Professional Documents
Culture Documents
RC8R Workshop Manul 3206077
RC8R Workshop Manul 3206077
86 m
Article no. 3206077en
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
INTRODUCTION 1
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this 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.
86 m
56 co
© 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.
9- k.
r
99 a
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
87 rt
a
P
CONTENTS 2
86 m
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
56 co
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
r
Vehicle level ................................................................. 17 Removing the passenger seat.......................................... 70
Adjusting front vehicle level............................................ 17
99 a
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
87 rt
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
86 m
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
56 co
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
9- k.
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
r
Updating the combination instrument software............... 105 Removing the force pump ............................................ 133
99 a
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
7- Sh
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
87 rt
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
a
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
86 m
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
56 co
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
r
rear cylinder................................................................ 169
Adjusting the front valve clearance................................ 202
Installing the primary gear............................................ 170
99 a
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
87 rt
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
86 m
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
56 co
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
r
Rollover sensor connector AP........................................ 393 STORAGE ....................................................................... 419
Throttle position sensor circuit A, connector AR.............. 393
99 a
Storage....................................................................... 419
Throttle position sensor circuit B, connector AR ............. 394 Putting into operation after storage ............................... 419
Fuel pump connector AR.............................................. 394 SERVICE SCHEDULE....................................................... 420
7- Sh
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
87 rt
Throttle stepper motor circuit B, connector CA ............... 395 OPERATING SUBSTANCES .............................................. 436
Lambda sensor cylinder 1, connector CA ....................... 396 AUXILIARY SUBSTANCES................................................ 438
P
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Formats used
The typographical formats used in this document are explained below.
86 m
Specific name Identifies a proprietary name.
56 co
Brand™ Identifies a brand available on the open market.
9- k.
r
99 a
7- Sh
87 rt
a
P
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.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
86 m
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
56 co
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.
9- k.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Notes/warnings
r
Pay close attention to the notes/warnings.
99 a
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
7- Sh
ing, you or others may not recognize sources of danger and may therefore be injured.
Grades of risks
87 rt
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
a
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
P
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
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
86 m
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
56 co
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
9- k.
Engine number
3.3
100655-10
87 rt
The fork part number is stamped on the inner side of the fork stub.
a
P
100656-10
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
The steering damper part number is stamped on the top of the steering damper.
100658-10
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
MOTORCYCLE 10
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
Info
Always jack up the rear of the motorcycle first.
86 m
100679-10
56 co
4.2
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
9- k.
– Secure the motorcycle against falling over.
– Remove the work stand from the front.
r
Jacking up the motorcycle in the middle (screw-in type)
99 a
4.3
Note
7- Sh
– Remove screw .
87 rt
200598-01
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.
Info
Check that the work stand is seated correctly.
86 m
56 co
200600-01
Note
9- k.
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
r
– Remove the motorcycle from the work stand and rest it on the side stand.
99 a
– Unscrew the holder of the special tool from the drill holes in the footrest brackets.
Remove the work stand.
7- Sh
200600-01
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
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
4.6
Note
P
– 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
Note
9- k.
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
r
– Insert the work stand adapter in the rear of the work stand.
99 a
– Stand the motorcycle upright, align the work stand to the link fork and the
adapters, and jack up the motorcycle.
87 rt
100680-10
4.8
Note
P
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.
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
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.
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.
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
Full payload 5 clicks
Info
Turn clockwise to increase suspension damping; turn counterclockwise to
reduce damping.
100683-10
01/FORK, TRIPLE CLAMP 16
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.
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
Info
Perform this action on both fork legs.
a
100684-10
P
01/FORK, TRIPLE CLAMP 17
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.
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.
01/FORK, TRIPLE CLAMP 18
– 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
Do not pull the hand brake lever when the brake calipers are removed.
7- Sh
100719-10
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
01/FORK, TRIPLE CLAMP 19
201058-10
– Unscrew screws of the triple clamps and handlebar stubs. Remove the fork legs
downward.
86 m
56 co
201059-10
Warning
9- k.
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.
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
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
201058-11
01/FORK, TRIPLE CLAMP 20
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
Guideline
Bolt, front axle M25x1.5 45 Nm
P
– 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
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
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
01/FORK, TRIPLE CLAMP 22
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) ( p. 451)
200606-10
Info
The Preload Adjuster cannot be removed yet.
86 m
– Unclamp the fork leg. Slide the outer tube down.
56 co
200607-10
200608-10
– Pull up Preload Adjuster . Mount the special tool on the hexagonal piece.
7- Sh
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
01/FORK, TRIPLE CLAMP 23
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.
Open-end wrench (T14032) ( p. 450)
86 m
– Release special tool .
Gripping tool (T14026S1) ( p. 449)
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
Info
200614-10
Hold the fork leg by the axle clamp.
a
Info
Pull out the piston rod and push back in a number of times to empty the
cartridge.
200615-10
01/FORK, TRIPLE CLAMP 24
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
200618-10
5.11
Info
These operations are the same on both outer tubes.
200619-10
01/FORK, TRIPLE CLAMP 25
200620-10
86 m
56 co
200621-10
200622-10
5.12
Condition
The fork legs must be disassembled.
– Check the inner tube and axle clamp for damage.
» If there is damage:
87 rt
200629-10
200630-10
01/FORK, TRIPLE CLAMP 26
200631-10
86 m
56 co
200632-10
200665-10
Guideline
Spring length with preload spacer(s) 405 mm (15.94 in)
» If the measured value is greater than the specified value:
– Reduce the thickness of the preload spacer.
87 rt
5.13
200664-10
01/FORK, TRIPLE CLAMP 27
Info
These operations are the same on both outer tubes.
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
200620-11
87 rt
200619-11
Info
These operations are the same on both fork legs.
– Slide the cartridge into the inner tube with spring seat and the preload bush.
200618-11
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
200616-11
200615-11
200623-10
01/FORK, TRIPLE CLAMP 29
200624-10
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.
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
200612-11
01/FORK, TRIPLE CLAMP 30
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)
200609-11
– Unclamp the fork leg. Slide the outer tube up and clamp in the area of the lower
triple clamp.
Clamping stand (T612S) ( p. 451)
87 rt
a
200606-10
P
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
01/FORK, TRIPLE CLAMP 31
Guideline
Rebound damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
Compression damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
– Turn the adjusting screw of spring preload all the way clockwise.
– Turn back counterclockwise by the number of turns according to the fork type.
86 m
Guideline
Spring preload - Preload Adjuster
Comfort 5 turns
56 co
Standard 5 turns
Sport 3 turns
Full payload 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
– Return the adjusting screws to the position determined when the unit was dis-
assembled.
87 rt
a
P
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 32
– 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!
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.
6.3
Info
The handlebar stub position must be identical on the left and right of the vehicle.
a
– Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
– Remove screw .
100756-10
Info
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
86 m
56 co
100759-10
100760-10
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
7- Sh
– Move the handlebar to and fro over the entire steering range.
» If the cables restrict the freedom of movement of the steering:
a
Info
It is imperative to use the KTM diagnostics tool for this.
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
301446-10
– Unscrew screw .
87 rt
a
P
301447-10
– Remove screw .
– Remove the spacer.
– Loosen screw .
301448-10
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 35
301449-10
86 m
56 co
301450-10
– Remove screws .
9- k. – Take off cover .
r
99 a
301451-10
301452-10
a
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
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 36
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
301456-10
301449-10
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 37
86 m
56 co
301447-10
301446-10
7- Sh
301457-10
301458-10
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 38
86 m
56 co
301459-10
301458-10
301457-10
– Select "Adjustment".
– "Please enter the password:"
P
– Press "Continue".
– Select "Throttle position sensor circuit A adjustment".
– Press "Continue".
Info
The motor drive moves the throttle valve in circuit A to the zero setting.
– Adjust the throttle cable play at the throttle grip using barrel adjusters .
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten lock nuts .
– Complete the adjustment by pressing the "Quit" button.
301461-10
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 39
301460-10
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
03/FRAME 40
Installation location
– The side stand switch is fitted to the side stand.
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
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
Info
The adjustable footrest bracket enables a more comfortable lower footrest
position or a sporting upper footrest position.
100700-10
100701-01
03/FRAME 41
100702-01
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
100762-10
– 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
86 m
56 co
100766-10
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
Screw, subframe M8 20 Nm Loctite® 243™
(14.8 lbf ft)
100764-01
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
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
– 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
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.
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.
Full payload 10 clicks
Info
r
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
99 a
8.2
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.
87 rt
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
a
Info
Do not loosen nut !
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
04/SHOCK ABSORBER, SWINGARM 45
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.
86 m
100688-10
Full payload 10 clicks
Info
56 co
Turn clockwise to increase damping; turn counterclockwise to reduce sus-
pension damping.
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.
Info
The spring preload can be adjusted correctly only if the rear wheel and the
swingarm are fully relieved of weight.
a
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.
04/SHOCK ABSORBER, SWINGARM 46
– Tighten screw .
Guideline
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
100689-11
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.
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
Info
87 rt
100697-10
The chassis height can be adjusted in both directions.
– Tighten screw .
a
Guideline
Screw, clamp, eccentric shaft of M8 18 Nm
P
100698-10
200602-10
04/SHOCK ABSORBER, SWINGARM 47
– Remove screw .
– Remove upper screw of the shock absorber.
– Remove nut . Pull out the pin of bell crank on the frame. Remove the bell
crank.
200603-10
86 m
56 co
200604-01
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
200602-11
04/SHOCK ABSORBER, SWINGARM 48
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
The shock absorber has been removed.
– Clamp the shock absorber into the vice with soft jaws.
99 a
– Measure and note the spring length while the spring is under tension.
– Loosen screw .
7- Sh
– Turn the adjusting ring until the spring is no longer under tension.
Hook wrench (T106S) ( p. 448)
87 rt
a
200561-01
200562-01
04/SHOCK ABSORBER, SWINGARM 49
200563-10
86 m
56 co
200564-10
200565-10
Info
Do not scratch the inside surface.
87 rt
a
P
200566-10
200567-10
200568-10
04/SHOCK ABSORBER, SWINGARM 50
– Remove compression damping adjuster . Remove the spring, sleeve and piston.
86 m
56 co
200569-10
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
Info
Slip the compression shim stack onto a screwdriver and set the shims down
together.
200572-10
04/SHOCK ABSORBER, SWINGARM 51
200573-10
86 m
56 co
200574-10
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
Piston rod
Diameter ≥ 13.95 mm (≥ 0.5492 in)
a
86 m
56 co
300460-01
– 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
200575-10
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
04/SHOCK ABSORBER, SWINGARM 53
– Mount rebound shim stack with the smaller shims at the top.
– Mount supporting plate .
200571-11
86 m
56 co
200570-11
200586-01
200567-11
04/SHOCK ABSORBER, SWINGARM 54
200587-01
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
200588-01
a
200563-11
Alternative 1
– Turn adjusting screw clockwise with a screwdriver to the last perceptible
click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
Comfort 20 clicks
200596-01 Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
04/SHOCK ABSORBER, SWINGARM 55
– Turn adjusting screw clockwise as far as it will go using an open end wrench.
– Turn back counterclockwise the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
– Turn adjusting screw clockwise to the last perceptible click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
86 m
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
56 co
Full payload 10 clicks
Alternative 2
Warning
9- k. Danger of accidents Modifications to the chassis can seriously alter the
vehicle's handling characteristics.
– Extreme modifications to the adjustment of the spring elements can
r
cause a serious deterioration in the handling characteristics and
overload some components.
99 a
handling characteristics.
– Turn adjusting screws , and to the position noted down when the unit
was disassembled.
– Install the spring. ( p. 59)
87 rt
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
Info
Hand-tighten only without using a tool.
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.
04/SHOCK ABSORBER, SWINGARM 56
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
200267-10
7- Sh
– When the pressure gauge reaches the required value, turn control lever Damper
to Pressure.
Guideline
0 bar
87 rt
3 bar
200268-10
P
– When the pressure gauge reaches the required value, turn control lever Damper
to Vacuum.
Guideline
3 bar
200269-10
– When the pressure gauge reaches the required value, turn control lever Oil reser-
voir to Vacuum.
Guideline
0 bar
200270-10
04/SHOCK ABSORBER, SWINGARM 57
– When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir to Equalize Pressure.
Guideline
8 mbar
200267-10
– When the pressure gauge reaches the required value, turn control lever Damper
to Pressure.
Guideline
0 bar
86 m
The pressure gauge increases to the required value.
3 bar
56 co
200268-10
– When the pressure gauge reaches the required value, turn control lever Damper
to Vacuum.
Guideline
3 bar
9- k.
The pressure gauge drops to the required value.
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
10 mm
– 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.
Info
Hold the damper so that the filling port is at the highest location.
86 m
56 co
200593-01
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
Info
Watch the pressure regulator dial.
Ensure that the damper is filled to the specified pressure.
86 m
Comfort 6 mm (0.24 in)
Standard 6 mm (0.24 in)
Sport 8 mm (0.31 in)
56 co
Full payload 8 mm (0.31 in)
– Following modifications, ride slowly at first to get the feel of the new
handling characteristics.
– Adjust the spring to the value determined when it was removed by turning the
adjusting ring.
87 rt
Guideline
Screw, adjusting ring, shock absorber M6 5 Nm (3.7 lbf ft)
P
200561-11
Info
The operations are the same for the upper and lower heim joints.
Condition
The shock absorber has been removed.
04/SHOCK ABSORBER, SWINGARM 60
– Clamp the shock absorber into the vice with soft jaws.
– Remove collar bushing of the heim joint with a drift.
– Turn the shock absorber around and remove collar bushing of the heim joint with
a drift.
200577-10
86 m
56 co
200578-10
200579-10
– Place special tool underneath and push out the heim joint with special tool .
7- Sh
200580-10
a
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
04/SHOCK ABSORBER, SWINGARM 61
200579-11
86 m
56 co
200578-11
200582-10
7- Sh
87 rt
a
P
05/EXHAUST 62
Lambda sensor
9.1
Installation location
– 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
"HEGO2AD"
Installation location
– 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.
Component description
– 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.
86 m
56 co
9- k.
200532-10
200532-11
Info
The radiator has only been removed to illustrate the procedure more clearly.
– Unplug connector of the lambda sensor (2nd cylinder). Open the cable binder.
200513-10
86 m
56 co
200514-10
200515-10
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
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
200515-11
Guideline
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft)
– Tighten nuts .
Guideline
87 rt
200516-11
– Plug in connector of the lambda sensor (2nd cylinder). Secure the cable with
the cable binders.
P
200513-11
200514-11
06/AIR FILTER 67
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.
Info
Watch out for the engine breather hose.
86 m
200496-10
56 co
– Clean the air filter box.
9- k.
200497-10
r
99 a
200497-11
– Position the filter box top with the engine breather hose. Mount clamp with the
engine breather hose.
P
– Tighten screws .
– Install the fuel tank. ( p. 71)
200496-11
200498-10
06/AIR FILTER 68
– Remove screws . Take off the retaining plates and holding brackets.
– Remove screw . Remove the cover.
200499-10
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
200502-10
a
– Raise the filter box bottom and pull off drain hoses .
– Detach the connector of the intake air temperature sensor.
P
200503-10
– 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.
Pliers for spring-loaded band-type clamp (60029057100) ( p. 442)
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
Guideline
Hose clip, intake flange M4 1.5 Nm
(1.11 lbf ft)
87 rt
a
200500-11
– Position the retaining plates and holding brackets. Mount and tighten screws .
200499-11
200498-11
07/FUEL TANK, SEAT, TRIM 70
– 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
– 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
100731-10
87 rt
Warning
a
Danger of accidents The passenger seat can come loose from the anchoring
if it is not mounted correctly.
P
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.
07/FUEL TANK, SEAT, TRIM 71
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.
86 m
200488-10
– Remove screws .
56 co
9- k.
r
200489-10
Info
7- Sh
200490-10
200491-10
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.
07/FUEL TANK, SEAT, TRIM 72
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.
86 m
200491-11
56 co
9- k.
200490-10
r
– Mount and tighten screws .
Guideline
99 a
200489-11
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
P
Info
The operations are the same on the left and right sides.
07/FUEL TANK, SEAT, TRIM 73
– Remove screw .
– Take off the fuel tank guard.
500246-10
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
– Press down the metal plate and disconnect the fuel hose connection .
99 a
7- Sh
87 rt
200559-01
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.
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.
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.
86 m
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
56 co
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.
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
When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)
» The specifications have not been met:
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.
– Remove the special tool.
– Connect the fuel hose connection.
08/MASK, FENDER, DECAL 75
Info
Watch out for the projections on the inside cover.
200492-10
86 m
Info
Watch out for the projections on the inside cover.
56 co
Guideline
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
200492-11
9- k.
Removing the inside cover
12.3
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
86 m
– Plug in the control unit of the electric starter lock .
56 co
200495-11
200494-11
200537-11
P
200493-11
09/FRONT WHEEL 77
Info
Do not pull the hand brake lever when the brake calipers are removed.
100719-10
86 m
wheel spindle out of the axle clamp. Remove screw .
Warning
56 co
Danger of accidents Reduced braking efficiency caused by damaged brake
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
– Clean and grease the shaft seal rings and mating surfaces of the spacers.
a
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.
86 m
– 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.
56 co
The brake calipers align themselves.
– Tighten screws on both brake calipers.
Guideline
100719-11 Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
9- k.
– Release the fixation of the hand brake lever.
– 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
Guideline
Fork end pinch bolts M8 15 Nm
(11.1 lbf ft)
87 rt
100782-10
13.3
Warning
P
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.
86 m
– Change the tires.
– 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.
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.
Info
The rubber seal in the dust cap prevents air leaking out of the tire if the
valve is defective.
09/FRONT WHEEL 80
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.
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
– Change the brake discs.
9- k.
r
99 a
7- Sh
87 rt
a
P
10/REAR WHEEL 81
100722-10
– Push the rear wheel as far forward as possible and then remove the chain from the
rear sprocket.
86 m
Warning
Danger of accidents Reduced braking efficiency caused by damaged brake
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.
– Remove spacer . Clean and grease the mating surfaces of the spacers and the
shaft seal rings.
P
100724-10
100725-10
10/REAR WHEEL 82
– Push the rear wheel as far forward as possible and place the chain on the rear
sprocket.
– Pull the rear wheel back and insert the axle.
100726-01
86 m
right chain adjusters must be in the same position relative to the reference
marks .
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)
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.
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.
Long-life grease ( p. 438)
a
– Clean the contact areas of the brake caliper support and swingarm.
100724-10
100725-10
10/REAR WHEEL 83
– Push the rear wheel forward as far as possible and place the chain on the rear
sprocket.
– Pull the rear wheel back and push in the wheel spindle.
100726-01
86 m
right chain adjusters must be in the same position relative to reference marks .
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)
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
400480-10
– Change the brake disc.
– Check the brake disc for damage, cracking and deformation.
P
400678-01
10/REAR WHEEL 84
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
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
– 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
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.
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
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
14.9
– 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
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
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
100710-10
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.
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
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
11/WIRING HARNESS, BATTERY 88
Installation location
– The electric starter lock control unit is located behind the right-hand side cover.
900013-01
Description of function
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
600852-10
a
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.
100734-10
86 m
56 co
100735-10
– Remove screws .
– Removing the securing bracket .
– Pull the battery up and out of the battery rack.
9- k.
r
99 a
100736-10
15.4
Info
The terminals of the battery must face the rear of the vehicle.
87 rt
100737-10
P
100738-10
100734-11
11/WIRING HARNESS, BATTERY 90
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.
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
Environmental hazard Hazardous substances cause environmental damage.
56 co
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it 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
– 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 .
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.
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 .
– Fit the seat. ( p. 70)
r
– Set the clock with SET CLOCK. ( p. 106)
99 a
7- Sh
100739-10
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.
100740-10
11/WIRING HARNESS, BATTERY 92
Info
A defective fuse can be identified by the burned-out fuse wire .
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
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.
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)
Warning
87 rt
– 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
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
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
– Remove screws .
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
301498-10
Info
Always change the brake linings in pairs and on both sides.
301499-10
13/BRAKE SYSTEM 95
– Position the brake caliper. Mount the screws but do not tighten them yet.
– Repeat the operation on the opposite side.
– 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
301496-10 Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
– Release the fixation of the hand brake lever.
– 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
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– 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
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
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.
13/BRAKE SYSTEM 96
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never 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.
– Loosen screw.
– Remove cover with membrane .
– Add brake fluid to the MAX level.
86 m
Brake fluid DOT 4 / DOT 5.1 ( p. 436)
– Position the cover with the membrane. Mount and tighten the screws.
56 co
Info
100714-10
Clean up overflowed or spilt brake fluid immediately with water.
100711-10
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
a
Note
P
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
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
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.
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.
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
r
Info
99 a
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.
7- Sh
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!
– 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 screws .
– Remove the brake caliper and pull the brake line out of the holder.
301491-10
13/BRAKE SYSTEM 98
301492-10
– Remove bolt .
86 m
56 co
301493-10
301494-10
– Mount bolt .
87 rt
301495-10
a
301492-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brakes according to the service schedule.
86 m
– Stand the vehicle upright.
– 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
Danger of accidents Failure of the brake system.
7- Sh
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
87 rt
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
a
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
P
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never 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!
13/BRAKE SYSTEM 100
Info
Clean up overflowed or spilt brake fluid immediately with water.
100717-10
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
– 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
locked.
100707-10
Info
Position of the foot brake lever may vary considerably, depending on the
setting.
100708-10
13/BRAKE SYSTEM 101
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
– Position the brake system. Position the brake line in the guide.
– Position the brake caliper. Mount and tighten screw .
r
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
99 a
7- Sh
200526-11
Guideline
Screw, rear footrest bracket M8 25 Nm
(18.4 lbf ft)
a
Installation location
– The ICU is located under the ignition lock.
86 m
Info
The engine may be started.
56 co
starter OK " ICUSTR"
Info
The engine cannot be started.
17.2
Info
7- Sh
The orange programming key must only be used for activating and deactivating!
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
86 m
– Press the emergency OFF switch into the position .
– Insert the orange programming key in the ignition lock.
– Switch on the ignition by turning the orange programming key to the ON posi-
tion .
56 co
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 .
9- k.
– 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.
r
The immobilizer indicator lamp lights up, switches off briefly, and
99 a
– Switch off the ignition by turning the orange programming key to the OFF posi-
tion .
– Pull out the orange programming key.
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
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.
– Press the emergency OFF switch into the position .
– 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
EFI warning lamp (MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp lights up.
7- Sh
– Switch off the ignition by turning the orange programming key to the OFF posi-
tion .
– Pull out the orange programming key.
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 .
EFI warning lamp (MIL) lights up, switches off, and then starts to flash.
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
– Press "Continue".
– Read the information page in the KTM diagnostics tool then using "Continue" pro-
gramm the ICU.
– Switch off the ignition by turning the black programming key to the position OFF .
– Switch on the ignition by turning the black programming key to the position ON .
– Carry out the start procedure. ( p. 13)
Guideline
The start procedure was successful.
– Delete trouble code.
– Switch off the ignition by turning the black programming key to the position OFF .
– Press the button MODEand keep it depressed.
– Switch on the ignition by turning the black programming key to the position ON .
86 m
– Press the button MODEand keep it depressed.
BOOTLOADER mode appears in the combination instrument.
– Release MODE button.
56 co
400661-10
– 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.
14/LIGHT SYSTEM, INSTRUMENTS 106
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.
– Press the MODE button briefly.
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
– Press the MODE button briefly.
86 m
Setting the clock with SET CLOCK
17.7
Condition
The ignition is on.
56 co
The motorcycle is stationary.
– Press the button and the button for 3 - 5 seconds.
– Press the button once until the symbol shows SET CLOCK in the info display.
– Press the MODE button briefly.
9- k. The hour is shown.
– Set the hour with the button or the button.
– Press the MODE button briefly.
r
The minutes are shown.
– Set the minutes with the button or the button.
99 a
400455-01
– Press the MODE button briefly.
The settings are stored and the display changes to the SET‑UP menu.
7- Sh
– Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
– Press the MODE button briefly.
87 rt
Condition
The ignition is on.
a
– Press the button twice until the symbol appears in front of SETTINGS in the
info display.
– Press the MODE button briefly.
– Press the MODE button briefly.
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.
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.
14/LIGHT SYSTEM, INSTRUMENTS 107
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.
– Press the MODE button briefly.
– Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
– Press the MODE button briefly.
86 m
Condition
The ignition is on.
The motorcycle is stationary.
– Press the button and the button for 3 - 5 seconds.
56 co
– Press the button twice until the symbol appears in front of SETTINGS in the
info display.
– Press the MODE button briefly.
– Press the button once until the symbol shows LAP BLANK T in the info display.
9- k.
– Press the MODE button briefly.
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
The settings are stored and the display changes to the SETTINGS menu.
– Press the button briefly and repeatedly until the symbol shows BACK... in the
P
info display.
– Press the MODE button briefly.
– Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
– Press the MODE button briefly.
Condition
The ignition is on.
The motorcycle is stationary.
– Press the button and the button for 3 - 5 seconds.
– Press the button twice until the symbol appears in front of SETTINGS in the
info display.
– Press the MODE button briefly.
– Press the button twice until the symbol is on SET NUM LAPS in the info dis-
play.
– Press the MODE button briefly.
TOTAL LAPS appears in the info display with the number of laps.
400462-01
14/LIGHT SYSTEM, INSTRUMENTS 108
Info
When delivered, the number of TOTAL LAPS is set to 99 laps.
Info
You can set TOTAL LAPS to between 1 and 99 laps.
86 m
– Press the MODE button briefly.
56 co
Condition
The ignition is on.
The motorcycle is stationary.
– Press the button and the button for 3 - 5 seconds.
– Press the button twice until the symbol appears in front of SETTINGS in the
9- k.
info display.
– Press the MODE button briefly.
– Press the button three times until the symbol shows TRIP F RESET in the info
r
display.
– Press the MODE button briefly.
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
– Press the button briefly and repeatedly until the symbol shows BACK... in the
info display.
– Press the MODE button briefly.
– Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
– Press the MODE button briefly.
Info
Making a country-specific setting.
Condition
The ignition is on.
The motorcycle is stationary.
14/LIGHT SYSTEM, INSTRUMENTS 109
86 m
Setting the temperature unit SET °C/°F
17.13
Condition
56 co
The ignition is on.
The motorcycle is stationary.
– Press the button and the button for 3 - 5 seconds.
– Press the button three times until the symbol shows UNITS in the info display.
– Press the MODE button briefly.
9- k.
– Press the button once until the symbol shows SET °C/°F in the info display.
– Press the MODE button briefly.
The selected unit appears on the left of the display.
r
– Select the unit with the button or the button.
99 a
– Press the button briefly and repeatedly until the symbol shows BACK... in the
info display.
– Press the MODE button briefly.
– Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
87 rt
17.14
Condition
The ignition is on.
P
Condition
The ignition is on.
The motorcycle is stationary.
– Press the button and button for 3-5 seconds.
– Press the button twice until the symbol appears in front of SETTINGS in the
info display.
– Press the MODE button briefly.
– Press the button and button for 3-5 seconds.
– Press the button repeatedly until the symbol appears in front of
SERVICE RESET.
– Press the MODE button briefly.
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 .
– Press the MODE button briefly.
The menu is closed.
r
99 a
7- Sh
400485-01
– 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)
14/LIGHT SYSTEM, INSTRUMENTS 111
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.
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.
100745-10
100746-10
100747-10
14/LIGHT SYSTEM, INSTRUMENTS 112
– 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
Info
Check for correct positioning and freedom of movement of the brake lines.
9- k.
– Mount and tighten screws .
Guideline
r
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
99 a
100745-12
7- Sh
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
87 rt
before mounting.
– Fold up the combination instrument. Pull the lug out of the rubber retainer .
– Remove the rubber retainer.
P
100742-10
100743-10
14/LIGHT SYSTEM, INSTRUMENTS 113
700295-01
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
– Fold down the combination instrument. Position the lug in the rubber retainer.
100744-10
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
before mounting.
100745-10
86 m
56 co
100746-10
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
Info
Check for correct positioning and freedom of movement of the brake lines.
100745-11
30/ENGINE 115
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
– Unplug connectors of the gear position sensor and of the side stand switch.
– Remove the exhaust system. ( p. 63)
P
200512-10
200520-10
30/ENGINE 116
– Remove screws . Remove the slave cylinder with the spacer and sleeves.
– Remove screws . Take off the engine sprocket cover.
200521-10
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
200523-10
200524-10
a
– Position the floor jack under the engine and screw it on using the special tool.
P
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.
200531-10
200530-11
30/ENGINE 118
Info
Do not forget the chain.
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.
Floor jack attachment (61229055000) ( p. 447)
– Install the rear brake system. ( p. 101)
r
99 a
7- Sh
200527-10
Guideline
Nut of engine sprocket M20x1.5 100 Nm Loctite® 243™
(73.8 lbf ft)
a
200528-10
200524-11
30/ENGINE 119
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
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
r
– Mount the engine sprocket cover. Mount and tighten screws .
99 a
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
7- Sh
200521-11
200520-11
– Plug in connector of the gear position sensor and of the side stand switch.
– Mount cable protector .
200512-11
30/ENGINE 120
200511-11
86 m
56 co
200510-11
200509-11 Guideline
Screw, starter motor M6 10 Nm (7.4 lbf ft)
7- Sh
– Read out the trouble code memory using the KTM diagnostics tool.
– Check the engine for leakage.
P
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
– Remove screw .
– 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.
Engine blocking screw (61229015000) ( p. 444)
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
301442-10
30/DISASSEMBLING THE ENGINE 122
Info
Have an assistant help you or use a crane.
301339-10
– Remove screws .
– 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
– Remove oil drain plug with the magnet, O-rings and oil screen.
– Completely drain the engine oil.
a
P
200480-10
30/DISASSEMBLING THE ENGINE 123
301336-10
86 m
– Remove the spark plug using the special tool.
Spark plug wrench (75029172000) ( p. 448)
56 co 301337-10
9- k.
Setting the engine to ignition top dead center of the rear cylinder
19.6
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
– Remove screw .
– 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)
301340-10
30/DISASSEMBLING THE ENGINE 124
301348-10
– Remove screws .
– Remove the oil filler tube with the O-ring.
86 m
56 co 301349-10
9- k.
Removing the heat exchanger
19.9
301350-10
87 rt
301366-10
301351-10
30/DISASSEMBLING THE ENGINE 125
Info
The cams should not activate the valves.
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
301357-10
Info
Push the cylinder up until the piston pin can be removed.
a
301354-10
Info
If no additional work needs to be performed on the cylinder and piston, the
piston can remain in the cylinder.
Setting the engine to ignition top dead center of the front cylinder
19.14
301358-10
86 m
56 co 301359-10
9- k.
Removing the front camshafts
19.16
Info
The cams should not activate the valves.
7- Sh
301360-10
87 rt
– Raise the camshaft at the rear and take the timing chain off of the rear sprocket.
Remove the camshaft.
a
P
301361-10
301362-10
30/DISASSEMBLING THE ENGINE 127
Info
Push the cylinder up until the piston pin can be removed.
Make sure that the two pins remain in place.
301363-10
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.
301392-10
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
200346-10
30/DISASSEMBLING THE ENGINE 128
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
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
200349-10
200350-10
200353-10
30/DISASSEMBLING THE ENGINE 129
– Remove the timing chain, needle bearing and the washer lying behind it.
Info
If the timing chain is to be used again, note the direction of travel and the
cylinder on which it was used.
200354-10
– 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
301391-10
– 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
30/DISASSEMBLING THE ENGINE 130
– Remove the screws. Remove gear position sensor with the O-ring.
301398-10
86 m
56 co
301399-10
301400-10
301401-10
30/DISASSEMBLING THE ENGINE 131
86 m
56 co
301402-10
– Remove screws .
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
200399-10
30/DISASSEMBLING THE ENGINE 132
200401-10
– 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
200405-10
– Remove clutch discs , the support ring and the pretension ring.
87 rt
a
P
200406-10
– 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
30/DISASSEMBLING THE ENGINE 133
301403-10
86 m
56 co
301404-10
– 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
301409-10
P
– Remove lock washer and washer . Take off oil pump gear .
301410-10
30/DISASSEMBLING THE ENGINE 134
301411-10
86 m
56 co
9- k.
r
99 a
301412-10
7- Sh
– Push sliding plate away from the shift drum locating . Remove shift shaft
with the washer.
87 rt
a
P
301413-10
– Remove screw .
– Press locking lever away from shift drum locating and take off the shift drum
locating.
– Release the locking lever.
301414-10
30/DISASSEMBLING THE ENGINE 135
– Remove screw .
– Take off locking lever with the sleeve and spring.
301415-10
86 m
56 co
9- k.
r
99 a
7- Sh
200421-10
– 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
301423-10
30/DISASSEMBLING THE ENGINE 136
200425-10
– Remove internal rotor and pin from the oil pump shaft .
– Remove external rotor .
86 m
56 co
200426-10
200427-10
Info
87 rt
200428-10
Info
Make sure not to misplace the shift rollers.
200429-10
30/DISASSEMBLING THE ENGINE 137
200430-10
86 m
56 co
200431-10
200432-10
Removing the timing chain rails of the right engine case section
19.44
200434-01
Removing the timing chain rails of the left engine case section
19.45
200447-10
30/ENGINE - WORK ON INDIVIDUAL PARTS 138
– Remove studs .
200442-10
– Remove jet .
– Remove oil jets .
86 m
56 co
9- k.
r
99 a
7- Sh
200440-10
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.
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.
30/ENGINE - WORK ON INDIVIDUAL PARTS 139
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
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
20.2
200435-10
200436-10
30/ENGINE - WORK ON INDIVIDUAL PARTS 140
86 m
56 co
200437-10
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
200439-10
200435-11
– Remove studs .
86 m
56 co
200448-10
– Remove screw .
– Remove oil jets .
9- k.
r
99 a
7- Sh
87 rt
a
P
200449-10
200450-10 Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
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.
86 m
(3 lbf ft)
– Mount oil jet .
Guideline
56 co
Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft)
– Mount and tighten screw .
Guideline
Plug, clutch lubrication M10x1 15 Nm
9- k.
(11.1 lbf ft)
r
99 a
7- Sh
200449-11
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
30/ENGINE - WORK ON INDIVIDUAL PARTS 143
200443-10
86 m
56 co
200444-10
200445-10
7- Sh
200439-10
200443-11
Info
Perform the operation on both connecting rods.
86 m
– Clamp each connecting rod separately using soft jaws.
– Remove screws .
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
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)
30/ENGINE - WORK ON INDIVIDUAL PARTS 145
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.
200456-10
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
30/ENGINE - WORK ON INDIVIDUAL PARTS 146
– Press in outer shaft seal ring fully, with the open side flush and facing outwards.
– Insert water pump cover .
200456-10
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
30/ENGINE - WORK ON INDIVIDUAL PARTS 147
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
Info
The width of the Plastigauge measuring strips indicates the bearing play.
200474-10
30/ENGINE - WORK ON INDIVIDUAL PARTS 148
– Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) ( p. 441)
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.
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
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
30/ENGINE - WORK ON INDIVIDUAL PARTS 149
301419-10
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
Guideline
Piston/cylinder - mounting clearance
New condition 0.015… 0.057 mm (0.00059… 0.00224 in)
a
Info
The following operations apply to both cylinder heads.
Info
This only applies to the front cylinder head!
86 m
56 co
200467-10
200468-10
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.
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
200467-11
Info
This only applies to the front cylinder head!
200466-10
Guideline
Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft)
30/ENGINE - WORK ON INDIVIDUAL PARTS 152
– 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 .
– 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
distortion
» If the measured value does not equal the specified value:
– 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.
» If there is damage or 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)
30/ENGINE - WORK ON INDIVIDUAL PARTS 153
86 m
Valve spring - length
New condition 42.0 mm (1.654 in)
56 co
Wear limit 41.2 mm (1.622 in)
» If the measured value does not equal the specified value:
– 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
» If there is damage or wear:
–
99 a
– Remove bushing .
a
– Remove O-ring .
– Remove inner bearing races and .
P
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
20.20
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
30/ENGINE - WORK ON INDIVIDUAL PARTS 155
Info
This position is necessary for installation.
If the timing chain tensioner is now pressed in once more (while it is
installed) and then pulled out no more than halfway (preventing it from
coming out fully), the latching system locks and the timing chain tensioner
can no longer be compacted; this function is necessary to ensure sufficient
tension of the timing chain, even at low oil pressure.
86 m
–
1 –
Change the spring.
Check control piston for damage and wear.
» If there is damage or wear:
56 co
301419-01
– Change the control piston.
– Check the control piston hole in oil pump cover for damage and wear.
» If there is damage or 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
200464-10
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
86 m
Wear limit 2.85 mm (0.1122 in)
» 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.
» If there is damage or wear:
– Change the pretension ring and support ring.
– Check inner clutch hub for damage and wear.
9- k.
» If there is damage or wear:
– Change the inner clutch hub.
– Check the components of clutch pressure booster for damage and wear.
r
» If there is damage or wear:
99 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
86 m
» If deep notches are present:
– Change the sliding plate.
– Check guide pin for looseness and wear.
56 co
» If the guide pin is loose and/or worn:
– Change the sliding plate.
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
– 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 .
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.
30/ENGINE - WORK ON INDIVIDUAL PARTS 159
Info
It only needs to be removed if worn.
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
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 the tooth profiles of main shaft and countershaft for damage and wear.
» If there is damage or wear:
7- Sh
– Check the shift dogs of idler gears and fixed gears for damage and wear.
» If there is damage or wear:
– Change the idler/fixed gear pair.
a
– Check the tooth faces of idler gears and fixed gears for damage and wear.
» If there is damage or wear:
P
Info
Use new lock rings and new stop disks with every repair.
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 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.
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
Installing the timing chain rails of the left engine case section
21.1
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
Ensure that there is no thread locking material at the collar of the screw;
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
Ensure that there is no thread locking material at the collar of the screw;
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
Ensure that there is no thread locking material at the collar of the screw;
otherwise, the timing chain tension rail could lock and break.
a
86 m
56 co
200433-01
together.
7- Sh
200431-10
200430-11
Info
Use a small amount of grease to fix the shift rollers to the shift forks.
200429-11
30/ASSEMBLING THE ENGINE 165
Info
Watch out for the shift rollers .
200428-11
Info
Use a small amount of grease to fix the pressure springs in the shift rails.
86 m
56 co
200427-11
200426-11
200425-11
P
Info
Position the connecting rod as shown in the photo.
301423-10
30/ASSEMBLING THE ENGINE 166
– Mount dowels .
– Mount gasket .
– Check that dowel is correctly seated.
301422-11
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.
Info
Screws must always be replaced with new screws.
– Mount screw .
86 m
200420-11
56 co
– Press locking lever down and position shift drum locating .
Info
The flat surfaces of the shift drum locating are not symmetric.
301414-11
a
– Slide shift shaft with the washer into the bearing seat.
P
301413-11
30/ASSEMBLING THE ENGINE 168
– Mount pin .
Info
Ensure that pins are seated correctly.
86 m
56 co
301416-10
301411-11
– Mount oil pump gear wheel , washer and lock washer .
87 rt
a
301410-11
P
30/ASSEMBLING THE ENGINE 169
– Mount pin .
– Mount internal rotor and external rotor .
Marking of the internal rotor is visible after mounting while that of the exter-
nal rotor is not.
– Oil the parts.
86 m
56 co
301405-10
301406-10
P
Setting the engine to ignition top dead center of the rear cylinder
21.13
301382-10
30/ASSEMBLING THE ENGINE 170
200412-11
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
hub.
Projections engage in recesses .
– Mount inner component of the clutch pressure booster.
a
200411-10
30/ASSEMBLING THE ENGINE 171
200408-11
86 m
56 co
9- k.
r
99 a
7- Sh
200407-10
3
P
200408-01
– Mount the outermost clutch facing disc with the wider elements offset by one
contact .
4 200406-11
200405-11
30/ASSEMBLING THE ENGINE 172
86 m
56 co
200404-10
200401-11
200402-10
200399-11
30/ASSEMBLING THE ENGINE 173
200398-11
86 m
56 co
301394-11
301399-11
– Mount gear position sensor with the O-ring. Mount and tighten the screws.
Guideline
87 rt
301398-11
86 m
56 co
200357-10
301445-10
– Slide on idler .
– Mount the needle bearing.
–
a
Mount washer .
P
200355-10
30/ASSEMBLING THE ENGINE 175
– 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.
– Mount and tighten screws .
Guideline
Remaining engine screws M5 6 Nm (4.4 lbf ft)
86 m
56 co
301395-10
200351-10
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)
30/ASSEMBLING THE ENGINE 176
– Mount the rear washer, needle bearing, idler and front washer.
– Mount torque limiter with the rear washer.
200347-11
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
301392-10
a
200480-10
30/ASSEMBLING THE ENGINE 177
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
200339-10
P
301365-10
– Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
301367-10
30/ASSEMBLING THE ENGINE 178
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
21.31
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)
30/ASSEMBLING THE ENGINE 179
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
301371-10
(13.3 lbf ft)
– Grease the O-rings and mount spark plug shaft insert .
– 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
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)
Setting the engine to ignition top dead center of the front cylinder
21.34
301382-10
86 m
The position notch of the crankshaft is visible in the hole.
– Screw in special tool .
Engine blocking screw (61229015000) ( p. 444)
56 co
200333-10
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
30/ASSEMBLING THE ENGINE 181
301383-10
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
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
30/ASSEMBLING THE ENGINE 182
301375-10
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
Info
The intake camshaft is labeled with ev.
a
– Place the timing chain over the rear sprocket of the intake camshaft.
Marking is aligned.
P
Info
The exhaust camshaft is labeled with av.
– Place the timing chain over the rear sprocket and position the camshaft in the
bearing seat.
Marking is aligned.
301377-10
30/ASSEMBLING THE ENGINE 183
– Thoroughly clean all oil jets and blow them out with compressed air.
– Position the camshaft bearing bridge.
– Mount screws and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
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 .
– After it has been positioned in the installation location, insert timing chain ten-
sioner with a new O-ring.
86 m
– Mount and tighten plug with the new seal ring .
Guideline
Plug, timing-chain tensioner M24x1.5 25 Nm
56 co
(18.4 lbf ft)
301379-10
9- k.
– 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)
r
The timing chain tensioner is unlocked.
99 a
301366-11
301349-10
86 m
Long-life grease ( p. 438)
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
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
301343-10
30/ASSEMBLING THE ENGINE 185
301342-10
86 m
Remove screws .
– Mount the new screws but do not tighten them yet.
56 co
301344-10
301464-10
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
– Remove screws .
7- Sh
301342-10
301382-10
30/ASSEMBLING THE ENGINE 186
– On all valves, check the valve clearance between the camshaft and cam lever.
Guideline
Valve clearance
Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098…
0.0118 in)
Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…
0.0059 in)
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
– Set the engine to ignition top dead center of the front cylinder. ( p. 126)
87 rt
301343-10
Info
P
The markings are shown with the camshafts removed for purposes of illus-
tration.
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
301343-10
30/ASSEMBLING THE ENGINE 187
301342-10
86 m
Remove screws .
– Mount the new screws but do not tighten them yet.
56 co
301344-10
301463-10
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
– Remove screws .
7- Sh
301342-10
Condition
The engine is positioned at ignition top dead center of the front cylinder
– 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)
301387-10
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
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.
Spark plug wrench (75029172000) ( p. 448)
– Mount ignition coil .
Info
The rear valve cover is equipped with a connector for the engine vent.
301337-11
– Mount and tighten the spark plug using a special tool.
Spark plug wrench (75029172000) ( p. 448)
30/ASSEMBLING THE ENGINE 189
301345-10
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
301334-10
87 rt
a
P
31/SECONDARY AIR SYSTEM 190
Installation location
– The exhaust air injection valve is located under the air filter box.
Function description
– 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
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
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.
100753-01
87 rt
a
P
34/SHIFT MECHANISM 192
86 m
56 co
100703-10
– The length of the shift rod can be adjusted by means of the screw thread.
Guideline
7- Sh
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
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
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)
Warning
Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.
7- Sh
– 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.
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
200505-10
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
200507-10
200507-11
35/WATER PUMP, COOLING SYSTEM 196
200506-11
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
Warning
9- k.
Danger of poisoning Coolants are poisonous and a health hazard.
– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
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
200534-10
– 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
The coolant level must be between MIN and MAX.
– Mount the cap of the compensating tank.
200535-10
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
86 m
engine and cooling system cool down first. If you get scalded, immediately flush the affected areas with lukewarm water.
Warning
Danger of poisoning Coolants are poisonous and a health hazard.
56 co
– 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.
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
Coolant ( p. 436)
100750-10 Alternative 2
Coolant (mixed ready to use) ( p. 436)
a
Installation location
– The engine coolant temperature sensor for cylinder 1 is located on the left-hand
side of the rear cylinder head.
900017-01
Component description
– 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
Function description
– The signal from engine coolant temperature sensor for cylinder 1 is transmitted to
r
the EFI control unit.
99 a
(−22 °F)
Resistance at: −20 °C 13.50… 16.50 kΩ
(−4 °F)
Resistance at: −10 °C 8.24… 10.08 kΩ
(14 °F)
87 rt
(50 °F)
Resistance at: 20 °C 2.21… 2.70 kΩ
P
(68 °F)
Resistance at: 30 °C 1.49… 1.83 kΩ
(86 °F)
Resistance at: 40 °C 1.04… 1.27 kΩ
(104 °F)
Resistance at: 50 °C 730… 892 Ω
(122 °F)
Resistance at: 60 °C 526… 642 Ω
(140 °F)
Resistance at: 70 °C 385… 471 Ω
(158 °F)
Resistance at: 80 °C 286… 350 Ω
(176 °F)
Resistance at: 90 °C 216… 264 Ω
(194 °F)
Resistance at: 100 °C 165… 202 Ω
(212 °F)
Resistance at: 110 °C 128… 156 Ω
(230 °F)
36/CYLINDER HEAD 199
Installation location
– The engine coolant temperature sensor for cylinder 2 is located on the right-hand
side of the front cylinder head.
900018-01
Component description
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
Function description
99 a
– The signal from engine coolant temperature sensor for cylinder 2 is transmitted to
the combination instrument.
7- Sh
(−4 °F)
Resistance at: −10 °C 8.24… 10.08 kΩ
(14 °F)
a
86 m
– Repeat these steps on the second cylinder.
– Set the engine to ignition top dead center of the rear cylinder. ( p. 120)
56 co
9- k.
r
200538-10
99 a
– On all valves, check the valve clearance between the camshaft and cam lever.
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)
– Set the engine to ignition top dead center of the front cylinder. ( p. 121)
– 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)
200540-10
86 m
56 co
200539-10
Guideline
Screw, valve cover M6 10 Nm (7.4 lbf ft)
7- Sh
200538-10
26.4
200546-10
36/CYLINDER HEAD 202
200552-10
Condition
86 m
The valve cover has been removed.
– Check the markings of the camshaft.
Info
56 co
The markings are shown with the camshafts removed for purposes of illus-
tration.
9- k. Removal is not necessary.
Align center marking of the camshaft with marking of the camshaft gear.
» If the markings do not align:
301389-10
– Adjust the rear cylinder control time. ( p. 203)
r
Checking the front cylinder control time
99 a
26.7
Condition
The valve cover has been removed.
7- Sh
301343-10
P
Info
The markings are shown with the camshafts removed for purposes of illus-
tration.
Removal is not necessary.
Align center marking of the camshaft with marking of the camshaft gear.
» If the markings do not align:
301389-10
– Adjust the rear cylinder control time. ( p. 203)
36/CYLINDER HEAD 203
– Set the engine to ignition top dead center of the rear cylinder. ( p. 120)
– Remove special tool .
Engine blocking screw (61229015000) ( p. 444)
Info
For purposes of illustration, the following operations are shown with the
engine deinstalled.
Removal is not necessary.
301343-10
86 m
Remove screws .
– Mount the new screws but do not tighten them yet.
56 co
301342-10
301344-10
Guideline
Screw, special tool M6 3 Nm (2.2 lbf ft)
a
301464-10
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
– Remove screws .
– Remove the special tool.
Adjustment gauge, control time, cylinder 1 (69129130000) ( p. 447)
– Remove special tool .
Engine blocking screw (61229015000) ( p. 444)
– Turn the engine one crankshaft turn in a counterclockwise direction.
Marking faces outward and is flush with the edge of the cylinder head.
– Fully tighten screws .
Guideline
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
301342-10
36/CYLINDER HEAD 204
– Set the engine to ignition top dead center of the front cylinder. ( p. 121)
– Remove special tool .
Engine blocking screw (61229015000) ( p. 444)
Info
For purposes of illustration, the following operations are shown with the
engine deinstalled.
Removal is not necessary.
301343-10
86 m
Remove screws .
– Mount the new screws but do not tighten them yet.
56 co
301342-10
301344-10
Guideline
Screw, special tool M6 3 Nm (2.2 lbf ft)
a
301463-10
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
– Remove screws .
– Remove the special tool.
Adjustment gauge, control time, cylinder 2 (69129030000) ( p. 447)
– Remove special tool .
Engine blocking screw (61229015000) ( p. 444)
– Turn the engine one crankshaft turn in a counterclockwise direction.
Marking faces outward and is flush with the edge of the cylinder head.
– Fully tighten screws .
Guideline
Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)
301342-10
36/CYLINDER HEAD 205
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
86 m
Info
The cams should not activate the valves.
56 co
– Remove the camshaft bearing bridge.
– Raise the camshaft at the rear and take the timing chain off of the rear sprocket.
Remove the camshaft.
301436-10
9- k.
Installing the rear camshaft
26.11
– Place the timing chain over the rear sprocket of the intake camshaft.
7- Sh
Info
The exhaust camshaft is labeled with ah.
87 rt
– Place the timing chain over the rear sprocket and position the camshaft in the
bearing seat.
a
– 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)
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
86 m
Info
The cams should not activate the valves.
56 co
– Remove the camshaft bearing bridge.
– Raise the camshaft at the rear and take the timing chain off of the rear sprocket.
Remove the camshaft.
301439-10
9- k.
Installing the front camshafts
26.13
– Place the timing chain over the rear sprocket of the intake camshaft.
7- Sh
Info
The exhaust camshaft is labeled with av.
87 rt
– Place the timing chain over the rear sprocket and position the camshaft in the
bearing seat.
Markings must be flush with the edge of the cylinder head.
a
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)
200549-11
– 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)
86 m
The timing chain tensioner unlocks.
– Mount and tighten screw .
56 co
Guideline
Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft)
9- k. 200554-10
Guideline
Plug, timing-chain tensioner M24x1.5 25 Nm
7- Sh
200550-11
87 rt
– 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)
a
Guideline
Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft)
200555-10
38/LUBRICATION SYSTEM 208
Oil circuit
27.1
86 m
56 co
9- k.
r
400492-60
99 a
5 Crankcase
6 Left suction pump
a
Info
The engine oil level must be checked at normal engine operating temperature.
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
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
Environmental hazard Hazardous substances cause environmental damage.
a
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
P
Info
Drain the engine oil only when the engine is warm.
38/LUBRICATION SYSTEM 210
– Remove screws .
– Take off the left exhaust cover .
86 m
56 co
100771-10
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
38/LUBRICATION SYSTEM 211
86 m
56 co
100771-10
Warning
9- k.
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.
r
Warning
99 a
100774-10
100775-10
38/LUBRICATION SYSTEM 212
100776-10
Info
86 m
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
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)
External tem- Engine oil
perature: < 0 °C (SAE 5W/40)
7- Sh
Danger
Danger of poisoning Exhaust gases are poisonous and can result in uncon-
87 rt
lation, and do not start or run the engine in a closed space without an
effective exhaust extraction system.
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
effective exhaust extraction system.
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
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.
Danger
Danger of poisoning Exhaust gases are poisonous and can result in uncon-
9- k.
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
r
effective exhaust extraction system.
99 a
Warning
Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.
87 rt
– Wear suitable protective clothing and protective gloves. If you get scalded, immediately flush the affected areas with luke-
warm water.
a
Warning
Environmental hazard Hazardous substances cause environmental damage.
P
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
– Remove screws .
– Take off the left exhaust cover .
86 m
56 co
100771-10
200557-10
– Position the special tool with the O-ring. Mount and tighten the screws.
P
Guideline
Remaining engine screws M5 6 Nm (4.4 lbf ft)
200558-10
– Check the engine oil level. ( p. 209)
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
effective exhaust extraction system.
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.
– Mount and tighten the screws.
Guideline
Remaining engine screws M5 6 Nm (4.4 lbf ft)
9- k. – Position the left exhaust cover .
– Mount and tighten screws .
Guideline
r
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
99 a
100771-10
– Remove screws .
– Take off the engine sprocket cover.
301426-10
38/LUBRICATION SYSTEM 216
– Remove plug .
301427-10
86 m
56 co
301429-11
301428-10
Guideline
Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft)
a
P
301429-10
301427-10
38/LUBRICATION SYSTEM 217
301426-11
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
39/IGNITION SYSTEM 218
Installation location
– The crankshaft position sensor is located below the generator cover on the left-hand
side of the engine.
Component description
– 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.
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
Ignition coil
28.2
7- Sh
Installation location
– 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
Installation location
– 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
Component description
– 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
Function description
– 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.
Condition
The ignition is on.
The diagnostic tool is connected and running.
7- Sh
– Select "Adjustment".
– "Please enter the password:"
– Press "Continue".
a
– 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).
Condition
The ignition is on.
The diagnostic tool is connected and running.
– Remove the throttle valve body to adjust. ( p. 221)
86 m
56 co
9- k.
400680-10
– Select "Adjustment".
– "Please enter the password:"
– Press "Continue".
– Select "Throttle position sensor circuit A adjustment".
87 rt
– Press "Continue".
– 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
200498-10
– Remove screws . Take off the retaining plates and holding brackets.
– Remove screw . Remove the cover.
86 m
56 co
200499-10
200500-10
– Loosen the spring-loaded band-type clamp using the special tool. Pull off the
fuel hose.
Pliers for spring-loaded band-type clamp (60029057100) ( p. 442)
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
41/THROTTLE VALVE BODY 222
Reinstalling the throttle valve body when the adjustments have been made
29.5
Info
The fuel hose must have a minimum distance of 4 mm to the throttle link-
age in all operating positions.
86 m
56 co
200501-11
200500-11
200499-11
P
200498-11
41/THROTTLE VALVE BODY 223
Installation location
– 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
Component description
– 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
Description of function
– 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).
29.7
Installation location
– 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.
Component description
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
Function description
– 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.
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
Connecting the vacuum hand pump to the manifold absolute pressure sensor
29.8
– Connect the vacuum hand pump to the vacuum hose of the manifold absolute
pressure sensor cylinder 1.
a
P
600856-10
600856-11
41/THROTTLE VALVE BODY 225
Installation location
– The ambient air pressure sensor is located on the right-hand side of the frame.
Component description
– 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
Function description
– 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.
(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
Installation location
– Injector cylinder 1 is located on the rear throttle valve body.
Injector cylinder 2 is located on the front throttle valve body.
Component description
– 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
41/THROTTLE VALVE BODY 226
Function description
– 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
Installation location
– The rollover sensor is located on the base of the air filter box.
86 m
56 co
900002-60
900004-10
A Normal position, left-hand corner
B Normal position, right-hand corner
7- Sh
Component description
– 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
Description of function
– 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"
41/THROTTLE VALVE BODY 227
Installation location
– 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!
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 diagnostic tool is connected and running.
The "ECU Flashing" process is complete.
– Select the model.
9- k. – Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
r
– Select "Coding".
– "Please enter the password:"
99 a
– Press "Continue".
– Select "Change VIN - New identity".
7- Sh
400687-60
– Press "Continue".
– Read the information page on the KTM diagnostics tool and using "Continue" start
the coding process.
– Overwrite the entry under the "Please enter VIN:" heading.
87 rt
– Press "Continue".
– Select "Code form".
– Press "Print".
a
Condition
The ignition is on.
The diagnostic tool is connected and running.
– Request the EFI control unit activation code. ( p. 227)
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
– Select "Coding".
– "Please enter the password:"
– Press "Continue".
– Select "Change VIN - New identity".
400687-60
– Press "Continue".
– Read the information page on the KTM diagnostics tool and using "Continue" start
the coding process.
41/THROTTLE VALVE BODY 228
Condition
The ignition is on.
86 m
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
56 co
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
– Select "ECU Flashing".
– "Please enter the password:"
9- k.
– Press "Continue".
– 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
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
IMMOBILIZER BLINK CODE 230
86 m
ICU antenna connector EL pin 1 – ICU antenna connector EL pin 2
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
opens.
– Check the cable from connector DO pin 2 to connector DV ( p. 401) pin 2 for
opens.
P
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
IMMOBILIZER BLINK CODE 232
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
IMMOBILIZER BLINK CODE 233
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
IMMOBILIZER BLINK CODE 234
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
IMMOBILIZER BLINK CODE 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
IMMOBILIZER BLINK CODE 236
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
IMMOBILIZER BLINK CODE 237
E²PROM malfunction
– Change the immobilizer control unit.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 238
86 m
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
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.
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
r
– Press "Continue".
99 a
– Press "Continue".
– Select "Lambda sensor heater cylinder 1".
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
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
86 m
The ignition is on.
EFI control unit is connected. ( p. 227)
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
56 co
9- k.
r
400646-10 400658-10
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 the cable from connector CA pin 1 to the next node in the wiring harness for opens.
» If the specifications have been met:
P
600850-12 400646-10
Lambda sensor heater cylinder 1 - check the control wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 33 – Lambda sensor cylinder 1, connector CA pin 2
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
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.
» If the specifications have been met:
56 co
– Check the next possible cause:
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 sensor ground
9- k.
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
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
Resistance ∞Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 240)
Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
ENGINE CONTROL TROUBLE CODE 241
600850-12 400658-10
Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 33 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
86 m
– 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
ground (terminal 31).
» If the specifications have been met:
56 co
– Contact customer service.
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 242
86 m
umented causes leads to elimi-
nation of the fault
56 co
Condition
The ignition is on.
The diagnostics tool is connected and active.
– Select the model.
9- k.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
r
– Select "Actuator Test".
–
99 a
Lambda sensor
Lambda sensor cylinder 1 voltage "HEGO1AD" at test end ≤ 0.5 V
a
400647-10
ENGINE CONTROL TROUBLE CODE 243
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
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)
– Measure the voltage between the specified points.
Break out box CO pin 33 – Measuring point Ground (−)
r
Voltage < 0.1 V
» If the specifications have not been met:
99 a
– 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
plus (terminal 30).
7- Sh
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
87 rt
Condition
The ignition is off.
a
600850-12 600850-11
Lambda sensor heater cylinder 1 - check the signal wire for a short circuit to ignition plus (terminal 15).
– Measure the resistance between the specified points.
Break out box CO pin 33 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
– 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
ignition plus (terminal 15).
ENGINE CONTROL TROUBLE CODE 244
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 245
86 m
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
56 co
Checking the lambda sensor heater cylinder 2
Condition
The ignition is on.
The diagnostics tool is connected and active.
9- k.
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
r
– Press "Continue".
99 a
– Press "Continue".
– Select "Lambda sensor heater cylinder 2".
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
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
» If the displayed value corresponds to the nominal value:
– Delete trouble code.
– Take a test ride.
– Read out the trouble code memory using the KTM diagnostics tool.
» If the displayed value does not correspond to the nominal value:
– Check the next possible cause:
Lambda sensor heater cylinder 2 - value not plausible ( p. 245)
86 m
The ignition is on.
The diagnostics tool is connected and active.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
56 co
9- k.
r
400646-10 400658-10
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
87 rt
– Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.
» If the specifications have been met:
P
600850-12 400646-10
Lambda sensor heater cylinder 2 - checking the control wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 15 – Lambda sensor cylinder 2, connector CA pin 2
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
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.
» If the specifications have been met:
56 co
– Check the next possible cause:
Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor ground ( p. 247)
Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor ground
9- k.
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
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
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit to
sensor ground.
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 247)
Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
ENGINE CONTROL TROUBLE CODE 248
600850-12 400658-10
Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 15 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
86 m
– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit to
ground (terminal 31).
» If the specifications have been met:
56 co
– Contact customer service.
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 249
86 m
umented causes leads to elimi-
nation of the fault
56 co
Condition
The ignition is on.
The diagnostics tool is connected and active.
– Select the model.
9- k.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
r
– Select "Actuator Test".
–
99 a
Lambda sensor
a
Lambda sensor heater cylinder 2 - the signal wire has a short circuit to plus (terminal 30)
86 m
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
56 co
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
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
– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit to
plus (terminal 30).
» If the specifications have been met:
a
Lambda sensor heater cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
600850-12 600850-11
Lambda sensor heater cylinder 2 - check the signal wire for a short circuit to ignition plus (terminal 15).
– Measure the resistance between the specified points.
Break out box CO pin 15 – Break Out Box AO pin 20
ENGINE CONTROL TROUBLE CODE 251
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit to
ignition plus (terminal 15).
» If the specifications have been met:
– Contact customer service.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 252
86 m
Last measure if none of the doc- – Replace the manifold absolute pressure sensor cylinder 1.
umented causes leads to elimi-
nation of the fault
56 co
Manifold absolute pressure sensor cylinder 1 - checking the voltage
Condition
The ignition is on.
9- k.
The diagnostic tool is connected and running.
The engine is switched off.
– Select the model.
– Select "ECU Diagnosis".
r
– Mark the "Engine management EFI LC8 RC8" control unit.
99 a
– Press "Continue".
– Select "Measured Values".
7- Sh
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
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
– Measure the resistance between the specified points.
Manifold absolute pressure sensor cylinder 1, connector DP pin 2 – Mani-
fold absolute pressure sensor cylinder 1, connector DP pin 3
Resistance ∞Ω
» If the specifications have not been met:
– 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
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
9- k.
The EFI control unit is disconnected. ( p. 227)
Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)
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
Resistance ∞Ω
» If the specifications have not been met:
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).
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 1 - the power supply is interrupted ( p. 253)
400590-10 400658-10
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.
» If the specifications have been met:
56 co
– Replace the manifold absolute pressure sensor cylinder 1.
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 255
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
Last measure if none of the doc- – Replace the manifold absolute pressure sensor cylinder 1.
umented causes leads to elimi-
nation of the fault
9- k.
Manifold absolute pressure sensor cylinder 1 - checking the voltage
Condition
The ignition is on.
The diagnostic tool is connected and running.
r
The engine is switched off.
99 a
Press "Continue".
– Highlight "Manifold absolute pressure sensor cylinder 1 voltage" and deselect the other parameters with "Select live data".
Manifold absolute pressure sensor cylinder 1, voltage "PM1AD"
a
Manifold absolute pressure sensor cylinder 1 - the signal wire has an open
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)
86 m
600850-11 400590-10
Manifold absolute pressure sensor cylinder 1 - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 3 – Manifold absolute pressure sensor cylinder 1, connector DP pin 3
56 co
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
r
Manifold absolute pressure sensor cylinder 1 - the ground wire has an open ( p. 256)
99 a
Manifold absolute pressure sensor cylinder 1 - the ground wire has an open
Condition
7- Sh
600850-11 400590-10
Manifold absolute pressure sensor cylinder 1 - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Manifold absolute pressure sensor cylinder 1, connector DP pin 2
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– Check EFI control unit connector AO ( p. 392) pin 7 and connector DP pin 2.
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector DP pin 2 for opens.
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 257)
ENGINE CONTROL TROUBLE CODE 257
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)
86 m
600850-11 400658-10
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 3 – Measuring point Ground (−)
56 co
Voltage < 0.1 V
» If the specifications have not been met:
– 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).
» If the specifications have been met:
– Check the next possible cause:
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
Resistance ∞Ω
» If the specifications have not been met:
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
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 1 - the signal wire has a short cir-
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)
ENGINE CONTROL TROUBLE CODE 258
Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to the
sensor power supply
– Measure the resistance between the specified points.
Break Out Box AO pin 3 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– 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 the sensor power supply.
600850-11
» If the specifications have been met:
– Replace the manifold absolute pressure sensor cylinder 1.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 259
86 m
nation of the fault
56 co
Condition
The ignition is on.
The diagnostic tool is connected and running.
– Select the model.
–
9- k.
Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
r
– Select "Measured Values".
– Highlight "Fuel management general".
99 a
– Press "Continue".
– Highlight "Intake air temperature sensor voltage (TAAD)" and deselect the other parameters with "Select live data".
7- Sh
600850-11
Resistance at: 100 °C (212 °F) 0.1553 kΩ
» If the specifications have not been met:
– Check the next possible cause:
Intake air temperature sensor - the signal wire has a short circuit to sensor
ground ( p. 260)
ENGINE CONTROL TROUBLE CODE 260
Intake air temperature sensor - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The intake air temperature sensor is disconnected.
Intake air temperature sensor - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break Out Box AO pin 22 – Break Out Box AO pin 7
86 m
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to con-
56 co
nector CM ( p. 397) pin 2 for a short circuit to sensor ground.
» If the specifications have been met:
600850-11
9- k. – Contact customer service.
Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
r
The break out box is connected to the wiring harness.
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)
– Measure the resistance between the specified points.
Break Out Box AO pin 22 – Measuring point Ground (−)
P
Resistance ∞Ω
» If the specifications have not been met:
– 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
ground (terminal 31).
» If the specifications have been met:
– Contact customer service.
ENGINE CONTROL TROUBLE CODE 261
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)
Intake air temperature sensor - value not plausible ( p. 264)
56 co
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
9- k.
Intake air temperature sensor - checking the voltage
Condition
The ignition is on.
r
The diagnostic tool is connected and running.
– Select the model.
99 a
– Press "Continue".
– Select "Measured Values".
– Highlight "Fuel management general".
– Press "Continue".
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
Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
ENGINE CONTROL TROUBLE CODE 262
600850-11 400658-10
Intake air temperature sensor - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 22 – Measuring point Ground (−)
Voltage ≤ 0.1 V
» If the specifications have not been met:
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).
» If the specifications have been met:
56 co
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
Intake air temperature sensor - check the signal wire for a short circuit to ignition plus
99 a
(terminal 15)
– Measure the resistance between the specified points.
Break Out Box AO pin 20 – Break Out Box AO pin 22
7- Sh
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to con-
nector CM ( p. 397) pin 2 for a short circuit to ignition plus (terminal 15).
87 rt
600850-11
» If the specifications have been met:
– Check the next possible cause:
a
Intake air temperature sensor - the signal wire has a short circuit to the sensor
power supply ( p. 262)
P
Intake air temperature sensor - the signal wire has a short circuit to the sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Intake air temperature sensor - check the signal wire for a short circuit to the sensor power
supply
– Measure the resistance between the specified points.
Break Out Box AO pin 1 – Break Out Box AO pin 22
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to con-
nector CM ( p. 397) pin 2 for a short circuit to the sensor power supply.
600850-11
» If the specifications have been met:
– Check the next possible cause:
Intake air temperature sensor - the signal wire has an open ( p. 263)
ENGINE CONTROL TROUBLE CODE 263
600850-11 400650-10
86 m
Intake air temperature sensor - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 22 – Connector CM pin 2
56 co
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
7- Sh
600850-11 400650-10
Intake air temperature sensor - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Connector CM pin 1
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Intake air temperature sensor - value not plausible ( p. 264)
ENGINE CONTROL TROUBLE CODE 264
600850-11
Resistance at: 100 °C (212 °F) 0.1553 kΩ
86 m
» If the specifications have not been met:
– Replace the intake air temperature sensor.
» If the specifications have been met:
56 co
– Contact customer service.
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 265
86 m
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
56 co
Engine coolant temperature sensor cylinder 1 - checking the voltage
Condition
The ignition is on.
9- k.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
r
– Press "Continue".
99 a
– Press "Continue".
– Highlight "Engine coolant temperature sensor voltage (TWAD)" and deselect the other parameters with "Select live data".
Engine coolant temperature sensor voltage "TWAD" 0.157… 4.843 V
» If the displayed value corresponds to the nominal value:
87 rt
– Read out the trouble code memory using the KTM diagnostics tool.
» If the displayed value is below the nominal value:
P
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-
cuit to ground (terminal 31) ( p. 266)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
56 co
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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)
– Measure the resistance between the specified points.
87 rt
Resistance ∞Ω
a
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to
sensor ground
– Measure the resistance between the specified points.
Break Out Box AO pin 9 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
600850-11
ENGINE CONTROL TROUBLE CODE 267
– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con-
nector AX ( p. 395) pin 2 for a short circuit to sensor ground.
» If the specifications have been met:
– Contact customer service.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 268
86 m
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor
power supply ( p. 270)
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)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
9- k.
Engine coolant temperature sensor cylinder 1 - checking the voltage
Condition
r
The ignition is on.
The diagnostic tool is connected and running.
99 a
– Press "Continue".
– Highlight "Engine coolant temperature sensor voltage (TWAD)" and deselect the other parameters with "Select live data".
Engine coolant temperature sensor voltage "TWAD" 0.157… 4.843 V
a
86 m
» If the specifications have not been met:
– Change the engine coolant temperature sensor cylinder 1.
» If the specifications have been met:
56 co
– Check the next possible cause:
Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
r
The break out box is connected to the wiring harness.
Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)
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)
– Measure the voltage between the specified points.
P
Voltage ≤ 0.1 V
» If the specifications have not been met:
– 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).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)
ENGINE CONTROL TROUBLE CODE 270
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to
ignition plus (terminal 15)
– Measure the resistance between the specified points.
Break Out Box AO pin 9 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con-
nector AX ( p. 395) pin 2 for a short circuit to ignition plus (terminal 15).
600850-11
» If the specifications have been met:
– Check the next possible cause:
Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-
cuit to the sensor power supply ( p. 270)
Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
86 m
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
56 co
Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)
Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to the
sensor power supply
– Measure the resistance between the specified points.
Break Out Box AO pin 9 – Break Out Box AO pin 1
9- k.
Resistance ∞Ω
» If the specifications have not been met:
r
– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con-
nector AX ( p. 395) pin 2 for a short circuit to the sensor power supply.
99 a
600850-11
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
a
600850-11 400586-10
Engine coolant temperature sensor cylinder 1 - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 9 – Engine coolant temperature sensor cylinder 1 connector AX pin 2
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
ENGINE CONTROL TROUBLE CODE 271
Engine coolant temperature sensor cylinder 1 - the ground wire has an open
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)
86 m
600850-11 400586-10
56 co
Engine coolant temperature sensor cylinder 1 - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Engine coolant temperature sensor cylinder 1 connector AX pin 1
Resistance ≤ 0.6 Ω
9- k.
» If the specifications have not been met:
– 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
» If the specifications have been met:
99 a
86 m
Throttle position sensor circuit A - the signal wire has an open ( p. 274)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
56 co
Throttle position sensor circuit A - checking the voltage
Condition
The ignition is on.
9- k.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
r
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
99 a
– Press "Continue".
– 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
– Read out the trouble code memory using the KTM diagnostics tool.
» If the displayed value is below the nominal value:
P
400584-10 400658-10
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.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
99 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
» If the specifications have not been met:
– 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
ground (terminal 31).
– 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).
» If the specifications have been met:
– Check the next possible cause:
Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground ( p. 274)
ENGINE CONTROL TROUBLE CODE 274
Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Throttle position sensor circuit A is disconnected. ( p. 219)
Throttle position sensor circuit A - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break Out Box AO pin 10 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to con-
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.
» If the specifications have been met:
– Check the next possible cause:
56 co
Throttle position sensor circuit A - the signal wire has an open ( p. 274)
600850-11 400584-10
Throttle position sensor circuit A - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 10 – Throttle position sensor circuit A, connector AR pin 2
a
Resistance ≤ 0.6 Ω
P
86 m
( p. 276)
Throttle position sensor circuit A - the ground wire has an open ( p. 277)
Last measure if none of the doc- – Contact customer service.
56 co
umented causes leads to elimi-
nation of the fault
Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Throttle position sensor circuit A is disconnected. ( p. 219)
ENGINE CONTROL TROUBLE CODE 276
600850-11 400658-10
Throttle position sensor circuit A - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 10 – Measuring point Ground (−)
Voltage ≤ 0.1 V
» If the specifications have not been met:
86 m
– 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
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).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
r
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
99 a
(terminal 15)
– Measure the resistance between the specified points.
Break Out Box AO pin 10 – Break Out Box AO pin 20
Resistance ∞Ω
87 rt
600850-11
– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR
( 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 sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Throttle position sensor circuit A is disconnected. ( p. 219)
Throttle position sensor circuit A - check the signal wire for a short circuit to the sensor
power supply
– Measure the resistance between the specified points.
Break Out Box AO pin 10 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
600850-11
ENGINE CONTROL TROUBLE CODE 277
– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to con-
nector CQ ( p. 398) pin 6 for a short circuit to the sensor power supply.
– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR
( p. 393) pin 2 for a short circuit to the sensor power supply.
» If the specifications have been met:
– Check the next possible cause:
Throttle position sensor circuit A - the ground wire has an open ( p. 277)
86 m
56 co 600850-11 400584-10
9- k.
Throttle position sensor circuit A - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Throttle position sensor circuit A, connector AR pin 3
r
Resistance ≤ 0.6 Ω
99 a
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector CQ ( p. 398) pin 2 for opens.
– 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.
» If the specifications have been met:
87 rt
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)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
9- k.
Lambda sensor cylinder 1 - checking the voltage
Condition
r
The engine is running at idle speed.
The diagnostic tool is connected and running.
99 a
Lambda sensor
P
Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground (terminal 31)
86 m
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
56 co
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
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).
– Measure the resistance between the specified points.
Break Out Box AO pin 11 – Measuring point Ground (−)
Resistance ∞Ω
87 rt
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 sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
Lambda sensor cylinder 1 - check the signal wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
Break Out Box AO pin 11 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to con-
nector CA ( p. 396) pin 4 for a short circuit to sensor ground.
» If the specifications have been met:
600850-11
– Check the next possible cause:
Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 280)
ENGINE CONTROL TROUBLE CODE 280
Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
86 m
600850-11 400658-10
Lambda sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30).
– Measure the voltage between the specified points.
Break Out Box AO pin 11 – Measuring point Ground (−)
56 co
Voltage < 0.1 V
» If the specifications have not been met:
– 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
9- k.
plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 280)
r
99 a
Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
7- Sh
(terminal 15).
– Measure the resistance between the specified points.
Break Out Box AO pin 11 – Break Out Box AO pin 20
a
Resistance ∞Ω
» If the specifications have not been met:
P
– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to con-
nector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).
600850-11
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor
power supply ( p. 280)
Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
ENGINE CONTROL TROUBLE CODE 281
Lambda sensor cylinder 1 - check the signal wire for a short circuit to the sensor power
supply.
– Measure the resistance between the specified points.
Break Out Box AO pin 11 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to con-
nector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.
600850-11
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor cylinder 1 - the signal wire has an open ( p. 281)
86 m
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 1 is disconnected. ( p. 62)
56 co
9- k.
r
600850-11 400646-10
99 a
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
a
600850-11 400646-10
Resistance ≤ 0.6 Ω
ENGINE CONTROL TROUBLE CODE 282
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 283
86 m
Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply
( p. 285)
Lambda sensor cylinder 2 - the signal wire has an open ( p. 286)
56 co
Lambda sensor cylinder 2 - the ground wire has an open ( p. 286)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
9- k.
Lambda sensor cylinder 2 - checking the voltage
Condition
The engine is running at idle speed.
r
The diagnostic tool is connected and running.
99 a
– Press "Continue".
– 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 - the signal wire has a short circuit to ground (terminal 31)
86 m
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
56 co
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
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).
– Measure the resistance between the specified points.
Break Out Box AO pin 12 – Measuring point Ground (−)
Resistance ∞Ω
87 rt
Lambda sensor cylinder 2 - the signal wire has a short circuit to sensor ground ( p. 284)
Lambda sensor cylinder 2 - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
Lambda sensor cylinder 2 - check the signal wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
Break Out Box AO pin 12 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to con-
nector CA ( p. 396) pin 4 for a short circuit to sensor ground.
» If the specifications have been met:
600850-11
– Check the next possible cause:
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (termi-
nal 30) ( p. 285)
ENGINE CONTROL TROUBLE CODE 285
Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
86 m
600850-11 400658-10
Lambda sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30).
– Measure the voltage between the specified points.
Break Out Box AO pin 12 – Measuring point Ground (−)
56 co
Voltage < 0.1 V
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA ( p. 396) pin 4 for a short circuit to
9- k.
plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 285)
r
99 a
Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
7- Sh
(terminal 15).
– Measure the resistance between the specified points.
Break Out Box AO pin 12 – Break Out Box AO pin 20
a
Resistance ∞Ω
» If the specifications have not been met:
P
– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to con-
nector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).
600850-11
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor
power supply ( p. 285)
Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
ENGINE CONTROL TROUBLE CODE 286
Lambda sensor cylinder 2 - check the signal wire for a short circuit to the sensor power
supply.
– Measure the resistance between the specified points.
Break Out Box AO pin 12 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to con-
nector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.
600850-11
» If the specifications have been met:
– Check the next possible cause:
Lambda sensor cylinder 2 - the signal wire has an open ( p. 286)
86 m
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Lambda sensor for cylinder 2 is disconnected. ( p. 62)
56 co
9- k.
r
600850-11 400646-10
99 a
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– Check EFI control unit connector AO ( p. 392) pin 12 and connector CA pin 4.
87 rt
– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA pin 4 for opens.
» If the specifications have been met:
a
600850-11 400646-10
Resistance ≤ 0.6 Ω
ENGINE CONTROL TROUBLE CODE 287
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 288
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)
Last measure if none of the doc- – Contact customer service.
56 co
umented causes leads to elimi-
nation of the fault
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Injector Operating noise
a
Injector
Resistance at: 20 °C (68 °F) 10.5… 13.0 Ω
» If the specifications have not been met:
400598-10
ENGINE CONTROL TROUBLE CODE 289
86 m
400591-10 400658-10
56 co
Injector cylinder 1 - check the power supply
– Measure the voltage between the specified points.
Injector cylinder 1 connector DQ pin 1 – Measuring point Ground (−)
Info
9- k.
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
r
» If the specifications have not been met:
99 a
– Check the cable from connector CQ ( p. 398) pin 13 to the next node in the wiring harness for opens.
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30) ( p. 289)
87 rt
Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30)
Condition
a
600850-12 400658-10
Injector cylinder 1 - check the control wire for a short circuit to plus (terminal 30).
– Measure the voltage between the specified points.
Break out box CO pin 5 – Measuring point Ground (−)
– 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).
» If the specifications have been met:
– Check the next possible cause:
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 ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Injector cylinder 1 is disconnected. ( p. 225)
86 m
56 co
600850-12 600850-11
Injector cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).
– Measure the resistance between the specified points.
9- k.
Break out box CO pin 5 – Break Out Box AO pin 20
Resistance ∞Ω
r
» If the specifications have not been met:
– 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
99 a
(terminal 15).
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 1 - the control wire has a short circuit to the sensor power supply ( p. 290)
87 rt
Injector cylinder 1 - the control wire has a short circuit to the sensor power supply
Condition
a
600850-12 600850-11
Injector cylinder 1 - check the control wire for a short circuit to the sensor power supply
– Measure the resistance between the specified points.
Break out box CO pin 5 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– 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
the sensor power supply.
ENGINE CONTROL TROUBLE CODE 291
– 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.
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 1 - the control wire has an open. ( p. 291)
86 m
56 co
600850-12 400591-10
Resistance ≤ 0.6 Ω
r
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 291)
87 rt
Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31)
Condition
a
600850-12 400658-10
Injector cylinder 1 - check the control wire for a short circuit to ground (terminal 31).
– Measure the resistance between the specified points.
Break out box CO pin 5 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
– 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
ground (terminal 31).
ENGINE CONTROL TROUBLE CODE 292
– 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).
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 1 - the control wire has a short circuit to sensor ground ( p. 292)
Injector cylinder 1 - the control wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Injector cylinder 1 is disconnected. ( p. 225)
86 m
56 co
600850-12 600850-11
Injector cylinder 1 - check the control wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
9- k.
Break out box CO pin 5 – Break Out Box AO pin 7
Resistance ∞Ω
r
» If the specifications have not been met:
– 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
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
86 m
Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 296)
Injector cylinder 2 - the control wire has a short circuit to sensor ground ( p. 297)
Last measure if none of the doc- – Contact customer service.
56 co
umented causes leads to elimi-
nation of the fault
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Injector Operating noise
a
Injector
Resistance at: 20 °C (68 °F) 10.5… 13.0 Ω
» If the specifications have not been met:
400598-10
ENGINE CONTROL TROUBLE CODE 294
86 m
400591-10 400658-10
56 co
Injector cylinder 2 - check the power supply
– Measure the voltage between the specified points.
Injector cylinder 2 connector DQ pin 1 – Measuring point Ground (−)
Info
9- k.
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
r
» If the specifications have not been met:
99 a
– Check the cable from connector CQ ( p. 398) pin 13 to the next node in the wiring harness for opens.
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30) ( p. 294)
87 rt
Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30)
Condition
a
600850-12 400658-10
Injector cylinder 2 - check the control wire for a short circuit to plus (terminal 30).
– Measure the voltage between the specified points.
Break out box CO pin 6 – Measuring point Ground (−)
– 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).
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 295)
Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Injector cylinder 2 is disconnected. ( p. 225)
86 m
56 co
600850-12 600850-11
Injector cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).
– Measure the resistance between the specified points.
9- k.
Break out box CO pin 6 – Break Out Box AO pin 20
Resistance ∞Ω
r
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for a short circuit to
99 a
(terminal 15).
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 2 - the control wire has a short circuit to the sensor power supply ( p. 295)
87 rt
Injector cylinder 2 - the control wire has a short circuit to the sensor power supply
Condition
a
600850-12 600850-11
Injector cylinder 2 - check the control wire for a short circuit to the sensor power supply
– Measure the resistance between the specified points.
Break out box CO pin 6 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for a short circuit to
the sensor power supply.
ENGINE CONTROL TROUBLE CODE 296
– 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.
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 2 - the control wire has an open. ( p. 296)
86 m
56 co
600850-12 400591-10
Resistance ≤ 0.6 Ω
r
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 296)
87 rt
Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31)
Condition
a
600850-12 400658-10
Injector cylinder 2 - check the control wire for a short circuit to ground (terminal 31).
– Measure the resistance between the specified points.
Break out box CO pin 6 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for a short circuit to
ground (terminal 31).
ENGINE CONTROL TROUBLE CODE 297
– 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).
» If the specifications have been met:
– Check the next possible cause:
Injector cylinder 2 - the control wire has a short circuit to sensor ground ( p. 297)
Injector cylinder 2 - the control wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Injector cylinder 2 is disconnected. ( p. 225)
86 m
56 co
600850-12 600850-11
Injector cylinder 2 - check the control wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
9- k.
Break out box CO pin 6 – Break Out Box AO pin 7
Resistance ∞Ω
r
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for a short circuit to
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
86 m
Throttle position sensor circuit B - the signal wire has an open ( p. 300)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
56 co
Throttle position sensor circuit B - checking the voltage
Condition
The ignition is on.
9- k.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
r
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
99 a
– Press "Continue".
– Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".
Throttle position sensor circuit B
Voltage "TAPAD" 0.156… 4.824 V
87 rt
400582-10 400658-10
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.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
99 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
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit to
ground (terminal 31).
– 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).
» If the specifications have been met:
– Check the next possible cause:
Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground ( p. 300)
ENGINE CONTROL TROUBLE CODE 300
Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Throttle position sensor circuit B is disconnected. ( p. 223)
Throttle position sensor circuit B - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break Out Box AO pin 2 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to con-
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
( p. 392) pin 1 for a short circuit to sensor ground.
» If the specifications have been met:
– Check the next possible cause:
56 co
Throttle position sensor circuit B - the signal wire has an open ( p. 300)
600850-11 400582-10
Throttle position sensor circuit B - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 2 – Throttle position sensor circuit B, connector AM pin 1
a
Resistance ≤ 0.6 Ω
P
86 m
( p. 302)
Throttle position sensor circuit B - the ground wire has an open ( p. 303)
Last measure if none of the doc- – Contact customer service.
56 co
umented causes leads to elimi-
nation of the fault
– Read out the trouble code memory using the KTM diagnostics tool.
» If the displayed value is above the nominal value:
– Check the next 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 plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Throttle position sensor circuit B is disconnected. ( p. 223)
ENGINE CONTROL TROUBLE CODE 302
600850-11 400658-10
Throttle position sensor circuit B - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 2 – Measuring point Ground (−)
Voltage ≤ 0.1 V
» If the specifications have not been met:
86 m
– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit to
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).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
r
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
99 a
(terminal 15)
– Measure the resistance between the specified points.
Break Out Box AO pin 2 – Break Out Box AO pin 20
Resistance ∞Ω
87 rt
600850-11
– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM
( 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 sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Throttle position sensor circuit B is disconnected. ( p. 223)
Throttle position sensor circuit B - check the signal wire for a short circuit to the sensor
power supply
– Measure the resistance between the specified points.
Break Out Box AO pin 2 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
600850-11
ENGINE CONTROL TROUBLE CODE 303
– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to con-
nector CQ ( p. 398) pin 10 for a short circuit to the sensor power supply.
– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM
( p. 392) pin 1 for a short circuit to the sensor power supply.
» If the specifications have been met:
– Check the next possible cause:
Throttle position sensor circuit B - the ground wire has an open ( p. 303)
86 m
56 co 600850-11 400582-10
9- k.
Throttle position sensor circuit B - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Throttle position sensor circuit B, connector AM pin 3
r
Resistance ≤ 0.6 Ω
99 a
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector CQ ( p. 398) pin 2 for opens.
– 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.
» If the specifications have been met:
87 rt
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)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
9- k.
nation of the fault
86 m
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The crankshaft position sensor is connected. ( p. 218)
56 co
Crankshaft position sensor - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 14 – Break Out Box AO pin 13
– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-
nector AL ( p. 391) pin 2 for opens.
7- Sh
– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-
nector AL ( p. 391) pin 1 for opens.
» If the specifications have been met:
– Check the next possible cause:
Crankshaft position sensor - the signal wires have a short circuit to ground (ter-
87 rt
Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)
a
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
P
600850-11 400658-10
Crankshaft position sensor - check the signal wires for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break Out Box AO pin 14 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
ENGINE CONTROL TROUBLE CODE 306
– 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
ground (terminal 31).
– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to connector AL ( p. 391) pin 1 for a short circuit to
ground (terminal 31).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The crankshaft position sensor is connected. ( p. 218)
Crankshaft position sensor - check the signal wires for a short circuit to sensor ground
–
86 m
Measure the resistance between the specified points.
Break Out Box AO pin 14 – Break Out Box AO pin 7
Resistance ∞Ω
56 co
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-
nector AL ( p. 391) pin 2 for a short circuit to sensor ground.
– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-
600850-11
nector AL ( p. 391) pin 1 for a short circuit to sensor ground.
9- k.
» If the specifications have been met:
– Check the next possible cause:
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
600850-11 400658-10
Crankshaft position sensor - check the signal wires for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 14 – Measuring point Ground (−)
Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The crankshaft position sensor is connected. ( p. 218)
Crankshaft position sensor - check the signal wire for a short circuit to ignition plus
(terminal 15)
– Measure the resistance between the specified points.
Break Out Box AO pin 14 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-
nector AL ( p. 391) pin 2 for a short circuit to ignition plus (terminal 15).
86 m
600850-11
– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-
nector AL ( p. 391) pin 1 for a short circuit to ignition plus (terminal 15).
» If the specifications have been met:
56 co
– Check the next possible cause:
Crankshaft position sensor - the signal wire has a short circuit to the sensor
power supply ( p. 307)
Crankshaft position sensor - the signal wire has a short circuit to the sensor power supply
9- k.
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
The crankshaft position sensor is connected. ( p. 218)
99 a
Crankshaft position sensor - check the signal wire for a short circuit to the sensor power
supply
–
7- Sh
Resistance ∞Ω
» If the specifications have not been met:
87 rt
– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-
nector AL ( p. 391) pin 2 for a short circuit to the sensor power supply.
600850-11
– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-
a
nector AL ( p. 391) pin 1 for a short circuit to the sensor power supply.
» If the specifications have been met:
P
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
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
– Press "Continue".
– Select "Actuator Test".
– "Please enter the password:"
– Press "Continue".
– Select "Ignition cylinder 1".
87 rt
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
a
Ignition coil
Primary winding resistance at: 20 °C 1.105… 1.495 Ω
(68 °F)
» If the specifications have not been met:
– Replace the ignition coil cylinder 1.
600851-10
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
56 co
Ignition coil cylinder 1 is disconnected. ( p. 218)
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
» If the specifications have not been met:
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
ground (terminal 31).
» If the specifications have been met:
a
Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Ignition coil cylinder 1 is disconnected. ( p. 218)
ENGINE CONTROL TROUBLE CODE 310
600850-12 600850-11
Ignition coil cylinder 1 - check the control wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
Break out box CO pin 29 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
86 m
– 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
sensor ground.
» If the specifications have been met:
56 co
– Check the next possible cause:
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 plus (terminal 30)
Condition
9- k.
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
Ignition coil cylinder 1 is disconnected. ( p. 218)
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
Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Ignition coil cylinder 1 is disconnected. ( p. 218)
ENGINE CONTROL TROUBLE CODE 311
600850-12 600850-11
Ignition coil cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).
– Measure the resistance between the specified points.
Break out box CO pin 29 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
86 m
– 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
ignition plus (terminal 15).
» If the specifications have been met:
56 co
– Check the next possible cause:
Ignition coil cylinder 1 - the control wire has an open ( p. 311)
400644-10 400658-10
Info
Establish a secure connection from the battery plus terminal to the break out box CO pin 29.
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Ignition coil cylinder 1 - the power supply is interrupted ( p. 312)
ENGINE CONTROL TROUBLE CODE 312
86 m
400644-10 400658-10
56 co
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
9- k.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– Check connector AS pin 2.
r
– Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.
» If the specifications have been met:
99 a
86 m
( p. 315)
Ignition coil cylinder 2 - the control wire has an open ( p. 316)
Ignition coil cylinder 2 - the power supply is interrupted ( p. 317)
56 co
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
– Press "Continue".
– Select "Actuator Test".
– "Please enter the password:"
– Press "Continue".
– Select "Ignition cylinder 2".
87 rt
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
a
Ignition coil
Primary winding resistance at: 20 °C 1.105… 1.495 Ω
(68 °F)
» If the specifications have not been met:
– Change the ignition coil cylinder 2.
600851-10
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
56 co
Ignition coil cylinder 2 is disconnected. ( p. 218)
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
» If the specifications have not been met:
87 rt
– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit to
ground (terminal 31).
» If the specifications have been met:
a
Ignition coil cylinder 2 - the control wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Ignition coil cylinder 2 is disconnected. ( p. 218)
ENGINE CONTROL TROUBLE CODE 315
600850-12 600850-11
Ignition coil cylinder 2 - check the control wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
Break out box CO pin 26 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
86 m
– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit to
sensor ground.
» If the specifications have been met:
56 co
– Check the next possible cause:
Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30) ( p. 315)
Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30)
Condition
9- k.
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
Ignition coil cylinder 2 is disconnected. ( p. 218)
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
Ignition coil cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Ignition coil cylinder 2 is disconnected. ( p. 218)
ENGINE CONTROL TROUBLE CODE 316
600850-12 600850-11
Ignition coil cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).
– Measure the resistance between the specified points.
Break out box CO pin 26 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
86 m
– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit to
ignition plus (terminal 15).
» If the specifications have been met:
56 co
– Check the next possible cause:
Ignition coil cylinder 2 - the control wire has an open ( p. 316)
400644-10 400658-10
Info
Establish a protected connection from battery plus to break out box CO pin 26.
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Ignition coil cylinder 2 - the power supply is interrupted ( p. 317)
ENGINE CONTROL TROUBLE CODE 317
86 m
400644-10 400658-10
56 co
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
9- k.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– Check connector AS pin 2.
r
– Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.
» If the specifications have been met:
99 a
86 m
Secondary air valve - the control wire has a short circuit to sensor ground ( p. 321)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
56 co
nation of the fault
– Press "Continue".
– Select "Actuator Test".
7- Sh
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Secondary air valve Operating noise
» If the specifications have been met:
a
– Read out the trouble code memory using the KTM diagnostics tool.
» The specifications have not been met:
– Check the next possible cause:
Secondary air valve - value not plausible ( p. 318)
600854-10
ENGINE CONTROL TROUBLE CODE 319
Secondary air valve - the control wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The exhaust air injection valve is disconnected. ( p. 190)
86 m
56 co
600854-10 400658-10
Secondary air valve - check the control wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Exhaust air injection valve, connector FE pin 2 – Measuring point Ground (−)
9- k.
Resistance ∞Ω
» If the specifications have not been met:
– Change the secondary air valve.
r
» If the specifications have been met:
99 a
600850-12 400648-10
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
Secondary air valve - the power supply is faulty ( p. 320)
ENGINE CONTROL TROUBLE CODE 320
400648-10 400658-10
86 m
Secondary air valve - check the power supply
– Measure the voltage between the specified points.
Secondary air valve connector CK pin 1 – Measuring point Ground (−)
56 co
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
9- k.
» If the specifications have not been met:
– Check connector CK pin 1.
– Check the cable from connector CK pin 1 to the next node in the wiring harness for opens.
r
» If the specifications have been met:
99 a
Secondary air valve - the control wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
87 rt
400648-10 400658-10
Secondary air valve - check the control wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Secondary air valve connector CK pin 2 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
– 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).
» If the specifications have been met:
– Check the next possible cause:
Secondary air valve - the control wire has a short circuit to sensor ground ( p. 321)
ENGINE CONTROL TROUBLE CODE 321
Secondary air valve - the control wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The exhaust air injection valve is disconnected. ( p. 190)
86 m
600850-12 600850-11
Secondary air valve - check the control wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
Break out box CO pin 13 – Break Out Box AO pin 7
56 co
Resistance ∞Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Contact customer service.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 322
86 m
Checking the secondary air valve
Condition
56 co
The ignition is on.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
9- k.
– Press "Continue".
– Select "Actuator Test".
– "Please enter the password:"
r
– Press "Continue".
99 a
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Secondary air valve Operating noise
» If the specifications have been met:
– Delete trouble code.
87 rt
Secondary air valve - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The exhaust air injection valve is disconnected. ( p. 190)
86 m
600850-12 400658-10
Secondary air valve - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break out box CO pin 13 – Measuring point Ground (−)
56 co
Voltage ≤ 0.1 V
» If the specifications have not been met:
– 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.
plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
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
600850-12 600850-11
Secondary air valve - check the signal wire for a short circuit to ignition plus (terminal 15)
– Measure the resistance between the specified points.
Break out box CO pin 13 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
– 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
ignition plus (terminal 15).
» If the specifications have been met:
– Contact customer service.
ENGINE CONTROL TROUBLE CODE 324
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.
umented causes leads to elimi-
99 a
Condition
The ignition is on.
The diagnostic tool is connected and running.
– Select the model.
87 rt
– Press "Continue".
– Select "motor drive circuit A".
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Idle speed control Operating noise
» If the specifications have been met:
– Delete trouble code.
– Take a test ride.
– Read out the trouble code memory using the KTM diagnostics tool.
» The specifications have not been met:
– Check the next possible cause:
Motor drive circuit A phase A - value not plausible ( p. 325)
ENGINE CONTROL TROUBLE CODE 325
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.
» If the specifications have been met:
– Check the next possible cause:
9- k. Motor drive circuit A phase B - value not plausible ( p. 325)
opens.
– Check connector CP pin 2.8 and connector AE ( p. 391) pin 1.
P
– Check the connector from CP pin 2.8 to connector AE ( p. 391) pin 1 for
opens.
– Disconnect connector CQ ( p. 398) from the throttle valve body. Check the
cable from connector CP pin 2.4 to pin 2.8 for a mutual short circuit.
– Change the throttle valve body.
» If the specifications have been met:
– Check the next possible cause:
Motor drive circuit A phase A - the signal wire has an open ( p. 325)
Motor drive circuit A phase A - check the signal wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 7 – Break out box CO pin 23
86 m
– Disconnect connector CQ ( p. 398) from the throttle valve body. Check the
cable from EFI control unit connector CO ( p. 392) pin 7 to pin 23 for a
mutual short circuit.
» If the specifications have been met:
56 co
– Check the next possible cause:
Motor drive circuit A phase B - the signal wire has an open ( p. 326)
Motor drive circuit A phase B - check the signal wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 3 – Break out box CO pin 11
7- Sh
– Check the cable from EFI control unit connector CO ( p. 397) pin 11 to con-
nector CQ ( p. 398) pin 8 for opens.
– Disconnect connector CQ ( p. 398) from the throttle valve body. Check the
cable from EFI control unit connector CO ( p. 397) pin 3 to pin 11 for a
mutual short circuit.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
ENGINE CONTROL TROUBLE CODE 327
600850-12 400658-10
Motor drive circuit A phase A - check the signal wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 23 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
86 m
– Check the cable from EFI control unit connector CO ( p. 397) pin 23 to connector CQ ( p. 398) pin 16 for a short circuit to
ground (terminal 31).
– 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 EFI control unit connector CO ( p. 397) pin 7 to connector CQ ( p. 398) pin 12 for a short circuit to
ground (terminal 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.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
7- Sh
600850-12 400658-10
Motor drive circuit A phase B - check the signal wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 11 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 11 to connector CQ ( p. 398) pin 8 for a short circuit to
ground (terminal 31).
– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to ground (terminal 31).
– Check the cable from EFI control unit connector CO ( p. 397) pin 3 to connector CQ ( p. 398) pin 4 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).
» If the specifications have been met:
– Check the next possible cause:
Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground ( p. 328)
ENGINE CONTROL TROUBLE CODE 328
Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
600850-12 600850-11
86 m
Motor drive circuit A phase A - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break out box CO pin 23 – Break Out Box AO pin 7
56 co
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 23 to connector CQ ( p. 398) pin 16 for a short circuit to
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.
– Check the cable from EFI control unit connector CO ( p. 397) pin 7 to connector CQ ( p. 398) pin 12 for a short circuit to
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.
» If the specifications have been met:
99 a
Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
87 rt
600850-12 600850-11
Motor drive circuit A phase B - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break out box CO pin 11 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 11 to connector CQ ( p. 398) pin 8 for a short circuit to
sensor ground.
– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to sensor ground.
– Check the cable from EFI control unit connector CO ( p. 397) pin 3 to connector CQ ( p. 398) pin 4 for a short circuit to
sensor ground.
– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to sensor ground.
ENGINE CONTROL TROUBLE CODE 329
Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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)
– Measure the voltage between the specified points.
Break out box CO pin 23 – Measuring point Ground (−)
– Check the cable from EFI control unit connector CO ( p. 397) pin 7 to connector CQ ( p. 398) pin 12 for a short circuit to
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).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
P
600850-12 400658-10
Motor drive circuit A phase B - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break out box CO pin 11 – Measuring point Ground (−)
– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to plus (terminal 30).
– Check the cable from EFI control unit connector CO ( p. 397) pin 3 to connector CQ ( p. 398) pin 4 for a short circuit to
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).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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)
– Measure the resistance between the specified points.
Break out box CO pin 23 – Break Out Box AO pin 20
r
Resistance ∞Ω
99 a
– 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).
– Check the cable from EFI control unit connector CO ( p. 397) pin 7 to connector CQ ( p. 398) pin 12 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).
» If the specifications have been met:
a
Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
600850-12 600850-11
Motor drive circuit A phase B - check the signal wire for a short circuit to ignition plus (terminal 15)
– Measure the resistance between the specified points.
Break out box CO pin 11 – Break Out Box AO pin 20
Resistance ∞Ω
ENGINE CONTROL TROUBLE CODE 331
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 332
86 m
Last measure if none of the doc- – Change the ambient air pressure sensor.
umented causes leads to elimi-
nation of the fault
56 co
EFI control unit - checking the power supply
Condition
The ignition is on.
The diagnostic tool is connected and running.
9- k.
The engine is switched off.
– Select the model.
– Select "ECU Diagnosis".
–
r
Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
99 a
– Press "Continue".
– Highlight "Battery voltage (VBAT)" and deselect the other parameters with "Select live data".
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the displayed value corresponds to the nominal value:
87 rt
– Read out the trouble code memory using the KTM diagnostics tool.
» If the displayed value is above the nominal value:
P
600850-11 400658-10
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
EFI control unit - the ground wire (I) has an open ( p. 333)
86 m
The break out box is connected to the EFI control unit and the wiring harness.
56 co
9- k.
600850-12 400658-10
r
EFI control unit - the ground wire (I) has an open
– Measure the voltage between the specified points.
99 a
Info
7- Sh
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
87 rt
600850-12 400658-10
Info
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Change the ambient air pressure sensor.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 335
86 m
The ignition is on.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
56 co
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
– Select "ECU Flashing".
– "Please enter the password:"
9- k.
– Press "Continue".
– 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
Last measure if none of the documented causes leads to elimination of the fault
– Change the EFI control unit.
a
P
ENGINE CONTROL TROUBLE CODE 336
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)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
87 rt
Condition
The ignition is on.
P
– Read out the trouble code memory using the KTM diagnostics tool.
» The specifications have not been met:
– Check the next possible cause:
Motor drive circuit B phase A - value not plausible ( p. 337)
86 m
» If the specifications have not been met:
– 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 connector CP pin 2.11 and connector CA ( p. 395) pin 3.
– 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.
cable from connector CP pin 2.15 to pin 2.11 for a mutual short circuit.
– Change the throttle valve body.
» If the specifications have been met:
r
– Check the next possible cause:
99 a
Condition
The ignition is off.
Connector CP is disconnected. ( p. 398)
Motor drive circuit B phase B - check the resistance
–
87 rt
86 m
600850-12
– Check the cable from EFI control unit connector CO ( p. 392) pin 21 to con-
nector CQ ( p. 398) pin 15 for opens.
– Check EFI control unit connector CO ( p. 392) pin 22 and connector CQ
56 co
( p. 398) pin 11.
– Check the cable from EFI control unit connector CO ( p. 392) pin 22 to con-
nector CQ ( p. 398) pin 11 for opens.
– Disconnect connector CQ ( p. 398) from motor drive circuit B. Check the
cable from EFI control unit connector CO ( p. 392) pin 21 to pin 22 for a
9- k. mutual short circuit.
» If the specifications have been met:
– Check the next possible cause:
r
Motor drive circuit B phase B - the signal wire has an open ( p. 338)
99 a
Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
600850-12 400658-10
86 m
Motor drive circuit B phase A - check the signal wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 22 – Measuring point Ground (−)
56 co
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 22 to connector CQ ( p. 398) pin 11 for a short circuit to
ground (terminal 31).
–
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).
– Check the cable from EFI control unit connector CO ( p. 397) pin 21 to connector CQ ( p. 398) pin 15 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).
» If the specifications have been met:
99 a
Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
87 rt
600850-12 400658-10
Motor drive circuit B phase B - check the signal wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 12 – Measuring point Ground (−)
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 12 to connector CQ ( p. 398) pin 7 for a short circuit to
ground (terminal 31).
– Check connector CP ( p. 398) pin 2.7 to connector CA ( p. 395) pin 2 for a short circuit to ground (terminal 31).
– Check the cable from EFI control unit connector CO ( p. 397) pin 4 to connector CQ ( p. 398) pin 3 for a short circuit to
ground (terminal 31).
– Check connector CP ( p. 398) pin 2.3 to connector CA ( p. 395) pin 4 for a short circuit to ground (terminal 31).
ENGINE CONTROL TROUBLE CODE 340
Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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
– Measure the resistance between the specified points.
Break out box CO pin 22 – Break Out Box AO pin 7
Resistance ∞Ω
9- k.
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 22 to connector CQ ( p. 398) pin 11 for a short circuit to
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
– Check the cable from EFI control unit connector CO ( p. 397) pin 21 to connector CQ ( p. 398) pin 15 for a short circuit to
sensor ground.
– Check connector CP ( p. 398) pin 2.15 to connector CA ( p. 395) pin 1 for a short circuit to sensor ground.
7- Sh
Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
a
600850-12 600850-11
Motor drive circuit B phase B - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break out box CO pin 22 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector CO ( p. 397) pin 12 to connector CQ ( p. 398) pin 7 for a short circuit to
sensor ground.
– Check connector CP ( p. 398) pin 2.7 to connector CA ( p. 395) pin 2 for a short circuit to sensor ground.
ENGINE CONTROL TROUBLE CODE 341
– Check the cable from EFI control unit connector CO ( p. 397) pin 4 to connector CQ ( p. 398) pin 3 for a short circuit to
sensor ground.
– Check connector CP ( p. 398) pin 2.3 to connector CA ( p. 395) pin 4 for a short circuit to sensor ground.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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.
Break out box CO pin 22 – Measuring point Ground (−)
– Check the cable from EFI control unit connector CO ( p. 397) pin 22 to connector CQ ( p. 398) pin 11 for a short circuit to
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
– Check the cable from EFI control unit connector CO ( p. 397) pin 21 to connector CQ ( p. 398) pin 15 for a short circuit to
plus (terminal 30).
– Check connector CP ( p. 398) pin 2.15 to connector CA ( p. 395) pin 1 for a short circuit to plus (terminal 30).
» If the specifications have been met:
87 rt
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)
– Measure the voltage between the specified points.
Break out box CO pin 12 – Measuring point Ground (−)
– Check the cable from EFI control unit connector CO ( p. 397) pin 12 to connector CQ ( p. 398) pin 7 for a short circuit to
plus (terminal 30).
– Check connector CP ( p. 398) pin 2.7 to connector CA ( p. 395) pin 2 for a short circuit to plus (terminal 30).
– Check the cable from EFI control unit connector CO ( p. 397) pin 4 to connector CQ ( p. 398) pin 3 for a short circuit to
plus (terminal 30).
– Check connector CP ( p. 398) pin 2.3 to connector CA ( p. 395) pin 4 for a short circuit to plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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)
– Measure the resistance between the specified points.
r
Break out box CO pin 22 – Break Out Box AO pin 20
99 a
Resistance ∞Ω
» If the specifications have not been met:
7- Sh
– Check the cable from EFI control unit connector CO ( p. 397) pin 22 to connector CQ ( p. 398) pin 11 for a short circuit to
ignition plus (terminal 15).
– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to ignition plus (terminal 15).
– Check the cable from EFI control unit connector CO ( p. 397) pin 21 to connector CQ ( p. 398) pin 15 for a short circuit to
87 rt
Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
600850-12 600850-11
Motor drive circuit B phase B - check the signal wire for a short circuit to ignition plus (terminal 15)
– Measure the resistance between the specified points.
Break out box CO pin 12 – Break Out Box AO pin 20
Resistance ∞Ω
ENGINE CONTROL TROUBLE CODE 343
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 344
86 m
Last measure if none of the doc- – Replace the manifold absolute pressure sensor cylinder 1.
umented causes leads to elimi-
nation of the fault
56 co
Manifold absolute pressure sensor cylinder 1 - checking the voltage
Condition
The ignition is on.
The diagnostic tool is connected and running.
9- k.
The engine is switched off.
– Connect the vacuum hand pump to the manifold absolute pressure sensor. ( p. 224)
– Create a vacuum with the vacuum pump.
r
– Select the model.
99 a
– Press "Continue".
– Select "Measured Values".
– Highlight "Fuel management general".
– Press "Continue".
– Highlight "Manifold absolute pressure sensor cylinder 1 voltage" and deselect the other parameters with "Select live data".
87 rt
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.
» If the specifications have not been met:
– Change the vacuum hose to the cylinder head.
» If the specifications have been met:
– Check the next possible cause:
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.
» If the specifications have not been met:
86 m
– Change the vacuum connection at the cylinder head.
» If the specifications have been met:
– Replace the manifold absolute pressure sensor cylinder 1.
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 346
86 m
Last measure if none of the doc- – Change the manifold absolute pressure sensor cylinder 2.
umented causes leads to elimi-
nation of the fault
56 co
Manifold absolute pressure sensor cylinder 2 - checking the voltage
Condition
The ignition is on.
The diagnostic tool is connected and running.
9- k.
The engine is switched off.
– Connect the vacuum hand pump to the manifold absolute pressure sensor. ( p. 224)
– Create a vacuum with the vacuum pump.
r
– Select the model.
99 a
– Press "Continue".
– Select "Measured Values".
– Highlight "Fuel management general".
– Press "Continue".
– Highlight "Manifold absolute pressure sensor cylinder 2 voltage" and deselect the other parameters with "Select live data".
87 rt
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.
» If the specifications have not been met:
– Change the vacuum hose to the cylinder head.
» If the specifications have been met:
– Check the next possible cause:
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.
» If the specifications have not been met:
86 m
– Change the vacuum connection at the cylinder head.
» If the specifications have been met:
– Change the manifold absolute pressure sensor cylinder 2.
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 348
86 m
Last measure if none of the doc- – Change the ambient air pressure sensor.
umented causes leads to elimi-
nation of the fault
56 co
Ambient air pressure sensor - checking the voltage
Condition
The ignition is on.
The diagnostic tool is connected and running.
9- k.
The engine is switched off.
– Select the model.
– Select "ECU Diagnosis".
–
r
Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
99 a
– Press "Continue".
– Highlight "Ambient air pressure sensor voltage (PAAD)" and deselect the other parameters with "Select live data".
Ambient air pressure sensor voltage "PAAD"
at: 800 mbar (11.6 psi) 2.97… 3.03 V
87 rt
Ambient air pressure sensor - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The ambient air pressure sensor is disconnected. ( p. 225)
ENGINE CONTROL TROUBLE CODE 349
Ambient air pressure sensor - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Ambient air pressure sensor connector DP pin 2 – Ambient air pressure sen-
sor connector DP pin 3
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from connector DP pin 3 to the EFI control unit connector AO
( p. 392) pin 23 for a short circuit to sensor ground.
400590-10 » If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The ambient air pressure sensor is disconnected. ( p. 225)
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)
– Measure the resistance between the specified points.
Ambient air pressure sensor connector DP pin 3 – Measuring point Ground (−)
7- Sh
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from connector DP pin 3 to EFI control unit connector AO ( p. 392) pin 23 for a short circuit to ground (ter-
87 rt
minal 31).
» If the specifications have been met:
– Check the next possible cause:
a
Condition
The ignition is on.
EFI control unit is connected. ( p. 227)
The ambient air pressure sensor is disconnected. ( p. 225)
400590-10 400658-10
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 351
86 m
( p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supply
( p. 353)
Last measure if none of the doc- – Change the ambient air pressure sensor.
56 co
umented causes leads to elimi-
nation of the fault
– Press "Continue".
– Select "Measured Values".
– Highlight "Fuel management general".
– Press "Continue".
87 rt
– Highlight "Ambient air pressure sensor voltage (PAAD)" and deselect the other parameters with "Select live data".
Ambient air pressure sensor voltage "PAAD"
at: 800 mbar (11.6 psi) 2.97… 3.03 V
a
86 m
600850-11 400590-10
Ambient air pressure sensor - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 23 – Ambient air pressure sensor connector DP pin 3
56 co
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– Check EFI control unit connector AO ( p. 392) pin 23 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.
» If the specifications have been met:
– Check the next possible cause:
r
Ambient air pressure sensor - the ground wire has an open ( p. 352)
99 a
600850-11 400590-10
Ambient air pressure sensor - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Ambient air pressure sensor connector DP pin 2
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– Check EFI control unit connector AO ( p. 392) pin 7 and connector DP pin 2.
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector DP pin 2 for opens.
» If the specifications have been met:
– Check the next possible cause:
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 353)
ENGINE CONTROL TROUBLE CODE 353
Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The ambient air pressure sensor is disconnected. ( p. 225)
86 m
600850-11 400658-10
Ambient air pressure sensor - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 23 – Measuring point Ground (−)
56 co
Voltage < 0.1 V
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 23 to connector DP ( p. 400) pin 3 for a short circuit to
9- k.
plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
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
(terminal 15)
– Measure the resistance between the specified points.
Break Out Box AO pin 23 – Break Out Box AO pin 20
a
Resistance ∞Ω
» If the specifications have not been met:
P
– Check the cable from EFI control unit connector AO ( p. 392) pin 23 to con-
nector DP ( p. 400) pin 3 for a short circuit to ignition plus (terminal 15).
600850-11
» If the specifications have been met:
– Check the next possible cause:
Ambient air pressure sensor - the signal wire has a short circuit to the sensor
power supply ( p. 353)
Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)
ENGINE CONTROL TROUBLE CODE 354
Ambient air pressure sensor - check the signal wire for a short circuit to the sensor power
supply
– Measure the resistance between the specified points.
Break Out Box AO pin 23 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 23 to con-
nector DP ( p. 400) pin 3 for a short circuit to the sensor power supply.
600850-11
» If the specifications have been met:
– Change the ambient air pressure sensor.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 355
86 m
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
nation of the fault
56 co
Checking the fuel pump relay
Condition
The ignition is on.
The diagnostic tool is connected and running.
9- k.
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
r
– Press "Continue".
99 a
– Press "Continue".
– Select "Fuel pump relay function test".
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
87 rt
86 m
600850-12 400653-10
56 co
Fuel pump relay - check the control wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 2 – Fuel pump relay connector EB pin 2
Resistance ≤ 0.6 Ω
9- k.
» If the specifications have not been met:
– 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.
» If the specifications have been met:
7- Sh
400653-10 400658-10
Info
Establish a protected connection from battery ground to break out box EB pin 1.
For measurement the measuring points must be subjected to a 12V/21W bulb load.
The value may not differ from the battery voltage "VBAT" by more than 1 V.
» If the specifications have not been met:
– Check connector EB pin 1.
ENGINE CONTROL TROUBLE CODE 357
– Check the cable from connector EB pin 1 to the next node in the wiring harness for opens.
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The fuel pump relay is disconnected. ( p. 404)
86 m
56 co
600850-12 400658-10
Fuel pump relay - check the control wire for a short circuit to ground (terminal 31)
– Measure the resistance between the specified points.
Break out box CO pin 2 – Measuring point Ground (−)
9- k.
Resistance ∞Ω
» If the specifications have not been met:
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
ground (terminal 31).
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
87 rt
Condition
The ignition is off.
a
600850-12 600850-11
Fuel pump relay - check the control wire for a short circuit to sensor ground.
– Measure the resistance between the specified points.
Break out box CO pin 2 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– 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
sensor ground.
ENGINE CONTROL TROUBLE CODE 358
– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to sensor ground.
» If the specifications have been met:
– Contact customer service.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 359
86 m
nation of the fault
56 co
Condition
The ignition is on.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
9- k.
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
– Select "Actuator Test".
r
– "Please enter the password:"
99 a
– Press "Continue".
– Select "Fuel pump relay function test".
7- Sh
– Press "Continue".
– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".
Fuel pump Operating noise
» If the specifications have been met:
87 rt
Fuel pump relay - the control wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The fuel pump relay is disconnected. ( p. 404)
86 m
600850-12 400658-10
Fuel pump relay - check the control wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break out box CO pin 2 – Measuring point Ground (−)
56 co
Voltage ≤ 0.1 V
» If the specifications have not been met:
– 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
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).
» If the specifications have been met:
r
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
87 rt
600850-12 600850-11
Fuel pump relay - check the signal wire for a short circuit to ignition plus (terminal 15)
– Measure the resistance between the specified points.
Break out box CO pin 2 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
– 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
ignition plus (terminal 15).
– 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).
» If the specifications have been met:
– Contact customer service.
ENGINE CONTROL TROUBLE CODE 361
86 m
Checking the side stand switch
Condition
The ignition is on.
56 co
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
– Mark the "Engine management EFI LC8 RC8" control unit.
9- k.
– Press "Continue".
– Select "Measured Values".
– Highlight "electric starter".
r
– Press "Continue".
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
Side stand switch - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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
– Measure the resistance between the specified points.
Side stand switch, connector AR pin 2 – Side stand switch, connector AR
pin 3
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 26 to con-
nector AR pin 3 for a short circuit to sensor ground.
400584-10 » If the specifications have been met:
ENGINE CONTROL TROUBLE CODE 362
Side stand switch - the signal wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
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)
– Measure the resistance between the specified points.
Side stand switch, connector AR pin 3 – Measuring point Ground (−)
9- k.
Resistance ∞Ω
» If the specifications have not been met:
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
86 m
nation of the fault
56 co
Condition
The ignition is on.
The diagnostic tool is connected and running.
– Select the model.
– Select "ECU Diagnosis".
9- k.
– Mark the "Engine management EFI LC8 RC8" control unit.
– Press "Continue".
– Select "Measured Values".
r
– Highlight "electric starter".
99 a
– Press "Continue".
– 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
» If the displayed value corresponds to the nominal value:
87 rt
400583-10 400658-10
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.
» If the specifications have been met:
56 co
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
The rollover sensor is disconnected. ( p. 226)
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
Resistance ∞Ω
» If the specifications have not been met:
– 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
ground (terminal 31).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The rollover sensor is disconnected. ( p. 226)
ENGINE CONTROL TROUBLE CODE 365
Rollover sensor - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break Out Box AO pin 4 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to con-
nector AP ( p. 393) pin 5 for a short circuit to sensor ground.
» If the specifications have been met:
600850-11
– Contact customer service.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 366
86 m
Rollover sensor - the signal wire has an open ( p. 368)
Rollover sensor - the ground wire has an open ( p. 368)
Last measure if none of the doc- – Contact customer service.
umented causes leads to elimi-
56 co
nation of the fault
– Press "Continue".
– Select "Measured Values".
7- Sh
Rollover sensor - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The rollover sensor is disconnected. ( p. 226)
ENGINE CONTROL TROUBLE CODE 367
600850-11 400658-10
Rollover sensor - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 4 – Measuring point Ground (−)
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).
» If the specifications have been met:
56 co
– Check the next possible cause:
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
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
r
The rollover sensor is disconnected. ( p. 226)
Rollover sensor - check the signal wire for a short circuit to ignition plus (terminal 15)
99 a
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to con-
nector AP ( p. 393) pin 5 for a short circuit to ignition plus (terminal 15).
87 rt
( p. 367)
P
Rollover sensor - the signal wire has a short circuit to the sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The rollover sensor is disconnected. ( p. 226)
Rollover sensor - check the signal wire for a short circuit to the sensor power supply
– Measure the resistance between the specified points.
Break Out Box AO pin 4 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to con-
nector AP ( p. 393) pin 5 for a short circuit to the sensor power supply.
» If the specifications have been met:
600850-11
– Check the next possible cause:
Rollover sensor - the signal wire has an open ( p. 368)
ENGINE CONTROL TROUBLE CODE 368
86 m
600850-11 400583-10
56 co
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
r
Rollover sensor - the ground wire has an open ( p. 368)
99 a
600850-11 400583-10
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Contact customer service.
ENGINE CONTROL TROUBLE CODE 369
86 m
– Read out the blink code at the immobilizer indicator lamp .
Immobilizer indicator lamp flashes
» If the specifications have not been met:
56 co
– Change the immobilizer control unit.
» If the specifications have been met:
– Correct the immobilizer fault.
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 370
86 m
Last measure if none of the doc- – Change the manifold absolute pressure sensor cylinder 2.
umented causes leads to elimi-
nation of the fault
56 co
Manifold absolute pressure sensor cylinder 2 - checking the voltage
Condition
The ignition is on.
9- k.
The diagnostic tool is connected and running.
The engine is switched off.
– Select the model.
– Select "ECU Diagnosis".
r
– Mark the "Engine management EFI LC8 RC8" control unit.
99 a
– Press "Continue".
– Select "Measured Values".
7- Sh
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to
sensor ground
– Measure the resistance between the specified points.
Manifold absolute pressure sensor cylinder 2 connector DP pin 2 – Manifold
absolute pressure sensor cylinder 2 connector DP pin 3
Resistance ∞Ω
» If the specifications have not been met:
– 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
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short cir-
cuit to ground (terminal 31) ( p. 371)
56 co
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
9- k.
The EFI control unit is disconnected. ( p. 227)
Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)
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
Resistance ∞Ω
» If the specifications have not been met:
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).
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 2 - the power supply is interrupted ( p. 371)
400590-10 400658-10
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.
» If the specifications have been met:
56 co
– Change the manifold absolute pressure sensor cylinder 2.
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 373
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
power supply ( p. 375)
56 co
Last measure if none of the doc- – Change the manifold absolute pressure sensor cylinder 2.
umented causes leads to elimi-
nation of the fault
9- k.
Manifold absolute pressure sensor cylinder 2 - checking the voltage
Condition
The ignition is on.
The diagnostic tool is connected and running.
r
The engine is switched off.
99 a
Press "Continue".
– Highlight "Manifold absolute pressure sensor cylinder 2 voltage" and deselect the other parameters with "Select live data".
Manifold absolute pressure sensor cylinder 2, voltage "PM2AD"
a
Manifold absolute pressure sensor cylinder 2 - the signal wire has an open
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)
86 m
600850-11 400590-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 24 – Manifold absolute pressure sensor cylinder 2 connector DP pin 3
56 co
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– Check EFI control unit connector AO ( p. 392) pin 24 and connector DP pin 3.
9- k.
– Check the cable from EFI control unit connector AO ( p. 392) pin 24 to connector DP pin 3 for opens.
» If the specifications have been met:
– Check the next possible cause:
r
Manifold absolute pressure sensor cylinder 2 - the ground wire has an open ( p. 374)
99 a
Manifold absolute pressure sensor cylinder 2 - the ground wire has an open
Condition
7- Sh
600850-11 400590-10
Manifold absolute pressure sensor cylinder 2 - check the ground wire for opens
– Measure the resistance between the specified points.
Break Out Box AO pin 7 – Manifold absolute pressure sensor cylinder 2 connector DP pin 2
Resistance ≤ 0.6 Ω
» If the specifications have not been met:
– Check EFI control unit connector AO ( p. 392) pin 7 and connector DP pin 2.
– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector DP pin 2 for opens.
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) ( p. 375)
ENGINE CONTROL TROUBLE CODE 375
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)
86 m
600850-11 400658-10
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break Out Box AO pin 24 – Measuring point Ground (−)
56 co
Voltage < 0.1 V
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 24 to connector DP ( p. 400) pin 3 for a short circuit to
9- k.
plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
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
Resistance ∞Ω
» If the specifications have not been met:
P
– Check the cable from EFI control unit connector AO ( p. 392) pin 24 to con-
nector DP ( p. 400) pin 3 for a short circuit to ignition plus (terminal 15).
600850-11
» If the specifications have been met:
– Check the next possible cause:
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short cir-
cuit to the sensor power supply ( p. 375)
Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply
Condition
The ignition is off.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)
ENGINE CONTROL TROUBLE CODE 376
Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to the
sensor power supply
– Measure the resistance between the specified points.
Break Out Box AO pin 24 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from EFI control unit connector AO ( p. 392) pin 24 to con-
nector DP ( p. 400) pin 3 for a short circuit to the sensor power supply.
600850-11
» If the specifications have been met:
– Change the manifold absolute pressure sensor cylinder 2.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
ENGINE CONTROL TROUBLE CODE 377
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
600850-12 400645-10
Resistance ≤ 0.9 Ω
ENGINE CONTROL TROUBLE CODE 378
86 m
The instrument panel is disconnected.
56 co
9- k.
600850-12 400645-10
Resistance ≤ 0.9 Ω
7- Sh
600850-12 400657-10
Resistance ≤ 0.9 Ω
ENGINE CONTROL TROUBLE CODE 379
86 m
The instrument panel is disconnected.
56 co
9- k.
600850-12 400657-10
Resistance ≤ 0.9 Ω
7- Sh
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)
– Measure the resistance between the specified points.
Break out box CO pin 19 – Measuring point Ground (−)
Resistance ∞Ω
ENGINE CONTROL TROUBLE CODE 380
86 m
CAN-low - the signal wire has a short circuit to ground (terminal 31)
Condition
The ignition is off.
The diagnostics tool is disconnected.
56 co
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The CAN bus terminating resistor is disconnected. ( p. 404)
The immobilizer control unit is disconnected. ( p. 102)
The instrument panel is disconnected.
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)
– Measure the resistance between the specified points.
87 rt
Resistance ∞Ω
a
86 m
600850-12 600850-11
56 co
CAN-high - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break out box CO pin 19 – Break Out Box AO pin 7
Resistance ∞Ω
9- k.
» If the specifications have not been met:
– 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
600850-12 600850-11
CAN-low - check the signal wire for a short circuit to sensor ground
– Measure the resistance between the specified points.
Break out box CO pin 20 – Break Out Box AO pin 7
Resistance ∞Ω
» If the specifications have not been met:
86 m
– Check the cable from connector EV ( p. 403) pin 5 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to sensor ground.
– Check the cable from connector DO ( p. 400) pin 8 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
56 co
to sensor ground.
– Check the cable from connector AT ( p. 395) pin 1 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to sensor ground.
– Check the cable from connector AP ( p. 393) pin 3 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to sensor ground.
9- k.
– Check the cable from connector CU ( p. 398) pin 4 to the EFI control unit connector CO ( p. 397) pin 20 for a short cir-
cuit to sensor ground.
» If the specifications have been met:
r
– Check the next possible cause:
99 a
CAN bus terminating resistor - the CAN-high wire has an open ( p. 382)
Condition
The ignition is off.
The diagnostics tool is disconnected.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
87 rt
600850-12 400585-10
CAN bus terminating resistor - check the CAN-high wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 19 – CAN bus terminating resistor connector AT pin 2
Resistance ≤ 0.9 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
– Check the next possible cause:
CAN bus terminating resistor - the CAN-low wire has an open ( p. 383)
ENGINE CONTROL TROUBLE CODE 383
86 m
600850-12 400585-10
56 co
CAN bus terminating resistor - check the CAN-low wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 20 – CAN bus terminating resistor connector AT pin 1
Resistance ≤ 0.9 Ω
9- k.
» If the specifications have not been met:
– 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
» If the specifications have been met:
99 a
600850-12 400588-10
Resistance ≤ 0.9 Ω
» If the specifications have not been met:
– 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.
» If the specifications have been met:
ENGINE CONTROL TROUBLE CODE 384
86 m
56 co
600850-12 400588-10
Resistance ≤ 0.9 Ω
» If the specifications have not been met:
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.
» If the specifications have been met:
7- Sh
600850-12 400583-10
Resistance ≤ 0.9 Ω
» If the specifications have not been met:
– Check EFI control unit connector CO ( p. 397) pin 19 and connector AP pin 2.
ENGINE CONTROL TROUBLE CODE 385
– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector AP pin 2 for opens.
» If the specifications have been met:
– Check the next possible cause:
Diagnostics connector - the CAN-low wire has an open ( p. 385)
86 m
56 co 600850-12 400583-10
9- k.
Diagnostics connector - check the CAN-low wire for opens
– Measure the resistance between the specified points.
Break out box CO pin 20 – Diagnostic connection plug AP pin 3
r
Resistance ≤ 0.9 Ω
99 a
– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector AP pin 3 for opens.
» If the specifications have been met:
– Check the next possible cause:
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
600850-12 400658-10
CAN-high - check the signal wire for a short circuit to plus (terminal 30)
– Measure the voltage between the specified points.
Break out box CO pin 19 – Measuring point Ground (−)
Voltage ≤ 0.1 V
ENGINE CONTROL TROUBLE CODE 386
86 m
CAN-low - the signal wire has a short circuit to plus (terminal 30)
Condition
The ignition is off.
The diagnostics tool is disconnected.
56 co
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The CAN bus terminating resistor is disconnected. ( p. 404)
The immobilizer control unit is disconnected. ( p. 102)
The instrument panel is disconnected.
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)
– Measure the voltage between the specified points.
87 rt
Voltage ≤ 0.1 V
a
CAN-high - the signal wire has a short circuit to ignition plus (terminal 15)
Condition
The ignition is off.
The diagnostics tool is disconnected.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
The CAN bus terminating resistor is disconnected. ( p. 404)
The immobilizer control unit is disconnected. ( p. 102)
The instrument panel is disconnected.
86 m
600850-12 600850-11
56 co
CAN-high - check the signal wire for a short circuit to ignition plus (terminal 15)
– Measure the resistance between the specified points.
Break out box CO pin 19 – Break Out Box AO pin 20
Resistance ∞Ω
9- k.
» If the specifications have not been met:
– 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 plus (terminal 30).
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 plus (terminal 30).
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 plus (terminal 30).
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 plus (terminal 30).
– 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 plus (terminal 30).
87 rt
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)
– Measure the resistance between the specified points.
Break out box CO pin 20 – Break Out Box AO pin 20
Resistance ∞Ω
» If the specifications have not been met:
86 m
– Check the cable from connector EV ( p. 403) pin 5 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to plus (terminal 30).
– Check the cable from connector DO ( p. 400) pin 8 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
56 co
to plus (terminal 30).
– Check the cable from connector AT ( p. 395) pin 1 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to plus (terminal 30).
– Check the cable from connector AP ( p. 393) pin 3 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to plus (terminal 30).
9- k.
– Check the cable from connector CU ( p. 398) pin 4 to the EFI control unit connector CO ( p. 397) pin 20 for a short cir-
cuit to plus (terminal 30).
» If the specifications have been met:
r
– Check the next possible cause:
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
The ignition is off.
The diagnostics tool is disconnected.
The EFI control unit is disconnected. ( p. 227)
The break out box is connected to the wiring harness.
87 rt
600850-12 600850-11
CAN-high - check the signal wire for a short circuit to the sensor power supply
– Measure the resistance between the specified points.
Break out box CO pin 19 – Break Out Box AO pin 1
Resistance ∞Ω
» If the specifications have not been met:
– 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 plus (terminal 30).
– 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 plus (terminal 30).
ENGINE CONTROL TROUBLE CODE 389
– 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 plus (terminal 30).
– 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 plus (terminal 30).
– 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 plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
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
The ignition is off.
The diagnostics tool is disconnected.
The EFI control unit is disconnected. ( p. 227)
86 m
The break out box is connected to the wiring harness.
The CAN bus terminating resistor is disconnected. ( p. 404)
The immobilizer control unit is disconnected. ( p. 102)
The instrument panel is disconnected.
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
– Measure the resistance between the specified points.
7- Sh
Resistance ∞Ω
» If the specifications have not been met:
– Check the cable from connector EV ( p. 403) pin 5 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
87 rt
– Check the cable from connector AT ( p. 395) pin 1 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to plus (terminal 30).
P
– Check the cable from connector AP ( p. 393) pin 3 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuit
to plus (terminal 30).
– Check the cable from connector CU ( p. 398) pin 4 to the EFI control unit connector CO ( p. 397) pin 20 for a short cir-
cuit to plus (terminal 30).
» If the specifications have been met:
– Check the next possible cause:
CAN bus terminating resistor - value not plausible ( p. 389)
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
CONNECTOR OVERVIEW 391
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
Pin overview
a
1 Ground
2 Signal wire
P
400581-10
Pin overview
1 System voltage
2 Signal wire
3 Sensor ground
400582-10
CONNECTOR OVERVIEW 392
Pin overview
1 Signal wire
2 Power supply
3 Sensor ground
400582-10
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
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
CONNECTOR OVERVIEW 393
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
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
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
Pin overview
1 Power supply
2 Signal wire
3 Sensor ground
400584-10
CONNECTOR OVERVIEW 394
Pin overview
1 Signal wire
2 System voltage
3 Sensor ground
400584-10
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
Pin overview
a
1 Control wire
2 System voltage
P
400644-10
Pin overview
1 Control wire
2 System voltage
400644-10
CONNECTOR OVERVIEW 395
Pin overview
1 CAN low
2 CAN high
400585-10
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
Pin overview
a
1 Sensor ground
2 Signal wire
P
400586-10
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
CONNECTOR OVERVIEW 396
Pin overview
1 Power supply, lambda sensor heater
2 Lambda sensor heater, control wire
3 Sensor ground
4 Signal wire
400646-10
Pin overview
1 Power supply, lambda sensor heater
86 m
2 Lambda sensor heater, control wire
3 Sensor ground
4 Signal wire
56 co 400646-10
9- k.
Lambda sensor cylinder 1, connector CE
32.26
Pin overview
r
1 Power supply, lambda sensor heater
2 Lambda sensor heater, control wire
99 a
3 Sensor ground
4 Signal wire
7- Sh
400647-10
87 rt
Pin overview
a
3 Sensor ground
4 Signal wire
400647-10
Pin overview
1 Power supply
2 Control wire
400648-10
CONNECTOR OVERVIEW 397
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
3 Motor drive circuit A phase BN, control wire
4 Motor drive circuit B phase BN, control wire
56 co
5 Injector cylinder 1, control wire
6 Injector cylinder 2, control wire
400643-10
7 Motor drive circuit A phase AN, control wire
8 Ground (terminal 31)
9- k.
9 Ground (terminal 31)
10 Not assigned
11 Motor drive circuit A phase BP, control wire
r
12 Motor drive circuit B phase BP, control wire
99 a
19 CAN high
20 CAN low
21 Motor drive circuit B phase AP, control wire
a
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 OVERVIEW 398
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
400652-10
7 Motor drive circuit B phase BP, control wire
8 Motor drive circuit A phase BP, control wire
87 rt
Connector CU
32.33
Pin overview
1 Not in use
2 Ground
3 CAN high
4 CAN low
400588-10
CONNECTOR OVERVIEW 399
Pin overview
1 Power supply
2 Control wire
400589-10
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
2 Side stand switch, signal wire
99 a
5 Ground
6 Signal wire status, electric starter lock control unit
600859-10
7 Signal wire status, electric starter lock control unit
8 Neutral switch, signal wire
87 rt
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
Pin overview
1 System voltage
2 Side stand switch, signal wire
3 Starter auxiliary relay
4 Clutch switch, signal wire
5 Ground
6 Control wire status, electric starter lock control unit
400657-10
7 EFI control unit, control wire status
8 Neutral switch, signal wire
CONNECTOR OVERVIEW 400
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
Pin overview
86 m
1 System voltage
2 Sensor ground
3 Signal wire
56 co
9- k. 400590-10
Pin overview
r
1 System voltage
99 a
2 Sensor ground
3 Signal wire
7- Sh
87 rt
400590-10
Pin overview
1 System voltage
P
2 Sensor ground
3 Signal wire
400590-10
Pin overview
1 Power supply
2 Control wire
400591-10
CONNECTOR OVERVIEW 401
Pin overview
1 Power supply
2 Control wire
400591-10
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
400653-10
87 rt
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
3 K bus wire to KTM diagnostics tool
4 Power supply (terminal 15)
5 CAN high
6 Not assigned
400683-10
7 Fuel evaporation valve, control wire
8 Power supply (terminal 30)
9 Power supply (terminal 15)
CONNECTOR OVERVIEW 402
10 CAN low
Connector ER
32.49
Pin overview
1 Not assigned
2 LED alarm system (optional), signal wire
3 K bus wire to KTM diagnostics tool
4 Power supply (terminal 15)
5 CAN high
6 Not assigned
400684-10
7 Fuel evaporation valve, control wire
8 Power supply (terminal 30)
9 Power supply (terminal 15)
86 m
10 CAN low
Connector ES
32.50
56 co
Pin overview
1 Power supply (terminal 15) fuse 3
2 Power supply (terminal 15) fuse 4
3 Power supply (terminal 30) fuse 8
9- k.
4 Power supply (terminal 15) fuse 9
5 Brake light switch, control wire
6 Power supply (terminal 15) fuse 2
r
400654-10
7 Right turn signal, control wire
99 a
10 Not assigned
11 Not assigned
12 Not assigned
13 Starter auxiliary relay
87 rt
Connector ET
32.51
Pin overview
1 Power supply (terminal 15) fuse 3
2 Power supply (terminal 15) fuse 4
3 Power supply (terminal 30) fuse 8
4 Power supply (terminal 15) fuse 9
5 Brake light switch, control wire
6 Power supply (terminal 15) fuse 2
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
13 Starter auxiliary relay
14 Power supply (terminal 15)
CONNECTOR OVERVIEW 403
Pin overview
1 Power supply
2 Power supply
3 Ground
4 CAN high
5 CAN low
6 Engine coolant temperature sensor cylinder 2, signal wire
86 m
400645-10
7 Engine coolant temperature sensor cylinder 1, signal wire
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
17 Neutral switch, signal wire
99 a
18 Ground
19 LED alarm system (optional), signal wire
7- Sh
24 Not assigned
25 Not assigned
26 Not assigned
a
32.53
Pin overview
1 System voltage
2 Control wire
600854-10
CONNECTOR OVERVIEW 404
Pin overview
1 Control circuit power supply
2 Control wire
3 Fuel pump power supply
4 Working circuit power supply
600852-10
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
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
Ignition system Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Generator 12 V, 390 W
a
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
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 407
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)
Valve - valve stem diameter
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
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
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
New condition 0.025… 0.055 mm (0.00098… 0.00217 in)
Wear limit 0.080 mm (0.00315 in)
Crankshaft - step bearing diameter 27.985… 28.000 mm (1.10177… 1.10236 in)
Crankshaft - radial clearance of step bearing
9- k.
New condition 0.030… 0.070 mm (0.00118… 0.00276 in)
Wear limit 0.090 mm (0.00354 in)
Clutch facing disc - thickness
r
New condition 2.92… 3.08 mm (0.115… 0.1213 in)
99 a
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)
Engine speed: 1,500 rpm
Coolant temperature: ≥ 70 °C (≥ 158 °F) 3.0… 4.0 bar (44… 58 psi)
Engine speed: 5,000 rpm
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
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, engine case M6x80 10 Nm (7.4 lbf ft) –
Screw, engine case M6x90 10 Nm (7.4 lbf ft) –
Screw, freewheel holder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, generator cover M6 10 Nm (7.4 lbf ft) –
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
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
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
Front 2.5 bar (36 psi)
Rear 2.5 bar (36 psi)
9- k.
Tire air pressure with passenger / full payload
Front 2.5 bar (36 psi)
Rear 2.9 bar (42 psi)
r
Secondary drive 17:37
99 a
Lighting equipment
36.1
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.
86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P
TECHNICAL DATA - FORK 413
86 m
Comfort 5 turns
Standard 5 turns
Sport 3 turns
56 co
Full payload 3 turns
Spring length with preload spacer(s) 405 mm (15.94 in)
Spring rate
Medium (standard) 9.5 N/mm (54.2 lb/in)
9- k.
Air chamber length 80+20 +0.79
−10 mm (3.15−0.39 in)
86 m
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
56 co
Full payload 10 clicks
Spring preload
Comfort 6 mm (0.24 in)
Standard 6 mm (0.24 in)
9- k.
Sport 8 mm (0.31 in)
Full payload 8 mm (0.31 in)
Spring rate
r
Medium (standard) 95 N/mm (542 lb/in)
99 a
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
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
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
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
– 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.
– Clean the chain. ( p. 84)
– 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
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.
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 coolant level. ( p. 194)
– 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 rear. ( p. 13)
– 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
– Take the front of the motorcycle off the work stand. ( p. 10)
87 rt
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
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
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
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
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
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
/2.B6 BJ/1
-X52
-B14 t°
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
-X200
2
152
1
-H7
231
CAN-H
7- Sh
-X19 /2.B6
142 141,142,158 91 155,180 52 237 237
3
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
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
X22 Plug-in connector for supplementary equipment (terminal 31) A6
99 a
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
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
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
– Power Synt 4T
P
86 m
corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
56 co
– Hydraulic Fluid 75
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
86 m
Guideline
– KTM recommends Motorex® products.
Supplier
56 co
Motorex®
– Protect & Shine 645
Long-life grease
Guideline
9- k.
– KTM recommends Motorex® products.
Supplier
Motorex®
r
– Fett 2000
99 a
Lubricant (T511)
Guideline
7- Sh
Lubricant (T152)
Guideline
a
– 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
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Clean 900
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
86 m
Guideline
– KTM recommends Motorex® products.
Supplier
56 co
Motorex®
– Clean & Polish
Bearing puller
Art. no.: 15112017000
400037-01
86 m
56 co 400059-01
9- k.
Extractor
Art. no.: 58429009000
r
99 a
7- Sh
400073-01
87 rt
400101-01
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
400123-01
400038-01
SPECIAL TOOLS 442
400136-01
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
500077-01
700270-01
SPECIAL TOOLS 443
500078-01
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
200312-01
SPECIAL TOOLS 445
Pressure bell
Art. no.: 61229016000
200313-01
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
200317-01
SPECIAL TOOLS 446
200318-01
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
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
301466-10
400160-01
SPECIAL TOOLS 448
400169-01
86 m
56 co 400170-01
9- k.
Puller, 2-arm
Art. no.: 78029033100
r
99 a
7- Sh
500166-01
87 rt
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
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
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
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
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
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
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
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