3 2015 KTM 350 EXC-F XCF-W Manual PDF

REPAIR MANUAL 2015 350 EXC-F EU 350 EXC-F Six Days EU 350 EXC-F Factory Edition EU 350 EXC-F AU 350 EXC-F BR 350 EXC-F US 350 XCF-W US 350 XCF-W Six Days US Art, no. 3206200enINTRODUCTION 1 Read this repair manual carefully and thoroughly before beginning work The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and propery. This repair manual was written to correspond to the latest state ofthis model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time, ‘We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic. All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply. © 2015 KTM Sportmotorcycle GmbH, Mattighofen Austria Al rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. TOV the maximum possible quality of the products. Issued by: TOV Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen, Austria 3206200en 05/2015TABLE OF CONTENTS 1 MEANS OF REPRESENTATION... 1.1 Symbols used 1.2. Formats used. 2 SAFETY ADVICE.. 2.1 Repair Manual... 2.2 Safety advice. 2.3. Degrees of risk and symbols. 2.4 Work rules. 3 IMPORTANT NOTES. 3.1 Guarantee, warranty 3.2 Operating and auxiliary substances, 3.3 Spare parts, accessories. 3.4 Figures 4° SERIAL NUMBERS 4.1 Chassis number. 4.2 Type label... 4,3. Key number (All EXC-F modes)... 4.4 Engine number: 4.5 Fork part number 4.6 Shock absorber part number 5 MOTORCYCLE i 5.1 Rising the motorcycle withthe lift stand 5.2 Removing the motorcycle from the lft stand.. 5.3 Starting... 5.4 Stating the motorcycle for a check 6 FORK, TRIPLE CLAMP... 6.1." Adjusting the compression damping of the OTK rrr 6.2 Adjusting the rebound damping ofthe fork. 6.3 Adjusting the spring preload of the He EAE ROUARAS , EXC-F Factory Edition) 6.4 Bleeding the fork legs.. 6.5 Cleaning the dust boots of the fork legs. 6.6 Loosening the fork protector. 6.7 Positioning the fork protector... 6.8 Removing the fork legs. 6.9 Installing the fork legs... 6.10 Removing the fork protector. 6.11 Installing the fork protector. 6.12 _EXC-F EV/AUSIBRIUS, XCF-W, EXC-F Factory Edition 6.12.1 Performing a fork service... 6.12.2 _ Disassembling the fork legs 6.12.3 Cartridge disassembly 6.12.4 Disassembling the compression damping fitting 6.12.5 Checking the fork legs. 6.12.6 Assembling the compression damping fitting 6.12.7 Assembling the cartridge. 6.12.8 Assembling the fork legs 6.12.9 Greasing the steering head bearing. 6.12.10 Removing the lower triple clamp (EXC-F EUIAUSIBR/US, XCF-W) 6.12.11 Installing the lower triple clamp (EXC-F EUIAUS/BR/US, XCF-W) 6.12.12 Removing the lower triple clamp (EXC-F Factory Ecition) 6.12.13 Installing the lower triple clamp (EXC-F Factory Edition) 6.12.14 Checking the steering head bearing play... OOOO RHOMBVIVIIAAD 21 21 21 24 26 . 26 27 29 33 & 36 37 6.12.15 Adjusting the play of the steering head bearing (EXC-F EU/AUS/BR/US, XCF-W)....... 39 6.12.16 Adjusting the play of the steering head bearing (EXC-F Factory Edition). 6.13 All Six Days models... 6.13.1 Performing a fork service 6.13.2 Disassembling the fork legs 6.13.3 Removing the Spring... 6.13.4 Disassembling the cartridge. 6.13.5 Disassembling the piston rod 6.13.6 Disassembling the hycrostop unit 6.13.7 Disassembling the seal ring retainer... 6.13.8 Checking the fork legs. 6.13.9 Assembling the seal ring retainer... 6.13.10 Assembling the hydrostop unit 6.13.11 Assembling the piston rod 6.13.12 Assembling the cartridge 6.13.13 Assembling the fork logs. a 6.13.14 Greasing the steering head bearing, 6.13.15 Removing the lower triple clamp 6.13.16 Installing the lower triple clamp i 6.13.17 Checking the steering head bearing play ..... 57 6.13.18 Adjusting the play of the steering head bearing... HANDLEBAR, CONTROLS. 7.1 Handlebar position 7.2 Adjusting handlebar position 7.3. Adjusting the basic position ofthe clutch lever 7.4 Checking throttle cable routing. 7.5 Checking the play in the thrattle cable .. 7.6 Adjusting the play in the throttle cable... FRAME 8.1 Checking the frame 8.2. Removing the engine guard (EXC-F AU, EXC-F Factory Ecition, All Six Days models) .... 62 8.3 Installing the engine guard (EXC-F AU, EXC-F Factory Ecition, All Six Days models) .... 62 ‘SHOCK ABSORBER, SWINGARM ... a 9.1 Adjusting the high-speed compression | damping of the shock absorber... 92 Adhsing he lo speed compression damping of the shock absorber 9.3 Adjusting the rebound sawing ofthe shock absorber. 5 9.4 Measuring rear wheel sag unloaded 9.5 Checking the static sag of the shock absorber... 64 9.6 Checking the riding sag of the shock absorber... 65, 9:7 Adgting te spring preload o the shock absorber. — 9.8 Adjusting the riding sag, 9.9 Removing the shock absorber... 9.10 Installing the shock absorber. 9.11 Servicing the shock absorber. 9.12 Removing the spring. 9.13 Disassembling the damper.. 9.14 Disassembling the piston rad 9.15 Disassembling the seal ring retainer... 9.16 Replacing the pilot bushing 9.17 Checking the damper 9.18 Disassembling the rebound adjuster. 9.19 Removing the heim joint. 9.20 Installing the heim joint...TABLE OF CONTENTS 10 nl 2 13 4 9.21 9.22 9.23 9.24 9.25 9.26 ‘Assembling the rebound adjuster. ‘Assembling the seal ring retainer. ‘Assembling the piston rod. Assembling the damper Bleeding and filling the damper Filling the damper with nitrogen 9.27 Installing the spring 9.28 Changing the heim joint. EXHAUST. 10.1 Removing the manifold. 10.2 Installing the manifold 10.3 Removing main silencer... 10.4 Installing the main silencer. 10.5 Changing glass fiber yarn filling in the main silencer 106 models) AIR FILTER .. 11.1 Removing the at filter bo« cover 11.2 _ Installing the air filter box cover 11.3 Sealing the air filter box. 11.4 Removing the air filter 11.5 _ Installing the air filter. 11.6 Cleaning the ar filter and ar filter box FUEL TANK, SEAT, TRIM 12.1 Opening filler cap 12.2 Closing filler cap 12.3. Removing the seat 12.4 Mounting the seat 12.5 Removing the fuel tank. 12.6 _ Installing the fue! tank... 12.7 Changing the fuel screen 12.8 Changing the fuel filter... 12.9 Changing the fuel pump 12.10 Checking the fuel pressure. MASK, FENDER... 413.1 | Removing the front fender 13.2 Installing the front fender si 13.3 Removing headlight mask with headlight. 134 Refiting the hong mak with tbe headlight nnn WHEELS... 14.1 Checking the tre lr pressure, 14.2 Checking the tire condition 14.3 Checking the brake discs 14.4 Checking spoke tension 14.5 Front wheel. 2 14.5.1 Removing the front whee 14.5.2 Installing the front whee! 14.5.3 Removing the front brake disc... 14.5.4 Installing the tront brake dise 14.6 Rear wheel 14.6.1 Removing the rear wheel 14.6.2 Installing the rear wheel... 14.6.3 Removing the rear brake disc 14.6.4 Installing the rear brake disc.. 14.6.5 Checking the chain tension... 14.6.6 Adjusting the chain tension 14.6.7 Checking the chain, rear sprocket, engine ‘sprocket and chain guide 14.6.8 Checking for chain dirt accumulation, 14.6.9 Cleaning the chain.. leaning spark a arrestor (EXC-F US, All XCF-W 5 78 76 7 82 83 87 87 87 101 103 103 103 103 104 106 106 106 107 107 .. 108 108 108 109 109 109 109 110 ul 11 2 2 13 115, us 15 16 W7 18 3 WIRING HARNESS, BATTERY... 116 15.1 Removing the main fuse 116 15.2 _ Installing the main fuse 16 15.3 Changing the fuses of individual power consumers, 116 15.4 Removing the battery 17 16.5 Installing the battery. us 15.6 Checking the charging voltage. 18 15.7 _ Checking the quiescent current 119 BRAKE SYSTEM se 120 16.1 Checking the front brake linings - 120 16.2 Changing the front brake linings... se 120 16.3. Checking free travel of hand brake lever wane 122 16.4 Adjusting the basic position of the hand brake lever (All XCF-W modets)... 122 16.5 Adjusting free travel of hand brake lever (All EXC-F models). 122 16.6 Checking the brake fluid level of the front Drake ere 123 16.7 Adding front brake tuld.. 123 16.8 Changing the front brake fluid... 124 16.9 Checking the rear brake linings 125 16.10 Changing the rear brake linings 125 16.11 Checking the free travel of fot brake lever... 127 16.12. Adjusting the basic position of the foot brake lever 127 16.13 Checking the rear brake fluid level. 128 16.14. Adding rear brake fluid 128 16.15. Changing the rear brake fluid 129 LIGHTING SYSTEM, INSTRUMENTS .... 131 17.1 Checking the headlight setting. 131 17.2. Adjusting the headlight range 131 17.3 Speedometer overview sn... 132 17.4 Activation and test 132 17.5. Setting kilometers oF miles... 132 17.6 Setting the speedometer functions. 133 17.7 Setting the clock. 133 17.8 Activating the additional functions. 133 17.9 Setting the wheel circumference 134 17.10 Viewing the lap time... 134 ENGINE 136 18.1 Removing the engine.. 136 18.2 _ Installing the engine... 140 18.3 _ Engine disassembly. 145 18.3.1 Preparations 145 18.3.2 Removing the clutch push rod... 145 18.3.3. Removing the spacer. 145 18.3.4 Draining the engine oil. 145 18.3.5 Removing the oil filter. 146 18.3.6 Removing the spark plug 146 18.3.7 Removing the valve cover. 146 18.3.8 Removing the kick starter 17 18.3.9 Removing the alternator cover 147 18.3.10 Removing the torque limiter.. 148 18.3.1 Positioning the engine a ignition top dead center. ne 148 18.3.12 Removing the timing chain tensioner... 148 18.3.13 Removing the camshaft. 149 18.3.14 Removing the cylinder head.. 149 18.3.15 Removing the piston .... 150 18.3.16 Removing the starter drive. 150 18.3.17 Removing the suction pump.. 151TABLE OF CONTENTS 18.3.18 18.3.19 183.20 18.3.21 183.22 Removing the water pump wheel Removing the clutch cover. Removing the clutch discs Removing the clutch basket... Removing the intermediate kick starter gear. 183.23 gear, Removing the shit shaft... : Removing the shift drum locating unit Removing the locking lever... Removing the force pump... Removing the primary gear Removing the timing chain Removing the spacer Removing the left section of the engine case ss i Removing the shit rails. Removing the shift drum... Removing the shift forks. 18.3.35 Removing the transmission shafts 18.3.36 Removing the crankshaft 18.4 work on individual parts, 18.4.1 Work onthe right section ofthe engine case Work on the left section ofthe engine Work onthe clutch cover Checking the oil pressure regulator valve Checking the lubrication system. Removing the crankshaft bearing Inner race... i installing the crankshaft beeing inner Changing the connecting od, conrod bearing and crank pin 18.3.24 18.3.25 18.3.26 183.27 18.3.28 18.3.29 18.3.30 183.31 183.32 18.3.3 18.3.34 18.4.2 18.4.3 18.4.4 18.4.5 18.46 18.4.7 18.48 18.49 bearing pin. Measuring the crankshaft end play Removing the drive wheel of the balancer shaft... Instaling the drive whee! ofthe balancer shaft... ‘ Cylinder -Nikasit® coating Checking/measuring the cylinder. CChecking/measuring the piston. 18.4.10 18.411 18.4.12 18.4.13 18.4.14 18.4.15 18.4.16 clearance Checking the piston ring end gap ‘Changing the camshaft bearing. Checking the camshafts Checking the pivot points of the camshafts. Removing the valves. Checking the valves, 7 Checking the valve springs... Checking the valve spring seat Checking the cam levers. ‘Checking the cylinder head... Installing the valves... Checking the freewheel Removing the freewheel Installing the freewheel 18.4.17 18.4.18 18.4.19 18.4.20 1384.21 18.4.22 18.4.23 18.4.24 18.4.25 18.4.26 18.4.27 18.4.28 18.4.2 18.4.30 Removing the Intermediate kick starter Checking the crankshaft run-out at the Measuring the plstoionder mounting 152 182 153 154 154 154 155, 155 155 155, 156 156 187 157 157 158 158 158 159 159 159 160 161 163 16s 164 164 165 166 166 167 167 167 167 168 169 169 169 170 170 im 172 172 172 173, 173 173 174 178, 175 19 4 184.31 Preassembling the kick starter shaft nee 176 184.32 Checking the electric starter drive 7 18.4.33 Checking the timing assembly 178 18.4.34 Preparing the timing chain tensioner for installation 179 18.4.35 Checking the clutch = 179 184.36 Checking the shift mechanism... 181 18.4.37 Preassembling the shift shaft 182 18.4.38 Disassembling the main shaft se 182 184.39 Disassembling the countershatt. 183 18.4.40 Checking the transmission 183 18.4.41 Assembling the main shaft... 184 18.4.42 Assembling the countersha 185 18.5 Engine assembly 186 18.5.1 Installing the crankshaft . 186 18.5.2 Installing the transmission shafts nnn 187 18.5.3 _ Installing the shift fors. 187 18.5.4 Installing the shift drum 187 18.5.5 Installing the shift rails, 188 18.5.6 Installing the left engine case 188 18.5.7 _ Installing the spacer... 169 18.5.8 Installing the timing chain... 189 18.5.9 Installing the primary gear. 189 1.5.10 Installing the force pump. + 190 18.5.1 _ Installing the suction pump . - 190 18.5.2 Installing the locking lever. igi 1.5.13 Installing the shift drum locating unit....... 191 18.5.14 Installing the shift shaft 192 18.5.15 Installing the intermediate kick starter gear. easisese, 198) 18,5.16 Installing the kick starter shaft. 192 18.5.17 Installing the outer clutch hub. 192 18.5.18 Installing the clutch dises. 193 18.5.19 Installing the clutch cover 194 18.5.20 Installing the water pump cover. 195 18.5.21 Installing the starter drive. 195 18.5.2 Installing the piston 196 18.5.23 Installing the cylinder head... 198 18.5.24 Installing the camshafts 199 18.5.25 Checking the valve timing. 199 18.5.26 Adjusting the valve timing. 200 18.5.27 Installing the timing chain tensioner........ 201 18.5.28 Checking the valve clearance... - 202 18.5.29 Adjusting the valve clearance. 202 18.5.30 Installing the torque limiter. 203, 18..31 Installing the alternator cover. 203 18.5.32 Installing the kick starter 203, 18.5.33 Installing the valve cover - 204 18.5.34 Installing the spark plug. 204 18.5.35 Installing the oll filter. . 204 18.5.36 Installing the oil screen 205 18.5.37 Installing the spacer... 205 18.5.38 Installing the clutch push rod 206 18.5.39 Removing the engine from the engine assembly stand. 7 206 CLUTCH. : . 207 19.1 Checkinglcorecting the fluid level of the hydraulic clutch. 207 19.2 Changing the hycrautiecluteh fui. . 207 WATER PUMP, COOLING SYSTEM 209 20.1 Cooling system _ sx 209 20.2 Checking the antifreeze and coolant level... 209TABLE OF CONTENTS 21 22. 23 24 25 26 27 28 29 20.3 Checking the coolant level 210 20.4 Draining the coolant. 210 20.5 Refilling coolant au LUBRICATION SYSTEM. snnnnn 2i2 21.1 Oilcircut. 212 21.2 Checking the engine ail level 212 21.3 Changing the engine oil and oil filter, Cleaning the oil screen. sn 213 21.4 Adding engine oil. 215 21.5 Checking the engine oil pressure svseceuee 215 IGNITION SYSTEM 217 22.1 Ignition coil - checking the secondary winding, 217 22.2 Checking the spark plug connector ...nenne 217 22.3 Alternator - checking the stator winding wnsuu 217 22.4 Removing the stator and ignition pulse generator. 21g 22.5 Installing the stator and ignition pulse generator... ssimanemaeamnanasec: 219 ELECTRIC STARTER vss 220 23.1 Checking the starter motor THROTTLE VALVE BODY.... eee 24.1 Adjusting the idle speed... 221 24.2. Throttle postion sensor circuit A- checking the basic settings. 221 24.3 Twat positon sensor -austng the basic $2RLNGB rere 22 24.4 Executing the initialization Puss 22 TECHNICAL DATA... at 224 28.1 Engine. 224 25.2 Engine tolerance, wear limits ..n.cnnnneinnee 228 25.3. engine tightening torques . 225 25.4 capacities, 226 25.4.1 Engine oil 226 25.4.2 Coolant... tatenapen 226) $2EAIS FUG essere 226 25.5 Chassis 227 25.6 electrical system 228 25.7 Tres. a es 228 25.8 Fork von 228 25.8.1 EXC EUIAUSIBRIUS, XCF-M, EXC-F Factory Edition 228 25.8.2 All Six Days model5....netnntnnnnisenines 229 25.9 shock absorber .... . 229 25.10 chassis tightening torques 230 CLEANING, CARE.... 232 26.1 Cleaning the motorcycle 232 262 Checks and maotenance steps fo winter operation... cana . STORAGE, 27.1 Storage... 27.2 Preparing for use ater storage... ‘SERVICE SCHEDULE 235, 28.1 Service schedule. sevens 235 28.2 Service work (as addtional oder 236 WIRING DIAGRAM 238 29.1 Page 1 of 8 (EXC-F EU, EXC-F Factory Edition) 238 29.2 Page 2 of 8 (EXC-F EU, oC 240 29.3. Page 3 of 8 (EXC-F EU, EXC-F Factory Edition) 242 30 31 32 33 34 29.4 29.5 296 29.7 298 29.9 29.10 29.11 29.12 29.13 29.14 29.15 29.16 29.17 29.18 29.19 29.20 29.21 29.22 29.23 29.24 29.25 29.26 29.27 29.28 29.29 29.30 29.31 29.32 29.33 29.34 29.35 29.36 29.37 29.38 29.39 29.40 29.41 29.82 29.43 29.44 29.45 29.46 29.47 29.48 29.49 29.50 29.51 29.52 Page 4 of 8 (EXC-F EU, EXC-F Factory Ecition) Poge 5 of 8 (EXC-F EU, EXC-F Factory Ecition) Page 6 of 8 (EXC-F EU, EXC-F Factory Ecition) Poge 7 of 8 (EXC-F EU, EXC-F Factory Ecition) Page 8 of 8 (EXC-F EU, EXC-F Factory Ecition) Poge 1 of 8 (EXC-F AU) Page 2 of 8 (EXC-F AU) Page 3 of 8 (EXC-F AU) Page 4 of 8 (EXC-F AU)... Page 5 of 8 (EXC-F AU).. Page 6 of 8 (EXC-F AU)... Page 7 of 8 (EXC-F AU)... Page 8 of 8 (EXC-F AU).. Page 1 of 8 (EXC-F BR)... Page 2 of 8 (EXC-F BR).. Page 3 of 8 (EXC-F BR)... Page 4 of 8 (EXC-F BR) Page 5 of & (EXC-F BR).. Page 6 of 8 (EXC-F BR)... Page 7 of 8 (EXC-F BR) Page 8 of 8 (EXC-F BR) Poge 1 of & (EXC-F US).. Page 2 of 8 (EXC-F US)... Page 3 of 8 (EXC-F US) Poge 4 of & (EXC-F US).. Page 5 of 8 (EXC-F US)... Page 6 of 8 (EXC-F US)... Page 7 of 8 (EXC-F US)... Page 8 of & (EXC-F US) Page 1 of & (EXC-F Six Days)... Page 2 of 8 (EXC-F Six Days)... Page 3 of & (EXC-F Six Days) Page 4 of 8 (EXC-F Six Days) Page 5 of & (EXC-F Six Days)... Page 6 of 8 (EXC-F Six Days)... Page 7 of 8 (EXC-F Six Days) Page 8 of & (EXC-F Six Days)... Page 1 of 6 (XCF-W).. Page 2 of 6 (XCF-W) Page 3 of 6 (XCF-M).. Page 4 of 6 (XCF-W). Page 5 of 6 (XCF-W). Page 6 of 6 (XCF-W).. Page 1 of 6 (XCF:W Six Days). Page 2 of 6 (XCF-W Six Days) Poge 3 of 6 (XCF-W Six Days) .... Page 4 of 6 (XCF-W Sik Days) .. Page 5 of 6 (XCF-W Six Days) Page 6 of 6 (XCF-W Six Days). ‘SUBSTANCES i" AUXILIARY SUBSTANCES SPECIAL TOOLS. STANDARDS... LIST OF ABBREVIATIONS. INDEX: 244 246 248, 250 282 . 254 - 256 258 s+ 260 1» 262 264 oe 266 » 268 270 . 272 274 276 . 278 - 280 282 284 1» 286 288 230 292 294 296 - 298 300 302 - 304 306 308 310 312 314 316 318 320 se B22 324 326 «328 330 332 . 334 - 336 338 340 342 344 . 346 359 . 360 . 3611 MEANS OF REPRESENTATION 8 The meaning of specific symbols is described below. Tndicales an expected reaction (e.g, of a work step or a function). Indicates a page reference (more information is provided on the specified page). x Indicates an unexpected reaction (e.g. of a work step or a function). i Indicates information with more details o tips. a Indicates the result of a testing step. Vv Denotes a voltage measurement, i” Denotes a current measurement. Q Denotes a resistance measurement The typographical formats used in this document are explained below. Proprietary name Tdentifies a proprietary name, Name? Identifies a protected name. Brand™ Identifies a trademark Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 SAFETY ADVICE 7 SEGRE RUSE oeETTTEEPDE DETTE DED PEEEDEEE TT TPPEEDDEOEEE Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. ‘A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. © Info The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken, Warning Indicates a danger that is likely o lead to fatal or serious injury if the appropriate measures are not taken. my c= Indicates a danger that may lead to minor injuries if the appropriate measures are not taken. Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning. Indicates a danger that will lead to environmental damage if the appropriate measures are not taken, Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After you complete the repair or service work, check the operating safety of the vehicle3 IMPORTANT NOTES 8 31 Guarantee, warranty ‘The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. Additional information on the guarantee or warranty and the procedures involved can be found jn the Service & Warranty Booklet Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. Only use spare parts and accessories approved andior recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http:/ivawn.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 nat be shown at all. It is not always necessary to disassemble the component to perform the activity in question, Please follow the instructions in the text.4 — SERIAL NUMBERS 402247-10 The chassis number @ is stamped onthe steering head on the right. —~/_s0194510 (EXC-F EUAUS/BR, XCF-W, EXC- Factory Edition, Al Six Days models) The type label @ is fixed to the front of the steering head. 40194610 (excFus) The type label @ is fixed to the front ofthe steering head Ase The additional type label for Canade @ is fixed tothe front of the front pipe. --@ ooose.10 (EXC-F EU/AU/BR, EXC-F Factory Edition, EXC-F Six Days) The key number @ forthe steering ock is stamped onto the key connector.4 — SERIAL NUMBERS 10 TT (EXC US) Key number @ for the ignition and steering lock is indicated on the KEYCODECARD. © Info You need the key number to order a replacement key. Keep the KEYCODECARD in a safe place 402246-10 —) The engine number @ is stamped on the left side ofthe engine under the engine sprocket 401949-10 “The fork part number @ is stamped onthe inne side of the fork tub 401947.10] ‘The shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring onthe engine sie. 40194210]5 MOTORCYCLE " ‘5.1 Raising the motoreycle with the litstand Note Danger of damage The parked vehicle may roll away or fall over = Always place the vehicle on a firm and even surface. ~ Rave the metorcle athe Fame underneath the enn © O) Tit stand (64829055000) 9.347 Neher whet sin eontac withthe ground ‘doisaz.o1] — Secure the motorcycle against falling over. Note Danger of damage The parked vehicle may roll away ofall over. = Always place the vehicle on a firm and even surface. = Remove the motorcycle from the lift stand. Remove the lift stand. ~ Topark the motorcycle, press side stand @ to te ground with your foot and lean the motorcycle on it. Info White riding, the side stand must be folded up and secured with the rubber band, 401048410 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Note Engine fallure High engine speeds in cold engines have a negative effect on the service life of the engine. ~ Always watm up the engine at low engine speeds. ~ Toke the motorcycle off of side stand @ and secure the side stand wit rubber band @ = Shift transmission to neutral. coce us ~ Tum the key inthe inition lock to the pesition ©: ~_ Tum the emergency OFF snitch othe poston ©. (EXC AU) = Tum the emergency OFF switch to the position ©. soiseé10] Condition ‘Ambient temperature: < 20 °C (< 68 °F) Pull the idle speed adjusting screw all the way out,5 MOTORCYCLE 2 = Press the electric starter button or press the kick starter robustly through its full range. Info Tress the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again. Warning lamp Fights up briefly asa functional control when starting. 400733.01 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Info I Press the starter for a maximum of 5 seconds. Wait for atleast 5 seconds before trying again. — Shift transmission to neutral (EXC US) = Tum the key in the ignition lock to the position ©. = Tum the emergency OFF switch to the position ©. (EXC AU) Tum the emergency OFF switch to the position ©, ~ Press the electric starter button or press the kickstarter robustly through its full range. Info Ho not open the throttle.6 FORK, TRIPLE CLAMP 13 (6.1 Adjusting the compression damping ofthefore © Info TThe nyerautic compression damping determines the fork suspension behavior. (1c F EUAUSERWS, XOF-W, XC Factory Eton) ~ Remove protection caps @. ~ Tum adjusting screws @ clockwise al the way TAcjusting screws @ are located atthe bottom end ofthe fork legs. Make the same adjustment on both fork logs. Tum back counterclockwise by the number of clicks corresponding to the fork type, Guideline Compression damping Comfort 22 clicks ‘Standard 20 clicks Sport 18 clicks © Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. = Mount protection caps @. {All Six Days models) = Tum the white adjusting screw @ all the way clockwise. = Info TL the adjusting screw @ is located at the upper end of the left fork leg The compression damping is located in the lef fork leg COMP (aite adjusting screw). The rebound damping is located in the right fork Jeg REB (red adjusting screw). - locks 7 Turn back counterleese bythe number of like corependng tthe fork Guideline Compression damping Comfort 15 clicks ‘Standard 13 clicks ‘Sport TI clicks Info ‘Tum clockwise to inerease damping; turn counterclockwise to reduce damping. © Info The nydrautic rebound damping determines the fork suspension behavior.6 FORK, TRIPLE CLAMP 14 (xc EUAUSIERNS, XCF-W) — Turn adjusting screws @ clockwise all the way. Info TAajusting serews @ are located at the top end ofthe fork legs. Make the same adjustment on bath fork legs. = Tum back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 20 clicks ‘Standard 18 clicks ‘Sport 16 clicks Info Tum clockwise to increase damping; turn counterclockwise to reduce damping. (EXC-+ Factory Edition) ~ Tum adjusting screws @ clockwise all the way. Info TW Aajusting serens @ are located at the top end ofthe fork legs. Make the same adjustment on both fork legs. = Tum back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 20 clicks ‘Standard 18 clicks ‘Sport 16 clicks © Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. {All Six Days models) = Tum the red adjusting screw @ all the way clockwise. s Info ‘The adjusting screw @ is located atthe upper end ot the right fork le. The rebound damping is located inthe right fock leg REB (red adjusting screw). The compression damping is located inthe lt fork eg COMP (white adjusting screw). = Tum back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 15 clicks ‘Standard 13 clicks ‘Sport TI clicks © Info TTurn clockwise to increase damping; tur counterclockwise to reduce damping6 FORK, TRIPLE CLAMP 15 (EXC EWAUSIBRIUS, XCF-W) Tum the adjusting sorews counterclockwise all the way. © Info Make the same adjustment on both fork legs. = Tum clockwise by the number of turns corresponding to the fork type. Guideline = | Spring preload - Preload Adjuster ucoasaat Comfort Tum ‘Standard 2 tums ‘Sport 2ums © Info Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. ‘Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring pretoad, (EXC Factory Edition) Tum the adjusting screvss counterclockwise all the way. Info Take the same adjustment on both fork legs. Tum clockwise by the number of turns corresponding to the fork type. Guideline Spring preload - Preload Adjuster Comfort Thum ‘Standard tums Sport 2 ums Info Tum clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. ‘Adjusting the spring preload has no influence on the absorption setting of the rebound damping, Basically, however, you should set the rebound damping higher with a higher spring prefoad Preparatory work ~ Raise the motorcycle with the lift stand. (** p. 11) ‘Main work (EXC-F EU/AUS/BRIUS, XCF-W) ~ Release bleeder screws @. 7 Any excess pressure escapes from the interior of the fork. ~ Tighten the bieeder screws.6 FORK, TRIPLE CLAMP 16 (EXC-+ Factory Edition) = Release bleeder screws @. Any excess pressure escapes from the interior ofthe fork Tighten the bieeder screws. (ai Six Days modes) = Release bleederscrens @ Any excess pressure escapes from the interior ofthe fork = Tighten the bieeder screws. s00626-10] Finishing work = Remove the motorcycle from the lift stand. (* p. 11) Preparatory work — Raise the motorcycle with the lift stand. ( p. 11) = Laos the fork protector ( p. 17) Main work (EXC-F EU/AU/BR, EXC-F Factory Edition, EXC-F Six Days) = Push dust bots @ ofboth fork legs downvard Into I The dust boots remove dust and coarse dirt particles from the insie fork tubes, Overtime, ditt can penetrate behind the dust boots. If this dit is not removed, the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oll or grease on the brake discs Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary. = Glean and oil the dust boots and inner fork tube of both fork legs. Universal oll spray (* p. 345) Press the dust boots back into their normal position, = Remove excess cil (EXC US, A XCF-W models) — Push dust boots @ of both fork legs downward. ? Info T The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is Fe not removed, the oll seals behind can start to leak. Warning yo0214-10 Danger of accidents Reduced braking efficiency due to oll or grease on the brake discs. = Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary6 FORK, TRIPLE CLAMP 7 = Clean and oil the dust boots and inner fork tube of both fork legs. Universal oll spray ( p. 345) Press the dust boots back into their normal position. = Remove excess cil Finishing work Position the fork protector. (*” p. 17) Remove the motorcycle from the lift stand. (* p. 11) (€XC-F EWAUSABR, XCF-W, EXC- Factory Edition, Al Six Days models) = Remove serous @) and take off the clamp. = Remove screws @ on the let fork leg. Push the fork protection downwards = Remove the screws on the ight fork leg, Push the fork protection downwards. faces = Remove screws @ and take ofthe clamp. = Remove screws @ onthe left fork leg. Push the fork protection downwards = Remove the screws on the ight fork leg, Push the fork protection downwards, (€XC-F EUAUSIBR, XOF-W, EXC- Factory Edition, Al Six Days models) = Position the fork protector on the left fork leg. Mount and tighten screws @ Guideline Remaining screws, chassis Ne TONm (7.4 tot) ~ Position the brake line, wiring harness, and clamp. Mount and tighten = Pesition the fork protector on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis Me TONm (7.4 tot (exoF US) = Position the fork protector on the left fork leg. Mount and tighten screws @ Guideline Remaining screws, chassis 6 TONm (7.4 tot ft) = Position the brake line, wiring harness, and clamp. Mount and tighten = Position the fork protector on the right fork eg. Mount and tighten the screws, Guideline Remaining screws, chassis rr TO Nm 7.4 toe6 FORK, TRIPLE CLAMP 8 68 Removing the fork legs uo0235-10| Preparatory work — Remove the headlight mask with the headlight. (*" p. 103) ~ Raise the motoreyele withthe if stand. (© p. 11) = Remove the tront wheel. (© p. 108) ‘Main work = Remove screvs @) and take ofthe clamp. Remove the cable binders) ~ Rerove screws @ and take ofthe brake caliper = Allow the brake caliper and brake line to hang tension re to the side, (EXC-F EU/AUS/BR, XCF-W) = Release screws @. Take out the let fork leg. ~ Release screws @. Take out the right fork leg. (EXC US) = Release screws @, Take out the left fork leg. = Release screws @. Take out the right fork leg. (EXC-F Factory Edition, All Six Days models) = Release screws @. Take out the let fork leg. = Release screws @. Takeout the right for leg Main work (€XC- EWAUSIBR, XCF-W) = Position the fork legs. Y Bleeder screws @ are positioned toward the tron. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp,6 FORK, TRIPLE CLAMP 19 Tighten screws @. Guideline Screw, top ple damp Me 20 Nm (14.8 tot 1 ~ Tighten srens © Guideline Serew, bottom tile clamp we 15 Wim (11.1 tf (exc us) ~ Pasion the fork legs. Y Bloader screvs @ are positioned toward the tront. © Info TGrooves are milled into the side ofthe upper end ofthe fork legs. The second milled groove (rom the top] must be flush with the top edge of the upper triple clamp. ~ Tighten serene @. Guideline Screw, top tiple lamp we 20 in freien = Tigmten serene © Guideline Seren, bottom Wple lamp We 15m ant tert) (€0+ Factory Elton) ~ Position the fork legs. Y Blader serevs @ are positioned toward the font. Info T_ Grooes are milled into the side of the upper end of the fork legs. The second milled groove (fram the top) must be flush with the top edge of the upper triple clamp. ~ Tighten screns @ Guiceline Serew, top Wple camp we 17 Nim (12.5 bf) ~ Tighten screns @ Guideline Screw, bottom Wipe camp we TS Nim (1.1 ee {All Six Days models) = Position the fork legs. Y Bleeder screws @ are positioned toward the front. Info The rebound damping is located in the right fork leg REB (red adjusting screw). The compression damping is located in the left fork leg COMP (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp,6 FORK, TRIPLE CLAMP 20 = Tighten screws @. Guideline ‘Screw, top tiple clamp me T7 Nm (12.5 tot = Tighten screws @ Guideline ‘Screw, bottom tiple clamp me 15 Nm (1 bt ~ Position the brake caliper and mount and tighten screws @. Guideline Serew, front brake caliper] MB 25 Nm Toctte® 243 (28.4 tor tt = Mount cable binder ~ Postion th brake line, wring hanes and clamp. Mount andtghten serene @ Finishing work = Install the front wheel. (* p. 108) Refit the headlight mask with the headlight. (** p. 104) Check the headlight setting. (** p. 131) Preparatory work Remove the headlight mask with the headlight. (© p. 103) = Reise the motorcycle with the lift stand. ( p. 11) = Remove the front wheel. (* p. 108) — Remove the fork legs. (** p. 18) = Remove screvs 9 onthe let fork lag. Remove the fork protector upwards. = Remove the screws on the rit fork lg. Remave the fork protector upwards 10122710 the fork protector onthe lft fork lg. Mount and tighten screws @. Guideline Remaining stews, chante 1 Tom 7a FA > ~ Position the ferk protector onthe right fork leg. Mount and tighten the sens. Guideline Remaining serews, chases 1 TON (7a TRY 1013270 Fishing work = Install the fork legs. (#* p. 18) = Install the front wheel. (** p. 108) Refit the headlight mask with the headlight, (** p. 104) = Check the headlight setting. (7 p. 131)6 FORK, TRIPLE CLAMP 2 (6.12 EXC-FEU/AUS/BRVUS, XCF-W, EXC-F Factory Edition 6.12.1 Performing a fork service Info These operations ae the same on both fork legs. 8 | e 20097001 00000 TT 10 6.12.2 _ Disassembling the fork legs Condition “The fork legs have been removed. = Disassemble the fork legs. (* p. 21) = Disassemble the cartridge. ( p. 24) Check the fork legs. (** p. 26) — Assemble the cartridge. (* p. 28) = Assemble the fork logs. (* p. 29) © Info The steps are identical for both fork legs. 200736-10| Condition ‘The fork legs are disassembled, ~ Remove protective cover @ = Note down the present state of rebound damping @) and compression damping @. Note down of the present state of the spring preload. ~ Completely open the adjusters of the rebound damping and compression damping, Clamp the fork leg in the area of lower triple clamp. Clamping stand (114038) (* p. 357)6 FORK, TRIPLE CLAMP 2 rl == 200690410] 4 ( | —e _« ff ve 2 8 a 20073910] \ 1 20124010] = Loosen Preload Adjuster ©. Pin wrench (T103) (*" p. 353) © Info ‘The Preload Adjuster cannot be taken off yet. Take out the fork leg and clamp with the axle clamp. Info Tse sot jaws. Push the outer tube downward, Pull the spring downward. Place the special tool on the hexagonal part. ‘Open-end wrench (114032) (* p. 357) Info T The preload spacers @ should be above the special tool. = Clamp the special tool in the bench vise. Loosen Preload Adjuster @ ~ Remove Preload Adjuster @ with preload spacers @ ~ Remove adjustment tube @ = Pull the spring downward. Remove the special tool Remove the spring.6 FORK, TRIPLE CLAMP 2 | 201349410] 201360-10| 200741-10| 200742410] 201361-10] = Drain the fork oil Info Hutt cut and push in the piston rod a few times to empty the cartridge. — Clamp the fork leg with the axle clamp. Guideline Use soft jaws. ~ Unscrew and remove the compression damping fiting @ Info H Piace a tuid collector beneath it, as usually some ol will drain out = Remove the cartridge. ~ Remove dust boot @ = Remove fork protector ring @. © Info ‘The fork protector ring does not necessarily need to be disassembled for the further repair. = Remove lock rng @. Info The lock ring has a coarsely finished end against which the serewdriver can be placed. — Warm up the outer tube in area @ of the lower sliding bushing, Guideline 50" (122 F) = Jerk the outer tube out of the inner tube. Info ‘The lower sliding bushing @ must be pulled out of its bearing seat when doing this.6 FORK, TRIPLE CLAMP 20065801 = Remove upper sliding bushing @. Info H Gently putt ther apart without using any too. ~ Toke off the lower sliding bushing © = Toke off support ring @. ~ Toke off seal ring @ Take off lock ring @. ~ Take off dust boot @ = Take out the fork lg. 20065911 6.12.3 Cartridge disassembly Info The steps are identical for both fork leg. 20074610] 200747-10| i lm, ~ 200748-10| Preparatory work = Disassemble the fork legs. (© p. 21) Main work =" Remote uid barrier @ trom the piston rod Clamping stand (T140168) (* p. 356) ~ Remove piston rod @ trom the cartridge, = Remove washer @ and spring seat @ trom the catridge.6 FORK, TRIPLE CLAMP Degrease the cartridge and clamp using the pecial too. Clamping stand (T14015S) (* p. 356) Warm up the carrie in the area of @ Guideline = somes 200697-10| v 20069810] 1 t [ ai 200700-10] -* 200701-10| BO" (122 F) Info ‘This step is unnecessary forthe further disassembly. Degrease the piston rod. Clamp the piston rod with the special too Unscrew and remove serensleeve @. Clamping stand (140168) (* p. 356) Remove nut © Remove shim stack @ completly Remove piston @. Remove shim stack @ completely. Remove spring @. Remove tap rebound @. Remove spring ®. Remove vale (B of the retound damping togother with the spring Take out the piston rod.6 FORK, TRIPLE CLAMP 2 6.12.4 Disassembling the compression damping fitting Info The steps are identical for both fork legs. \ | 0702-10] 200706-10| 6.12.5 Checking the fork legs — _% —————_—_—- 200726-10| Preparatory work Disassemble the fork legs. (¥" p. 21) work = Clamp the compression damping fitting in a bench vise using soft jaws. ~ Remove nut @ = Remove the spring ~ Remove washer @ — Remove piston © ~ Remove shim stack @ ~ Remove O-ring @ and seal ring @ from the compression damping fitting. Extract the compression damping fitting. Condition ‘The fork legs must be disassembled. = Check the inner tube and axle clamp for damage. > I there is damage: = Change the inner tube. = Measure the outside diameter at several locations on the inner tube ‘Outside diameter of the inner tube | 47.975... 48.005 mm (1.88878... 1.88996 in) » I the measured value is below the specified value: = Change the inner tube,6 FORK, TRIPLE CLAMP 2 = Measure the run-out of the inner tube. Trner tub run-out "0.20 mm (= 0.0079 in) » If the measured value is greater than the specified val Change the inner tube. — Check the outer tube for damage. > I there is damage: = Change the outer tube. = Check the surface of the sliding bushing. » Ifthe bronze-colored layer @ under the sliding layer @ is visible: Replace the sliding bushing, = Check the spring length. Guideline Spring length with preload spacers) Weight of rider: 65... 75 kg (143... | 513 mm (20.2 in) 165 1b.) Weight of rider; 75... 85 kg (165... | 513 mm (20.2 in) 187 1b.) Weight of rider: 85... 95 kg (187... [ 513 mm (20.2 in) 200666-10| 209 Ib.) » If the measured value is greater than the specified value: = Reduce the thickness of the preload spacer. > Ifthe measured value is less than the specified value: = Increase the thickness of the preload spacer. 6.12.6 Assembling the compression damping fitting © Info The steps are identical for both fork legs. Clamp the compression damping iting in a bench vise using soft jas. = Mount Oxing @ and seal ring @. = Grease the Oring Lubricant (T158) (* p. 344) 20070116 FORK, TRIPLE CLAMP 6.12.7 Assembling the cartridge 28 = Mount shim stack @. Into TH sount the smatier shims below. = Mount pistons @ with O-ring @. Info ‘The side with the largest inside diameter @ faces upward, = Grease the piston O-ing Fork oll (SAE 4) (HBGOLIGEST) (> p, S42) ~ Mount washer @ = Mount spring @ withthe tighter col facing downward ~ Mount and tighten nut @. Guideline ‘Compression damping fitting nut GOS Shim (22 bi © Info The washer @ must have freedom of movement relative to the spring force. Secure the nut by locking. Extract the compression damping fitting Info The steps are identical for both fork legs. 20071810] 200739410] Clamp in the piston rod. Clamping stand (T14016S) (* p. 356) Nount valve @ ofthe rebound damping, with the spring and ing Grease the Oring Lubricant (1158) (* p. 344) Mount spring @. Grease tap rebound @ O-ring. Lubricant (T158) (* p. 344) Mount and tighten the tap rebound, Guideline Tap rebound MOK 18m Toatite® 2701 (13.3 Ibe fe Position spring @. Mount shim stack @ Info TH Mount the smatier shims below. Press the shim stack downward against the spring force. Info The shim stack must be pressed downward over the collar. Mount piston with he piston ive6 FORK, TRIPLE CLAMP 2 * ' 20074911 tay ~ 2o074e-11 ~ ~ 20074711 a fa —— 20074611 6.12.8 Assembling the fork legs Info ‘The side with the largest inside diameter faces downward = Mount shim stack @. © Info Align the triangular plate exactly withthe piston opening. Mount and tighten nut @ Guideline Tap rebound nut NGOS 5 Nm (3.7 Ibi) Info TH Mount the nut with the collar facing downward = Secure the nut by locking. = _Degrease the cartridge and clamp using the special tool Clamping stand (1140158) (* p. 356) = Mount and tighten scensleeve © Guideline Serewsieeve MODxT TENm Tocito® 247 (33.9 BF ~ Mount washer @® and spring seat @. ~ Push piston rod (@ into the cartridge ~ Screw on tuid barter tothe stop. Info “The fluid barrier must be screwed on tightly against the stop. Do not use a tool. © Info The steps are identical for both fork legs.6 FORK, TRIPLE CLAMP Preparatory work = Check the fork legs. (** p. 26) ~ Assemble the cartridge. (* p. 28) Assemble the compression damping fitting. (* p. 27) ‘Main work = Clamp in the inner tube with the axle clamp. Guideline Use soft jaws. = Install the special too. Protecting sleeve (T1401) (* p. 356) 20066910] > 200670-10 200671-10| Ss e ele zo12se:0 ~ Grease and slide on dust boot @ Lubricant (1511) (* p. 344] Info ‘Always change the dust boot, seal ring, lock ring, and support ring. Mount the sealing lip with the spring expander facing downward, = Slide on lock ring @. ~ Grease and slide on seal ring @. Lubricant (7511) (* p. 344) Info ‘The sealing lip should face downward and the open side upward = Slide on support ring @. = Remove the special tool ~ Roughen, clean, and grease the edges of the sliding bushings using 600 grit sand- Paper. Fork oll (SAE 4) (4860116651) (* p. 342) = Slide on tower sliding bushing @. ~ Mount upper siding busing @. ‘© Info Gently pull them apart without using any tool = Slide on the outer tube = Warm up the outer tube inthe lower sliding bushing area of @. Guideline 50°C (122 F) = Hold the lower sliding bushing with the longer shoulder of the special tool ‘Assembly tool (114028) ( p. 356) — Press the outer tube all the way in.6 FORK, TRIPLE CLAMP 20074211 20074 1-11 [20072511 Position the support ring Hold the seal ring with the shorter shoulder of the special tool. 3 ‘Assembly tool (T14028) (* p. 356) Mount lock ring @ Info Press the outer tube all the way in. The tock ring must audibly lock into place. = Install dust boot @. = Mount fork protector ring @. Mount adjustment tube @ of the rebound damping in the cartridge. The adjustment tube extends 5 mm (0.197 in) out from the cartridge and can be pressed inward against the spring force. 2 The adjustment tube extends more than 7 mm (0.276 in) out from the car tridge and cannot be pressed inward against the spring force. ~ Screw on water exclucer @ to the stop. © Info ‘The water excluder must be screwed on tightly against the stop, Do not use tool Mount the special tool on the cartridge. Gripping tool (11402681) (* p. 356) Info Push the cartridge into the inner tube. Mount and tighten compression damping fitting @. Guideline The special too! must be used in order that the adjustment tube is nat raised. Otherwise, oil will each the piston rod ‘Compression damping fiting M251 35 Nm (25.8 Ibf f) © Info If the cartridge turns as well, press the piston rod slightly to the side.6 FORK, TRIPLE CLAMP 32 7 Clamp in the fork vertically, Fill with fork oil % Fork oll per fork [620 mi Fork oll (SAE 4) (4860116651) leg. (20.96 11.02.) __| (¥ p. 342) Info Pull out the piston rod and push back in a number of times to bleed the car tridge. 20136610] ~ Remove pin @ of the special too. Gripping tool (T4026ST (=p. 356) = Pull out the piston rod, Install the spring. Reinstall the pin Guideline Spring rate Weight of rider: 65... 75 kg (143... | 4.0 Nimm (22.8 Ibfin) 165 Ib.) 201369410] Weight of rider: 75... 85 kg (165... | 4.2 Nimm (24 Ib/in) 187 Ib.) Weight of rider: 85... 95 kg (187... | 4.4 Nimm (25.1 Ibfin) 209 Ib.) Pull the spring downward. Place the special too! on the hexagonel part 7 ‘Open-end wrench (114032) (+ p. 357) = Remove the special too! Gripping tool (11402681) ( p. 356) 20067910] Clamp the special too! in the bench vise. ~ Grease the thread of the piston rod. Lubricant (1159) (¥ p. 344) — Grease the upper edge @ of the piston rod. Lubricant (1158) (* p. 344) Screw the Preload Adjuster with preload spacer onto the piston rod. 200743-10| Info The Pretoad Adjuster must be screwed in all the way before the piston rod also begins to turn. In case of tight piston rod threads, it must be held to keep it from turning. If the Prelaad Adjuster is not screwed in all the way, the rebound adjustment will not function. Tighten the Preload Adjuster. Guideline Preload Adjuster on the piston rod Mina 25 Nm aga tbr fo ~ Take pressure off of the special tool. Pull the spring downward and remove the spe- ial tool, : 200738116 FORK, TRIPLE CLAMP cl 33 Push the outer tube upward, lamp the outer tube in the area of lower triple clamp. Clamping stand (1403S) (* p. 357) iV) or rease the Preload Adjuster O-ring. Lubricant (1158) (* p. 344) a 200744-10| Screw on and tighten the Preload Adjuster. uideline Preload Adjuster on the outer tube MBIxLS 30 Nm (26.9 Ibf FO Pin wrench (1103) (* p. 353) Alternative 1 Turn adustng screw of compression damping @ and adjusting screw of rebound damping @ clockwise all th way ‘Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Confort Bale Standard Te alas a Sport 16 clicks Compression damping Comfort Balke Standard 20 clicks Sport Te clas ~ Tum the adjusting screw of spring preload QD counterclockwise all the way. — Turn clockwise by the number of turns corresponding to the fork type. Guideline ‘Spring preload - Preload Adjuster Comfort Tum Standard 2 ums Sport Zumns ternative 2 Warning Danger of accident Modifications to the suspension setting may se cus alter the handling characteristic. Extreme modifications tothe suspension setting may cause a serious deterioration in the handling characteristic and overioad components. = Only make adjustments within the recommended range. = Ride slowly to start with after making adjustments to get the fee of the new hancling cheacteristie, ~ Set the adjusting srens tothe poston determined beter removal. ~ Mount protective cover @. 6.12.9 Greasing the steering head bearing -900010-10 (EXC-F EWAUS/BRUS, XCF-W) Remove the lower triple clamp. (* p. 34) Install the lower triple clamp. (** p. 34) (EXC-+ Factory Edition) Remove the lower triple clamp. (* p. 36) Install the lower triple clamp. (** p. 37)6 FORK, TRIPLE CLAMP 6.12.10 Removing the lower triple clamp (EXC-F EU/AUS/BR/US, XCF-W) L02471-10, 6.12.11 201605-10] Preparatory work =""Remove the headlight mask withthe healigt. (&* p, 108) = Raise the motorycle with the it stand. (&” p. 11) = Remove the tront wheel. (© p. 108) = Remove the fork legs. (© p. 18) = Remove the front fender. (© p. 103) = Remove the handlebar cushion. Main work = Open the cable holder in font of the right radiator and detach the wing harness. = Remove screvs @ and hang the voltage regulator to one side. = Release screw @ and remove screw @. Take of the upper triple clamp withthe handlebar and sett aside. Info Protect the components against damage by covering them. o not bend the cables and lines. ~ Remove O-ring @. Remove protective ring @ Take off the lower triple clamp with the steering stem, ~ Remove the upper steering head bearing, Installing the lower triple clamp (EXC-F EW/AUS/BR/US, XCF-W) ‘Main work = Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (¥" p. 344) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. ~ Check whether the upper steering head seal @ is cortectly positioned. = Slide on protective ring @ and O-ring © Position the upper triple clamp with the handlebar. Mount screw @ but do not tighten yet Position the clutch line, wiring harness, and voltage regulator. Mount and tighten screws @. Guideline Remaining screws, chassis Ne TO Nm (7-4 Tot6 FORK, TRIPLE CLAMP = Position the fork legs. 7 Bleeder screws @ are posit Info Upper triple clamp. ned toward the front. 35, T Grooves are milled into the side of the upper end of the fork legs. The sec- ‘ond milled groove (from the top) must be flush withthe top edge of the (2XC-F EUAUSAR, XCF-W) = Tighten scons @. Guideline Serew, bottom Wipe camp We TS Nim (11.1 bef exer us) ~ Tighten sevens @ Guideline Serew, bottom Wile clamp we TS Nim (11.1 bef = Tiehten screw @. Guideline Serew, top steering head M205 TZ Nim GS FR) ~ Tighten screw @. Guideline Serew, top steering stem ME 20Nm (14.8 Ibf ft) (EXC-F EUAUSAR, XCF-W) ~ Tighten screns @. Guideline Screw, top tiple camp we 20 Nm Gast ~ Secure the wing harness with cable holder @®6 FORK, TRIPLE CLAMP 36 6.12.12 Removing the lower tri clamp ( coe us) ~ Tighten scres ©. Guideline ‘Screw, top tiple clamp We 20m (24.8 tot A) = Secure the wiring harness with cable holder @). ~ Poston the brake caliper. Mount an tighten screws @. Guideline Screw, front brake caliper] MB 35 Nm | Loctna 245 (18.4 er f9 = Mount cable binder. ~ Position the brake line, wring hanes and clamp. Mount andtghten sere @. Finishing work = Mount the handlebar cushion. = Install the front fender. (€ p. 103) = Install the front wheel. (** p. 108) Refit the headlight mask with the headlight. (** p. 104) = Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly. — Check the steering head bearing play. ( p. 38) = Remove the motorcycle from the lift stand. (#* p. 11) Check the headlight setting. (* p. 131) (EXC-F Factory Edition) Preparatory work ~ Remove the headlight mask with the headlight. (* p. 103) Raise the motorcycle with the lift stand. (** p. 11) Remove the front wheel. (* p. 108) Remove the fork legs. ( p. 18) ~ Remove the front fender. (* p. 103) ~ Remove the handlebar cushion, ‘Main work ~ Open the cable holder in front of the right radiator and detach the wiring harness. = Remove screws @ and hang the voltage regulator to the side, ~ Remove screw @. Remove screw @). Takeoff the upper triple clamp with the handlebar and set it asice © Info Protect the components against damage by covering them. Do not bend the cables and lines. 500653-10] ~ Remove O-ring @. Remove protective ring @ Toke off the lower triple clamp with the steering stem. Remove the upper steering head bearing6 FORK, TRIPLE CLAMP 37 6.12.13 Installing the lower triple clamp (EXC-F Factory Edition) ‘Main work = Clean the bearing and sealing elements, check for damage, and grease, High viscosity grease (*" p. 344) Insert the lowe bearing. Check whether the upper stering head seal @ is correctly positioned Slide on protective ring @ and O-ring ©. le clamp with the steering stem. Mount the upper steering head ~ Position the upper triple clamp with the handlebar. = Mount screw @ but donot tighten yet. — Position the clutch fine, wiring harness, and voltage regulator, Mount and tighten Guideline Remaining screws, chassis, Me 10 Nm (7.4 THO, = Postion the fork legs 7 Bleeder screws @ are poi ned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ‘ond milled groove (from the top) must be flush with the top edge of the Upper triple clamp. = Tighten screws @ Guideline Screw, Botiom triple clamp me TS Nm 1.1 ibe fo ~ Tighten screw @. Guideline Screw, top steering head 20x15 12 Nm (9 Tor)6 FORK, TRIPLE CLAMP 38 10132611 = Mount and tighten screw @. Guideline Screw, top steering stem] MB T7 Nin Tectia 2437" (2st ~ Tighten screws @. Guideline Serew, top triple clamp mB T7 Him a2.s5ibt ~ Secure the wiring harness with cable holder @ Position the brake caliper. Mount and tighten screws @. Guideline Screw, front brake caliper | MB 25 Nm Toctite® 2437" (18.4 tof ft = Mount cable binder @. ~ Position the brake line, wring hamess, and clamp. Meunt and tighten screws @®. Finishing work = Mount the handlebar cushion, Install the front fender. (** p. 103) = Install the front wheel, (#* p. 108) Refit the headlight mask with the headlight, (** p. 104) = Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play. (* p. 38) Remove the motorcycle from the lift stand. ( p. 11) = Check the headlight setting. (** p. 131) 6.12.14 Checking the steering head bearing play Warning (a erect sci Unstteeice anng tom noc sting head benny. = Adjust the steering head bearing play without delay. © Info aged over time. I the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- Preparatory work = Reise the motorcycle with the lift stand. ( p. 11)6 FORK, TRIPLE CLAMP 29 ‘Main work = Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing. > I there is noticeable play present (EXC-F EWAUS/BRVUS, XCF-W) ~ Adjust the play of the steering head bearing. (* p. 39) (EXC-+F Factory Edition) LL | soora8-i1 ~ Adjust the play of the steering head bearing. (** p. 40) Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable + If click positions are noticeable: (EXC-F EWAUS/BRUS, XCF-W) — Adjust the play ofthe steering head bearing. (*" p. 39) (EXC-+ Factory Edition) ~ Adjust the play of the steering head bearing. (* p. 40) = Check the steering head bearing and replace if required. Finishing work = Remove the motorcycle from the lift stand. (* p. 11) 6.12.15 Adjusting the play of the steering head bearing (EXC-F EU/AUS/BR/US, XCF-W) Preparatory work = Reise the motoreycle with the lft stand. (* p. 11) ‘Main work (EXC-F EWAUS/BR, XCF-W) = Loosen screws @ and @. = Loosen and retighten screw @ Guideline Screw, top seering head M20K.5 12 Nm (ea bt) = Using aplastic hammer, tap lightly on the upper tiple clamp to avoid strains = Tiehten screns @. Guideline Screw, op tiple camp me 20 Nm (14.8 i = Tighten screw @ Guideline Screw, top seering sem we 20 Nm (14.8 bt (exo us) = Loosen screws @ and @. = Loosen and retighten screw @ Guideline Screw, top sieering head M205 12 Nim (9 bit) = Using @ paste hammer, tap lightly onthe upper tiple clamp to avold strains ~ Tighten seve @. Guideline Screw, op tiple camp we 20 Nm (14.8 io ~ Tighten screw @ Guieline Screw, top steering stem we 20 Nm (14.8 bot 1)6 FORK, TRIPLE CLAMP 40 Finishing work = Check the steering head bearing play. (* p. 38) Remove the motorcycle from the lift stand. ( p. 11) 6.12.16 Adjusting the play of the steering head bearing (EXC-F Factory Edition) Preparatory work = Raise the motorcycle with the lift stand. (# p. 11), Main work ~ Release screns @. Remove screw @. = Loosen and etighten screw @. Guideline Screw, top steering head M205 T2Nm 9 or ~ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. = Tighten screws @. Guideline Screw, top Wiple clamp we T7 Nim (12.5 tot tb = Mount and tighten screw @. Guideline Screw, top steering stem] MB 17 Nn Toctte® 243" (22.5 tof Finishing work = Check the steering head bearing play. (# p. 38) = Remove the motorcycle from the lift stand. ( p. 11) 6.13.1 Performing a fork service Condition The fork legs have been removed ~ Disassemble the fork legs. (*" p. 40) A = Remove the spring. (F p. 42) — Disassemble the cartridge. ( p. 43) — Disassemble the piston rod. ( p. 44) — Disassemble the hydrostop unit. (* p. 45) — Disassemble the seal ring retainer. (*" p. 46) ~ Check the fork legs. (* p. 46) = Assemble the seal ring retainer. (* p. 47) ~ Assemble the hydrostop unit. (* p. 48) ~ Assemble the piston rod. (Fp. 48) = Assemble the caridge. (* p. 50) = Assemble the fork legs. (Fp. 51) 2 8 2 2 i | 6.13.2 _ Disassembling the fork legs CommnonRANENN MG : g 5 s t S °o s o 20192601 Info The steps are identical for both fork legs. Condition ‘The fork legs are disassembled,6 FORK, TRIPLE CLAMP “1 201699-10| 20170010] [ 201701-10| » fi 201702410] 2017081] Note down the current state of rebound damping @ REB (red adjuster of right fork leg). Note down the current state of compression damping @ COMP (white adjuster of left fork leg). Fully open the adjusters of the rebound and compression damping. Clamp the fork leg in the area of the lower triple clamp. Clamping stand (714038) (* p. 357) Remove the screw. Remove adjuster Release screw cap @. Special socket (114047) (* p. 357) Info The cartridge cannot be taken off yet. Unclamp the fork leg Push the outer tube down. Drain the fork oil Clamp the fork le withthe ate clamp, Release hyerostop unit @ and remove it © Info Do not use an impact wrench. Place a pan underneath since oil will run out. Remove the cartridge from the fork le. Press-out tool (T14051) (* p. 358) Info Removing the O-ring seat from the cartridge usually requires the application of force.6 FORK, TRIPLE CLAMP 2 201705-10| 201706-10| 201707-10| 201708.10] 20170910] 6.13.3 Removing the spring ~ Remove dust boot @. = Remove fork protection rng @ © Info ‘The fork protection ring does not necessarily need to be removed for repair work: = Remote lock rng @. Info The tock ring has a ground end against which a screwdriver can be positioned. ~ Warm the outer tube in area @ of the lower sliding bushing. Guideline 50°C (122 7) = Pull the outer tube forcefully off of the inner tube. info The lowe sliding bushing @ must be ple oto its bearing seat. = Remove the upper sliding busting © Info Ho not use a toot; pull the ends apart slightly by hand Take off the lower sliding bushing @ = Take of support ring @. Take off seal ring @. ~ Takeoff lock ring @. = Take off dust boot @. = _Unclamp the fork eg. Info The steps are identical for both fork legs. Preparatory work = Disassemble the fork legs. (** p. 49)6 FORK, TRIPLE CLAMP 43 ir 201722411 p EN 20172641 6.13.4 Disassembling the cartridge ‘Main work = Pull the spring down. Mount the open end wrench on the hexagonal part ~ Clamp the open end wrench in the vse. Release screw cap @@) but do not remove it yet Special socket (114047) (* p. 357) = Pull the spring down. Remove the open end wrench. = Remove the screw cap. Remove the spring with the preload spacer(s). Info The steps are identical for both fork legs. 202480-10] 20172612 Preparatory work = Disassemble the fork legs. (* p. 40) = Remove the spring. (* p. 42) ‘Main work ~~ Degrease piston rod @ and clamp it in the vise. (Clamping stand (140498) (* p. 3577, ~ Remove adjusting tube @. Unscrew spring guide @ ~ Remove spring sat @. — Pull the piston rod out of the cartridge.6 FORK, TRIPLE CLAMP Clamp the tube of the cartridge into a vise. Clamping stand (T140498) (* p. 357) = Release sea ring retainer @ and remove wth the washer. 202481-10| = Remote lock rng @. : i DY — rat rservir @ ci of te ube i. 10 we ~ Pull sleeve @ out of the reservoir. = Remove spring @. 201796-10| = Remove seal rings @® and O-ring @. Re = Remore pilot bushings ®. = 20179011 6.13.5 _ Disassembling the piston rod © Info The steps are identical for both fork legs, except for the hydrastop needle and valve. Preparatory work = Disassemble the fork legs. (* p. 49) Remove the spring. (** p. 42) = Disassemble the cartridge. (* p. 43) 0. 0 Main work = Degrease the piston rod o = Clamp the piston rod with the special tool as far up as possible, Clamping stand (1140498) (* p. 357) = = Release hydrostop needle @ and remove it from the piston rod. : > The valve @ usually remains in the hydrostop needle. f= If there is damage: = Change the inner tube. 200728-10|6 FORK, TRIPLE CLAMP 200665-10| 200666-10| 6.13.9 Assembling the seal ring retainer 47 Measure the outside diameter at multiple locations of the inner tube. ‘Outside diameter of inner tube 47.975... 48.005 mm (1.88878... 1.88996 in) » Ifthe measured value is smaller than the specified valve: = Change the inner tube, Measure the run-out of the inner tube. Thner tube run-out *€0.20 mm (= 0.0079 in) » If the measured value is larger than the specified value: = Change the inner tube. Measure the inside iameter at multiple locations of the outer tube. Inside diameter of outer tube *€49.20 mm (= 1.937 in) > Ifthe measured value is larger than the specified value: = Change the outer tube, Check the outer tube for damage. » If there is damage: = Change the outer tube, Check the surface of the sliding bushings. + If the bronze-colored layer @ under sliding layer @) is visible o the surtace is rough = Change the sling bushings Check the spring length. Guideline Spring length with preload spaceris) | 472 mm (18.58 in) » If the measured value is larger than the specified value: = Reduce the thickness of the preload spacers. » If the measured value is smaller than the specified valve: = Increase the thickness of the preload spacers. Info The steps are identical for both fork legs.6 FORK, TRIPLE CLAMP Y\ 201800-10] 6.13.10 Assembling the hydrostop unit = Mount and grease seal ring @. Lubricant (1158) (* p. 344) ~ Mount and grease O-ring @. Lubricant (1158) (¥ p. 344) ~ Postion plot bushing suppor @. Info HThe steps are identical for both fork legs. ~ Mount and grease O-ring @ Lubricant (1158) (* p. 344) = Mount washer @ Mount shim stack @ with the smaller washers facing downward — Mount the new O-ring on hub @ = Mount the hub with washers @ Info Its possible that only one or no washer is present. Mount and tighten adapter Guideline Hydrostop unit adapter NGOS 7 Nm (5.2 It) ~ Mount shim stack @ with the smaller washers facing downwar = Mount and tighten sleeve @ Guideline rd. Hydrostop unit sleeve 6x05 7 Nm (5.2 Wot ft) ~ Check distance @ and total length @ Guideline Of the hydrastop, Hydrostop distance 21.5 mm @ 0.059 in} Hydrostop length 1085) 4.311 in) 109.5 mm (4.272, 201976-10| 6.13.11 Assembling the piston rod > Ifthe dimensions are out of tolerance: = Add or remove washers @ Info The steps are identical for both fork legs, except for the hydrostop needle and valve.6 FORK, TRIPLE CLAMP 2 201790-10] = 201732411 201792410] Degrease the piston rod. Clamp the piston rod with the special too. 43 Clamping stand (140498) (= p. 357) Lubricate the Ong. Mount valve needle @ inthe piston rod Lubricant (T7158) (* p. 344) Mount spring @. Guideline Mount and tighten adapter @ with spring @ and washer ‘Adapter of piston rod MOS 12.Nm (8.9 Wot Position the spring. Mount the compression shim stack @ with the smaller washers facing downward, Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring Fork ol (SAE 4) (4860116651) (7 p. 342) Nount the piston with chamfer @) facing down, Nount the ebound shim stack @ with the smaller washes facing upward Press the piston downward against the sping. The piston should not squeeze the shims. Postion valve @® inthe hydrostop needle @. Mount and tighten the hyérostop needle. Guideline Hydrostop needle on piston rod MOS 7 Nm (5.2 Wtf) Info DQ -sitver hydrostop needle on compression damping side © ~ rex hycostop needle on rebound damping sie.6 6.13.12 Assembling the cartridge FORK, TRIPLE CLAMP — Unclamp the piston rod. Info T The steps are identical for both fork legs. ees 20179810] Ga wa-e 20179511 adr 201796-10| Preparatory work = Assemble the seal ring retainer. (# p. 47) ‘Assemble the piston rod. (* p. 48) work ~ Mount and grease seal rings @ and O-ring @ Lubricant (1158) (¥ p. 344) = Mount and lubricate pilot bushings ©. Fork oll (SAE 4) (4860116651) (+ p. 342) = Check the length of the reservoir spring. Guideline Reservoir spring length with preload spacer 46 mm (1.81 in) » If the length is out of tolerance: = Correct the preload spacers. = Position the spring with the preload spacers in the reservoir. ~ Position sleeve @ in the reser. Clamp the tube of the cartridge into a vise. Clamping stand (1140498) (+ p. 357) = Slide reservoir @ onto the tube. Info Hold the sleeve in the reservoir to prevent it from sliding out. = Mount lock ring @ ~ Mount seal ring retainer @ with the washer and tighten, Guideline Seal ring retainer M23 50.75 46 Nm (33.9 Ibf fo Toatite® 2701 2024s 11 SS tue, 201797-10| = Unclamp the cartridge. ~ Sle piston rod @ into the cartridge Info H Ensure that the piston ring is seated correctly ~ Mount spring eat ©6 FORK, TRIPLE CLAMP st i = ® ete 6.13.13 Assembling the fork legs Degrease piston rod @ and clamp in the vise, (Clamping stand (1140498) (* p. 3577 ~ Screw spring guide @ all the way on. Info ‘The nut must be firmly tightened against the stop by hand. Do not use a tol ~ Mount adjusting tube ® Unclamp the piston od. Mount the preload spaces) Info T When assembling, ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is mounted ‘on the corresponding screw cap. Compression damping side ~ screw cap with mark COMP, brake caliper holder, white adjuster Rebound damping side - screw cap with mark REB, no brake caliper holder, red adjuster. Preparatory work = Assemble the hydrostop unit. (** p. 48) ‘Main work = Clamp the inner tube with the axle clamp. Guideline Use soft jaws. = Mount special tool Protecting sleeve (T1401) (* p. 356) 2orne10| wae 2o.ns.10| ~ Lubricate and mount dust boot @ Cubrcant (T51D) p. 348) Into ‘Always change the dust boo, sea ring, lock ring and suppor ring Mount the sealing lip with the spring expander facing downward = Slide on tock ring @ ~ Lubricate and side on seal ring @ Lubricant (T511) (* p. 344) Info Mount with the sealing lip facing down and the open side facing up. = Slide on support ring @ = Remove the special tool ~ Grind the edges of the siding bushings with sandpaper grit 600, clean the bushings and lubricate them. Fork oil (SAE 4) (4860116681) (* p. 342)6 FORK, TRIPLE CLAMP 82 20.76.10] 201717.10| 20170611 201705411 20208910] Slide on the lower sliding bushing @ Mount the upper sing bushing @ Info o not use a tool; pull the ends apart slightly by hand, ~ Warm the outer tube in area @) ofthe lower sliding bushing Guideline 50°C 22°F) = Slide the outer tube onto the inner tube ~ Hold the lover siding bushing withthe longer section of the special too Mounting tool (T14040S) (*" p. 357) ~ Pash the sliding bushing al the way into he outer tube, Position the support ring. Hold the seal ring with the shorter section of the special tool Mounting tool (1140408) (* p. 357) = Push the seal ring and support ring all the way into the auter tube. Mount lock ring @. © Info ‘The lock ring must engage audibly. = Mount dust boot @ ~ Mount fork protection ring @. = Lubricate the O-ring. Slide the cartridge all the way into the fork leg Fork oil (SAE 4) (4860116651) (= p. 342)6 FORK, TRIPLE CLAMP 53 = Turn the fork, Have the entire filling quantity of fork oil available, Oil capacity per] 635 mi Fork oll (SAE 4) (48601 16681) fork leg (21.47 thoz) | (# p. 342) Add some of the fork oll white pulling out and pushing in the piston rod numerous S| times. Guideline Fork oll quantity 510 mi (17.24 Hl. oz) 201719410] = Mount and tighten hydrostop unit @. Guideline Hydrostop unit 30x 40m (29.5 Ibt FD) = Clamp the fork vertically. = Add the remaining quantity of fork cil. = Pull out the piston rod and push it back in numerous times while pressing it to one i 202091-10| side slighty = V Air bubbles emerge and the cartridge is bled. = Keep bleeding until no more air bubbles emerge. The piston rod moves out automatically to the middle of the total stroke distance. Info T Wen fully bled, the correct air chamber length is achieved automatically. 20209010] = Postion spring ~ = Pull the sping down, Mount screw cap @. © Info ‘When assembling, ensure that the screw caps are correctly mounted accord. ing to the hydrostop needles. Rebound damping side - red hydrostop needle, screw cap with mark REB. 4 Compression damping side ~ silver hydrostop needle, screw cap with mark COMP. 2o172e-1| [GT] -‘Pullthe spring down. Mount the open end wrench on the hexagonal part, = Hold the open end wrench, Tighten screw cap @, @ Guideline = Screw cap on piston rod MBO75 TEN fe (13.3 io Special socket (T4047) (* p. 357) 201722410]6 FORK, TRIPLE CLAMP 5 = Pash the outer tube up ~ Clamp the outer tube inthe area ofthe loner triple clamp. Clamping stand (T1403) (* p. 357) ~ Tighten screw cap @ Guideline Carridge on oar be WSIS 70m _ (29:5 lot fy eoRToit Special socket (714047) (* p. 357) ~ Mount the acjuster, Mount and tighten serew @ Guideline Screw, adjuster WO ZeNm 84 rf» soto erative 1 = Tum the adjuster of compression damping €B (merk COMP) and the adjuster of ® rebound damping QD (mark REB) all the way cocks. Guideline Rebound damping Comfort Tete Standard 13 licks Sport Tr leks oe Compression damping Comfort Ticks Standard 13 leks Sport Ti clcke = Tum counterclockwise by the number of clicks corresponding to the fork type. Alternative 2 Warning Danger of accident Modifications to the suspension setting may seri ously alter the handling characteristic. Extreme modifications to the suspension setting may cause @ serious deterioration in the handling characteristic and overload components. = Only make adjustments within the recommended range. Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. = Set the adjusters to the positions determined upon removal 6.13.14 Greasing the steering head bearing = Remove the lower triple clamp. (*" p. 55) Install the lower triple clamp. (* p. 55) 200030410]6 FORK, TRIPLE CLAMP 55 6.13.15 Removing the lower triple clamp 80065210] 6.13.16 Installing the lower triple clamp 2 Preparatory work =""Remove the headlight mask withthe healigt. (&* p, 108) = Raise the motoreycle withthe it stand. p. 11) = Remove the tront wheel. (© p. 108) = Remove the fork eg. (p18) = Remove the front fender. (© p. 103) = Remove the handlebar cushion. Main work = Open the cable holder in font of the right radiator and detach the wing harness. = Remove screvs @ and hang the voltage regulator to the sce ~ Remove screw @. Remove screw @. Take off the upper triple clamp with the handlebar and set it aside. Info Protect the components against damage by covering them. o not bend the cables and lines. ~ Remove O-ring @. Remove protective ring @ Take off the lower triple clamp with the steering stem, ~ Remove the upper steering head bearing, ‘Main work = Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (¥" p. 344) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. ~ Check whether the upper steering head seal @ is cortectly positioned. = Slide on protective ring @ and O-ring © ~ Position the upper triple clamp with the handlebar. ~ Mount screw @ but donot tighten yet Position the clutch line, wiring harness, and voltage regulator. Mount and tighten screws @. Guideline Remaining screws, chassis Ne TO Nm (7-4 Tot6 FORK, TRIPLE CLAMP 58 = Position the fork legs. Bleeder screws @ are posit ned toward the front. © Info The rebound damping is located in the right fork leg REB (red adjusting screw). The compression damping i located inthe left fork leg COMP (white adjusting crew). Grooves are milled into the side of the upper end ofthe fork legs. The sec- con milled groove (from the top) must be flush withthe top edge ofthe upper triple clamp. = Tighten serewe Guideline Screw, bottom tiple camp MB TS Nm (1.1 i = Tighten screw @. Guideline Screw, top steering head M2015 T2Nm 9 Tor = Mount and tighten screw @. Guideline Screw, top steering stem | WB T7 Nm Toctite® 243° (22.5 tor 9 ~ Tighten screws @. Guideline Screw, top Wiple clamp we T7Nm (12.5 io to ~ Secure the wiring harness with cable holder @. = Position the brake caliper. Mount and tighten screws @. Guideline Screw, front brake caliper] MB 25 Nm Toatte® 243 (28.4 tor fo 2 = Mount cable binder @. j. ~ Position the brake line, wiring harness, and clamp. Mount and tighten screws 1o1e116 FORK, TRIPLE CLAMP 37 Finishing work = Mount the handlebar cushion. Install the front fender. (** p. 103) Install the front wheel. (* p. 108) Refit the headlight mask with the headlight. (% p. 104) Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly — Check the steering head bearing play. (© p. 57) Remove the motorcycle from the lift stand. (#* p. 11) Check the headlight setting. (* p. 131) 6.13.17 Checking the steering head bearing play Warning Danger ef accidents Unstable vehicle handling from incorrect steering head bearing play = Adjust the steering head bearing play without delay. Info Hr the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time. Preparatory work = Raise the motorcycle with the lift stand. ( p. 11) Main work Ss — Move the handlebar to the straight-ahead position. Move the fork legs to and fro in Dl the direction of travel PSL To play should be noticeable Inthe sleering head bearing (FA > Where iets ley event ~~ LY, = Adjust the play ofthe steering head bearing. (*” p. 57) (O)) CC) — wove the handlebar te andro ver the enti tering rane. Ww of | SJ cane | aout The handlebar must be able To move easly over The entire steering range. No resting locations should be noticeable » If lick positions are noticeable: — Adjust the play of the steering head bearing. (* p. 57) Check the steering head bearing and replace if required. Finishing work = Remove the motorcycle from the lift stand, (7 p, 11) 6.13.18 Adjusting the play of the steering head bearing Preparatory work — Raise the motoreycle with the lft stand. (** p. 11) ‘Main work ~ Release screws @. Remove screw @. = Loosen and retighten screw @. Guideline Screw, top steering head 20x15 12 Nm (89 oh) — Using a plastic hammer, tap lightly on the upper tripe clamp to avoid strains. = Tighten screws @. Guideline Screw, top Wiple clamp MB 17 Nim (2.5 bt to ~ Mount and tighten screw @ Guideline Serew, top steering stem | MB T7 Nm [lect 25] (12.5 tof ft6 FORK, TRIPLE CLAMP Finishing work = Check the steering head bearing play. (© p. 57) Remove the motorcycle from the lift stand. ( p. 11) 587 HANDLEBAR, CONTROLS 59 Bu (nthe upper triple clamp, thee are two holes at a distance of @ to each oth Hi aa g 8 rg The holes on the handlebar supports are placed ata distance of @ from the center. 9 @ Hole distance @ 3.5 mm (0.138 in) ie ‘The handlebar supports can be mounted in four different positions. 1o1487-10 Warning Danger of accidents Handlebar breakage. = Ifthe handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handlebar. ~ Remove screws @. Take off the handlebar clamps. Remove the handlebar and lay Lie ito one side, ad +o Info g 3 Hover the components to protect them against damage. eS Do not bend the cables and lines. = Remove screws @. Take off the handlebar supports. = Place the handlebar supports in the required position. Mount and tighten 1o14se-10) screws @. Guideline Screw, handlebar holder] M10 40 Nm Toctite® 2437 (29.5 lot ft) Info I Position the left and right handlebar supports evenly. = Position the handlebar. Info Tttake sure the cables and wiring ate positioned correctly = Position the handlebar clamps. Mount and tighten screws @ evenly. Guideline Screw, handlebar clamp me 20Nm (4.8 bt Info Hake sure the gap width is even, Adjust the basic setting of the clutch lever to your hand size by turning adjusting serew © Info Tum the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. ‘Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. ‘The range of adjustment is limited. ‘Tum the adjusting screw by hand only, and do not apply any force. Do not make any adjustments white riding!7 HANDLEBAR, CONTROLS 60 74 Checking throtle cable routing Preparatory work = Remove the seat. (* p. 93) — Remove the fuel tank. (* p. 94) ‘Main work (EXC EWAUS/BR, XCF-W, EXC-+ Factory Edition, All Six Days models) = Check throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing. » If the throttle cable routing is not as specified: ~ Correct throttle cable routing. (EXC US) = Check throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing. » If the throttle cable routing is not as specified: ~ Correct throttle cable routing, Finishing work = Install the fuel tank. (#* p. 95) = Mount the seat. (#* p. 94) = Check the throttle grip for smooth operation. Move the handlebar to the straight-shead position. Move the throttle grip back and. forth slightly to ascertain play @ in the throttle cable. Play in throttle cable a. 5mm (0.12... 02 in) > If the throttle cable play does not meet specifications: = Adjust the play in the throttle cable. (#* p. 61) 400192411HANDLEBAR, CONTROLS 61 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result In unconsciousness andlor death. ~ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system, = Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change » If the idle speed changes: = Adjust the play in the throttle cable. (#* p. 61) Preparatory work = Remove the seat. (© p. 93) = Remove the fuel tank. p. 94) — Check throttle cable routing. (* p. 60) Main work = Move the handlebar tothe straight-ahead pesition. ~ Push back leaves @. ~ Loosen nut @. Tur adjusting screw @ in as far as possible ~ Loosen nut @. Turn adjusting screw @ so that there is playin the thot cable atte thotle grip Guideline Play in ttt cable 3, 5mm (0.12.02 a) ~ Tighten nut @. ~ Press and hod the throttle grip in the closed setting. Turm adjusting screw @ out unt there is no play in throttle cable @ ~ Tighten nut @ ~ Push sleeves @ on. Check the throttle grip for smooth operation. Fishing work = ntall the fuel tank. (* p. 95) = Mount the seat. (© p. 94) = Check the play inthe throttle cable. ( p. 60)8 FRAME 40134001, 01396-10| = Check the frame for cracking and deformation » If the frame exhibits cracking or deformation due to a mechanical impact: ~ Change the frame. © Info ‘Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. = Turn quick release @ counterclocivse uti it disengage. Remove the engine usd. 01595-10] = Attach the engine guard onthe frame atthe rear and swing up atthe font. = Turn quick release @ clockwise all the way.9 SHOCK ABSORBER, SWINGARM Caution Danger of accidents Disassembly of pressurized parts can lead to injury = The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info T The high-speed setting can be seen during the fast compression of the shock absorber. type, Guideline Compression damping, highspeed Comfort Zeus Standard TS tums Sport 1.25 tums © Into ~ Tum adjusting screw @ all the way clockwise with a socket wrench, Info Do not loosen nut @! Turn counterclockwise by the number of turns corresponding to the shock absorber ‘Turn clockwise to increase damping; turn counterclockwise to reduce damping. Caution’ Danger of accidents Disassembly of pressurized parts can lead to injury = The shock absorber is filled with high density nitrogen. Adhere to the description provided, Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. ~ Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click. Info To not tosen nut @! Turn counterclockwise by the number of clicks corresponding to the shock absorber type, Guideline Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 16 chicks © Info ‘Tum clockwise to increase damping: turn counterclockwise to reduce damping.9 SHOCK ABSORBER, SWINGARM 6 Caution Danger of accidents Disassembly of pressurized parts can lead to injury = The shock absorber is filled with high density nitrogen. Adhere to the description provided. ~ Turn adusting screw @ clockwise upto the ast perceptible cick. © Info To not loosen nut @: = Turn counterclockwise by the number of clicks corresponding to the shock absorber type. auidetne atom aia Comfort Baas Sirverd Zick Spor Picks info Tum cots to increase damping tun coutrclockws to reduce damp in Preparatory work - Raise the motorcycle with the lift stand. (* p. 11) invert = Measure the distance ~ as vertically 2s possible ~ between the rear avle and a fixed point such as a mark on the side cover. Make note ofthe value as measurement @. e so0s8e-10] Finishing work Remove the motorcycle from the lift stand. (#* p. 11) ~ Measure distance @ cf rear wheel unloaded. (F p. 64) = Hold the motorcycle upright with the ad of an assistant. ~ Measure the distance between the rear ale and the fixed point again, ® | ~ ote down the value as dimension @. Info The static sag isthe citference between measurements @ and @ = Check the static sag. Static sag 33... 35 mm (1.3. 1.38 in) » If the static sag is less or more than the specified value: = Adjust the spring preload of the shock absorber. (%* p. 65) ® 400969-109 SHOCK ABSORBER, SWINGARM 85 KG Measure dstance @ of rear wheel unloaded. (* p. 64) — With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up ‘and down a few times The rear whee! suspension levels out. = nother person now measures the dstance between the rear axle and a fied point. ~ Note dovn the value es dimension @. Info TL the riding sag is the difference between measurements @ and @. = Check the riding sag. Riding sag 108. TIS mm (4.13... 453 in) > Ifthe riding sag differs trom the specified measurement: Adjust the riding sag. (* p. 66) Caution Danger of accidents Disassembly of pressurized parts can lead to injury = The shock absorber is filled with high density nitrogen. Adhere to the description provided, © Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. Preparatory work = Raise the motoreele with the lift stand. (# p. 11) = Remove shock absorber. p. 66) = ter removing the shock absorber, clean it thoroughly. Main wok = Loosen screw @ Turn adjusting ring @ until the spring is no longer under tension, Hook wrench (T106S) (*" p. 353) = Measure the overall spring length while the spring is not under tension ~ Tighten the spring by turning adjusting ring @ to measurement @ Guideline Spring preload mm (0.31 in) © Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. = Tighten screw @ Guideline 401026.10] Screw, shock absorber adjusting ring _ | M5 5 Nm (3.7 WI) Finishing work = Install the shock absorber. (#* p. 66) Remove the motorcycle from the lift stand. (* p. 11)9 SHOCK ABSORBER, SWINGARM 6s 1200292.10| Preparatory work Reise the motoreycle with the lift stand. (* p. 11) Remove shock absorber. (7 p. 66) [After removing the shock absorber, clean it thoroughly. ‘Main work Choose and mount a suitable spring, Guideline Spring rate Weight of rider: 65... 75 kg (143... | 66 Nimm (377 Iblin) 165 Ib.) Weight of rider: 75... 85 kg (165... | 69 Nimm (394 Ib/in) 187 1b) Weight of rider: 85... 95 kg (187... | 72 Nimm (411 Ib/in) 209 Ib.) Info ‘The spring rate is shown on the outside of the spring, ‘Smaller weight differences can be compensated by changing the spring preload, inishing work Install the shock absorber. (* p. 66) Remove the motoreycle from the lift stand. (* p. 11) Check the static sag of the shock absorber. (* p. 64) Check the riding sag of the shock absorber. (*" p. 65) [Adjust the rebound damping of the shock absorber. ( p. 64) Preparatory work Reise the motoreycle with the lift stand. (* p. 11) ‘Main work = Remove screw @ and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. ~ Remove screw @, push splash protector © to the side, and remove the shock absorber. ~ Push splash protector @ to the side and position the shock absorber. Mount and tighten screw @ Guideline Screw, top shock absorber | MI2 ‘30 Nm Toctte? 2701 (59 Ibf ft) Mount and tighten screw @. Guideline Screw, bottom shock m2 0 Nm Toctte® 2701 absorber (59 Ibf ft Info ‘The helm joint forthe shock absorber at the swing arm is Teflon coated. It must not be greased with grease or with other lubricants. Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life,9 SHOCK ABSORBER, SWINGARM 67 Finishing work Remove the motorcycle from the lift stand. ( p. 11) Caution Danger of accidents Disassembly of pressurized parts can lead to injury. = The shock absorber is filled with high density nitrogen. Adhere to the description provided. C080 ©0000 20098901 “I 201613410] “Ee Condition ‘The shack absorber has been removed. = Remove the spring, (** p. 67) = Disassemble the damper. (* p. 68) ~ Disassemble the piston rod. (** p. 69) = Disassemble the seal ring retainer. (* p. 70) = Check the damper. (* p. 72) = Disassemble the rebound adjuster. (7 p. 72) Remove the heim joint. (* p. 73) = Install the heim joint. (* p. 74) Assemble the rebound adjuster. (& p. 75) Assemble the seal ring retainer. (* p. 75) Assemble the piston rod. (* p. 76) Assemble the damper. (€ p. 77) = Install the spring. (** p. 83) Condition ‘The shack absorber has been demounted, = Clamp the shack absorber in a bench vise using soft jaws. Measure and note down the spring length in a preloaded state. ~ Loosen screw @. Turn the adjusting ring until the spring is no longer under tension. Hook wrench (T1065) (# p. 353) = Remove Oxing @. = Remove spring retainer @ and intermediate washer @ = Remove the spring9 SHOCK ABSORBER, SWINGARM 201616-10| 20161610] Preparatory work ~ Remove the spring. (* p. 67) Main work = Note down the present state of rebound damping @ and compression damping @. ~ Completely open the adjustment elements of the rebound damping and compression damping. ~ Remove rubber cap @ of the reser ~ Soniy unscrew screw @ The pressurized nitrogen is bled of = Remove locking cap @ = Press seal rng retainer @ all the way in withthe special tol Disassembly tool (T1216) (* p. 355) = Remove lock ring @. Info Do not scratch the inner surface Take out the damper. = Remove screw @. Drain the ol9 SHOCK ABSORBER, SWINGARM 6 201620410] te 2o1601-10| 200760-10| = Remove the piston rod. Drain the remaining ol ~ Remove agjustng rng @ with the intermediate washer, ~ Remove compression adjuster QD. Remove the spring and piston, ‘ © A 200r61.0 ” 200762-10| Preparatory work = Remove the spring. (* p. 67) Disassemble the damper. (€ p. 68) ‘Main work = Clamp the piston rod with the fork in a bench vise. Guideline Use soft jaws. = Remove nut @. Info Tir mount @ is ioosened, apply counteractve force. ~ Remove rebound damping shim stack ©. Info Guide the rebound damping shim stack onto a screwdriver and put them aside together. ~ Remove piston @ ~ Remove compression damping shim stack @ © Info Guide the compression damping shim stack onto a screwdriver and put them aside together.9 SHOCK ABSORBER, SWINGARM 70 Unscrew and remove mount @. = Remove rebound damping shim stack @ Info Guide the rebound damping shim stack onto a screwdriver and put them aside together p if (ore 10 — Remove piston @ @ = Remove compression damping shim stack @ Y info Huis ne compression damping shim stck onto a screwaiver and pt them ede topther. fi f Spa dics & 200765-10| ~ Remove rebound damping washer @. ~ Remove seal ring retainer @. = Remove locking cap QD and bump rubber @. 200766-10| Preparatory work ~ Remove the spring. (* p. 67) = Disassemble the damper. p. 68) ~ Disassemble the piston rod. (7p. 69) Main work = Remove rebound rubber @). ~ Remove centering disk @.9 SHOCK ABSORBER, SWINGARM n 200787-10| = Remove seal ring @. ~ Remove washer @ from sea ing @ = Remove washer @ = Remove Oving @. = Remove dus boot @. Preparatory work = Remove the spring. (** p. 67) Disassemble the damper. (* p. 68) = Disassemble the piston rod. (** p. 69) = Disassemble the seal ring retainer. ( p. 70) ‘Main work ~ Press pilot bushing @ out of seal ring retainer @ using the special tool. Press drift (T1508) (* p. 358) ~ Side the rew plot bushing @ ont the special oo Press rift (T1504) (*" p. 358) = Position the plot bushing inthe sea ring relane using the special oo ress GR TTSON (= SSB) ~ Support sea ring retainer @ with te sleeve @) ofthe special tool Press the pilot bushing all the way in, ‘Assembly tool (T1508) (* p. 358) = Lubricate the special too. ‘Shock absorber fluid (SAE 2.5) (5018075181) (* p. 343) Calibration pin (T1205) (*" p. 354) ~ Support sea rng retainer @ with the sieeve @ ofthe special tol ‘Assembly tool (T150S) (* p. 358) Press the special tool through the new pilot bushing. Calibration pin (T1205) (* p. 354) 7 The pilot bushing is to be calibrated Finishing work = Assemble the seal ring retainer. ( p. 75)9 SHOCK ABSORBER, SWINGARM n 20081110] s—= 200832.10] 200812410] Gs. Condition ‘The damper has been disassembled. Measure the inside diameter on both ends and in the middle of the damper car- tridee. Damper cartridge Diameter 50.08 mm (1.9716 inl > If the measured value is greater than the specified value: = Replace the damper cartridge — Check the damper cartridge for damage and wear. > If there is damage or wear: = Replace the damper cartridge Check the heim joint for damage and wear. » If there is damage or wear: = Replace the heim joint. Measure the diameter of the piston rod. Piston rod Diameter 17.95 mm (0.7067 in) » If the measured value is smaller than the specified valve: = Replace the piston rod. = Measure the run-out of the piston rod. Piston rod Run-out (0.02 mm (0.0008 in) > Ifthe measured value is greater than the specified value: = Replace the piston rod. = Check the piston rod for damage and wear. > If there is damage or wear: = Replace the piston rod. Check the piston rings for damage and wear. » If damage or a bronze-colored surface is visible: = Replace the piston rings. Preparatory work = Remove the spring. (** p. 67) = Disassemble the damper. (* p. 68) = Disassemble the piston rod. (** p. 69) ‘Main work = Warm up the piston red in the area of the rebound damping valve seat. Guideline 80°C 176 F) ~ Remove rebound damping valve sat @9 SHOCK ABSORBER, SWINGARM ~ Remove serewsleeve @. Remave adjusting screw @ Info To not lose batts @ and spring. Remove rubber plug @ From the oppesite side, press rebound needle @ out ofthe piston rod. Condition “The shock absorber has been demounted, CClamp the shock absorber in a vise using soft jaws. Remave the collar bushing of the heim joint. Pin (7120)(* p. 354) ‘Turn the shock absorber around and remove the second heim joint collar bushing. Remove seal ring @ on both sides. Press the heim joint against a lock ring using the special tool Pressing tool (112078) (* p. 355) Remove the second lack ring @.SHOCK ABSORBER, SWINGARM ~ Pace special to! @ undermesth and press out heim joint @ using special ‘001 @ 4 Pressing tool (112075) (* p. 355) ~ Peston new heim jint @ and special oo. Pressing tool (11206) (*" p. 354) ~ Press in the heim joint all the way. = Press the heim joint against the lock ring using the special tool. Pressing tool (112075) (* p. 355) = Mount the second lek ring @. Mount seal ring @ on both sides. = Postion both ella bushings @) and press in9 SHOCK ABSORBER, SWINGARM 8 wo Be P. a & | egue 0s:030 ~ Grease Oring @ ofthe rebound needle. Lubricant (T158) (*" p. 344) ~ Mount rebound needle @ inthe piston rod © Info Hush in the rebound needle to the point where itis possible to mount the rebound damping adjusting screw. = Mount rubber plug @. ~ Lubricate spring, balls @ and O-ring © Tobricant (7155 ( p S44) = Screw inthe rebound damping adjusting screw @ all the way. Mount and tighten screw sleeve @. Guideline Screw sieeve Midd 8m 3.3 bt fo ~ Screw out the rebound damping agjusting srew @) tothe stop. = Grease the Ong of the rebound damping seat. Lubricant (1158) (* p. 344) Mount and tighten rebound damping valve seat @ Guideline Rebound damping valve | x1 6 Nm Toctite® 2701 seat (4.4 Ibf ft Info TE The rebound damping valve seat must be pressed inward before tightening. = Mount dust boot @ withthe special tol Mounting sleeve (T1204) (*" p. 354) — Grease the sealing lp ofthe dust bot. Tubicant 625) p.344) = Grease the O-ring groove. Lubricant (1158) (* p. 344) = Mount O-ring @ Mount washer ©.9 SHOCK ABSORBER, SWINGARM 6 Biers. f e Sa ~ Position washer @ on seal ring @. Grease the seal ring and mount with the washer facing downward. Lubricant (TS11) (#9. 344) — Mount centering disk @ = Mount rebound rubber @. Preparatory work = Assemble the seal ring retainer. ( p. 75) = Assemble the rebound adjuster. (* p. 75) ‘Main work = Clamp the piston rod wit the fork in a bench vice Guideline Use sot ave, ~ Mount bump rubber @ and locking cap @ ~ Position the special tool on the piston rod. Mounting sleeve (T1215) (*" p. 355) ~ Grease the dust boot and slide seal rng retainer @ onto the piston rod Tabricant (7625) p SAA) = Remove the special too = Mount rebound damping washer @. ~ Mount the compresion shim stack withthe smaller shims facing downward ~ Grind piston @ on both sides, using 1200 grit sandpaper on a surfacing plate, 20076#-10| | crane piston. suidetine view @ TTop view of piston @° view Bottom vew of piston9 SHOCK ABSORBER, SWINGARM n Mount rebound damping shim stack @ with the smaller shims at the top. — Apply thread locker to the threads of the piston rod. Toetite® 2707 = Screw on mount @ to the pont where the piston can stil be tuned. rly, wl, i [Pfoores.10 a ~ Mount the compression shim stack € withthe smaller shims facing downward 200770.10| o|- Grind piston ® on both sides on a surface plate using 1200 grit sandpaper. = Clean the piston Guideline o| [ine Top vew of piston eo View @ Bottom view of piston és 200771-10) ~ Mount rebound damping shim stack QD with the smaller shims facing upward ®@ | crease the threads ofthe mount Lubricant (1152) (* p. S44) = Mount nut €B), but do not tighten it yet 200772.10| = Align both pistons using the special tool Centering sleeve (T1214) (= p. 355) = Tighten the nut. zi Guideline Piston rod nut Mix 40m (29.5 lot f) = Remove the special tool. 20077610] Preparatory work = Assemble the seal ring retainer. (* p. 75) Assemble the rebound adjuster. ( p. 75) Assemble the piston rod. ( p. 76)9 SHOCK ABSORBER, SWINGARM 8 ‘Main work ~ Slide the spring and piston onto compression adjuster @. Grease the O-ring, Lubricant (1158) (* p. 344) Grease the threads. Lubricant (1159) (* p. 344) Mount and tighten the compression adjuster, Guideline Compression adjuster Maia S0Nm (36.9 Ibf FY) 200776-10| Install adjusting ring @ with an intermediate washer. © Info ‘The adjusting ring cannot be mounted after the piston rad has been assem- e bled! 201621-11 ~ Mount screw @ but donot tighten yet. Grease the O-ring of the seal ring retainer Lubricant (1158) (* p. 344) = Fill the damper cartridge approximately half way. = ‘Shock absorber fluid (SAE 2.5) (5018075181) (* p. 343) Carefully mount the piston rod, 20162010 ~ Mount seal rng retainer @ and slide it under the ring groove Mount lock ring @ Info Do not scratch the inner surface. Pall out the piston rod in order that the seal ring retainer fits closely against the lock ring. Mount locking cap @ of the damper cartridge Bleed and fil he damper. p. 80) Fil the damper with nitrogen. (7 p. 82) 201622410]9 TT 201623410] SHOCK ABSORBER, SWINGARM ~ Mount rubber cap @ of the reservoir. 79 = Turn adjstng ring @ completely down toward the boom ternative 1 = Tum adjusting screw @ clockwise with a screwdriver up tothe last perceptible click = Tum countrclockvise by the numberof licks coresponding to the shock ® absorber type. Guideline Compression damping, low-speed r Comfort 25 alcks Eo.) Siandad 20 lls Sport 1S clicks ~ Tum asusting crew QD clocknise wth an open end wrench unt it stops = Tum counterclockwise by the numberof tums corresponding to the shock absorber type, Guideline Compression damping, high-speed Comfort 2 tums ‘Standard 15 tums ‘Sport 1.25 tums ~ Tum acjustng screw QD clocknise up t Tum counterclockwise by the number of clicks corresponding to the shock absorber type, Guideline fo the last perceptible click Rebound damping Comfort 2B clicks ‘Standard 24 clicks ‘Sport 22 clicks Alternative 2 Warning Danger of accident Modification i to the suspension setting may ser ously alter the handling characteristic. Extreme modifications to the suspension setting may cause 2 serious deterioration in the handling characteristic and overload components. = Only make adjustments within the recommended range. = Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. ~ Mount adjusting screws @, and (D in the positions determined when dis assembling.9 SHOCK ABSORBER, SWINGARM 80 Info Before working with the vacuum pump, carefully read the vacuum pump operating manual, Completely open the adjusters of the rebound and compression damping. Ssor62e10] - It 201626-10| Remove the screw from the filling port. Mount adapter @ on the damper. Info HD Hand-tignten only without using a tool. Connect adapter @ to connector @ of the vacuum pump. Vacuum pump (112408) (* p. 355) Clamp the damper with soft jaws or hold it as shown in the photo. Info TH ciamp the damper ony lightly. The filing port must be locate atthe highest point. ‘The piston rod moves in and out during filing: do not immobilize it by holding it with your hand. Position the control lever as shown in the photo. % Control lever External tank @ is set to Closed; Damper @ is set to Vacuum; and Ol reserveir @ is set to Vacuum, Activate OwoHl switch @ The suction process begins. Y Pressure gauge @ drops tothe required value. =O bar Vacuum gauge @ drops to the required value, ‘timber Determine distance @ between the floating piston and reservoir hole with the spe- ial tool, Depth micrometer (T1078) (* p. 354) 7 The floating piston is positioned in the lowermost position en the vacuum gauge reaches the required value, tum conrl lever i eser- voir @ to Eaualize pressure Guideline ‘a mbar 7 The pressure gauge increases to the required value. Obar9 SHOCK ABSORBER, SWINGARM — When the pressure gauge reaches the required value, turn control lever Damper @ to Pressure 81 Guideline bar ‘ Oil is pumped into the damper. The pressure gauge increases to the required value. bar = Whe to Vacuum, nthe pressure gauge reaches the required value, turn conto lever Damper @ Guideline v aber “The pressure gauge drops to the required value Obar voir ‘Guideline n the pressure gauge reaches the required value, turn control lever Oil reser- = Whe to Vacuum, ‘O bar ‘The vacuum gauge drops to the required value. a ‘Bmbar voir the vacuum gauge reaches the required value, turn control lever Oil reser- =~ Whe © to Equatize Pressure. eline Guide 7 ‘B mbar “The pressure gauge drops to the required value Obar When the pressure gauge reaches the required value turn conto lever Damper @) to Pressure Guideline ‘bar 7 Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar n the pressure gauge reaches the requited value, turn control lever Damper @) = Whe to Vacuum, Guideline bar ‘The pressure gauge drops to the required value. v When the pressure gauge reaches the required value, activate the On/Off switch. Oar Guideline bar The vacuum pur9 SHOCK ABSORBER, SWINGARM 82 201626-10| = Slide O-ring @ to the end of the special tool by the specified value (distance @) minus specified value). Guideline To mm Depth micrometer (T1078) (= p. 354) Push the floating piston into the reservoir to the distance described above using the special tool Info TWinen the piston rod is fully extended, the floating piston must be at pre- cisely this position; otherwise, damage will occur when the shock absorbor compresses and rebounds. — Remove the special too! ~ Remove adapter @ from connector @ of the vacuum pup. © Info Hold the damper so that the filling port is at the highest point. — Remove the adapter. ~ Mount and tighten screw @ Guideline ; Filing pod screw WOK Ta Nim Stace fos ero ~ Screw inthe screw @ approx. to tums, but do nt tighten, Info ‘The piston rod is completely extended oreieit 2062210] = Keep the special too! in place in the bench vise. Nitrogen filling tool (117051) (= p. 358) — Connect the special tool to the pressure regulator ofthe filing cylinder. Filling gas - nitrogen = Adjust the pressure regulator. Guideline Gas pressure 10 bar (145 psi) = Position the shock absorber in the special tool The hexagonal part of tap handle @ engages in the hexagon socket of the screw ofthe fling prt. ~ Open spigot @. Fill the shock absorber for atleast 15 seconds. Guideline Gas pressure 10 bar (145 psi Info HW onitor the pressure control valve indicator Ensure that the shack absorber has been filled to the specified pressure.9 SHOCK ABSORBER, SWINGARM 83 ~ Screw the filing pot shut with tap hance @. ~ Clase spigot @ and remove the damper trom the special tol = Tighten the screw ofthe filing pot Guideline Reservoir filing port screw MS 35 Nm (2.58 Ibf FO) EE 20161410 20075111 = Ensure that adjusting ring @ is screwed on withthe intermediate washer. = Measure the overall spring length when not under tension, = Position the spring. Guideline Spring rate Weight of rider: 65... 75 kg (143... | 66 Nimm (377 Ib/in) 165 1D.) Weight of rider: 75... 85 kg (165... | 69 Nimm (394 Ib/in) 187 Ib.) Weight of rider: 85... 95 kg (187... | 72 Nimm (411 Ib/in) 209 Ib.) ~ Mount intermediate washer @ and spring retainer @ = Mount ring @ ternative 1 = Tighten the sping by turning adjusting ing to measurement Guideline Spring preload & mm (0.31 in) Hook wrench (T1068) (* p. 353) Alternative 2 Warning Danger of accident Modifications to the suspension setting may seri ‘ously alter the handling characteristic. Extreme modifications to the suspension setting may cause 2 serious deterioration in the handling characteristic and overload components. = Only make adjustments within the recommended range. = Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. = Tighten the spring by turning the adjusting ring to the measured value deter- ‘mined when it was removed. Hook wrench (T1068) (* p. 353)9 SHOCK ABSORBER, SWINGARM 24 Tighten screw @. , Guideline © Screw, shock absorber adjusting ing [MS Shin a7 IA oer Preparatory work = Raise the motorcycle with the lift stand. (* p. 11) ‘Main work ~ Remove screw @ and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. Info Raise the wheel slightly to make it easier to remove the screw. Swing back the shock absorber. Remove spacers @ on both sides. ~ Remove shaft seal rings © on both sides, = Mount special tol @ Mounting tool, heim joint (50329000044) (*" p. 346) — Press out the heim joint by screwing in the screw.9 SHOCK ABSORBER, SWINGARM 85 = Position the new heim joint. ~ Mount special tool @. Mounting tool, heim joint (60329000044) (* p. 346) Press in the heim joint by screwing in the screw. — Press in shaft seal rings @ on bath sides with the open side facing inward Info The heim joint forthe shock absorber at the swingarm is Teflon coated. It ‘must nat be greased with grease or with other lubricants. Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life. ~ Mount spacers @ on both sides. = Postion the shock absorber = Mount and tighten screw @ Guideline Screw, bottom shock Miz ‘30 Nm Toctite® 2701 absorber (59 Ibt ft) © Info Raise the wheel slightly to make it easier to mount the screw. Finishing work = Remove the motorcycle from the lift stand. ( p. 11)10 EXHAUST 88 Preparatory work = TRaie the motoreyce withthe it stand. (© p. 11) = Remove shock absorber p. 66) = Remove the main silencer. (© p. 87) ‘Main work = Remove springs ©. = Disconnect the plug-in connector of the lambda sensor and remove the cable binder. = Expose the cable, = Remove screw @ and take of the manifold. ‘Main work = Position the manifold and mount springs @. Spring hooks (50305017000) ( p. 346) = Mount and tighten screw @ Guideline Remaining screws, chassis, me 25 Nm (18.4 tbr fo — Connect the plug-in connector of the lambda sensor. = Route the cable loosely and secure with a cable binder. Finishing work = Install the main silencer. (* p. 87) = Install the shack absorber. (* p. 66) Remove the motorcycle from the lift stand. (#* p. 11)10 EXHAUST 37 10.3 Removing mainsilencer Warning Danger of bums The exhaust system gets very hot when the vehicle is driven. = Allow the exhaust system to cool down. Do not touch hot components. = Disconnect spring @. ‘Spring hooks (50305017000) (* p. 346) ~ Remove screws @ and take off main silencer. = Position the main silencer. Mount screws @, but do not tighten yet. = Reconnect spring @ Spring hooks (50305017000) (* p. 346) = Tighten screws @ Guideline Remaining serews, chassis Me TO Nm (7-4 Tot Warning Danger of buns The exhaust system gets very hot when the vehicle is driven. = Allow the exhaust system to cool down, Do not touch hot components. = Info (Over time, the fibers of the glass fiber yarn escape and the damper "burns" out. Not only isthe noise level higher, the performance characteristic changes. Preparatory work = Remove the main silencer. (¥ p. 87)10 EXHAUST 101956-10 101426-10| Main work (€XC-F EWAUBR, EXC- Factory Editon, EXC-F Six Days) — Remove screws @ ~ Take off silencer cap @ with O-ring @. = Remove old glass fiber yarn filing. = Clean the parts that ned tobe reinstalled and check for damage ~ Fit neuglass fiber yarn filing @ into the main silencer = Mount the O-ring onthe silencer cap. = Position the silencer cap. = Mount an tighten all of the screws Guideline Screws on the main slencer um 7 Nm (5.2 IF) (©XC-F US, ll XCF-W models) ~ Remove screws @ of connecting cap @ = Remove connecting cap @ with the perforated pipe, Oxing @, and glass fiber yarn filing @. = Remove screws @ and silencer cap @ with O-ring @. = Remove screws @ and insert @ together wit insulating pad @. = Clean the paris that need tobe reinstalled and check for damage = Mount the new insulating pad on the insert and fasten with adhesive tape = Position the insert with the insulating pad in outer tube = Mount and tighten serews ©). Guideline Serews on the main sTenser ue 7 Nm (5.2 It ~ Mount Ong @ onthe silencer cap. = Fit the new loss fiber yer lag onto the perforated pipe. = Fitthe connecting cap with the gas fier yan fing in the outer tube Info Tress the glas fier yarn tiling into the outer tube using a blunt tool = Mount and tighten screws @ Guideline Screws on the man slender M5 7 Nm (5.2 It) ~ Mount Oxing @ on the silencer cap ~ Position the silencer cap with O-ring @ in the outer tube = Mount and tighten screws @. Guideline Serews onthe main silencer M5 7 Nm (5.2 Ib ft) Finishing work = Install the main silencer. (* p. 87)10 EXHAUST 88 Warning Danger of bums The exhaust system gets very hot when the vehicle is driven. = Allow the exhaust system to cool down. Do not touch hot components. ‘© Info ‘Soot particles accumulate on the screen of the spark arrestor over time. This changes the performance characteristics. Preparatory work = Remove the main silencer. (¥ p. 87) 40226810] Main work = Remove screws @ and take off silencer cap @ with O-ring @. Warning Danger to health Soot particles irritate the eyes and mucuous membranes, = Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen, Clean the main silencer housing @@ and screen @ ofthe spark arestor with compressed ar. = Mount a new o-ring @ on siencer cap @ = Position silencer cap @. Mount and tighten screns @. Guideline Screws on the main silencer M5 Tm G21 Finishing work = Install the main silencer. (** p. 87)11 AIR FILTER 90 MOOI 401527-10 (EXC-+F EWAUS/BR, XCF-W, EXC-F Factory Edition, All Six Days models) ~ Pull off the air filter box cover in @ area sideways and remove it toward the front. cjocrus = ul ofthe air iter box cover in @) area sideways and remove it toward the front (EXC-F EWAUSIER, XCF-W, EXC-F Factory Edition, Al Six Days models) = Insert the ai filler box cover int rear rea @) and clip it int font area @. (xc Us) Insert the ai filter box cover into rear area @ and clip tint font area @. Preparatory work = Remove the air filter box cover. ( p. 90) ‘Main work — Seal the air filter box in the marked area @. Finishing work = Install the ai11 AIR FILTER 31 (1L4— Removingthe airfter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine, = Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Wan Environmental hazard Hazardous substances cause environmental damage liters, uel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. = Oil, grease, Preparatory work = "Remove the ai fiter box cover. (* p. 90) Main work ~ Detach air fiter holding bracket @ a the bottom and swing it toone side. Remove the at iter with the a fier support. = Remove the air filter fom the ai filter support ‘Main work = Mount the clean air filter on the = Grease the air filter in area @. Longelife grease (* p. 344) filter support. Lo0943-10 Insert both parts together, position them and fasten them using the ar filter holding bracket The arrow of marking UP faces up. Info H itthe air iter is not corectly mounted, dust and dirt can enter the engine and cause damage. Finishing work = Install the air filter box cover. (* p. 90) Warning Environmental hazard Hazardous substances cause environmental damage Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in ap ble regulations. = Info Ho not clean the air filter with fuel or petroleum since these substances attack the foam. Preparatory work = Remove the air filter box cover. (* p. 90) Remove the air filter. (* p. 91)11 AIR FILTER 92 ‘Main work = Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner ( p. 344) © Info Only press the air filter to dry it, never wring it out = Oil the dry air filter with a high quality filter ol. Oil for foam air filter (* p. 345) = Clean the air filter box. = Check the intake flange for damage and firm seating, Finishing work = Install the air filter. (Fp. 91) Install the air filter box cover. (** p. 90)12 FUEL TANK, SEAT, TRIM 93 Danger Fire hazard Fuel is highly flammable. Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine fist. Be careful that no fu! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. ‘The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Warning Environmental hazard improper handling of fuel is @ danger to the environment. Do net allow fuel to get into the ground water, the ground, or the sewage system, = Pres release button @, tur filler cap counterclockwise and lift it upwards and remove. — Replace the filler cap and turn clockwise until the release button @ locks in Place. Info Toute the fuel tank breather hose @ without kinking. = Remove screw @ Lit up the seat atthe rear, pul it bak and then remove it fom above12 FUEL TANK, SEAT, TRIM Es Mount the front the seat on to the collar bushing of the fuel tank, lower it at the rear and simultaneously push it forward. mt on tent srw of the sn fing “ | Guideline Remaining screws, chassis, Me TO Nm (74 [oF Danger Fire hazard Fuel is highly flammable. = Never refuet the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fue! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. The fuel in the fuel tank expands when warm and may emerge if overilled. Follow the instructions on refueling. Warning. Danger of poisoning Fuel is poisonous and a health hazard. Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Preparatory work = Remove the seat. (¥ p. 93) Main work = Detach connector @ of the fuel pump, Remove the tube from the fuel tank breather. (EXC-# EWAUS/BR, XCF-W, EXC-F Factory Editon, All Six Days models) Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel tine. Dit in the fuel line clogs the injection valve. = Disconnect the plug-in connection of the fuel line. = Mount the wash cap set @. Wash cap set (81212016100) (EXC US) Thoroughly clean the plug-in connection of the fuel line using compressed air. Info HW Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve ~ Disconnect the plugin connection ofthe ue ne, = Mount the wash cap set @) Wash cap sat (1212016100)12 FUEL TANK, SEAT, TRIM 95 (EXC-F EWAU/BR, EXC-F Factory Edition, EXC-F Six Days) = Disconnect the connector of the horn. = Remove screws @ with the colar bushings and hor, (€xC US, Al xCF-W models) = Remove screws @ with the collar bushings. ~ Remove screw @ with the rubber bushing. = Pull both spoilers off of the sides ofthe radiator bracket and liftoff the fuel tank. 1900207-10] Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fue! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately, ~The fuel in the fuel tank expands when warm and may emerge if overilled. Follow the instructions on refueling Warning. Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with, soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel. ‘Main work = Check throttle cable routing, (* p. 60)12 FUEL TANK, SEAT, TRIM 96 ~ Position the fuel tank and ft the two spoilers to the sides of the radiator bracket. ~ Make sure that no cables are trapped or damaged. — Mount the fuel tank breather, = Mount and tighten screw @ with the rubber bushing. Guideline Remaining Serews, chassis MB TON (74 Tor (€X0- EWAUAR, EXC Factory Eton, EXC Sic Days) = Postion the collar bushings and horn, and mount and tighten screws @ Guideline Remaining screws, chassis We TO Nm (7.4 tot A) — Connect the connector of the horn. (EXC US, al xCF-W models) = Postion the collar bushings, and mount and tighten screws @ Guideline Remaining screws, chassis Ne 10 Nm (7.4 tot 1 (EXC-F EU/AUS/BR, XCF-W, EXC-F Factory Edition, All Six Days madels) ~ Plug in connector © of the fuel pump. ~ Remove the wash cap set. ~ Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dit in the fuel line clogs the injection valve Lubricate the O-ring and connect plug-in connection @ of the fuel line. Info TE Route the cable and fuel line at a safe distance from the exhaust sys tem: {EXC-+ US) ~ Plug in connector @ of the fuel pump. = Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line, Dit in the fuel line clogs the injection valve = Lubricate the O-ring and connect plug-in connection @ of the fuel line. Info Route the cable and fuel line at a safe distance from the exhaust system: work = Mount the seat. (#* p. 94)12 FUEL TANK, SEAT, TRIM 7 ‘127 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fue! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. The fuel in the fuel tank expands when warm and may emerge if overilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clething. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel. Warning, Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. (EXC-F EU/AUS/BR, XCF-W, EXC-F Factory Edition, All Six Days models) Clean the plug-in conection @ ofthe fuel line throughly with compressed Info Under no circumstances should dirt enter into the fuel line, Dit in the {uel line clogs the injection valve Disconnect the plugin connection ofthe fue ne, Pull fuel screen @ out ofthe connecting plece = Insert the new fuel screen al the way into the connecting piece Lubricate the O-ring and connect plugin connection ofthe fue ine Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andlor death, When running the engine, always make sure there is sufficient vent lation, and do nat start or run the engine in an enclosed space with- ‘out an effective exhaust extraction system, = Start the engine and check the response. (EXC US) = Clean the plug-in connection @ of the fuel line thoroughly with compressed Info Under no circumstances should dirt enter into the fuel line. Dit in the fuel ine clogs the injection valve Disconnect the plugin connection ofthe fuel ne Pull ful screen @ out ofthe connecting plece = Insert the new fuel screen al the way into the connecting piece. = Lubricate the Oring and connect plug-in connection ofthe fuel line Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andor death, When running the engine, always make sure there is sufficient vent lation, and do not start or run the engine in an enclosed space with- ‘out an effective exhaust extraction system. = Start the engine and check the response.12 FUEL TANK, SEAT, TRIM 98 12.8 Changing the fuel ter Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fu! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. = The fuel in the fuel tank expands when warm and may emerge if overilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water, If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Warning Environmental hazard improper hancling of fuel is @ danger tothe environment, = Do not allow fuel to get into the ground water, the ground, or the sewage system. Preparatory work = Drain the fuel from the fuel tank into a suitable container, = Remove the seat. (* p. 93) = Remove the fuel tank. (* p. 94) Main work ~ Remove nut @ with the gasket. = Remove fuel connection @ with the gasket. = Remove screws @. = Pull out the fuel pump. = Remove hose clamps @. = Remove fuel filter @.12 FUEL TANK, SEAT, TRIM 306217-10] f30s312.10| 30531610] 305213410] Press lock @ Pall back fuel pump housing @. Change fuel screen @ Mount the fue! pump housing Mount fuel filter @. % Arrow @ points away from the fuel pump. Mount hose clamps @. 99 Hose clamp pliers (60029057000) (* p. 349) Position the fuel pump. Guideline Mount fuel connection @ with the gasket but donot tighten yet Fuel connection on fuel pump me TO Nm (74 TOFD Mount and tighten nut @ with the gasket. Guideline 30891410] Nut, fuel pump fixation iz 15 Nm 1.1 bf fo Tighten fuel connection @. Guideline Fuel connection on fuel pump Me 10 Nm (7.4 Tot ft) Mount and tighten screws @ Guideline Screw, fuel pump wor Pre ‘SNe (2.2 It) Finishing work Install the fuel tank. (* p. 95) Mount the seat. (* p. 94)12 FUEL TANK, SEAT, TRIM 100 (129 Changing the fuel ume Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fu! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. = The fuel in the fuel tank expands when warm and may emerge if overilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clething. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Warning Environmental hazard improper handling of fuel is @ danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Preparatory work = Drain the fuel from the fuel tank into a suitable container, = Remove the seat. (* p. 93) = Remove the fuel tank. (* p. 94) Main work ~ Remove nut @ with the gasket. = Remove fuel connection @ with the gasket. = Remove srens @. = Pal out the fuel pump. = Position the fuel pump. Mount fuel connection @ with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump. me Tom 7a TAD = Mount and tigten nut @) withthe gasket Guideline Tut, fuel pomp Fration wie TS Nim 1.1 bro ~ Tighten fue! connection @. Guideline Fuel connection on fuel pump Me TO Nm (7-4 Tot)12 FUEL TANK, SEAT, TRIM 101 = Mount and tighten screws @. Guideline Screw, fuel pump Ear Pr 3Nm (22 bi 305314410] Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fue! is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. The fuel in the fuel tank expands when warm and may emerge if overilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Condition “The fuel tank is full Ensure that the battery voltage does not drop below 12.5 V. ‘The diagnostics tool is disconnected. Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fue! line. Dit in the fuel tine clogs the injection valve = Press on the small metal plate and disconnect fuel hose connection Info A Remaining fuel may flow out of the fuel hose. = Mount special tool @ Pressure testing tool (61029094000) (*" p. 349), ~ Mount special too! @ with nozzle label 0,60. Testing hose (61029093000) (*" p. 349), = Position the hose end in a fuel cannister. Gs cuidate Minimum size of fuel cannister 1012.6 US gal) 400926-10] = Connect the diagnostics tool and stat it = Select the “Function test of fuel pump control” actuator tes. Guideline Maximum duration of the actuator test_ | 3 min12 FUEL TANK, SEAT, TRIM 102 Check the fuel pressure with the filler cap closed. Fuel pressure When the fuel pump is active SS... 3.65 bar (8.6... 52.9 ps) 400927-01 40092801 > If the specification is not reached: = Open the filler cap. (** p. 93) Check the tank air vent system, Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pump is active ‘335... 3.65 bar 486... 52.9 ps) » If the specification is not reached = Check that the fuel line is clear. Change the fuel filter, (& p. 98) Change the fuel pump. (* p. 100) Stop the ‘Function test of fuel pump control" actuator test by pressing the “Quit” button, Remove the special tools. Join the fuel hose connection13 MASK, FENDER 103 Preparatory work — Remove the headlight mask with the headlight. (*" p. 103) Main work = Remove screvs @. ~ Remove screws @. Remove the front fender. Main work = Postion the front fender. Mount and tighten screws @. Guideline Remaining stews, chasis 1 TOR (7a TTD = Mount and tighten screns @ Guideline Remaining serews, chassis 1 TON (7A BOL6Os-11 Finishing work Refit the headlight mask with the headlight, (** p. 104) — Check the headlight setting. (7 p. 131) (EXC-+ EW/AUS/BR, XCF-W, EXC-F Factory Edition, All Six Days models) = Switch off all power consumers and switch off the engine ~ Remove screw @) and take ofthe clamp. ~ Release rubber straps @. Slide the headlight mask up and swing it forward13 MASK, FENDER 104 (EXC-F EWAU/BR, EXC-F Factory Edition, EXC-F Six Days) ~ Detach plug-in connectors @ and take off the headlight mask with the headlight. (AIL xCF-W meets) = Detach plugin connector @ and take off th headlight mask withthe head light. (EXC US) = Switch off all power consumers and switch off the engine = Remove screw @ and take off the clamp. = Release rubber straps @. Slide the headlight mask up and swing it forward, ~ Detach plug-in connectors @ and take off the headlight mask with the headlight. ‘Main work (EXC-+ EWAU/BR, EXC-F Factory tition, EXC-F Six Days) = Connect plug-in connectors @. (411 X-W models) = Connect plugin connector @13 MASK, FENDER 105 (@XC-FEUAUS/ER, XOF-W, EXC Factory Eton, Al Sc Daye mol Position the heasight mask and txt wth ruber straps @) © Info Ensure the holding lugs engage in the fender. ~ sition the Brake line and wiring harness, Pu the clamp on and mount and tighten screw @ coc us) ~ Connect plugin connectors @ ~ Position the headlight mask and fix it with rubber straps @. Info Ensure the holding lugs engage in the fender. = Position the brake line and wiring harness. Put the clamp on and mount and. tighten screw Finishing work = Check the headlight setting. (** p. 131)14 WHEELS 108 “V1 Checking the tire air pressure © Info How tire air pressure leads to abnormal wear and overheating ofthe tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. = Remove the protection cap. = Check the tite air pressure when the tres are cold, Tite air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi Road tire pressure (All EXC-F models) Front 15 bar (22 paid some a Rear 15 bar (22 pst) » If the tire air pressure does not meet specifications: = Correct the tre air pressure. = Mount protection cap, Info Only mount tires approved andlor recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the ties all have a significant impact on the handling characteristics of the motorcycle. The tires mounted on the front and rear wheels must have a similar profile, Worn tires have a negative effect on handling characteristics, especially on wet surfaces, — heck he on adres os cj nd danas D> Fite te xt cuts nin abet ter coma or cvanes tee = check te depth he wed Info y Tote iocat national regulations concerning the minimum tread depth AOS oosso| [nina read depth 2am e O08 >the read depth es than the minimum pemisibe depts Chang the te = check he te age Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indi cate the week of manufacture and the last two digits the year of manutac- ture KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. » If the tire is older than five years: ~ Change the tire.14 WHEELS 107 V4.3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). = Change the worn brake disc(s) without delay. = Check the thickness of the front and rear brake discs at several places on the disk 1 to see if it conforms to measurement _ info 8 BB esr ecuose te mccartney ta, vote ines. Tae ease Tt Fe TE mm O OW er) ‘Rear 3.5 mm (0.138 in) >If the brake dise thickness is less than the specified value. = Change the brake disc. = Check the front and rear brake discs for damage, cracking and deformation, » If the brake disc shows signs of damage, cracking, or deformation: = Change the brake disc. Warning Danger of accidents Instable handling due to incorrect spoke tension. = Ensure that the spoke tension is correc. Info HA iccse spoke can cause wheel imbalance, which leads to more loose spokes in a short time, If the spokes are too tight, they can break due to local overload Check the spoke tension regulary, especially on a new motorcycle. ~ Tap each spoke with a screwdriver © Info “The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear @ high nate, » I the spoke tension varies: = Correct the spoke tension Check the spoke torque. Guideline ‘Spoke nipple, front whe mas 6 Nm (4-4 Itt) Spoke nipple, rear wheel Mas 6 Nem (4.4 It) Torque wrench with various accessories in set (58429094000) (* p. 348)14 WHEELS 108 Preparatory work = Raise the motorcycle with the lift stand. (* p. 11), ‘Main work — Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. © Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. Loosen screw @ by several turns, ~ Release serens @. ~ Press on setew @ to push the wheel spindle out ofthe ale clamp. ~ Remove screw @). 'wo0137-19| Holding the front wheel, withdraw the wheel spindle, Take the front wheel out of ete ito — ID or put tenant bat ver nn tort tes ome Aas lay he wee! do cs way othe rake ek a teed 0018-10] ~ Remove spacers @. 14.5.2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oll or grease on the brake discs. = Always keep the brake discs free of cil and grease, and clean them with brake cleaner when necessary ~ Check the wheel bearing fr damage and weer. > Ifthe wheel baring is damaged or worn = Change the wheel bearing = Clean and grease shat sea rings @) and beating sutace @ ofthe spacers Longelife grease ( p. 344) ~ Insert the spacers.14 WHEELS Moo17-11 14.5.3 Removing the front brake disc 0187-10 14.5.4 _ Installing the front brake disc 601387-10 108 ~ Postion the front whee! and insert the whee! spindle. 7 The brake linings are comecty positioned, = Mount and tighten screw @ Guideline Serew, front wheel spindle M2ax1.5 45 Nm (33.2 Ibt FO = Activate the hand brake lever multiple times until the brake linings are in contact with the brake dise Remove the motorcycle from the lift stand. (#* p. 11) Pull the front whee! brake and push down hard on the fork several times to align the fork legs. = Fully tighten screw © Guideline Seren, rT we 15 Nm 1.1 bf fo Preparatory work ="Rais the motorycle with the it stand. (# p. 11) = Remove the front wheel. (© p, 108) Main work = Remove screvs @). Take ofthe brake dis. ‘Main work = Clean the contact surface of the brake disc. ~ Position the brake disc with the label facing outward. Mount and tighten screws @. Guideline Screw, front brake disc | M6 14Nm Toatite® 243 (10.3 tbe fe Finishing work = Install the front wheel. (** p. 108) Preparatory work = Raise the motorcycle with the lift stand. (* p. 11),110 ‘Main work = Press the brake caliper by hand on to the brake disc in order to press back the brake piston. © Info ‘Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. = Remove nut @ ~ Remove cain adjuster @. Withdraw wheel spindle @ only encush to alow the rear wheel tobe pushed forward = Push the rea wheel forard as far as possible. Remove the chain trom the rear sprociet. Info Cover the components to protect them against damage. = Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the swingarm, Info Do not operate the foot brake when the rear whee! is removed, ‘Always lay the wheel down in such a way that the brake disc is not dam: aged. ~ Remove spacers @. 14.6.2 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary Main work = Check the wheel bearing for damage and wear >It the wheel bearing is damaged or worn = Change the wheel bearing ~ Clean and greace shaft seal rings @) and bearing surtace @) ofthe spacers. Tong ie grease (* p. 34a) = Insert the spaces ~ Postion the rear wheel and inset wheel spindle @ The brake linings are correctly postioned. = Attach the chain.14 WHEELS 14.6.3 Removing the rear brake dise .601388-10 1464 Installing the rear brake disc 601388-10 nm ~ Position chain adjuster @. Mount nut @ but do not tighten it yet. ~ Make sure that chain adjusters @ are fitted cerrecty on adjusting screws @ = Check the chain tension. p. 112) = Tighten aut @ Guideline Nut, rear wheel spindle M2Ox15 BO Nm (69 BF Info ° The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables diferent secondary ratios with the same chain length Chain adjusters @ can be tured by 180° = Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Finishing work = Remove the motorcycle from the lift stand. ( p. 11) Preparatory work = Raise the motorcycle with the lift stand. (# p. 11) = Remove the ear wheel. (* p. 109) Main work = Remove screws @. Take af the brake cis. ‘Main work = Clean the contact surface of the brake disc. = Postion the brake dsc wth the label facing outward, Mount and tighten screws @ Guideline Screw, rear brake dee] MB Tam | Loetta® 243" (10.3 fr 9 Fishing work = Install the rear wheel. ( p. 110) Remove the motorcycle from the lift stand. (# p. 11)14 WHEELS 112 14.6.5 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension, = Ifthe chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, beat- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear viieel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary. Preparatory work = Raise the motorcycle with the lift stand. ( p. 11) ‘Main work = Pull the chain at the end of the chain sliding component upwards to measure chain tension Info TL The tower chain section @) must be taut. Wen the chain guard is mounted, it must be possible to pull up the chain Bt least othe pot where t makes contact with chan guard @. Chain wear isnot always even so you should repeat this measurement at ciferent chain postions Chain tension 55... 58 mm (2.17... 2.28 in) » If the chain tension does not meet specifications: = Adjust the chain tension, ( p. 112) Finishing work = Remove the motorcycle from the lift stand. ( p. 11) 14.6.6 Adjusting the chain tensi Warning Danger of accidents Danger caused by incorrect chain tension = Ifthe chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear: ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary. Preparatory work = Raise the motorcycle with the lift stand. (# p. 11) = Check the chain tension, (* p. 112)14 WHEELS 113, Main work = Loosen nut @. = Loosen nuts @ — Adjust the chain tension by turning adjusting screws @ left and right. Guideline Chain tension 35, 58 mm @17.. 2281) Turn adjusting serews @ on the left and right so that the markings on the left and right chain adjusters ae in the same position relative to reference marks @. The rear wheel is then correctly aligned. = Tighten nuts @ ~ Make sure thatthe chain adjusters @ are fitted correctly onthe adjusting screws ©. ~ Tighten nut @ Guideline Nut, rear wheel spindle M25 30 Nm 69 FA © Info ‘The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondaty ratios with the same chain length Chain adjusters @ can be turned by 180° Finishing work = Remove the motorcycle from the lift stand. (* p. 11) 14.6.7 Checking the chain, rear sprocket, engine sprocket and chain gui Preparatory work = Raise the motorcycle with the lift stand. (* p. 11), Main work = Shift gear to neutral Check the rear sprocket and engine sprocket for wear Ifthe rear sprocket or engine sprocket is worn: = Change the poner set © Info The engine sprocket, rea sprocket and chain should always be replaced together. 400227.01 ~ Pullon the upper part ofthe chain with the specified weight @) Guideline Weight of chain wear measurement | 10... 15 kg (22... 33151) 0 = Measure the distance @ of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at diferent chain positions Maximum distance @ at the longest | 272 mm (10.71 in) chain section » Ifthe distance @ is greater than the specified measurement: = Change the poner set. a IYGGK.-—--3OBY ‘When the chain is replaced, the rear sprocket and engine sprocket COeH COCO should also be changed. 123 161718 New chains wear out faster on old, worn sprockets. 4008671014 WHEELS 114 = Check the chain sliding guard for wear. + I the bottom edge of the chain bolt is in line with or below the chain sliding guard: = Change the chain sliding guard. Check that the chain sliding guard is firmly seated, » If the chain sliding guard is loose: = Tighten the screws on the chain sliding guard, Guideline ‘Screw, chain sliding | M6 Nm Lootite® 243 guard (4.4 tbe A) 0266-01 ~ Check the chain sliding piece for wear. » If the bottom edge of the chain bolt isin line with or below the chain sliding piece: = Change the chain sliding piece = Check that the chain sliding piece is firmly seated. >If the chain sliding piece is loose: = Tighten the screw of the chain sliding piece. Guideline ‘Serew, chain sliding piece me 15 Nm (11.1 Ibe fe Lo2466-01 = Check the chain guide for wear, Info Wear is visible on the front of the chain guide. >If the light part of the chain guide is worn: = Change the chain guide, 40176001 Check that the chain guide is firmly seated. ep we ar a Remove the motorcycle from the lift stand. (* p. 11)14 WHEELS 115 14.6.8 Checking for chain dirt accumulation = Check the chain for coarse dirt accumulation. > Ifthe chain is vey dirty = Clean the chain. (* p. 115) 40067201 14.6.9 Cleaning the chain Warning AD anget secon itr sreaseon the tes reduces thei rip. Remove oil and grease with a suitable cleaning material Warning. FA sangeet scott: Reduce braking etiiency due to olor grease on the brake ccs. = Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage ~ Oil grease fiers, ful, cleaners, brake fu, eo, should be disposed of as stipulate inapplicable regulations, © Info The service lite ofthe chain depends largely on its maintenance. Preparatory work = Reise the matoryce withthe it stand. (© p. 11) Min wok uw = Clean the chain regualy and then teat with chain spray. Chain cleaner (* p. 344) Offoad chain spray (© p 345) KEVGICVUE soores01 ishing work = Remove the motorcycle from the lift stand. (* p. 11)15 WIRING HARNESS, BATTERY 116 Preparatory work = Switch off all power consumers and switch off the engine. — Remove the air filter box cover. (* p. 90) Main work = Remove the protection cover @. Info T the main fuse @ is located in the starter relay @ under the filter box cover ~ Remove main fuse @. 400270-10| Warning Fite hazard The electrical system can be overloaded ifthe wrong fuses are used = Use only fuses with the prescribed amperage. Never bypass or repair fuses. ‘Main work = Insert the main fuse. Fuse (75011088010) (* p. 228) Info A reserve tuse @) is located in the starter rely Replace a burned-out fuse @ only by an equivalent fuse. Replace the protection cover Finishing work = Install the air filter box cover. (** p. 90) Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work = Switch off all power consumers and switch off the engine = Remove the seat. (=p. 93) Main work = Open fuse box cover @.15 WIRING HARNESS, BATTERY "7 = Remove the defective fuse, Guideline Fuse 1-10 A- EFI control unit Fuse 2- 10 A- fuel pump Fuse 3 10 A high beam, low beam, parking light, tal light, license plate lamp Fuse 4 10 A- horn, brake light, tum signal, radiator fan (optional) (EXC US) Fuse 5- 10 A ignition Fuses res 10 A spare fuses = Info A defective fuse can be identified by the burned-out fuse wire @. Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used, = Use only fuses with the prescribed amperage. Never bypass or repair fuses. ~ Use spare fuses with the correct rating only. Fuse (75011088010) (* p. 228) Tip H Repiace the spare fuse in the fuse bor so that itis available if needed. = Check that the power consumer is functioning properly. = Clase the fuse box cover Finishing work = Mount the seat. (#* p. 94) Warning VAR sicko nry attr acid and battery gases cause svicus chemical bums. Keep batteries out of the reach of children. Wear suitable protective clothing and goggles. ‘Avoid contact with battery acid and battery gases. Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms. In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician. 1900232-10| Preparatory work = Switch off all power consumers and switch off the engine. = Remove the seat. (* p. 93) Remove the air filter box cover. (* p. 90) ‘Main work Disconnect negative cable @ trom the battery. Pull back positive terminal cover @ and disconnect the positive cable from the battery = Detach rubber band @ at the bottom, = Lift the battery up and out15 WIRING HARNESS, BATTERY 118 ‘Main work Insert the battery into the battery compartment with the terminals facing forwerd. (EXC-F EW/AUS/US, EXC-F SIX DAYS, XCF-W, EXC-F Factory Edition) Condition Battery (YIXAL-BS) (* p. 228) (EXC-F BR) Coneition Battery (YIXSL-BS) (* p. 228) ~ Reconnect rubber band @) ~ Postion the positive cable @ and mount and tighten the screw. Guideline Screw, battery terminal 5 2.5.Nm (2.84 tbr ro ‘Info Contact disk @ must be mounted between screw @ and cable lug @ with the claws facing down ~ Slide postive terminal cover @ over the positive terminal ~ Postion the negative cable @ and mount and tighten the screw. Guideline Screw, battery terminal 5 2.5 Nm (1.84 tbr fo Info T contact disk @ must be mounted between screw @ and cable lus @ withthe claws facing down, Finishing work = Install the air filter box cover. (** p. 90) = Mount the seat. (* p. 94) Condition ‘The battery must be fully functional and completely charged. Carry out the start procedure. (* p. 11) z Measure the voltage between the specified points VW easuring point Pus (4)~ Measuring point Ground (-) Charging voltage 5,000 rpm 135. 150V » If the displayed value is less than the specified value: Check the plug-in connections from the alternator to the voltage regulator. Check the plug-in connectors from the voltage regulator to the wiring har- = Check the stator winding ofthe alternator. (** p. 217) » I the displayed value is greater than the specified value: Change the voltage regulator.15 WIRING HARNESS, BATTERY 119 (15.7 Checking the quiescent current Preparatory work = Switch off all power consumers and switch off the engine. Remove the seat. (* p. 93) ‘Main work = Disconnect the negative cable from the battery Measure the current between battery ground (-) and the negative cable © Info ‘The value of the quiescent current applies only to vehicles in the original state, i.e, without additional power consumers. Maximum closed-circuit current = 1.0 mA » If the measured value is higher than the specified value: = Disconnect the voltage regulator from the wiring hamess and perform the measurement again,16 BRAKE SYSTEM 120 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. = Change worn brake linings immediately = Check the brake linings for minimum thickness @). ‘Minimam thickness @ 21mm @ 004A) » If the minimum thickness is less than specified: = Change the front brake linings. (* p. 120) ~ Check the brake linings for damage and cracking. » If damage or cracking is visible: = Change the front brake linings. (® p. 120) Warning Danger of accident Brake system failure, = Maintenance work and repairs must be carried out professionally. Wan ‘Skin iritation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. Wear suitable protective clothing and goggles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately ~ Change the brake fluid of the front and rear brake according tothe service schedule. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. — Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. ~ Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can dtfer considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the orig nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer v Wart Ve rrr crits Reduced angie du tl ae Fi Marin FE nme brad Hazes sttrces cate emicent anag rin hart id, bl pnd of tps in apt guts, = Oil, grease, fil Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid, Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.16 BRAKE SYSTEM 12 Move the brake fluid reservoir mounted on the handlebar to horizontal position Remove screws @. Remove cover @ with membrane @ Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info ‘Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. Remove cater pins @, pull out pin @, and remove the brake linings. Clean the brake caliper and brake caliper support Check that leaf spring @ in the brake caliper and sliding piate @ in the brake caliper support are seated correctly. Insert the new brake linings, insert the pin, and mount the cotter pins. © Info ‘Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Correct the brake fuid quantity to evel @. Guideline Level @ (brake fluid level below con- | 5 mm (0.2 in) tainer rim) Brake fluid DOT 4 / DOT 5.1 ( p. 342) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water.16 BRAKE SYSTEM 12 Warning Danger of accidents Brake system failure. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. (All EXC-F models) Push the hand brake to the handlebar and check free travel @). Free travel of hand brake lever = 3mm 0.12 in) A ithe ee travel does not meet specifications y — Adjust the free travel of the hand brake lover. (* p. 122) fH00107-10| {AIL XCF-W madels) = Push the hand brake lever forwards and check free travel @. Free travel of hand brake lever = 3mm (0.12 in) » If the free travel does not meet specifications: = Adjust the basic position of the hand brake lever. (** p. 122) Check the free travel of the hand brake lever, (#* p. 122), — Adjust the basic setting ofthe hand brake lever to your hand size by turning adjusting screw Info Tum the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar. ‘Tur the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. ‘The range of adjustment is limited, ‘Tur the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while ridingt = Check the free travel of the hand brake lever. (#* p. 122), ~ Adjust the free travel of the hand brake lever with adjusting screw @. Info Tur the adjusting screw clockwise to reduce free travel. The pressure point moves away from the handlebar ‘Tur the adjusting screw counterclockwise to increase free travel. The pressure point moves towards the handlebar, ‘The range of adjustment is limited, “Tur the adjusting screw by hand only, and do not apply any force. o not make any adjustments while riding?16 BRAKE SYSTEM 123 (16.6 Checking the brake fluid level ofthe font brake Warning Danger of accidents Brake system failure. = Ifthe brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. Change the brake fluid of the front and rear brake according to the service schedule. = Move the brake fluid reseroir mounted onthe handlebar to horizontal postion. = Check the brake fluid level in level viewer @ + the brake lid level has dropped below marking @ = Add front brake fluid. (* p. 123) Warning Danger of accidents Brake system failure, = Ifthe brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Wan ‘kin iritation Brake fluid can cause skin irritation on contact. = Avoid contact with skin and eyes, and keep out of the reach of children. = Wear suitable protective clothing and gogeles = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. = Change the brake fluid of the front and rear brake according to the service schedule. Wan Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. © Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluld and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work - Check the front brake linings. (* p. 120) Main work = Move the brake fluid reservoir mounted on the handlebar toa horizontal position. ~ Remove serous @. = Remove cover @ with membrane @ ‘Add brake fuid to level @) Guideline (brake fluid level below con- | 5mm (0.2 in) tainer rim)16 BRAKE SYSTEM 124 Brake fluid DOT 4 / DOT 5.1 (* p. 342) ~ Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. Warning ‘Skin ivitation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. Wear suitable protective clothing and goggles. — If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. © Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. = Move the brake fluid resericr mounted onthe handlebar to a horizontal position ~ Cove the painted parts ~ Remove screvs @ ~ Remove cover @ with membrane = Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fu Bleed syringe (60329050000) (Fp 347) Brake fluid DOT 4 / DOT 5.1 (" p. 342) .601391-10 = Mount beeder cover ©. Bleeder cover (00029013005) (** p. 346) = Connect the bleeding device. Beeding device (00029013100) p 346) €01292.10 = Open shut-off valve @. © Info Follow the operating instructions of the bleeding device. Ensure that the filling pressure is correctly set at pressure gauge @. If necessary, adjust the filing pressure at pressure regulator Guideline Filling pressure 2... 2.5 bar (29... 36 ps)16 BRAKE SYSTEM 125 Pull off protection cap @ of the brake caliper bleeder screw. Connect the hose of the bleeder botte. Bleeding device (00029013100) (* p. 346) = Open bleeder screw @ by approx. one-half turn. Into HE Bioed until fresh brake fluid emerges from the bleeder bottle hose without bubbles = Tighten the bieeder screw = Close shut valve @ = Open the bleder screw agsin until no more brake tuid emerges Info This prevents overiling ofthe brake fluid reservoir. — Tighten the bleder screw. Remove the hose ofthe bleeder bole, Mount the protection cap. ~ Disconnect the bleeding device. Remove the bleeder cover. ~ Cotect the brake ud to teve! @ Guideline eve! @ 5mm O29) Brake fluid DOT 47 DOT 5.1 (* p. 342) = Position the cover with the membrane. Mount and tighten the screws. Info 400379-10 T clean up overflowed or spilt brake fluid immediately with water — Check the hand brake lever for a firm pressure point. Warning. Danger of accidents Reduced braking efficiency caused by worn brake linings. = Change worn brake linings immediately Check the brake linings for minimum thickness @, Minimum thickness @ 2 1 mm (2 0.04 in) > Ifthe minimum thickness is less than specified: = Change the rear brake linings. (* p. 125) ~ Check the brake linings for damage and cracking, » If damage or cracking is visible: = Change the rear brake linings. (7 p. 125) Warning Danger of accident Brake system failure, Maintenance work and repairs must be carried out professionally Warning ‘Skin iritation Brake fluid can cause skin irritation on contact. = Avoid contact with skin and eyes, and keep out of the reach of children. = Wear suitable protective clothing and gogeles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately16 BRAKE SYSTEM 128 Warning. Danger of accidents Reduced braking efficiency due to old brake fluc. Change the brake fluid of the front and rear brake according to the service schedule. Warning Danger of accidents Reduced braking efficiency due to oll or grease on the brake discs. = Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary Wan Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor ofthe brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origh- ral license, The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer vali Warning Environmental hazard Hazardous substances cause environmental damage. = il, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations —_ Info Never use DOT 5 brake fluid. [tis silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. = Stand the vehicle upright. ~ Remove screw cap @ with membrane @ and the O-ring. ~ Press the brake piston back to its basic position and make sure that no brake fluid ‘overflows from the brake fluid reservoir, extracting it if necessary. © Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. ~ Remove cotter pins @, pull out pin @, and remove the brake linings. Clean the brake caliper and brake caliper support. ~ Check that leat spring @ in the brake caliper and sling pate @ in the brake caliper suppot are seated correct 100407-1016 BRAKE SYSTEM ry Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs. = Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. ~ Ad brake fuid to evel @ Brake uid DOT 4 [DOT 5. (> p. 342) ~ Mount screw cap @ with membrane @ and 0: Info Clean up overflowed or spilt brake fluid immediately with water. Warning Danger of accidents Brake system failure. = If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to ‘overheating. Adjust the free travel on foot brake lever according to specification. = Disconnect spring @. = Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at Toot brake lever 3.5 mm (0.12... 0.2 in) \o + Ifthe tree travel does not meet specifications: ~ Adjust the basic position of the fot brake lever. (*" p. 127) SF ton00610] - Reconnect spring @. Warning Danger of accidents Brake system failure. = If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to ‘overheating. Adjust the free travel on foot brake lever according to specifications.16 BRAKE SYSTEM 128 = Disconnect soring @. = Loosen nut @ and, with push rod @, turn it back until you have maximum fee travel ~ Toadjust the basic position of the foot brake lever individually, loosen nut @ and turn screw @ accordingly. Info The range of adjustment is limited. ~ Turn push rod @ accordingly until you have tee travel @. If necessary, adjust the basic position ofthe foot brake lever. Guideline Free travel at Toot brake lever 3 Bram (O12... 02) Hold screw @ and tighten nut @. Guideline Nat, foot brake Tever stop me 20 Nm (4.8 tbr FO voxasi1o] ~ Hold push rod @ and tighten nut @. Guideline Remaining nuts, chassis 3 TONm (74 FR = Reconnect spring @. Warning Danger of accidents Brake system failure, = Ifthe brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely warn down. Check the brake system and do not continue riding Warning Danger of accidents Reduced braking efficiency due to old brake fluid = Change the brake fluid of the front and rear brake according tothe service schedule, = Stand the vehicle upright ~ Check the brake tui level in level viewer @. > Ifthe brake fluid level has dropped below marking @. ~ Add rear brake fluid, ( p. 128) Warning Danger of accidents Brake system failure. = Ifthe brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Warning, ‘Skin iritation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. = Wear suitable protective clothing and gogeles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.16 BRAKE SYSTEM 128 Warning. Danger of accidents Reduced braking efficiency due to old brake fluc. Change the brake fluid of the front and rear brake according to the service schedule. Warning, Environmental hazard Hazardous substances cause environmental damage = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. © Info Hever use DOT 5 brake fluid. Iti silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work = Check the rear brake linings. (** p. 125) in work = Stand the vehicle upright. — Remove screw cap @ with membrane @ and the Oring. ~ Aad brake fuid to level @ Brake Huid DOT 4 /DOT 5.1 p. 342) Mount the screw cap with the membrane and the O-ring, Info Tclean up overiowed or spilt brake fluid immediately with water. Warning ‘Skin irritation Brake fluid can cause skin irritation on contact = Avoid contact with skin and eyes, and keep out of the reach of children, ~ Wear suitable protective clothing and goggles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult 2 physician immediately Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations, Info HAvoia contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container16 BRAKE SYSTEM 130 Cover the painted parts. Remove screw cap @ with membrane and the O-ring. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe (50329050000) (* p. 347) Brake uid DOT 4 / DOT 5.1 (* p. 342) Mount bleeder cover Bleeder cove (00029013006) (= p. 346) Connect the bleeding device. Bleeding device (00029013100) p. 46) Open shut-off valve Info I Fotiow the operating instructions of the bleeding device. Ensure thatthe filing pressure is correctly set at pressure gauge @). Wf necessary adjust the filling pressure at pressure regulator @ Guideline Filing reSsure 225 bar (23. 36 pa Pull off protection cap @ of the bleeder screw. Connect the hose of the bleeder bottle. Bleeding device (00029013100) (+ p. 346) Open bleeder screw @ by approx. one-half turn. © Info Bleed until new brake fluid emerges from the bleeder bottle hose without bubbles. Tighten the bleede screw Close shut of valve @. (pen the Bleeder screw again until no more brake fluid emerges © Info ‘This prevents overiiling ofthe brake fluid reservoir. Tighten the Bleeder serew, Remove the hose ofthe bleeder bottle, Mount the pro tection 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 ( p. 342) Fit and tighten plug with oil screen and 0 Info Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point.17 LIGHTING SYSTEM, INSTRUMENTS 131 171 Checking the headlight setting = Position the vehicle upright on a horizontal surface in front ofa light wall and make a mark at the height of the center of the low beam headlight. ~ Make another mark a distance @ under the fist mark Guideline Distance @) Bem @ iA) ~ Postion the vehicle vertically dstance @ away trom the wall Guideline scorze10] [Distance @ Emaew = The rider now sits down on the motoreycle. = Shiteh on the fw beam, = Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a mtoreyele with iver, > Tf the light-dark border does not meet specifications — Adjust the headlight range. ( p. 131) Preparatory work = "Check the headlight setting. (* p. 131) Main work (XCF EUAUS/ER, XCF-W, EXC- Factory Eton, Al Six Days models) = Loosen screw @ = Adjust the headlight range by pivoting the headlight. Guideline The bourdary between ight and dark must be exaty on the Tower mark fora motorcycle with driver (instructions on how to apply the mark: Checking te headlight setting). Info HA change in weight on the vehicle may require a correction of the head light range. = Tighten screw @. cjoceus = Loosen screw @. = Adjust the headlight range by pivoting the headlight Guideline The boundary between light and dark rmust be exaclly on the lower mark for @ ‘motorcycle with driver (instructions on how to apply the mark: Checking the heaalight setting). © Info TA change in weight on the vehicle may require a correction ofthe head: light range = Tighten screw @.17 LIGHTING SYSTEM, INSTRUMENTS 132 “17.3 Speedometer overview = Press the button # to control different functions. Press the button § to control different functions. Info Tsien tov is dtr, nly the SPEED and SPEEDRDO dle modes are activated, 401761-01, 40031301 s00316.01 ‘Activating the speedometer ‘The speedometer is activated when one of the buttons is pressed or an impulse comes {rom the wheel speed sensor. Display test ‘To enable you to check that the display is functioning propery, all display segments light up briefly. Ws (wheel size) Aer the display function check, the wheel size WS is displayed briefly. © Info T The number 2205 equals the circumference ofthe 21" front whee! with standard tires. ‘The display then changes to the last selected mode. Info Tit you change the unit, the value 000 is retained and converted accordingly. The values TRI, TR2 AL, AZ and St are cleared when the unit of measure is changed. wow AS Sah Hh 000 UP a 40032901, Condition ‘The motorcycle is stationary. = Repeatedly press the button # briefly until H appears at the bottom right of the display. = Press the button # for 2-3 seconds, The Setup menu is displayed and the active functions are shown, — Repeatedly press the button # briefly until KnvivMph flashes. ‘Setting the Kuh Press the button #. ‘Setting the Mph = Press the button =, Wait 3-5 seconds The settings are stored. Info Tir no button i pressed for 10-12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.17 LIGHTING SYSTEM, INSTRUMENTS 133 (17.6 Setting the speedometerfunctions © Info T Wnen the vehicle is delivered, only the SPEEDM and SPEED/ODO display modes are activated. Condition ‘The motorcycle is stationary, = Repeatedly press the button briefly until H appears at the bottom right ofthe spay. = Pres the button for 2-3 seconds. SHEE MM SIS The Setup menu is displayed and the active functions are shown, oo we xe on T_ rno button is pressed for 10-12 seconds, the settings are automatically saved. If no button is pressed for 20 seconds, or it an impulse comes ftom the 4oos1601 whoo! speod sensor, the settings are automatically saved and te sotup menu is closed = Repeatedly press the button # briefly until the dasired function flashes. 7 The selected function flashes. ‘Activating the function = Press the button #, The symbol conti: appears, Deactivating a function — Press the button =. 1 The symbol disappears in the display and the next function appears. conten Frere stone 1 ety res heb iy url CX peas athe oto Ht he em Pact ten Wr 2 me \7 The hour display flashes. D- 24S Bez247 | Saneror sonnet ser ton aa || = ats sonoma 7 "The wa segen ofthe delay es nd can best — You can set the following segments in the same way as the hours by pressing. 40035001, the button # and the button =. ues to appear in the display and the next function Info the seconds can only be set to zero. If no button is pressed for 15 -20 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed, Danger Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on public roads in the homologated version. = Ifthe vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle ‘owner and rider of this. Ifyou undertake any modifications, please insist on receiving a signed workshop order from your customer in which you inform the customer in writing that these modifications are performed at the customer's own risk and that the vehicle will ‘no longer be approved for use on public roads once modified Preparatory work = Remove the headlight mask with the headlight. (& p. 103)17 LIGHTING SYSTEM, INSTRUMENTS 14 eg Main work = Expose connector CZ @. ~ Sever the blaclvbrown cable @ Insulate both cable ends Finishing work = Refit the headlight mask with the headlight. (** p. 104) Check the headlight setting. (** p. 131) Condition ‘The motorcycle is stationary. Preparatory work = Remove the headlight mask with the headlight. (€ p. 103) = Activate the additional functions. (* p. 133) ‘Main work = Repeatedly press the button # briefly until H appears at the bottom right of the display, Press the button ## for 2-3 seconds, When WS flashes, press the #E button briefly. wR AMS ‘Info ‘The wheel circumference is displayed in millimeters, 40033501] Enlarging the wheel circumference = Press the button #: Reducing the wheel circumference = Press the button =. Info Tf no button is pressed for 20 seconds, or if no impulse comes from the \whee! speed sensor, the settings are automatically saved and the Setup menu is closed ‘© Info This function can only be opened if lap times have actually been timed, Condition ‘The motorcycle is stationary.17 LIGHTING SYSTEM, INSTRUMENTS 135 400321-01 Repeatedly press the button 4 briefly until LAP appears at the bottom right of the display, Briefly press the button i. LAP 1 appears on the left side ofthe display. The laps 1-10 can be viewed with the button =. Press and hold the button # for 3-5 seconds, AF The lap times are deleted. Briefly press the button #. Next display mode © Info ‘When an impulse is received from the wheel speed sensor, the left side of the display changes back to the SPEED mode,18 ENGINE 136 18.1 Removing the engine Preparatory work Drain the coolant. (* p. 210) = Rais the motoryele with the ft stand. (# p. 11) = Remove the main silencer. (© p. 87) — Remove the seat. (* p. 93) — Remove the fuel tank. (*" p. 94) Main work = Remove screw @ = Disconnect the negative cable from the batter. Remove screws @ with washers Remove the cable binder), Take off the frame protector on both sides Info Tay attention to the holding lugs. = Loosen hose clip © = Slide back cover. = Unplug connector @18 ENGINE 137 Push back hose clamp @. Pull off the vent hose. ~ Remove screw @. ~ Loosen serow @ = Repeat the operation onthe opposite side Swing up the subframe and secure it. Remove screw @. = Swing back the shock absorber. Remove springs ©. Spring hooks (50305017000) (* p. 346)18 ENGINE Unplug the connector ofthe lambda sensor. Remove the cable binders) and expose the cable Remove screw @B. Remove the manifold. Slide back cover. Remove nut @. Detach the cable. Loosen hose clip @®. Take off the radiator hose. Disconnect spring ®. Remove screw Remove sere ®. Take of the engine sprocket cove. Remove the connecting link of the chain Take off the chain,18 ENGINE 138 Remove screws @®. Take off the clutch slave cylinder and hang it to the side, ® Info D0 not kink the cluteh tine. Do not activate the clutch lever ifthe clutch slave cylinder has been removed. Disconnect plugin connector D. Disconnect plugin connector Slide back coer. Unplug connector ®. Pll ofthe spark plug connector. Loosen hose clip @, Pull off the throttle valve body from the rear. Loosen hose clip @®. Take off the radiator hose, Remove screw connections @ Remove the engine braces. Remove nut @, Remove the swingarm pivot. Pull the swingarm slightly toward the rear.18 ENGINE 140 ~ Remove screws @. — Lift out the engine from the side. Info H You shoutd have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage. ‘Main work = Position the engine in the frame. ~ Mount screws @ but do not tighten yet. Guideline Engine aitachment Bolt mi0 GO Nm (44.3 Io 0 ~ Postion the swingarm, = Mount the swingarm pivot. = Mount nut @ but donot tighten it yt. Guideline Nut, swingarm pivot MIE 100 Nm (73.8 io) ~ Postion the engine braces. = Mount and tighten screw caps @. Guideline Serew, engine brace m8 Zahm Toatte® 2707" (24.3 toe #0 ~ Tighten screws @ and nut18 ENGINE 14 Guideline Engine attachment bolt mio GONm (44.3 Ibf FO) Nut, swingarm pivot MI65 100 Nm (73.8 Ibt HD) Noun the radiata hose. Position and tighten hose clip @. Mount the throttle valve body. Pasiton and tighten hose clip @. Plugin connector @ Peaiton the cover Connect plugin connector @ Connect plug-in connector @. Mount the sparkplug connecter, Position the clutch slave cylinder withthe gasket, Mount and tighten screws @. Guideline Screw, clutch slave cylinder MB TONm (7-4 (oF Mount the chain. Connect the chain with connecting link @.18 ENGINE 142 = Position the engine sprocket cover. Mount and tighten screw @®. Guideline Screw, clutch slave olinder MG TO Nm (7.4 Tor) = Mount and tighten screw @®. Guideline Remaining screws, chassis Me 25 Nm (28.4 Ibf FO ~ Mount spring ®. = Mount the radiator hose. ~ Position and tighten hose clip @. = Postion the cable. = Mount and tighten nut @. = Position the cover. = Posi the mi id and mount springs @ Spring hooks (50305017000) (* p. 346) = Mount and tighten screw @. Guideline Remaining serews, chassis we 25 Nim (18.4 io 0 Route the lambda sensor cable and secure it with a cable binder. Plug in connector.18 ENGINE 143 Position the shock absorber. Mount and tighten screw @®. Guideline Screw, top shock absorber | M12 ‘80 Nm Toatite® 2701" (59 It ft) Remove the fixation and position the subframe. Info Watch out for the intake flange. Mount and tighten screw @®. Guideline Screw, subframe Me 35 Nm Toctite® 2701" (25.8 lef fo Remove screw @ Mount and tighten screw @. Guideline Screw, subframe Me 35 Nm Toctite® 2701 (258 Ibe ft) Repeat the operation on the opposite side. Mount the vent hose. Position hose clamp @. Pug in connector @. Position the cover. Position and tighten hose clip @.18 ENGINE a ~ Position the frame protector on both sides. Info Pay attention to the holding lugs. Mount and tighten screws @) with the washers, Guideline Screw, frame protector M5 Shim 22) ~ Connect negative cable @ of the battery Guideline Screw, battery terminal 5 2.5.Nm (2.84 Ibf FY Info Contact disk @ must be mounted between battery terminal and cable socket with the claws facing up. — Refill the coolant. (* p. 211) = Install the main silencer. (#* p. 87) Remove the motorcycle from the lift stand. (#* p. 11) Install the fuel tank. (#* p. 95) = Mount the seat. (#* p. 94) ~ Remove screw cap @ on the clutch cover and fl in engine ol Engine ot TOTUT ak) [nine of AE TOWBON™ p. 342) Aermaive engine | Engine a ai for harsh oper- | (SRE 10W/60) ating conditions | (00082010035) and increased pe. | ( p.342) ference Mount and tighten fitting ©. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result In unconsciousness andlor death. = When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system, Start the engine and check that itis ol-tght. Switch off the engine. Check the engine oil level. (7 p. 212) Check the coolant level. (** p. 210) = Execute the initialization run. (* p. 222)18 ENGINE 145 Finishing work Take atest ride. Read out the fault memory using the KTM diagnostics tol. ~ Check the engine for leakage. = Check the engine oil level. (F p. 212) Check the coolant level, (** p. 210) 18.3.1 Preparations Mount the special tool on the engine mounting block. Engine fixing arm (77229002000) (* p. 350) Engine assembly stand (61229001000) (* p. 349) Mount the engine on the special too! Info ‘Work with an assistant or a motorized hoist 18.3.2 Removing the clutch push rod = Remove clutch push rod @ 18.3.3 Removing the spacer ~ Remove spacer @ ofthe countershatt Remove O-ring Remove plug @ with oll screen andthe O-rings18 ENGINE 146 Remove oil drain plug @ with the magnet. Completely drain the engine oil. Remove screws @. Remove the oil filter cover @ with the O-ring, Pull oil filter @ out of the oil filter housing, Circlip pliers reverse (51012011000) (* p. 347) 18.3.6 Removing the spark plug = Remove the spark plug using special too! @. Spark plug wrench (77229072000) (+ p. 353) 18.3.7 Removing the valve cover ~ Remove screws @ Remove the valve cover with the valve cover sel18 ENGINE 308576-10| 18.3.8 Removing the kick starter 147 Remove the spark plug shaft insert. Remove screw @ with the washer. Take off the kick starter Remove distance sleeve @, Remove screws @. Remove the eterator cover. Take off the alternator cover gasket Y Dowels @ remain inthe engine case.18 ENGINE 148 18.3.10 Removing the torque limiter = Remove torque timiter @ 18.3.1 Positioning the engine at ignition top dead center = Turn the crankshaft counterclockwise until markings @ on the cylinder head are located flush above the flat areas @ of the camshafts. = Remove screw @ withthe washer. Info Check through the hole whether the position notch ofthe crankshaft is is ble ~ Mount and tighten screw @ without the washer. [3.12 Removing the timing chain tensioner = Loosen screw @. ~ Remove screw @ with the seal ring 308584.10| ~ Pullout timing chain tensioner @. Remove O-ring @ (c00447-10,18 ENGINE 18.3.13 Removing the camshaft 149 Loosen serens @ from the ouside tothe inside and remove Takeoff guide rail @ Take off the camshaft bearing bridge Take the timing chain off the camshaft gear Remove the camshafts. Remove nut @ with the washer = Loosen nuts @ in a crisscross pattern and remove them with the washers. Remove the cylinder head. ~ Remove cylinder head gasket ©18 ENGINE 18.3.15 Removing th 0859910] 150 = Push the cylinder upward, Info Only push the cylinder as far up as necessary to take the piston pin out = Remove the piston pin retainer @ = Remave the piston pin = Takeoff the cylinder and piston. ~ Push the piston upward out ofthe cylinder. Info Tir no further work is to be performed on the cylinder and piston, the piston ccan remain in the cylinder. ~ Toke off elinder base gasket @ Remove screw @. ~ Insert special too! @ into the crankshatt. Protection cover (75029090000) p. 350) ~ tach special too! @) tothe rotor, Hold i tight using the special oo and pl of the rotor by tuning the scre in Extractor (58012009000) (* p. 347) Info Ensure that the woodruff key remains in place. = Remove lock ring @. = Take off the starter idler gear with the washer.18 ENGINE 151 = Remove freewheel gear @ ~ Remove screvs @ = Remove the inside alterator cover ~ Take off gasket @. = Remove screws @ = Take of the starter moter. Remove screws @. ~ Take off oil pump cover @ ~ Remove Oxing ©18 ENGINE 308616-10] 152 Remove suction pump @. Remove needle roller @. Remove screws @. Take off the water pump cover. Remove nut @ Take off the two-part water pump impeller @ Remove screws @. Take off the clutch cover Remove the clutch cover seal.18 ENGINE 153 18.3.20 Removing the clutch dises Remove screws @. Take off spring retainer @. ~ Take off spring washer ©. ~ Take of pretension ring @ ~ Take off pressure cap @. Completely remove clutch cise pack @. — Remove clutch pressure piece @.18 ENGINE 154 18.3.21 Removing the clutch basket = Bend open lock washer, ~ Hold the inner clutch hub withthe special tol. Loosen nut @ Clutch holder (51125003000) (* p. 347) Remove the nut with the lock washer. Dispose of the lock washer. ~ Take off inner clutch hub @ and washer @. Info ‘The washer usually sticks to the inner clutch hub. = Take off clutch basket ~ Take off needle bearing @ and collar sleeve @ 18.3.2 Removing the intermediate kick starter gear = Detach kick starter spring @. ~ Turn kick starter shaft @ counterclockwise and pull it out. Info ‘The stop disk of the kick starter shaft usually sticks to the bearing, 18.3.23 Removing the intermediate kick starter gear = Remove the lock rng. Teke of the washer. = Takeoff intermediate kick starter gear @

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3 2015 KTM 350 EXC-F XCF-W Manual PDF

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