REPAIR MANUAL 2015 1290 Super Adventure Art. no. 3206220enINTRODUCTION ' Read this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on it ifthe specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this 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. Al 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 madel without prior natice. 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. © 2017 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: TUV Management Service This document is valid for the following models: 1290 Super Adventure EU (F99030A) 1290 Super Adventure FR (F99230A) 1290 Super Adventure AU (F99600A) 1290 Super Adventure JP (F99860A) 1290 Super Adventure US (F99750A) 1290 Super Adventure CN (F99870A) 3206220en 01/2017TABLE OF CONTENTS 1 MEANS OF REPRESENTATION... 1a 12 2 SAFETY ADVICE... 2a 22 23 24 3. IMPORTANT NOTES. al 3.2 33 34 4 SERIAL NUMBERS 4d 42 43 44 45 46 47 ‘Symbols used Formats used. Repair Manual Safety advice Degrees of risk and symbols Work rules Warranty ee Operating and auilary substances... ‘Spare parts, accessories Figures . Chassis number... ‘Type label. Key number. Engine number Fork part number ‘Shock absorber article number... Steering damper item number... 5 MOTORCYCLE 51 52 53 5A 55 56 87 58 6 FORK, TRIPLE CLAMP 61 62 63 64 65 66 67 68 69 6.10 6.11 6.12 6.13 6.14 6.15 6.16 7 HANDLEBAR, CONTROLS. 7a 72 73 74 75 76 8 FRAME Bl 82 83 Lifting the motorcycle with the front lifting gear Taking the motorcycle from the front tne gear. Reising the mater withthe rear lifting gear Removing the rear of motorcycle fom the litting gear . Raising the vehicle with the center stan Removing the vehicle from the center stand Starting, Starting the motorcycle to check the function Cleaning the dust boots ofthe fork legs. Removing the fork legs. Installing the fork legs... Performing a fork service Disassembling the fork legs. Removing the spring Installing the spring. Checking the fork legs. ‘Assembling the fork legs... Checking the steering head bearing play ‘Adjusting the steering head bearing play Lubricating the steering head bearing Removing the lower triple clamp... Installing the lower triple clamp .. Changing the steering head bearing Changing the steering damper... ‘Adjusting basic position of clutch lever ‘Adjusting the handlebar position Removing the crash bar Installing the crash bar.. Changing the throttle grip. Replacing the heated grips Rider footrests. ‘Adjusting the footrest. Removing the engine guard... 12 ig 15 16 20 os 2A, os 2 31 u 12 13 2B 14 4 4 7 19 19 21 25 28: 1 26 28 29 31 31 1 32 32 33 36 os AZ 42 42 1 43 10 u 12 1B 4 8.4 Installing the engine guard weenie AB 8.5 Checking the frame. SHOCK ABSORBER, SWINGARM 9.1 Measuring the rear wheel dimension unloaded. 45, 9.2 Checking the static sag of the shock absorber... 45 9.3 Adjusting the spring pretension of the shock absorber. 45 9.4 Removing the shock absorber 1 46 9.5. Installing the shock absorber. aaa 7) 9.6 Removing the spring. 48 9.7 Installing the spring 49 9.8 Removing the heim joint... on) 9.9. Installing the heim joint. 50 9.10 Checking the swingarm. 51 9.11 Checking the swingarm bearing for play wr 51 9.12 Removing the swingarm. 1 82 9.13 Changing the swingarm bearing. 54 9.14 Installing the swingarm. 87 9.15 Programming the shock absorber control motor. 59 9.16 Programming the swing angle sensor. 59 EXHAUST. - 60 10.1 Disassembling the main silence vwvssnsveorors 60 10.2 _ Installing the main silencer...nnnnnnnnnnne 60 10.3 Removing the manifold 1 61 10.4 _ Installing the manifold 1 63 AIR FILTER .. a 66 11.1 Removing the upper part ofthe ai iter box... 66 11.2 Changing the air filter, cleaning the air filter box. 11.3 _ Installing the upper part of the ar filter bot... 67 11.4 Removing the lower part of the air filter box... 68, 11.5 _ Installing the lower part ofthe air filter Dox ...- 69 [FUELS TANCE SEAT; TIM esestectesties ternary 7 12.1 Adjusting the front rider's seat. n 12.2 Removing the front rider's seat... see 7 12.3 Mounting the front rider's seat. n 12.4 Removing the passenger seat 72 12.5 Mounting the passenger seat.. 72 12.6 Removing the fuel tank... 73 12.7 _ Installing the fuel tank... 74 12.8 Checking the fuel pressure. 76 12.9 Changing the fuel pump ... 7 12.10. Changing the fuel filter MASK, FENDER, DECAL... 13.1 _ Removing the front side cover 13.2 _ Installing the front side cover. 87 13.3 Removing the tank COVE. wrrnnnnrnnnnnnnne 89 13.4 _ Installing the tank cover 389 13.5 Removing the mask spoiler... ets) 13.6 _ Installing the mask spoiler. 92 13.7 _ Removing the bottom triple clamp cover. 93 13.8 Installing the bottom triple clamp cover .nnnne 98 13.9 _ Removing the front fender. 13.10 Installing the front fender... 13.11 Removing the wind shield 13.12 Installing the wind shield... 13.13. Adjusting the wind shield 13.14. Adjusting the windshield adapter position wu. 95 WHEELS 97 14,1 Checking the tire air pressure 97TABLE OF CONTENTS 15 16 14.2 Checking the tire condition 14.3 Checking the rim run-out... 14.4 Checking the wheel bearing fo pay 14.5 Checking spoke tension. e 14.6 Programming the tire pressure sensor 14.7 Front wheel... 14.7.1 Removing the front whee! 14.7.2 Installing the front wheel . 14.7.3 Changing te front wheel bearing 14.7.4 Tubeless tire system. é 14.7.5 Changing the front tubeless sealing profile. 14.7.6 Changing the front tire pressure sensor. 14.7.7 Checking the brake discs.. 14.7.8 Changing the front brake dises. 148 Rear wheel 14.8.1 Removing the rer whee. 14.8.2 Installing the rear wheel 14.8.3 Changing the rear wheel bearing 14.8.4 Changing the rear tubeless sealing profile. 14.8.5 Changing the rear tire pressure sensor. 14.8.6 Changing the rear brake discs 14.8.7 Checking the chain tension... 14.8.8 Adjusting the chain tension 14.8.9 Checking the chain, rear sprocket and engine sprocket. 148,10 Cleaning the chain 14.8.11 Checking the rear hub rubber dampers. 148.12 Changing the utber dampers inthe ear rupees : 148.12, Changing te beaing ‘ofthe rear sprocket carrer. i ee 14.8.14 Opening the chain . 14.8.15 Riveting the chain.. 148.16 Changing the drivetrain ki WIRING HARNESS, BATTERY. 15.1 15.2 153 15.4 15.5 15.6 15.7 158 159 BRAKE 16.1 16.2 16.3 16.4 16.5 16.6 167 16.8 16.9 16.10 16.11 16.12 Removing the battery Installing the battery Disconnecting the negative (minus) cable of the battery Connecting the negative cable of the battery. Recharging the battery Changing the main fuse. Changing the fuses in the fuse box Checking the charging voltage Checking Wn cpr coe SYSTEM sss Checking the front brake linings. Changing the front brake linings. Checking the brake fluid level ofthe front brake : emcee Adding front brake fuid. Changing the front brake fluid ‘Adjusting the basic position of the hand brake lever Checking the rear brake linings. Changing the rear brake linings. ‘Adjusting the basic position of the foot brake lever. . Checking the rear brake fluid level ‘Adding rear brake fluid Changing the rear brake fluid... 136 139 7 9B -. 98 99 99 99 99 100 101 103, 103 105 106 107 107 107 108 109 111 113 114 115 115 16 117 18 us ug 120 120 121 125 125 125 126 127 128 129 130 132 133 134 134 134 136 137 139 139 ua 142 142 143, v7 18 LIGHTING SYSTEM, INSTRUMENTS ... 17.1 Removing the headlight mask with the headlight... Installing the headlight mask withthe headlight. Changing the low beam bulb.. Changing the high beam bulb. Checking the setting ofthe lighting system, Adjusting the headlight range. ‘Adjusting the cornering light range Activating/deactivating the ignition key Programming the switch for the cruise control system... Resetting the service display using the KTM diagnostic toa ENGINE 18.1 Removing the engine. 18.2 _ Installing the engine... ee 18.3 Preparing the engine for installation. 18.4 Preparing the engine for clamping in the engine assembly stand Seting te engine to ignition top dead center of the rear cylinder. Setting the engine to ignition top dead center of the front cylinder... aoe Engine disassembly... . Clamping the engine into the engine assembly stand. Removing the engine bearer Draining the engine oi... Removing the front valve cover Removing the rear valve cover... Setting the engine to ignition top dead center of the rear cylinder : Removing the starter motor... Removing the oil filler tube. Removing the heat exchange 72 173 174 5 176 WT 78 179 17.10 18.5 18.6 18.7 18.7.1 18.7.2 18.7.3 18.7.4 18.7.5 18.7.6 18.7.7 18.7.8 18.7.9 18.7.10 187.11 187.12 18.7.13 187.14 Removing te rear camsha Removing the rear cylinder head Removing the rear piston... Setting the engine to ignition top dead center of the front cylinder Removing the front timing chain tensioner. Removing the front camshafts Removing the front cylinder head Removing the front piston.. Removing the alternator cover Removing the ignition pulse generator Removing the torque limite Removing the rotor., Removing the idler and timing chain on the left nn Removing the oil filter... Removing the balancer shaft. Removing the drive wheel of the balancer shaft Removing the gear position senso Removing the left suction pump Removing the water pump wheel Removing the clutch cover. Removing the clutch discs 18.7.15 187.16 187.17 18.7.18 18.7.19 187.20 18.7.21, 18.7.2 18.7.23 18.7.24 18.7.25 18.7.26 18.7.27 187.28 18.7.29 18.7.30 18.7.31 . 160 Removing the rear timing chain tensioner... 175 173 145 145 145 1. 146 a7 148 149 ~. 149 150 1. 182 153 1. 184 154 168 168 .. 169 . 169 170 . 170 170 170 17 171 171 ~. 172 172 172 172 173 173 oe 174, 174 174 175 . 176 176 v7 77 177 7 1. 178 179 179 179 180 181 181TABLE OF CONTENTS 18.7.32 18.7.3 Removing the clutch basket. . Remeving the le and timing chain on the right esotiees Removing the primary ger . Removing the force pump. Removing the shift shaft. Removing the shift drum locating Removing the locking lever. Removing the left engine case. Removing the crankshaft. Removing the middle suction pump. Removing the transmission shaft Removing the oil spray tube... Removing the timing chain rails ofthe right engine case section Removing the timing chain rails of the left engine case section... 18.8 Working on individual parts 18.8.1 Work on the right section of the engine case o Removing the right main bearing... Selecting the main bearing shells Installing the right main bearing... Work on the left section of the engine coset Removing the left main bearing. Installing the left main bearing Changing the contod bearing Work on the clutch cover Changing the support bearing of the crankshaft 7 Checking the radial clearance of the bottom connecting rod bearing Checking/measuring the cylinder Checking/measuring the piston... Checking the piston ring end gap hecking he piste inde mounting clearance = Work on the eylinder head Checking the cylinder head... Work on the right idler... Checking the timing assembly. Preparing the timing chain tensioner for installation Pretensioning the spread transmission . Checking the oil pressure regulator valve Checking the lubrication system... Checking the clutch . Checking the shift mechanism. reassembling the shift shaft Disassembling the main shaft .. Disassembling the countershatt. Checking the transmission... Assembling the main shat... Assembling the countershaft 0 ‘Measuring the main shaft axial pla... Checking electric starter operation. Checking the free-whee! Engine assembly Installing the timing chain rails of the left engine case section... Installing the timing chain rails ofthe right engine case section 18.7.34 18.7.35 18.7.36 187.37 18.7.38 18.7.39 18.7.40 187.41 18.7.42 18.7.43 18.7.4 18.7.45 18.8.2 18.83 18.8.4 18.8.5 18.86 18.8.7 18.8.8 188.9 18.8.10 18.811 18.812 18.813, 18.814 18.815 18.8.16 18.817 18.8.18 18.8.19 18.8.20 18.8,21 18.8.2 18.8.23 18.8.24 18.8.25 18.8.26 18.8.27 18.8.28 18.8.29 18.8.30 18.831 18.832 18.8.3 18.8.34 18.9 18.91 18.9.2 199 182 183, 183, 183 184 184 184 185 185 185 186 187 187 187 187 187 189 190 190 191 193 193 194 196 197 197 198 200 .. 200 200 203 205 205 206 206 207 207 208 209 210 211 212 213 214 214 216 216 Betei7) ~. 217 217 217 19 20 a 18.9.3 Installing the oll spray tube. 18.9.4 Installing the transmission shat. 18.9.5 Installing the middle suction pump 18.9.6 Installing the crankshaft 18.9.7 Installing the left engine case 18.9.8 Installing the locking lever. 18.9.9 Installing the shift drum locating.. 18.9.10 Installing the shift shaft 18.9.1 Installing the force pump... 189.12 Installing the left suction pump. 18.9.13 Setting the engine to ignition top dead center of the rear cylinder. . 18.9.14 Installing the primary gear. 18.9.15 Installing the clutch basket. 18.9.16 Installing the clutch discs... 18.9.17 Installing the ici and timing chain onthe right 18.9.18 Installing the clutch cover, 18,9.19 Installing the water purnp wheel.. 18.9.20 Installing the gear position sensor... 169.21 Instaling te dive whee ofthe balancer shaft. 18.9.2 Installing the balancer shaft. 18,9.23 Installing the idler and timing chain on the left 18.9.24 Installing the oi filter. 18.9.25 Installing the rotor. 18.9.26 Installing the torque limiter... 18,9.27 Installing the ignition pulse generator. 18.9.28 Installing the alternator cover. 18.9.29 Rear piston assembly . 18.9.30 Installing the rear cylinder head 18.9.31 Installing the rear camshatts.. 18.9.32 Installing the rear timing chain tensioner .. 18.9.3 Setting the engine to ignition top dead center ofthe front cylinder 18.9.34 Installing the front piston 18.9.35 Installing the front cylinder head. 18.9.36 Installing the front camshafts... 18.9.37 Installing the front timing chain tensioner... 18.9.38 Installing the heat exchanger. 18.9.39 Installing the starter motor. 189.40 Checking the rear valve clearance. 18.9.41 Adjusting the rear valve clearance orn 18.9.42 Checking the front valve clearance. 18.9.43 Adjusting the front valve clearance 18.9.44 Installing the ol filler tube... 18.9.45 Installing front valve cover 18.9.46 Installing rear valve cover 18.9.47 Installing the oil drain plug. 18.9.48 Mounting the engine bearer .. 18,9.49 Removing the engine from the engine assembly stand SECONDARY AIR SYSTEM SAS 19.1 Changing the SAS membrane. CLUTCH 20.1 CCheckingirectiying the fuid level of the hydraulic clutch. Fi = 20.2 Changing the hydraulic cluteh fluid 20.3 Checking the clutch SHIFT MECHANISM 21.1 Checking the basi postion ofthe shift lever. . 218 . 218 219 . 219 219 ss 221 221 221 ss 221 ns 222 223 sn» 223 . 223 » 224 225 . 225 226 1. 227 227 227 228 228 1. 229 . 223 230 1» 230 230 . 232 233 233 234 ns 234 1» 236 . 236 237 1. 237 . 238 238 ns 238 238 239 . 239 1» 240 . 240 241 ns 241 2a ns 242 ns 242 . 208 os 2A, os 2M, 245 1. 251 251TABLE OF CONTENTS 21.2 Adjusting the basic position of the shift lever 21.3 Changing the gear position sensor 21.4 Programming gear position sensor 22. WATER PUMP, COOLING SYSTEM 22.1. Checking the coolant level in the compensating tank.. Correcting the coolant level in the compensating tank. 222 22.3 22.4 Draining the coolant... 22.5 Adding coolantibleeding the cooling system.. 23 CYLINDER HEAD. 23.1. Checking the valve clearance 23.2. Checking the valve clearance (ar filter and spatk plugs removed)... Setting the value clearance of the rear cylinder, Setting the valve clearance of the front cylinder... Disassembling the camshafts ofthe rear cylinder, Installing the camshafts of the rear cylinder Disassembling the camshafts of the front cylinder 23.8 Installing the camshafts of the front cylinder 24 LUBRICATION SYSTEM 23.3 23.4 23.5 23.6 23.7 24.1 Oil circuit, _ 24.2. Checking the engine oil level. 24.3 Changing the engine ol and fier, cleaning the oll screens... ee 24.4 Adding engine ol 24.5 Checking the engine oil pressure. 24.6 Removing the oil nozzle for the clutch lubrication. 24.7 Checkinglcleaning the oil nozzle for clutch lubrication... 24.8 Installing the oll nozzle forthe clutch lubrication. 25 IGNITION SYSTEM. 25.1 Alternator - checking the stator winding .. 25.2 Changing spark plugs (ar filter removed). 26 THROTTLE VALVE BODY... 26.1. Removing the throttle valve body. 26.2 Installing the throttle valve body... 26.3 Executing the initialization run 26.4 Checking the CO adjustment using the KTM diagnostics too. so 27 TECHNICAL DATA.. 2IA eNgINe orn 27.2 Tolerance, engine wear limits. 27.3 Engine tightening torques. 27.4 Capacities. 27.4.1 Engine oil 27.4.2 Coolant.. 27.4.3 Fuel . A Chee 27.6 Electrical system. 27.7 Tires. 27.8 Fork 27.9 Shock absorber... 27.10 Chassis tightening torques Checking the coolant fil level and antifreeze. 281 251 253 254 254 1 254 255 256 287 259 259 . 267 270 27 an 272 273, 273 sos 275, 1. 275 276 276 278 279 1. 280 280 281 282 282 284 . 292 292, 293 294 sons 298 . 296 296 296 299 300 300 300 300 301 301 302 302 302 302 5 28 CLEANING/PROTECTIVE TREATMENT... . 305 28.1 Cleaning motorcycle... snes 305, 28:2 Checks and maintenance steps for winter [operat lnrsseesoereeeseterresrenremrere 0G) 29° STORAGE 307 29.1 Storage . 307 29.2 Preparing for use afte storage. 307 29.3 Checks and maintenance measures when preparing for use. 307 30 SERVICE SCHEDULE «309 30.1 Additional information 309 30.2 Required work 309 30,3 Recommended work... ~. 310 31 WIRING DIAGRAM 312 31.1 Page 1 of 13 312 31.2 Page 2 of 13. 314 31.3. Page 3 0f 13. 316 31.4 Page 4 of 13, . 318 31.5 Page Sof 13. 320 31.6 Page 6 of 13, ns 322 31.7 Page 7 of 13 . 324 31.8 Page 8 of 13. 326 31.9 Page 9 of 13. 1. 328 31.10 Page 10 of 13. 1» 330 1.11 Page 11 of 13. 332 31.12 Page 12 of 13. 334 31.13 Page 13 of 13. =. 336 32. SUBSTANCES . 338, 33 AUXILIARY SUBSTANCES .. . 340 34 SPECIAL TOOLS ns 342 35 STANDARDS 358 INDEX . 3591 MEANS OF REPRESENTATION 6 At Symbols sed The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function) Indicates a page reference (more information is provided on the specified page). xX Indicates an unexpected reaction (e.g, of a work step or a function). 7 Indicates information with moce details o tips. » Indicates the result of a testing step. wi Indicates a voltage measurement, iA Indicates a current measurement, a Indicates a resistance measurement. The typographical formats used in this document are explained below. Proprietary name Indicates @ proprietary name. Name? Indicates a protected name. Brand™ Indicates a brand available on the open market. Undertined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 + SAFETY ADVICE 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 ate 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 to lead to fatal or serious injury if the appropriate measures are not taken. Caution 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, Wi @ FRE tats cane tat wi eat tenement dae te anmprate meas ae ot ake, ‘Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring mounter (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. Where thread lockers are used on screw connections (e.g., Locite®), follow the instructions for use from the manufacturer. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Following repairs or servicing, the vehicle must be checked for roadworthiness.3 > IMPORTANT NOTES 8 Bh Warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. No warranty claims can be con- sidered for damage resulting from manipulations andior alterations to the vehicle. Additional information on the manufacturer or implied warranty and the procedures involved can be found in the service & warranty booklet. Warning Environmental hazard Improper handling of fuel is @ danger to the environment, = Do not allow fuel to enter the groundwater, the sol, 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:/iwav.ktm.com The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis- assemble the component to perform the activity in question. Please follow the instructions in the text.4 SERIAL NUMBERS 9 4oz294.10) 40217410) aozi74.10) 402298-11 “The chassis number @ is stamped on the bottom right of the frame behind the steer ing head. ‘The chassis number is also shown on the type label. (Super Adventure EU/FR/AU/P/CN) ‘The type label @ is on the top right of the frame behind the steering head. (Super Adventure US) Type label USA @ is affixed tothe frame behind te steering head atthe top right (Super Adventure US) “ype label Canada @ is affixed to the frame behind the stering head atthe top tet ‘The key number Gode number @ can be found on the KEYCODECARD. i Into You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions. 40224010)4 — SERIAL NUMBERS 1 The engine number @ is stamped onthe rigt side ofthe engine. ‘402296.10| ‘The frk part number @ is stamped on the inner side ofthe fork stub 20229510 “The shock absorber article number @ is marked ona sicker onthe shock absorber case under the spring 6229120 Steering camper item number @ is embossed on the underside ofthe steering camper5 MOTORCYCLE n Note Danger of damage The parked vehicle can roll away ofall over. = Park the vehicle on a firm and level surface. Preparatory work = Raise the motorcycle with the rear lifting gear. (®* p. 11) Remove the bottom triple clamp cover. (= p. 93), Main work = Mave the handlebar to the straight-ahead position. = Attach the front lifting gear with the adapters on the steering stem. Mounting pin (69329965030) (= p. 353) Lifting gear, front (69329965000) ("= p. 352) = Align the front lifting gear with the fork legs. © Info 310661-10] TH Always raise the motorcycle at the rear first. = Raise the motorcycle atthe front. Note Danger of damage The parked vehicle can roll away offal over. = Park the vehicle on a firm and level surface Main work = Secure the motorcycle against falling over. = Remove the front lifting gear. 310661-10) Finishing work Install the bottom triple clamp cover. (= p. 93) Note Danger of damage The parked vehicle can roll away or fall over. ~ Park the vehicle on a firm and level surface, = Mount iting bushings on the swingarm. e Insert the adapter in the rear lifting gear. Retaining adapter (61029956144) (= p. 348) Lifting pear, rear (69329956000) (7 p. 352) = Place the motorcycle vertically, use the adapters to direct the lifting gear towards a the swingarm and lft the motorcycle. 310660-105 MOTORCYCLE 12 Note Danger of damage The parked vehicle can roll away o fall over. = Park the vehicle on a firm and level surface. = Secure the motorcycle against falling over. ~ Remove the rear lifting gear and lean the motorcycle on the side stand @. = Remove the lifting bushings from the swingarm. SoS 4092029.10] Note Danger of damage The parked vehicle can roll away or fall over. — Park the vehicle on a firm and level surface Note Material damage Damage and destruction of components from excessive load. = The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when itis resting, (on the center stand. The center stand or the frame may become damaged and the motorcycle may fall over. = Pall the motorcycle up onto the center stand at the grab handles. = Stand to the et ofthe vehicle. = Hold the handlebar with your lft hand and push the center stand onto the ground with your right foot ~ Putyourentie weight on arm @ ofthe center stan while pulling the vehicle up at the let grab hale @) 7 The center stand is folded out to the stop. 202032210] Note Danger of damage The parked vehicle can roll away or fall over. — Park the vehicle on a firm and level surface = Make sure that the steering is unlocked. Move the vehicle forward with both hands on the handlebar. While the vehicle tips off of the center stand, activate the front brake to stop the vehicle from rolling away. ~ Check that the center stand @ is folded all the way up. ©) 20203310)5 MOTORCYCLE 13 BT Sang Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. — Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing, — Never operate the vehicle with a discharged battery or without a battery Note Engine damage High rewing speed with a cold engine negatively impacts the lifespan of the engine = Always run the engine warm at a low speed. = Press the emergency OFF switch to the position ON ©. = Switch on the ignition by turning the black ignition key to the position ON O. 7 After you switch on the ignition, you can hear the fuel pump working for about a ‘two seconds, The function check of the combination instrument is run at the 5 same time. ‘7 The ABS lamp lights up and goes back out after starting of = Shift the transmission to idle U 7 The green idling speed indicator lamp Il lights up. y = Press the electric starter button ©, ‘® Info To not press the electric starter button until the combination instrument function check is finished. When starting, B0 NOT open the throttle. If you open the throttle during the starting procedure, fuel isnot injected by the engine management system and the engine cannot start Press the electric starter button © for at most § seconds. Wait for a least 8 seconds before trying again. This motorcycle is equipped with a safety starting system. You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged. Ifthe side stand is folded out and you shift into gear, the engine stops. M00829-01 = Remove the motorcycle from the center stand or side stand, Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. = Use an effective exhaust extraction system when starting or running the engine in an enclosed space. © Info Press the starter for a maximum of 5 seconds. Wait for a least § seconds before trying again. Press the emergency OFF switch to the position ONO. = Switen on the ignition by turning the black ignition key to the position ON ©. = Shift the transmission to idle Hl || ®| F= Td not open the throttle, 0078210)6 FORK, TRIPLE CLAMP 14 Preparatory work Raise the vehicle with the center stand. (= p, 12) = Remove the front fender. (2 p. 94) Main work = Push dust boots @ of both fork legs downward Info TL The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is ‘not removed, the oil seals behind can start to leak, Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oll and grease. — Clean the brake discs with brake cleaner when necessary. Clean and oll the dust boots and inner fork tubes of both fork legs. Universal oll spray (© p. 341) ~ Press dust boots @ back into ther installation position. = Remove excess cil Finishing work = Install the front fender. (02 p. 94) = Remove the vehicle from the center stand. (* p. 12) Preparatory work Raise the vehicle with the center stand. (= p. 12) = Clamp down the rear of the vehicle, Remove the front fender. (= p. 94) = Remove the front wheel. (=* p. 99) = Remove the bottom triple clamp cover. (=! p. 93), Main work = Detach connectors @ and @. s6 FORK, TRIPLE CLAMP 15 = Loosen screws @ ofthe lover triple clamp. ~ Remove screw @ of the steering darmper, = Loosen serew @ of the steering damper clamp. = Loosen screws @ of the lower triple clamp. ~ Loosen screws ( ofthe upper triple clamp. = Remove the fork legs fom the bottom Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. = Following modifications, ride slowly at fist to get the feel of the new ride behavior. Main work = Slide the left-hand fork leg into the triple clamps and the steering damper clamp. ‘7 The left-hand fork leg has a white connector; the right-hand fork leg has a red connector 7 The connector faces forward at an angle toward the center of the vehicle. = Push the right fork leg into the triple clamps. 7 The left-hand fork leg has a white connector; the right-hand fork leg has a red connector, 7 The connector faces forward at an angle toward the center of the vehicle. ~ Align the fork legs inthe specified position by means of fork rings @ Guideline Upper tiple clamp Tish with 2nd rng 0 Tork eas.6 FORK, TRIPLE CLAMP 16 = Tighten screws @ of the upper triple clamp. Guideline Seren, op tiple clamp we 20 Nm (148 Wor ~ Tighten screws @ of the lower triple clamp. Guideline Seren, bottom tiple lamp we T2Nm GSI 1078541 ~ Tighten screws @ of the lower triple clamp. Guideline Seren, bottom tiple lamp we 12m GIR) = Alig the steering damper clamp tothe loner triple clamp. Guidetine The clamp i aligned withthe contour ofthe ower tiple lamp and Wes on top of the loner triple lam ~ Tighten screw @ Guideline Screw, steering damper damp we T2Nm GS TOFD = Position the steering damper. = Mount and tighten serew @ Guideline Screw, steering damper | MB 25 Nm Loctite® 243 (18.4 tof ft) ~ Plug in connectors @ and @. fs10787-11 Finishing work Install the bottom triple clamp cover. (© p. 93) Install the front wheel. (= p. 100) Install the front fender. (Pp. 94) Condition ‘The fork legs have been removed.6 FORK, TRIPLE CLAMP 7 A A co <@ mai) 0 = "xe 0000 00 @_ 0000 00 @ 03057.01 Disassemble the fork legs. (= p. 17) = Remove the spring. (= p. 19) = Check the fork legs. (28 p. 20) = Install the spring, (© p. 19) = Assemble the fork legs. (# p. 21) ‘These operations are the same on both fork legs. P| @ f202002-01 Condition ‘The fork legs have been removed. = Clamp the fork leg in the area of the lower triple clamp. ‘Clamping stand (714035) p. 357) ~ Release screw cover @ with special tool @. ‘Special socket (T14071) ("© p. 357) © Info T_The screw cover cannot be removed. = Unclamp the fork, Drain the fork ol. = Remove cartridge screw @ with the washer.6 FORK, TRIPLE CLAMP 02002-01 2o2115:12 202108-12| 2oei16-11 ANA >), — Remove the cartridge, = Remove dust boot @. = Remove lock ring Info The lock ring has @ beveled end where a screwdriver can be applied. ~ Heat up the outer tube in area ofthe lower siding bushings Guideline 50°C (122 °F Pull the outer tube from the inner tube with a jerk Info T the tower sliding bushing @ must be pulled from its bearing seat. = Remove the upper sliding bushing @. © Info T without using a toot, carefully pull the stack apart by hand. 202108-11 ~ Take off the lower sing bushing @ — Take off support ring @. = Take off seal ring @. = Takeoff look ing @. ~ Take off dust boot @. = Unclamp the fork leg.6 FORK, TRIPLE CLAMP 19 ‘These operations only apply to the left fork le, I it Preparatory work = Disassemble the fork legs. (= p. 17) Main work = Clamp the cartridge into a vise. Clamping stand (TIA0T5S) (= p 356) ~ Hold nut securely and loosen threaded bushing @ with special oo Fin wench (103) (= p. 366) = Remove threaded bushing @. ~ Pull the spring down and remove nut @) withthe washer. ~ Remove spring ide @ with preload spacer @ = Remove the spring. Unclamp the cartridge. ‘These work steps only apply to the lett fork leg. — 0301410) 03006-10 = Observe the installation position ofthe springs. Y Tight coil @ points toward the spring guide. = Clamp the cartridge into a vise. Clamping stand (TIAOTES)(™ p. 366) = Position the spring. ~ Postion spring guide @ with preload spacer @. ~ Pullthe spring down and mount nut @) with the washer, Serew te nut al the way down.