24.021 mm (0.94488… 0.94571 in)
7- Sh
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)
87 rt
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)
a
Piston/cylinder - mounting clearance

P

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
Connecting rod - radial clearance of lower conrod bearing
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 408

Connecting rod - large end width 20.950… 21.000 mm (0.8248… 0.82677 in)
Crankshaft - axial clearance
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
Yellow 53.965… 53.975 mm (2.1246… 2.125 in)
86 m
Blue 53.976… 53.985 mm (2.12504… 2.12539 in)
Red 53.986… 53.995 mm (2.12543… 2.12578 in)
Crankshaft - radial clearance of main bearing
56 co
Crankshaft - step bearing diameter 27.985… 28.000 mm (1.10177… 1.10236 in)
Crankshaft - radial clearance of step bearing
9- k.
Clutch facing disc - thickness
r
99 a

Intermediate disk - thickness
7- Sh

Clutch discs - thickness of total package
87 rt

Clutch spring - length 33.00… 34.00 mm (1.2992… 1.3386 in)
Outer clutch hub - contact surface of clutch facing discs
a

Oil pressure regulator valve - minimum spring length 40.5 mm (1.594 in)
P
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)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 409
Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) –

Remaining engine screws M5 6 Nm (4.4 lbf ft) –
Screw, bearing retainer 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™
Camshaft drive sprocket bolt 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™
Remaining engine screws M6 10 Nm (7.4 lbf ft) –
Screw, camshaft bearing support 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™
86 m
Screw, coolant connection on cylinder M6 10 Nm (7.4 lbf ft) –
head
Screw, engine case M6x60 10 Nm (7.4 lbf ft) –
56 co
Screw, freewheel holder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, generator cover M6 10 Nm (7.4 lbf ft) –
9- k.
Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, oil pump cover M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
r
Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 243™
99 a
Screw, starter motor M6 10 Nm (7.4 lbf ft) –

Screw, stator clamp M6 10 Nm (7.4 lbf ft) Loctite® 243™
7- Sh
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) –
87 rt
Vacuum connection M6 5 Nm (3.7 lbf ft) Loctite® 243™

Jet 140 M6x0.75 4 Nm (3 lbf ft) Loctite® 243™
Loctite® 243™
a
Oil jet M6x0.75 4 Nm (3 lbf ft)

Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft) –
P
Plug, crankshaft retainer M8 15 Nm (11.1 lbf ft) –

Screw, camshaft bearing support M8 Step 1 –
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
Screw, camshaft bearing support M8 Step 1 Only applies when using:
8.5 Nm (6.27 lbf ft) Hex key bit
Step 2 (61229025000)
14.5 Nm (10.7 lbf ft) ( p. 446)
Screw, engine case M8 18 Nm (13.3 lbf ft) –
Screw, engine console 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™
Screw, timing chain tensioning rail 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) –
Plug, clutch lubrication M10x1 15 Nm (11.1 lbf ft) –
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 410
Screw, conrod bearing M10x1 Step 1 –

25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) –
Cylinder head screw M11x1.5 Tightening sequence: lubricated with engine oil
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
86 m
90°
Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –
Rotor screw M12x1.5 90 Nm (66.4 lbf ft) –
56 co
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™
9- k.
Plug, timing-chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –
Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft) –
Nut, primary gear M33LHx1.5 130 Nm (95.9 lbf ft) Loctite® 243™
r
99 a
7- Sh
87 rt
a
P
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
Front 320 mm (12.6 in)
Rear 220 mm (8.66 in)
86 m
Brake discs - wear limit
Front 4.5 mm (0.177 in)
Brake disc - wear limit
56 co
Rear 4.5 mm (0.177 in)
Tire air pressure, Solo
9- k.
Tire air pressure with passenger / full payload
r
Secondary drive 17:37
99 a
Chain 5/8 x 5/16” X‑ring

Steering head angle 66.7°
7- Sh
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)
87 rt
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.)
a
Maximum permissible rear axle load 240 kg (529 lb.)

Maximum permissible total weight 380 kg (838 lb.)
P
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
Lighting equipment
36.1
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 12 V
5W
TECHNICAL DATA - CHASSIS 412
Front tire Rear tire

120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL
Pirelli Dragon Supercorsa Pro 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, 16.5 l (4.36 US gal) Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 437)
approx.
Fuel reserve, approx. 3.5 l (3.7 qt.)
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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
Rebound damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
86 m
Comfort 5 turns
Standard 5 turns
Sport 3 turns
56 co
Spring length with preload spacer(s) 405 mm (15.94 in)
Spring rate
Medium (standard) 9.5 N/mm (54.2 lb/in)
9- k.
Air chamber length 80+20 +0.79
−10 mm (3.15−0.39 in)
Fork length 735 mm (28.94 in)

r
Fork oil per fork leg 520 ml (17.58 fl. oz.) Fork oil (SAE 5) ( p. 437)
99 a
7- Sh
87 rt
a
P
TECHNICAL DATA - SHOCK ABSORBER 414
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
Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Rebound damping
86 m
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
56 co
Spring preload
Comfort 6 mm (0.24 in)
9- k.
Spring rate
r
Medium (standard) 95 N/mm (542 lb/in)
99 a
Spring length 160 mm (6.3 in)

7- Sh
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)
87 rt
a
P
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 415
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite® 243™

Remaining frame bolts M5 5 Nm (3.7 lbf ft) –
Screw, brake fluid reservoir of rear M5 5 Nm (3.7 lbf ft) Loctite® 243™
brake
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™
Remaining chassis nuts M6 15 Nm (11.1 lbf ft) –
Remaining chassis screws M6 10 Nm (7.4 lbf ft) –
86 m
Screw for wheel speed sensor bracket M6 3 Nm (2.2 lbf ft) Loctite® 243™
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft) –
Screw, exhaust heat shield M6 15 Nm (11.1 lbf ft) –
56 co
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™
9- k.
Screw, shift rod M6 12 Nm (8.9 lbf ft) Loctite® 243™
Screw, shift shaft deflector on chain M6 10 Nm (7.4 lbf ft) Loctite® 243™
securing guide
r
Screw, shift shaft deflector on shift M6 18 Nm (13.3 lbf ft) Loctite® 243™
shaft
99 a
Fork end pinch bolts M8 15 Nm (11.1 lbf ft) –

Nut, forked bracket on foot brake pedal M8 30 Nm (22.1 lbf ft) Loctite® 243™
7- Sh

Screw of rear brake caliper M8 22 Nm (16.2 lbf ft) Loctite® 243™
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
87 rt
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™
a
Screw, handlebar stub M8 20 Nm (14.8 lbf ft) –

Screw, ignition lock (ratchet screw) M8 Loctite® 243™
P
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 M8 15 Nm (11.1 lbf ft) Loctite® 243™
bracket
Screw, steering damper clamp on con- M8 20 Nm (14.8 lbf ft) Loctite® 243™
sole
Screw, steering damper fixing bracket M8 10 Nm (7.4 lbf ft) Loctite® 243™
on triple clamp
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, subframe M8 20 Nm (14.8 lbf ft) Loctite® 243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Screw, work stand adapter M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, connecting lever, shock M10 45 Nm (33.2 lbf ft) Loctite® 243™
absorber deflector
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 416
Screw, engine bearer M10 45 Nm (33.2 lbf ft) –

Screw, shock absorber 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™
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Nut of bell crank on frame 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) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased
Screw, steering head M25x1.5 18 Nm (13.3 lbf ft) –
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
CLEANING/CONSERVATION 417
Cleaning motorcycle
40.1
Note
Material damage Damage 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 electri-
cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
86 m
– Before cleaning, seal the exhaust system to prevent water from entering.
– Remove loose dirt first with a soft jet of water.
56 co
– 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.
9- k.
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.
r
Warning
99 a
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.
7- Sh
– 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.
87 rt
– After the engine has cooled down, lubricate or grease all moving parts and bearings.
– Treat bare metal (except for brake discs and the exhaust system) with an anticorrosive.
a
Cleaning and polishing materials for metal, rubber and plastic ( p. 438)
P
– 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. ( p. 417)

– Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.
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 418
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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. ( p. 417)
– Change the engine oil and filter, clean the oil screens. ( p. 209)
– Check the antifreeze. ( p. 194)
– Check the tire pressure. ( p. 79)
– Remove the battery. ( p. 88)
86 m
– Recharge the battery. ( p. 90)
Guideline
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F)
56 co
– The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends jacking up the motorcycle.
9- k.
– Jack up the motorcycle at the front. ( p. 10)
– Cover the motorcycle with a porous sheet or blanket.
r
99 a
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
7- Sh
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. ( p. 10)
87 rt

– Recharge the battery. ( p. 90)
– Install the battery. ( p. 89)
a

– Fill up with fuel.
P
– Make checks before putting into operation.

SERVICE SCHEDULE 420
Important service tasks to be carried out by an authorized KTM-RC8 workshop.

42.1
K10N K75A K150A J1A J2A

Engine Change the engine oil and filter, clean the oil screens. ( p. 209) • • • • •
Check the valve clearance. ( p. 200) •
Replace the spark plugs. •
Check the engine attachment bolts and other engine bolts accessi-
• • •
ble from outside to ensure that they are tight.
Check the clutch. •
Check / clean the oil jet for clutch lubrication. ( p. 216) •
Fuel injection Read out the status request and fault memory with the KTM diag-
• • •
nostics tool.
Check bellows for tears and leaks, and check the linkage of the
•
throttle valve spigot for freedom of movement.
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.
56 co
Check the fuel hose for damage, correct routing and leaks. • • • • •
Check the fuel pressure. ( p. 73) • •
Attachments Check the cooling system for leaks. • • • • •
Check the water pump for leaks (visual check). • • •
9- k.
Check the coolant level. ( p. 194) • • • • •
Check the antifreeze. ( p. 194) • • • • •
Check radiator fan operation. • • •
r
Check the exhaust system for leaks and correct fitting and check
• • •
99 a
that the exhaust brackets are tight.

Check the control cables for damage, smooth operation, kink-free
• • • • •
7- Sh
routing and adjustment.

Check the fluid level of the hydraulic clutch. ( p. 191) • • • •
Check the air filter and change if necessary. Clean the air filter
•
box.
Drain the drainage hose of the air filter box. • • • • •
87 rt
Check cables for damage and kink-free routing. • • •

Check the headlight setting. ( p. 110) • • • • •
a
Check that the electrical equipment is functioning properly. • • • • •

Check the fairing parts for damage and breakage. • • •
P
Check the fasteners for tightness. • • •

Brakes Check the front brake linings. ( p. 93) • • •
Check the rear brake linings. ( p. 96) • • •
Check the front brake discs. ( p. 80) • • •
Check the rear brake disc. ( p. 83) • • •
Check the front brake fluid level. ( p. 95) • • • • •
Check the rear brake fluid level. ( p. 99) • • • • •
Change brake fluid. • •
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. • • •
Chassis Check the operation of the forks and the rear shock absorber, also
• • • • •
check for leaks.
Bleed fork legs. ( p. 16) • • • • •
Check the steering head bearings and adjust if necessary. • • •
Check the swingarm bearings. • • •
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. ( p. 78) • • •
Check the tire pressure. ( p. 79) • • • • •
Check the chain wear. ( p. 86) • • •
Check the rear sprocket / engine sprocket / chain sliding guard to
• • •
ensure that they are tight.
Check the rear sprocket / engine sprocket for wear. ( p. 85) • • •
Check the chain tension. ( p. 84) • • •
Clean the chain. ( p. 84) • • • • •
Check chain sliding guard. ( p. 86) • • • • •
Check wheel bearings for play. • • •
Check the rear hub cush drive. ( p. 86) • • • • •
86 m
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
56 co
J2A: every 2 years
Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job)
42.2
K150N K150A K300A J1A J2N J2A J4A

9- k.
Perform a fork service. ( p. 21) • • • •
Perform a shock absorber service. ( p. 48) • •
Clean and grease the steering head bearing and sealing elements. • • • •
r
Clean the battery terminals and treat with contact grease. • • •
99 a
Change the coolant. • •

K150N: after 15,000 km (9,320 mi)
7- Sh
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
87 rt
J4A: every 4 years

a
P
422
1 2 3 4 5 6 7 8
600859-01
-V1 4,5,6 lig-X3
/3.A7
A A
-S1 -S2 gn
-X3
1 1
BI/2 EL/2 BK/4 AI/2
AU/2 DV/2 BR/4
1 2 11,12,13 30
-X4 A
1 2 2 1 1 2 3 4 M
12
13
11
-K1 -G1
2
3
24,25
-M1
175
176
177
86 m
86
32
7,8,9,10,14
82,177
1 1 1 1 1 AF/4 1
178
146
145
-F1 -F2 -F5 -F6 -F8

#Ant-1 4 3 2 1 2
/2.B3
#Ant-2
/2.B3
68 2 U
39
38
10
AU/2
9
BI/2
10A 15A 10A 10A 10A
69 1
2 2 2 2 2 -N1
144,153,169,182 -X1
B /3.D1 B
20
15
16
19
21
EM/3
EN/3
83 fuel-A4
-X405
56 co
/2.E5
81 STR-A3 7 1 1 68
/2.B5
175,176,144,153,169,182
74 ACC1 16 2 2 71 tlig-H1
/3.B6 /3.E1
66 3 3 70 GND#1
/2.C2
3 G
-X403 8 4 4 69
74 3 3 21 -G2
AF/4 EU/4
81 13 13 35
9- k.
82 14 14 31
83 15 15 26
84 84 16 16 32
-X1
C 178 -X2 85 17 17 15 C
86 18 18 37
95
ES/18 ET/18
98,152,147
r
64 2
-X401
99 a
2 93 #702 147 B+
7- Sh
/2.B3 /2.B3
65 4 4 95
63 8 8 98 152 B+
D /3.B2 D
ER/10 EQ/10
87 rt flaL-X200
/3.D6
33,62
-X5
27,28,30,39,46,66 46
29
GND#1
K4-X8
/2.B1
/2.C1
54,55
flaR-X200
/3.D6
GND#1
/3.D6
E E
a
WIRING DIAGRAM
62
34
58
57
33
34
63
60
64
65
60
61
61
36,37
30
38
36
35
26
24
23
27
23
29
25
28
20
31
19
14
1
2 1
BS/2
4 2 1 3 BV/2
4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3
-A1
1
EF/14
2 3 4 5 6 7 8 9 10 11 12 13 14
P BP/4
DG/4
-X150 -S3
EB/4
-K2
3
AM/3
AR/3
2
M
1
-M2
EB/4
-K3
EB/4
-K4
EB/4
-K5
F F
Page:1
1 of 3
1190 RC8 (R) 2009 3 P.
1 2 3 4 5 6 7 8
43.1
WIRING DIAGRAM 423
Components
A1 Plug-in connector for alarm system (optional) F1‑2
G1 Battery A7
G2 Generator B‑C8
K1 Starter relay with main fuse A6
K2 Fuel pump relay F4
K3 Light relay F5‑6
K4 Power relay F6
K5 Start auxiliary relay F7
M1 Starter motor A‑B6
M2 Fuel pump F5
N1 Voltage regulator/rectifier B8
S1 Ignition/steering lock, ICU antenna A1‑2
86 m
S2 Emergency OFF switch, electric starter button A2‑3
S3 Seat monitoring switch (optional) F3‑4
V1 Diode A4
56 co
X150 Resistance F3
Cable colors
gn Green
1 Green
9- k.
2 Green
3 Green
4 Green
r
5 Green
99 a
6 Green
7 White-red
7- Sh
8 White-red
9 White-red
10 White-red
11 White-red
87 rt
12 White-red
13 White-red
14 White-red
a
15 White-red
16 Yellow
P
19 Black-yellow
20 Black-green
21 Yellow-red
23 Black-blue
24 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
WIRING DIAGRAM 424
37 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
86 m
65 Yellow-orange
66 Brown
68 White-red
56 co
69 White-red
70 Brown
71 Yellow
74 Yellow-red
9- k.
81 Green-orange
82 Red
83 Blue-gray
r
84 Yellow-orange
99 a
85 White-red
86 Red-violet
7- Sh
93 Blue-red
95 Yellow-orange
98 White-red
144 Yellow-orange
87 rt
145 Green
146 Black-green
147 White-red
a
152 White-red
153 Yellow-orange
P
169 Yellow-orange
175 Yellow-orange
176 Yellow-orange
177 Red
178 White-red
182 Yellow-orange
P
WIRING DIAGRAM
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
425
426
1 2 3 4 5 6 7 8
600860-01
-X50 AP/6
-X51 -A2 -A3
1 2 3 4 5 6
A AL/2
A
AT/2 -Y1 -B1
3th 2nd N
1 2 DN/8 -S4 DO/8
DF/2 DO/8 DN/8
AM/3
1 2 1 2 3 4 5 6 7 8 AR/3 AR/3
1 2 3 4 5 6 7 8
-B12 -B13
1 3 2 AM/3
202
222
226
227
228
229
230
STR-A3 81
AM/3 AR/3
260
145
146
147
148
149
150
151
1 2 3
AR/3 AM/3
122
123
124
113
114
115
#Ant-1
42
48
50
47
45
46
49
41
44
86 m
/1.B2 -X15 1 2 3 2 1 3
#Ant-2 228,206 168 CLU-S6
/1.B2 /3.F1
242
258
245
257
246
241
B+
/1.B4
/1.D3 -X301
261
-X401 /1.D3
#702 93 #702
/3.B2 115,204,230
-X16
161 Neu-P1
241,243
48 3 3 94 -X26 /3.B2
42 41,40 40 5 5 96 96,149 155,180,217 155,180 CAN-H 245,244 246
B /3.D3 B
50 7 7 97 2.1
9 87 6 5 4 321
-X6 -X8 -X17 223 2.2 244 -X302
47 67 9 9 100 209 2.3 252
208 2.4 247
45 44,43 43 10 10 99 210 2.5 251
56 co
203 2.6 258
216 2.7 254
-X7 ER/10 EQ/10
29
215 2.8 248

211 2.9 256
16 15 14 13 12 11 10
200 2.10 257
GND#1 46 220 2.11 253
/1.E7 212 2.12 249
224 2.13 238
CQ/16
CP/16
225 2.14 243
219 2.15 255
221 2.16 250
K4-X8 29
9- k.
/1.E7
-X300
-X9
238,239
109,118,129,167,171,181,213,214,229 -X303
GND#1 70
/1.B6
109,118,129,167,171,181,150
C C
197
GND#2
252
239
256
240
250
247
248
249
253
254
255
251
/3.E1
-X101 198
100,148,224
1 2 1 2 3 4 1 2 4 3 2 1
r 154 GND-P1 DQ/2 DQ/2 AE/4
99 a
CA/4
/3.B2
CE/4
156,179,218
-X13
M
99,151
227
-X11 -M4 M
CAN-L
/3.D3 -M5
-Y3 -Y4
193,125,205,120,191,106
-X10 122 207
7- Sh
188,127,195,183 89,101,124,186,201,223,116
-X14
-X12
D 185,90,102,189 123,226,225,199 D
157 TAC-P1
/3.B2
163 MIL-P1
87 rt
/3.B2
/1.B4
E E
a
WIRING DIAGRAM
fuel-A4
102
192
184
183
189
190
188
196
195
194
193
128
127
126
125
103
187
186
185
105
104
120
107
106
117
116
101
191
121
88
89
90
2 1 2 1
200
190
198
202
203
196
105
114
205
184
187
207
209
211
213
216
157
163
218
220
192
222
83
4 3 2 1 4 3 2 1 AS/2 AS/2
CA/4 2 1
199
201
117
128
104
113
204
103
206
208
210
212
214
215
107
194
217
219
221
121
126
CA/4
88
94
97
2 1 2 1 2 1
CM/2
t°
-B2
6
AP/6
5 4
-B3
L
CE/4
t° -B4
L
CE/4
t°
P
-B5
3 2
DP/3
p
1
-B6
3 2
DP/3
p
1
-B7
3
DP/3
2
p
1
-B8
AL/2
AT/2
-L3
1
AO/26
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 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
CO/34
-A4 -L1 -L2
CK/2
FE/2
-Y2
AX/2
t°
-B16
F F
Page: 2
2 of 3
1190 RC8 (R) 2009 3 P.
1 2 3 4 5 6 7 8
43.2
WIRING DIAGRAM 427
Components
A2 Immobilizer control unit A3
A3 Control unit of electric starter lock A5
A4 EFI control unit F4‑7
B1 Side stand switch A4
B2 Intake air temperature sensor F1
B3 Roll angle sensor F1
B4 Lambda sensor (cylinder 2) F1‑2
B5 Lambda sensor (cylinder 1) F2
B6 Ambient air pressure sensor F2‑3
B7 Pressure sensor, induction manifold (cylinder 2) F3
B8 Pressure sensor, induction manifold (cylinder 1) F3
B12 Throttle position sensor circuit A A7
86 m
B13 Throttle position sensor circuit B A8
B16 Coolant temperature sensor (1st cylinder) F8
L1 Ignition coil (cylinder 2) F7
56 co
L2 Ignition coil (cylinder 1) F7
L3 Crankshaft position sensor F4
M4 Motor drive circuit A C‑D8
M5 Motor drive circuit B C‑D8
9- k.
S4 Gear position sensor A4‑5
X50 Diagnostics connector A1
X51 CAN bus terminating resistor A2
r
Y1 Fuel evaporation valve (USA version only) A2
99 a
Y2 Secondary air valve F8

Y3 Injection valve (cylinder 2) C‑D7
7- Sh
Y4 Injection valve (cylinder 1) C‑D7

Cable colors
29 Orange
40 Black-blue
87 rt
41 Black-blue
42 Black-blue
43 White-blue
a
44 White-blue
45 White-blue
P
46 Brown
47 Orange
48 Light blue
49 Orange
50 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
WIRING DIAGRAM 428
101 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
86 m
118 Brown
120 Orange
121 White-violet
56 co
122 Pink
123 Blue
124 Black
125 Orange
9- k.
126 White-orange
127 Black
128 Brown-red
r
129 Brown
99 a
145 Green
146 Black-green
7- Sh
147 White-red
148 Orange
149 Black-blue
150 Brown
87 rt
151 White-blue
154 Brown-violet
155 Black-blue
a
156 White-blue
157 Black-brown
P
161 Black-green
163 White
167 Brown
168 Yellow
171 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
WIRING DIAGRAM 429
192 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
86 m
205 Orange
206 Yellow
207 Pink
56 co
208 Blue-orange
209 Blue-pink
210 Black-gray
211 Yellow-orange
9- k.
212 White-red
213 Brown
214 Brown
r
215 Green
99 a
216 White-green
217 Black-blue
7- Sh
218 White-blue
219 Brown-gray
220 Yellow-green
221 Green-orange
87 rt
222 Blue-brown
223 Black
224 Orange
a
225 Blue
226 Blue
P
227 Pink
228 Yellow
229 Brown
230 Black-green
238 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
WIRING DIAGRAM 430
251 Violet
252 Blue
253 Yellow
254 Red
255 Gray
256 Black-blue
257 Green-red
258 White
260 Blue-orange
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
P
WIRING DIAGRAM
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
431
432
1 2 3 4 5 6 7 8
600861-01
lig-X3 4,5,6
AN/4 /1.A5
-X500 -B11 -S8 -M3 -S9 -X23 CR/1 -X24 CR/1 -X21 CR/1 -X22 CR/1
5
6
4
CU/4 M
1 1 1 1
1 2 3 4 1 1 1
A R P -F3 -F4 -F9 A
t
BI/2
76,77
2
AU/2
130
131
75
74
AL/2
1 2 10A 10A 10A
2 2 2
AH/2
AK/2
174 CR/1
AT/2 AV/2
1
22
17
18
1 2 2 1
-S5
-X18
ACC1
/1.B4
259
182
180
179
119
118
108
108
109
181
73
130,131,138,159,162,129,150,133,132
86 m
132
2
CW/2
CX/2
134
-H2
-S10
B B+ 152 77
B
/1.D3
1
GND-P1 154
P
/2.C3
AH/2
AK/2
141 TAC-P1 157 87
2
56 co
/2.D7 2.1
2
1
140 Neu-P1 161

CW/2
CX/2
/2.B6 BJ/1
-X52
-B14 t°
#702 261 AY/1

/2.B3
MIL-P1 163 1
/2.D7
112
-H5
9- k.
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
236
CW/2
CX/2
1
166 231
165
2
164
163
C 261
162
-X403 C
161 72 1 1 17
160
112 73 2 2 18
-H6
159
75 4 4 22
158
140
r 76 5 5 51 51
99 a
157
6 6
1
143 78 53 52,53
9
BG/3
119
AJ/3
2
7 7
8
79 56 54
7
-P1
92
8
3
8
6
156 80 59
5
155
4
154
EV/26
3
153 ES/18 ET/18
-X200
2
152
1
-H7
231
CAN-H
7- Sh
-X19 /2.B6
142 141,142,158 91 155,180 52 237 237
3
2.4 2.3 2.2 2.1

1
1
144 CAN-L GND#1 55,54 55 234 232
2
DI/2
D /2.D6 156,179
/1.E4 D
2
AM/3
AR/3
G
143 flaR-X200 57 56,57 236 -X201

/1.E3
CV/4
3
BY/4
flaL-X200 58 58,59 235
-B10
/1.E3
4
-X1 144,153,169,182
/1.B3
-H8
high
-X25
139 72,174 87 235
78
4
87 rt
CW/2
CX/2
1
138 233
3
low
71,136,137,172
2
137
2
-X20
136
EW/4
1
pos.
-H1
tlig-H1 71
/1.B6
170,171
79,134
80,135
139,160
E GND#2 109,118,129,167,171,181,150 E
/2.C3
a
172
110
173
166
169
170
165
164
110
111
WIRING DIAGRAM
92
91
133
2
CW/2
CX/2
1 8 2 4 7 5 6 3 9 4 3 2 1
1
135
AD/12 DA/4
2 1
-H3
167
P C_AX/2
BD/12 DB/4
2 1
2
LO HI P.light L R
AT/2
AL/2
1
168
t°
-B15 -S7 -S11 -H4
-S6
CLU-S6
/2.B7
F F
Page:3
3 of 3
1190 RC8 (R) 2009 3 P.
1 2 3 4 5 6 7 8
43.3
WIRING DIAGRAM 433
Components
B10 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 D‑E1
H2 Front right flasher B1
H3 Front left flasher E1
H4 Horn F5‑6
H5 Rear right flasher C8
H6 Brake/tail light C‑D8
H7 License plate lamp D8
H8 Rear left flasher D‑E8
86 m
M3 Radiator fan A4‑5
P1 Combination instrument C‑D1
S5 Front brake light switch A1
56 co
S6 Clutch switch F1
S7 Horn switch, light switch, headlamp flasher button, flasher switch F3‑4
S8 Oil pressure sensor A4
S9 Thermoswitch A5
9- k.
S10 Rear brake light switch B8
S11 MODE/LAP button F5
X21 Plug-in connector for supplementary equipment (terminal 30) A6
r
99 a

X24 Plug-in connector for supplementary equipment (terminal 31) A5‑6
7- Sh
X500 Plug-in connector not used A3

Cable colors
4 Green
5 Green
87 rt
6 Green
17 Yellow-blue
18 White-black
a
22 Black-red
51 White-green
P
52 Yellow
53 Yellow
54 Brown
55 Brown
56 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
WIRING DIAGRAM 434
87 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
86 m
131 Brown
132 Brown
133 Brown
56 co
134 Black
135 Violet
136 Yellow
137 Yellow
9- k.
138 Brown
139 Blue
140 Gray
r
141 Yellow-green
99 a
142 Yellow-green
143 Black-orange
7- Sh
144 Yellow-orange
150 Brown
152 White-red
153 Yellow-orange
87 rt
154 Brown-violet
155 Black-blue
156 White-blue
a
157 Black-brown
158 Yellow-green
P
159 Brown
160 Blue
161 Black-green
162 Brown
163 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
WIRING DIAGRAM 435
180 Black-blue
181 Brown
182 Yellow-orange
231 Brown
232 Brown
233 Brown
234 Brown
235 Violet
236 Black
237 White
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
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 corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
86 m
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
56 co
−49 °F) 50 % distilled water
Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)
9- k.
Supplier
Motorex®
– Anti Freeze
r
Engine oil (SAE 10W/50)
99 a
According to
– JASO T903 MA (
7- Sh
p. 452)
– SAE ( 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 corre-
sponding properties. KTM recommends Motorex® products.
87 rt
Fully synthetic engine oil

Supplier
Motorex®
a
– Power Synt 4T
P
Engine oil (SAE 5W/40)

According to
– JASO T903 MA ( p. 452)
– SAE ( 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 corre-
sponding 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)
Guideline
– Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the
86 m
corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
56 co
– Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 452) (SAE 2.5)
9- k.
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.
r
Super unleaded (ROZ 98 / RON 98 / PON 94)
99 a
According to
– DIN EN 228 (ROZ 98 / RON 98 / PON 94)
7- Sh
87 rt
a
P
AUXILIARY SUBSTANCES 438
Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean 611
Chain lube for road use

Guideline
Supplier
Motorex®
– Chain Lube 622 Strong
Cleaning and polishing materials for metal, rubber and plastic
86 m
Guideline
Supplier
56 co
Motorex®
– Protect & Shine 645
Long-life grease
Guideline
9- k.
Supplier
Motorex®
r
– Fett 2000
99 a
Lubricant (T511)
Guideline
7- Sh
– KTM recommends Lubcon® products.

Supplier
Lubcon®
– Turmsilon® GTI 300 P
87 rt
Lubricant (T152)
Guideline
a
– KTM recommends Bel‑Ray® products.

Supplier
Bel‑Ray®
P
– Molylube® Anti‑Seize
Lubricant (T159)
Guideline
– KTM recommends Bel‑Ray® products.
Supplier
Bel‑Ray®
– MC‑11®
Lubricant (T158)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmogrease® PP 300
AUXILIARY SUBSTANCES 439
Lubricant (T625)
Guideline
– KTM recommends Molykote® products.
Supplier
Molykote®
– 33 Medium
Motorcycle cleaner
Guideline
Supplier
Motorex®
– Moto Clean 900
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
86 m
Guideline
Supplier
56 co
Motorex®
– Clean & Polish
Universal oil spray

Guideline
9- k.
Supplier
Motorex®
r
– Joker 440 Universal
99 a
7- Sh
87 rt
a
P
SPECIAL TOOLS 440
Bearing puller
Art. no.: 15112017000
400037-01
Circlip pliers reverse

Art. no.: 51012011000
86 m
56 co 400059-01
9- k.
Extractor
Art. no.: 58429009000
r
99 a
7- Sh
400073-01
87 rt
Valve spring mounter

Art. no.: 59029019000
a
P
400101-01
Limit plug gauge

Art. no.: 59029026006
400104-01
SPECIAL TOOLS 441
Feeler gauge
Art. no.: 59029041100
35
30
25
20
15
12
10
5
400110-01
Graduated disc
Art. no.: 60029010000
86 m
56 co 400120-01
9- k.
Plastigauge measuring strips
Art. no.: 60029012000
r
99 a
7- Sh
400122-01
87 rt
Piston ring mounting tool

Art. no.: 60029015000
a
P
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

Art. no.: 60029057100
86 m
56 co 400085-01
9- k.
Multi-tooth wrench socket 10 mm; ½" drive
Art. no.: 60029075000
r
99 a
7- Sh
400145-01
87 rt
Work stand rear

Art. no.: 61029055100
a
P
500077-01
Work stand adapter

Art. no.: 61029055120
700270-01
SPECIAL TOOLS 443
Front work stand

Art. no.: 61029055300
500078-01
Pressure testing tool

Art. no.: 61029094000
86 m
56 co 400149-01
9- k.
Engine work stand
Art. no.: 61229001000
r
99 a
7- Sh
200306-01
87 rt
Engine holder
Art. no.: 61229002000
a
P
200307-01
Clutch holder
Art. no.: 61229003000
200308-01
SPECIAL TOOLS 444
Mounting sleeve
Art. no.: 61229005000
200309-01
Pressure piece
Art. no.: 61229008000
86 m
56 co 200438-01
9- k.
Extractor
Art. no.: 61229010000
r
99 a
7- Sh
200310-01
87 rt
Press drift
Art. no.: 61229013000
a
P
200311-01
Engine blocking screw

Art. no.: 61229015000
200312-01
SPECIAL TOOLS 445
Pressure bell
Art. no.: 61229016000
200313-01
Arms for extractor 78029033100

Art. no.: 61229017000
86 m
56 co 200314-01
9- k.
Pressure piece
Art. no.: 61229018000
r
99 a
7- Sh
200315-01
87 rt
Extractor
Art. no.: 61229020000
a
P
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

Art. no.: 61229044000
86 m
56 co 200319-01
9- k.
Press sleeve
Art. no.: 61229045000
r
99 a
7- Sh
200320-01
87 rt
Frame support
Art. no.: 61229050000
a
P
400490-01
Centering pin
Art. no.: 61229051000
400491-01
SPECIAL TOOLS 447
Floor jack attachment

Art. no.: 61229055000
400184-01
Work stand
Art. no.: 62529055000
86 m
56 co 400151-01
9- k.
Adjustment gauge, control time, cylinder 2
Art. no.: 69129030000
r
99 a
7- Sh
301465-10
87 rt
Adjustment gauge, control time, cylinder 1

Art. no.: 69129130000
a
P
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

Art. no.: 75029172000
86 m
56 co 400170-01
9- k.
Puller, 2-arm
Art. no.: 78029033100
r
99 a
7- Sh
500166-01
87 rt
Valve spring mounting device

Art. no.: 78029060000
a
P
500165-01
Hook wrench
Art. no.: T106S
301085-01
SPECIAL TOOLS 449
Depth micrometer
Art. no.: T107S
300577-10
Pressing tool
Art. no.: T1206
86 m
56 co 200583-10
9- k.
Pressing tool
Art. no.: T1207S
r
99 a
7- Sh
200585-01
87 rt
Pressing tool
Art. no.: T129
a
P
200584-01
Gripping tool
Art. no.: T14026S1
200639-10
SPECIAL TOOLS 450
Open-end wrench
Art. no.: T14032
200640-10
Nitrogen filling tool

Art. no.: T170S1
86 m
56 co 300574-10
9- k.
Mounting sleeve
Art. no.: T313
r
99 a
7- Sh
300578-10
87 rt
Key
Art. no.: T524
a
P
200641-10
Clamping stand
Art. no.: T526S
200636-10
SPECIAL TOOLS 451
Clamping stand
Art. no.: T612S
200638-10
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
STANDARDS 452
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. 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
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
INDEX 453
torque limiter and idler, installing . . . . . . . . . . . . . . . 176

INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 transmission shaft, installing . . . . . . . . . . . . . . . . . . 164
water pump wheel, installing . . . . . . . . . . . . . . . . . . 173
Air filter
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 B
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Battery
Ambient air pressure sensor . . . . . . . . . . . . . . . . . . . . . . 225 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Antifreeze
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Blank time of the LAP button LAP BLANK T
Assembling the engine
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
balancer shaft, installing . . . . . . . . . . . . . . . . . . . . . 174
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 172 Blink code
clutch facing, installing . . . . . . . . . . . . . . . . . . . . . . 171 engine control . . . . . . . . . . . . . . . . . . . . . . . . . 238-390
crankshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 165 immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 229-237
drive wheel of the balancer shaft, installing . . . . . . . . 173 Brake disc of rear brake
86 m
engine bracket, mounting . . . . . . . . . . . . . . . . . . . . 189 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
engine, dismounting from work stand . . . . . . . . . . . . 189
Brake discs, front
force pump, installing . . . . . . . . . . . . . . . . . . . . . . . 168
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
56 co
front camshafts, installing . . . . . . . . . . . . . . . . . . . . 182
Brake fluid
front cylinder control time, adjusting . . . . . . . . . . . . . 186
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 95
front cylinder control time, checking . . . . . . . . . . . . . 186
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 99
front cylinder head, installing . . . . . . . . . . . . . . . . . . 182
front piston, installing . . . . . . . . . . . . . . . . . . . . . . . 180 Brake fluid level
9- k. front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 95
front timing chain tensioner, installing . . . . . . . . 183, 207
front valve clearance, adjusting . . . . . . . . . . . . . . . . 188 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 99
front valve clearance, checking . . . . . . . . . . . . . . . . . 187 Brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
r
front valve cover, installing . . . . . . . . . . . . . . . . . . . 188 front brake linings, changing . . . . . . . . . . . . . . . . . . . 93
gear position sensor, installing . . . . . . . . . . . . . . . . . 173 front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 93
99 a
generator cover, installing . . . . . . . . . . . . . . . . . . . . 176 rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 97

heat exchanger, installing . . . . . . . . . . . . . . . . . . . . 183 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 96
7- Sh
idler and timing chain on the left, installing . . . . . . . . 174

C
idler and timing chain on the right, installing . . . . . . . 172
ignition pulse generator, installing . . . . . . . . . . . . . . 176 Camshaft, rear
ignition top dead center of the front cylinder, setting . . 180 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
ignition top dead center of the rear cylinder, setting . . 169 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
87 rt
left engine case, installing . . . . . . . . . . . . . . . . . . . . 166 Camshafts, front

left suction pump, installing . . . . . . . . . . . . . . . . . . 169 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 167 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
a
middle suction pump, installing . . . . . . . . . . . . . . . . 165 Chain

oil drain plug, installing . . . . . . . . . . . . . . . . . . . . . . 176 checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
P
oil filler tube, installing . . . . . . . . . . . . . . . . . . . . . . 184 checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 175 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
oil spray tube, installing . . . . . . . . . . . . . . . . . . . . . 164
Chain sliding guard
outer clutch hub, installing . . . . . . . . . . . . . . . . . . . 170
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 170
rear camshaft, installing . . . . . . . . . . . . . . . . . . . . . 179 Chain tension
rear cylinder control time, adjusting . . . . . . . . . . . . . 184 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
rear cylinder control time, checking . . . . . . . . . . . . . . 184 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
rear cylinder head, installing . . . . . . . . . . . . . . . . . . 178 Clutch
rear piston, installing . . . . . . . . . . . . . . . . . . . . . . . 177 fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . 191
rear timing chain tensioner, installing . . . . . . . . 179, 207 fluid level, correcting . . . . . . . . . . . . . . . . . . . . . . . 191
rear valve clearance, adjusting . . . . . . . . . . . . . . . . . 186 Clutch lever
rear valve clearance, checking . . . . . . . . . . . . . . . . . 185 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 32
rear valve cover, installing . . . . . . . . . . . . . . . . . . . . 188
Combination instrument
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
activating BOOTLOADER mode . . . . . . . . . . . . . . . . . . 105
shift drum locating, installing . . . . . . . . . . . . . . . . . . 167
updating software . . . . . . . . . . . . . . . . . . . . . . . . . . 105
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 167
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 184 Connector overview . . . . . . . . . . . . . . . . . . . . . . . . . 391-404
timing chain rails of the left engine case section, installing 163 Conservation for winter operation . . . . . . . . . . . . . . . . . . . 417
timing chain rails of the right engine case section, Control unit of electric starter lock . . . . . . . . . . . . . . . . . . . 88
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
INDEX 454
Coolant E
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
EFI control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Coolant level activation code, requesting . . . . . . . . . . . . . . . . . . . 227
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Cooling system flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228, 335
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Engine
filling compensating tank . . . . . . . . . . . . . . . . . . . . . 197 ignition top dead center of the front cylinder, setting . . 121
Crankshaft position sensor . . . . . . . . . . . . . . . . . . . . . . . 218 ignition top dead center of the rear cylinder, setting . . 120
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
D
preparing for installation . . . . . . . . . . . . . . . . . . . . . 117
Disassembling the engine removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
balancer shaft, removing . . . . . . . . . . . . . . . . . . . . . 129
Engine - Work on individual parts
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 131
clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
clutch facing, removing . . . . . . . . . . . . . . . . . . . . . . 132
clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 135
86 m
conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
engine bracket, removing . . . . . . . . . . . . . . . . . . . . . 122
countershaft, assembling . . . . . . . . . . . . . . . . . . . . . 161
engine oil, draining . . . . . . . . . . . . . . . . . . . . . . . . . 122
countershaft, dismantling . . . . . . . . . . . . . . . . . . . . 159
engine, clamping into engine work stand . . . . . . . . . . 122
cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
56 co
force pump, removing . . . . . . . . . . . . . . . . . . . . . . . 133
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . 152
front camshafts, removing . . . . . . . . . . . . . . . . . . . . 126
cylinder, checking/measuring . . . . . . . . . . . . . . . . . . 147
front cylinder head, removing . . . . . . . . . . . . . . . . . . 126
left engine case section . . . . . . . . . . . . . . . . . . . . . . 141
front piston, removing . . . . . . . . . . . . . . . . . . . . . . . 127
left main bearing, installing . . . . . . . . . . . . . . . . . . . 143
front timing chain tensioner, removing . . . . . . . . . . . . 126
9- k. left main bearing, removing . . . . . . . . . . . . . . . . . . . 143
front valve cover, removing . . . . . . . . . . . . . . . . . . . . 123
main bearing of the right engine case section, removing 139
gear position sensor, removing . . . . . . . . . . . . . . . . . 130
main bearing shells, selecting . . . . . . . . . . . . . . . . . 140
generator cover, removing . . . . . . . . . . . . . . . . . . . . 127
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 161
r
heat exchanger, removing . . . . . . . . . . . . . . . . . . . . 124
main shaft, dismantling . . . . . . . . . . . . . . . . . . . . . . 158
idler and timing chain on the left, removing . . . . . . . . 128
99 a
oil pressure regulator valve, checking . . . . . . . . . . . . 155

idler and timing chain on the right, removing . . . . . . . 132
oil pumps, checking . . . . . . . . . . . . . . . . . . . . . . . . 155
ignition pulse generator, removing . . . . . . . . . . . . . . . 127
piston ring end gap, checking . . . . . . . . . . . . . . . . . . 149
7- Sh
ignition top dead center of the front cylinder, setting . . 126

piston, checking/measuring . . . . . . . . . . . . . . . . . . . 148
ignition top dead center of the rear cylinder, setting . . 123
piston/cylinder mounting clearance, checking . . . . . . . 149
left engine case, removing . . . . . . . . . . . . . . . . . . . . 135
radial clearance of the bottom connecting rod bearing,
left suction pump, removing . . . . . . . . . . . . . . . . . . . 130
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 135
right engine case section . . . . . . . . . . . . . . . . . . . . . 138
87 rt
middle suction pump, removing . . . . . . . . . . . . . . . . 136

right idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
oil filler tube, removing . . . . . . . . . . . . . . . . . . . . . . 124
right main bearing, installing . . . . . . . . . . . . . . . . . . 140
oil filter, removing . . . . . . . . . . . . . . . . . . . . . . . . . 129
shift mechanism, checking . . . . . . . . . . . . . . . . . . . 157
a
oil spray tube, removing . . . . . . . . . . . . . . . . . . . . . 137

shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . 158
outer clutch hub, removing . . . . . . . . . . . . . . . . . . . 132
step bearing of the crankshaft, changing . . . . . . . . . . 146
P
rear camshaft, removing . . . . . . . . . . . . . . . . . . . . . 125

timing assembly, checking . . . . . . . . . . . . . . . . . . . . 154
rear cylinder head, removing . . . . . . . . . . . . . . . . . . 125
timing chain tensioner for installation, preparing . . . . . 154
rear piston, removing . . . . . . . . . . . . . . . . . . . . . . . 125
transmission, checking . . . . . . . . . . . . . . . . . . . . . . 160
rear timing chain tensioner, removing . . . . . . . . . . . . 124
rear valve cover, removing . . . . . . . . . . . . . . . . . . . . 123
cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
shift drum locating, removing . . . . . . . . . . . . . . . . . . 134
shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 134 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
starter motor, removing . . . . . . . . . . . . . . . . . . . . . . 124 Engine oil
timing chain rails of the left engine case section, removing 137 adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
timing chain rails of the right engine case section, remov- changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
transmission shaft, removing . . . . . . . . . . . . . . . . . . 136 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
water pump wheel, removing . . . . . . . . . . . . . . . . . . 131
Engine oil level
Dismantling the engine checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
drive wheel of the balancer shaft, removing . . . . . . . . 129
Engine oil pressure
primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 133
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
torque limiter and idler, removing . . . . . . . . . . . . . . . 128
Exhaust air injection valve . . . . . . . . . . . . . . . . . . . . . . . 190
Exhaust cover
installing completely . . . . . . . . . . . . . . . . . . . . . . . . . 63
INDEX 455
removing completely . . . . . . . . . . . . . . . . . . . . . . . . . 63 Handlebar height

Exhaust system adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Headlight adjustment
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
External temperature display checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 High beam bulb
F changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Filter box bottom I

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Ignition key
Foot brake pedal activating/deactivating . . . . . . . . . . . . . . . . . . . . . . . 102
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Immobilizer control unit . . . . . . . . . . . . . . . . . . . . . . . . . 102
Foot brake pedal stub activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Injector
86 m
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Footrest position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Inside cover
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
56 co
Fork
adjusting rebound . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 K
adjusting the spring preload . . . . . . . . . . . . . . . . . . . . 16 Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
compression damping, adjusting . . . . . . . . . . . . . . . . . 15
Kilometers/miles SET KM/MILES
fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 16
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9- k.
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L
Fork legs Lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
r
assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lambda sensor heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Low beam bulb
99 a
disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

fork service, performing . . . . . . . . . . . . . . . . . . . . . . . 21 Lower DU bush
7- Sh
lower DU bush, changing . . . . . . . . . . . . . . . . . . . . . . 26 fork legs, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 26

outer tubes, assembling . . . . . . . . . . . . . . . . . . . . . . . 27
outer tubes, disassembling . . . . . . . . . . . . . . . . . . . . . 24 M
Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Main fuse

Fork service, performing . . . . . . . . . . . . . . . . . . . . . . . . . . 21 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
87 rt
Front cylinder control time Manifold absolute pressure sensor . . . . . . . . . . . . . . . . . . 223

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
a
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Motorcycle

Front wheel cleaning . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 417
jacking up front . . . . . . . .. . . . . . . . . . . . . . . . . . . . 10
P
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 jacking up in the middle . .. . . . . . . . . . . . . . . . . 10, 12
jacking up rear . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 13
Fuel pressure
taking front off work stand .. . . . . . . . . . . . . . . . . . . . 10
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
taking rear from work stand . . . . . . . . . . . . . . . . . . . . 13
checking during the actuator test . . . . . . . . . . . . . . . . 74
work stand, removing from .. . . . . . . . . . . . . . . . . . 11-12
Fuel reserve display TRIP F RESET
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N
Fuel tank Number of laps SET NUM LAPS

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 O
Fuel tank guard Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Oil filter
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fuse installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
individual power consumers, changing . . . . . . . . . . . . . 91 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
H Oil jet for clutch lubrication
checking / cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 216
Hand brake lever
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 96
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
INDEX 456
Oil screen Shift lever stub

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Oil screens Shift speed RPM1/2
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Outer tubes Shock absorber
fork legs, assembling . . . . . . . . . . . . . . . . . . . . . . . . 27 adjusting the spring preload . . . . . . . . . . . ... . . . . . . 45
fork legs, disassembling . . . . . . . . . . . . . . . . . . . . . . 24 bleeding and filling . . . . . . . . . . . . . . . . . ... . . . . . . 55
P compression damping, high-speed, adjusting .. . . . . . . 44
compression damping, low-speed, adjusting ... . . . . . . 44
Parking light bulb damper, assembling . . . . . . . . . . . . . . . . ... . . . . . . 53
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 damper, checking . . . . . . . . . . . . . . . . . . ... . . . . . . 51
Passenger seat damper, disassembling . . . . . . . . . . . . . . ... . . . . . . 49
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 heim joint, installing . . . . . . . . . . . . . . . . ... . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 heim joint, removing . . . . . . . . . . . . . . . . ... . . . . . . 59
Putting into operation installing . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . 47
86 m
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 nitrogen, filling damper with . . . . . . . . . . ... . . . . . . 58
piston rod, assembling . . . . . . . . . . . . . . ... . . . . . . 52
R
piston rod, disassembling . . . . . . . . . . . . ... . . . . . . 50
56 co
RACE mode rebound damping, adjusting . . . . . . . . . . . ... . . . . . . 45
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 removing . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . 46
Radiator servicing . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . 48
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 spring, installing . . . . . . . . . . . . . . . . . . ... . . . . . . 59
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 spring, removing . . . . . . . . . . . . . . . . . . . ... . . . . . . 48
9- k.
Rear brake system Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 8
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Side covers
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
r
Rear cylinder control time removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
99 a
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Side stand switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7- Sh
Rear frame position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Steering damper
Rear hub cush drive adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Steering damper part number . . . . . . . . . . . . . . . . . . . . . . . . 9
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
87 rt
Rear sprocket / engine sprocket

checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 T
Rear wheel Technical data
a
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 chassis . . . . . . . . . . . . . . . .... . . . . . . . . . . . 411-412

installing - when installing the engine . . . . . . . . . . . . . 82 chassis tightening torques . . .... . . . . . . . . . . . 415-416
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
P
engine . . . . . . . . . . . . . . . .... . . . . . . . . . . . 405-406

ROAD mode engine - tolerance, wear limits ... . . . . . . . . . . . 407-408
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 engine tightening torques . . .... . . . . . . . . . . . 409-410
Rollover sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 fork . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . 413
shock absorber . . . . . . . . . . .... . . . . . . . . . . . . . . 414
S
Throttle cable at throttle valve
Seat adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Throttle cable play
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Service interval SERVICE RESET
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Throttle position sensor circuit A . . . . . . . . . . . . . . . . . . . 219
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 420-421
adjusting the position . . . . . . . . . . . . . . . . . . . . . . . 220
Servicing the shock absorber . . . . . . . . . . . . . . . . . . . . . . 48
checking in the "zero" position . . . . . . . . . . . . . . . . . 219
SET °C/°F temperature unit
Throttle position sensor circuit B . . . . . . . . . . . . . . . . . . . 223
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Throttle valve body
SET CLOCK
reinstalling when adjustments have been made . . . . . . 222
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
removing to adjust . . . . . . . . . . . . . . . . . . . . . . . . . 221
Shift lever
Tire air pressure
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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
Vehicle identification number ....................... 8
86 m
Vehicle level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
front, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
rear, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
56 co
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 422-435
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9- k.
r
99 a
7- Sh
87 rt
a
P
*3206077en*
3206077en
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
04/2009
Photo: Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com

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RC8R Workshop Manul 3206077 PDF

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REPAIR MANUAL 2009

1190 RC8 R EU/UK

Only use ORGINAL KTM SPARE PARTS.

ISO 9001(12 100 6061)

to the maximum possible quality of the products.

Servicing the shock absorber .......................................... 48

MEANS OF REPRESENTATION ............................................ 6

Mounting the passenger seat .......................................... 70

08/MASK, FENDER, DECAL ............................................... 75

Removing the inside cover.............................................. 75

Checking the headlight setting...................................... 110 section ....................................................................... 137

Checking the rear cylinder control time.......................... 202

Installing the front camshafts ....................................... 206

38/LUBRICATION SYSTEM .............................................. 208

Installing the ignition pulse generator............................ 176

Clutch switch connector AT .......................................... 395 1 of 3......................................................................... 422

Lambda sensor cylinder 2, connector CA ....................... 396 SPECIAL TOOLS.............................................................. 440

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).

Name® Identifies a protected name.

Spare parts, accessories

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

Steering damper part number

Jacking up motorcycle front

– Jack up the motorcycle at the rear. ( p. 13)

– Jack up the motorcycle at the front.

Taking front of motorcycle off work stand

Danger of damage The parked vehicle can roll away or fall over.

– Remove screws . Take off the footrest bracket.

– Unplug connector  of the brake light switch. Remove cable binder .

Removing the motorcycle from the work stand (screw-in type)

Work stand (62529055000) ( p. 447)

– Position the footrest bracket. Mount and tighten screws .

– Position the footrest bracket. Mount and tighten screws .

Jacking up the motorcycle in the middle (insertable type)

Removing the motorcycle from the work stand (insertable type)

Danger of damage The parked vehicle can roll away or fall over.

Jacking up motorcycle at the rear

Work stand adapter (61029055120) ( p. 442)

Taking the rear from the workstand

Danger of damage The parked vehicle can roll away or fall over.

– Secure the motorcycle against falling over.

– Press the emergency OFF switch into the position .

Adjusting the compression damping of the fork

– Turn adjusting screws  clockwise until they stop.

Adjusting the rebound damping of the fork

The hydraulic rebound damping determines the fork rebound behavior.

the zero position.

– Turn adjusting screws  clockwise to the stop.

Adjusting the spring preload of the fork

– Turn adjusting screws  clockwise to the stop.

Bleeding fork legs

– Lean the motorcycle on the side stand.

– Loosen screws  on the lower triple clamp.

– Loosen screw  of the handlebar stub.

– Jack up the motorcycle in the middle (insertable type). ( p. 12)

– Loosen screws  and .

– Remove screws . Hang the wheel speed sensor to the side.

Installing the fork