CaO REPAIR MANUAL 2017 125 Duke Art. no. 3206293enRead this tepair manual carefully and thoroughly before beginning work ‘The vehicle will only be able to meet the demands placed an it if the specified service work is performed regularly and propery 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 atthe 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 thatthe 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, et., without prior notice ‘and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular ‘made! without prior notice. KTM accepts no liailty for delivery options, deviations from figures and descriptions, misprints, and other errors. The mode's portrayed partly contain special equipment that does not belong to the regular scope of supply. © 2018 KTM Sportmotorcyele GmbH, Mattighofen Austria Al rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only withthe express written permission of the copyright owner. 180 9001112 100 6061) ‘According to the international quality management standard ISO 9001, KTM uses quality assur ance processes that lead to the maximum possible quality of the products. Issued by- TOV Management Service Tov’ KTM Sportmotoreycle GmbH Stallhofnerstrabe 2 5230 Matlighofen, Austria This document is valid for the following models: 125 Duke EU (F400301, F400302, F400303, F400304) 32062936" oveoisMEANS OF REPRESENTATION 7 1.1 Symbols used 7 1.2 Formats used. 7 SAFETY ADVICE, 8 2.1 Repair Manual. 8 22 — Safety advice... | 23° Degrees of risk and Symbols wescsonone 8 2.4 Work ules. 8 IMPORTANT NOTES. 9 3.1 Manufacturer and implied warranty... 9 3.2 Operating and auxiliary substances... 9 3.3 Spare parts, accessories 9 34 Figures 9 SERIAL NUMBERS 7 10 4.1 Chassis number... 10 42 Type label 43° Key number. 44 Engine number... MoToRCYCLE, u 5.1 Raising the motoreycle with the rear liting gear won M1 5.2 Removing the rear of the motoreyele ‘rom the lifting gear... u 5.3 Lifting the motoreycle with the front litting gear aot 5.44 Taking the motoryele of the front lifting gear 12 5.5. Raising the motorcycle withthe work St0N0 2 5.6 Removing the merece from the work stand... soe 1B 87 Starting... 4 5.8 Stating the motoreyee to make ‘checks 15 FORK, TRIPLE CLAMP cscs 16 6.1 Cleaning the dust boots of the fork Ne es “ 16 6.2 Removing the fork legs. 16 6.3 Installing the fork legs. rece AT 64 Disassembling the fork Ieg5...n.n. 19 6.5 Checking the fork legs.. vo 21 66 Assembling the fork legs. 22 6.7 Removing the lower triple clamp..on.. 24 68 Installing the lower triple clamp... 26 69 Checking the play of the steering head bearing 23 6.10 Adjusting the steering head bearing play 30 6.11 Changing the steering head bearing... 31 10 u 2 HANDLEBAR, CONTROLS, 33 7A Checking the playin the throttle cable. si 33 7.2 Adjusting the play inthe throttle BIE nnn son 33 7.3. Checking the clutch lever play.---- 33 7.4 Adjusting play in the clutch lever... 34 FRAME . 36 8.1 Changing footrest brackets... 8.2 Checking the frame... SHOCK ABSORBER, SWINGARM 9.1 Measuring the rear wheel dimension unloaded. a 9.2 Checking the static sag of the shock absorber. 41 9.3 Adjusting the spring preload of the SHOCK ABSORDET nn 9.4 Checking the heim joint for play... 9.5 Removing the shock absorber. 9.6 Installing the shock absorber 9.7 Removing the spring. 9.8 Installing the spring... 9.9 Checking the swingarm 9.10 Removing the swingarm. 9.11 Installing the swingarm, 9.12 Checking the swingarm bearing for PY er 82 9.13 Changing the swingarm bearing wnnnne 53 EXHAUST. cuntnnnnnninnnnnsnnnes SP 10.1 Removing the exhaust system. 10.2 Installing the exhaust system 10.3. Removing the main silencer: 10.4 Installing the main silencer. AIR FILTER 111 Changing the a iter, leaning the FUEL TANK, SEAT, TRIM sen 12a 122 123 124 12.5 126 127 128 129 12.10 i241 1212 air filler box. £ Opening the filer cap... Closing the filer cap “ Removing the front riders seat Mounting the front rider's seat Removing the passenger seat Mounting the passenger seat, Removing the fuel tank cover Installing the fuel tank cover, Removing the fuel tank Installing the fuel t20K se. Removing the front spoiler 73 Fitting front spoiler RSsa13 4 16 12.13 Removing front fender 12.14 Installing front fender... 12.15 Checking the fuel pressure. 12.16 Changing the fuel filter 12.17 Changing the fuel pump... WHEELS 13 132 133 134 13 Checking the tire condition Checking the brake discs... Front wheel 1 Removing the front whee! . 13.4.2 Installing the front whee! 13.4.3 Changing the front brake disc 13.4.4 Changing front whee! bearing 13.4.5 Checking the wheel bearing for Play’ 13.5 Rear wheel 1351 13.52 1353 13.5.4 Changing the rear wheel bearing... 13.5.5 Checking the chain tension 13.5.6 Adjusting the chain tension 13.5.7 Checking the chain, rear Sprocket, and engine sprocket... 13.5.8 Cleaning the enain. 185.9 Cheeing the rear ub ubear damper... . i 13.5.10 Opening the chain 13.45.11 Riveting the chain. 13.5.12 Changing the drivetrain kt WIRING HARNESS, BATTERY... 14a 142 143 Removing the battery Installing the battery. ' Disconnecting the negative cable ofthe battery Senneting te negative cable ot the battery soi Recharging the baer Checking the charging voltage Checking the open-circuit current Changing the fuses of individual power consumers. BRAKE SYSTEM. 18.1 152 183 4a 145 46 147 438 Checking the brake fluid level of the font bra... . Adding front brake id Changing the front brake fluid 16.4 155 186 187 (Checking the tire ai pressURe. nn ~ 100 108 Checking the front brake linings... Changing the front brake linings... (Checking the rear brake linings... Changing the rear brake linings... ” 75 75 7 78 80 80 80 81 82 82 aa 4 86 a7 39 90 94 95 95 97 98 99 99 103 104 104 105 105 106 107 107 108 109 109 soe 2 112 na 6 6 16 15.8 Checking the free travel of foot brake lever ng 15.9. Adjusting the free travel of the foot brake lever 19 15.10 Checking the rear brake fluid level 120 18.11 Adding rear brake fluid. 121 15.12 Changing the rear beake fluid 122 COMBINATION INSTRUMENT 125 16.1 Combination instrument. 125 16.2 Activation and 16S on 125, 16.3. Day Night mode. 125, 16.4 Waring notes... 126 16.5 Indicator lamps. 126 16.6 Display 127 16.7 Speed nnennnnne 128 16.8 Shift warming light oo. 128, 16.9 Speed. 129 16.10 000 display z 129 416.11 Coolant temperature Indiator sn 129 16.12 Fuel lev! display 130 16.13 Time sii 130 16.14 Favourites display. 130 16.15 Quick Selector 1 display. 131 16.16 Quick Selector 2 display. 131 16.17 Menu. 131 16.17.1_ KTM MY RIDE (optional. 131 16.172 Into. 132 1617.3 Motorcycle. 132 16.174 Settings... 132 1617.5. Preferences.. 133 16.17.6 Pairing (optional) 133 1617.7 Audio (optional)... 134 16.178 Telephony (optional) 134 16.17.9 General Info 135 16.17.10 Trip 1 135 16.17.11 Tep2. 135 16.17.12 Warning... 136 16.17.13 ABS. - 136 16.17.14 Favourites. so 137 16.17.15 Quick Selector 1 137 16.17.16 Quick Selector 2 137 16.17.17 Bluetooth, 138, 16.17.18 Shift Light. 138 16.17.19 Setting the time and date 138 16.17.20 DRL 139 16.17.21 Distance .. 140 16.17.22 Temperature, 140 16.17.23 Fuel Cons. ui 16.17.24 Language 141 16.17.25 Service i 16.17.26 Extra Functions on uiv7 18 16.18 Setting the service interval display LIGHTING SYSTEM, INSTRUMENTS 17.1 Daytime running light (ORD. 17.2 Checking the headlight setting . 17.3. Adjusting the headlight range.. ENGINE 18.1 Removing the engine... 18.2 _ Installing the engine 18.3 _ Engine disassembly. 18.3.1 preparations. 18.3.2 Draining he engine oi. 18.3.3. Removing the chain securing guide... Removing the valve cover Removing the spark plug Removing the clutch cover Setting the engine to ignition top dead center Removing the starter motor. Removing the timing chain tensioner Removing the camshaft Removing the cylinder head Removing the piston Removing the water pump wheel. Removing the alternator cover Removing the roto. Removing the starter drive. Removing the drive wel of the balancer shaft Removing the gear position sensor. Removing the spacer. Removing the clutch basket... Removing the primary gear. Removing the oil pump Removing the shift shaft Removing the shift drum locating Removing the locking lever Removing the oil iter... left engine case, removing Removing the sift rails. Remeving the shift drum Removing the shift forks. Removing the transmission shatts.. Removing the balancer shat. Removing the crankshatt 18.3.4 18.35 18.3.6 18.37 18.3.8 13.39 183.10 183.11 18.312 18.3.13 18.314 183.15 18.3.16 18.3.17 18.3.18 183.19 18.3.20 18.3.21 18.322 18.3.23 183.24 18.3.25 18.3.26 18.327 18.3.28 183.29 18.3.30 18.3.3) 18.3.2 18.3.33 142 143 143 143 14d 145 145 150 157 157 157 187 158 158 158 159 159 160 160 161 161 . 162 . 163 163 164 165 166 166 167 168 168 169 . 169 169 170 170 im 172 172 172 172 173 18.4 Working on individual parts 173 18.4.1 Working on the lft section of the engine case... oo IB 18.4.2 Werk on the right section of the engine case. 174 18.4.3 Changing the shaft seal tinge the water PUMP sn 178 18.4.4 Removing the main bearing... 175 18.4.5 Checking the racial play of the lower contod beating ....nnme 176 18.4.6 Changing the conrod bearing... 177 18.4.7 Changing the balancer shaft bearing. 19 18.4.8 Changing the camshaft bearing... 180 18.4.9 Work on the cylinder head... 181 18.4.1 Checking the cylinder Mead... 182 184.11 Checkingheasuring the eylinder sow 182 184.12. Checking the piston ring end BAP rn vs 183 184.13 Checkingimeasuring the piston... 183 18.4.14 Checking the piston/cylinder mounting Clearancesnnnene 184 184.15 Checking the oil pump 134 18.4.16 Checking the oll pressure regulator valve. 125 18.4.7 Checking the lute ecurnnne 186 18.4.18 Preassembling the clutch... 187 18.4.19 Checking the shift mechanism... 188 18.4.20 reassembling the shift shaft... 189 18.4.21 Disassembling the main shaft... 189 18.4.2 Disassembling the counters nn 190 18.4.23 Checking the transmission ...... 191 18.4.24 Assembling the main shaft... 192 18.4.25 Assembling the countershatt.... 193 18.4.26 Checking the timing assembly... 194 18.4.27 Changing the stt0rmenncmnee 195 18.4.28 Checking the electric starter drive... i 196 184.29. freenieel, checking v0 197 18.5 Engine assembly 197 18.5.1 Installing the crankshaft nue 197 18.5.2 Installing the balancer shaft... 197 18.5.3 Installing the transmission shafts. 198 18.5.4 Installing the shift Fork... 198 18.5.5 Installing the shift drum 199 18.5.6 Installing the shift rails 18.5.7 Installing the left engine case . 18.5.8 Installing the ol itr. 18.5.9 Installing the locking ever... 201 18.5.10 Installing the sift crum locating 201 18.5.1 Installing the shift shaft neue 202185.12 Installing the oll pump. 202 23.3 Checking the engine oil pressure... 241 16.5.13 Inetaling the primary gear... 203 «23.4 Changing te engine ci an oil 18.5.14 Installing the clutch basket... 203 filter leaning the of See. 283 18.5.15 Installing the spacer. 208 23.5. Adding ENGINED sensnanenrrrn 244 18.5.16 gear poston sensor, instaling... 205 > GNITION SYSTEM... 246 185.17 Insalng the balancer shat drive whee 205 24.1. cackig te stat 18.5.18 Installing the starter drive......... 206 winding. 246 185.19 Instalng the rotor 207 24.2. Changing the sparkplug. 248 18.5.20 atterator cover, istling vss 208 25 THROTTLE VALVE BODY ooseocs-o--.-. 250 25.521 _Insling the water pum Gee cenam 208 25.1 _Adljstng service intrval display 185.22 Installing the piston 209 ‘with KTM diagnostics tool . vee 250 16.5.23 Instaling ejinder Meads. 211 26. TECHNICAL O4TA Ei 18.5.28 Installing the camshafts ae . 18.5.25 Installing the timing chain igine ~ senslenet = aia 26.2. Tolerance, engine wear limits... 252 185.26 Checking the valve clearance... 213 26.3 Engine tightening torques 252 185.27 Adjusting the valve clearance... 214 26.4 Capacities .asnnnnnennnnnsenine 254 18.5.28 Installing the starter motor... 214 26.4.1 Engine oll 254 18.5.29 Installing the clutch cover 215 26.4.2 Coolant... sane 254 18.5.30 Installing the spark plug 215 2643 FUel sens 254 18.5.31 Installing the vahe cover ses 215 26:5 CHASSIS on : 254 18.5.32 Installing the chain securing 26.6 Electrical system.......... 255 se 216 266.1 Diagnostics connector 255 18.5.33 Installing the il screens. 216 26.6.2 _ Front ACC and ACC2 256 18.5:34 engine, removing fom the 256 ‘engine assembly stand. 27 : 256 26.9. Shock absorber 256 CLUTCH so 0 218 26.10 Chassis tightening torques ............ 256 221 Chectngthe etch nuononnne 218 95 QLeANINGPROTECTIVE TREATMENT. 260 SHIRT MEGHAN Mn =a 27.1 Cleaning the motorcycle .. 260 20.1 Adjusting te shift everson 223 27.2 Cheeks and maintenance steps fr WATER PUMP, COOLING SYSTEM. 224 winter operation. 261 21.1 Draining the Coolant... 224 28) RIORAGE: a ee) 212 Filingbeeding the cooling 28.1 Storage 262 sysiem 224 26.2. Prepating for vse after storage... 263 21.3. Checking the antieze and 29. SERVICE SCHEDULE a 264 214 Checking the coolant level 227 29.1 Additonal information 264 215 Changing the coolat..n.0mns 228 28.2 Required work... BBA CYLINDER HEAD 230 29.3 Recommended work 265 22.1 Checking valve clearance veces 230 30 WIRING DIAGRAM sal 22.2 Checking the valve clearance 30.1 Page 10f 9.. 266 changing the spark pugs 233 302 pees. ae 22.3 hcjusting the valve clesrance ns. 237303. Pane 301 Oa Bap 224 Camshafts, removing 238 30a pease ae 22.5. camshafts installing. 238308 Paneag on LUBRICATION SvSTEM 240-308 Page Gof 9 276 30.7 Page 7 of 9 : 278 =i Mane. «oe 30.8 Page 8 of 9. wiminaresiessersenveniee SEE 23.2 Checking the engin ll levels 240309 Prog eda 2 3 34 35 36 ar INDEX... SUBSTANCES 24 AUXILIARY SUBSTANCES .o..0.ssnsnonnn 286 SPECIAL TOOLS 288 STANDARDS 7 INDEX OF SPECIAL TERMS... LIST OF ABBREVIATIONS LIST OF SYMBOLS. 27.1 Red symbols. . 37.2 Yellow and orange symbols. 308 37.3 Green and blue SyMBOIS..urnn 306‘The meaning of specific symbols is described below. V Tndicates an expected reaction (eg. ofa work step ara function) x Indicates an unexpected reaction (eg. of a work step or @ function). Indicates a page reference (more information is provided on the specified page) i Indicates information with more detalls or tips. Indicates the result ofa testing step. Indicates a voltage measurement. Indicates a resistance measurement. in Indicates a current measurement, Indicates the end of an activity including potential rework, “The typographical formats used inthis document are explained below. Proprietary name Indicates a proprietary name. Name® Indicates a protected name. Brana Indicates @ brand available on the open market. Undertined terme Reter to technical details of the vehicle or indicate technical terms, whieh are explained in the glossary.Read this Repair Manual carefully and thoroughly before beginning work, It contains useful information and tips that will help you repair and maintain your vehicte This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are anilable. ‘A numberof safety instructions need to be followed to operate the product described safely. Therefore ead this, instruction and all further instructions included carefully. The safety instructions ate highlighted in the text and are referred to atthe relevant passages. = Info Various information and warning labels are attached in prominent locations on the product described. Do ‘not remove any information or warning labels. If they are missing, you or others may not recognize dangers ‘and may therefore be injured Danger nw Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identities @ danger that is likely to lead to fatal or serious injury i the appropriate measures are not taken, A ation Identities @ danger that may lead to minor injuries ifthe appropriate measures are not taken. Note Identities @ danger that will lead to considerable machine and material damage if the appropriate measures are not taken, Note Indicates @ danger that wil lead to environmental damage if the appropriate measures are not taken. ‘Special tools are necessary for certain tasks. The tools are not @ component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000) During assembly, use new pats to replace parts which cannot be reused (e.g, sel-locking screws and nuts, seals, sealing rings, O-rings, pins, and lock washers). Inthe case of certain screws, a thread locker (e.g. Lactte®) is required. Apply according to the manufacturer's instructions, Aer disassembly, clean the parts that ae to be reused and check them for damage and wear. Change damaged ‘or worn parts. ‘After completing a repair or service work, check the operating safety ofthe vehicle‘The work specified in the service schedule may only be performed in an authorized KTM workshop and must be tecorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with andor conversions on the vehicle are not ‘covered by the warranty. ‘Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Sewvice & Warranty Booklet, Note Environmental hazard improper handling of fuel is @ danger tothe environment. = Dornot allow fuel to enter the groundwater, the soll or the sewage system. Use the operating and auxiliary substances (such as {uel and lubricants) as specified in the manual ‘Only use spate parts and accessories approved andor recommended by KTM. KTM accepts no liability for other products and any resulting damage oF loss. “The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http-/vwwktm.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. Its not always necessary to disassemble the component to perform the actvily in question. Please follow the instructions Inthe test.‘The chassis number @ is stamped on the right side of the steer- ing head The type label @ is on the right of the frame behind the steering, head. ‘The key umber @ canbe fund on the KEYCODECARD. Into T You need the key number to order a spare key. Keep the KEYEODECARD ina sate place ‘The engine number @ is stamped on the lft side of the engine Lnder the engine sprocket 10MOTORCYCLE 5 5.1 Raising the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle can roll away ofall over. = Park the vehicle on a firm and level surface ~ Mount the supports of the lifting gear. — Insert the adapter in the rear lifting gear Universal V adapter with bushings (61029955244) (a8 p. 292) Rear wheel work stand (69329955000) (= p. 293) — Stand the motorcycle upright, align the lifting gear withthe ‘swingarm and the adapters, and lit the motorcycle. “amcor < 5.2 Removing the rear of the motorcycle from the lifting gear Note Danger of damage The parked vehicle can roll away ofall over. = Pak the vehicle on a firm and level surface Secure the motorcycle against falling over. — Remove the rear iting gear and lean the vehicle on side stand @ = Remove bushings kit < 5.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fll over. = Park the vehicle on a firm and level surface Preparatory work = Raise the motoreycle withthe rear iting gear. (©* p. 11) Condition — Remove protection cap @. u= oe dete shah tn, Pon Tg a TROT AT nN Fe a oH ROROOT TS i A im : ‘Note a = ame te eine = Mount protection cap @. rae wot : Note Danger of damage The parked vehicle can rll away or fall over. = Park the vehicte on a firm and level surface.MOTORCYCLE 5 ~ Remove scons @ and @. = Screw in the special too! holder all the way. Select the right height and with of the work stand. Wark stand (62529086100) = Raise the motoreyce, 93) e Info CCheck thatthe work stand is propey seated. reoss70 « Note Danger of damage The parked vehicle can roll away ofall over. = Park the vehicle on a firm and level surface. ~ Secure the motorcycle against falling over. = Remove the special tool Wark stand (62529055100) (= p. 293) ~ Mount and tighten screws @ and @. Guideline Seren, engine bearer [WB 22m 162 BIT a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 stating or running the engine in an enclosed space. A nution Danger of accidents Electronic components and safety devices will be damaged ifthe battery is discharged or missing. = Never operate the vehicle with a discharged battery or without a battery. Note Engine damage Unfiltered intake air has a negative effect on the service life ofthe engin Dust and dirt wil enter the engine without an air filter. — Never start to use the vehicle without an air filter. Note Engine damage High rewing speed with 2 cold engine negatively impacts the lifespan of the engine. = Always run the engine warm at a low speed. = Unlock the steering = Si on the vehicle, take the weight off of the side stand, and ‘move up all the way. = Tutte onepney OFF sich oe pesto © Q ® atch on he pon by urig the ton ey othe pas toed 7 After you switet on the ignition, you can hear the fuel pump working for about two seconds. The function check 0078210 ofthe combination instrument is run at the same time, = Shift gear to neutral. ‘ Thegreen idle indicator lamp W lights up. The ABS indicator amp lights up and goes back out after starting of, = Press the electric starter button ©. Info Do not press the electric starter button until the combi ration instrument function check is finished. ‘When starting, DO NOT open the throttle. Ifyou open the throttle during the starting procedure, fue is nat Injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds betore tying again, ‘This motoreycl is equipped with a safety stating sys tem. You can only start the engine ifthe transmission is in neutral or ifthe clutch lever is pulled when a gear is engaged. Ifthe side stand is folded out and you shift into gear and release the clutch, the engine stops. 4Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death, = Always make sute there is sufficient ventilation when running the engine, = Use an effective exhaust extraction system when stating or running the engine in an enclosed space. Info Tress the starter for a maximum of 5 seconds. Wait fora least 5 seconds before trying again. © wy ‘Turn the emergency OFF switch tothe position ©. Shift gear to neutral. Switch on the ignition by turnin the ignition key to the post- tion 0, Press the electric starter button Info Do net open the throttle. 186 FORK, TRIPLE CLAMP 6.1 Cleaning the dust boots of the fork legs 6.2 Removing the fork legs Preparatory wrk = Rais the metoreyele with the rearing gear. (© p. 11) = Lift the motorcycle with the tont iting gear. © p. 11) Min work Push dust boots @ ofboth fork legs downward Info The dust boots should remove dust and coarse dirt par ticles tram the fork tubes. Over time, art can accumu: late behind the dust boots. If this dit is not removed, the cil seals behind can start to leak A Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when nec- essary. = Clean and oll the dust boots and inner fork tubes of bath fork leas. Universal ol spray (2p. 287) ~ Press the dust boots back into their installation postion = Remove excess oll Finishing work = Take the motorcycle off the front lifting gear. (E® p. 12) = Remove the rear of the motorcycle from the lifting gear. (mp. reparatry work = Raise the motoreycle with the work stand, (© p. 12) = Clamp don the rear of the vehicle ~ Remove font fender. (2! p. 74) Main work = Remove screw @ = Remove the cable te(s). ~ Pull the whee! speed sensor out ofthe hole and hang tothe side, 16FORK, TRIPLE CLAMP 6 = Remove screws @. = Press back the brake linings with a light lateral titing of the brake caliper on the brake dise, Pull the brake caliper carefully back from the brake disc and hang it to one side Info Hoot operate the hand brake lever when the brake caliper is removed, 7 = Loosen serew @ by several rotations. Loosen screws @. ~ Presson screw @ to sh the whee! spindle out of the axle clamp. ~ Remove screw @. A wearing Danger of accidents Reduced braking effect caused by damaged broke dises. = Always lay the wheel down in such a way thatthe brake discs are not damaged. = Holding the front wheel, withdraw the wheel spinle, Take the ‘ont wheel out ofthe fork ~ Leceen serene @. Remove the fork legs from the bottom, /e e- 6.3 _ Installing the fork legs A Werine Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris- tie. = Ride slowly to start with ater making adjustments to get the feel of the new handling characteristic. Main work = Pus the fork legs into the tiple clamps. Align the fork legs in the required position using the fork rings. p ”6 FORK, TRIPLE CLAMP Teen srevs @ Guidetine ‘Screw, top tiple | NB clamp TS Nm G11 br Tighten serews @ Guidetine ‘Screw, botiom tiple | MB clamp 12 Nin 6.9 wr) ‘heck the whee! bearing for damage and wear 2 If the whee bearing is damaged or worn: = Change front whee bearing. (3 p. 84) ‘lean and grease shaft seal rings @) and contact surfaces @ ofthe spacers Tong life grease (Wp. 286) Insert the spacers, ‘Clean the thread of the wheel spindle and screw @. (Clean and grease wheel spindle, Tongife grease (Ep. 286), Position the front wheel and insert the wheel spindle Mount and tighten serew @. Guideline ‘Screw, front wheel | MB spindle 25 Nm (18.4 Ib) Pesiton the brake caliper and check that the brake linings are seated coecty Mount serens @ but donot tighten yt. Operate the hand brake lever repateay uti the bake lin- ings ae in contact withthe brake dic and there i a pressure Doin Fc the hand brake lever in the activates postin, Tho brake caliper straights Tighten screws @. Guideline Screw, ont] WB BO Win 221 AI brake caliper Loctite 204m Remeve the leckng piece ofthe Rand brake lever Peston whee speed sensor inthe dil hol. Mount and tighten stew @. Guidetine ‘Screw, wheel speed] ME sensor holder Nm 6.9 oF Route the cable and secure with cable te(s). 18FORK, TRIPLE CLAMP 6 = Remove the load from the rear ofthe vehicle = Operate the front brake and compress the fork a fw times fil. 7 The fork tog strlghten ~ Tighten screws @ Guideline ([Serew, onestub [WS TSNimdLs BIR Finishing work — Remove the motorcycle from the work stand. (® p. 13) ~ Install front fender. (2p. 78) 6.4 Disassembling the fork legs Info TThe operations are the same on both fork legs. Condition The fork legs have been removed, Clamp the fork leg in the atea ofthe loner triple clamp. eo Clamping stand (T6125) p. 302) | ~ team term conr @ © Info The screw cover cannot be removed yet. ~ _Unclamp the for le. = Drain the fark ol ~_ Unclamp the fork eg with the ane elamp, ‘® Info Use sot jaws, ~ Remove carvidge sren @ with the washer. Info H Fiace a container underneath as oll will run out in mast 196 FORK, TRIPLE CLAMP Remove the cartridge. Remove dust boot @ Remove lock ring @. Info “The lock ring has a beveled end where a screwdriver can be applied Warm up the auter tute in area @ ofthe lever siding bush ing Guidetine 50°C 1207) Pll the outer tube from the inner tube with a jerk Info Tower sliding bushing @ must be pulled trom its bear- ing seat Remove uper sing bushing @ Info ‘Without using tool, pul the stack slightly apart by hand Take off lower sliding bushing @. Toke off support ring @ Tako off eal ing @ Tek of lock ing @ Takeoff dust boot @ Unelamp te fork egCondition The fork legs have been disassembled. ‘Check the inner tube and the axle clamp for damage. > damage is founds = Change the inner tube, Measure the outside diameter of the inner tube in several places: External diameter of inner | 42.975 .. 43.005 mm tube (1.69193. 1.69311 in) Ifthe measured value is less than the specified value: = Change the inner tube, Measure the run-out ofthe inner tube, ps Run-out of inner tube *€0.20 mm (3 0.0079 in) » Ifthe measured value is greater than the specified value: 35 = Change the inner tube. = Check the outer tube for damage. >If damage is found: = Change the outer tube, = Check the surface ofthe sling bushings > tt the dark layer @ is worn of = Change the sing bushings. 21i™ The procedures are the same on both fork legs. E fe. Preparatory work = Check the fork legs. (© p. 21) Main work = Glamp the inner tube using the axle clamp. Guideline Use soft jaws Mount the special too. Protecting sleeve (7512) (Sp. 30D = Grease and push on dust boot Tubricant (714034) (Ep, 286) = Into HAtways change the dust boot, seal rng, lock ‘support rng, Mount the sealing lip a the bottom, = Pash on lock ing @ ~ crease and push on ea rng @ Tubvicant (714084) 1p. 286) 7 The sealing lip points downvard, the ope side upward. = Remove the special tol ~ Push on supporting @ = Sand the edges ofthe sliding bushings with 600-grit sandpa- per, then clean and grease them, Fork oil (SAE 4) (4860116681) (Bp. 285), = Push on lover sing busting @. = Mount upper siding bushing @ Info TD without using tool, pull the stack slightly apart by hand. ~ Heat up outer tube in area @ of the lower sliding bushings. Guideline ‘50°01122 7) = Hold the lower sliding bushing with the longer side ofthe spe- cial tool Mounting tool (T5288) (@ p. 302) Push on the outer tube. = Press the sting bushing all the way into the outer tube,= Position the support ring — Hold the soa ring with the shorto side of the special too. Mounting tool (TS28S) (& p. 302) — Press the seal ring and support ring all the way into the outer tube, = Mount ok ing @ Info The lock ring must engage audibly. = Mount dust boot @. = Slide the cartridge into the inner tube, ~ Mount and tighten cartridge serew @ with the washer Guideline Screw, cartridge [MI0x.5 | 25Nm(18.4 [bf ft)6 FORK, TRIPLE CLAMP = Clamp the left fork leg vertically: Guideline —. Use soft jaws = Fle with fork oi Fork ol a0 mi | Fork all SAE A) (15.21.02) | (4860116651) (8p. 285) * Info TAtter approx. att the oil capacity has been filled, close the screw cap ofthe outer tube, unclamp the frk and bounce a numberof times so that the cated fills with oil Then add the remaining amount. — Push the outer tube upward. = Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T6128) (© p. 302) ~ Grease the O-ring of the screw cover. Lubricant (7158) (© p, 286) ~ Mount ana tighten screw cap @ M47x1.5 ‘30 Nm (22.2 bf ft) Screw cap on outer tube 6.7 Removing the lower triple clamp Preparatory work =" Raise the motoreyle withthe work stand, (8 p. 12) = Clamp down the rear ofthe vehicle = Remove front fender. (3p. 74) = Remove the fork legs. ( p. 16) Main work = Remove srens @= Remove the upper triple lamp with the handlebar and set aside. Info Cover tne components to protect them against damage. = Take off cover ©. ~ Expose the cable, = Remove aut @ ‘Groove nut wrench (90129050100) (2! p. 297) = Take out the lower triple clamp with the steering tem, ~ Takeoff washer @. ~ Remove steering head bearing @® Main work = Clean the bearing and sealing elements, check for damage, and grease, High viscosity grease (© p. 286) ~ Mount upper steering head bearing @. ~ Moun washer @) itn he cut-out facing connor 26Alternative 1 ‘A new steeting head bearing is used. = Insert the lower triple clamp with the steering stem. = Mount and tighten nut @ Guideline Nut, steering head | M3Ox Ist stage 45 Nm (33.2 bt) 2nd stage (loosen, counterclockwise) 2 tums Sed stage 5.Nm (3.7 lot ft) ‘Groove nut wrench (90129050100) (& p. 297) Alternative 2 The stecring head bearing is used again, = Insert the lover triple clamp wth the steering stem. = Mount and tighten nut Guideline Nut, steering head _| M30xI Nm G7 iff) “Groove nut wrench (90128050100) (© p. 297) = Secure the cable in the bracket ~ Position cover @. = Position the upper triple clamp with the handlebar. ~ Mount screw @ but donot tighten yet Guldeline Screw, steering |MI6xL.5 | 49Nm(36.1 ibFfD he Loctite*243™Route the cable without tension and secure with cable ties. Position the headlight mask, Plug in connector @. Swivel the headlight mask up, ‘Mount and tighten screw @. Guideline Screw, head) M6 light mask Ti Nim @.1 FD Loatite®24a™ ‘Mount and tighten screws @ on both sides. Guideline Screw, head | M6 11 Nim @.1 WFD light mask Lootite?243™ Install the fork legs. = p.17) 2FORK, TRIPLE CLAMP 6 Loosen serous @ Using 2 plastic hammer, tap lightly onthe upper triple clamp to avid stesses. Tighten screw @. Guideline Screw, teeing [M165 [49 Nm 6.1 ir head, top Laoiter2a™ — Tighten screws @. Guideline Screw, top triple | WB 15 Nw GL WF clamp Finishing work = Check that the wiring harness, throttle cables, and brake line hhave the necessary freedom of movement and are correctly routed, Check the play of the steering head bearing. (tp. 29) = Remove the motoreyele trom the work stand. (22 p. 13) 6.9 Checking the play of the steering head bearing A Waring Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components = _Comect incorrect steering head bearing play immediately. © Info Tit the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. Preparatory work = Raise the motorcycle with the work stand, (2 p. 12) — Clamp down the rear ofthe vehicle, Main work = Move the handlebar tothe straight-ahead position, Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bearing. >If there is detectable pay: — Adjust the steering head bearing play. (£2 p. 30) = Move the handlebar to and fro over the entire steering range TTimust be possible to move the handlebar easly over the entire steering range. There should be no detectable detent positions, If detent positions are detected: Adjust the steering head bearing play. (© p. 30) — Check the steering head bearing and adjust if neces- say.6 FORK, TRIPLE CLAMP Finishing work = Remove the motoreycle from the work stand. (& p. 13) 6.10 Adjusting the steering head bearing play Preparatory work = Raise the motoreycle wth the work stand. (& p. 12) Main work = Loosen screws @. A ~ Loosen screw @. = Tighten nut © with the special too unt there sno play in the steering head bearing Holding wrench (90129051000) (&& p. 298) = Using a plastic hammer, tap lightly on the upper triple clamp 10 avo stresses. ~ Remove scm @. = Mount and tigen sew @. Guidetine ‘Screw, steering [MIGKL5 _]49Nm@6.l tT (ee head, top Loctite®243™ , °FORK, TRIPLE CLAMP 6 = Tgitenserews @ Guideline Serew, top Wiple [WS TEN GTI BW clamp Finishing work = Check the play ofthe steering head bearing. (8p. 28) ~ Remove the motorcycle from the werk stand. (& p, 13) 6.11 Changing the steering head bearing Preparatory work ~ Raise the motorcycle with the work stand, (© p, 12) = Clamp down the rear ofthe vehicle — Remove front fender. (£8 p. 74) ~ Remove the fork legs. (E8 p. 16) ~ Remove the loner tiple clamp. (8p. 24) in work Remove the lover bearing race @ using a suitable tool ~ Press in the new bearing ring all the way using a suitable tol = Remove the upper bearing race @ using a sultable tool 31= Press in the new bearing ring al the way using 2 suitable tool = ern ve sting tsi @ = Remove the sal rg Grease ne sel ing and press on al the way witha suitable ftbe = Matt ean Finishing work = Install the lower triple clamp. (## p. 26) = Check thatthe witing harness, throttle cables, and brake line have the necessary freedom of movement and are correctly routed, = Check the play of the steering head bearing. (28 p. 29) = Remove the motoreycle trom the work stand, (& p. 13)= Check the tate wip for smaeth operation, ~ Move the handlebar othe sraigh-ahead postion, Tur the throttle grip back and forth ight and determine the ply in throttle cable @ Thrtie cable play QS Sm O12... OF + Ifthe throttle cable play does not meet the specified valve: “= Adjust the play in the thrttle cable. (82 p. 33) Danger Danger of poisoning Exhaust gases are toxic and inal- ing them may result in unconsciousness and death. Always make sue there i sufficient ventilation when running the engine, Use an effective exhaust extraction system when starting o running the engin inant enclosed space, — Start the engine and let it run idle. Move the handlebar to and {to over the entire steering range ‘The idle speed must not change. Ifthe ile speed changes: = Check throttle cable routing < ~ Move the handlebar tothe sraight-ahead postion, ~ Push back sieeve @. ~ Loosen lock nut @. = Aajust the payin the tattle eabe by turing adjusting screw Guldetne Tote cable play 3. Sam O12.. 02m ~ Tighten ick nut @ ~ slide on sieeve @ Note Cluteh damage If there is no free travel by the clutch lever, the clutch will begin to slp. = Check the free travel ofthe clutch lever each time before using the motorcycle. Adjust the free travel ofthe clutch ever when necessary in accordance with the specification.7 HANDLEBAR, CONTROLS = Check the clutch lever fer smooth operation = Move the hanclbar to the staght ahead position. Pull the lute lever until resistance is perceptible, and deter. rine the play in the clutch lever @ hac ever play © 1. a mm (O04 0.12 ia) > Ifthe clutch lever play does not meet the specified value: = Adjust play in the clutch lever. ( p. 34) = Move the handlebar to and fro over the entre steering range. The clutch lever play must not change. > Ifthe clutch lever play changes: Check the routing ofthe clutch cable, 7.4 Aaljusting play in the clutch lever = Move the handlebar othe straight ahese postion, ~ Pash back sleeve @ ~ Loosen tock nut @. = Adjust the ply inthe clutch level @) by tuning adusting screw @. Guideline Clutch lever play @ 1.3 mm (0.04 0.12) ~ Tighten tock nut @ 04 ~ Position bellows @. iyPreparatory work = Remove the front spoiler. (= p. 73) = Raise the motoreycle with the rear iting gear. (ES p. 11) = Liftthe motorcycle with the front lifting gear. (# p. 11) Main work = Secure the engine and swingarm against turning using the ‘oor jack. © Info Cover the components to protect them against damage. Remove screw @ with the washers. ‘Take off shift lever and hang tothe side. Remove sores @ Remove titing © = Remove nut @ with the washer. = Remove fitting @. ~ Remove screw @. = Toke of the footrest bracket.Remove chain guise @. Remove serve @. Remove the side stand from the fotrest bracket. Peston the side stand on the new footrest bracket. Mount and tighten stews @. Guideline ‘Serew, side | MIOxI.25 stand bracket Position chain guide @. Position the footrest bracket. Mount and tighten screw @. Guideline ‘Serew, font footrest bracket Mi0Ki.25 25 Nm (184 Tot “44 Nm (32.5 11) Adjust adjusting ving @ with specie to Guideline ‘Swingarin bearing | M22xi Tighten and ensure adjusting ting that there is no play {Groove nut wrench (45229021000) (Bi p. 289) 7 The adjusting rng is flush with the collar bushing 6= Remove seem © Procuring the too (pin): - Pin @. e Guideline ia zee ETT oo Diameter 15 mm (0.59 in) vehicle lever. = Push pin @ through tote @ inthe swingarm Pin @ replaces the swingarm pivot and stabilizes the = Remove screw @ with the washers. Take off the foot brakeRemove the sri Remove screw (B and expose cables Remove screw Toke the brake cylinder off the footrest bracket Peston the brake cylinder onthe new feorest bracket Mount and tighten screw @®. Guidetine Remaining serews, | MB TON (74 Tot chassis ount the spring Peston cables. Mount and tighten screw @ Guidetine Remaining serews, | ME IO Nm (7.4 Wet ft) chassis Position the footrest bracket with the spacer. Peston the fot brake lever ont and tighten screw Q with washers. Guideline ‘Screw, foot | MB T6Nm 18 ira brake lever Loctitee®243™ ‘7 Thestep on the washers isin contact with the bearing ‘Mount and tighten fitting @ Guideline ‘Screw, front footrest | MI0s1.25 _] 49 Nm (36.1 FR) bracket / engine bearer Mount and tighten srew @. Guideine ‘Serew, front footrest | MIOsL.25 | 44 Nm (32.5 IDF) bracket~ Adjust the acjustng rng with special oot @ Guideline ‘Swingarm bearing | M22xI adjusting ring Tighten and ensure that there is no play (Groove nut wrench (45229021000) (& p. 289) 7 The adjusting ring is flush with the collar bushing. = Mount the singarm pve wth washer 7 Recess @ is aligned tothe pin. The tool (pin is removed wien the swingarm pivot is ‘mounted = Mount and tighten serews @. Guideline Remaining screws, | WB chassis TO Nim (7-4 Toh = Mount and tghten tine @ Guietine Remaining nuts, | MB chassis TO New (7-4 Tor) — Position the shift lever. ~ Mount and tighten screw @ with washers Guldeline ‘Screw, shift lever ue T6 Nm ALB iF Loctites243™ ‘7 The step on the washers is In contact with the bearing ~ Mount and igten nut @ withthe washer Guldeline Nut, swingarm pivot_[ M14x1.5 98 Nm 72.3 1 1 Recess @ is aligns tothe pin = Remove the too ac Finishing work = Take the motorcycle off the front lifting gear. (22 p. 12) = Remove the rear of the motorcycle from the lifting gear. (p.1DFit te front spoiler Cp. 74) ‘Check the frame for cracks and deformation. If the frame exhibits cracks or deformation due to @ ‘mechanical impact = Change the frame. Info DW Ainrays replace @ frame that has been dam- ‘aged due to @ mechanical impact. Repair of the frame is not authorized by KTM.Preparatory work = Raise the motoreycle withthe work stand, (2! p. 12) Main work = Measure the distance ~ as vertical as possible — between the rear axe and a fixed point, for example, a mark on the rear o firing Note down the value as dimension @. Finishing work = Remove the motoreyele from the work stand. ( p. 13) ~ Measure cimension @ of rar whee! unloaded. (p41) = Hold the motoreyele upright withthe a of an assistant ~ Measure the distance between the rear ade and the fied point o azn. = Note down the value a5 dimension @. Info The static sag isthe difference between measurements @ and @. Check the static see. Guideline Satie sag Ta mn (0.55 in) Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris: tie = Ride slowly to start with after making adjustments to get the feel ofthe new handling characteristic. Info the spring preload defines the initial status of the spring operation on the shock absorber. “The best spring preload setting is achioved when i is set for the weight ofthe rider and that of any lug- ‘gage and a passenger, thus ensuring an ideal compromise between handling and stability= Adjust he sorng preload by turing adjusting ring @. cuidetine Soing pad Sanda Teles Hook wrench, shock absorber (90529077000) Extension for hook wrench (90129099025) = Info The spring preload can be set to 10 different postions. Preparatory work = Raise the motoreycle with the work stand. (&8 p. 12) Main work = Check the upper heim joint = Move the swingarm up and down. > Ht there is detectable play Change shock absorber. = Check the loner heim joint ~ Mote the swingarm up and down. > It there is detectable play = Change shock absorber. Finishing work = Remove the motoreycle from the work stand. (Ep. 13) « Preparatory work = Raise the motoreycle withthe work stand. (#8 p. 12)Main work = Remove nut @. = Remove serens @. Remove screus @. Takeoff the over Remove screws @ and @. Remove the chein guard. Remove screw @. = Info TFrotect the swingarm and components from damage. Ensure that the chain and brake line are not damaged. ~ Remove fitting @ ~ Remove the shock absorber @ toward the rear.Main work BI Nm (7.6 [of Loetite®2aa™ = Poston shock absorser @. = Mount fitting @ but donot igton yet. Guidetine Fitng, shack MTOxI.25 sbsarber, bot tom Lift the swingarm. ~ Mount and tighten screw @. Guideline shock absorber ‘Serew, top 10x01 25 51 Nm (37.6 [ot 0) Loctite?243™ Tighten fitting @. Guideline ‘absorber, bot- tom Fitting, shock | MIOx1.25 51 Nm 7.6 ot Lootite®243™ = Position the chain guard. ~ Mount and tighten screw @. Guideline Remaining screws, chassis we Nm G7 br) Mount and tighten screw @. = Position the cover = Mount an tighten sews @ Guideline Remaining seravs chassis we TON (74 eT = Mount an tighten sews @ Guide Remaining screws, chassis Me TO Nm (7-4 Tot A = Mount ond tighten nit ©. Guideline Remaining nuts, chassis MB Nm G7 FT)Finishing work ~ Remove the motorcycle from the work stand. (®2 p. 13) ce _ & Condition The shack absorber has been removed. = Clamp the shock absorber into the vise with soft javs = Note the position ofthe spring preload. ~ Loosen adjusting ring @ using the special too. Hook wrench (T1065) (© p. 301) ~ Clamp the shock absorber into the special too! ‘Spring compressor (T140505) (Ht p. 301) © Info Use suitable ring ofthe special tool with the smallest posible inside diameter. = Compress the spring = Remove spring retainer @. = Release the spring. Remove the shock absorb frm the spe- cia too ~ Remove washer @ = Remove the speing ~ Mount the sie 1 Thetight col ofthe springs atthe bottom ~ Postion washer @.‘Clamp the shock absorber into the special tool. ‘Spring compressor (T140508) (HH p. 301) = Into Use suitable ring ofthe special tol wth the smallest possible inside diameter Mount spring retainer @. ‘The open end is opposite the spring end. Release the spring. Remove the shock absorber from the spe- cial tool ‘Clamp the shock absorber into the vise with soft jaws. Arnatve 1 Tension he sring tothe prescribed poston by tring acting rine @ Guideline Spring pred Standard Tales Hook wench (T1065) (&p, 307) ternative 2 ‘Warning, Danger of accident Notifications tothe suspen- sion setting may seriously alter the handling char- acteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling ‘characteristic and overload components. = Only make adjustments within the recommended range, = Ride slowly to start with after making adjust- ‘ments to get the fea of the new handling char- acteristic. Tension the spring to the position measured during dis- ‘mantling by turning adjusting ring @. < ‘Check the swingarm for damage, cracking, and deformation > Ifthe swingarm shows signs of damage, cracking, oF defor- ‘mation: Change the swingarm, Info HAiways change 3 damaged swingarm. Repair of the swingarm is not authorized by KTM,Preparatory work ~ Remove the front spoiler. (33 p. 73) = Raise the motoreycle with the work stand. (® p. 12) Main work = Secure the engine and swingarm against turning using the floor jack, Info Cover the components to protect them against damage. = Remove nut @. = Remove screws — Remove screws @. = Take off the cover. ~ Remove scens @ and @. = Remove the chain guard 41= Clamp down the front ofthe vehicle 7 The rear wheel is notin contact withthe ground, ~ Remove screw @ and pull whe! speed sensor @ out ofthe hole. ~ Remove nut @ with the washer. Remove chain adjuster ©, Holding the rear whee, withdraw whee! spindle @ withthe ‘washer and chain adjuster QD, Push the fear whet forward as far as possible and tke the chain ofthe rer sprocket. = Expose cable @ and brake line @. = Remove the rar whee Info Ho not operate the foot brake lever while the brake caliper is removed. = Take off the brake caliper and hang tothe side. = Info Tcover the components to protect them against damage. = Hang chain @ to the side = Remove ting ® v= Ph be eng doin i rte shock aba= Remove nut with te washer. = Remove swingarm pivet @ withthe washer = Loosen adjusting ings €@ using the special too (Groove nut wrench (45229021000) (& p. 289) = Lift the swingarm. Main work = Position the swingarm. = Aajut adjusting rings @ evenly onthe right and et using a special tool Guideline ‘Swingarm bearing | W22xI Tighten and ensure adjusting ring that there is no play (Groove nut wrench (45229021000) (=p. 289) ‘7 The adjusting ring is flush withthe collar bushing.Mount the swingarm pat @) with the washer. 7 The holding lug engages in recess @. Mount and tighten nut @) with the washer. Guideline Nut, swingarm pivot_| MI4x1.5 38 Nm (72.3 FT A The holding lug engages in recess Litt the swingarm and p Mount and tighten fitting @. Guideline tion the shock absorber. Fitting, shock | MIOx1.25 absorber, bot tom BI Nm (7.6 ot) Loctite®243™ Position the chain. Position the brake caliper. Position rear wheel and mount wheel spindle @ with the washer and chain adjuster @ © Info position, Mount nut @ with the washer. Mount left and rigt chain adusters @ inthe same Pash the rear wheel forward so thatthe chain adjusters aren contact with the srevs, and tighten nut @. Guideline Nut, rear wheel spin- | MIAX1.S dle BE Nm 72.31 Trorder forte ear wheal Tobe corecly aligned, te mark ings onthe left and right ehainadusters must be inthe same postin relate to reference matings Position wheel speed sensor @ inthe rl hole Mount and tighten screw @.Guideline ‘Screw, wheel speed | MB sensor holder Nm 69 bi AD Remove oad trom the font ofthe vehicle. Secure cable @ and brake tne (in the bracket. Position the chain guard. Mount and tighten screw @®. Guideline Remaining soews, | WE SNe (3.7 FD chassis Mount and tighten screw @ Position the cover. Mount and tighten screws @®. Guideline Remaining sens, | WE TON (74 RD chassis Guldeline Mount and tighten screws @@ with the washers, Remaining screws, | WB chassis TO New 7-4 Tor Mount and tiahten nut © Guideline Remaining nuts, [WB chassis Nm (37 TA) 51= Remove the floor jack. Finishing work = Check the chain tension. (2 p. 94) = Remove the motorcycle from the work stand, (2 p. 13) = Fit the front spoiler. (© p. 74) « Preparatory work = Raise the motoreycle with the work stand. (8 p. 12) = Place a load on the front ofthe vehicle ‘Y Therear wheel isnot in contact withthe ground, work = Move the swingarm up and down, > If there is detectable play Change the swingarm bearing, (2 p. 53) = Move the swingarm from one side tothe other. > If there is detectable play Change the swingarm bearing. (€ p. 53) Finishing work = Remove the motoreycle from the work stand, (Ep. 13)Preparatory work ~ Remove the front spoiler. (33 p. 73) ~ Raise the motoreycle withthe work stand. (®8 p. 12), = Remove the swingatm. (8 p. 47) Left swingarm beating = Remove collar bushings @. oi jo ~~ Remove bushing @. = Remove shat seal rings @ using a sitable tol ~ Remove stop disks @ = Press out bearing @ using suitable too = Using a suitable to, press in new bearing @ ~ Position stop disks @ ~ Press in shat sea sings @