READY TO RACE REPAIR MANUAL 2018 390 Duke Art. no, 3206338enRead this repair manual carefully and thoroughly before beginning work. The vehicle wll 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 tothe latest state ofthis model series. We reserve the right to make Changes inthe interest of technical advancement without updating this repair manus at the same time. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop ‘ate not specified here. It is assumed thatthe repair work wil be performed by a fully trained mechanic. Al specitications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, ec., without prior notice ‘and without specifying reasons, to adapt these to local conditions, as well as to stop production ofa particular ‘model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions. misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply. © 2018 KTM Sportmotorcycle GmbH, Mattighofen Austria Allrights reserved Reproduction, even in part, as well as copying ofall kinds, is permitted only withthe express written permission of the copyright owner Iso 9001(12 100 6061) ‘According tothe international quality management standard ISO 9001, KTM uses quality assur ance processes that lead to the maximum possible quality ofthe products Issued by: TOV Management Service Tov KTM Sportmotoccycle GmbH StallhotnerstraBe 3 5230 Mattighofen, Austria This document is valid forthe following models: ‘390 Duke EU (F4303R1, F4303R2) 390 Duke EU (F4303R3, F4303R4) 390 Duke AU (F4360R1, F4360R2) 390 Duke JP (F4386R1, F4386R2) 390 Duke AR (F4342R1, F4342R2) 390 Duke BR (F4340R1, Fa340R2) 390 Duke CN (F4387R1, F4387R2) 390 Duke CO (F4341R1, F4341R2) ‘390 Duke MY (F4389R1, F4389R2) 390 Duke PH (F4382R1, F4382R2) 390 Duke TH (F4383R4, F4383R5) 390 Duke US (F4375R1, F4375R2) 3206338en o12018MEANS OF REPRESENTATION 1.1 Symbols used 1.2 Formats used. SAFETY ADVICE, 2.1 Repair Manual 2.2 — Safety advice. 2.3 Degres of risk and symbols. 24 — Work rules. IMPORTANT NOTES. 3.1 Manufacturer and implied warranty. 3.2 Operating and auxiliary substances 3.3 Spare parts, accessories 34 Figures SERIAL NUMBERS 4.1 Chassis number. 42 Type label 43° Key number. 4.4 Engine number... MOTORCYCLE 5.1 Raising the motorcycle with the rear iting gear 5.2. Removing the rear of the motorcycle from the lifting gear 5.3 Lifting the motorcycle withthe front iting gear 5.4 Taking the motoreyele off the front lifting gear 5.5 Raising the motorcycle withthe work stand 5.6 Removing the motoreyle from the ‘work stand 5.7 Starting.. 5.8 Starting the motorcycle to make checks. FORK, TRIPLE CLAMP 6.1 Cleaning the dust boots ofthe fork legs : 6.2. Removing the fork legs 6.3 Installing the fork legs. 6.4 Disassembling the fork legs. 6.5 Checking the fork legs. 6.6 Assembling the fork logs. 6.7 Removing the lower triple clamp. 6.8 Installing the lower tripe clamp 6.9 Checking the play of the steering head bearing 6.10 Adjusting the steering head bearing play 6.11 Changing the steering head bearing 2 2 12 13 13) 4 15 16 v7 a7 17 18 20 22 23 26 28 al as 10 u 12 HANDLEBAR, CONTROLS. 7.1 Checking the clutch lever pay. 7.2 Adjusting pay inthe clutch lever. 7.3 Changing the throttle grip FRAME 8.1 Changing footrest brackets. 2 Checking the frame ‘SHOCK ABSORBER, SWINGARM . 9.1 Measuring the rear wheel dimension unloaded. Checking the static sag of the shock absorber. Adjusting the spring preload of the shock absorber Checking the heim join fr play Removing the shock absorber. Installing the shock absorber... Removing the spring Installing the spring Checking the swingarm, Removing the swingarm, Installing the swingarm... Checking the swingarm bearing for play 9.13 Changing the swingarm bearing EXHAUST. 10.1 10.2 92 93 oa 95 96 a7 98 99 9.10 9. 912 Removing the exhaust system. Installing the exhaust system 10.3 Removing the main silencer: 10.4 Installing the main silencer. AIR FILTER, 11.1 Changing the air iter, cleaning the air filter box. FUEL TANK, SEAT, TRIM.. 12a 122 123 124 125 126 127 128 129 12:10 12a 122 1243 12a 125 Opening the filler cap... Closing the filer cap, Removing the front rider's seat Mounting the front riders seat... Remouing the passenger sea . Mounting the passenger seat Removing the fuel tank cover... Installing the fuel tank cover... Removing the fuel tank. Installing the fuel tank Remouing the front spoiler Fitting front spoiler Removing front fender. Installing front fender. Checking the fuel pressure, 35 35 35 36 41 a1 46 47 47 47 a7 48 48, 49 51 51 52 53 55 58 58 62 63 66 66 67 67 69 69 69 70 70 70 a a 73 76 78 80 80 81 al 8113 4 15 12.16 Changing the fuel filter 12.17 Changing the fuel pump . WHEELS 13.1 Checking the tre alr pressure 13.2 Checking the tite condition 13.3 Checking the brake discs... 13.4 Front whee! 13.4.1 Removing the front whee! 13.4.2 Installing the front whee! 13.4.3 Changing the front brake dise 13.4.4 Changing font whee! bearing 13.4.5 Checking the wheel bearing for play 13.5 Rear wheel 13.5.1 Removing the rear whee! 13.5.2 Installing the rear whee! 13.5.3 Changing the rear brake disc 13.5.4 Changing the rear whee! bearing 13.5.5 Checking the chain tension 13.5.6 Adjusting the chain tension 13.5.7 Checking the chain, rear sprocket, and engine sprocket. 13.5.8 Cleaning the chain, 13.5.9 Checking the rear hub rubber dampers 135.10 Opening the chain 13.5.11 Riveting the chain 13.5.12 Changing the drivetrain kt. WIRING HARNESS, BATTERY... 14.1 Removing the battery 14.2 _ Installing the battery . 14,3 Disconnecting the negative cable of the battery. 14.4 Connecting the negative cable of the battery 14.5 Recharging the battery 14.6 Checking the charging voltage 14,7 Checking the open-circuit current. 14.8 Changing the fuses of individual power consumers BRAKE SYSTEM 15.1 Checking the front brake linings, 15.2 Changing the front brake linings. 15.3 Checking the brake fluid level of the front brake 15.4 Adding front brake fud.. 15.5 Changing the front brake fluid 15.6 Checking the rear brake linings. 15,7 Changing the rear brake linings... 158 Checking te fe ave! oft brake lever. 29 = 90) 83 84 86 86 86 87 92 92 = 92 93 95, 96 100 101 101 103 104 105 105 106 109 109 10 no ul ul 112 113 3. 115, 18 115 us. 18. 120 122 122 125, 16 15.9 Adjusting the free travel of the foot brake lever 15.10 Checking the rear brake fluid level 15.11 Adding rear brake fluid 15.12 Changing the rear brake fluid. COMBINATION INSTRUMENT 16.1 Combination instrument. 16.2 Activation and test 16.3 _Day-Night mode... 16.4 Warning notes. 16.5 Indicator lamps... 16.6 Display 16.7 Speed. 16.8 Shift warning light. 16.9 Speed. 16.10 000 display 16.11 Coolant temperature indicator 16.12 Fuel level display 16.13 Time 16.14 Favourites display 16.15 Quick Selector 1 display. 16.16 Quick Selector 2 dispay. 16.17 Menu. 1.17.1 KTM MY RIDE (optional) 1617.2. Info 16.17.3 Motorcycle 16.17.4 Settings 16.17.5 Preferences. 16.17.6 Pairing (optional. 16.17.7 Audio (optional) 1617.8 Telephony (optional). 1.17.9. General Info 16.17.10 Trip 1 16.17.11 Trip2 16.17.12 Warning. 16.17.13 ABS. 16.17.14 Favourites, 16.17.15 Quick Selector 1 16.17.16 Quick Selector 2. 16.17.17 Bluetooth.. 16.17.18 Shift Light 16.17.19 Setting the time and date... 16.17.20 DRL. 16.17.21 Distance 16.17.22 Temperature... 16.17.23 Fuel Cons... 16.17.24 Language 16.17.25 Service 16.17.26 Extra Functions... 16.18 Setting the service interval display... 125 126 127 128 131 131 131 11 132 132 133 134 134 135 135 135 136 136 136 137 137 137 137 138 138 138, 139 139 40 140 11 ML 141 142 142 143 143 143. 144 144 14a 145 146 146 447 147 147 447 14817 LIGHTING SYSTEM, INSTRUMENTS 17.1 Daytime running light (ORL) 17.2 Checking the headlight setting 17.3 Adjusting the headlight range... 18 ENGINE 18.1 Removing the engine. 18.2 Installing the engine. 18.3 _ Engine disassembly. 18.3.1 preparations. 18.3.2 Draining the engine oil 18.3.3. Removing the chain securing, ude Removing the valve cover Removing the spark plug Removing the clutch cover. Setting the engine to ignition top dead center Removing the timing chain tensioner Removing the camshaft Removing the cylinder head Removing the piston Removing the starter motor Removing the timing chain. Removing the water pump wheel Removing the alternator cover. rotor, removing Removing the starter drive Removing the drive wheel of the balancer shaft Reming he gear postion Removing the suction pump... Removing the clutch basket Removing the primary gear Removing the force pump. Removing the shift shat. Removing the shift drum locating Removing the locking lever Removing the oil filter. Removing the left engine case. Removing the shift rails Removing the shift drum Removing the shift forks. Removing the transmission shatts 18,3.33 Removing the balancer shaft. 18.3.34 Removing the crankshaft 18.4 Working on individual parts 18.4.1 Working on the lft section of the engine case 18.3.4 18.35 18.36 18.37 18.38 18.39 183.10 18.311 18.3.12 183.13 18.3.4 183.15 18.3.16 183.17 183.18 183.19 18.3.20 183.21 183.22 183.23 183.24 183.25 183.26 18.327 18.3.28 183.29 18.330 18.331 183.32 ag aaa 449 150 151 151 157 164 164 165 165 166 166 167 167 168, 169 169 170 a rr 172 172 473 173. 174 174 175 176 7 178 179 179 180 180 180 382 182 182 183 183 183 183 183 18.42 18.43 1844 18.45 18.4.6 18.47 18.48 18.49 18.4.10 18.4.1 184.12 18.4.13 184.14 18.4.15 18.4.16 184.17 18.4.18 18.4.19 18.4.20 18.4.21 18.4.22 18.4.23 184.24 18.4.25 18.4.26 18.4.27 Working on the right section of the engine case ‘Changing the shaft seal ring of the water pump ‘Checking the radia play of the loner conrod bearing... ‘Changing the conrod bearing, ‘Changing the balancer shaft Dearing Work onthe eyinder head. Checking the cylinder head. Checking the pivot point of the camshafts Checking/measuring the oylinder ‘Checking the piston ring end wp. CChecking/measuring the piston Checking the piston/cylinder ‘mounting clearance, ‘Checking the oil pump Checking the ol pressure regulator vale... ‘Checking the cluteh Checking the shift mechanism reassembling the shift shaft Disassembling the main shaft Disassembling the countershatt.. ‘Checking the transmission. Assembling the main shat. Assembling the countershatt. ‘Checking the timing assembly. Changing the stator... Checking the electric starter rive. ‘reewnee, checking 18.5 Engine assembly... 185.1 18.52 1853 1854 1855 1856 1857 1858 18.59 185.10 185.11 185.12 185.13 185.14 185.15 Instaling the crankshaft Installing the balancer shaft Installing the transmission shafts Installing the shift forks Installing the shift drum Installing the shift ralls Installing the left engine case Installing the ol filter. Installing the locking lever Installing the shift drum Focating instaling the shit shaft Installing the oil pump Installing the primary gear Installing the clutch basket. Installing the spacer... 185 186 186 187 . 190 190 191 192 193 193 194 195 195 196 196 197 198 199 1 200 200 202 202 204 1 208 206 207 207 207 207 208 208 208 209 209 aul au 212 212 212 214 215 21719 20 2 22 23 185.16 185.17 Installing the suction pump Installing the gear position sensor Installing the balancer shaft drive wheel Installing the starter drive. Installing the rotor alternator cover, installing Installing the water pump Installing the timing chain Installing the starter motor. Installing the piston Installing the cylinder head. Installing the camshafts Installing the timing chain tensioner. 185.18 185.19 185.20 185.21 18.5.22 185.23 185.28 185.25 185.26 18.5.27 185.28 185.29 185.30 185.31 18.5.32 185.33 185.34 Adjusting the valve clearance: Installing the clutch cover Installing the spark plug. Installing the valve cover Installing the chain securing suide, Installing the oil sereen engine, removing from the engine assembly stand 185.35 18.5.36 cuuteH 19.1 SHIFT MECHANISM 20.1 Adjusting the shift lever. 20.2. Progamming te gear positon WATER PUMP, COOLING SYSTEM aul 212 (Checking the clutch Draining the coolant Filling/bleeding the cooling system Checking the antiteeze and coolant level 21.4 Checking the coolant level 21.8 Changing the coolant. CYLINDER HEAD 221 222 a3 Checking valve clearance. Checking the valve clearance, changing the spark plugs ‘Adjusting the valve clearance 224 Camshatts, removing 22.5 Installing the camshatts. LUBRICATION SYSTEM. 231 223 Olt circuit Checking the valve clearance .. 2u7 218 219 220 220 221 221 222 222 222 228 225 226 226 227 228 229 229 230 230 231 232 232 239 239 239 240 280 240 242 283. 2a 246 286 250 255, 256 257 259 259 24 25 26 27 28 29 30 23.2 23.3 234 checking the engine cil level. Changing the engine ol and oil filter, cleaning the oll screens 23.5 Adding engine ol. IGNITION SYSTEM. 24.1. Alternator - checking the stator winding... 24.2 Changing the spark pug. THROTTLE VALVE BODY 25.1 Resetting the service display using the KTM diagnostic tol... 25.2 Performing the initialization run... TECHNICAL DATA. 26.1. Engine 26.2 Tolerance, engine wear limits. 26.3 Engine tightening torques. 26.4 Capacities 26.4.1 Engine oil 26.4.2 Coolant. 26.4.3 Fuel 26.5 Chassis 26.6 Electrical system. 26.6.1 Diagnostics connector 26.6.2 Front ACC and ACC2.. 26.7 Tires. 268 Fork 26.9 Shock absorber 26.10 Chassis tightening torques CLEANING/PROTECTIVE TREATMENT, and Cleaning the motorcycle. 27.2 Checks and maintenance steps for winter operation STORAGE, 28.1 Storage.. 28.2 Preparing fr use after storage. SERVICE SCHEDULE 29.1 29.2 29.3 WIRING DIAGRAM 30.1 Page 1 of 9 (EWAUNIPIARIBR, CNIMYIPHITHICO) nnn Page 2 of 9 (EU/AUIIPIARIBR, (CNIMYIPHITHICO) Page 3 of 9 (EU/AUJPIARIBR, CNIMYIPHITHICO) Additional information Required work Recommended work 30.2 30.3 CChecking the engine oil pressure... 259) 259 261 263 264 264 266 268 268, 268 269 269 270 270 272 272 272 272 273 273 274 274 274 274 275 278, 279 279 220 281 281 282 283, 283 283 284 286 286 288 290304 305 306 307 308 20.9 30.10 30.11 30.12 30.13, 30.14 30.15, 30.16 30.17 30.18, Page 4 of 9 (EUIAU/IP/ARIBR, CNIMYIPH/THICO) Page 5 of 9 (EUIAU/IPIARIBR, CNIMYIPH/THICO) age 6 of 9 (EUIAU/JP/ARIBR, CNIMYIPHITHICO) Page 7 of 9 (EUIAU/IPIARIBR, CNIMYIPH/THICO) Page 8 of 9 (EUAU/JPIARIBR, CNIMYIPHITHICO) son Page 9 of 9 (EUIAU/JP/ARIBR, CNIMYIPH/THICO) Page 1 of 9 (US). Page 2 of 9 (US). Page 3 of 9 (US). Page 4 of 9 (US). Page 5 of 9 US) oun Page 6 of 9 (US Page 7 of 9 (US), Page 8 of 9 (US). Page 9 of 9 US).ounn 31 SUBSTANCES 32 AUXILIARY SUBSTANCES... 33 SPECIAL TOOLS 34 STANDARDS 35. INDEX OF SPECIAL TERMS. 36. LIST OF ABBREVIATIONS. 37, LIST OF SYMBOLS. 37.1 37.2 37.3 INDEX Red symbols. Yellow and orange symbols. Green and blue symbols, 292 204 296 298 300 302 304 306 308 310 312 314 316 318 320 322 324 326 340 3a 382 343 343 343 343 344‘The meaning of specific symbols is described below. Indicates an expected reaction (eg. of a work step ora function) Indicates an unexpected reaction (eg. of a work step ora function). Indicates a page reference (more information is provided on the specified page) Indicates information with more detalls or tips. Indicates the result ofa testing step. Indicates a voltage measurement, Indicates a current measurement, Indicates a resistance measurement. Indicates the end of an activity including potential rework ‘The typographical formats used in this document are explained below. Proprietary name Name® Brana™ Indicates a proprietary name. Indicates a protected name. Indicates a brand available on the open market. Refer to technical details ofthe vehicle or indicate technical terms, which ate explained in the glossary.Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips ‘that wil nelp you repair and maintain your vehicle. ‘This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are availabe, ‘A numberof safety instructions need to be followed to operate the product described safely, Therefore read this Instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to atthe relevant passages. ‘= Info Various information and warning labels are attached in prominent locations on the product described, Do ‘ot remove any information or warning labels. If they are missing, you or others may not recognize dangers {and may therefore be injured. Danger Identifies @ danger that will immediately and invariably lead to fatal or serious permanent injury ifthe ‘appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury ifthe appropriate measures are not taken. A cation Identities @ danger that may lead to minor injuries if the appropriate measures are not taken, Note Identities a danger that will lead to considerable machine and material damage ifthe appropriate measures are not taken, Note Indicates a danger that wll lead to environmental damage if the appropriate measures are not taken ‘Special tools are necessary fr certain tasks. The tools are not @ component of the vehicle, but can be ordered Using the number in parentheses. Example: bearing puller (15112017000) During assembly, use new parts to replace parts which cannot be reused (eg, sel-locking screws and nuts, seals, ‘sealing rings, O-rings, pins, and lock washers) In the case of certain screws, a thread locker (e.g. Loctite® is required. Apply according to the manutacturer's, instructions [After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged ‘or worn parts After completing a repair or service work, check the operating safety of the vehicle.‘The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with andlor conversions on the vehicle are not ‘covered by the warranty. ‘Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty Booklet Note Environmental hazard Improper handling of fel is a danger to the environment. = Do not allow fuel to enter the groundwater, the soil, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. nly use spare parts and accessories approved andlor recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. ‘The curtent KTM PowerParts for your vehicle can be found on the KTM website, International KTM Website: httpliwaw ktm,com ‘The figures contained in the manual may depict special equipment, In the interest of clarity, some components may be shown disassembled or may not be shown at al. Its not ‘always necessary to disassemble the component to perform the activity in question. Please follow the instructions, inthe text.‘se ‘The chassis number @ is stamped on the right side of the steer- ing head > (EUAP/ARIBRIENICOMY/PHITH) ‘The type label @ is on the right of the frame behind the steering head. (390 Duke AU) The type label @ is on the left of the frame behind the steer- ing head, ws) ‘The type label USA @ is acted onthe tp frame on the rien. ws) “The type label Canada @ is located onthe bottom frame on the let.‘The key number @ can be found on the KEYCODECARD, Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. ‘The engine number @ is stamped on the left side of the engine under the engine sprocketNote Danger of damage The parked vehicle can roll away or fall ver. = atk the vehicle on a firm and level surface = Mount the supports of the lifting gear. Insert the adapter in the rear lifting gear. Universal V adapter with bushings (61029955284) (8p. 330) ‘Rear wheel work stand (68329956000) (fp. 331) Stand the motorcycle upright, align the lifting gear withthe ‘swingarm and the adapters, and lift the motorcycle, Note Danger of damage The parked vehicle can roll away of fll ver. = Patk the vehicle on a firm and level sur ~ Secure the motorycte against fling ver. = Remove the rea iting gear and lean the vehicle onside sind @. = Remove bushings kit Note Danger of damage The parked vehicle can roll away or fall over. = atk the vehicle on a firm and level surface. Preparatory work = Raise the motoreycle withthe rear lifting gear. (© p. 12) ‘condition = Remove protection cap @. 2MOTORCYCLE 5 7 “<] = Move the handlebar to the straight-ahead position, Position the lifting gear. Mounting pin (6932965030) (= p. 332) Front wheel work stand, large (69329965000) (= p. 332), © Info Aways raise the motorcycle atthe rear first “wazusai] — Lift the motorcycle atthe font. 5.4 Taking the motorcycle off the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. = Park the vehicle on a firm and level surtace. Main work = Secure the motoreycle against falling over. = Remove the front iting gear, = Mount protection cap @. Finishing work jemove the rear of the motorcycle from the lifting ger. (@p.12) 5.5 Raising the motorcycle with the work stand Note Danger of damage The parked vehicle can roll away or fall over. = Park the vehicle on a firm and level surface, 13~ Remove serous @ Screw in the special tool holder all the way. Select the right height and width of the work stand. Work stand (62529055100) (© p. 331) = Raise the motorcycle. Into check thatthe work stand is properly seated, Danger of damage The parked vehicle can rll away or fall over. = Patk the vehicle on a firm and level surface = Mount and tighten screws @ Secure the motoreycle against falling over, = Remove the special tool Work stand (62529055100) (@ p. 331) Guideline ‘Screw, engine bearer | MB 22 Nm (16.2 Io 4Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death, = Always make sure there is sufficient ventilation when running the engine. = Use an effective exhaust extraction system wien starting or running the engine in an enclosed space. A aution Danger of accidents Electronic components and safety devices wil be damaged ifthe battery is discharged or missing. Never operate the vehicle with a discharged battery or without a battery. Note Engine damage Unfiltered intake air has @ negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter = Never start to use the vehicle without an air filter. Note Engine damage High rewing speed with a cold engine negatively impacts the lifespan of the engine. = Always run the engine warm at a low speed. = Unlock the steering = Sito the vehicle, take the weight off of the side stand, and ‘move up all the way. = Tune onergney OFF eich othe postion Q WN GG) | = Serie te geo eps ton Aer sc ne ten, can ea pu wating sau to seconds. Te turn check semzso| _ scone er un at eee ie ~ nt azrt oul 7 Tre geen de indexr ony High. 7 “Te ABS nda gi up nd ges ako tr Soret = Pres the eect arr buton © Info Do not press the electric starter button until the combi- nation instrument function check is finished. When starting, DO NOT open the throttle. If you open ‘the throttle during the starting procedure, fuel is not Injected by the engine management system and the ‘engine cannot stat, 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 stating sy. tem. You can only start the engine ifthe transmission isin neutral or ifthe clutch lever is pulled when a gear is engaged. Ifthe side stand is folded out and you shift into gear and release the clutch, the engine stops. 15Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. = Always make sure there is sufficient ventilation when running the engine. = Use an effective exhaust extraction system when starting or running the engi in an enclosed space. © Info Tress the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again. = Turn the emergency OFF switch to the position ©. = Shift gear to neutral. Switch on the ignition by turning the ignition key tothe posi- tna. QO ® Pre the eect starter ton Info Ho not open the throttle.Preparatory work = Raise the motoreycle withthe rear lifting gear. (8 p. 12) = Lift the motoreycte withthe front iting gear. © p. 12) Main work =" Push dust boots @ ofboth fork lags downward Info The dust boots should remove dust and coarse dirt par- ticles from the fork tubes. Over time, ditt can accumu- late behind the dust boots. If this dit is nat removed, the oil seals behind can start to leak. Warning. Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oil and grease. = Clean the brake dises with brake cleaner when nec- essary. = Clean and oll the dust boots and inner fork tubes of both fark legs. Universal ol spray (© p. 325) Press the dust boots back into their installation position. = Remove excess oil Finishing work = Take the matorcyce off the front lifting gear. (& p. 13) = Remove the rear of the motorcycle from the lifting gear. (@p.12) < Preparatory work = "Raise the meoreyele with the work stand, (© p, 13) = Clamp down the rea ofthe vehicle. = Remove font fender (Ep. 81) Main work =" Remove screw @ = Remove the cable tes. — Pl the wheel speed sensor out ofthe le and hang tothe side 76 FORK, TRIPLE CLAMP 63 Installing the fork legs ~ Remove serous @ ~ Press ack the brake linings witha light lateral iting ofthe brake caliper onthe brake ose ~ Pll the brake caliper with spacers carefully back fom the brake disc and hang the side Info To net operate the hand brake lever when the brake caliper is removed. ~ Loosen screw @ by several rotations. ~ Loosen screws @ ~ Pres on screw @) to push the wheel spindle out ofthe ante clamp, ~ Remove screw @ A Waring Danger of accidents Reduced braking effect caused by damaged brake discs. = Always ly the wheel down in such a way that the brake discs are not damaged. Holding the front wheel, withdraw the wheel spindle. Take the front wheel out ofthe fork = Loosen screws @. Remove the fork legs from the bottom: A Waring Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris: Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Main work Push the fork legs into the triple clamps. = Align the fork legs inthe required position using the fork rings.igen screws @ Guidetne Screw, top tiple [NS TS Rim CLT AAD clamp Tighten screws @. Guideline Screw, bottom Wiple [WB TE Rim BTA clamp ‘Check the whee! bearing for damage ond wear. If the whee! bearing is damaged or wern: = Change front whee! bearing. (3 p. 90) Clean and grease shaft seal rings @) and contact sutaces @ ofthe spacers. Tongrife grease (© p, 328) Insert the spacers Clean the thread of the wheel spindle and screw @. Clean and grease wheel spindle. Tongiife grease (ip. 324) Position the front wheel and insert the wheel spindle ‘Mount and tighten screw @, Guideline ‘Screw, front wheel | MB 25 Nm (18-4 Ib ft) spindle Position brake caliper with spacers. © Info H ensure thatthe brake linings are seated properly Mount screws @ but donot ighten yet. Guideline ‘Screw, front) MB 30 Nm @2.1 Tot brake caliper Loctite? 2047 Operate the hand brake lever repeatedly unti the brake lin- ings are in contact with the brake disc and there is a pressure Point. Fix the hand brake lever in the activated position ‘The brake caliper straightens, Tighten screws @. Guideline ‘Screw, front) MB 30 Nm @2.1 Tot brake caliper Loctite? 204" Remove the locking plece of the hand brake lever.= Position wheel speed sensor inthe drill hole, = Mount and tighten screw @, Guideline ‘Screw, wheel speed | MG Nm (5.9 FD sensor holder Route the cable and secure with cable tits) = Remove the load from the rear of the vehicle. = Operate the front brake and compress the fork a few times firmly The fork legs straighten. = Tighten screws @. Guideline Screw, fork stub | MB 15 Nm C.1 WAT Finishing work = Remove the motorcycle from the work stand. (28 p. 14) Install front fender. (2 p, 81) Info The operations are the same on both fork legs. , Condition “The fork legs have been removed. Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T6125) (@ p. 339) ~ Loosen the screw cover @. Info T The screw cover cannot be removed yet = Unclamp the fork leg = Drain the fork oi 20Unclamp the fork leg with the axe clamp, © Info Use soft jaws = Remove cartridge screw @ with the washer. Info Place a container underneath as oll will run out in most = Remove the cartridge Remove dust boot @. Remove lock rng @. @ © Info The tck rng has beveled end where a screniver ) can be applied Warm up the outer tube in area @ of the lower sliding bush ing Guideline 50°C EF) info Tower stiging bushing © must be pulled from its bear- soos bindRave uper sling bushing @ = Info Dwithout using a tool, pull the stack slightly apart by hand. Take off lower sliding bushing @. Take off support ring @ Take off seal ring @. Take off lock ring @. Take off dust boot @. Unclamp the fork le. Condition “The fork legs have been disassembled ae CCheck the inner tube and the axle clamp for damage. » If damage is found: = Change the inner tube. Measure the outside diameter of the inner tube in several places. External diameter of inner | 42.975... 43,005 mm tube (1.69193 ... 1.69311 in) Ifthe measured value is less than the specified value: = Change the inner tube. Measure the run-out ofthe inner tube. 0.20 mm (= 0.0079 in) » Ifthe measured value is greater than the specified value: = Change the inner tube ‘Run-out of inner tube 2= Check the outer tube for damage. If damage is found: = Change the outer tube ~ Check the surface ofthe sling bushings tf the dark layer @ is worn off = Change the slicing bushings ‘ Info I The procedures ae the same on both fork legs. Preparatory work = "Check the fork legs. (2 p. 22) Main work = "Clamp the inner tube using the ase clamp. Guideline Use sft ave ~ Mount the special tol, Protecting sleeve (T512) (3p. 338) ~ Grease and push on dust boot @. pores Lubricant (T14034) (®8 p. 324) Info H Atways change the dust boot, sel ring, lock ring, and suppor ring Mount the sealing lip atthe boom. = Push on tock ring @ ~ Grease and push on seal ring @. Lubricant (714034) p. 324) 7 The sealing lip points downward, the open side upward = Remove the special tol, 23fi. fu )) ~ Push on supposing @ = Sand the edges ofthe sing bushings with 6O0-git sendpa per then len and pase ter Fork oll (GAE 4) (48601 16651) (@ p. 323) = Pash on toner sting bushing @. = Mount uper sing bushing @. Info HWithout using a tool, pull the stack slightly apart by hand. ~~ Heat up outer tube in area @ of the lower sliding bushings. Guideline 50 °0 (122) Hold the lower sliding bushing with the longer side ofthe spe- cial tool. ‘Mounting tool (T5285) (Et p. 339) Push on the outer tube. Press the siding bushing all the way into the outer tube. = Position the support ring. = Hold the seal ring wth the shorter side ofthe special tool ‘Mounting tool (T5285) (Ep. 339) = Press the seal ring and support ring all the way into the outer tube. = Mount lock ring @. na” ‘The lock ring must engage audibly. = Mount dust boot @. zSlide the cartridge into the inner tube. = Mount and tighten catidge screw @) withthe washer Guidetine Screw, carvidge [W10d.5 [25 Nm (18-4 I) = Clamp the left fork leg vertically. Guideline =~. Use soft avs = iit with fork ot Fork oi 50 mi | Fork ol SAE @) (05.2102) | 4960116681) (2p. 323) Info After approx. half the oll capacity has been filled, clase ‘the screw cap of the outer tube, unclamp the fork and bounce a number of times so that the cartridge fils with ol. Then add the remaining amount. = Push the outer tube upward. = Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T6125) (=p, 339) = Grease the O-ring ofthe serew cover. Lubricant (7958) (@ p. 328) = Mount and tighten screw cap @. Guideline ‘Screw cap on outer [M47x1.5 | 30Nm(22.1 Ibf ft) tube 25om MCA SECT ili Preparatory work Mfrs the motorcycle withthe work stand (p13) = Clamp dou thera ofthe eile, ~ Remove ton ender. (© p81) = Rerve the fork gs. (© p17) Main work = Remove srens @ = Remove screw @. Lift the headlight mask slightly and swing, forward. ~ Unpiug connector @ ~ Take ofthe headlight mask. 28= Remove the cable tes. Expose the cable. = Remove screw @. Remove the upper triple clamp with the handlebar and set ide, Info Protect the vehicle and its attachments from damage by covering them. ~ Tate off cover ©. = Expose the cable. a~ Remove nut @ rears nk wrench (90 ZIOSOTOO) Cw S35 Take out the lower triple clamp with the steering ster, ~ Take off waster @. Remove steering head bearing @. ‘Main work = Clean the bearing and sealing elements, check for damage, and grease, [High waconty grease =p. S24) —————SSSSS—~*d = Mount upper steering head bearing @. = Mount washer @) withthe cutout facing downward ternative 1 ‘new steering head bearings used = Insert the loner triple clamp withthe steering stem, = Mount and igen nut @. Guideline Nt, steering heed | NSO | Tatstage 45 Nm (23.2 b1 Foon 2nd stage (loosen, counterclockwise) tums 3rd stage 5 Nm (3.7 Io ft (Groove nut wrench (90129050100) (& p. 335) Alternative 2 ‘The steering head bearing is used again, = Inset the lower triple clamp with the steering stem, = Mount and tighten nut ©. 28Guideline Nat, steering head _| W0xI Nm (37 tot A ‘Groove nut wrench (90129050100) (3 p. 335) = Secure the cable in the bracket. = Position cover @, Position the upper triple clamp with the handlebar. — Mount seren @ but donot tighten ye: Guideline ‘Screw, steering | MI6xL.5 149 Nm @6.1 let fo head, top Loctite®24a™Route the cable without tension and secure with cable ties. = Position the headlight mask. = Plug in connector @ Swivel the headlight mask upward. Mount and tighten screw @. Guideline Screw, headlight | M6 Nm 5.9 1 = Mount and tighten screws @ on both sides. Guideline Screw, headlight [M6 Nim (5.9 1M) Install the fork legs. (@2 p. 18) 30= Loosen screws @. = Using aplastic hammer, tap lightly onthe upper triple clamp to avoid stresses. = Tighten screw @. Guideline Screw, steering [MIGI.5 [49 Nn G61 er head, top Loctiter2a3 = Tighten screws @. Guideline Screw, top tiple | NB TSM CL wT clamp Finishing work = Check that the wiring harness, throttle cables, and brake line hhave the necessary freedom of movernent and are correctiy routed, = Check the play of the steering head bearing. (2! p. 31) = Remove the motoreycle from the work stand. (Sp. 14) Warning Danger of accidents Incorec stern head bearing play impairs the handling characteristic and dam- ‘ages components. = Correct incorect steering head bearing play immediately. Info If the vehicle is operated fora lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged overtime. Preparatory work = Raise the motorcycle withthe work stand, (#8 p. 13) = Clamp down the rear ofthe vehicle. Main work = Move the handlebar to the straight-ahead position. Move the {ork legs to and fro in the direction of travel Fray sould no be detectabe onthe sterng head bean > if thee is detectable a ~ Adjust the steering head bering ply. p. 32) (OJ \\G ~ Mote tte nto ant rte ne serine. sora Ttmust be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions. If detent postions are detected = Adjust the steering head bearing play. (®® p. 32) Check the steering head bearing and adjust i neces- sary atFinishing work = Remove the motoreycle from the work stand. (8 p. 14) Preparatory work = Raise the motoreycle withthe work stand. (&* p. 13) ‘Main work = Loosen screws @. = Loosen screw @. ~ Tighten nut @ withthe special toot unl there is no playin the steering head bearing. Holding wrench (90129051000) (& p. 335) = Using a plastic hammer, tap lightly on the upper tiple clamp to avoid stresses. ~ Remove screw @ = Mount and tighten screw @. Guideline Screw, steering |MI6xL.5 | 49 Nm (36.1 ioffD head, top Loctte®2aa™ 32~ Tighten serene @ Guidetne ‘Screw, top tiple] MB TS Nm (11 IFA clamp Finishing work = Check the play ofthe steering head bearing. (2 p. 31) = Remove the motorcycle from the work stand. (Sp. 14) Preparatory work = Raise the motorcycle with the work stand. (#8 p. 13) ~ Clamp down the ear ofthe vehicle. = Remove fot fender (=p. 81) = Remove the fork ees. © p. 17) — Remove the loner triple clamp. (© p. 26) Main work = Remove the ler bearing race @ using suitable too oe TS = Press in the new bearing ring all the way using a suitable tool Remove the upper bearing race @ using a suitable tool.= Press in the new bearing rng all the way using a suitable too ~ Remove over steering head beating @ = Remove the sealing Grease new sel ing and press on lhe way witha suitable tbe = Mount ne bering Finishing work = Install the lower triple clamp. (£8 p. 28) = Check that the wiring harness, throttle cables, and brake line hhave the necessary freedom of movement and are correctly routed, = Check the play of the steering head bearing. (2 p. 31) Remove the motoreycle from the work stand. (= p. 14)HANDLEBAR, CONTROLS 7 7.1 Checking the clutch lever play Note {Clutch damage If there is no free travel by the clutch lever, the clutch will begin to si = Check the free travel ofthe clutch lever each time before using the motorcycle. = Adjust the free travel of the clutch lever when necessary in accordance with the specification = Check the lute lever for smooth operation 0 = Move the handlebar tothe straight-ahead position. = Pll the elute lever until resistance is perceptible, and deter ~~ nine the play in the clutch lever Ciuc ever ploy @ Tm (0008 0.12in) Ifthe clutch lever ply does nat meet the specified value Pe — oj layin iene 9.38 = Move the handlebar to and fro over the entire steering range. ‘The clutch lever play must not change Ifthe clutch lever play changes: Check the routing ofthe clutch cable, tz Adjusting play in the clutch lever = Move the handlebar tothe straight-ahead position. = Push back sleeve @. = Loosen fk nut @ = Adjust the play in the clutch level @ by turning adjusting Guideline Clute lever play @ T..3 mm (004 0.12 im = Tighten lock nut @ = Position betious @. 35= Remove screw @ — Liftthe headlight mask slightly and swing forward. ~ Unpiug connector @ ~ Take ofthe headlight mask. Remove the cable tes = Detach connector @ Remove the cable te().veg , Disconnet plugin connectors @ Expose the cable. Loosen screw @. Remove the handlebar weight Remove screw @. Remove screw @ Pull the throtle grip and accelerator position sensor unit from the handlebar. Remove the thrattle grip, © Info Hush the accelerator position sensor slightly to the side. a= Position new throttle grip. = Pins @ engage in inner clutch hub @. Af Info o Push the accelerator position sensor slightly tothe side. Position the throttle grip and accelerator position sensor unit on the handlebar. Pin @ engages in hole @. = Mount and tighten screw @. = Mount and tighten screw @. Guideline ‘Screw for throttle [MB 35 Nm rip (2.58 ibt 1) ~ Poston handlebar weight ~ Tighten screw @ Guideline ‘Screw, handlebar | M6 ‘ON (6.6 ior) weightRoute the cables without tension, Join plug-in connectors @, = Plugin the connectors @ Secure the cables withthe cable ies Secure the cables with the cable tes, Position the headlight mask. = Plug in connector @ Swivel the headlight mask upward. — Mount and tighten screw @. Guideline Screw, headlight [M6 Nm 6.9 1b) 39~ Mount nd tighten screws @ on both sides Guideline ‘Screw, headlight Me Nm (59 oFPreparatory work = Remove the front spoiler. (2! p. 80) = Raise the motorcycle withthe rear lifting gear. (E2 p. 12) Lift the motoreyele withthe front liting gear. (© p. 12) Main work = Secure the engine and swingarm against turning using the floor jack, Info Cover the components to protect them against damage. ~ Remove screw @ with the washers. Take off shift lever and hang tothe side Remove screws @. = Remove nut @ with the washer = Remove fitting @. ~ Remove screw @ = Takeoff the fotest bracket. a~ Remove chain guise @ ~ Remove nuts @. = Remove the side stand from the footrest bracket. Remove the pins. Mount the pins on the new footrest bracket and tighten, Guideline Threaded bolt, | MI0xL25 | 27 Nm (19.9 1bt side stand Loctite®24a™ bracket Position the side stand on the new footrest bracket = Mount and tighten nuts @. Guideline ‘Nut, side stand bracket MlOx125 35 Nm @B FR) = Position chain guide @. Position the footrest bracket Mount and tighten screw @ Guideline ‘Screw, front footrat bracket MIO 25 4 Nm (32.5 ITA Loctite®2a3™= Aajstadusting ing @ with special to! Guideline ‘Swingarm bearing | M22x1 Tighten and ensure adjusting ring that there is no play ‘Groove nut wrench (65229021000) (&i p. 327) 7 The adjusting rng is flush withthe collar bushing ~ Remove screw @ Procuring the to! (pin): = Pin Guideline Length = 300 mm (@ 181i) Diameter 15mm (0.59 in) = Push pin @ trough hote @ in the swingarm, 7 The pin @ replaces the swingarm pivot and stabilizes the vehicle~ Remove sew (with the washers. Takeoff the foot brake lever = Remove the sring ~ Remove screw @ and expose cables. = Remove screw ®. Take the brake cylinder off the footrest bracket. Position the brake cylinder on the new footrest bracket. = Mount and tighten screw @. Guideline Remaining screws, | M6 chassis TO Nm (7-4 Ibi Mount the spring. — Position cables. Mount and tighten screw @®. Guideline Remaining stews, | MG chassis TO Nm (74 1ot Position the footrest bracket with the Position the foot brake lever. spacer. = Mount and tighten screw @ with washers. Guideline Screw, foot) MB 16 Nm (11.8 It) brake lever Loctte®243™ 7 The step on the washers isin contact with the BearingMount ana tihten ting @. Guiding ‘Screw, front footrest] MIOx1.25 bracket / engine “43.Nin G61 FA bearer Mount and tighten screw @®. Guideline ‘Screw, front | MI0x1.25 | 44 Nm @2.5 Ibt tO footrest bracket Lootite®243™ Guideline Adjust the adjusting ring with special tol @ ‘Swingarm bearing | M22x1 adjusting ring Tighten and ensure that there is no play ‘Groove nut wrench (45229021000) (@ p. 327) ‘7 The adjusting ring is flush withthe collar bushing. ‘Mount the swingarm pivot with washer @. Recess @ is aligned tothe pin The tool (pin) is removed when the swingarm pivot is mounted, Mount and tighten screws @ Guideline Remaining sree, —] WE Town 7A chassis Mount and tighten ting @. Guiding Remaining nuts] WE Town AT chassisPosition the shift lever = Mount and tighten screw @ with washers, Guideline ‘Screw, shift | MB Te Nm (18 bf Ay lever Loctite®243™ The step on the washers isin contact with the Bearing = Mount and tighten nut @ with the washer. Guideline ‘Nut, swingarm pivot_[Mi4xi.5 [98 Nm (72.3 1bf 7 Recess @ is aligned to the pin. Remove the floor jack Finishing work = Take the motorcycle off the front lifting gear. (£3 p. 13) = Remove the rear of the motoreycle from the lifting gear. (p12) = Fit the front spoiler. (© p. 80) = Check the frame for cracks and defermation. +» Ifthe frame exhibits eracks or deformation due to a ‘mechanical impact: ~ Change the frame, © Info DH Atways replace 2 frame that has been dam- ‘aged due to a mechanical impact. Repair of the frame is not authorized by KTM,Preparatory work = Raise the motoreycle withthe work stand. (#8 p. 13) Main work = Measure the distance - as vertical as possible - between the rear axle and a fixed point, for example, a mark on the rear o fairing. = Note down the value as dimension @. Finishing work = Remove the motoreycle from the work stand. (2 p. 14) ~ Measure dimension @ of ter whee! unloaded. (8 p. 47) ~ Hold the mtoryete upright wth te ad of an assistant = Measure the dstance between the rear ane andthe fted pint again LY = Note down the value as dimension @. = Check he sai sg Or | The static sag isthe dltference between ‘Static 58 Tamm 0.55 in) < oO measurements @ and @ oe Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characters- tie = Ride slomly to start with ater making adjustments to get the feel ofthe new hancling characteristic. Info ‘The spring preload defines the inital status of the spring operation on the shock absorber. ‘The best Spring preload setting is achieved when itis set forthe weight of the rider and that of any lug- gage and a passenger, thus ensuring an ideal compromise between handling and stability. aGuideline ~ Adjust th sing preload by turing acusting ring @. Spring preload Standard Belicks Hook wrench, shock absorber (90529077000) Extension for hook wrench (90123099025) = Info HThe spring preload can be set to 10 different positions Preparatory work ‘Main work + If there is detectable play: = Change shock absorber. Finishing work Preparatory work Mein work = Remove nut @. ~ Remove serous @. = Raise the motoreycle withthe work stand. (& p. 13) = Check the top and bottom heim joints. = Move the swingarm up and down. = Remove the motorcycle from the work stand, (® p. 14) = Raise the motorcycle withthe work stand. (&8 p. 13)~ Remove screws © = Takeoff the cover = Remove screws @ and @ = Remove the chain guard = Remove screw @. Info Protect the swingarm and components from damage. Ensure that the chain and brake line are not damages. ~ Remove ting @. ~ Remove the shock absorber toward the er Main work =" Postion shock absorber @ = Mount tting @ but donot ten yet Guideline Fiting, shock | WI0xi,25 51 Nem 7.6 Tt absorber, bot Loctte’24a0 tom= Lift the swingarm Mount and tighten screw @ Guideline Screw, top Mi0KL25 | SI Nm (37.6 ot shack absorber Loctite®2aa™ = Tighten fitting @. Guideline Fitting, shock | M1Ox1.25 | 51 Nm (37.6 IbffD) absorber, bot Locttee24a™ tom = Position the chain guard. Mount and tighten screw @. Guideline Remaining screws, | M5 5 Nim (3.7 IFA) chassis ~ Mount and tighten screw @. Guideline ‘Screw, chain guard [EOTPT® [7 NmiS2 lr) 60x30 Position the cover. = Mount and tighten screws @ Guideline Remaining stews, | M6 TON (74 1bT chassis = Mount and tighten screws @. Guideline Remaining screws, | M6 TO Nm (74 oI chassis, = Mount and tighten nut @. Guideline Remaining nuts, | MS 5 Nm 3.7 WFR chassis Finishing work = Remove the motorcycle from the work stand. (2 p. 14) 50Consltion “The shock absorber has been removed, = Clamp the shock absorber into the vise with sot jaws. '= Note the position ofthe spring preload. = Loosen adjusting ring @) using the special too Hook wrench (T1068) (© p. 338) Clamp the shock absorber into the special too ‘Spring compressor (1140508) (© p, 338) = Info Use suitable ring ofthe special too! withthe smallest possible inside ciameter. ~ Compress the spring. = Remove spring retainer @. — Release the spring. Remove the shock absorber fram the spe- cial tol ~ Remove washer @ = Remove the soring Fees = Mount the spring. A The tight coil ofthe springs atthe boom o ~ Poston waster @. - stClamp the shock absorber into the special too ‘Spring compressor (T14050S) (@ p. 338) = Into Tse sutabie ring of the special too! with the smallest possible inside diameter. Mount spring retainer @. 17 The open end is opposite the spring end Release the spring. Remove the shock absorber frm the spe- cial too! Clamp the shock absorber nto the vise with sot jaws Alternative 1 Tension the spring to the prescribed position by turning agjusting ring @ Guideline Spring preload Standard Balas Hook wrench (T1065) (i p. 338) Alternative 2 Warning Danger of accident Modifications tothe suspen- sion setting may seriously alter the handling char acteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. = Only make adjustments within the recommended range. ~ Ride slowly to start with after making adjust- ‘ments to get the feel ofthe new handling char- acteristic Tension the spring to the position measured during dis- ‘mantling by turning adjusting ring @. . CCheck the swingarm for damage, cracking, and deformation » Ifthe swingarm shows signs of damage, cracking, or defor- ‘mation = Change the swingarm, Info Aways change a damaged swingarm. Repair of the swingarm is not authorized by KTM. 52Preparatory work = Remove the front spoiler. (2! p. 80) = Raise the motorcycle withthe work stand. (#8 p. 13) Main work Secure the engine and swingarm against turning using the floor jack, ‘© Info Cover the components to protect them against damage. = Remove nut @ = Remove serens @. = Remove screws @. = Take off the cover. — Remove screws @ and @ = Remove the chain guardClamp down the front ofthe vehicle ‘The rear wheel isnot in contact withthe ground, ~ Remove screw @ and pull whee! speed sensor @ out of the hoe. - Remove nut @ with the washer. Remove chain adjuster @, ~ Holding the rear whet, withdraw whee! spindle withthe washer and chain adjuster @ Push the rear wheel forward as far as possible and take the chain off the rear sprocket. ~ Expose cable @ and brake line ® = Remove the rear wheel. Info Ho not operate the foot brake lever while the brake Caliper is removed, Take off the brake caliper and hang tothe side. © Info Tcover the components to protect them against damage, = Hang chain ® to the side, ~ Remove ting @. = Push the swingarm down and away ftom the shock absorber.~ Remove nut €B withthe washer. ~Remeve swingarm pivot with the washer. = Loosen adlusting rings Busing the special too reavenu wrench @E2Z5ORTOOOH (Hw. S27 = Take off the swingarm. ‘ Main work = "Position the swingarm: = Adjust adjusting ring @ with special tol Guideline ‘Swingarm bearing | W223i Tien and ensure adjusting ring that there is no play “Groove nut wench (85229021000) (ip. 327) The adjusting rng is fash withthe colar bushing. = Mount the swingarm pivot @ wit the washer. Y Recess @ is aligned tothe pin = Mount and tighten rut @ with the washer. Guideline ‘ut, swingarm pivot _[WT4xI.S [98 Nim (72.3 tf) Y Recess @ is aligned to the pin. 55= iff the swingarm and postion the shock absorber. = Mount and tighten fitting @. Guideline Fitting, shock | MI0x1.25 | 51 Nm (G7.6 IbtfD absorber, bot- Loctite®2aa™ tom Position the chain. Position the brake caliper. = Position rear wheel and mount whee! spindte @ withthe washer and chain adjuster @ Info He sount tet and right chain adjusters @ in the same position, ~ Mount nut @ with the washer ~ Push the ear whee! forward so thatthe chain adjusters ar in ‘contact with the screws, and tighten nut @ Guideline ‘Nut, rear wheel spin” Mix. _]98.Nm (72.3161 a de Tn order for the rear wheel to be correctly aligned, the mark- ‘ngs on the left and right chain adjusters must be in the same position relative to reference markings @. = Position wheel speed sensor @ in the drill hole, Mount and tignten screw @. Guideline ‘Screw, wheel speed | MG Nm (5.9 FA sensor holder ~ Remove load rom the font ofthe vehicle = Secure cable @ and brake tine @ in the bracket.Position the chain guard. Mount and tighten screw ® Guideline Remaining screws, | WB Nm 7 rT chassis = Mount end tighten sorew @®. Guideline ‘Screw, chain guard OT PT® 7 Nm 2 FA) 60x30 = Poston the cover. = Mount and tighten serens @. Guideline Remaining screws, | MB TONM (7-4 OFT chassis = Mount and tighten sens @®. Guideline Remaining screws, | M6 TO Nm (7-4 16110 chassis = Mount and tighten nut @. Guideline Remaining nuts, | WB Nm (7 rR) chassis = Remove the flor jack ing work = Check the chain tension. (& p. 100) = Remove the motorcycle from the work stand. (Ep. 14) = Fit the front spoiler. (© p. 80) 37Preparatory work = Raise the motorcycle withthe work stand. (&# p. 13) = Place a load on the front ofthe vehicle. 7 The rear whee! isnot in contact withthe ground, ‘Main work = Move the swingarm up and down, » If there is detectable play: ~ Change the swingarm bearing. (52 p. 58) Move the swingarm from one side tothe other. » If there is detectable play: ~ Change the swingarm bearing. (© p. 58) = Remove the motoreycle from the work stand. (=p. 14) Preparatory work = Remove the front spoiler. (3p. 80) Raise the motorcycle withthe work stand. (8 p. 13) Remove the swingarm. (E p. 53) Let swing bearing = Remove collar bushings @. oj jo—_— e oi) jo ~ Remove bushing @. = Remove shat sea ings @ using suitable tol = Remove stop disks @ = Pross out bearing @ using a suitable tol = Using a suitable tool, press in new bearing @. = Position stop asks @ = Press in shaft seal rings @. = Mount bushing @. = Grease the shaft seal ws. Toneplife grease (© p. 328) ~ Postion colar bushings @ with the shoulder facing inwardRy e eo a F-© t ight swingarm beating = "Remove collar bushings @ = Remove bushing @ ~ Remo shaft seal rings @) using a suitable tok ~ Press out bearing @ using a suitable tol ~ Using sutabie too, press in new bearing @ ~ Press in shat sel rings @ = Mount bushing @ 60Al. = Grease the shaft seal ws. Tonglife grease (Tp. 324) ~ Poston colar bushings @ with the shoulder facing inward Finishing work Install the swingarm. (£2 p. 55) ‘Check the chain tension. (8% p, 100) Remove the motoreycle from the work stand. (& p. 14) Fit the front spoiler. (© p. 80) 6Preparatory work = Remove the main silencer. (® p. 66) (Main work = Remove screw @. Remove the clamp. = Remove screws @ = Remove serow @ = Remove the peslener ina downward rection = Remove screws @. Take off the protective plate = Remove screw @. Remove the clamp. = Remove the catalytic converter sideways, 62~ Remove screws @ with the bushings = Remove the cover = Hang inition coil and cable othe sie = Remove the cable tes. ~~ Expose and disconnect plug-in connector @ of the lambda ~ Remove nuts @. = Toke off the exhaust manifold tard he front Main work = Position the exhaust manifold ~ Mount nuts @ but do not tighten yet. Guideline Nut, exhaust flange | MB Nm 6.9 IFAD 63~Join plugin connector @ = Route the cable without tension and secure with cable ties. Position the ignition col = Position the cover = Mount and tighten screw @ with ground wire and bushing. Guideline Remaining screws, | M6 chassis TO Nm (74 et — Mount and tighten screw @ with the bushing. Guideline Remaining sews, | M6 chassis TO Nm (74 1bt = Position catalytic converter with clamp, Mount screw @ but do not tighten yet Guideline Exhaust clamp 20 Nm (48 1bPosition presilencer with clamp, = Mount and tighten screws @, Guideline Screw, presilencer [M6 T2 Nm 9 TT Mount and tighten screw @. Guideline Screw, presilencer [MB 23 Nm (17 1otfD — Mount screw @ but do not tighten yet. Guideline Exhaust clamp = 20 Nm (14.8 Ibt ft) eo) Guideline "Nut, exhaust flange | MB 8 Nm 6.9 br ~ Tighten screw @ and @ evenly. Guideline Exhaust clamp : 20 Nim (14.8 IFA ~ Poston protective pate. = Mount and tighten seus @. Guideline ‘Screw, protective | M6 plate 8 Nm (5.9 IBFD Finishing work Install the main silencer. (© p. 66) 65Remove screw @, Remove the clamp, Remove screw @. Take off the main silencer. ‘ Pasion the main silencer withthe gasket. Mount screw @ but donot tighten yet. Guideline Screw, main sencer [ME 23 Nim (17 tw Position the clamp. Mount and tighten screw @. Guideline Exhaust clamp 20 Nm (14.8 FY Tighten screw @. Guideline Screw, main silencer [Mi 2a Nm 07 tw) ‘a + \ Ai. aratry work Remove the passenger seat (8p. 70) = Remove te front rider’ seat (© p. 70) Main work =" Remove screws @ = Takeoff the airiter box Push the holding lugs forwards. = Remove the air filter. = Clean the ai filter bax = Position new air filter in the guides. Engage holding lugs tothe rea. 7= Mount the air filter box lid Info Make sure the air filter box lid is seated correctly. = Mount and tighten screws @. Guideline ‘Screw, air filter box | M6 ‘3 Nm (2.2 FF) Finishing work = Mount the front rider's seat (28 p. 70) = Mount the passenger seat (© p. 71)FUEL TANK, SEAT, TRIM 12 12.1. Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled = Do not refuel the vehicle in the vicinity of open flames o it cigarettes. = Switch off the engine for refueling, — Make sure that no fuel is spilled particularly not on hot pars of the vehicle. = any fue is spilled, wipe it off immediately = Observe the specifications for refueling, A Marine Danger of poisoning Fuel is poisonous and a health hazard, = Avoid skin, eye and clothing contact with ful. = Immediately consult @ doctor if you swallow fuel = Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult @ doctor in case of fuel contact with the eyes, Change your clothing in case of fuel spills on them. = Keep fuels correctly in a suitable canister, and out ofthe reach of children Note Environmental hazard Improper handling of fuel isa danger to the environment. = Do not allow fuel to enter the groundwater, the soll, or the sewage system, = Lift cover @ of the filler cap and insert the ignition key in the lock. Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced. = Push down on the fille cap t take pressure off the ini ton key. = Turn the ignition Key 90° clockwise = Open the filer cap. A warning Fire hazard Fuel is highly flammable, toxic and @ health hazard. = Check the filler cap is locked correctly after clos- ing. = Change your clothing in case of fuel spills on them. = Rinse the affected area immediately with plenty of water in the event of contact with the ski, 69Fold down the filler cap. Turn the ignition key 90° clockwise. Push down the filer cap and turn the ignition key counter- Clockwise until the tank lock engages. = Remove the ignition key and close the cove. « Preparatory work = Remove the passenger seat. (2p. 70) Main work = Raise the rear of the front rider's seat, pull it towards the rear, and remove it upwards. « ‘Main work = Attach the front rider's seat in area @ and lower at the rear. = Finally, check that the drivers seat is correctly mounted, = Mount the passenger seat (© p. 71) ~ Insert the ignition key in seat lock @ and turn it eochwise. Raise the rear of the seat, push it towards the ear, and lft it off. = Remove the ignition key from the seat lock. 10= Attach hooks @ on the passenger seat to seat mounting @ ‘on the subframe, and lower it at the rear while pushing for- ward, Press passenger seat downward until it clicks into plac. Warning Danger of accidents The seat can come lose from the © anchoring i itis not mounted correctly. ogo = Alter assembly, check whether the seat is correctly locked and cannot be pulled up. — Finally, check that the passenger seat i corectly mounted. < Danger Fire hazard Fuel is highly flammable. ‘The fuel in the fuel tank expands wen warm and can escape if overilled, = Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. ‘= Switch off the engine for refuting, ~ Make sure that no fuel is spilled particularly not on hot parts ofthe vehicle. = If any fuel is spilled, wipe it off immediately. "= Observe the specifications for refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel. = Immediately consult a doctor if you swallow fuel = Do not inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult @ doctor in case of fuel contact with the eyes, = Change your clothing in case of fuel spills on them. = Keep fuels correctly in a suitable canister, and out ofthe reach of children Note FE onmen taza mroper handing of felis a ange tothe enone. "ona allo ul ene te ound te sol othe swag spe Preparatory work = Remove the passenger seat (8 p. 70) = Remove the front rider's seat. (£8 p, 70)Main work =" Remove screws @ ~ Remove screws @ = Remove screws @ with the washers. Remove the spoiler to the rea. = Pull trim @ upward and remove.~ Remove screws @ with the bushings = Remove screws @. ~ Remove screw @ = Remove screw @. = Remove cap @. ~ Remeve screws @ with the washers. = Takeoff the tim Main work = Position the trim, = Mount and tighten serens @ withthe washers Guideline Sere, side cover [NB Thin BBD = Mount cap @ of the compensating tank B~ Loosen screw @, = Mount and tighten serew @. Guideline ‘Screw, compensating | M6 5 Nm 3.7 iF) tank = Tighten screw @. Guideline Screw, compensating | M6 5 Nm (3.7 br tank = Mount and tighten screw @. Guideline Screw, side cover | M6 7 Nm (5.2 FA — Mount screws @ with bushings and tighten. Guideline Seren, side cover [M6 7 Nm (6.2 1 = Mount and tighten screws @ Svidetine Seren, side cover [M6 Tm? wR) = Mount tim @ ™Position the spoiler and hook it in to the front. = Mount and tighten screws @ with the washers. Guidetne Seren, side cover [NS Thin BFAD = Mount and tighten screws @. Guideline Serew, side cover [N6 Thin 62 FAD = Mount and tighten seus @. Guideline Screw, side cover [W6 Thin BFAD = Mount the front rider’ seat. (&8 p. 70) = Mount the passenger seat. (2 p. 71) 5Danger Fire hazard Fuel is highly flammable, “The fuel in the fuel tank expands when warm and can escape if overile. = Do not refuel the vehicle inthe vicinity of open flames or lit cigarettes. = Switch off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. = If any fue is spilled, wipe it off immediately. ‘= Observe the specifications for refueling. A Waring Danger of poisoning Fuel is poisonous and a health hazard, ‘Avoid skin, eye and clothing contact with fuel Immediately consult a doctor i you swallow fuel Do not inhale fue! vapors = Iincase of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact withthe eyes = Change your clothing in case of fuel spills on them. Keep fuels correctly in a suitable canister, and out ofthe reach of children. Note Environmental hazard Improper handling of fuel is @ danger to the envitonment. Do not allow fuel to enter the groundwater, the soll, or the sewage system. Preparatory work ~ "Remove the passenger seat. (Ep. 70) ~ Remove te front ede’ seat. (8p. 70) = Remove the fuel tank cover (Ep. 71) Main work =" Remove screw @ with collar bushing and hang the compen- satin tank othe side Info coolant can escape from the compensating tank. — Pull active carbon filter @ off of the holder and hang to the side 18FUEL TANK, SEAT, TRIM 12 — Remove screws @ withthe collar bushings ~ Remeve screw @ withthe washer. Raise the fue tank npg connector @ ~ Disconnect uel nose connection @ Info Remaining fuel may flow out ofthe fuel hose, ~ Push back hose clamp @ and pull ff the ent hese Spring Band carps plier (6002805700) p 530) = Take off the fuel tank n12 FUEL TANK, SEAT, TRIM 12.10 Installing the fuel tank Danger Fire hazard Fuel is highly flammable, The fuel inthe fuel tank expands when warm and can escape if ovefilled = Do not refuel the vehicle inthe vicinity of open flames or lit cigarettes. = Switch of the engine for refueling, = Make sure that no fue i spilled; particularly not on hot parts of the vehicle. = Ifany fuel is spilled, wipe it off immediately. = Observe the specifications for refueling. A Waring Danger of poisoning. Fuel is poisonous and a health hazard = Avoid skin, eye and clothing contact with fuel. = Immediately consult a doctor if you swallow fuel = Donnot inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. — Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. = Change your clothing in case of fuel spills on them. = Keep fuels correctly in a suitable canister, and out of the reach of children. Note Environmental hazard Improper handling of fuel is @ danger to the envitonment. = Do not allow fuel to enter the groundwater, the sol, or the sewage system. Main work = Mount the vent hose. = Mount spring band clamp @. [Spring band clamps plier (60029057100) (= p. 330) ~ Pugin fue hose connection @ aFUEL TANK, SEAT, TRIM 12 ~ Plugin connector @ Position the fuel tank. — Mount and tighten screw @ with the washer. Guideline Screw, fuel tank [MB 20 Nm (14.8 1bF — Mount and tighten screws @ with the collar bushings. Guideline ‘Screw, fuel tank [MB 20 Nm (14.8 1bt ~ Mount active carbon titer @. = Position the compensating tank Mount and tighten screw @® with the collar bushing. Guideline ‘Screw, compensating | M6 5 Nm 7 br tank Finishing work Install the fuel tank cover. (@ p. 73) = Mount the tron rider's seat. © p. 70) = Mount the passenger seat. (2 p. 71) 7912 FUEL TANK, SEAT, TRIM 12.11 Removing the front spoiler ~ Remove screws @ = Remove screws @ Take off the front spoiler. 12.12 _ Fitting front spoiler = Postion the font speller. Mount screws @ but donot tighten vet = Mount and tighten screws @ Guideline ‘Screw, front spoiler] MGx9 ‘O Nim (6. FA ~ Tighten serene @ Guideline Screw, front spoiler] M@xI3 ‘ON (6.6 Io A)— Remove screws @. Take off the front fender, ~ Position font fender, Mount and tighten serens @) Guideline (Screw, font fender [MS Tin 52 WFD Fire hazard Fuel is highly flammable. The fuel inthe fuel tank expands when warm and can escape if overlld. Do not refuel the vehicle in the vicinity of open flames or it cigarettes. = Switch off the engine for refueling. |= Make sute that no fuel i spilled; particularly nat on het pats ofthe vehicle. = It any uel is piled, wipe i off immediately. ~ Observe the specifications for refueling. A Warning Danger of poisoning. Fuel is poisonous and a health hazard, = Avoid skin, eye and clothing contact with fuel ~ Immediately consulta doctor it you swallow fuel = Donnot inhale fuel vapors. ~ Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult doctor in case of fuel contact with the eyes = Change your clothing incase of fuel spills on them. = _Keep fuels correctly in a suitable canister, and out ofthe reach of children, Condition “The fuel tank is completely ful Ensure that the battery voltage does not drop below 12.6 V. “The ignition is off. “The diagnostics tool is connected.~ isconnect uel hose connection @. = Info D Remsining tuet may flow out of the fue! hose | ~ Remove connection @) from the hose. = Mount special tool @ Pressure testing tool (61029094000) (© p. 330) = Mount special tool @ with nozzle code 0,60. “Testing hose (61029093000) (Ht p. 330) Position the hose end in a fuel can, GA Guideline reabear Minimum size, uel can [ 101(2.6 US gad = Switch the ignition on. Execute “Actuator Test" > “Function test of fuel pump contra, Check the fuel pressure with the filler cap closed, Fuel pressure When the fuel pump is] 32... 3.7 bar (46 active 54 psi) » Ifthe specification is not reached: 7 = Open the filler cap. (& p. 69) Gs = Check the tank air vent system. = Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pumpis] 32... 37 bar (46 active 54 psi) \ If the specification isnot reached Gi ~ Check that the fuel line is clear. ana = Change the fuel filter. (8 p. 83) fee = Change the fue! pump. ( p. 84) Stop the Function test of fuel pump contol actuator test by pressing the “aut button — Remove the special tots. 82~ Jin tue! nase connection @ cd Danger Fite hazard Fuel is highly flammable The fuel inthe fuel tank expands when warm and can escape if overilled. ~ Donotrefuel the vehicle in the vicinity of open flames or it cigarettes. = Switch off the engine for refueling |= Make sute that no fel i spilled; particularly at on ht pats ofthe vehicle. = any fue is spilled, wipe it off immediately. = Observe the specifications for refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel = Do not inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult @ doctor in case of fuel contact with the eyes, = Change your clothing in case of fuel spills on them, Keep fuels correctly in a suitable canister, and out ofthe reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to enter the groundwater, the soll, or the sewage system, Preparatory work = Remove the passenger seat. (Ep. 70) = Remove the front rider's seat. (#2 p. 70) = Remove the fuel tank cover. (£8 p. 71) = Remove the fuel tank. (88 p. 76) Drain the fuel from the fuel tank into a suitable container. 8312 FUEL TANK, SEAT, TRIM 12.17 Changing the fuel pump Main work = Take fuel fiter @ out ofthe holder. = Remove fuel hose connection @ and @ = Remove fuel filter = Position new fue iter Brow faces inthe direction of travel Join fuet hose connection @ and @. Peaiton fuel iter @ in the holder Finishing work =" astall the fel tank (8 p. 78) = Install the fuel tank cover Ep. 73) = Mount te font rider's seat. (3p, 70) ~ Mount the passenger seat. (8p. 71) Danger Fire hazard Fuel is highly flammable, The fue inthe fuel tank expands when warm and can escape it overfilled = Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switch off the engine for refueling. = Make sure that no fuel is spilled; particulary not on hot pats ofthe vehicle. =f any fue i spilled, wipe it off Immediately. = Observe the specifications for refueling. Warning. Danger of po Fuel is poisonous and a health hazard = Avoid skin, eye and clathing contact with ful = Immediately consult a doctor if you swallow fuel = Do not inhale fuel vapor. = Incase of skin contact, rinse the affected area with plenty of water. ~ Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes, ~ Change your clothing in case of fuel spills on them, = Keep fuels correctly in a suitable canister, and out ofthe reach of children. Note Environmental hazard Improper handling of fuel i a danger to the environment. = Do not allow fuel to enter the groundwater, the sol, or the sewage system. Preparatory work Remove the passenger seat. (© p, 70) Remove the front rider's seat. (© p. 70) = Remove the fuel tank cover. (E8 p. 71) Remove the fuel tank. (£2 p. 76) Drain the fuel from the fue! tank into a suitable container.FUEL TANK, SEAT, TRIM 12 Main work =" Remove screws @ = Remove the fuel pump with the gasket = Mount the gasket @) onthe new fue pump. Position the fuel pump withthe gasket = Mount serens @ and tighten na rsseress pattern Guideline Screw, foel pump [NS TON (ATF ing work Install the fuel tank. (@ p. 78) Install the fuel tank cover. (2p. 73) = Mount the front rider's seat. (© p. 70) = Mount the passenger seat. p.7 85Info Ton tice air pressure ieads to abnormal wear and overheating ofthe tire. Correct tire air pressure ensures optimal riding comfort and maximum tre serie ite = Remove the dust eap. = Check tire air pressure when the tres are cold Tie air pressure, solo front 2.0 bar (29 psi) rear 2.0 bar (29 psi) Tire air pressure with passenger full payload Tront 2.0 bar (29 psi) reat 2.2 bar (32 psi) » Ifthe tire air pressure does not meet specifications: ~ Correct the tte alr pressure. = Mount the dust cap. Warning Danger of accidents Ifa tire bursts while riding, the vehicle becomes uncontrollable. = Ensure that damaged or worn ties are replaced immediately. A Warning Danger of exathing Different tte tread patter on the front and tear wheel impair the handling charac- teristic Different tice tread patterns can make the vehicle significantly mare dificult to contro. = Make sure that only tres witha similar tire tread pattern are fitted to the front and rear wheel. Aa Warning Danger of accidents _Non-approved or non-recommended tires and wheels impact the handling character- istic = Only use tires/wheels approved by KTM with the coresponding speed index. Info ‘The type, condition, an air pressure of the tires all have a major impact on the handling ofthe motorcy- cle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces.~ Check the front and rear tires for cuts, usin objets, and Ifthe rear sprocket and engine sprocket are wen: = Change the drivetrain kit. (@ p. 106) Into T The engine sprocket, rear sprocket and chain should always be replaced together. Shift gear to neutral = Pull the lower chain section with spect Guideline Weight, chain wear measure- ment a) 15 Kg (33 1b) ~ Measure distance @ of 20 chain ols inthe lower chain section, Info TD Chain wear is not always even, so you should repeat this measurement at different chain positions. ‘Maximum distance @ from | 301.6 mm (11.874 in) 20 chain rollers at the longest chain section + if istance @ is peter than the specified measurement ~ Change the drivetrain kit. (8p. 106) Info TH Wmen a new chain is mounted, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprock- ess. 102WHEELS 13 = Check the chin sliding ead for wear * tfin area @ by the chain slicing guard screw @ is visi ble trom above = Change the chain slicing guar = Check thatthe chain sliding guard isfy seated 1 Ifthe chain sliding guard is lose: = Tighten the serw ofthe cain sliding guard Guideline Screw, chain | MS 7 Nin 2 br A) guard Loctitee®243™ ing work = Remove the rear of the motorcycle from the lifting gear. p. 12) 13.5.8 Cleaning the chain A Waring Danger of accidents Oil or grease on the tres reduces the road grip. = Remove the lubricant from the tires using a suitable cleaning agent. A Waring Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oll and grease. = Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage, — Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc, correctly and in compliance with the applicable regulations. Info TThe service fe ofthe chain depends largely on its maintenance Preparatory work = Raise the motorcycle withthe rear lifting gear. (58 p. 12) 103(Main work = Clean the chain regularly Rinse of loose dirt witha soft jt of water. = Remove old grease remains with chain cleaner. Chain cleaner (© p. 324) After deyng, apply chain spray. Street chain spray (& p. 325) Finishing work = Remove the rear of the motoreycle from the lifting ger. (p12) 13.5.9 Checking the rear hub rubber dampers Info I The engine power is transmitted from the rear sprocket tothe rear wheel via 6 rubber dampers. They even tually wear out during operation. Ifthe rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged, Preparatory work = "Raise the motorcycle with the rer Iiting gear. (© p12) ~ Remove the rear wheel (=p. 92) Main work ~ Check bearing @ + Ith bearing is damaged or worn = Change the bearing Check the rubber dampers @) of the eer hub for damage and + ifthe rubber dampers ofthe rear hub ae damaged or worn = Change all ubber dampers inthe rear hub. Lay the read wheel on a workbench with the rear sprocket fac- ing upwards and insert the wheel spindle in the hub. To check the play @, hold the rear wheel tight and try to rotate the rear sprocket. Into HMeasure the play onthe outside of the rear sprocket. Play in rubber dampers, rear | #5 mm (0.2 in) wheel » It play @ is larger than the specified value: = Change all rubber dampers in the rear hub. Finishing work = Install the rear wheel. (2 p. 93) Remove the rear of the motoreycle from the lifting gear. (p12) = Check the chain tension. (& p. 100) 10413.5.10 Opening the chain oie, $8, Be 13.5.11 Riveting the chain ‘Mount press dritt @ with the larger diameter in the spindle of the special tol. Turn the spindle counterclockwise. Chain rivet too! (60029020000) =p. 329) ‘Make the connecting link of the chain accessible. Fret the iv ting point. Position the special tol with the press drift on one ofthe 2 pins ofthe connecting lnk ofthe chain. Y Locking serew @ paints upwards. Position retaining clamp @ of the special tool on the chain from the rer. Markings and B point upwards Slide retaining clamp @ of the special tool into the pressing tool ‘YThe artow of marking A points to locking screw @). Screw the locking screw handstight as far as it wil go. The retaining clamp is fixed Hold the special tol and serew inthe spindle ‘The chain pin is pressed out through te retaining clamp ail noe Unscrew the locking screw and remave the special tol Repeat the process on the secand pin ofthe chal ink. Grease new connecting link @ anc position an xing @ each pin Connect the chain ends with a connecting ink Postion another Xing @ on each pin ‘Mount press drift @ with the smaller diameter in the spindle of the special tool. Turn the spindle counterclockwise. Chain rivet tool (60029020000) (= p. 329) Position press plate @ of the special tool on the press dit. Position chain joint plate @ in the press plete. 105135.12 Changing the drivetrain ki = Position the special tool on the chain, Y Locking serew @ points upwards = Pesition retaining clamp @ of the special tool on the chain {rom the rer. (7 Markings A and B point upwards. = Slide retaining clamp @ of the special too into the pressing tool 7 The arrow of marking A points to locking screw @ —Serew the locking Seren hand:-tight as far as it wl go. 7 The retaining clamp is fred — Hold the special too! and serew in the spindle Press drift @ of the special tool presses against the cen- ter of the chain joint plate © 7 The chain joint plate is pressed on. — Unscrew the locking screw and remove the special too. = Rivet the two pins of the connecting link with special oo Tivet tool (60029020000) (= p. 329) Preparatory work = Raise the motoreycle withthe rear lifting gear. (#® p. 12) Remove the rear wheel. (2 p. 92), ‘Main work ~ Remove fittings @. Take off the rear sprocket. = Psition the new rear sprocket. = Mount and tighten the fittings. Guideline ‘Nut, rear sprocket | MB 27 Nm 09.9 1 ~ Remove serene @. ~ Remove screw @ with the spacer. = Take ofthe engine sprocket cover 106= Remove screws @. Takeoff lock washer @ ~ Remove engine sprocket © = Open the chain (8p. 105) = Mount the new chain = Rivet the chain, (© p. 105) = Position engine sprocket @ in the chain and mount on the countershatt. = Mount tock washer @) and ts slighty 7 The lock washer engages inthe ger teeth ofthe counter shat. = Mount and tighten screws @. Guideline Screw, lock] T2 Nin 9H washer, engine Loctite®243 sprocket Position the engine sprocket cover, ~ Mount and tighten screws @. Guideline ‘Screw, engine Me 8 Nm 6.9 ib) sprocket cover = Mount and tighten screw @) wit the spacer Guideline Serew, engine [6 Bhim GSA rocket cover Finishing work Install the rear whet. (2 p. 93) = Check the chain tension. (&% p. 100) 107Remove the rear of the motorcycle from the lifting gear. (ep. 12)WIRING HARNESS, BATTERY 14 14.1, Removing the battery A Wanine Risk of injury Battery acid and battery gases cause serious chemical burns. = Keep battries out of the teach af children. = Wear suitable protective clothing and safety glasses, = Avoid contact with battery acid and battery gases, = Keep sparks or open flames away from the battery. ~ Only charge batteries in well-ventilated rooms. — Rinse the affected area immediately with plenty of water in the event of contact with the skin. = Rinse eyes with water fr at least 16 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes. Preparatory work = "Snitch af the ignition by turning the ignition key tothe pos: tion 5 = Remove the passenger seat. (8p. 70) = Remove the front rae’ eat © p. 70) Main work ~ Disconnect negative cable @ trom the battery = Pull back positive terminal cover @. = Disconnect positive cable @ from the battery = Detach rubber band @. = Pull the batery up and out of the battery holder. Info T Never operate the motoreycte witha discharged battery or without battery. In both cases, electrical compa- nents and safety devices can be damaged. The vehicle wil therefore no longer be roadworthy. 10914 WIRING HARNESS, BATTERY 14.2. Installing the battery Main work = Position the battery in the battery holder. Battery (ETZ9-88) @ p. 273) = Reconnect rubber band @. ~ Postion postive cable @ and mount and tighten the sre = Pesition postive terminal cover @. = Position negative cable @; mount and tighten the screw. Finishing work Mount the front riders seat. (22 p, 70) Mount the passenger seat. (© p. 71) = Set the time and date. (&* p. 144) 14.3 Disconnecting the negative cable of the battery Preparatory work = "Snitch ff the ignition by turing the ignition Key tothe pos tion, = Remove the passenger seat. (Ep. 70) ~ Remove the front rider's seat. (8p. 70) Main work = Disconnect negative cable @ ofthe batteryMain work = Connect negative cable @ of the battery. Finishing work = Mount the front rider's seat. (© p. 70) = Mount the passenger seat. (8 p. 71) Set the time and date, (£3 p, 144) (145 Recharging the batery A Warning Risk of injury Gattery acid and battery gases cause serious chemical burns. = Keep battries out of the teach af children. = Wear suitable protective clothing and safety glasses. = Avoid contact with battery acid and battery gases. = Keep sparks or open flames away from the battery. = Only charge batteties in well-ventilated rooms. = Rinse the affected area immediately with plenty of water in the event of contact with the skin, = Rinse eyes with water fr at least 15 minutes and consult @ doctor immediately it battery acid and battery gases get into the eyes. ote RE nomen hazards contain envenmerally aradous mails =” Doms of bates os owl ws bipte of atersat coecton pin fr sed batrs Hote FE toronto soe cause enone ona = Diie of wes it, claig age bate i fe coc and in compliance th the apt rete. Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important forthe service life ofthe battery Rapid recharging with a high charging current shortens the service life of the battery It the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed. Ifthe battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately Ifthe battery i left in a discharged state for an extended period, it will become over-disciarged and sul- fated, destroying the battery. The battery is maintenance-free, i.e, the acid level does not have to be checked.Preparatory work Switch off the ignition by turning the ignition key to the pos tion & Remove the passenger seat, (Sp. 70) Remove the front rider's seat. (© p. 70) = Disconnect the negative cable ofthe battery. (© p. 110) (Main work = Connect the battery charger tothe battery. Set the battery charger EU battery charger XCharge-professional (00029095050) (ep. 326) Alternative 1 US battery charger XCharge-pofessional (00029095051) (& p. 327) ‘Alternative 2 UK battery charger XCharge-professional (00029095052) (# p. 327) Alternative 3 CCH battery charger XCharge-professional (00029095053) (i p. 327) = Info TFotiow the instructions ofthe charger and the manual Disconnect the battery charger after charging the batter. Guideline The charging current, charging voltage, and charging time must not be exceeded, Charge the battery regularly [3 months, winen the motorcycle is not Finishing = Connect the negative cable ofthe battery. (&® p. 111) = Mount the front rider's seat. (8 p. 70) Mount the passenger seat. (© p. 71) = Set the time and date. (&® p. 144) Condition “The battery must be fully functional and completely charged, Preparatory work = Remove the passenger seat. (& p. 70) Remove the front riders seat. (© p. 70) (Main work = Start the motoreycle to make checks. (= p. 16) 12. Measure the voltage between the specified points V> iteasuring point Pus (+ ~ Measuring pont Ground (-) Charging voltage 5,000 rpm 135. 150V Ifthe displayed value is less than the specified value: = Check the cable from the alternator tothe voltage regu: lator. = Check the cable from the voltage regulator to the witing hamess. Check the stator winding of the alternator. (E# p. 264) » Ifthe displayed value is greater than the specified value: = Change the voltage regulator. Preparatory work Switch off the ignition by turing the ignition key to the posi- ton = Remove the passenger seat (8 p. 70) = Remove the front rider's seat. (£2 p. 70) Main work sconnect the negative cable ofthe battery. = Measute the current between battery ground (-) and the nega- tive cable Into TH The value of tne open-circuit current only applies to vehicles in ther orginal state without additonal power Maximum open-circuit cur- | < 1.0 mA rent Ifthe measured value is greater than the specified value: = Disconnect the voltage regulator from the wiring har- ness and perform the measurement again Finishing work = Mount the front rider's seat. (© p. 70) = Mount the passenger seat. (8 p. 71) Info ‘The fuse box withthe main fuse and the fuses ofthe individual power consumers is located under the pas- senger seat. Preparatory work = Switch off the ignition by turing the ignition key to the posi ton Remove the passenger seat. (8 p, 70) 11314 WIRING HARNESS, BATTERY Main work =" Open fusebox cover @ = Remove the faulty fuse Souideline Fuse 1- 30 A~ main fuse Fuse 2-10 A combination instrument Fuse 3- 10 A~ power relay Fuse 415 A ignition col, fuel pump, tart auxiliary relay, horn Fuse 5-10 A~ radiator fan Fuse 6-15 A brake light, turn signa, high beam, iow beam, parking light, tll ight, license plate lamp Fuse 7- 10 A engine electronies control unit, ABS control unit Fuse 8 10 A alarm system (optional) Fuse 9-10 A - permanent positive for auxiliary equipment (ACI tront) Fuse 10- 10 A- positive connected with ignition for aul ary equipment (ACC2 front) Fuse SPARE - 10 A/I5 AO A~ spare fuses Info Ta tauity tase nas a burned-out fuse wire @. A Waning Fire hazard Incorrect {uses overload the electrical sys- tem, = Only use fuses withthe required ampere value = Do not bypass or repair fuses. Insert spare fuses with the correct rating only Fuse (75011088010) (© p. 273) Fuse (75011088015) (= p. 273) Fuse (75011088030) (= p. 273) . Tip Replace the spare fuse in the fuse box so that itis available if needed ~ Check that the power consume is functioning propery ~ ose the fuse box cover @. Finishing work Mount the passenger seat. =p. 71) 415.1 BRAKE SYSTEM 15 Checking the front brake linings Warning. Danger of accidents Worn-out brake linings reduce the broking effect. = Ensure that woen-out brake linings are replaced immediatly Warning Danger of accidents Damaged brake discs reduce the braking effect. It the brake tings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed, = Check the brake linings regularly. = Check te brake lnings for minimum thickness @ Minimum thickness @ [21mm (0.04 in) Ifthe minimum thickness is less than specified: = Change the front brake linings. (&2 p, 115) = Check the brake linings for damage and cracking » If there is wear or tearing: = Change the front brake linings. (© p. 115) 15.2 Changing the front brake linings A Waring ‘Skin initation Brake fluid causes skin iitation. A A = Keep brake fluid out of the reach of children = Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact with the skin, the eyes or clothing. = Consult a doctor immediately if brake fluid has been swallowed. = Rinse the affected area with plenty of water in the event of contact with the skin, = Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect. = Make sure that brake fluid forthe front and rear brake is changed in accordance with the service schedule, Warning Danger of accidents Oil or grease on the brake discs reduces the braking effec. ~ Always keep the brake dises fre of oil and grease = Clean the brake discs with brake cleaner when necessary 115A Waning Danger of accidents Brake linings which have not been approved alter the braking efficiency. [Not all brake linings are tested and approved for KTM motorcycles, The structure and friction cceticient Of the brake linings, and thus their brake power, may vary greatly from that of orignal brake linings. If brake linings are used that differ from the original equipment, compliance with the original omologa- tion isnot guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void. = Only use brake linings approved and recommended by KTM. Note Environmental hazard Hazardous substances cause environmental damage. ~ Dispose of ols, grease, filters, fuel, cleaning agents, brake fluid, etc, correctly and in compliance with the applicable regulation. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. = More the brake lid resenoir mounted on the handlebar toa horizontal position. ~ Remove screws @ ~ Takeoff cover @ with membrane @ = Remove locking clip @ = Remove pin @. ~ Take of spring @~ Remove brake nings @ = Clean the brake caliper, Press the brake piston back to its basic positon and make sure that no brake fluid overflows from the brake fluid reservoir, ‘extracting it if necessary © Info Protect the components against damage, = Position new brake linings @ Into TH Atways change the brake linings in pairs = Poston spring © {7 The at onthe sping point in the dection of rave ~ Mount pin @ Info IND take sue te springs ave seated corectly. = Mount king ip @. = neta the hand brake oe ntl you each fm pressure point 715 BRAKE SYSTEM ~ Ald brake id up to level @. Guideline Dimension @ Bram (02 im) Brake fluid DOT 4 /D0T 5.1 (=p. 322) = Position the cover with the membrane. Mount and tighten the Info TCiean up overtiowed or spilled brake fluid immediately with water. 15.3. Checking the brake fluid level of the front brake A Waning Danger of accidents An insufficient brake fluid evel wll cause the brake system to fal It the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are wor dawn, = Check the brake system and do not continue riding until the problem is eliminated A Waring Danger of accidents Old brake fluid reduces the braking effect. = Make sure that brake fluid forthe front and rear brake is changed in accordance with the service schedule, = More the brake ud reservoir mounted on the handlebar toa horizontal postion, = Check the bake fui level in viewer @. Ifthe brake flu levels below the MINmrking ~ Ad rot brake fui, (2p. 118) 15.4 Adding front brake fluid A waning Danger of accidents in insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are wor down, = Check the brake system and do not continue riding until the problem is eliminated.A Waning BRAKE SYSTEM 15 initation Brake fluid causes skin iitation. = Keep brake fluid out of the reach of children = Wear suitable protective clothing and safely glasses. = Do not allow brake fluid to come into contact with the skin, the eyes or clothing. = Consult a doctor immediately if brake fluid has been swallowed. = Rinse the afected area with plenty of water in the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult @ doctor if brake fluid comes into contact with the eyes = If brake fluid spills on to your clothing, change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect = Make sure that brake fluid forthe front and rear brake is changed in accordance with the service schedule. Note Environmental hazard Hazardous substances cause environmental damage. = Dispose of cls, grease, filters, fue, cleaning agents, brake fluid, etc, correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. I is slicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint Only use clean brake fluid from a sealed container. Preparatory work = Check the front brake linings. (€® p. 115) Main work = "Move the brake fluid reservoir mounted onthe handlebar toa horizontal positon. ~ Remove serens @. = Remove cover @ with membrane @. = Add brake fud to tevel @ Guideline Level @ ‘5 mm (0.2 in) Brake fluid DOT 4 7 DOT 5.1 (=p. 322) = Position the cover with the membrane. Mount and tighten the Info Clean up overflowed or spilled brake fluid immediately walter. 1915 BRAKE SYSTEM 15.5 (Changing the front brake fluid A Warning Skin initation Brake fluid causes skin iitation. = Keep brake fluid out of the reach of children. = Wear suitable protective clothing and safety glasses. ~ Do not allow brake fluid to come into contact with the skin, the eyes or clothing. = Consult a doctor immediately i brake fluid has been swallowed. = Rinse the affected area with plenty of water in the event of contact with the skin ~ Rinse eyes thoroughly with water immediately and consult a doctor i brake fluid comes into contact with the eyes, = If brake fluid spills on to your clothing, change the clothing, Note Environmental hazard Hazardous substances cause environmental damage. = Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc, correctly and in compliance with the applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. = More the brake fluid resenoir mounted on the handlebar toa horizontal position. ~ Cover painted pars = Remove serous @ ~ Takeoff cover @ with the membrene. = Draw the old brake tus out ofthe Brake fluid reservoir using a syringe and fil wth fresh brake fig ‘Syringe (50329050000) (& p. 328) Brake fluid DOT 4 / DOT 5.1 (&2 p. 322) = Mount bleeder cover @. Biceder cover (00029013009) (@ p. 326) Connect the bleeding device Bleeding device (00028013100) (© p. 326) 120Open shut off ave @ © Info TFotiow the instructions in the Owner's Manual of the bleeding device. Ensure that the filling pressure is set on pressure gauge @. Correct the filling pressure on pressure regulator @ if neces- say. Guideline Filling pressure 2 25 bar 9. 36 pall Pall tt dust cap @ ofthe bleder screw on the brake caliper. Connect the Bleeder bottle hose. Bleeding device (00029013100) (mp. 326) Open bleeder screw @ by approximately one hal tum Info Train untit tresh brake tuid emerges in the bleeder bot- te hose without bubbles Tighten the bleeder screw. Close shut-off valve @. pen the bleeder screw again until brake fluid stops emerging. Info TD overtting oF the brake fluid reservoir is prevented. Tighten the bleeder screw. Remove the bleeder battle hose Altach the dst cap. Disconnet the bleeding device. Remove the bleeder cover Add brake tid up to level @. Guideline Dimension @ 5mm 02a Brake fluid DOT 4 / DOT 5.1 (@® p. 322) Position the cover with the membrane. Mount and tighten the © Info Clean up overtlaned or spilled brake fluid immediately with water ‘Check the hand brake lever fora firm pressure point.Warning Danger of accidents Worn-out brake linings reduce the braking effect "= Ensure that worn-out brake linings are replaced immediately A Warning Danger of accidents Damaged brake discs reduce the braking effec. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed. = Check the brake linings regularly. = Check the brake linings for minimum thickness @ Winimam thickness @ [= 1mm @ O04 in) tf the minimum thickness is less than specified = Change the rear brake linings. (& p. 122) ~ Check the brake linings fo damage and cracking 1 tere is wear of tearing = Change the rear brake linings = p.122) A Warning Skin initation Brake fluid causes skin iitation. = Keep brake fluid out ofthe reach of children. = Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact withthe skin, the eyes or clothing, = Consult a doctor immediately if brake fluid has been swallowed. = Rinse the affected area with plenty of water inthe event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact ‘withthe eyes. = If brake fluid spills on to your clothing, change the clothing. (A Waring Danger of accidents Old brake fluid reduces the braking effect. = Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule, (A Waning Danger of accidents Oil or grease on the brake discs reduces the br = Always keep the brake discs fee of oll and grease = Clean the brake discs with brake cleaner when necessary. 122ZA Waring Danger of accidents Brake linings which have not been appraved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient ofthe brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings ae used that differ from the original equipment, compliance with the original homologa tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void, = Only use brake linings approved and recommended by KTM. Note Environmental hazard Hazardous substances cause environmental damage, = Dispose of ols, grease, filters, fuel, cleaning agents, brake uid, etc, correctly and in compliance with the applicable regulations. Info Avoid contact between brake fluid and painted parts, Brake fluid attacks paint! Use only clean brake fluid from a sealed container Condition The screw cap is locked. oO — Remove screw @ and take off the screw cap lock. stand the vile ui ~ Remove sere cap @ with membrane @ = Pres the brake caliper na the brake di by hand o push back the trake piston and ensire tat bake fd doesnt flow out ofthe rake fd reserva, extract necessary ~ Remove locking clips @ = Remove pin @. 123~ Remove brake tnings © = Clean the brake cai ~ Position new brake inings @ Info HAiays change the brake tinings in pair. = Mount pin @. = Mount locking clips @. Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point Add brake fluid to the MAX marking, ‘Brake Tid DOT 47 DOT 5:1 (ip. 322) = Mount screw cap with membrane, Info Hiean up overtiowed or spilled brake fluid immediately with water Condition The screw cap is locked. = Position the screw cap lock and mount and tighten screw @. Guideline Screw, compensat- | MS ‘3 Nim GO ior) Ing tank cap lock, rear brake 124Warning Danger of accidents The brake system fails in the event of overheating, If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake, Set the ree travel onthe foot brake lever in accordance with the specification ~ Disconnect spring @ = Move te fot brake lever back and frth between the end stop and the contact tothe foot brake cylinder piston and check free travel © Guideline Free travel at fot brake ever [3.8 mm (O12. O2 Tm) Ifthe fee travel does not meet specications = Adjust the fee travel ofthe foot brake lever (@p. 125) = Reconnect spring @. A Waring Danger of accidents The brake system falls in the event of overheating, It there is no free travel on the foot brake lever, pressure builds up inthe brake system on the rear brake, = Set the free travel on the foot brake lever in accordance with the specification. 125= Detach spring @. ~ Release nut @ and use screw @ to adjust the specified tree travel @. Guideline Free travel at foot brake lever [ 3... 5 mm (0.12... O.2in) Info H The range of adjustment is limited = Hold screw @ and tighten nut @. = netachsoring @. < A waning Danger of accidents An insufficient brake fluid level wil cause the brake system to fal Ifthe brake fluid level drops below the MIN marking, the brake system Is leaking or the brake linings are worn down, = Check the brake system and do not continue riding until the problem is eliminated. A Waring Danger of accidents Old brake fluid reduces the braking effect. ~ Make sure that brake fluid forthe front and rear brake is changed in accordance with the service schedule = Stand the vehicle upright ~ Check the brake fui level ofthe brake fluid reser. ® Ifthe fluid level reaches the MIN marking @: ~ Add rear bake fluid (8 p. 127) < 126BRAKE SYSTEM 15 15.11 Adding rear brake fluid A Marine Danger of accidents An insufficient brake fluid level will cause the brake system to fal If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are vworn down, = Check the brake system and do nat continue riding until the problem is eliminated. A Waring initation Brake fluid causes skin ititation. = Keep brake fluid out of the reach of children — Wear suitable protective clothing and safely glasses. = Do not allow brake fluid to come into contact with the skin, the eyes or clothing. = Consult @ doctor immediately if brake fluid has been swallowed. = Rinse the affected area with plenty of water In the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult @ doctor if brake fluid comes into contact with the eyes, = If brake fluid spills on to your clothing, change the clothing, A Waring Danger of accidents Old brake fluid reduces the braking effect. = Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. ote RE honmena taza Hazardous sustrcs cause entonmatl dana =” Depeae fos eos iter clearing get, take i ef. conecy and conpiance wit the apeate relatos ino Toi contact between brake fd and pinted pas rake ud altacks paint Ue ony clean brake trom a sete conti Preparatory work Check the rear brake linings. ( p. 122) Main work Condition The screw cap is locked. Remove screw @ and take off the screw cap lock. 127= Stand the vehicle upright ~ Remove screw cap @ with membrane @, ~ kd brake id to evel @ Brake uid DOT 47DOT SIG p32 — Mount screw cap with membrane Info Clean up overflowed or spilled brake fluid immediately with water Condtion The screw capi locked co = Position the screw cap lock and mount and tighten G seew @. ) cue ‘Screw, compensat- | MB ‘3 Nm G6 1oF AD) ing tank cap lock, rear brake A Waring Skin initation Brake fluid causes skin iitation. = Keep brake fluid out ofthe reach of children. = Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact withthe skin, the eyes or clothing, = Consult a doctor immediately i brake fluid has been swallowed. = Rinse the affected area with plenty of water in the event of contact with the skin = Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing, ote 3 tool ead zara ssancs case enone damage =” Def ert clang ger ate corecy and incon with the seste ets Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. 128= Mount bleeder cover ©. = Connect the bleeding device Conltion The screw cap is locked. — Remove screw @) and take off the screw cap lock. ~ cover painted pats. = Tae ff screw cap @ with membrane = Draw theo rae uid ut of the brake i resenor using 2 syringe a il fresh brake fig Synge (50326050000) (5p. 328) Brake fuid DOT 4 [DOT 5.1 (3p. 322) Bleeder cover (00029013014) (= p. 326) Bleeding device (00029013100) (= p. 326) ~ open shut otf vane @ © Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure thatthe filing pressure is set on pressure gouge @ Correct the filing pressure on pressure regulator @ it neces- sary Guideline Filling pressure 2 25 bar (29... 36 pail~ Plloft dust cap @ ofthe bleder screw. Connect the bleder ote hose ‘Bleeding device (00029013100) (Wp. 326) ~ Open bleeder screw @ by approximately one hal tun Info Drain untttresh brake uid emerges in the bleeder bot- te hose without bubbles. — Tighten the bleeder screw. Close shut-off valve @. = Open the bleeder screw again until brake fluid stops emerging. = Info DW overting of the brake fluid reservoir is prevented, = Tighten the bleeder screw. Remove the bleeder bottle hose. Attach the dust cap, = Disconnect the bleeding device. Remove the bleeder cover = Stand the vehicle upright, = Correct the brake fluid to marking @ ‘Brake fluid DOT 4 7 DOT 5.1 (@ip. 322) ~ Mount screw cap @ with the membrane Info Hiean up overtiowed or spilled brake fluid immediately with water = Check the foot brake lever fora firm pressure point. Condition The screw cap is locked. = Position the screw cap lock and mount and tighten screw @. Guideline ‘Screw, compensat- | MS ‘3 Nim (6. IoF AD Ing tank cap lock, rear brake 130‘The combination instrument is attached in front of the handlebar. “The combination instrument is divided Int two function areas. @ incicator amps (3p. 132) Display Activation “The combination instrument is activated when the ignition is ‘switched on. © Info ‘The brightness ofthe displays is controlled by a brightness sensor in the combination instrument. Test ‘The welcome text appears on the display and the indicator lamps. TRSESL are briefly activated for a function test. Day made is shown ina bright color. [Night mode is shown in a dark color. Info The light sensor in the combination instrument measures the brightness of the environment and automatically switches the display to day or night mode. The display is brightened, darkened or switched to the other mode depending on the brightness measured by the light sensor. The display mode cannot be changed manually. 13116 COMBINATION INSTRUMENT 16.4 — Warning notes ‘Warning notes appear on the top andior bottom edge of the dis play, these are marked yellow ot red depending on their relevance, Yellow warning notes @ indicate ertors or information which requires prompt intervention or an adjustment tothe riding style. Red warning notes @ indicate errors or information which requires immediate intervention Info BD irvng reese cleared by resting ay but. ‘ltenting warning notes er dopayed he Warning men url these ae no ng active. 16.5 Indicator lamps The indicator lamps offer addtional information about the operating state ofthe motoreyle When the ignition is switched on, all indicator lamps light up briefly Info The malfunction indicator lamp always lights up as long as the engine is not running. Ifthe engine is run- ‘ing and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road users inthe process) and contact an authorized KTM workshop. The oil pressure warning lamp always lights up as long as the engine is not running. Ifthe engine is run- ring and the oil pressure warning lamp lights up, stop immediately (taking care not to endanger yourself or other road users in the process) and switch off the engine, The ABS Indicator lamp lights up for so long, until @ speed of approx. 6 kmh (approx. 4 mph) or more has. been reached. 132COMBINATION INSTRUMENT 16 Possible states “The turn signal indicator lamp flashes green simultaneously withthe turn signal - The turn signal is switched on, = Malfunction indicator lamp lights up yellow ~ The OBD has detected an error in the vehicle =| electronics. Come safely toa halt, and contact an authorized KTM workshop. "ABS indicator lamp lights up yellow ~ Stalus or evvor messages relating to ABS. The ABS Indi- cator lamp flashes if the ABS mode Super Mota is enabled. The ide indicator lamp lights up green ~ The transmission isin idle, “The oll pressure warning lamp lights up red - The oil pressure Is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine ‘Alarm system indicator lamp flashes red ~ Status message on the alarm system (optional “The high beam indicator Tamp lights up blue - The high beam is switched on “The general warning lamp Tights up yellow — An operating safely/waming message was detected. Ths is shown in addition 16.6 Display @ Speed (2 p, 134) @ Sit vain ae cp, 138) ‘The shift warning light is integrated inthe tachometer display. @ Cear display © Unit for the speed display © Speed (2p. 135) © Unit forthe speedometer 133(000 display (#2 p. 135) Fuel level display (2! p. 136) Bluetooth® (optional) Time (8p. 136) set Favourites display (= p. 136) Coolant temperature indicator (© p. 135) Only shown where the menu overview is closed. “The speed @ is measured in evolutions per minute light always lights up at a A ‘e In the Shift Light menu, the engine speed for the shift warning ‘ut toss tuacc Tain oa tics the dates th yo np a rrunning-in phase (up to 1,000 km / 621 mi). The shift warning Up light can only be deactivated, and the values for RPM and RPM2 tm by pes. “The sift warning | 6.500 rpm light Coolant temperature [> 35°C (> 95°F) ‘000 51,000 km (> 620 mi RPMIT shift warning [Tights up light RPM shift warning | Flashes 134Speed @ is shown in kilometers per hour kmh or in miles per hour mph. ‘The total distance covered 000 is shown in area @ of the display. Info This value is retained, even ifthe battery is disconnected from the vehicle or the fuse blows. “The coolant temperature indicator consists of bars. The mote bars that light up, the hotter the coolant. Note Engine failure Overheating damages the engine. = If the coolant temperature warning is displayed, stop imme- lately and take care not to endanger yourself or other traffic participants in the process. = Allow the engine and cooling system to coo! down. = Check and, if necessary, correct the coolant level onthe cool- ing system while its ina cooled state, nm When all bars light up, the fll rote ENGINE TEMP HIGH appears. {the cooling system overheats, the maximum engine speed is limited 1 warning Possible states +The engine is cold ~ Up to three bars light up. Engine warm = Four to five bars light up. ‘© Engine hat ~ Six to eight bars light up. ‘Engine very hot ~ Al eight bars light up red 135ea ‘The fuel tank contents are shown in area @ of the display. “The fuel level indicator consists of bars. The more bars are lit, the ‘more fuel is inthe fuel tank. Info I the fuel level is getting low, the last segment flashes red {and the following warning note also appears LOW FUEL. ‘The fuel level i displayed with a slight delay to prevent the Indicator from constantly moving while riding. ‘The fuel level display is not updated while the side stand is {folded out or the emergency off switch is switched of ‘Once the side stand is folded up and emergency OFF ‘switch is switched on, the fuel level display is next updated after 2 minutes. ‘The fuel level display flashes if the combination instrument does not receive @ signal from the fuel level sensor. 7 == Ne cea ‘The time is shown in area @ of the display. “The time is displayed in 24 hour format in al languages except for EN-US. The time is displayed in 12 hour format if the language is set to EN-US. “The time can be contiguted in the Cloek/Date menu. Info The time must be reset after the battery was disconnected cr the fuse was removed. Up to eight items of information are shown in the Favourites dis- play. “The Favourites display can be freely configured in the Favourites menu. Info Tone to four items of information selected are displayed on ‘wo lines. Five to eight items of information selected are ‘displayed on a single line.|When the menu is closed, the Quick Selector 1 menu is opened by pressing the UP button. Press the BAGK button to close Quick Selector 1. © Info The auick selector 1 can be configured in the Quick Selec- tor 1 menu. Any information can be selected. |When the menu is closed, the Quick Selector 2 menu is opened by pressing the DOWN button. Press the BAGK button to close Quick Selector 2. Info The asic sector 2 canbe congue in he ik Sle tor2.menu. Any information can be selected 16.17.1_ KTM MY RIDE (optional) a come Info Press the SET button @ in the standard display to open the menu, ‘Navigate through the menu using the UP button @ or the DOWN button @. Press the BACK button @ to close the current menu or the Condition + The motorcycle is stationary. ‘Function KTM MY RIDE activated (optional). + Function Bluetooth® activated = Press the SET button when the menu is closed, Press the UP or DOWN button until KTM MY RIDE is marked Press the SET button to open the menu. In KTM MY RIDE a suitable cellphone can be paired with the com- bination instrument via Bluetooth®. 137© Info Not every ceiphone is suitable for pairing with the combi- nation instrument ‘The standard Bluetooth® 2.1 must be supported. ‘The app KTM MY RIDE CONNECT® must be installed for Android devices. 1617.2 Info = Press the SET button when the menu is closed, mow Press the UP or DOWN button until Info is marked. Press the SET bution to open the menu. General information can be accessed in Info 16.7.3 Motorcycle Press the SET button when the menu is closed ms = Press the UP or DOWN button until Motoreyee is marked. Press the SET button to open the menu. wo “The vehicle drive made can be configured in Motorcycle. 16.17.4 Settings ‘condition mows * The motorcycle is stationary. wo Press the SET button when the menu is closed a Press the UP or DOWN button until Setings is marked. Press = the SET button to open the menu. eres Favorites and quick selection can be configured in Settings.16.17.5. Preferences 16.17.6 Pairing (optional) comune encom Press the SET button when the menu is closed = Press the UP or DOWN button until Preferences is markes. Press the SET button to open the menu. ‘The combination instrument display can be configured in Prefer- fences. Settings can be made for units or various values. Several functions can be enabled ot disabled, Conltion + The motorcycle is stationary. ‘Function KTM MY RIDE activated optional, ‘Function Bluetooth® activated ‘+The Bluetooth® function should also be activated in the device to_be paired. = Press the SET button when the menu is closed, = Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. = Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu. Press the UP or DOWN button until Pairing is marked. Press the SET button to pair suitable cellphone with the combina- tion instrument via Bluetooth®, = Confirmation of the Passkey successfully completes the pai ing. © Info When a suitable cellphone has been successfully paired, the name of the paired celiphone is displayed. Press the UP or DOWN button until paited device is ‘marked on the display. The paired device can be deleted by pressing the SET button. The device most recently linked is automaticaly paired with the combination instrument when Bluetooth® is. ‘switched on and as soon as this device is in range and has not been previously deleted. [Not every cellphone is suitable for paiting withthe combination instrument, 13916 COMBINATION INSTRUMENT 16.7.7. Audio (optional) Coneition + Function KTM MY RIDE activated (optional) * Function Bluetooth® activated, ‘The Bluetooth® function should also be activated in the device to be pared. Press the SET button when the menu is closed, = Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu: A Waning Danger of accidents Headphone volume which is too high distracts attention from teatfic activity = Always select headphone volume which is low enought for you to still clearly hear acoustic signals. = Press the UP or DOWN button until Audio is marked. Press| the SET button to open the menu. Press and hold the UP button to increase the audio volume, Press and hold the DOWN button to reduce the audio volume, = Press the UP button briefly to change tothe next audio track Press the DOWN button brietly to change to the previous audio track. Press the SET button to play or pause the audio track, = Info I The ausio function can be added to Quick Selector 1 or uick Selector 2 for easier operation 16.17.8 Telephony (optional) eel ode eueel ‘+ Headset linked with appropriate cellphone =a A Waring Danger of accidents. Headphone volume which is too high distracts attention from trattic activity. ey = Always select headphone volume which is low {enough for you to still clearly hear acoustic signal. Press the BAGK button to reject an incoming cal. Press and hold the UP button to increase the audio volume. = Press and hold the DOWN button to reduce the audio volume, = Press the SET button to accept an incoming call o& I a comme 14016.17.9. General info 16.17.10 Trip 1 16.17.11 Trip2 COMBINATION INSTRUMENT 16 Info ‘The call duration and contact are displayed. Depend: ing on the celiphone settings, the contact is shown by Press the SET button when the menu is closed, = Press the UP or DOWN button until Ife is marked. Press the SET button to open the menu. = Press the UP or DOWN button until General Info is marked, Press the SET button to open the menu. Date shows the date (00 shows the total distance covered Battery indicates the battery voltage = Press the SET button when the menu is closed, = Press the UP or DOWN button until Info is marked. Press the SET button to open the menu. Press the UP or DOWN button until Tip 1 is marked. Press the SET button to open the menu. shows the distance since the last reset, such as between two refueling stops. Trip is running and counts up to 9899, {Cons indicates the average fuel consumption based on Trip. ‘BSpeed indicates the average speed based on Trip and Trip Time Time shows the journey time on the basis of Tip and runs as ‘soon as a speed signal is receive. Fuel Range indicates the possible distance you can cover with the ual reserve Press and | Allenivies in the Tip 1 menu are reset hold the SET button foe 3-5 seconds, = Press the SET button when the menu is closed, = Press the UP or DOWN button until Info is marked. Press the SET button to open the menu. = Press the UP or DOWN button until Tip 2 is marked. Press the SET button to open the menu. Trip shows the distance since the lat reset, such as between two refueling stops. Trip is running and counts up to 9999, {Cons indicates the average fuel consumption based on Tip. {BSpeed indicates the average speed based on Trip and Trp Time Trip Time shows the journey time on the basis of Tip and runs as ‘soon as a speed signal is received. Fuel Range indicates the possible distance you can cover with the fuel reserve 14116.17.12 Warning 16.17.13 ABS Press and | Alleniries in the Tip 2 menu are reset hold the SET button for 3.5 seconds. ‘condition + Message or warning is present, = Press the SET button when the menu is closed, = Press the UP or DOWN button until Inf is marked. Press the SET button to open the menu, Press the UP or DOWN button until Warning is marked. Press the SET button to open the menu. = Use the UP or DOWN button to navigate through the warnings. Inthe Warning menu, all warnings that have occurred are dis Played and stored Condition * The motorcycle is stationary. Press the SET button when the menu is closed = Press the UP or DOWN button until Motorcycle is marked. Press the SET button to open the menu, Note Voiding ofthe government approval fr road use andthe insurance coverage Ifthe ABS is switched off completely, the vehicle's approval for road use is invalidated = Only operate the vehicle in closed-off areas remote from public road tatfc ifthe ABS is switched aff completely = Press the UP or DOWN button until ABS is marked. Press| the SET button to open the menu, Activate the menu item using the UP or DOWN button, Press the ABS button to switch off SET or to select between ABS modes. Info I The ABs can only be reactivated by switching on the ignition again, If the ABS mode Road is enabled, ABS controls both wheels Ifthe ABS mode Super Moto is enabled, ABS only con- trols the front whee!. The rear whee! Is not controlled by ABS and may lock duting braking maneuvers, The [ABS indicator lamp flashes slowiyto remind you that the Super Moto ABS mode is enabled Press and | Activation of the different ABS modes, hold the SET button for 3-5 seconds. 14216.17.14 Favourites - Consltion 1 eavounes , + The motorcycle is stationary. = Press the SET button when the menu is closed Press the UP or DOWN button until Settings is marked. Press aa the SET button to open the menus woe ~ Press the UP or DOWN button until Favourites is marked. Press ooo the SET button to open the menus = Press the UP or DOWN button to activate the menu item and = you168-01, select it with the SET button, Up to eight items of information can be selected in the Favourites menu. 16.17.15 Quick Selector 1 - Coneltion qvexseiecrons + The motorcycle is stationary. = Press the SET button when the menu is closed, moo = Press the UP or DOWN button until Settings is marked. Press [Eo the SET button to open the menu, are = Press the UP or DOWN button until Guick Selector 1 is marked. comme 3 Press the SET button to open the menu. eooan Press the UP or DOWN button to activate the menu item and ono] select it withthe SET button, Information can be selected in the Quick Selector 1 menu. When the menu is closed, the Quick Selector 1 menu is opened by pressing the UP button. 16.17.16 Quick Selector 2 Coneltion 1 vexseuecrons The motorcycle is stationary moo Press the SET button when the menu is closed. mo Press the UP or DOWN button until Settings is marked. Press on the SET button to open the menu. anya = Press the UP or DOWN button until Quick Selector 2 is marked. Press the SET button to open the menu. senna = Press the UP or DOWN button to activate the menu item and wonoor| select it with the SET button Information can be selected in the Quick Selector 2 menu. When the menu is closed, the Quick Selector 2 menu is opened by pressing the DOWN button. 14316 COMBINATION INSTRUMENT 16.17.17 Bluetooth 2 16.17.18 Shift Light 16.17.19. Setting the time and date Coneition * The motorcycle is stationary. Press the SET button when the menu is closed, = Press the UP or DOWN button until Preferences is marked Press the SET button to open the menu. = Press the UP or DOWN button until Bluetooth is marked. Press the SET button to open the menu. Activate the men item using the UP or DOWN button, Press the SET button to switch the Bluetooth® function on or of. = T The etntoot tunction can oly be used in onunetin With KIM MY RDECoptona Vor the Bates uri i svitched on andthe device is connected the Butoat® symbol appears inthe display ef the combination Istument Condition * The motorcycle is stationary + 000 > 1000 km (621 m) = Press the SET button when the menu is closed, Press the UP or DOWN button until Preferences is marked Press the SET button to open the menu. Press the UP or DOWN button until Shift Light's marked, Press the SET button to open the menu. = Aetivate the men item using the UP or DOWN button, = Press the SET button to switch the shift warning light on or off ‘and to adjust the engine speed for the gearshift recommenda tion Info Wren the engine speed reaches RPM 1, the speed dis Play lights up red. ‘When the engine speed reaches RPM 2, the speed dis play flashes red. Conaition “The motoreycle is stationary. 14416.17.20 DRL Press the SET button when the menu is closed Press the UP or DOWN button until Preferences appears. Press the SET button to open the menu. Press the UP or DOWN button until Clock/Date is marked. Press the SET button to open the menu. Setting the clock “= Press the UP or DOWN button until the time is marked. Press the SET button 7 The hour flashes and is underlined. Press the UP or DOWN button unti the current hour is set. = Press the SET button 7 The minutes flash and are undertined. = Press the UP or DOWN button until the current minute is set. Press the SET button The time is stored. Setting the date “= Press the UP or DOWN button until the date is marked, = Press the SET button ‘The day flashes and is underlined = Press the UP of DOWN button until the current day is set Press the SET button 7 The month flashes and is underlined = Press the UP of DOWN button until the current month is set. = Press the SET button ‘The year flashes and is underlined. = Press the UP of DOWN button until the current year is set Press the SET button 7 The date is store. Consltion * The motorcycle is stationary. Press the SET button when the menu is closed = Press the UP or DOWN button until Preferences is markes. Press the SET button to open the menu, 14516 COMBINATION INSTRUMENT 16.17.21 Distance 16.17.22 Temperature A Waring Danger of accidents When visibility is poor, the day- time running light isnot a substitute for the low beam. ‘Automatic switching between the daytime running light and low beam may only be partially available ‘when visibility is significantly impaired due to fog, = Ensure that the appropriate type of lighting is always selected. = If necessary switch off the daytime running lights using the menu before going on a ride or wien stopped so that the law beam is switched on per. manently Note the egal regulations regarding the daytime running light Press the UP or DOWN button until BRL is marked. Press the SET button to open the menu. Activate the menu item using the UP or DOWN button, Press the SET button to switch the daytime running light on or off. Condition * The motorcycle is stationary Press the SET button when the menu is closed, = Press the UP or DOWN button until Preferences is marked Press the SET button to open the menu. = Press the UP or DOWN button until Units is marked. Press the SET button to open the menu. = Press the UP or DOWN button until Distance is marked. Press the SET button to open the menu. = Activate the meny item using the UP or DOWN button, = Press the SET button to confi the desired unit. Condition * The motorcycle is stationary. Press the SET button when the menu is closed Press the UP or DOWN button until Preerences is marked Press the SET button to open the menu. = Press the UP or DOWN button until Units is marked. Press the SET button to open the menu. Press the UP or DOWN button until Temperature is marked. Press the SET button to open the menu, Activate the meny item using the UP or DOWN button, = Press the SET button to confirm the desired unit. 14616.17.23 Fuel Cons pi 16.17.24 Language 16.17.25 Service 16.17.26 Extra Functions Consltion + The motorcycle is stationary. = Press the SET button when the menu is closed. Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. Press the UP or DOWN button until Units is marked. Press the SET button to open the menu, = Press the UP or DOWN button until Fuel Cons is matked. Press, the SET button to open the menu, — Aetivate the menu item using the UP or DOWN button, Press the SET button to confirm the desired unit. Coneltion * The motorcycle is stationary. Press the SET button when the menu is closed = Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. = Press the UP or DOWN button until Language is marked. Press the SET button to open the menu. = Press the UP or DOWN button to activate the menu item and select it withthe SET button ‘The menu languages are US English, UK English, German, Italian, French and Spanish. Consition + The motorcycle is stationary. Press the SET button when the menu is closed = Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu, = Press the UP or DOWN button until Serv the SET button to open the menu. “The next service due is shown in the Service menu, is marked. Press Conltion + The motorcycle is stationary. Motorcycle with optional supplementary function, Press the SET button when the menu is closed = Press the UP or DOWN button until Preferences is markes. Press the SET button to open the menu. = Press the UP or DOWN button until Extra Functions is marked Press the SET button to open the menu. = Use the UP or DOWN button to navigate through the extra func- tions. ‘The optional extra functions are listed in Extra Functions. 147© Info TThe current KTM PowerParts and the available software for your vehicle can be found on the KTM website. oe ‘condition ‘The motorcycle is stationary. Press the SET button when the menu is closed = Press the UP or DOWN button until Preferences is marked Press and hold the UP and DOWN buttons simultaneously for 3 seconds until the menu Serviee opens. Press the UP or DOWN button until the riding distance display is marked, Press the SET button to increase the kilometers in intervals of 500, Press the UP or DOWN button until the date display is marked Press the SET button to advance the date in intervals of one ‘month, Press the BACK button to lose the current menu and save the settings. <Warning Danger of accidents When visibility is poor, the daytime running light is nota substitute forthe iow beam ‘Automatic switching between the daytime running ligt ‘and low beam may only be partially available when visi- bility is significantly impaired due to fog. snow or rain. "= Ensure that the appropriate typeof lighting is always selected, = If necessary switch off the daytime running lights Using the menu before going on a ride or when stopped ‘0 that the low beam is switched on permanently = Note the legal regulations regarding the daytime run- ning light. “The daytime running light (ORL) is integrated in the main head- light. “The daytime running light (ORL) must only be switched on when Uisibility conditions are good. ‘Activate the daytime running light (DRL) in the combination instrument. Control is provided by the brightness sensor inthe combination instrument. When visibility conditions are good, the low beam is ‘switched off and the daytime running light is switched on, Info T the position tight @ tights up with all types of lighting ~ Poston the vehicle upright ona horizontal surface intont of a ight wall and make a marking atthe height ofthe center of the ow beam heat = Make another mark at a stance @ under the fst ma Guidetine Distance @ Sena) ~ Poston the vehicle perpendicular tothe wal at a distance @ from the wall and snitch onthe low bea Guideline Distance @ Smaew = The rider now mounts the motorcycle with luggage and passen- fer if applicable. = Check the headlight setting The light-dark boundary must lie exactly on the Tower mark- ing when the motoreyce is ready to operate with the rider ‘mounted along, with any luggage and a passenger if applica- ble. Ifthe light-dark border does not meet specifications: 149~ Adjust the headlight range. (E8 p. 150) . Preparatory work = Check the headlight seting. (Fp. 149) ‘Main work ~ Tum adjusting screw @ to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range. I you have a payload, you may have to corect the headlight range. Screw @ also secures the headlight. Ensure the screw Foss010 is always screwed in far enough. — Set the headlight to marking @. Guideline The light dark Boundary rst Tie erly on Tower mark ing ® when the motorejle is eady to operate with the rider mounted along wth any luggage and a passenger i applicablePreparatory work = Raise the motorcycle withthe rear lifting gear. (E8 p. 12) = Remove the front spoiler. (= p. 80) = Remove the passenger seat. (© p. 70) = Remove the front rider's seat. (© p. 70) Remove the fuel tank cover. (© p. 71) = Remove the fuel tank. (£8 p. 76) Switch off the ignition by turning the ignition Key to the pos: ton 3. Disconnect the negative cable ofthe battery. (#2 p. 110), Drain the coolant. (3p. 240) Main work = Remove nuts @. = Remove screws @. Take off the protective plate, ~ Remeve screw @. Remove the clamp.Remove screws @ wth the bushings. Remove the cove. Hang ignition coi and cable to the side Remove the cable tes. Expose and disconnect plug-in connector @ of the lambda Take off the exhaust manifold toward the front. Remove screw @). Remove the clamp. Remove the catalytic converter sideways, 152Push back protection cap, Remove nut @ with washers. Hang the cable to the side Remove screw @. Hang the cable to the side Bend up lock washer @ Detach the inner clutch cable and expose it Unplug connector @. bush back hose elms @ Pull of blederhses. 153Disconnect sparkplug connector @. Remove screws @). Remove screw @. Take off the engine sprocket cover, Remove screws (@ and take off the lock washer. Remove nut with the washer. Remove chain adjuster @ Push the ear wheel int the feremest poston Pall the engine sprocket off ofthe countershatt and remove it.— Remove screw @ Pall tt the shit linkage and hang it to one side — Push back protection cap. Remove nut @ with the washer = Remove the cable tes = Expose heat protector = Remove the cable te(s). Disconnect plug-in connectors @ and @ = Expose the cable. 155Loosen hase cp @ Pash the throttle valve body upward out ofthe intake Range Remove nuts @ with washers. Remove screws @ withthe washes. Remove fiting @. Remove both engine fing arms. Push back hose clamp ‘Spring band clamps plier (60029057100) (== p. 330), Pall off the radiator hose Remove serous @. Pll off radiator pipe with O-ring and hang to the side.Position the floor jack under the engine and secure using the special tol Floor jack attachment (75029055000) (© p. 332) Remove fitting @. Remove titing @. Hang round wie @ to the sie. Loner the engine Info The help of an assistant is useful in this step. Make sure thatthe engine i sufficiently secured against falling over. Protect the frame and attachments against damage. Preparatory work Lift the engine onto the special tool and secure it, Floor jack attachment (75029055000) (© p. 332) 187‘Main work = Position the engine inthe frame. = Info T The neip of an assistant is useful in tis stp. Protect the fame and attachments against damage = Postion ground wire @ = Mount fitting @ but do not tghten yet. Guideline Fitting, e Mio ‘mounting bracket 49 Nm (36.1 IBF = Mount fitting @ but do not tighten yet. Guideline Fitting, engine Mi0 ‘mounting bracket 49 Nm (36.1 FR Remove the flor jack with the special too Floor jack attachment (75029055000) (@ p. 332) = Mount the radiator pipe with the O-ring = Mount and tighten screws @. Guideline Remaining screws, | M6 chassis 10 Nm (74 1bt = Mount the radiator hse. = Position nose clamp © ‘Spring band clamps plier (60029057100) (= p. 330),Position both engine fixing arms. = Mount and tighten screws @ with the washers. Guideline ‘Screw, engine bearer [ MB 22 Nm (16.2 It A = Mount and tighten fitting @ Guideline Fitting, engine Mio 49 Nm (36.1 bff ‘mounting bracket = Mount and tighten nuts @ withthe washer. Guideline Nakai We Shim G7 BRD ~ Tigon tings @ and @ Guideline Fiting engine] WIO Zann GEIB ‘mounting bracket Position the throttle valve body in the intake flange. = Tighten hose clip ®. = Connect plug-in connectors @ and @®. = Route the cable without tension and secure with cable ties. Position heat protector and secure it with cable ties.Route the cable without tension and secure it with a cable tie Mount and tighten nut ® with the washer. Guideline Remaining nuts, | M6 TO Nm (74 It chassis Position the protection cap, Position the shift linkage. Mount and tighten screw @®. Guideline Screw, shift) MB TI Nm @.1 ior lever linkage Loctite®2a™ Position the engine sprocket in the chain and mount on the countershatt Pall the rear wheel back Nount chain adjuster Mount and tighten nut with the washer. Guideline Tn oxder for the rear wheel to be correctiy aligned, the mark lings on the left and right chain adjusters must be in the same position relative to the reference marks. TNut, rear wheel spine [MI4sL.5 _) 98 Nm (72.3 1bt de= Mount the lock washer and turn it lightly, ‘7 The lack washer engages in the gear teeth of the counter. shaft Mount and tighten screws @, Guideline ‘Screw, lock | M6 12 Nm 6.9 ior washer, engine Loctite’243™ sprocket ~ Position the engine sprocket cover, = Mount and tighten seeus @®. Guideline Remaining screws, | WB TON (7-4 TOF chassis = Mount nd tighten soew @®. Guideline Remaining serena, | M6 TO Nin (A HRY chassis ~ Plugin spark plug connector @. = Mount vent hoses. = Position hose clamps @. 161= Plugin connector @ = tach the inner lute cable. ~ Secure the inner clutch cable with lock washer @. Position the ground wire = Mount and tighten screw @. Guideline Screw, starter motor_| M6 12m 3 wim ~ Poston the postive cable on the starter motor. = Mount and tighten nut @ with the washes Suidetine Remaining nuts, | M5 5 Nm (3.7 oF AY chassis = Position the protection cap, = Position catalytic converter with clamp, — Mount screw @ but do not tighten yet. Guideline Exhaust clamp : 20 Nm (4.8 FT = Poston exhaust manifold wth clamp, — Mount screw @ but donot tighten ye. Guideline Exhaust clamp 20 Nm (148 bt 162Join plugin connector @ Route the cable without tension and secure with cable ties. Position the ignition col Position the cover. ‘Mount and tighten screw @® with ground wire and bushing. Guideline Remaining screws, | MB TO Nm (7.4 HT chassis ‘Mount and tighten screw @ with the bushing. Guideline Remaining screws, | WB chassis TON (7-4 FTO Mount and tighten nuts @. Guideline TNut, exhaust flange | MB Nm 6.9 IFA) Tighten serews @ and @ even Guideline Exhaust clamp : ON (148 it Ay Position protective plate Mount and tighten serews @ Guideline Me Nm 6.9 IBFD) 163Remove flr plug @ from the clutch cover together withthe ing, and fill up wth engine ol Engine oil T71@8 qt) | Engine oi! (SAE 150/50) (3p. 322) Mount and tighten the filler plug together with the O-ring. Finishing work Connect the negative cable ofthe battery. (&® p. 111) Set the time and date. (E® p. 144) Install the fuel tank. (& p. 78) Install the fuel tank cover. (8p. 73) Mount the front rider's seat. (22 p. 70) Mount the passenger seat. (@ p. 71) Remove the rear of the motorcycle from the lifting gear. (8p. 12) Fillbleed the cooling system. (=p. 240) Fit the front spoiler. (% p. 80) Read out the fault memory using the KTM iagnostics tol. Perform the initialization run. (88 p. 268) Go fora short test ride (Check the engine for leak tightness. Ccheck the engine oll level. (& p. 259) CCheck the coolant level. (E® p. 243) Mount special tots @ and @ on the engine assembly stand older and fitting for work stand (90129002000) (ep. 333) Engine work stand (61229001000) = p. 331) Mount the engine on the special too = Info TH Work with an assistant ot @ motorized hoist. 16418.3.2 Draining the engine Remove oil drain plug @ with the O-ring. Remove oil screen @ with the Ong ‘Completely dain the engine ci Remove screw plug @ with the O-ring and oil screen. Remove serens @. “Take off the chain securing guide18.3.4 Removing the valve cover ~ Remove screws @ with the gasket. Take of the valve cover with the valve cover seal. ~ Take off gasket @. = Remove the sparkplug shat insert @ = Remove the spark plug using special tool @. ‘Spark plug wrench with link (77229172000) (@ p. 333)18.3.6 Removing the clutch cover = Remove serens @. Take off the clutch cover. © Info Putte clutch lever forward slightly Remove dovels @. ~ Takeoff clutch cover gasket @ top dead center = Remove serew plug @ = Remove screw plus @. 167~ Tum the cranishatt countercoetwise until makings @ alien with the edge ofthe einer head Markings @ and @ alin. = Remove screw @. ~ Mount special oo! @ Locking screw (61229015000) (& p. 331) 18.3.8 Removing the timing chain tensioner = Remove screw @ with the O-ring18.3.9 Removing the camshaft = Turn the timing chin tensioner sew clockwise The timing chain tensioner is locked — Remove screw @ ~ Remeve the timing chain tensioner withthe gasket. Release screws @ from the outside to the inside and remove them. = Remove the camshaft bearing bridge = Remove dowels. = Remove intake camshaft @. — Remove exhaust camshatt @ ~ Remove screws @18.3.1 Removing the piston Release screws @ na crisscross pattem and remove them with the washers Takeoff the cylinder hea Take off the ylnder head gasket © Remove dowels @. Remove timing chain guide rail @. Push the cylinder upward, Info Hush the cylinder upward only far enough to allow temoval ofthe piston pin Remove piston pin retainer @ Remove the piston pin Take off the cylinder with the piston Push the piston upward out ofthe cylinder. Info HW tno other work is requited on the cylinder and the pis- ton, you can leave the piston in the cylinder. 170~ Takeoff eylinder base gasket @ = Remove dowels @ = Remove serens @. Take off the starter mator. = Feed out timing chain @. © Info If the timing chain is to be reused, mark the direction of travel ~ Remove screw @ ~ Take ofthe timing chain tensioning rail toward the top. m18.3.14 Removing the water pump wheel Remove screws @ Remove the water pump cover with the gasket. Remove locating pins @. Remove nut @ with washer Takeoff the water pump impeiter @. Remove screws Take off the alternator cover. Remove dovels @. Takeoff alternator cover gasket @ 1218.3.16 rotor, removing. 18.3.17 Removing the starter drive Remove screw @ with the washer. Peston the special toot @) inthe crankshaft. resting ool (BOT2B020000) 6% p. 334) Mount special too! @) on the rotor, © Info Left-handed thread! Hold it tight using the special tool and pull off the rotor by turning the screw in Puller (60228009000) (© p. 336) Remove the woodruff key. Takeoff torque miter @ Remove starter idler gsar @ Remove screw @ Remove the retaining bracket. 173~ Remove freewnee! goar @ 18.3.18 Removing the drive wheel of the balancer shaft = Remove screw @ with the washer, Remove balancer shaft gear @ with a wedge. Remove nut @ with washers. (Groove nut wrench (80129022000) (© p. 334) = Take off drive whee! ofthe balancer shat Remove the woodrutf key. Remove screws @ = Take oft the retaining bracket. Remove screws @ Pull ofthe ignition pulse generator. 1”~ Remove screws © “Take off the gear position sensor and crankshaft position sen- ‘sor withthe cable. . 183.20 Removing the suction pump GS. a ~ trons @ ms HB] — T2kc off the cil pump housing ofthe suction pump, = Remove dowels @. ~ Remove external rotor @ and internal ctor @ = Take ott pin @, ‘ 17518.3.21 Removing the clutch basket Remove screws @ Remove pressure pate @ rove springs @ Take off pressure cap @. Remove pull rod @. Remove clutch disks @ ‘Take off support ring and pretension ring @. Hold the clutch basket using the special tol Holding wrench (51129003000) (© p. 328) Remove nut @ with washers. Info Left-handed thread! 176“Take off ane clutch hub @ and washer @ © Info The washer usually sticks tothe inner clutch hub. ‘Take off clutch basket @. Remove citar sleeve @ Remove nut @ with the washer. remove washer @ Remove te timing chain sprocket © "7Remove primary gear @ Remove wodkut key ©. Remove lock ring @ Take off washer @ Remove the oil pump gear @. Remove pin @ = Take off the washer. Remove screws @ ‘Take off the pressure pump housing. 178Remove dowels @ Remove external rotor @ Remove internal rotor @. Remove pin @, Remove the il pump shatt @ Pash slicing plate @ avay rom the sit um locating @ Remove shit shat @) withthe washer, Remove screw @ Press locking lever @ away from shift drum locating @ and take off the shit drum locating. Release the locking lever, 1791.3.26 Removing the locking lever = Remove screw @. Takeoff locking lever @ together with the washers and sing. ‘ ~ Remove screm @ = Remove ol fiter cover @ withthe Ong. = Patt oi titer @ out ofthe ol fiter housing. ‘ = Remove special tol Locking serew (61229015000) (© p. 331)— Remove screw @ = Remove screws @ = Tilt the left section of the engine case upward and remave the fiting ofthe engine fixing arm, = Mount special too! @ Pressing tool (90128020000) (=p. 334) Mount special too! @) with suitable screws Palle (S0725048100) ( p. 334) © Info Huse the dri note with marking 902. Pull off the section ofthe engine case by serewing intheInfo Ho not tension the section of the engine case. “The washer ofthe main shaft usually sticks tothe boar- ing = Takeoff the left section of the engine ese = Remove the special tol = Remove dowels @. = Remove il spray tube @ — Remove shit rail @ together with upper sri andthe lower soving ~ Remove shit rit @. ~ Swing shit orks @ to onesie ~ Remove shit drum ~ Remove shift forks @. 18218.3.32 Removing the transmission shafts = Pull both transmission shafts @) out of the bearing seats together. ‘ = Remove serew = Take ofthe lock washer. = Remove balancer shaft @ ‘ ~ Remove crankshatt @. ‘ ‘18.4.1 Working on the left section of the engine case = Remove spacer @ ofthe countershat.Remove al dowels. Remove lock ring @. Remove shatt seal i countershatt. Remove oil nozzle @. Remove any remnants of sealing compound and clean the sec- tion of the engine case thoroughly. \Warm the section ofthe engine case in an oven Guideline 150°C (302 °F) Knock the section of the engine case against a level wooden ‘board. This will cause the bearings to drop out ofthe bearing seats, © or the smite att and @ othe Info ‘Any bearings that remain in the section of the engine ‘case must be removed using a suitable too Insert the new cold bearings in the bearing seat of the heated section of the engine case; if necessary, use a suitable press drift to push them all the way in and make them flush. 1 The closed side ofthe transmission output bearing points towards the engine sprocket. = Info TWnen pressing in, ensure that the section of the engine case lies flat inorder prevent damage. Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in [iter the section ofthe engine case has cooled, check that the bearings ae firmly seated. = Info I the bearings are not firmly seated after cooling, it is likely that they wil rotate in the engine case when warm. In this case, the engine case must be renewed. ‘Mount the dowels. Press in shaft sal ring @) of the shit shat oi is lush with the open side facing inward Press in shaft seal ring @ ofthe countershatt oi is fush withthe open sie facing in Mount lock ring @. Mount and tighten ait nozzle @ Guideline Oil nazele [WE ENA eT Loctter2aar™ Blow out the oil channel with compressed air and check that it is clear 184‘on the right section ofthe engine case Remove all dels. Remove screws @. Remove the bearing retainers, Remove any remnants of sealing compound and clean the sec- tion ofthe engine case thoroughly Warm the engine case section in an oven. Guideline 150° (302 °F) Knock the engine case section against a level wooden board, This will cause the bearings to drop out of the bearing seats. Info Any bearings that remain in the engine case section ‘must be removed using a suitable tool Insert the new cold bearings in the bearing seats of the heated section ofthe engine case; if necessary, use a suitable press. ft to push them all the way in and make them flush, Info When pressing the bearings 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 winen they are pressed in. Ater the engine case section has cooled, check that the bear- ings ae firmly seated. Info Tir the bearings are not firmly seated after cooling, it is ikely that they wil oat in the engine case when warm, inthis case, the engine case must be renewed Hount the dows Position al bearing retainers Mount and tighten serews @. Guideline Serew, bearing [6 T2Nm GTR tainer Loctte*24a0 Blow out the oil channel with compressed air and check that it is clear. 185ing ofthe water pump = Remove shatt seal ring @. ~ Remove shat sealing @. ~ Gress the new shat sel ring @ and push in ll the way. igh viscosity grease (© p. 324) Pressing tool (93829043000) (= p. 336) 1 Shaft seal ring has 2 sealing lips. ~ Grease the now shaft sel ring @ and press in all the way wit the open sie facing outwards igh viscosity grease (@ p. 324) Pressing tool (93829043000) (© p. 336) 18.4.4 Checking the radial play ofthe lower conrod bearing Condition “The conrad bearing is bulging.Clamp the connecting rod with soft jaws. Position the crankshat. Position the bearing shells. Insert the Plastigauge clearance gauge @ offset by 90° to the bearing face. Plastigauge clearance gauge (60029012000) (@ p. 329) Position the conrod bearing cover. Mount and tighten the screws. Guideline ‘Screw, conrod bear] M@xL 34 Nm (25.1 IBF A ing © Info Do not twist the connecting rod. Remove the conrod bearing cover again. Compare the Plas ‘auge clearance gauge with the specifications on the packag- ing. Changing the conrod bearing Guideline Connecting rod - radial play of lower conrod bearing ‘New condition 0.048... 0.088 mm (0.00177 ... 0.00268 in) Wear timit (0.080 mam (0.00315 in) Info the wiatn of the Ptastigauge clearance gauge is equiva- lent tothe bearing pay. ‘Clean the parts. Clamp the connecting rod with soft jaws. Remove screws @. Remove the conrod bearing cover and crankshaft, Remove the bearing shells. 187New crankshaft ‘Select new bearing shells according to the crankshaft clas- sification and connecting rod classification. Guldeline Cranishaft= ameter, nk pin Ceankshalt cesiice- 31.970. 31.877 mm ton (0.25866 1.25893 n) Cranks dassica. 31.978 31.385 mm ton {0.25897 1.25925 Tilo ene Sarod ear el Geen Crankshaft esticaionB and connecting od cas eaten 1 Toe Cranks asiicaonB tre conectng rod cas eatin 2 Tone Crankshaft dasTicton A and connecting od eas eatin 1 aoe CrankshattCasTicaion A and connecting od cas eatin 2 tno Dthecontsnatclassteation fs indcaed by mark- ing ® The conectng od clasfiatini inated by marking © heck he rede playa the lower coved bearing ep. 186) Used eran sat Measure the crank pin diameter and select the new bearing shells according to the crankshaft classification and the connecting rod classification,Guideline (Crankshaft ~ diameter, crank pin Crankshaft classifica. 31.970... 31.977 mm tion A (1.25866 ... 1.25893 in) Crankshaft classifica 31.978 .. 31.985 mm tion B (1.25897 ... 1.25925 in) Color coding for conrod bearing shell Green ‘Crankshaft classification B and connecting rod classi- fication 1 Tone ‘Crankshaft classification B and connecting rod classi- fication 2 None ‘Crankshaft classification A and connecting rod classi- fication 1 Blue ‘Crankshaft classification ® and connecting rod classi- fication 2 Info The crankshatt classification is indicated by mark: ing @. The connecting rod classification is indicated by marking @ Check the radial play of the lower conrod bearing. (Fp. 186) Position and oil the bearing shells a = Position the connecting rod and conrod bearing cover accord- Ing to markings @ = Mount and tighten screws @. Guideline ‘Screw, conrod bear- | MBxL 34 Nim (25.1 IBF A ing Info Always replace the contod bearing screws,18 ENGINE 18.4.6 Changing the balancer shaft bearing = Mount special tools @. [Pressing tool (90129056000) (& p. 335) Position the balancer shaft in the press using a sultable tool Press out the bearing, = Press on the balancer shaft bearing witha suitable tool Remove the special tools. Pressing tool (90129056000) (@= p. 335) = Fold cam lever @ up. ~ Take the shims @ out ofthe valve spring retainers and lay them to onesie according to their normal built-in psi Tension the valve spring with a special too Valve spring mounter (68029019000) (tp. 328) Insert for valve spring ever (77029041200) (© p. 333) 19018.4.8 Checking the cylinder head ENGINE 18 Remove valve keys @) and release tension on te va spring Remove valve spring retainer @ Remove valve sping valve stem seal @, and valve spring seat . Info BL race the vavesin carton conespondig to thelr instalation position and label them: Check the eylnder head, (ip. 191) Mount valve spring seat @ and the new vale stem seal @ Mount the va spring Mount valve spring retainer @. Tension the valve spring with a special too ‘Valve sping mounter (59029019000) (© p, 328) Insert for valve sping lever (77029081200) (=p. 333), "Mount the valve keys, Release the tension on the valve spring © Info when mounting the valve keys, check that they are seated correctly preferably, fix the valve keys to the valve with a litte grease, Place the shims in the valve spring retainers corresponding to their instalation position, < Check vaive guides @ with the special tool Limit plug gauge (77029026000) (= p. 332) Ifthe special tool is easy to insert into the valve guide: = Change the valve guides and valves. Check the sealing area ofthe spark plug thread and the valve seats for damage and tearing. + If there is wear or tearing: = Change the cylinder head, Check the sealing area ofthe cylinder for distortion using a straight edge and the special tool, Feeler gauge (68029041100) (& p. 325) Cylindereylinder head dis- | = 0.10 ram (= 0.0039 in) tortion of sealing area Ifthe measured value does not equal the specified value = Change the cylinder head, 191Check sealing seat @ of the valves, Valve ~ sealing seat width Tntake 090 T10 mm (0.0354 (0.0433 in) Valve ~ sealing seat width Exhaust 0.90... 1.10 mm (0.0354 0.0433 in) + Ifthe measured value does not equal the specified value = Machine the valve seat. Blow compressed air through allo holes and check that they 18.4.9 Checking the pivot point of the camshafts CCheck the pivat points ofthe camshafts, » Hf there is damage or wear: = Change the cylinder head withthe camshatt bearing bridge. Position the camshafts. 7 The valves are not actuated. Insert the Plastigauge clearance gauge in area @. Plastigauge clearance gauge (60029012000) (© p. 329) inside to the outside. Guideline Position camshaft bearing bridge @. Mount the screws and tighten in a crisscross pattern from the Screw, camshaft beating support We TO Nm (74 It Info Tttake sure the dowel pins are seated correctly o not twist the camshaft. 19218.4.10 Checking/measuring the cylinder 18.4.11 Checking the piston ring end gap ~ Remove the camshaft bearing bridge @ again Compare the Plasigauge clearance gage withthe data on the packaging Guideline omaha bearing side bearing Toda clearence 0085. 0053 mmm (0.00038 0.09209 in) 0,065 mn (0.00256 mn) Wear li Info HThe wiath of the Ptastigauge clearance gauge is equal to the bearing play. = Take off the camshafts and clean the parts ~ Check the einer bearing surface for damage. + the eylinder bearing surface is damage: = Change the eyinder and piston. = Measure the cylinder diameter a several places inthe @ and @ aves using a micrometer to check for oval wee. Guideline Cylinder bore diameter | GB. 982 .. 66.938 mm (3.50322 .. 3.50385 in) = Check the sealing area ofthe cylinder head for distortion using. a straight edge and the special tool. Feeler gauge (59029041100) (& p. 329) Gylindereylinder head dis- | #010 mm (S 0.0039 in) tortion of sealing area » Ifthe measured value does not equal the specified value = Change the cylinder and piston = Remove the piston ring from the piston, = Place the piston ring inthe cylinder and align it with the pis ton. Guideline Under the upper edge afte [20 rm (0.79) oylinger ~ Using special toot @, measure the end wap. Guideline Piston ring end gap Compression ring | #040 nm (@ 0157 i serape tng 0.80 nm (#00315 n) Feeler gauge (68029041100) (& p. 325) 19318 ENGINE 184.12 Checking/measuring the piston + Ifthe end gap is more than the specified value: = Check/measure the cylinder. (2 p. 193) + Ifthe eylinder wear is within the tolerance range: = Change the piston ring Mount the piston ring with the marking facing toward the pis ton head < CCheck the piston bearing surface for damage. + Ifthe piston bearing surface is damaged = Replace the piston and, if necessary, the cylinder. CCheck thatthe piston rings move easily in the piston ring grooves, » Ifthe piston ring is stf: = Clean the piston ring groove. Tip An old piston ring can be used to clean the pis ton ring groove. CCheck the piston rings for damage + Ifthe piston ring is damaged = Change the piston ring Into TH Mount the piston ring with the marking facing upward Check the piston pins for discoloration or signs of wea. > Ifthe piston pin shows severe siscolorationsigns of wear: ~ Change the piston pin Place the piston pin inthe connecting rod and check the seat. ing fr ply + Ifthe piston pin seating has excesive pla: ~ Change the connecting rod and piston pn, Measure the piston atthe piston skit, at ight angles tothe piston pin, at a distance @ Guideline Distance @ 30 mim (LTB Piston - diameter 38.931... 86.949 mm (3.50121 .. 3.50192 in) 19418.4.13 Checking the piston/cylinder mounting clearance 18.4.14 Checking the oi! pump ~ Checkimeasure the cylinder. (E# p. 193) = Check/measure the piston. (#8 p. 194) The pistonfeylinder mounting clearance is the result of the cylinder bore diameter minus the piston diameter. Guideline Pistonieyinder - mounting clearance ‘New condition (0.033 ... 0.067 mm (0.0013 ... 0.00264 in) Wear iit (0.08 mm (0.0031 in) Info T The folowing operations apply to both oil pumps. = With special toot @, check the play between the internal rotor and external rotor and between the external oor an the ol pump housing Feeler gauge (68029041100) (& p. 328) Oi pump Play between external] 0.10 ... 0.20 mm (0,039 rotor and internal rotor | .. 0.0079 in) Oi pump Play between external | 0.09 .. 0.20 mm (0.0035 rotor and oil pump hous- | .. 0.0079 in) ing > Ifthe play exceeds the specification: = Change the oil pump and, if necessary, the oil pump housing. = Check axial play @ ofthe oil pump. Oil pump ‘ial play O10 ... 0.25 mm (0.0039 0.0098 in) > Ifthe play exceeds the specification: = Change the oil pump and, if necessary, the oil pump housing. 19518.4.15 Checking the 18.4.16 Checking the clutch il pressure regulator valve Remove washer @. Remove spring @. Measure the length of spring @. Oil pressure regulator valve 30.00 mm (1.1811 in) ‘minimum spring length >t? the measured length i less than the specified valu: = Change the spring. Check control piston @) for damage and wear. > tf tere is damage or wear: = Change the conto piston, Check the control piston inthe pressure pump housing for smooth operation. > If the control piston does not move eas ~ Change the conto piston or the pressure pump hous- ing Check the contol piston bore in the pressure pump hous- ing @ for damage and wear + lf there is damage or wea: ~ Change the pressure pump housing Cit contet piston @ and spring @ well and mount them, Mount washer @. $ ig? oe 2 = Check collar sleeve @ for damage and wear. tf there is damage or wea: — Change the collar sleeve. = Check te lenath of clutch springs @.Glutch spring fength 250mm @ 1.97 im) > Ifthe clutch spring length is es than the specified value = Change al euteh springs. = Check inner clutch hub @ for damage and wear 2 iftheeis damage or wear: = Change the inner clutch hub ~ Cheek elute pressure cap @ for damage and wea. 2 there is damage or wear: = Change the clutch pressure cap. ~ Check the contact surfaces ofthe elutch facing iss inthe outer clutch hub @) for wea. Contact surface, clutch facing discs in clutch basket [= 0.5 mm (= 0.02 in} >t contact surace is very worn ~ Change the clutch facing discs and the outer clutch hub ~ Check cute facing ses @ tor discoloration and scoring +I there i discoloration or scoring: = Change all elute facing dies = Check the thickness of clutch facing discs @ and intermediate discs @. ‘Thickness of overall package 32.00 mm (2 1.2598 in) Ifthe clutch facing dises do not meet specifications: = Change all clutch facing discs. ~ Check intermediate discs @ for damage and wear. + Ifthe intermediate discs are not level or ae pitted: = Replace all intermediate discs. 18.4.17 Checking the shift mechanism “> oe “#0 “a —~R . = Check the shitt forks @ (see @) tor damage and wear (visual check). + If there is damage or wear: = Change the shift fork and gear wheel par. 19718 ENGINE = check sit grooves @ of shite crum @ for wear. 1 Tf the shift groove is wom = Change the shift roller, ~ Check the seat ofthe shift drum in bearing @. + Ifthe shift role isnot seated correctly = Replace the shift drum andor the bearing = Check bearing @ for titfness and wear 2 I the bearing is tif or woe: = Change the bearing = Check shit rit @ on ata surface for run-out. > Hh there is runout: = Change the shit rail = Check the shift rail for scoring, signs of comesin and stiffness inthe shift forks +» If there i scoring or corrosion or ifthe shift ok sti = Change the shit al. = Check siding pate @ in contact areas @ for wear. +I the sliding plate is worn = Change the shit shat = check return sutace @ onthe siding pate fr wea. >» If deep notches are preset ~ Change the shift shatt ~ Check guide pin @ for looseness and wear. + If the guide pin is lose andr wor = Change the shit shat ~ check locking lever @ for damage and wea. > When the lacking evr is damaged or worn = Change the locking lever ~Preassemble the shit shat. (2p. 198) = Check the pay @ between the slicing pate andthe shite quadrant Shift shaft - play in sliding [0.15 .. 0.45 mm (0.0059 platelshift quadrant 0.0177 in) » Ifthe measured value does not equal the specified value = Change the shit shat. 18.4.18 reassembling the shift shaft = Fhuthe short end of the shift shaft in a vise. Guideline Use soft jaws = Mount siding plate @ with the guide pin facing down and attach the guide pin tothe shift quacrant ~ Mount preload spring @ 198ENGINE 18 = Push on spring guide @, push return spring @ over the Spring guide wth the offset end facing upward and If the off set end over abutment bolt @. ~ Mount washer @. ‘ 184.19 Disassembling the main shaft / ° o 9 0 W4 Sa, 6 ‘i = Secure the main shaft inthe vise withthe gear teeth facing downward Guideline Use soft fas ~ Remove stop isk @ and secona-gear tines gear @. = Remove sbth-ger idler gear @. = Remove collar bushing @. = Remove lack ring @. Remove thirdourth-gear sliding gear @. = Remove lack ring @. = Remove collar bushing @. ~ Remove fifth-gear idler gear @. . 19918 ENGINE 18. 4.20 isassembling the countershaft ae @ 9 - oO é oy" “6 7 somnss.1 18. ‘Secure the countershaft in the bench vise withthe toothed end facing downward. Guideline Use soft jaws, Remove stop disk @ and fst gear iler gear @ Remove collar bushing @. Remove sixth-gear sliding gear @ Remove lock ring @. Remove colar bushing @ Remove thrd-gear idler gear @. Remove washer @. Remove fouth-gear idler gear ©, Remove fith-gear sliding gear @. Remove the second-ger idler gear @. Remove collar bushing @. 4.21 Checking the transmission The transmission has been disassembled, 200ENGINE 18 Check collar bushings @ for damage and wear, +I there is damage or wear: = Change the cllar bushings. Check the pivet points of main shatt @ and countershatt @) for damage and wear. tf there is damage or wear: ~ Change the main shaft andor countershaft Cheek the tooth profiles of main shatt @ and countershatt @ for damage and wear > tf there is damage or weer = Change the main shaft andor countrshatt, Check the pivt points af cer gears @ for damage and wear 2 tf there fs damage or wear = Change the gear whee! pai. Check the shift dogs of fler gears @ and slicing gears @) for damage and wear > tf there is damage or wear = Change the gear wheel pal Check the tooth faces of idler gears @ 5 + If there is damage or wear = Change the gear whee! pair Check the toot profiles of siding ears @ for damage and wear tf there is damage or wear: = Change the gear whee! pir Cheek siding gears @ for smooth operation inthe profile of main shatt @. + tfthe sliding gear does not move easily = Change the sliding gear or the main shat Check siding gears @ for smooth operation in the profile of countershat @ + Ifthe sliding gear does not move easily ing gears @, and fixed gear @ for damage and wear. = Change the slicing gear or the countrshat Check stop disks @) for damage and wea. > there is damage or wer = Change the stop disk 20118 = Use new lock rings @ with every rept 18.4.2 Assembling the main shaft Info Use new lock rings with every repair. paratory work Carefully ubeicate all parts before assembling = Check the transmission. (2% p. 200) Main work ‘Secure the main shaft in the vise with the gear teeth facing downward, Guideline Use soft jaws, Mount fith-gear idler gear @. Mount colar bushing @ Mount lock ing @. Mount thia/ourth-gear slicing gear @ with the small gear wheel facing downward Mount lock ing @. Mount cola bushing @ Mount sixth-gear idler gear @. Mount second-gear fixed gear @ and stop disk @. Finally, check al the gear wheels for smooth operation, 18.4.23 Assembling the countershaft Info Use new lock rings with every repair. 202Preparatory work = Carefully lubricate all parts before assembling. — Check the transmission. (E2 p. 200) Main work = Secure the countershaft in the bench vise with the toothed end facing downward Guideline ENGINE 18 Use soft jaws = Mount colar bushing @. = Mount second-gear cir gear @. = Mount itth-gear sliding gear @ withthe shift groove facing up. ~ Mount fouth-gear idler gear @ = Mount washer Mount third-gear idler gear @. = Mount collar bushing @. Mount lock ring @ ~ Mount sith-gear sliding ear @ with the shitt groove facing downward = Mount collar bushing @. = Mount trst-ger idler gear @. = Mount stop disk @ = Replace O-ring € of the countershat ~ Finally, check al the gear wheels for smooth operation 20318 ENGINE Check timing chain @) for damage and wea. >» tf there is damage or wear ~ Change the timing chain. Check that the chainlink ofthe ting chain can move easily » the timing chain is sti = Change the timing chain, Let the timing chain hang down ely. Check thatthe timing chain links move easly +I the chain inks no longer straighten out = Change the timing chain, Check timing chain guide ral @) for damage and wear. If there fs damage or wear: = Change the timing chain guide rai Check timing chain tensioning rat @) fr damage and wear. >If there is damage or wear ~ Change the timing chain tensioning rai Check timing chain sprocket @ for damage and wear. > Hf there is damage or wear = Change the timing chain sprocket. Check camshat gears @ for damage and wear >t there is damage or wear: = Change the camshaft gears. 204184.25 Changing the stator Remove sevens @. Remove the cable retainer. remove screws @. Remove the stator. Position the new stator Mount and tighten Guideline ‘Screw, stator 5 BNm 5.9 iF Loctitee2a3™ Position the cable guide inthe alter Position the cable retainer. Mount and tighten Guideline mator cover. Screw, retaining bracket, stator cable 5 B Nm (5.9 1B) Loctite®243™18 ENGINE 18. 4.26 Checking the electric starter drive “Ce. 0—e Check the teeth and seating ofthe starter ier gear @ for damage and wear. >» tf there is damage or wear ~ Change the sate idler gear Check the teeth and seating ofthe torque limiter @) for damage and wear. + if there fs damage or wear = Change the trque imiter. Check the tocthng and bearing of freewheel gear @) for damage and wear >t there is damage or wear: = Replace the freewheel gear andor the bearing Check toothing @ ofthe starter motor for damage and wear > If there is damage or wer — Replace the starter moter, Replace the O-ring @ of the starter motor. Clamp the minus (negative) cable of a 12 Volt power supply tothe starter motor housing, Briefly connect the positive cable of the power supply to the starter motor connection + Ifthe starter motor doesnot turn when you close the power cic = Replace the starter moter, 20618.4.27 freewheel, checking — Insert freewheel gear @ into the freewheel hub, turning the freewheel gear clockwise; do not wedge = Check the locking action ofthe freewheel gear. » The freewtieel gear cannot be turned clockwise and does not block counterclockwise: = Change the freewheel. . 18.5.1 Installing the crankshaft = Oi the bearing = Slide crankshaft @ into the bearing seat . 18.5.2 _ Installing the balancer shaft = Mount special tool @). Protection cap (0125005000) =p. 334) = Mount balancer shaft @ withthe bearing = info if necessary, heat the engine case = Position the retaining bracket = Mount and tighten screw @. Guideline Farm] [Sc bearing [6 T2 Nim @.9 WER) retainer Lctte®24am™ ~ Remove the special oo Protection cap (0129008000) (ep. 334) ‘ 20718.5.3 _ Installing the transmission shafts ll the bearing = Slide both transmission shafts @ into the bearing seats together. 18.5.4 Installing the shift forks = Oilall parts carefully before assembling = shit fork @ has a smaller inside ciameter: mount iti the Shift groove ofthe main shaft ~ Mount shit ork @ inthe loner shit woove of the counter shaft = Mount shit fork @ nthe upper shit groove of the counter shaft Slide shift crum @ into the bearing seat. ~ Hang shift forks @ into the shift drum. 20818.5.6 Installing the shift rails Oilall parts carefully before assembling. = Mount shitt rail @) together with upper spring and the lower spring. = Mount shitt rail @. 18.5.7 Installing the left engine case = Clean the sealing areas. = Mount dowels, = Mount the new O-ingson oil spray tube @. = Mount the ol spay tube 7 Catch @ engages in recess @. = Apply sealing compaund to the left section ofthe engine case Loctite® 5910“Mount the section ofthe engine case. If necessary, tap lightly with a rubber mallet while turning the transmis- sion shafts, © Info Do not use the serews to pull the two sections ofthe engine case together. — Mount screws @ but donot tigen yo. Guideline Sere, engine case Wes T2Nm GTI Loctite®243™ = Mount screws @ and tighten all screws in a crisscross pattern, Guidetine Screw, engine case Woes T2Nm GSI Screw, engine case Wex75 T2Nm 6 9iot Loctte2aam™ = Mount the serew ep of the engine txing arm, = Mount and tighten screw @. Guideline Screw, engine case [W6@S [12 Nm BOARD 21018.5.8 18.5.9 Installing the ol filter Installing the locking lever ~ Postion crankshaft to TDC and tock wth special tool @) Tocking screw (61225015000) (p33 = Tilt the motorcycle to one side and fill the ol filter housing to about % full wth engine ol. ~ Fill iter @ with engine it and place i in the oi iter hows = Oil the Oring af the ol fiter cover = Mount oi iter cover @. = Mount and tighten screws @. Guideline Serew, ote cover [NS TORT Tw ~ Mount lcking lever @ withthe sleeve, washers and sping. = Mount and tighten screw @ wit the washer Guideline ‘Screw, locking [ M6 Teh BOW lever Lectiter243 au18.5.10 Installing the shift drum locating. rE ~ Mount spacer ing @ on the sit dum locating un. = Press locking lever @ away from the shit drum locating and position the shift drum locating @. Y Pins @ engage in hole @ = Release the locking lever. = Mount and tighten screw @. Guideline Screw, shit] 6 T2Nm GTR drum locating Loctt24am™ . 18.5.1 Installing the shift shaft ~ Slide shit shat withthe washer into the bearing sea ~ Push sling pate @ away from the shit crum locating @ set the shit shaft all he way. ~ Let the siding plate engage in the shift drum locating = hit through the transmission ‘ = Mount dowels @. 212= Position pin @ and interna rotor @ onthe oil pump shat. = Postion the oi pump shat with the internal rotor inthe pres sure pump housing ~ Poston externa ctr @ in the pressure pump housing Y Markings @ are visible ater assembiy = Check thatthe ol holes ae clear and fl with a small amount ol ~ Poston the oil pump. = Mount and tightn seus @. Guideline ‘Screw, oll pump ] MB T2 Nm @.9 ibe Loctitee243™ = Position the washer. = Position pin @ ~ Position the ot pump gear @ = Position washer @. ~ Mount lock ring @. ~ Crank the cil pump gear and check for sttines. 213,