Manuale Officina Superduke 3.0

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REPAIR MANUAL 2020
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Item no. 3206404en
1290 Super Duke R
04
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Matthew ashforth, Mattashforth@hotmail.com,

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INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
The vehicle will only be able to meet the demands placed on it in the long run if the specified service work is per-
formed 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.
All specifications contained herein 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 produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2020 KTM Sportmotorcycle GmbH, Mattighofen Austria
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All rights reserved
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Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
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of the copyright owner.
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ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
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defined in the ISO 9001 international quality management standard.
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Issued by: TÜV Management Service
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KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
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5230 Mattighofen, Austria
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This document is valid for the following models:

1290 Super Duke R EU (F9903T9, F9903T2)
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1290 Super Duke R JP (F9986T2)

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1290 Super Duke R US (F9975T2, F9975T9)

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*3206404en*
3206404en
07/2020
INDEX
6.6 Servicing the fork............................. 27

INDEX
1 MEANS OF REPRESENTATION ...................... 9

6.7 Disassembling the fork legs............... 27
1.1 Symbols used .................................... 9
6.8 Removing the spring......................... 29
1.2 Formats used..................................... 9
6.9 Checking the fork legs ...................... 30
2 SAFETY ADVICE.......................................... 10 6.10 Installing the spring ......................... 31
6.11 Assembling the fork legs................... 32
2.1 Repair Manual ................................. 10
6.12 Checking steering head bearing
2.2 Safety advice................................... 10
play ................................................ 36
2.3 Degrees of risk and symbols .............. 10
6.13 Adjusting the steering head bearing
2.4 Work rules....................................... 10 play ................................................ 37
3 IMPORTANT NOTES.................................... 11 6.14 Lubricating the steering head
bearing ........................................... 38
3.1 Manufacturer and implied warranty.... 11 6.15 Removing the lower triple clamp........ 38
3.2 Fuel, auxiliary substances ................. 11 6.16 Installing the lower triple clamp ........ 42
3.3 Spare parts, accessories ................... 11 6.17 Changing the steering head bearing ... 48
3.4 Figures ........................................... 11 6.18 Changing the steering damper ........... 49
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4 SERIAL NUMBERS ..................................... 12 7 HANDLEBAR, CONTROLS............................ 50
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4.1 Vehicle identification number............ 12 7.1 Adjusting the basic position of the
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4.2 Type label ....................................... 12 clutch lever ..................................... 50
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4.3 Key number..................................... 13
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7.2 Adjusting the handlebar position ....... 50
4.4 Engine number ................................ 13 7.3 Changing the throttle grip ................. 51
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4.5 Fork part number ............................. 13 7.4 Changing the combination switch ...... 54
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4.6 Shock absorber article number .......... 13
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8 FRAME ...................................................... 56
4.7 Steering damper article number ........ 14
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8.1 Checking the frame .......................... 56
5 MOTORCYCLE ............................................ 15
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9 SHOCK ABSORBER, LINK FORK.................. 57
5.1 Lifting the motorcycle with the front
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lifting gear ...................................... 15 9.1 Adjusting the low-speed

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5.2 Taking the motorcycle off the front compression damping of the shock
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lifting gear ...................................... 15 absorber.......................................... 57

5.3 Raising the motorcycle with the work 9.2 Adjusting the high-speed
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stand (screw-in type) ........................ 15 compression damping of the shock

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5.4 Removing the motorcycle from the absorber.......................................... 57

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work stand (screw-in type) ................ 16

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9.3 Adjusting the rebound damping of

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5.5 Raising the motorcycle with the work the shock absorber ........................... 58
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stand (inserted) ............................... 17 9.4 Adjusting the spring preload of the

5.6 Removing the motorcycle from the shock absorber ................................ 59
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work stand (inserted)........................ 18 9.5 Removing the shock absorber ............ 59

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5.7 Lifting the motorcycle with the rear 9.6 Installing the shock absorber............. 60
lifting gear ...................................... 18 9.7 Servicing the shock absorber............. 62
5.8 Removing the rear of motorcycle 9.8 Removing the spring......................... 63
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from the lifting gear ......................... 19

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9.9 Disassembling the damper ................ 64

5.9 Starting the vehicle .......................... 19 9.10 Disassembling the piston rod ............ 65
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5.10 Starting the motorcycle to check the 9.11 Disassembling the rebound
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function .......................................... 20 adjuster .......................................... 67

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6 FORK, TRIPLE CLAMP ................................ 22 9.12 Disassembling the compression

adjuster .......................................... 68
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6.1 Adjusting the compression damping 9.13 Disassembling the seal ring
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of the fork ....................................... 22 retainer ........................................... 69

6.2 Adjusting the rebound damping of
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9.14 Checking the damper ....................... 70

the fork........................................... 22
9.15 Changing the heim joint.................... 72
6.3 Cleaning the dust boots of the fork
9.16 Assembling the seal ring retainer ....... 73
legs ................................................ 23
9.17 Assembling the compression
6.4 Removing the fork legs ..................... 24
adjuster .......................................... 74
6.5 Installing the fork legs ...................... 24

9.18 Assembling the rebound adjuster....... 76
2
INDEX
9.19 Assembling the piston rod................. 77 13.2 Installing front fender..................... 135
9.20 Assembling the damper .................... 78
14 WHEELS .................................................. 136
9.21 Bleeding and filling the damper ........ 81
9.22 Filling the damper with nitrogen ........ 85 14.1 Checking tire pressure .................... 136
9.23 Installing the spring ......................... 86 14.2 Checking the tire condition ............. 136
9.24 Checking the link fork ...................... 87 14.3 Checking the brake discs ................ 137
9.25 Checking the fork bearing ................. 87 14.4 Checking the wheel bearings ........... 138
9.26 Removing the link fork...................... 88 14.5 Changing the tire pressure sensor
9.27 Installing the link fork ...................... 90 (EU/US) ........................................ 138
9.28 Changing the link fork bearing........... 93 14.6 Programming the tire pressure
sensor (EU/US) .............................. 139
10 EXHAUST SYSTEM ..................................... 97 14.7 Front wheel ................................... 140
10.1 Removing the main silencer .............. 97 14.7.1 Removing the front wheel ........... 140
10.2 Installing the main silencer............... 97 14.7.2 Installing the front wheel ............ 140
10.3 Removing the presilencer.................. 98 14.7.3 Changing the front brake discs .... 142
10.4 Installing the presilencer ................ 100 14.7.4 Changing the front wheel
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bearing ..................................... 142
10.5 Removing the manifold................... 101
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14.8 Rear wheel .................................... 144
10.6 Installing the manifold ................... 103
14.8.1 Removing the rear wheel with
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10.7 Removing control motor of exhaust
the work stand........................... 144
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valve controller .............................. 104
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14.8.2 Installing the rear wheel with
10.8 Installing control motor of exhaust
the work stand........................... 145
valve controller .............................. 106
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14.8.3 Removing the rear wheel ............ 146
10.9 Changing throttle cables of exhaust
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valve controller .............................. 108 14.8.4 Installing the rear wheel ............. 146
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10.10 Checking throttle cable tension of 14.8.5 Checking that the rear wheel nut
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the exhaust valve controller............. 109 (right side) is tightened to the
10.11 Adjusting throttle cable tension of
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the exhaust valve controller............. 110 14.8.6 Changing the rear brake disc....... 148
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14.8.7 Checking the chain tension......... 150

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11 AIR FILTER .............................................. 112 14.8.8 Adjusting the chain tension ........ 151
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11.1 Removing the upper part of the air 14.8.9 Checking the chain, rear
filter box ....................................... 112 sprocket, engine sprocket, and
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11.2 Changing the air filter, cleaning the chain guide ............................... 151
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air filter box................................... 112 14.8.10 Removing the rear sprocket

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carrier....................................... 153
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11.3 Installing the upper part of the air

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filter box ....................................... 113 14.8.11 Installing the rear sprocket

carrier....................................... 154
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11.4 Removing the air filter box .............. 114

11.5 Installing the lower part of the air 14.8.12 Opening the chain ..................... 155
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filter box ....................................... 115 14.8.13 Riveting the chain...................... 156

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14.8.14 Changing the drivetrain kit.......... 156

12 FUEL TANK, SEAT, TRIM .......................... 118
14.8.15 Cleaning the chain ..................... 158
12.1 Removing the front rider's seat ........ 118 14.8.16 Checking/changing the rear hub
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shock absorbers of the rear

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12.2 Mounting the front rider's seat......... 118

sprocket carrier.......................... 159
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12.3 Removing the passenger seat .......... 118

12.4 Mounting the passenger seat........... 119 14.8.17 Removing the rear hub ............... 161
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12.5 Removing the spoiler...................... 119 14.8.18 Installing the rear hub ................ 162
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12.6 Installing the spoiler....................... 120 14.8.19 Measuring the rear wheel
bearing clearance ...................... 164
12.7 Removing the fuel tank................... 121
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14.8.20 Greasing rear wheel bearing ........ 167

12.8 Installing the fuel tank ................... 123
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14.8.21 Measuring the wheel bearing

12.9 Checking the fuel pressure.............. 125
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play and greasing the rear hub .... 168

12.10 Changing the fuel pump ................. 127
14.8.22 Changing the rear wheel
12.11 Changing the fuel filter................... 128 bearing ..................................... 176
13 MASK, FENDER, DECAL............................ 135 15 WIRING HARNESS, BATTERY.................... 180
13.1 Removing front fender .................... 135 15.1 Removing the 12-V battery.............. 180
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INDEX
15.2 Installing the 12-V battery .............. 181 18.5.4 Navigation information
15.3 Disconnecting the negative cable (optional) .................................. 214
of the 12-V battery......................... 182 18.5.5 Volume (optional) ...................... 214
15.4 Connecting the negative cable of 18.5.6 Pairing (optional) ....................... 215
the 12-V battery............................. 182 18.5.7 Telephony (optional) .................. 216
15.5 Charging the 12-V battery ............... 183 18.5.8 Trip 1 ....................................... 217
15.6 Changing the main fuse .................. 185 18.5.9 Trip 2 ....................................... 217
15.7 Changing the fuses in the fuse 18.5.10 General Info ............................. 218
box ............................................... 186 18.5.11 TPMS ....................................... 218
15.8 Checking the charging voltage ......... 187 18.5.12 Warnings................................... 219
15.9 Changing the RACE-ON key 18.5.13 Service ..................................... 219
battery .......................................... 188
18.5.14 Extra Functions ......................... 219
16 BRAKE SYSTEM ....................................... 189 18.5.15 Ride Mode ................................ 219
18.5.16 Track (optional) ......................... 220
16.1 Checking the front brake linings ...... 189
18.5.17 Throttle Response (optional) ....... 220
16.2 Changing the front brake linings ...... 189
18.5.18 Anti Wheelie Mode (optional) ...... 221
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16.3 Checking the front brake fluid
18.5.19 Launch Control (optional) ........... 221
level ............................................. 192
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18.5.20 Motorcycle ................................ 222
16.4 Adding front brake fluid.................. 192
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18.5.21 Heated Grips (optional) .............. 222
16.5 Changing the front brake fluid ......... 193
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18.5.22 Heated Seat (optional) ............... 222
16.6 Bleeding the brake system .............. 195
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18.5.23 MTC+MSR (optional).................. 223
16.7 Adjusting the basic position of the
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hand brake lever ............................ 196 18.5.24 ABS.......................................... 223
18.5.25 Quickshifter + (optional)............. 223
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16.8 Checking the brake linings of the
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rear brake...................................... 196 18.5.26 Settings .................................... 224
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18.5.27 C1 and C2 buttons..................... 224
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16.9 Changing the rear brake linings ....... 197
16.10 Checking the rear brake fluid tm ed 18.5.28 Bluetooth (optional) ................... 224
level ............................................. 200 18.5.29 Headset Type ............................ 225
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16.11 Adding rear brake fluid ................... 200 18.5.30 Display Theme........................... 225
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16.12 Changing the rear brake fluid .......... 201 18.5.31 Button Illumination.................... 226
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16.13 Setting the step plate of the foot 18.5.32 Shift Light ................................ 226
brake lever .................................... 203 18.5.33 Daytime Runn. Light .................. 226
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16.14 Adjusting the basic position of the 18.5.34 Setting the time and date ........... 227
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foot brake lever.............................. 203 18.5.35 Programming the cruise control

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16.15 Checking the wheel speed sensor system ...................................... 228

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distance........................................ 204
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18.5.36 Units ........................................ 228

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17 LIGHTING SYSTEM, INSTRUMENTS .......... 205 18.5.37 Distance ................................... 229

18.5.38 Temperature.............................. 229
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17.1 Programming the ignition key .......... 205 18.5.39 Pressure ................................... 229
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17.2 Checking the headlight setting ........ 206 18.5.40 Consumption ............................. 230
17.3 Adjusting the headlight range.......... 207 18.5.41 Language .................................. 230
17.4 Changing the turn signal bulb 18.5.42 Heated Grips (optional) .............. 230
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(US) ............................................. 207

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18.5.43 Heated Seat (optional) ............... 231

17.5 Resetting the service display using
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18.5.44 Small widget ............................. 231

the KTM diagnostic tool.................. 208
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18.5.45 Large widget.............................. 231

17.6 Steering lock (antenna)................... 208
18.5.46 KTM MY RIDE widget................. 232
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18 COMBINATION INSTRUMENT ................... 210 18.5.47 NAVIGATION widget .................. 232

18.5.48 FAVORITES widget .................... 233
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18.1 Combination instrument ................. 210

18.5.49 Widget INFO ............................. 233
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18.2 Activation and test ......................... 210

18.5.50 HEATING widget........................ 234
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18.3 Day-night mode ............................. 211

18.5.51 MUSIC widget ........................... 234
18.4 Warnings....................................... 211
18.5 Menu............................................ 212 19 ENGINE ................................................... 235
18.5.1 KTM MY RIDE (optional) ............ 212
19.1 Removing the engine...................... 235
18.5.2 Audio (optional) ......................... 212
19.2 Installing the engine....................... 242

18.5.3 Navigation (optional) .................. 213
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INDEX
19.3 Preparing the engine for 19.7.31 Removing the water pump
installation .................................... 251 wheel ....................................... 265
19.4 Preparing the engine for clamping 19.7.32 Removing shift shaft sensor ........ 266
in the engine assembly stand .......... 251 19.7.33 Removing the clutch cover.......... 266
19.5 Setting the engine to ignition top 19.7.34 Removing the clutch discs .......... 267
dead center of the rear cylinder ....... 252 19.7.35 Removing the clutch basket ........ 267
19.6 Setting the engine to ignition top 19.7.36 Removing the intermediate gear
dead center of the front cylinder...... 252 and the timing chain on the
19.7 Engine disassembly........................ 253 right ......................................... 268
19.7.1 Clamping engine into the engine 19.7.37 Removing the primary gear
work stand ................................ 253 wheel ....................................... 268
19.7.2 Removing the engine bearer........ 253 19.7.38 Removing the force pump........... 269
19.7.3 Draining the engine oil ............... 254 19.7.39 Removing the shift shaft............. 269
19.7.4 Removing the front resonator ...... 254 19.7.40 Removing the shift drum
19.7.5 Removing the rear resonator........ 254 locating .................................... 270
19.7.6 Removing the front valve cover.... 255 19.7.41 Removing the locking lever ......... 270
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19.7.7 Removing the rear valve cover ..... 255 19.7.42 Removing the left engine case..... 270
19.7.8 Setting the engine to ignition 19.7.43 Removing the crankshaft ............ 271
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top dead center of the rear 19.7.44 Removing the middle suction
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cylinder .................................... 255 pump ....................................... 271
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19.7.9 Removing the starter motor......... 256 19.7.45 Removing the transmission
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19.7.10 Removing the oil filler neck ........ 256 shaft......................................... 272
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19.7.11 Removing the heat exchanger...... 256 19.7.46 Removing the oil spray tube........ 273
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19.7.12 Removing the rear timing chain 19.7.47 Removing the timing chain rails
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tensioner................................... 257 of the right section of the engine
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case ......................................... 273
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19.7.13 Removing the rear camshafts ...... 257
19.7.14 Removing the rear cylinder 19.7.48 Removing the timing chain rails
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head......................................... 258 of the left section of the engine
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19.7.15 Removing the rear piston ............ 258 case ......................................... 273
19.8 Working on individual parts............. 273
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19.7.16 Setting the engine to ignition

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top dead center of the front 19.8.1 Working on the right section of
cylinder .................................... 259 the engine case ......................... 273
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19.7.17 Removing the front timing chain 19.8.2 Removing the right main
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tensioner................................... 259 bearing ..................................... 275

19.8.3 Selecting the main bearing
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19.7.18 Removing the front camshafts..... 259

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19.7.19 Removing the front cylinder shells ....................................... 276

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head......................................... 260 19.8.4 Installing the right main

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19.7.20 Removing the front piston........... 260 bearing ..................................... 276

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19.7.21 Removing the alternator cover ..... 261 19.8.5 Working on the left section of
the engine case ......................... 277
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19.7.22 Removing the crankshaft speed

sensor....................................... 261 19.8.6 Removing the left main
bearing ..................................... 280
19.7.23 Removing the torque limiter and
19.8.7 Installing the left main bearing ... 280
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the intermediate gear ................. 262

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19.7.24 Removing the rotor..................... 262 19.8.8 Changing the conrod bearing....... 281
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19.7.25 Removing the intermediate gear 19.8.9 Working on the clutch cover........ 283
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and the timing chain on the 19.8.10 Changing the support bearing of
left ........................................... 263 the crankshaft ........................... 284
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19.7.26 Removing the oil filter ................ 263 19.8.11 Checking the radial clearance of
the bottom connecting rod
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19.7.27 Removing the balancer shaft....... 264

bearing ..................................... 285
19.7.28 Removing the drive gear wheel
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of the balancer shaft .................. 264 19.8.12 Checking/measuring the

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cylinder .................................... 286

19.7.29 Removing the gear position
sensor....................................... 264 19.8.13 Checking/measuring the piston.... 286
19.7.30 Removing the left suction 19.8.14 Checking the piston ring end
pump ....................................... 264 gap........................................... 288
19.8.15 Checking the piston/cylinder
mounting clearance.................... 288
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INDEX
19.8.16 Working on the cylinder head ...... 289 19.9.17 Installing the clutch discs........... 317
19.8.17 Checking the cylinder head......... 293 19.9.18 Installing the clutch cover .......... 319
19.8.18 Working on the right 19.9.19 Installing the shift shaft sensor ... 319
intermediate gear....................... 294 19.9.20 Installing the water pump
19.8.19 Checking the timing assembly..... 295 wheel ....................................... 320
19.8.20 Preparing the timing chain 19.9.21 Installing the gear position
tensioner for installation ............. 296 sensor....................................... 320
19.8.21 Checking the oil pressure 19.9.22 Installing the drive gear wheel of
control valve.............................. 296 the balancer shaft...................... 320
19.8.22 Checking the lubrication 19.9.23 Installing the balancer shaft........ 321
system ...................................... 297 19.9.24 Installing the intermediate gear
19.8.23 Checking the clutch ................... 298 and the timing chain on the
19.8.24 Checking the shift mechanism .... 299 left ........................................... 321
19.8.25 Preassembling shift shaft ........... 301 19.9.25 Installing the oil filter................. 322
19.8.26 Removing magnetic holder.......... 301 19.9.26 Installing the rotor ..................... 322
19.8.27 Installing magnet holder ............. 301 19.9.27 Installing the torque limiter and
the intermediate gear ................. 323
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19.8.28 Disassembling the main shaft ..... 302
19.8.29 Disassembling the 19.9.28 Installing the crankshaft speed
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countershaft .............................. 303 sensor....................................... 323
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19.8.30 Checking the transmission .......... 304 19.9.29 Installing the alternator cover...... 323
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19.8.31 Assembling the main shaft.......... 305 19.9.30 Assembling the rear piston.......... 324
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19.8.32 Assembling the countershaft ....... 306 19.9.31 Installing rear cylinder head........ 326
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19.8.33 Measuring the main shaft axial 19.9.32 Installing the rear camshafts....... 327
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play .......................................... 307 19.9.33 Installing the rear timing chain
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19.8.34 Checking the electric starter tensioner................................... 327
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drive......................................... 307 19.9.34 Setting the engine to ignition
19.8.35 Checking the freewheel .............. tm ed 308 top dead center of the front
cylinder .................................... 328
19.9 Engine assembly ............................ 308
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19.9.35 Installing the front piston ........... 328
19.9.1 Installing the timing chain rails
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of the left section of the engine 19.9.36 Installing the front cylinder
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case ......................................... 308 head......................................... 330

19.9.2 Installing the timing chain rails 19.9.37 Installing the front camshafts...... 331
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of the right section of the engine 19.9.38 Installing the front timing chain
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case ......................................... 309 tensioner................................... 332

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19.9.3 Installing the oil spray tube......... 309 19.9.39 Installing the heat exchanger ...... 332
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19.9.40 Installing the starter motor.......... 333

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19.9.4 Installing the transmission

shafts ....................................... 309 19.9.41 Checking the rear valve
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19.9.5 Installing middle suction pump ... 310 clearance .................................. 333
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19.9.6 Installing the crankshaft ............. 311 19.9.42 Adjusting the rear valve
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19.9.7 Installing the left engine case ..... 311 clearance .................................. 333
19.9.8 Installing the locking lever .......... 313 19.9.43 Checking the front valve
clearance .................................. 334
19.9.9 Installing the shift drum
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locating .................................... 313 19.9.44 Adjusting the front valve

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clearance .................................. 334

19.9.10 Installing the shift shaft ............. 313
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19.9.45 Installing the oil filler neck ......... 335

19.9.11 Installing the force pump............ 314
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19.9.46 Installing the front valve cover..... 335

19.9.12 Installing the left suction
pump ....................................... 315 19.9.47 Installing the rear valve cover...... 336
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19.9.13 Setting the engine to ignition 19.9.48 Installing the oil drain plug ......... 336
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top dead center of the rear 19.9.49 Installing the rear resonator ........ 336
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cylinder .................................... 316 19.9.50 Installing the front resonator ....... 337
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19.9.14 Installing the primary gear 19.9.51 Mounting the engine bearer ........ 337
wheel ....................................... 316 19.9.52 Removing the engine from the
19.9.15 Installing the intermediate gear engine work stand...................... 338
and the timing chain on the
right ......................................... 316 20 SECONDARY AIR SYSTEM SAS.................. 339
19.9.16 Installing the clutch basket......... 317 20.1 Changing the SAS membrane .......... 339
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INDEX
21 CLUTCH ................................................... 341 25.7 Checking/cleaning the oil nozzle for

clutch lubrication........................... 383
21.1 Checking/correcting the fluid level
25.8 Installing the oil nozzle for the
of the hydraulic clutch.................... 341
clutch lubrication........................... 383
21.2 Changing the hydraulic clutch
fluid ............................................. 342 26 IGNITION SYSTEM.................................... 385
21.3 Checking the clutch ....................... 343
26.1 Alternator - checking the stator
22 SHIFT MECHANISM.................................. 349 winding......................................... 385
26.2 Changing the spark plugs................ 387
22.1 Adjusting the basic position of the
26.3 Changing the spark plugs (air filter
shift lever...................................... 349
removed)....................................... 390
22.2 Changing the gear position sensor.... 349
22.3 Programming the gear position 27 THROTTLE VALVE BODY ........................... 396
sensor........................................... 352
27.1 Removing the throttle valve body ..... 396
22.4 Changing the shift shaft sensor ....... 352
27.2 Installing the throttle valve body...... 397
22.5 Programming the shift shaft
27.3 Performing the initialization run ...... 399
sensor........................................... 354
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27.4 Resetting
23 WATER PUMP, COOLING SYSTEM ............. 355 the engine electronics control unit ... 399
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23.1 Checking the coolant level in the 28 TECHNICAL DATA..................................... 401
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compensating tank......................... 355
28.1 Engine .......................................... 401
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23.2 Checking the coolant fill level and
antifreeze...................................... 355 28.2 Tolerance, engine wear limits .......... 402
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23.3 Draining the coolant ....................... 356 28.3 Engine tightening torques ............... 404
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23.4 Adding the coolant/bleeding the 28.4 Capacities ..................................... 406
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cooling system............................... 357 28.4.1 Engine oil ................................. 406
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23.5 Changing the coolant...................... 359 28.4.2 Coolant ..................................... 406
23.6 Correcting the coolant level in the tm ed
28.4.3 Fuel ......................................... 406
compensating tank......................... 361 28.5 Chassis ......................................... 407
ho ns
28.6 Electrical system............................ 407

24 CYLINDER HEAD ...................................... 363
e
28.6.1 Diagnostics connector ................ 408

h@ Lic
24.1 Checking the valve clearance .......... 363 28.6.2 Front ACC1 and ACC2 ................ 408
24.2 Checking the valve clearance (air 28.6.3 ACC1 and ACC2 rear .................. 408
fo r |
filter and spark plugs removed) ....... 368 28.7 Tires ............................................. 409
sh fü
24.3 Setting the valve clearance of the 28.8 Fork.............................................. 409

rt
ta rt
rear cylinder .................................. 371 28.9 Shock absorber .............................. 409

at ie
24.4 Setting the valve clearance of the 28.10 Chassis tightening torques .............. 410
M ns
front cylinder................................. 371

24.5 Disassembling the camshafts of the 29 CLEANING/PROTECTIVE TREATMENT........ 414
h, ze
rear cylinder .................................. 372

29.1 Cleaning the motorcycle ................. 414
Li
24.6 Installing the camshafts of the rear

29.2 Checks and maintenance steps for
cylinder......................................... 372
winter operation............................. 415
24.7 Disassembling the camshafts of the
t
front cylinder................................. 373 30 STORAGE ................................................. 416

or
24.8 Installing the camshafts of the

hf
front cylinder................................. 374 30.1 Storage ......................................... 416

as
30.2 Preparing for use after storage......... 417

25 LUBRICATION SYSTEM............................. 376
ew
31 SERVICE SCHEDULE ................................ 418

25.1 Oil circuit...................................... 376
31.1 Additional information .................... 418
th
25.2 Checking the engine oil level........... 377

31.2 Required work ............................... 418
at
25.3 Changing the engine oil and oil

31.3 Recommended work ....................... 419
M
filter, cleaning the oil screens ......... 377

25.4 Adding engine oil ........................... 380 32 WIRING DIAGRAM .................................... 420
25.5 Checking the oil pressure................ 381
25.6 Removing the oil nozzle for the 32.1 Page 1 of 13 ................................. 420
clutch lubrication........................... 382 32.2 Page 2 of 13 ................................. 422
32.3 Page 3 of 13 ................................. 424
7
INDEX
32.4 Page 4 of 13 ................................. 426

32.5 Page 5 of 13 ................................. 428
32.6 Page 6 of 13 ................................. 430
32.7 Page 7 of 13 ................................. 432
32.8 Page 8 of 13 ................................. 434
32.9 Page 9 of 13 ................................. 436
32.10 Page 10 of 13 ............................... 438
32.11 Page 11 of 13 ............................... 440
32.12 Page 12 of 13 ............................... 442
32.13 Page 13 of 13 ............................... 444
33 SUBSTANCES .......................................... 446
34 AUXILIARY SUBSTANCES ......................... 448
35 SPECIAL TOOLS ....................................... 450
36 STANDARDS ............................................ 469
72
37 GLOSSARY OF TECHNICAL TERMS............ 470
04
38 LIST OF ABBREVIATIONS.......................... 471
0
/0
INDEX ............................................................. 472
57
0 04
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l.c r:
ai fo
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tm ed
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h@ Lic
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8
MEANS OF REPRESENTATION 1
1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
72
04
Indicates the result of a testing step.
0
/0
57
Indicates a voltage measurement.
0 04
,0
l.c r:
ai fo
om
Indicates a current measurement.
tm ed
ho ns
Indicates a resistance measurement.

e
h@ Lic
fo r |
Indicates the end of an activity including potential rework.

sh fü
rt
ta rt
at ie
1.2 Formats used

M ns
The typographical formats used in this document are explained below.

h, ze
Li
Proprietary name Indicates a proprietary name.
Name® Indicates a protected name.

t
or
hf
Brand™ Indicates a brand available on the open market.

as
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
ew
are explained in the glossary.

th
at
M
9
2 SAFETY ADVICE
2.1 Repair Manual

Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips
to help you repair and service your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are
available.
2.2 Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the 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
72
and may therefore be injured.
0 04
2.3 Degrees of risk and symbols
/0
57
Danger
04
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
0
appropriate measures are not taken.
,0
l.c r:
ai fo
om
Warning
tm ed
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
ho ns
taken.
e
Caution
h@ Lic
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
fo r |
Note
sh fü
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
rt
ta rt
not taken.
at ie
M ns
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
h, ze
Li
2.4 Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
t
or
with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
hf
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
as
using the number in parentheses. Example: bearing puller (15112017000)

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
ew
expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instruc-
th
tions.
at
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
M
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
10
IMPORTANT NOTES 3
3.1 Manufacturer and implied warranty

The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con-
firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) specified in the manual.
3.3 Spare parts, accessories
72
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other
04
products and any resulting damage or loss.
0
The latest news KTM PowerParts on your vehicle can be found on the KTM website.
/0
International KTM Website: http://www.ktm.com
57
04
3.4 Figures
0
,0
l.c r:
The figures contained in the manual may depict special equipment.
ai fo
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
om
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
tm ed
in the text.
ho ns
e
h@ Lic
fo r |
sh fü
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ta rt
at ie
M ns
h, ze
Li
t
or
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as
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11
4 SERIAL NUMBERS
4.1 Vehicle identification number

The vehicle identification number 1 is stamped on the right side
of the steering head.
The vehicle identification number is also shown on the type label.
402324-10
4.2 Type label

(Super Duke R EU/JP)
The type label 1 is located on the steering head.
72
0 04
/0
57
0 04
,0
l.c r:
402302-10
ai fo
om
(US)
tm ed
The type label for the USA 1 is located on the steering head.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
402302-10
at ie
(US)
M ns
The type label for Canada 1 is located on the frame on the

h, ze
left.
Li
t
or
hf
as
402293-10
ew
th
at
M
12
SERIAL NUMBERS 4
4.3 Key number

The key number Code number 1 can be found on
the KEYCODECARD.
Info
You need the key number to order a spare key. Keep
the KEYCODECARD in a safe place.
F01249-10
4.4 Engine number

The engine number 1 is stamped on the right side of the engine.
72
0 04
/0
57
0 04
,0
l.c r:
402296-10
ai fo
om
4.5 Fork part number tm ed
ho ns
The fork part number 1 is stamped on the inside of the axle
clamp.
e
h@ Lic
fo r |
sh fü
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ta rt
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M ns
402295-10
h, ze
4.6 Shock absorber article number

Li
The shock absorber article number 1 is stamped on the top of

the shock absorber above the adjusting ring towards the engine
t
or
side.
hf
as
ew
th
at
402798-10
M
13
4 SERIAL NUMBERS
4.7 Steering damper article number

Steering damper item number 1 is embossed on the underside
of the steering damper.
H01060-10
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
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M ns
h, ze
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14
MOTORCYCLE 5
5.1 Lifting the motorcycle with the front lifting gear
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Preparatory work
– Lift the motorcycle with the rear lifting gear. ( p. 18)
Main work
– Move the handlebar to the straight-ahead position. Align the
front lifting gear with the fork legs.
Front wheel work stand, small (61129965000) ( p. 456)
Info
72
Always raise the motorcycle at the rear first.
04
E00696-01
– Lift the motorcycle at the front.
0
/0
57
5.2 Taking the motorcycle off the front lifting gear
0 04
Note
,0
l.c r:
ai fo
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– Park the vehicle on a firm and level surface. tm ed
ho ns
– Secure the motorcycle against falling over.
e
– Remove the front lifting gear.

h@ Lic
fo r |
sh fü
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ta rt
at ie
M ns
402777-01
h, ze
Li
5.3 Raising the motorcycle with the work stand (screw-in type)
Note
t
or

hf

as
Condition
ew
th
at
M
15
5 MOTORCYCLE
– Remove screw 1.
– Remove screws 2. Take off the footrest bracket.
G04651-10
– Remove screws 3. Hang the footrest bracket to the side.
72
0 04
/0
G04652-10
57
– Screw the holder of the special tool all the way into the upper
04
drill holes of the footrest brackets. Select the right height and
width of the work stand.
0
,0
l.c r:
Work stand (62529055200) ( p. 461)
ai fo
om
– Raise the motorcycle.
tm ed
ho ns
Info
Check that the work stand is properly seated.
e
h@ Lic
G04653-10
fo r |
5.4 Removing the motorcycle from the work stand (screw-in type)
sh fü
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Note
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M ns

h, ze
Li
– Remove the motorcycle from the work stand and rest it on the
side stand.
– Remove the work stand.
t
or
Work stand (62529055200) ( p. 461)

hf
as
ew
th
G04653-10
at
M
16
MOTORCYCLE 5
– Position the footrest bracket. Mount and tighten screws 1.

Guideline
Screw, front M8 25 Nm (18.4 lbf ft)
rider footrest Loctite®243™
bracket
G04652-11
– Position the footrest bracket. Mount and tighten screws 2.

Guideline
bracket
72
– Position the shift rod. Mount and tighten screw 3.
04
Guideline
0
Screw, shift rod M6 5 Nm (3.7 lbf ft)
/0
G04651-11
Loctite®243™
57
0 04
5.5 Raising the motorcycle with the work stand (inserted)
,0
l.c r:
ai fo
om
Note
tm ed
ho ns
e
h@ Lic
– Remove the plastic caps on both sides.

– The plastic bushing of the work stand should engage in the
fo r |
opening of the swingarm pivot. Select the right height and

sh fü

rt
ta rt
Work stand (62529055200) ( p. 461)

at ie
M ns

h, ze
Info
Li

t
or
hf
as
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S04100-01
M
17
5 MOTORCYCLE
5.6 Removing the motorcycle from the work stand (inserted)
Note
side stand.
Work stand (62529055200) ( p. 461)
– Insert the plastic caps on both sides.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
S04101-01
tm ed
ho ns
5.7 Lifting the motorcycle with the rear lifting gear

e
h@ Lic
Note
fo r |

sh fü

rt
ta rt
at ie
– Place the adapter into the rear lifting gear.

M ns
Rear wheel work stand for single-sided swing arm

h, ze
(61329955000) ( p. 460)
Li
– Position the motorcycle upright, place the lifting gear in the

axle, and raise the motorcycle.
t
or
hf
E00695-01
as
ew
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at
M
18
MOTORCYCLE 5
5.8 Removing the rear of motorcycle from the lifting gear
Note
– Secure the motorcycle against falling over.

– Remove the rear wheel stand and lean the vehicle on side
stand 1 .
72
402029-10
04
5.9 Starting the vehicle
0
/0
57
Danger
04
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
0
Always make sure there is sufficient ventilation when running the engine.
,0
l.c r:
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
ai fo
om
Caution tm ed
Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis-
ho ns
charged or missing.
e
– Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
h@ Lic
Note
fo r |
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
sh fü
– Always run the engine warm at a low speed.

rt
ta rt
at ie
– Take the motorcycle off the side stand and sit on the motorcy-
M ns
cle.
h, ze
– Bring the RACE-ON key within the range of the steering lock.
Li
– Ensure that the RACE-ON key stays in range while riding.

Guideline
Maximum range of the 1.5 m (4.9 ft)
t
or
RACE-ON key around the

hf
steering lock
as
S03900-01
Info
ew
The range may be reduced by decreases in battery volt-

th
age of the RACE-ON key and by interfering radio waves.

If the battery voltage of the RACE-ON key is too low,
at
one of the ignition keys must be placed in the area of

M
the steering lock ( p. 208) and must be safely stored

again after starting.
– Make sure that the emergency OFF switch/electric starter but-

ton is in the middle position .
19
5 MOTORCYCLE
– Switch on ignition; to do this, briefly press the RACE-ON but-

ton (maximum of 1 second).
The steering is unlocked.
The function check of the combination instrument is run.
The ABS warning lamp goes out when starting off.
Info
If the handlebar does not unlock, move the handlebar
slightly.
– Shift the transmission into neutral.

The N neutral position is displayed.
– Turn emergency OFF switch/electric starter button to the lower
position .
Info
72
Only press the emergency off switch/electric starter but-
04
ton into the lower position when the combination
0
instrument function check has been completed.
/0
When starting, DO NOT open the throttle.
57
Press the emergency OFF switch/electric starter button
04
S03901-01 into the lower position for a maximum of 5 seconds.
0
Wait for a least 5 seconds before trying again.
,0
l.c r:
This motorcycle is equipped with a safety starting sys-
ai fo
tem. You can only start the engine if the transmission
om
tm ed is in neutral or if the clutch lever is pulled when a gear
is engaged. If the side stand is folded out and you shift
ho ns
into gear, the engine stops.
e
h@ Lic
fo r |
5.10 Starting the motorcycle to check the function

sh fü
rt
Danger
ta rt
at ie
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
M ns
– Always make sure there is sufficient ventilation when running the engine.
h, ze
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Li
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
t
or
hf
– Ensure that the RACE-ON key stays in range.

as
Guideline
ew
Maximum range of the 1.5 m (4.9 ft)

RACE-ON key around the
th
fuel tank
at
M
S03900-01
20
MOTORCYCLE 5
Info
The range may be reduced by decreases in battery volt-
age of the RACE-ON key and by interfering radio waves.
If the battery voltage of the RACE-ON key is too low,
one of the ignition keys must be placed in the area of
the steering lock ( p. 208) and must be safely stored
again after starting.
– Turn emergency OFF switch/electric starter button to the mid-

dle position .
– Press RACE-ON button briefly (for a maximum of 1 second).
The steering is unlocked.
The ABS warning lamp lights up and goes back out after
starting off.
Info
72
If the handlebar does not unlock, move the handlebar
04
slightly.
0
/0
57
The gear display N is shown.
04
– Turn emergency OFF switch/electric starter button to the lower
0
position .
,0
l.c r:
ai fo
om
Info
tm ed
Only press the emergency OFF switch/electric starter
button into the lower position when the combination
ho ns
instrument function check has been completed.

e
When starting, DO NOT open the throttle. If you open

h@ Lic
the throttle during the starting procedure, fuel is not

S03901-01 injected by the engine management system and the
fo r |
engine cannot start.

sh fü
Press the emergency OFF switch/electric starter button

rt
ta rt
into the lower position for a maximum of 5 seconds.

at ie
Wait for a least 5 seconds before trying again.

M ns
This motorcycle is equipped with a safety starting sys-

tem. You can only start the engine if the transmission
h, ze
is in neutral or if the clutch lever is pulled when a gear

Li
is engaged. If the side stand is folded out and you shift

into gear, the engine stops.
t
or
hf
as
ew
th
at
M
21
6 FORK, TRIPLE CLAMP
6.1 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Turn white adjusting screw 1 clockwise as far as it will go.

Info
Adjusting screw 1 is located at the upper end of the
left fork leg.
The compression damping is located in left fork
leg COMP (white adjusting screw). The rebound
damping is located in right fork leg REB (red adjusting
screw).
S03908-11
72
Turn counterclockwise by the number of clicks corresponding
to the fork type.
04
Guideline
0
/0
Compression damping
57
Comfort 21 clicks
04
Standard 15 clicks
0
Sport 7 clicks
,0
l.c r:
Full payload 7 clicks
ai fo
om
tm ed Info
ho ns
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping.
e
h@ Lic
fo r |
6.2 Adjusting the rebound damping of the fork

sh fü
rt
ta rt
Info
at ie
The hydraulic rebound damping determines the fork suspension behavior.

M ns
h, ze
– Turn red adjusting screw 1 clockwise as far as it will go.

Li
Info
Adjusting screw 1 is located at the upper end of the
t
or
right fork leg.

The rebound damping is located in right fork leg REB
hf
(red adjusting screw). The compression damping is

as
located in left fork leg COMP (white adjusting screw).

ew
S03908-12 – Turn counterclockwise by the number of clicks corresponding

th
to the fork type.

at
M
22
FORK, TRIPLE CLAMP 6
Guideline
Rebound damping
Comfort 21 clicks
Standard 15 clicks
Sport 7 clicks
Info
6.3 Cleaning the dust boots of the fork legs

Preparatory work
72
04
– Lift the motorcycle with the front lifting gear. ( p. 15)
0
/0
Main work
– Push dust boots
57
1 of both fork legs downward.
04
Info
0
The dust boots remove dust and coarse dirt particles
,0
l.c r:
from the inside fork tubes. Over time, dirt can accumu-
ai fo
om
late behind the dust boots. If this dirt is not removed,
tm ed
the oil seals behind can start to leak.
ho ns
S03950-10
e
Warning
h@ Lic
Danger of accidents Oil or grease on the brake discs

reduces the braking effect.
fo r |
– Always keep the brake discs free of oil and grease.

sh fü
–
rt
Clean the brake discs with brake cleaner when nec-

ta rt
essary.
at ie
M ns
– Clean and oil the dust boots and inner fork tubes of both fork
h, ze
legs.
Li
Universal oil spray ( p. 449)

– Press dust boots back into the installation position.
t
–
or
Remove excess oil.

hf
Finishing work
– Take the motorcycle off the front lifting gear. (
as
p. 15)
– Remove the rear of the motorcycle from the lifting gear.
ew
( p. 19)
th
at
M
23
6.4 Removing the fork legs

Preparatory work
– Remove front fender. ( p. 135)
– Raise motorcycle with the work stand (inserted). ( p. 17)
– Clamp down the rear of the vehicle.
Main work
– Remove screws 1 from both brake calipers.
– Press back the brake linings by slightly tilting the brake
calipers laterally on the brake disc. Pull the brake calipers
carefully back from the brake discs and hang to the side.
Info
Do not operate the hand brake lever if the brake
calipers have been removed.
R01917-10
72
– Remove screw 2. Hang the wheel speed sensor to the side.
04
– Loosen screw 3 and screws 4.
0
/0
– Unscrew screw 3 about six turns and press your hand on the
57
screw to push the wheel spindle out of the axle clamp. Remove
04
screw 3 .
0
,0
l.c r:
Warning
ai fo
om
Danger of accidents Damaged brake discs reduce the
tm ed braking effect.
– Always lay the wheel down in such a way that the
ho ns
R01918-10
brake discs are not damaged.

e
h@ Lic
– Hold the front wheel and remove the wheel spindle. Take the
fo r |
front wheel out of the fork.

sh fü
– Loosen screws 5 on both sides. Remove the fork legs from

rt
ta rt
the bottom.
at ie
M ns
h, ze
Li
t
or
M01776-11
hf
6.5 Installing the fork legs

as
ew
Warning
th
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris-
tic.
at
–
M
Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
24
Main work
– Position the fork legs in the triple clamps.
– Align the fork leg in the desired position by means of the fork
rings.
Guideline
Upper triple clamp flush 0 mm (0 in)
with upper edge of fork legs
Upper triple clamp flush 2.5 mm (0.098 in)
R01920-10 with 1st ring of fork legs
Upper triple clamp flush 5 mm (0.2 in)
with 2nd ring of fork legs
(standard)
Info
The basic setting provides the best vehicle handling.
72
When the fork is compressed, the basic chassis setting
04
changes, causing the vehicle to become more stable
but also more difficult to handle.
0
/0
–
57
Tighten screws 1.
04
Guideline
Screw, top triple M8 18 Nm (13.3 lbf ft)
0
,0
l.c r:
clamp
ai fo
om
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp tm ed
ho ns
e
M01776-10
h@ Lic
– Check the wheel bearing for damage and wear.

fo r |
» If the wheel bearing is damaged or worn:

sh fü
– Change front wheel bearing. ( p. 142)

rt
–
ta rt
On both sides, clean and grease shaft seal ring 2 and con-
at ie
tact surface A
of the spacers.
M ns
Long-life grease ( p. 448)

h, ze
Li
Info
R01921-10
Insert the wide spacer on the left in the direction of
travel.
t
or
Arrow B indicates the direction of travel of the front

wheel.
hf
as
ew
Warning
th

at

M
– Clean the brake discs with brake cleaner when nec-

essary.
R01922-10 – Clean screw 3 and the wheel spindle.

25
– Jack up the front wheel into the fork, position it, and insert the
wheel spindle.
– Mount and tighten screw 3.
Guideline
Screw, front M25x1.5 45 Nm (33.2 lbf ft)
wheel spindle Thread greased
– Position wheel speed sensor 4. Mount and tighten the screw.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Position the brake calipers and check that the brake linings
are seated correctly.
– Mount screws 5 on both brake calipers but do not tighten
yet.
72
R01917-11
Guideline
04
0
brake caliper Loctite®243™
/0
57
– Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
04
point. Fix the hand brake lever in the activated position.
0
,0
l.c r:
The brake calipers straighten.
ai fo
–
om
Tighten screws 5 on both brake calipers.
tm ed
Guideline
ho ns
e
h@ Lic
– Remove the locking piece of the hand brake lever.

– Check the wheel speed sensor distance. ( p. 204)
fo r |
– Remove the load from the rear of the vehicle.

sh fü
– Operate the front brake and compress the fork a few times
rt
ta rt
firmly.
at ie
The fork legs straighten.

M ns
– Tighten screws 6.
h, ze
Guideline
Li
Screw, axle clamp M8 15 Nm (11.1 lbf ft)

t
or
R01918-11
hf
Finishing work
as
– Remove the motorcycle from the work stand (inserted).

( p. 18)
ew
– Install front fender. ( p. 135)

th
at
M
26
6.6 Servicing the fork

Condition
The fork legs have been removed.
– Disassemble the fork legs. ( p. 27)
– Remove the spring. ( p. 29)
– Check the fork legs. ( p. 30)
– Install the spring. ( p. 31)
– Assemble the fork legs. ( p. 32)
72
0 04
/0
57
0 04
,0
l.c r:
Z00845-10
ai fo
om
6.7 Disassembling the fork legs tm ed
ho ns
Info
e
The operations are the same on both fork legs.

h@ Lic
fo r |
Condition
The fork legs have been removed.
sh fü
rt
– Make a note of the present state of rebound 1 and compres-

ta rt
at ie
sion damping 2 .
M ns
– Open the adjusters of the rebound and compression damping

completely.
h, ze
– Clamp the fork leg in the area of the lower triple clamp.
Li
Guideline
Use soft jaws.
t
or
– Release screw cap 3 with the special tool.

Z00819-10
hf
Ring wrench (T14017) ( p. 466)

as
Info
ew
The screw cap cannot be removed yet.

th
at
M
27
– Unclamp the fork.

– Drain the fork oil.
Z00820-10
– Remove cartridge screw 4 with the washer.
72
0 04
/0
Z00821-10
57
– Remove the cartridge.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
Z00838-10
– Remove dust boot 5.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
Z00822-10
– Remove retaining ring 6.

t
or
hf
Info
as
The retaining ring has a beveled end where a screw-

driver can be applied.
ew
– Remove fork protection ring 7.

th
at
Info
M
Z00823-10
Disassembly of the fork protection ring is not absolutely
necessary for further repair, but is recommended due to
the build up of heat.
28
– Warm up the outside fork tube in area A of the lower sliding

bushings.
Guideline
50 °C (122 °F)
– Pull the outside fork tube off the inside fork tube with a jerk.
Info
Z00824-10
Lower sliding bushing 8 must be drawn from its bear-
ing seat.
– Remove upper sliding bushing 9.

Info
Without using a tool, pull the stack slightly apart by
hand.
72
– Take off lower sliding bushing 8.
04
– Take off support ring bk.
0
/0
Z00825-10
– Take off seal ring bl.
57
– Take off retaining ring 6.
04
– Take off dust boot 5.
0
–
,0
Take off lift indicator bm.
l.c r:
ai fo
– Unclamp the fork leg.
om
tm ed
ho ns
6.8 Removing the spring

e
h@ Lic
Info
fo r |
sh fü
Preparatory work
rt
ta rt
– Disassemble the fork legs. ( p. 27)

at ie
M ns
Main work
– Clamp the cartridge into a bench vise.
h, ze
Clamping stand (T14015S) ( p. 465)

Li
– Hold nut 1 and remove screw cap 2 with special tool.

t
or
hf
as
Z00843-10
ew
th
at
M
29
– Remove spring 3.
Z00826-10
– Remove spring washer4.

– Remove spring seat 5.
– Remove shim 6.
72
0 04
/0
Z00827-10
57
– Remove adjusting tube 7.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
Z00828-10
fo r |
6.9 Checking the fork legs

sh fü
Condition
rt
ta rt
The fork is disassembled.

at ie
– Check the inside fork tube and the axle clamp for damage.
M ns
» If damage is found:
h, ze
– Change the inside fork tube.

Li
t
or
hf
as
Z00829-10
ew
– Measure the outside diameter of the inside fork tube at several

places.
th
Outside diameter of the 47.975 … 48.005 mm

at
inside fork tube (1.88878 … 1.88996 in)

M
» If the measured value is less than the specified value:

200684-10
30
– Measure the run-out of the inside fork tube.

Run-out of the inside fork ≤ 0.20 mm (≤ 0.0079 in)
tube
» If the measured value is greater than the specified value:
200685-10
– Check the outside fork tube for damage.

» If damage is found:
– Change the outside fork tube.
72
0 04
/0
Z00830-10
57
– Check the surface of the sliding bushings.
04
» When bronze-colored layer A becomes visible under glid-
0
ing layerB :
,0
l.c r:
– Change the guiding bushes.
ai fo
om
tm ed
ho ns
e
h@ Lic
200665-10
– Check the spring length.

fo r |
Guideline
sh fü
Spring length with preload 303 mm (11.93 in)

rt
ta rt
spacer(s)
at ie

M ns
– Reduce the thickness of the preload spacers.

h, ze

Li
– Increase the thickness of the preload spacers.

Z00831-10
t
or
6.10 Installing the spring

hf
as
Info
ew
th
at
M
31
– Clamp the cartridge into a bench vise.

– Mount adjusting tube 1.
Z00828-11
– Mount shim 2.
– Mount spring seat 3.
– Mount spring washer 4.
72
04
0
/0
Z00841-10
57
– Mount spring 5.
04
– Pull spring down and hold nut 7.
0
– Mount screw cap 6 all the way with special tool.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
Z00842-10
fo r |
6.11 Assembling the fork legs

sh fü
rt
Info
ta rt
at ie

M ns
Preparatory work
h, ze
– Check the fork legs. ( p. 30)

Li

Main work
t
– Clamp the inside fork tube using an axle clamp.

or
Guideline
hf
Use soft jaws.

as
– Mount the special tool.

ew
Protecting sleeve (T1401) ( p. 465)

th
– Mount stroke indicator1.

at
–
M
Z00834-10
Mount retaining ring 2.
– Lubricate and mount dust boot 3.
Lubricant (T14034) ( p. 448)
32
Info
Always change the dust boot, seal ring, retaining ring,
and support ring.
Mount the sealing lip with the spring expander facing
down.
– Push on retaining ring 4.

– Grease and push on seal ring 5.
Lubricant (T14034) ( p. 448)
Info
Sealing lip downward, open side upward.
– Push on support ring 6.

Z00835-10
– Sand edges of the sliding bushings with 600 grit sandpaper;
72
then clean and grease the bushings.
04
Fork oil (SAE 4) (48601166S1) ( p. 447)
0
/0
– 7.
Push on lower sliding bushing
57
– Mount upper sliding bushing 8.
0 04
Info
,0
l.c r:
Without using a tool, pull the stack slightly apart by
ai fo
om
hand.
tm ed
– Warm up the outside fork tube in area A of the lower sliding
ho ns
bushings.
e
h@ Lic
Guideline
Z00837-10
50 °C (122 °F)
fo r |
– Hold the lower sliding bushing with the longer side of the spe-
sh fü
cial tool.
rt
ta rt
Mounting tool (T14040S) ( p. 466)

at ie
M ns
– Slide on the outside fork tube.

– Press the slide bearing all the way into the outside fork tube.
h, ze
Li
– Position the support ring.

– Hold the seal ring with shorter side of the special tool.
Mounting tool (T14040S) ( p. 466)
t
or
– Press the seal ring and support ring all the way into the out-
hf
side fork tube.

as
ew
th
Z00836-10
at
M
33
– Mount retaining ring 4.

The retaining ring engages audibly.
– Mount fork protection ring 9.
Z00823-11
– Mount dust boot 3.
72
0 04
/0
Z00822-11
57
– Assemble the individual components that belong together.
04
Info
0
,0
l.c r:
Compression damping side: cartridge with additional oil
ai fo
holes B , white adjuster, axle clamp marked L.
om
tm ed Rebound damping side: cartridge without additional oil
holes, red adjuster, axle clamp marked R.
ho ns
e
h@ Lic
202929-10
– Slide the cartridge into the inside fork tube.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
Z00838-11
– Mount and tighten cartridge screw bk with the washer.

t
or
Guideline
hf
Screw, cartridge M10x1 25 Nm (18.4 lbf ft)

as
ew
th
at
M
Z00821-11
34
– Clamp the fork vertically.

– Fill with fork oil.
Fork oil per fork leg 615 ± 15 ml Fork oil (SAE 4)
(20.79 (48601166S1)
± 0.51 fl. oz.) ( p. 447)
Z00840-10
Alternative 1
– Push the outside fork tube upward.
– Clamp the outside fork tube in the area of the lower triple
clamp.
72
– Grease the O-ring of the screw cap.
04
Lubricant (T158) ( p. 448)
0
–
/0
Z00839-10 Mount and tighten screw cap bl.
57
Guideline
04
Screw cap on the M51x1.5 40 Nm
outside fork tube (29.5 lbf ft)
0
,0
l.c r:
– Turn the adjusting screw of rebound bm
and the adjusting
ai fo
om
screw of compression damping
tm ed bn
clockwise as far as pos-
sible.
ho ns
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
e
h@ Lic
Guideline
Rebound damping
fo r |
Comfort 21 clicks
sh fü
Standard 15 clicks
rt
ta rt
Sport 7 clicks
at ie

M ns
Compression damping
h, ze
Comfort 21 clicks
Li
Standard 15 clicks
Sport 7 clicks
t

or
hf
as
ew
th
at
M
35
Alternative 2
Warning
Danger of accident Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
characteristic and overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.
72
– Turn the adjusting screws to the position they were in
04
before removing.
0
/0
57
6.12 Checking steering head bearing play
0 04
Warning
,0
l.c r:
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ai fo
om
ages components.
–
tm ed
Correct incorrect steering head bearing play immediately.
ho ns
e
Info
h@ Lic
If 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.
fo r |
sh fü
Preparatory work
rt
ta rt

at ie
Main work
M ns
– Place a load on the rear of the vehicle.

h, ze
The front wheel is not in contact with the ground.

Li
– Move the handlebar to the straight-ahead position. Move the

fork legs back and forth in the direction of travel.
Play should not be detectable on the steering head bearing.
t
or
» If there is detectable play:

hf
– Adjust the steering head bearing play. ( p. 37)

as
400738-11
– Move the handlebar back and forth over the entire steering
ew
range.
th
It must be possible to move the handlebar easily over the

at
entire steering range. There should be no detectable detent

M
positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 37)
– Check the steering head bearing and adjust if neces-
sary.
36
6.13 Adjusting the steering head bearing play

Preparatory work
Main work
– Remove screws 1.
– Remove screw 2.
– Take off the combination instrument and place it at the front.
G04477-10
– Remove screws 3 with handlebar clamps.
72
– Take off the handlebar and place it at the front.
04
Info
0
Cover the components to protect them against damage.
/0
Do not kink the cables and lines.
57
0 04
,0
l.c r:
G04473-10
ai fo
om
– Loosen screws 4. Remove screw 5.
–
tm ed
Loosen and retighten screw 6.
ho ns
Guideline
e
Screw, steering head, M20x1.5 12 Nm (8.9 lbf ft)

h@ Lic
top
– Using a plastic hammer, tap lightly on the upper triple clamp
fo r |
to avoid stresses.
sh fü
rt
ta rt
Guideline
at ie
M ns

clamp
h, ze
–
Li
Mount and tighten screw 5.

Guideline
Screw, steering M8 20 Nm (14.8 lbf ft)
t
Loctite®243™
or
stem clamp
hf
as
G04476-10
– Position the handlebar.

ew
– Position the handlebar clamps. Mount and tighten screws 3.

th
Guideline
at
Screw, handlebar M8 20 Nm (14.8 lbf ft)

M
clamp
G04473-10
37
– Position the combination instrument.

Guideline
Screw, instrument M6 2 Nm (1.5 lbf ft)
support
– Mount and tighten screws 1.
G04477-10
Finishing work
– Check steering head bearing play. ( p. 36)
6.14 Lubricating the steering head bearing
72
– Remove the lower triple clamp. ( p. 38)
04
– Install the lower triple clamp. ( p. 42)
0
/0
57
0 04
,0
l.c r:
ai fo
om
R01950-10
tm ed
6.15 Removing the lower triple clamp
ho ns
e
h@ Lic
Warning
Skin irritation Brake fluid causes skin irritation.
fo r |
– Keep brake fluid out of the reach of children.

sh fü
– Wear suitable protective clothing and safety glasses.

rt
ta rt
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
at ie
– Consult a doctor immediately if brake fluid has been swallowed.

M ns
– Rinse the affected area with plenty of water in the event of contact with the skin.
h, ze
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
Li
with the eyes.

– If brake fluid spills on to your clothing, change the clothing.
t
Note
or
Environmental hazard Hazardous substances cause environmental damage.

hf
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
as
the applicable regulations.

ew
Preparatory work
th

at

M

– Remove the fork legs. ( p. 24)
38
Main work
– Loosen screw 1.
– Swing the headlight toward the front.
Info
G04567-10
– Unplug connector 2.
72
0 04
/0
G04560-10
57
04
– Remove the headlight.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04568-10
fo r |
– Take off the cover.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04569-10
t
or
hf
as
ew
th
at
M
G04570-10
39
– Remove screw 6.
– Take off the combination instrument and hang to the side.
G04571-10
– Remove screw 7.
– Expose brake lines.
– Remove screw 9 with gasket.
72
Info
04
Place a collecting container underneath because brake
fluid will run out.
0
/0
Avoid contact between brake fluid and painted sur-
57
faces. Brake fluid corrodes paint.
Immediately wash off any spilled brake fluid with water.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04572-10
– Take off the brake line and hang it to the side.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04573-10
–
t
Loosen screw bk.

or
hf
as
ew
th
at
M
G04574-10
40
– Remove screw bl.
G04575-10
– Remove washer bm.

– Remove the upper triple clamp.
Info
Hold the lower triple clamp.
72
004
/0
G04576-10
57
– Remove protective ring bn.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04577-10
– Remove seal ring retainer bo.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04578-10
– Remove upper steering head bearing bp.

t
or
– Take out the lower triple clamp with the steering stem.
hf
as
ew
th
at
M
G04579-10
41
6.16 Installing the lower triple clamp
Warning
with the eyes.
Note
72
04
0
/0
57
Main work
– Grease the bearing, clean the sealing elements, and check for
04
damage.
0
,0
l.c r:
High viscosity grease ( p. 448)
ai fo
om
– Insert the lower triple clamp with the steering stem.
–
tm ed
Mount upper steering head bearing 1.
ho ns
e
h@ Lic
G04579-11
– Mount seal ring retainer 2.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04578-11
– Mount protective ring 3.

t
or
– Position the upper triple clamp.

hf
as
ew
th
at
M
G04577-11
42
– Mount washer 4.
Guideline
damper on triple Loctite®243™
clamp
G04576-11
– Mount screw 5, but do not tighten yet.

Guideline
top
– Route the cable without tension.
72
0 04
/0
G04575-11
57
– Position the brake line under the triple clamp.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04573-11
– Position the brake line with the new gasket.

fo r |
– Mount and tighten screw 6 with new gasket.

sh fü
Guideline
rt
ta rt
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft)

at ie
M ns
Info
h, ze
Place a collecting container underneath because brake

Li
fluid will run out.

Avoid contact between brake fluid and painted sur-
faces. Brake fluid corrodes paint.
t
Immediately wash off any spilled brake fluid with water.

or
hf

as

ew
Guideline
th

at
clamp
M
G04572-11
43
– Position the fork legs in the triple clamps.

The left-hand fork leg has a white adjuster; the right-hand
fork leg has a red adjuster.
– Position turn signal bracket.
Holding lugs A engage in triple clamp B.
– Route cable of the wheel speed sensor so it is not under ten-
sion and secure with a cable tie.
G04580-10
– Align the fork legs in the specified position by means of fork

ringsC .
Guideline
Upper triple clamp flush 0 mm (0 in)
with upper edge of fork legs
72
Upper triple clamp flush 2.5 mm (0.098 in)
with 1st ring of fork legs
04
Upper triple clamp flush 5 mm (0.2 in)
0
with 2nd ring of fork legs
/0
G04581-10
(standard)
57
04
Info
0
,0
The basic setting provides the best vehicle handling.
l.c r:
ai fo
When the fork is compressed, the basic chassis setting
om
changes, causing the vehicle to become more stable
tm ed but also more difficult to handle.
ho ns
– Tighten screws 9 of the lower triple clamp.

e
h@ Lic
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
fo r |
clamp
sh fü
rt
ta rt
at ie
M ns
h, ze
G04582-10
Li
– Tighten screw 5.
Guideline
t
or
top
hf
– Remove screw bk.

as
– Mount and tighten screw bk.

ew
Guideline
th
G04574-11 Screw, steering M8 20 Nm (14.8 lbf ft)

stem clamp Loctite®243™
at
M
44
– Tighten screws bl of the upper triple clamp.

Guideline
clamp
G04583-10

– Mount and tighten screw bm.
72
0 04
/0
G04571-11
57
– Plug in connector bn.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04570-11
– Position the cover.

fo r |
– Mount and tighten screws bo.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04569-11
– Position the headlight.

t
or
– Mount and tighten screws bp.

hf
as
ew
th
at
M
G04561-11
45
– Plug in connector bq.
G04560-11
– Swing up the headlight.

– Tighten screw br hand-tight.
72
0 04
/0
G04559-11
57
04
0
,0
l.c r:
– On both sides, clean and grease shaft seal ring bs and con-
ai fo
om
tact surface
tm ed D
of the spacers.
ho ns
e
Info
h@ Lic
G04584-10
Insert the wide spacer on the left in the direction of
travel.
fo r |
Arrow E indicates the direction of travel of the front

sh fü
wheel.
rt
ta rt
at ie
M ns
Warning
h, ze

Li

t
essary.
or
hf
G04585-10 – Clean screw bt and the wheel spindle.

as
ew
wheel spindle.
–
th
Mount and tighten screw bt.

at
Guideline
M

46
– Position wheel speed sensor ck. Mount and tighten the screw.
Guideline
Screw, front wheel M6 4 Nm (3 lbf ft)
speed sensor
– Position brake calipers and check that the brake linings are
seated correctly.
– Mount screws cl on both brake calipers, but do not tighten
yet.
G04586-10
Guideline
– Add front brake fluid. ( p. 192)

– Bleed the brake system. ( p. 195)
72
04
point. Secure the hand brake lever in the activated position.
0
/0
– Tighten screws cl on both brake calipers.
57
Guideline
04
0
,0
l.c r:
ai fo
om
– Check the wheel speed sensor distance. (
tm ed p. 204)
ho ns
e
h@ Lic
firmly.
fo r |
– Tighten screws cm.

sh fü
Guideline
rt
ta rt

at ie
M ns
h, ze
G04587-10
Li
Finishing work
t
or

hf
( p. 18)
–
as
Adjust the headlight range. ( p. 207)

ew
th
at
M
47
6.17 Changing the steering head bearing

Preparatory work
– Remove the fork legs. ( p. 24)
– Remove the lower triple clamp. ( p. 38)
Main work
– Remove lower bearing ring 1 using a suitable tool.
72
04
T00912-10
0
/0
– Press in the new bearing ring all the way using a suitable tool.
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
T00913-10
e
h@ Lic
– Remove upper bearing ring 2 using a suitable tool.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
T00914-10
– Press in the new bearing ring all the way using a suitable tool.
t
or
hf
as
ew
th
at
T00915-10
M
48
– Remove lower steering head bearing 3.

– Remove the seal ring retainer.
– Grease and mount a new seal ring retainer.
– Mount a new bearing.
T00911-10
Finishing work
– Install the lower triple clamp. ( p. 42)
( p. 18)
72
– Adjust the headlight range. ( p. 207)
0 04
/0
6.18 Changing the steering damper
57
04
– Remove screw 1.
0
,0
l.c r:
– Remove the steering damper.
ai fo
om
– Position a new steering damper.
tm ed
ho ns
Guideline
e

h@ Lic
damper bracket Loctite®243™

G04588-10
on frame
fo r |
sh fü

rt
ta rt
Guideline
at ie

M ns

h, ze
clamp
Li
t
or
hf
as
ew
th
at
M
49
7 HANDLEBAR, CONTROLS
7.1 Adjusting the basic position of the clutch lever

– Push the clutch lever forward.
– Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw 1 .
Info
Turn the adjusting screw clockwise to increase the
distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease
the distance between the clutch lever and the handle-
S03891-10
bar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use
force.
Do not make any adjustments while riding.
72
0 04
7.2 Adjusting the handlebar position
/0
57
Warning
04
Danger of accidents A repaired handlebar poses a safety risk.
0
,0
l.c r:
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
ai fo
result.
om
– tm ed
Change the handlebar if the handlebar is damaged or bent.
ho ns
– Remove screws 1 . Take off the handlebar clamps 2. Posi-

e
tion the handlebar so that screws 3 are accessible.

h@ Lic
Info
fo r |

sh fü
Do not kink the cables and lines.

rt
ta rt
at ie
– Remove screws 3. Take off handlebar supports 4.

M ns
– Move the handlebar supports into the desired position A

h, ze
S01727-10
orB . Mount and tighten screws 3 .
Li
Guideline
Mount the left and right handlebar supports in the same
position.
t
or
Screw, handle- M10 40 Nm (29.5 lbf ft)

hf
bar support Loctite®243™

as
– Position the handlebar.

ew
Info
th
Make sure the cables and wiring are positioned cor-

at
rectly.
M
– Position the handlebar clamp. Mount screws 1 and tighten

evenly.
50
HANDLEBAR, CONTROLS 7
Guideline
Screw, handlebar M8 20 Nm (14.8 lbf ft)
clamp
7.3 Changing the throttle grip

Preparatory work
– Remove the passenger seat. ( p. 118)
– Remove the front rider's seat. ( p. 118)
– Remove the spoiler. ( p. 119)
– Remove the fuel tank. ( p. 121)
Main work
– Loosen screw 1.
– Swing the headlight toward the front.
72
04
Info
0
/0
57
04
G04559-10
0
,0
–
l.c r:
Unplug connector 2.
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04560-10
rt
– 3.
ta rt
Remove screws
at ie
– Remove the combination instrument.

M ns
h, ze
Li
t
or
G04561-10
hf
– Remove the cable ties.

as
ew
th
at
M
G04562-10
51
– Open plug box 4.
G04563-10
– Disconnect plug-in connector 5.
72
0 04
/0
G04564-10
57
– Loosen screw 6.
04
– Remove the handlebar weight.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04565-10
fo r |

sh fü
– Pull the throttle grip and accelerator position sensor from the
rt
ta rt
handlebar.
at ie
M ns
h, ze
Li
G04566-10
– Position a new throttle grip with a sensor unit.

t
or
Holding lug B engages in inner clutch hub C.

hf
as
ew
th
at
M
R01818-10
52

Guideline
Screw for throttle M5 3.5 Nm
grip (2.58 lbf ft)
G04566-10
– Position handlebar weight.

72
0 04
/0
G04565-10
57
– Connect plug-in connector 5.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04564-10
– Close plug box 4.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04563-10
– Route the cable without tension and secure it with a cable tie.
t
or
hf
as
ew
th
at
M
G04562-10
53

Guideline
Screw, instrument M6 2 Nm (1.5 lbf ft)
support
G04561-10
– Plug in connector 2.
72
0 04
/0
G04560-10
57
– Position the headlight.
04
– Tighten screw 1 hand-tight.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04559-10
Finishing work
fo r |
– Install the fuel tank. ( p. 123)

sh fü
– Mount the front rider's seat. ( p. 118)

rt
ta rt
– Mount the passenger seat. ( p. 119)

at ie
– Install the spoiler. ( p. 120)

M ns
– Reset the engine electronics control unit. ( p. 399)

h, ze
– Program the gear position sensor. ( p. 352)

Li

t
or
7.4 Changing the combination switch

hf
Preparatory work
as

–
ew
Remove the front rider's seat. ( p. 118)

th

at
– Remove the handlebar weights and handles.

M
54
Main work
– Disconnect the plug-in connectors from the combination
switches.
– Loosen screws 1.
Guideline
Do not loosen any other screws on the combination switch.
The combination switches must not be opened.
– Pull the combination switches off the handlebar.
– Position new combination switches.
Guideline
Screw, combination M5 5 Nm (3.7 lbf ft)
switch, left
Screw, combination M5 5 Nm (3.7 lbf ft)
72
switch, right
04
– Join the plug-in connectors of the combination switches.
0
– Route the cables without tension and secure.
/0
M01775-10
– Mount handles and handlebar weights.
57
Guideline
04
Screw for throttle M5 3.5 Nm
0
,0
grip (2.58 lbf ft)
l.c r:
ai fo
Screw, fixed grip, left M4 2 Nm (1.5 lbf ft)
om
Finishing work
tm ed
– Install the fuel tank. (
ho ns
p. 123)
e
h@ Lic

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
55
8 FRAME
8.1 Checking the frame

– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a
mechanical impact:
– Change the frame.
Info
Always replace a frame that has been dam-
aged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
G04496-10
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
56
SHOCK ABSORBER, LINK FORK 9
9.1 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided.
Info
The low-speed compression adjuster takes effect during slow to normal compression of the shock absorber.
– Turn adjusting screw 1 clockwise with a screwdriver as far as

the last perceptible click.
Info
72
Do not loosen fitting 2!
0 04
– Turn counterclockwise by the number of clicks corresponding
/0
to the shock absorber type.
57
Guideline
04
S03909-10
Low-speed compression damping
0
Comfort 21 clicks
,0
l.c r:
ai fo
Standard 12 clicks
om
Sport tm ed 7 clicks
ho ns
e
Info
h@ Lic

fo r |
sh fü
rt
ta rt
at ie
9.2 Adjusting the high-speed compression damping of the shock absorber

M ns
h, ze
Caution
Li
t
or
hf
Info
as
The high-speed compression adjuster takes effect during fast compression of the shock absorber.
ew
th
at
M
57
9 SHOCK ABSORBER, LINK FORK
– Turn adjusting screw 1 all the way clockwise with a socket

wrench.
Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of turns corresponding
Guideline
S03906-10
High-speed compression damping
Comfort 1.5 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
72
Info
04
0
/0
57
04
9.3 Adjusting the rebound damping of the shock absorber
0
,0
l.c r:
ai fo
Caution
om
tm ed
ho ns

e
h@ Lic
– Turn adjusting screw 1 clockwise up to the last perceptible

fo r |
click.
sh fü
– Turn counterclockwise by the number of clicks corresponding

rt
ta rt

at ie
Guideline
M ns
Rebound damping
h, ze
Comfort 21 clicks
Li
Standard 15 clicks
S03910-10
Sport 10 clicks
t
or
hf
Info
as

ew
th
at
M
58
9.4 Adjusting the spring preload of the shock absorber

– To increase the spring preload, turn handwheel 1clockwise.
– To reduce the spring preload, turn hand-
wheel 1 counterclockwise.
Guideline
Spring preload
Standard 0
Maximum 15
Minimum −5
S03907-01
9.5 Removing the shock absorber

Preparatory work
72
04
– Remove main silencer. ( p. 97)
0
– Removing the rear wheel with the work stand. ( p. 144)
/0
– Remove the presilencer. ( p. 98)
57
Main work
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04535-10
fo r |
– Remove screw 2.
sh fü
– Take off the splash protector.

rt
ta rt
at ie
M ns
h, ze
Li
G04536-10
t
or
– Remove covering cap 3.

hf
as
ew
th
at
M
G04537-10
59
G04538-10
– Remove screw 5.
– Push the link fork down.
72
04
0
/0
G04539-10
57
– Remove screw 6.
04
– Pull the shock absorber from its bracket.
0
,0
l.c r:
Info
ai fo
om
tm ed
ho ns
e
h@ Lic
G04540-10
– Remove the shock absorber toward the rear.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04541-10
t
9.6 Installing the shock absorber

or
hf
– Position the shock absorber.

as
Info
ew

th
at
M
G04541-10
60

Guideline
Screw, top M14x1.5 80 Nm (59 lbf ft)
shock absorber Loctite®243™
G04540-11
– Lift the link fork.

Guideline
Screw, bottom M14x1.5 80 Nm (59 lbf ft)
72
0 04
/0
G04539-11
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04538-11
– Mount covering cap 4.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04537-11
– Position the splash protector.

t
or
hf
Info
as
Pay attention to the brake hose and cable of the wheel

speed sensor.
ew

th
Guideline
at

M
G04536-11
chassis
61

Guideline
chassis
G04535-11
Finishing work
– Install the presilencer. ( p. 100)
– Install the main silencer. ( p. 97)
– Check the throttle cable tension of the exhaust valve con-
troller. ( p. 109)
72
04
9.7 Servicing the shock absorber
0
/0
57
Caution
04
0
,0
l.c r:
ai fo
om
tm ed
Condition
The shock absorber has been removed.
ho ns

e
h@ Lic
– Disassemble the damper. ( p. 64)

– Disassemble the piston rod. ( p. 65)
fo r |
– Disassemble the rebound adjuster. ( p. 67)

sh fü
– Disassemble the compression adjuster. ( p. 68)

rt
ta rt
– Disassemble the seal ring retainer. ( p. 69)

at ie
– Check the damper. ( p. 70)

M ns
– Change the heim joint. ( p. 72)

h, ze
– Assemble the seal ring retainer. ( p. 73)

Li
– Assemble the compression adjuster. ( p. 74)

– Assemble the rebound adjuster. ( p. 76)
– Assemble the piston rod. ( p. 77)
t
or
– Assemble the damper. ( p. 78)

hf

as
ew
th
Z00794-10
at
M
62
9.8 Removing the spring

Condition
– Measure and note the spring length while the spring is under
tension.
– Turn adjuster 1 on the preload adjuster all the way counter-
clockwise.
Z00750-10
– Clamp the shock absorber into the special tool.
72
Spring compressor (T14050S) ( p. 467)
04
Info
0
/0
Use the suitable ring of the special tool with the small-
57
est possible inside diameter.
Ensure that the ring lies only on the spring.
0 04
– Remove spring seats 2.
,0
l.c r:
Z00751-10
ai fo
om
– Remove washer
tm ed
4 .
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
Z00753-10
at ie
– Remove washer 5.
M ns
h, ze

Li
t
or
hf
as
Z00752-10
ew
th
at
M
63
9.9 Disassembling the damper

Preparatory work
Main work
– Make a note of the present state of rebound 1 and compres-
sion damping 2.
completely.
Z00754-10
– Clamp the damper in the bench vise.
72
Guideline
Use soft jaws.
04
–
0
Remove protection cap 3.
/0
– Slowly open screw 4.
57
The nitrogen pressure dissipates.
04
– Remove screw 4 with the O-ring.
0
,0
l.c r:
Z00755-10
ai fo
om
– Remove preload adjuster 5.
–
tm ed
Remove locking cap 6 .
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
Z00756-10
at ie
– Push in seal ring retainer 7.

M ns
– Remove circlip 8.
h, ze
Li
Info
Check inner surface; do not scratch. If necessary,
remove any burrs with sandpaper.
t
or
– Remove the piston rod.

hf
as
Z00757-10
– Unclamp the damper and drain the oil.

ew
th
at
M
Z00758-10
64

Guideline
Use soft jaws.
– Remove screw cap 9 of the compression adjuster with the O-
ring.
Socket (T17002S) ( p. 468)
Z00759-10 Info
Place a collecting container underneath.
– Remove compression adjuster bk.

– Heat up thread area A of the shock absorber case.
Guideline
50 °C (122 °F)
72
– Degrease damper cartridge bl and remove using the special
04
tool.
0
/0
Mounting tool (T146) ( p. 467)
57
Clamping bush (T147) ( p. 467)
04
Z00760-10
– Remove O-ring bm.
0
,0
l.c r:
– Clamp the shock absorber case as shown.
ai fo
om
Guideline
tm ed
Use soft jaws.
ho ns
– Push in reservoir cover bn.
e
– bo.
Remove circlip
h@ Lic
– Mount screw bp and remove the reservoir cover.

fo r |
sh fü
Z00761-10
rt
ta rt
– Remove pistonbq of the reservoir using a suitable tool.

at ie
– Remove screw br with the O-ring.

M ns
h, ze
Li
t
or
hf
Z00762-10
as
9.10 Disassembling the piston rod

ew
Preparatory work
th

at

M
65
Main work
– Clamp the foot section of the piston rod into the vise.
Guideline
Use soft jaws.
– Heat the thread in area A.
Guideline
50 °C (122 °F)
Z00776-10 – Remove screw 1 with shim stack 2 and put them to one
side together.
Info
Guide the shim stack onto a screwdriver and put them
to one side together.
72
Remove nut 3.
– 4.
04
Remove compression damping shim
0
/0
57
0 04
,0
l.c r:
ai fo
om
Z00777-10
– tm ed
Remove rebound shim stack 5.
ho ns
Info
e
Guide the rebound shim stack onto a screwdriver and

h@ Lic
put them to one side together.

fo r |
– Remove piston 6.
sh fü
rt
ta rt
at ie
Z00778-10
M ns
– Remove compression shim stack 7.

h, ze
Li
Info
Guide the compression shim stack onto a screwdriver
and put them to one side together.
t
or
– Remove rebound washer 8.

hf
as
Z00779-10
ew
th
at
M
66
– Remove seal ring retainer 9.

– Remove locking cap bk.
– Remove rubber buffer bl.
Z00785-10
9.11 Disassembling the rebound adjuster

Preparatory work
–
72
Disassemble the piston rod. ( p. 65)
04
Main work
– Heat up and loosen lock nut 1.
0
/0
Guideline
57
50 °C (122 °F)
0 04
,0
l.c r:
ai fo
om
Z00780-10 tm ed
ho ns
– Turn piston rod, degrease and clamp using the special tool.
e

h@ Lic
– Heat the foot section in area A and remove with a suitable

fo r |
tool.
sh fü
Guideline
rt
ta rt
50 °C (122 °F)
at ie
– Remove lock nut 1.

M ns
Z00781-10
h, ze
– Remove grub screw 2.

Li
– Remove rebound adjuster 3.

t
or
hf
as
ew
Z00782-10
th
at
M
67
– Remove adjusting screw 4 with the needle from screw

cap 5 using the suitable tool.
Info
Do not misplace the balls and the spring.
Z00783-10
9.12 Disassembling the compression adjuster

Preparatory work
72
Main work
– Screw in adjusting screw 1 as far as it will go.
04
– Remove lock ring 2.
0
/0
57
0 04
,0
l.c r:
ai fo
om
T03021-10
–
tm ed
Remove adjusting screw 1.
ho ns
Info
e
h@ Lic
Do not misplace the ball and the spring.

fo r |
sh fü
rt
ta rt
at ie
T03022-10
M ns
– Remove O-ring 3.
h, ze
Li
t
or
hf
as
T03023-10
ew
th
at
M
68
– Clamp the compression adjuster on the damping adapter with

the special tool.
– Remove adapter 4 with the spring and washer.
Info
Ensure that the adapter is not damaged.
T03024-10
– Remove nut 5.
– Remove piston 6.
72
0 04
/0
T03025-10
57
– Remove compression shim stack 7.
04
Info
0
,0
l.c r:
Guide the compression shim stack onto a screwdriver
ai fo
om
and put them to one side together.
–
tm ed
Remove spring seat 8.
ho ns
e
h@ Lic
T03026-10
– Remove O-rings 9 and bk.

fo r |
– Remove adjusting screw bl by turning clockwise with the O-

sh fü
ring.
rt
ta rt
at ie
M ns
h, ze
Li
T04321-10
t
9.13 Disassembling the seal ring retainer

or
hf
Preparatory work
as

ew
– Disassemble the piston rod. ( p. 65)

th
at
M
69
Main work
– Remove rebound rubber 1.
B04492-10
– 3.
Remove seal ring
– Remove washer 4 from seal ring 3.
72
0 04
/0
B04493-10
57
04
0
– Remove dust boot 7.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
B04494-10
fo r |
9.14 Checking the damper

sh fü
Condition
rt
ta rt
The damper has been disassembled.

at ie
– Measure the inside diameter on both ends and in the middle of

M ns
the damper cartridge.

h, ze
Damper cartridge
Li
Diameter ≤ 46.10 mm (≤ 1.815 in)

t
– Replace the damper cartridge.

or
– Check the damper cartridge for damage and wear.

hf
as
Z00774-10 » If there is damage or wear:

– Replace the damper cartridge.
ew
th
at
M
70
– Measure the diameter of the piston rod.

Piston rod
Diameter ≥ 17.95 mm (≥ 0.7067 in)
– Replace the piston rod.
– Measure the run-out of the piston rod.
Piston rod
Z00846-10
Run-out ≤ 0.03 mm (≤ 0.0012 in)
– Check the piston rod for damage and wear.
» If there is damage or wear:
72
– Check the rebound needle for damage and wear.
04
0
– Change the rebound needle.
/0
–
57
Check the heim joint for damage and wear.
04
– Change the heim joint.
0
,0
–
l.c r:
Check the shock absorber case for damage and wear.
ai fo
om
– tm ed
Change the shock absorber case.
ho ns
e
Z00773-10
h@ Lic
– Check the piston ring for damage and wear.

fo r |
» If damage or a bronze-colored surface is visible:

sh fü
– Change the piston ring.

rt
ta rt
at ie
M ns
h, ze
Li
Z00793-10
– Check the piston ring and O-ring for damage and wear.
t
or

–
hf
Change the piston ring and O-ring.

as
ew
th
at
M
Z00772-10
71
9.15 Changing the heim joint

Condition
– Clamp the shock absorber into the vise.
Guideline
Use soft jaws.
– Remove both collar bushings 1 of the heim joint with a spe-
cial tool.
Drift (T120) ( p. 463)
Z00812-10
– Remove seal rings 2.
72
0 04
/0
57
0 04
,0
l.c r:
Z00813-10
ai fo
om
– Use a suitable tool to press the heim joint against a circlip.
– tm ed
Remove second circlip 3.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
Z00814-10
at ie
– Place special tool A underneath and press out heim joint 4

M ns
using special tool B.

h, ze
Pressing tool (T1207S) ( p. 464)

Li
t
or
hf
as
Z00815-10
– Push in new heim joint 4 with the rounded side facing

ew
inward.
th
Pressing tool (T1206) ( p. 464)

at
M
– Use a suitable tool to press the heim joint against the circlip.
Z00816-10
72
Info
Only press the bearing in via the outer bearing race,
otherwise the bearing will be damaged when it is
pressed in.
– Mount second circlip 3.
Z00818-10
72
Mount new seal rings 2.
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
Z00813-10
– tm ed
Individually position and press in collar bushings 1.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
Z00817-10
M ns
9.16 Assembling the seal ring retainer

h, ze
Li
– Mount dust boot 1 with the special tool.

Mounting sleeve (T1204) ( p. 464)
t
– Grease the sealing lip of the dust boot.

or
hf

as
ew
th
B04496-10
at
M
73
– Grease the O-ring groove.

– Mount O-ring 2.
– Mount washer 3.
B04495-10
– Position washer 4 on seal ring 5.

– Grease the seal ring and mount with the washer facing down-
ward.
72
004
/0
B04493-11
57
– Mount washer 6.
04
– Mount rebound rubber 7.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
B04492-11
fo r |
9.17 Assembling the compression adjuster

sh fü
– Grease the O-ring of the adjusting screw.

rt
ta rt

at ie
M ns
– Grease the thread of the adjusting screw.

h, ze

Li
– Mount adjusting screw 1 with the O-ring all the way to the
stop.
– Mount and grease O-ring 2.
t
or
T04322-10
hf
as
– Mount O-ring 3.
–
ew
Clamp the damping adapter with the special tool.

th
at

M
– Mount compression shim stack 5 with the smaller washers

facing downward.
Info
Note the setting list.

T03029-10
74
– Clean piston 6.
– Mount the piston.
Guideline
View A of piston from above
View B of piston from below
T03030-10
– Mount and tighten nut 7.

Guideline
Nut on the M6 6 Nm (4.4 lbf ft)
damping Loctite®2701™
adapter
72
0 04
/0
T03031-10
57
– Mount the washer and the spring.
04
– Position adapter 8.
0
– Unclamp the compression adjuster.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
T03032-10
– Press adapter8 as far as it will go.

fo r |
– Mount O-ring 9.
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
T03033-10
– Grease the O-ring.

t
or

hf
– Grease the spring, ball, and thread.

as

ew
– Mount adjusting screw bk and screw in as far as it will go.

th
at
M
T03034-10
75
– Mount lock ring bl.

– Unscrew adjusting screw bk as far as it will go.
T03021-11
9.18 Assembling the rebound adjuster

– Lubricate the spring, ball, and O-rings.
– Mount adjusting screw 1 with the needle in screw cap 2.
72
0 04
/0
57
04
Z00790-10
0
– Clamp the foot section into the vise.
,0
l.c r:
Guideline
ai fo
om
Use soft jaws.
tm ed
– Lubricate the O-ring of rebound adjuster 3.
ho ns

e
h@ Lic
– Position the rebound adjuster with O-ring and mount in the

foot section with adjusting screw . 1
fo r |
Z00791-10 – Mount grub screw 4 .

sh fü
– Clamp the piston rod using the special tool.

rt
ta rt
at ie

M ns
– Mount lock nut 5 all the way on.

h, ze
Guideline
Li
Lock nut, foot M18x1 110 Nm (81.1 lbf ft)

section. Loctite®2701™
– Mount and tighten foot section 6 using a suitable tool.

t
or
Z00792-10
Guideline
hf
Foot section on M18x1 50 Nm (36.9 lbf ft)

as
piston rod. Loctite®2701™

ew
th
at
M
76
– Turn the piston rod over and clamp the foot section of it into
the vise.
Guideline
Use soft jaws.
– Tighten lock nut 7.
Guideline
Lock nut, foot M18x1 110 Nm (81.1 lbf ft)
section. Loctite®2701™
Z00780-11
9.19 Assembling the piston rod

Preparatory work
72
Main work
04
– Mount rubber buffer 1.
0
–
/0
Mount locking cap 2.
57
– Grease the seal ring and mount seal ring retainer 3.
04
0
,0
l.c r:
ai fo
om
Z00785-11 tm ed
–
ho ns
Mount rebound washer 4.
–
e
Mount compression shim stack 5 with the smaller washers

h@ Lic
facing downward.
fo r |
Info
sh fü

rt
ta rt
at ie
M ns
Z00786-11
h, ze
– Mount piston 6.
Li
Guideline
View A of piston from above
t
View B of piston from below

or
hf
as
ew
Z00787-10
th
at
M
77
– Mount rebound shim stack 7 with the smaller washers facing

upward.
Info
– Mount compression damping shim 8.
Z00788-10

Guideline
Nut, setting support M12x1 40 Nm (29.5 lbf ft)
– Mount shim stack bk on screw bl with the smaller washers
facing downward.
72
04
Info
0
/0
Z00789-10
57
Mount screw bl with the shim stack and tighten.
04
Guideline
Screw, setting M6x0.5 5 Nm (3.7 lbf ft)
0
,0
l.c r:
support Loctite®243™
ai fo
om
tm ed
9.20 Assembling the damper
ho ns
e
Preparatory work
h@ Lic
– Assemble the compression adjuster. ( p. 74)

fo r |

sh fü
– Assemble the piston rod. ( p. 77)

rt
ta rt
Main work
at ie
– Mount screw 1 with the O-ring and tighten.

M ns
Guideline
h, ze
Screw, filling port 1/8" 14 Nm (10.3 lbf ft)

Li
t
or
hf
Z00765-10
as
– Grease the piston ring and the piston O-ring.

ew

th
– Mount piston 2 of the reservoir.

at
M
Z00801-10
78
– Mount and lubricate the O-ring of the reservoir cover.

– Mount reservoir cover 3.
– Mount circlip 4 .
Z00766-10
– Clamp the shock absorber case as shown.

Guideline
Use soft jaws.
– Mount and grease O-ring 5.
72
–
04
Mount and tighten damper cartridge 6 using the special tool.
Guideline
0
/0
Z00767-10
Damper car- M53x1 110 Nm (81.1 lbf ft)
57
tridge Loctite®2701™
04
Mounting tool (T146) ( p. 467)
0
,0
l.c r:
Clamping bush (T147) ( p. 467)
ai fo
om
– Grease the O-rings of the compression adjuster.
tm ed
ho ns
– Engage high-speed compression adjuster 7 and mount

e
together.
h@ Lic
– Tighten screw cap 8 with a suitable tool.

fo r |
Guideline
sh fü
High-speed compres- M31x1 35 Nm (25.8 lbf ft)

rt
ta rt
Z00768-10 sion adjuster

at ie
– Fill the damper cartridge about half full.

M ns
Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 447)

h, ze
Li
t
or
hf
as
Z00795-10
ew
– Lubricate the O-ring of the seal ring retainer.

th
at
– Mount the piston rod carefully.

M
– Mount seal ring retainer 9.

– Mount circlip bk on the reservoir.
Z00769-10
79
– Mount locking cap bl.

– Mount preload adjuster bm with anti-twist protection and posi-
tion as shown.
Info
The preload adjuster cannot be mounted after the pis-
ton rod has been mounted.
– Bleed and fill the damper. ( p. 81)

Z00770-10
– Fill the damper with nitrogen. ( p. 85)
– Mount rubber cap bn.
72
0 04
/0
Z00771-10
57
Alternative 1
04
– Turn adjusting screw boclockwise with a hexagon socket
0
wrench up to the last perceptible click.
,0
l.c r:
ai fo
om
ing to the shock absorber type.
tm ed
Guideline
ho ns
e
Comfort 21 clicks
h@ Lic
Z00754-11 Standard 12 clicks

Sport 7 clicks
fo r |

sh fü
rt

ta rt
at ie

M ns
Guideline
h, ze

Li
Comfort 1.5 turns

Standard 1.5 turns
Sport 1 turn
t
or
Full payload 1 turn

hf
– Turn adjusting screw bpclockwise with a hexagon socket

as
wrench up to the last perceptible click.

–
ew
Turn counterclockwise by the number of clicks correspond-

th
Guideline
at
Rebound damping
M
Comfort 21 clicks
Standard 15 clicks
Sport 10 clicks
80
Alternative 2
Warning
acteristic.
recommended range.
acteristic.
72
– Turn adjusting screws bo
and bp
to the position deter-
04
mined when the part was removed.
0
/0
57
9.21 Bleeding and filling the damper
0 04
Info
,0
l.c r:
Before working with the vacuum pump, it is essential that you carefully read through the Owner's Manual
ai fo
om
included for the vacuum pump.
tm ed
ho ns
completely.
e
–
h@ Lic
Ensure that vacuum pump 1 is higher than the shock

absorber to be filled.
fo r |
Guideline
sh fü
Ensure that connection line 2 between the vacuum pump

rt
and filling adapter is as short as possible.

ta rt
at ie
Vacuum pump (T1240S) ( p. 465)

M ns
Z00732-10
Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 447)
h, ze
Li

Guideline
Use soft jaws.
t
or
The filling port is at the highest point.

hf
as
Info
The piston rod moves in and out during filling; do not
ew
immobilize it by holding it with your hand.

th
Z00733-10
– Remove filling port screw 3 with the O-ring.
at
M
81
Alternative 1
without bleed container
– Mount adapter 4 on the damper.
Guideline
Hand-tighten only without using a tool.
Filling adapter (T1245S) ( p. 465)
Z00734-10 Info
When filling without a bleed container, air may
become trapped inside the shock absorber.
Alternative 2
with bleed container
– Mount adapter 4 on the damper.
72
Guideline
04
Hand-tighten only without using a tool.
0
Filling adapter (T1245S) ( p. 465)
/0
Filling adapter (T12128) ( p. 464)
57
04
Z00735-10
0
– Connect vacuum pump connection 5.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
Z00738-10
sh fü
– Adjust the control lever as shown.

rt
ta rt
Control lever External tank6 is set to Closed, Damper 7

at ie
is set to Vacuum and Oil reservoir8 is set to Vacuum.

M ns
– Activate On/Off switch bl.

h, ze
The suction process begins.

Li
Pressure gauge 9 drops to the required value.

< 0 bar
t
or
Z00739-10
Vacuum gauge bk drops to the required value.
hf
4 mbar
as
– Determine distance A between the floating piston and reser-

ew
voir hole with the special tool.

th
Depth micrometer (T107S) ( p. 463)

at
The floating piston is located in the lowermost position.

M
Z00736-10
82
– When the vacuum gauge reaches the required value, turn con-
8
trol lever Oil reservoir to Equalize pressure.
Guideline
4 mbar
The pressure gauge rises to the specified value.
0 bar
Z00740-10
– When the pressure gauge reaches the specified value, turn

control lever Damper 7 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
72
04
3 bar
0
/0
Z00741-10
57
04
control lever Damper 7 to Vacuum.
0
Guideline
,0
l.c r:
3 bar
ai fo
om
The pressure gauge drops to the specified value.
tm ed
0 bar
ho ns
e
h@ Lic
Z00740-11

fo r |
8
control lever Oil reservoir to Vacuum.
sh fü
Guideline
rt
ta rt
0 bar
at ie
M ns
The vacuum gauge drops to the specified value.

h, ze
4 mbar
Li
Z00742-10
– When the vacuum gauge reaches the required value, turn con-
t
or
8
trol lever Oil reservoir to Equalize Pressure.
hf
Guideline
as
4 mbar
ew

th
0 bar
at
M
Z00740-10
83
– Build up a counter pressure by hand when extending the pis-

ton rod.
Info
This opens the shims and better fills the spaces
between the shock absorbers.
Z00744-10

control lever Damper 7to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
72
04
3 bar
0
/0
Z00741-10
57
04
control lever Damper 7to Vacuum.
0
Guideline
,0
l.c r:
3 bar
ai fo
om
For an optimal filling process, carry out the entire procedure
tm ed
at least three times.
ho ns
e
0 bar
h@ Lic
Z00740-11
– When the pressure gauge reaches the required value, activate

fo r |
switch On/Off.
sh fü
Guideline
rt
ta rt
0 bar
at ie
The vacuum pump is switched off.

M ns
– Slide O-ring B
to the end of the special tool by the specified
h, ze
value (distance A minus specified value).

Li
Guideline
10 mm
t
or
Depth micrometer (T107S) ( p. 463)

hf
– Slide the floating piston into the reservoir to the shortened

as
position using the special tool.

ew
Z00737-10
Info
th
The floating piston must be positioned at exactly this

at
point when the piston rod is fully extended, otherwise

damage will occur during compression of the shock
M
absorber.
– Remove the special tool.

84
– Remove adapter 4 from connector 5 of the vacuum pump.

– Remove the adapter.
Guideline
Screw, filling port 1/8" 14 Nm (10.3 lbf ft)
Z00743-10
9.22 Filling the damper with nitrogen

– Mount screw 1 with the O-ring and screw in approx. 2 full
turns, but do not tighten it fully.
Guideline
72
The piston rod should be retracted. If the piston rod extends
during filling, it is ensured that nitrogen flows into the con-
04
tainer.
0
/0
57
04
Z00745-10
0
– Secure the special tool in the vise.
,0
l.c r:
Filling tool (T170S1) ( p. 468)
ai fo
om
Filling adapter (T1565) (
tm ed p. 467)
– Connect the special tool to the pressure regulator of the filling
ho ns
cylinder.
e
h@ Lic
Filling gas - nitrogen

– Adjust the pressure regulator.
fo r |
Z00746-10
Guideline
sh fü
Gas pressure 10 bar (145 psi)

rt
ta rt
– Position the damper in the special tool.

at ie
M ns
The hexagonal part of tap handle Aengages in the

hexagon socket of the filling port screw.
h, ze
– Open filler tap B.

Li
– Fill the damper for at least 15 seconds.

Guideline
t
or
Watch the pressure regulator dial. Ensure that the damper is

filled to the specified pressure.
hf

as
– Screw the filling port shut with tap handle A.

ew
– Close spigot B and take the damper out of the special tool.
th
– Tighten the filling port screw 1.

at
Guideline
M
Screw, filling port, M5 4 Nm (3 lbf ft)

reservoir
– Push in the piston rod by hand.
The piston rod extends automatically.
85
9.23 Installing the spring

– Measure the total spring length while the spring is not under
tension.
– Mount spring 2.
Guideline
Spring rate
Weight of rider: 65 … 75 N/mm (428 lb/in)
75 kg (143 … 165 lb.)
Z00763-10
85 kg (165 … 187 lb.)
95 kg (187 … 209 lb.)
72
– Mount washer 3.
04
– Mount washer 4.
0
/0
57
0 04
,0
l.c r:
ai fo
om
Z00764-10
tm ed
ho ns
– Clamp the shock absorber into the special tool.

e
h@ Lic
Spring compressor (T14050S) ( p. 467)

fo r |
Info
sh fü
Use the suitable ring of the special tool with the small-
rt
est possible inside diameter.

ta rt
Ensure that the ring lies only on the spring.

at ie
M ns
– Mount spring seats 6.

Z00751-11
h, ze
– Release the spring. Remove the shock absorber from the spe-
Li
cial tool.
Alternative 1
– Tighten adjuster 7 on the preload adjuster clockwise to
t
or
the specified dimension.

hf
Guideline
as
Spring preload
Standard 8 mm (0.31 in)
ew
Info
th
at
Z00750-11
Corresponds to
position 0 on the
M
preload adjuster.
86
Info
One complete turn of the screw is equivalent to
1 mm (0.04 in) of the preload.
Alternative 2
Warning
acteristic.
recommended range.
72
04
acteristic.
0
/0
57
– Adjust the spring to the dimension determined when it was
04
removed by turning adjuster 7 clockwise.
0
,0
Info
l.c r:
ai fo
One complete turn of the adjuster is equivalent to
om
1 mm (0.04 in) of the preload.
tm ed
ho ns
e
h@ Lic
9.24 Checking the link fork

– Check the link fork for damage, cracking, and deformation.
fo r |
» If the link fork shows signs of damage, cracking, or defor-

sh fü
mation:
rt
ta rt
– Change the link fork.

at ie
M ns
Info
h, ze
Always replace a damaged link fork. Repairing

Li
the link fork is not authorized by KTM.

R01988-10
t
or
9.25 Checking the fork bearing

hf
Preparatory work
as

ew
th
at
M
87
Main work
– Move the link fork up and down.
– Change the link fork bearing. ( p. 93)
– Move the link fork from one side to the other.
– Change the link fork bearing. ( p. 93)
72
0 04
/0
R01908-10
57
Finishing work
04
( p. 18)
0
,0
l.c r:
ai fo
om
9.26 Removing the link fork tm ed
ho ns
Preparatory work
e
h@ Lic

– Raise the motorcycle with the work stand (screw-in type).
fo r |
( p. 15)
sh fü
Main work
rt
ta rt
– Remove inside locking wire 1.

at ie
– Remove outside locking wire 2.

M ns
h, ze
Li
t
or
G04542-10
hf
– Have an assistant operate the rear brake.

as
– Loosen nut 3 and remove it with washer 4.

ew
th
at
M
G04543-10
88
– Take off the rear wheel.
G04511-10
– Remove screws 5. Hang the slave cylinder of the clutch to

the side.
Info
Do not activate the clutch lever while the slave cylinder
of the clutch is removed.
72
–
04
Remove screws 6. Take off the engine sprocket cover.
0
/0
G04545-10
57
– Loosen screw 7.
04
– Turn hub housing 8 clockwise.
0
,0
Holding wrench (61329085000) ( p. 460)
l.c r:
ai fo
Handle for holding wrench (60012060000) ( p. 453)
om
tm ed
The chain is loosened.
–
ho ns
Open the chain. ( p. 155)
– Remove the chain.
e
h@ Lic
B04141-10
Info
fo r |

sh fü
– 9 and bk.
rt
Remove screws
ta rt
–
at ie
Take off the splash protector.

M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
G04546-10
89
– Remove screws bl and bm.

– Lift the chain sliding guard.
G04551-10
– Remove screw bn and pull off wheel speed sensor.

– Remove screws bo.
– Take off the brake caliper and hang to the side.
Info
72
Protect the link fork and the components from damage.
0 04
/0
G04548-10
57
– Remove screws bp.
04
– Push the link fork down. Support the link fork at the rear.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04547-10
– Remove nut bq.

fo r |
– Remove the swingarm pivot. Take off the link fork.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04550-10
t
9.27 Installing the link fork

or
hf
Main work
as
– Position the link fork. Mount the swingarm pivot.

ew
Guideline
th
Nut, fork pivot M19x1.5 130 Nm (95.9 lbf ft)

at
Thread greased
M
G04550-11
90
– Lift the link fork and position the shock absorber.

Guideline
Screw, bottom M14x1.5 80 Nm (59 lbf ft)
G04547-11
– Position the brake caliper. Mount and tighten screws 3.

Guideline
Screw, rear M8 25 Nm (18.4 lbf ft)
– Position the wheel speed sensor. Mount and tighten screw 4.
72
Guideline
04
0
chassis
/0
G04548-11
57
Check the wheel speed sensor distance. ( p. 204)
04
– Mount and tighten screws 5 and 6.
0
– Mount the chain.
,0
l.c r:
– Rivet the chain. ( p. 156)
ai fo
om
tm ed
ho ns
e
h@ Lic
G04551-11
fo r |
– Position the splash protector.

sh fü
rt
Info
ta rt
at ie
Pay attention to the brake line and cable of the wheel

M ns
speed sensor.
h, ze
– Mount and tighten screws7.

Li

t
or
hf
as
ew
th
at
M
G04546-11
91
– Position the engine sprocket cover.

Guideline
chassis
– Position the clutch slave cylinder. Mount and tighten
screws bk
.
Guideline
G04552-11
Clutch slave cylinder M6 10 Nm (7.4 lbf ft)
screw
– Check the rear wheel bearing for damage and wear.
» If the rear wheel bearing is damaged or worn:
– Change the rear wheel bearing. ( p. 176)
72
– Clean and grease the threads of the wheel axle and axle nut.
04
0
/0
– Slide the rear wheel onto the axle.
57
Driving pins A engage in drilled holes B of the rim.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04544-10
rt
ta rt
– Mount washer bl and nut bm.

at ie

M ns
– Tighten nut bm.

h, ze
Guideline
Li
Nut, rear axle M50x1.5 250 Nm (184.4 lbf ft)

Thread greased/lock
locking wire with locking
t
or
varnish
hf
G04543-11
as
– Mount outside locking wire bn.

–
ew
Mount inside locking wire bo.

The pins of the locking wires engage in the drilled holes of
th
the wheel axle.

at
– Adjust the chain tension. ( p. 151)

M
G04542-11
92
Finishing work
– Remove the motorcycle from the work stand (screw-in type).
( p. 16)
troller. ( p. 109)
9.28 Changing the link fork bearing

Preparatory work
– Raise the motorcycle with the work stand (screw-in type).
( p. 15)
72
– Remove the link fork. ( p. 88)
04
Right fork bearing
0
– Remove outer collar bushing
/0
1.
57
– Remove inner collar bushing 2 together with bushing.
0 04
,0
l.c r:
ai fo
om
tm ed
203081-10
ho ns
– Remove radial shaft seal rings 3 and 4.

e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
203082-10
Li
– Position special tool 5 in the needle bearing from the

inside.
Pressing tool (61329004100) ( p. 460)
t
or
– Position special tool 6 on the link fork from the outside.

hf
as
Pressing tool (61329004200) ( p. 460)

–
ew
Push out the needle bearing.

th
203083-10
at
M
93
– Position new needle bearing 7 on the special tool 5.

Pressing tool (61329004100) ( p. 460)
– Position special tool with bearing on the link fork from out-
side.
– Push in the needle bearing until it is flush.
72
0 04
/0
203084-10
57
– Grease new radial shaft seal rings 3 and 4 and press in
04
until they are flush.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
203082-10
– Grease the needle bearing.

fo r |
sh fü

rt
–
ta rt
Mount inner collar bushing 2 together with the bushing.

at ie
– Mount outer collar bushing 1.

M ns
h, ze
Li
203081-10
Left fork bearing

t
or
– Remove the inner collar bushing 8.

hf
– Remove the outer collar bushing 9 together with the

as
bushing.
ew
th
at
M
203085-10
94
– Remove radial shaft seal rings bk and bl.
203086-10
– Remove stop disks bm and bn.
72
0 04
/0
203087-10
57
– Position special tool 5 in the needle bearing.
04
Pressing tool (61329004100) ( p. 460)
0
,0
–
l.c r:
Position special tool 6 in the link fork.
ai fo
om
Pressing tool (61329004200) ( p. 460)
–
tm ed
Push out the needle bearing.
ho ns
e
h@ Lic
203088-10
– Position new needle bearing bo on the special tool 5.

fo r |
sh fü
Pressing tool (61329004100) ( p. 460)

rt
–
ta rt
Position the special tool with bearing on the link fork.

at ie
– Push in the needle bearing until it is flush.

M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
203089-10
95
– Position stop disks bm and bn.
203087-10
– Grease new radial shaft seal rings bk and bl and press in

until they are flush.
72
0 04
/0
203086-10
57
– Grease the needle bearing.
04
0
–
,0
8.
l.c r:
Mount inner collar bushing
ai fo
–
om
Mount outer collar bushing 9 together with the bushing.
tm ed
ho ns
e
h@ Lic
203085-10
Finishing work
fo r |
– Install the link fork. ( p. 90)

sh fü
– Remove the motorcycle from the work stand (screw-in type).

rt
ta rt
( p. 16)
at ie

M ns

h, ze

Li
troller. ( p. 109)
t
or
hf
as
ew
th
at
M
96
EXHAUST SYSTEM 10
10.1 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
– Remove screws1 and take off the cover.

– Remove screw 2 and take off exhaust clamp.
72
S03915-10
04
– Remove screw 3 with the washer.
0
/0
Warning
57
Risk of injury Moving parts of the exhaust valve con-
04
stitute a risk of injury.
0
– Do not touch the exhaust valve if the main silencer
,0
l.c r:
has been removed.
ai fo
om
– Make sure that nobody gets caught when the
tm ed
S03916-10 exhaust valve is actuated.
ho ns
–
e
Take off the main silencer.

h@ Lic
– Remove seal ring 4.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
S03917-10
10.2 Installing the main silencer

t
or
hf
Warning
as

ew

th
has been removed.

at

M
exhaust valve is actuated.

S03917-11
– Mount seal ring 1.

97
10 EXHAUST SYSTEM
– Position the main silencer.

– Mount screw 2 with the washer, but do not tighten yet.
S03916-11
– Position the exhaust clamp.

Guideline
Screw, exhaust M6 8 Nm (5.9 lbf ft)
clamp on main
72
silencer
04
0
Guideline
/0
S03915-11
57
chassis
04
0
,0
–
l.c r:
Tighten screws 4.
ai fo
om
Guideline
tm ed
Screw, heat guard on M5 4 Nm (3 lbf ft)
main silencer
ho ns
e
h@ Lic
10.3 Removing the presilencer

fo r |
Preparatory work
sh fü

rt
ta rt
Main work
at ie
– Loosen lock nuts 1.

M ns
– Screw barrel adjusters 2 in as far as possible.

h, ze
– Loosen nut 3 .
Li
– Detach both throttle cables.
Info
t
or
Do not kink the throttle cables.

hf
G04497-10
as
ew
th
at
M
98
EXHAUST SYSTEM 10
– Remove screw 4.
– Remove screw 5.
– Remove screw 6.
72
04
0
/0
G04498-10
57
– Remove lambda sensor 7.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04499-10
fo r |
– Take off the exhaust clamp.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04500-10
– Take off the presilencer.

t
or
– Remove seal ring 9.

hf
as
ew
th
at
M
G04501-10
99
10 EXHAUST SYSTEM
10.4 Installing the presilencer

Main work
Warning
has been removed.
G04501-11 exhaust valve is actuated.
– Mount seal ring 1.

– Position the presilencer.
– Position the exhaust clamps and mount and tighten
72
screws 2 .
04
Guideline
0
Screw, presi- M6 8 Nm (5.9 lbf ft)
/0
lencer exhaust Copper paste
57
clamp
0 04
,0
G04500-11
l.c r:
ai fo
–
om
Mount and tighten lambda sensor 3.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
G04499-11
ta rt
at ie

M ns

h, ze

Li
Guideline
chassis
t
or
hf
as
ew
th
at
M
G04498-10
100
EXHAUST SYSTEM 10
– Attach the throttle cables to the mount of the exhaust valve.

– Tighten nut 7.
– Unscrew barrel adjusters 8.
– Hold the barrel adjusters and tighten lock nut 9.
G04497-11
Finishing work
troller. ( p. 109)
72
10.5 Removing the manifold
04
Preparatory work
0
– Remove the passenger seat. (
/0
p. 118)
57
04
0
,0
l.c r:
ai fo
om
Main work
tm ed
ho ns
–
e
Expose the cable.

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
G04513-10
M ns

h, ze
– Expose the cable.

Li
t
or
hf
as
ew
G04512-10
th
at
M
101
10 EXHAUST SYSTEM
– Remove nuts 2.
– Take off the manifold.
G04514-10

72
04
0
/0
G04519-10
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04518-10
– Remove nuts 4.
fo r |
– Take off the manifold.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04515-10
– Remove exhaust gaskets 5.

t
or
hf
as
ew
th
at
M
G04520-10
102
EXHAUST SYSTEM 10
10.6 Installing the manifold

Main work
– Position exhaust gaskets 1.
G04520-11
– Position the manifold.

– Mount and tighten nuts 2.
Guideline
72
Nut, manifold on M8 Tightening
cylinder head sequence:
04
Tighten the nuts
0
evenly. Do not warp
/0
the metal plate.
57
G04515-11 25 Nm (18.4 lbf ft)
04
0
,0
l.c r:
– Position the cable ties and secure the cable.
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
G04518-10
sh fü
– Join plug-in connector 3.

rt
ta rt
at ie
M ns
h, ze
Li
t
or
G04519-10
hf
– Mount and tighten nuts 4.

as
Guideline
ew
Nut, manifold on M8 Tightening

cylinder head sequence:
th
Tighten the nuts

at
evenly. Do not warp

M
the metal plate.

25 Nm (18.4 lbf ft)
G04514-11
103
10 EXHAUST SYSTEM

– Position the cable ties and secure the cable.
G04512-10
72
04
0
/0
G04513-11
57
Finishing work
04
0
,0
l.c r:
troller. ( p. 109)
ai fo
om
– tm ed
Install the fuel tank. ( p. 123)
ho ns

e
h@ Lic

fo r |
sh fü
10.7 Removing control motor of exhaust valve controller

rt
ta rt
Preparatory work
at ie

M ns
Main work
h, ze

Li
– Screw barrel adjusters 2 in as far as possible.

– Loosen nut 3.
t

or
hf
Info
as
Do not kink the throttle cables.

ew
G04497-10
th
at
M
104
EXHAUST SYSTEM 10
G04525-10
72
0 04
/0
G04526-10
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04522-10
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04523-10
t
or
hf
as
ew
th
at
M
G04524-10
105
10 EXHAUST SYSTEM
– Lower the lower part of the subframe.
G04527-10
– Remove the actuator.
72
0 04
/0
G04528-10
57
– Detach throttle cable bk.
04
– Detach throttle cable bl.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04529-10
fo r |
10.8 Installing control motor of exhaust valve controller

sh fü
Main work
rt
ta rt
– Attach throttle cables 1 and 2 on the exhaust valve actua-

at ie
tor.
M ns
h, ze
Li
t
or
G04529-11
hf
– Position the actuator.

as

ew
Guideline
th
chassis
at
M
G04528-11
106
EXHAUST SYSTEM 10
– Position the lower part of the subframe.

Guideline
chassis
G04524-11

Guideline
chassis
72
0 04
/0
G04523-11
57
04
Guideline
0
,0
l.c r:
chassis
ai fo
om
tm ed
ho ns
e
h@ Lic
G04522-10

fo r |
Guideline
sh fü

rt
ta rt
chassis
at ie
M ns
h, ze
Li
G04526-11

t
or
Guideline
hf

as
chassis
ew
th
at
M
G04525-11
107
10 EXHAUST SYSTEM

– Tighten nut 9.
– Unscrew adjusting screws bk.
– Mount and tighten screws bl.
There is no play in the throttle cable, but it is not under
tension.
G04497-12
Finishing work
– Adjust throttle cable tension of the exhaust valve controller.
( p. 110)
troller. ( p. 109)
72
0 04
10.9 Changing throttle cables of exhaust valve controller
/0
57
Preparatory work
04
– Remove control motor of exhaust valve controller. ( p. 104)
0
,0
l.c r:
Main work
ai fo
om
– tm ed
Screw barrel adjusters 2 in as far as possible.
ho ns
– Loosen nut 3.
e

h@ Lic
fo r |
sh fü
G04497-10
rt
ta rt
– Detach throttle cable 4 on the exhaust valve actuator and

at ie
remove.
M ns
h, ze
Li
t
or
hf
G04603-10
as
– Turn the cable disk counterclockwise by 90°.

–
ew
Detach throttle cable 5 on the exhaust valve control motor

and remove.
th
at
M
G04604-10
108
EXHAUST SYSTEM 10
– Attach new throttle cable 7 on the exhaust valve control

motor.
Info
The shorter throttle cable with the smaller spoke nipple
is mounted in location A .
G04605-10
– Turn the cable disk clockwise by 90°.

– Attach new throttle cable 8 on the exhaust valve control
motor.
Info
The longer throttle cable with the larger spoke nipple is
72
mounted in location B.
0 04
/0
G04606-10
57
04
– Tighten nut 9.
0
Guideline
,0
l.c r:
Lock nut, exhaust M6 5 Nm (3.7 lbf ft)
ai fo
om
valve throttle cable
tm ed
– Push down the exhaust flap until you feel resistance.
ho ns
– Unscrew barrel adjusters bk until the exhaust valve is as far

e
as it will go.
h@ Lic
G04497-12
fo r |
There is no play in the throttle cable, but it is not under

sh fü
tension.
rt
Finishing work
ta rt
– Install the control motor of exhaust valve controller.

at ie
M ns
( p. 106)
h, ze
– Adjust throttle cable tension of the exhaust valve controller.

Li
( p. 110)
troller. ( p. 109)
t
or
hf
as
10.10 Checking throttle cable tension of the exhaust valve controller

ew
Warning
th
Risk of injury Moving parts of the exhaust valve constitute a risk of injury.

at
– Do not touch the exhaust valve if the main silencer has been removed.
M
– Make sure that nobody gets caught when the exhaust valve is actuated.
109
10 EXHAUST SYSTEM
Info
This work can only be performed when the engine is cold.
Condition
The diagnostics tool is connected and running.
– Execute "Exhaust value controller SAC" > "Functions" > "Adjust
throttle cable tension".
The black bar is in the green area of the indicator.
» If the specifications have been met:
– Close the program and unplug the diagnostics tool.
» If the measured value is less than the specification:
– Adjust throttle cable tension of the exhaust valve con-
troller. ( p. 110)
H02627-01
72
04
10.11 Adjusting throttle cable tension of the exhaust valve controller
0
/0
Info
57
This work can only be performed when the engine is cold.
0 04
Condition
,0
l.c r:
ai fo
om
Preparatory work
tm ed
ho ns
troller. ( p. 109)
e
Main work
h@ Lic
Warning
fo r |

sh fü

rt
ta rt

at ie
has been removed.

M ns

h, ze
G04521-10 exhaust valve is actuated.

Li
– Loosen lock nut 1.

– Adjust the throttle cable tension by turning the adjusting
t
or
screw .2
hf
Info
as
Turning clockwise increases the throttle cable tension.

ew
Turning counterclockwise reduces the throttle cable

tension.
th
The throttle cable tension is adjusted only on the upper

at
rebound.
M
– Hold adjusting screw 2 and tighten lock nut 1.

Guideline
Lock nut, exhaust M6 5 Nm (3.7 lbf ft)
valve throttle cable
110
M
at
th
ew
as
hf
or Li
th, ze
M ns
Finishing work
at ie
ta rt
sh fü
troller. ( p. 109)
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0
04
111
57
/0
0 04
72
EXHAUST SYSTEM 10

11 AIR FILTER
11.1 Removing the upper part of the air filter box

Preparatory work
Main work
– Unplug connector 1. Expose the cable.
– Pull off vent hose 2.
Spring band clamps plier (60029057100) ( p. 455)
– Pull off the vent hose.
72
G04478-10
04
– Open clamps 3.
0
/0
– Remove the upper part of the air filter box.
57
0 04
,0
l.c r:
ai fo
om
tm ed
G04479-10
ho ns
e
11.2 Changing the air filter, cleaning the air filter box
h@ Lic
Preparatory work
fo r |

sh fü

rt
ta rt

at ie

M ns
– Remove the upper part of the air filter box. ( p. 112)

h, ze
Main work
Li
– Remove air filter 1 upward.

– Clean the air filter box.
t
or
hf
as
ew
G04480-10
th
at
M
112
AIR FILTER 11
– Fit new air filter 1.
G04480-10
Finishing work
– Install the upper part of the air filter box. ( p. 113)
–
72
Install the spoiler. ( p. 120)
004
11.3 Installing the upper part of the air filter box
/0
57
Main work
04
– Position the upper part of the air filter box.
0
– Fasten clamps 1.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04479-11
– Mount vent hose 2.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04478-11
Finishing work
t
or

hf

as

–
ew

th
at
M
113
11 AIR FILTER
11.4 Removing the air filter box

Preparatory work
Main work
– Remove air filter 1.
72
04
G04480-10
0
/0
– 2.
Unplug connector
57
04
– Disconnect fuel connection 4.
0
– Take off the fuel line.
,0
l.c r:
ai fo
om
Info
tm ed Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
ho ns
Info
e
h@ Lic
Remaining fuel may flow out of the fuel line.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04492-10
–
t
Remove the intake trumpet.

or
hf
as
ew
th
at
G04482-10
M
114
AIR FILTER 11
– Remove spring band clamp 6.

– Pull off the SAS hose.
G04491-10

– Expose and disconnect plug-in connector 8.
– Lift the lower part of the air filter box carefully.
72
0 04
/0
G04493-10
57
– Remove the lower part of the air filter box with O-rings 9.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04494-10
fo r |
11.5 Installing the lower part of the air filter box

sh fü
Main work
rt
ta rt
– Position the base of the air filter box with O-rings 1 in the
at ie
frame.
M ns
– Push intake snorkel A onto intake channel B.

h, ze
Guideline
Li
Ensure that the intake snorkels and O-rings are positioned

correctly.
t
or
hf
as
ew
th
at
M
G04494-11
115
11 AIR FILTER

G04493-11
– Mount the SAS hose.

– Mount spring band clamp 4.
72
0 04
/0
G04491-11
57
– Position the intake trumpet.
04
0
Guideline
,0
l.c r:
ai fo
om
chassis
tm ed
ho ns
e
h@ Lic
G04482-10
– Position the fuel line and injection valves.

fo r |
– Join fuel connection 6.

sh fü

rt
ta rt
– 8
at ie
Join connector .
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
G04492-11
116
AIR FILTER 11
– Mount air filter 9.
G04480-11
Finishing work
–
72
004
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
117
12 FUEL TANK, SEAT, TRIM
12.1 Removing the front rider's seat

Preparatory work
Main work
– Unlock the front rider's seat with loop 1 underneath the pas-
senger seat.
– Raise the front rider's seat at the rear and remove it.
S03913-10
12.2 Mounting the front rider's seat
72
Main work
04
– Hook recess 1 of the front rider's seat into guide 2, lower it
0
at the rear and push it forward.
/0
57
– Position the locking pin in the lock housing and push the pas-
senger seat down at the front.
04
The locking pin engages with an audible click.
0
,0
– Check that the front rider's seat is mounted correctly.
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
S03914-10
h, ze
Finishing work
Li

t
or
12.3 Removing the passenger seat

hf
– Insert the RACE-ON key or the black ignition key into seat
as
lock 1 and turn clockwise.

– Lift passenger seat at the front and pull it out of the bracket
ew
toward the front.

th
– Remove the passenger seat.

at
– Remove the ignition key.

M
S03911-10
118
FUEL TANK, SEAT, TRIM 12
12.4 Mounting the passenger seat

– Hook recesses 1 of the passenger seat in guides 2 and
lower the front seat while pushing it back.
– Position the locking pin in the lock housing and push the pas-
senger seat down at the front.
The locking pin engages with an audible click.
– Check that the passenger seat is mounted correctly.
72
0 04
/0
57
04
S03912-10
0
12.5 Removing the spoiler
,0
l.c r:
ai fo
om
Info tm ed
The operations are the same for the left and right sides.
ho ns
e
– Raise fuel tank cover 1 at the front and take it off in an

h@ Lic
upward direction.
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
G04484-10
Li
t
or
hf
as
ew
th
at
M
119
– Remove screws 2 and 3.

– Take off the spoiler at the front.
72
04
0
/0
G04483-10
57
12.6 Installing the spoiler
0 04
,0
Info
l.c r:
ai fo
The operations are the same for the left and right sides.
om
tm ed
– Position the spoiler.
ho ns
Screws A engage in the brackets B.

e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
G04485-10
th
at
M
120

Guideline
Screw for spoiler M5 3 Nm (2.2 lbf ft)
72
0 04
/0
G04483-11
57
– Mount fuel tank cover 3.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04484-11
fo r |
12.7 Removing the fuel tank

sh fü
rt
ta rt
Danger
at ie
Fire hazard Fuel is highly flammable.

M ns
The fuel in the fuel tank expands when warm and can escape if overfilled.
h, ze
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
Li
– Switch off the engine for refueling.

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
t
or
– Observe the specifications for refueling.

hf
as
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
ew
– Avoid skin, eye and clothing contact with fuel.

th
– Immediately consult a doctor if you swallow fuel.

at
– Do not inhale fuel vapors.

M
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
121
Preparatory work
Main work
G04465-10
72
0 04
/0
57
0 04
,0
l.c r:
G04466-10
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
G04467-10
at ie

M ns
– Pull off vent hoses 5.

h, ze
Li
t
or
hf
as
G04468-10
ew
– Carefully raise the fuel tank and move it backwards.

– Thoroughly clean fuel hose connection 6 of the fuel line
th
using compressed air.

at
M
Info
Under no circumstances should dirt enter into the fuel
– Press the metal plate and disconnect the fuel hose connection.
G04469-10
122
Info
Remaining fuel may flow out of the fuel hose.
– Assemble the wash cap set.

Wash cap set (81212016000)
– Remove the fuel tank towards the rear.
72
04
G04470-10
0
/0
12.8 Installing the fuel tank
57
04
Danger
0
,0
l.c r:
ai fo
om
–
tm ed
Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
ho ns
e
h@ Lic

fo r |
sh fü
Warning
rt
ta rt

at ie

M ns

h, ze

Li
t
or
hf
as
Main work
– Position the fuel tank.
ew
th
at
M
G04470-10
123
– Raise the fuel tank at the rear.

– Thoroughly clean the fuel hose connection of the fuel line
Info
G04469-11 line. Dirt in the fuel line clogs the injection valve!
– Remove the wash cap set.

– Join fuel hose connection 3.
– Mount vent hoses 4.
72
0 04
/0
57
04
G04468-11
0
,0
– Position the fuel tank.
l.c r:
ai fo
–
om
Mount screws 6.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04467-11
rt
– Position the fuel tank cover.

ta rt
at ie
– Mount screws 7.
M ns
h, ze
Li
t
or
G04466-11
hf
–
as
Mount screws 8.
ew
th
at
M
G04465-11
124
Finishing work
12.9 Checking the fuel pressure
Danger
72
04
0
/0
Warning
57
04
–
0
Immediately consult a doctor if you swallow fuel.
,0
l.c r:
ai fo
om
–
tm ed
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
ho ns
–
e
Keep fuels correctly in a suitable canister, and out of the reach of children.
h@ Lic
Condition
fo r |
The fuel tank is completely full.

sh fü
Ensure that the battery voltage does not drop below 12.5 V.
The ignition is switched off.
rt
ta rt
The diagnostics tool is connected.

at ie
M ns
– Thoroughly clean fuel hose connection 1 of the fuel line

h, ze
Li
Info
t
or
– Press the metal plate and disconnect the fuel hose connection.
hf
as
G04488-10 Info
ew
Remaining fuel may flow out of the fuel hose.

th
at
M
125
– Mount special tool 2.

Pressure testing tool (61029094000) ( p. 456)
– Mount special tool 3 with nozzle code 1,05.
Testing hose (61029093000) ( p. 456)
– Position the hose end in a fuel can.
Guideline
Minimum size, fuel can 10 l (2.6 US gal)
400926-10
– Start the diagnostics software.

– Execute "Engine Electronics" > "Actuator Test" >
"Function test of fuel pump controller".
– Check the fuel pressure with the fuel tank filler cap closed.
Fuel pressure
72
When the fuel pump is 3.8 … 4.2 bar (55 …
active 61 psi)
0 04
» If the specification is not reached:
/0
– Open the fuel tank filler cap.
57
– Check the fuel tank breather.
04
400927-01
0
,0
l.c r:
– Check the fuel pressure with the fuel tank filler cap open.
ai fo
om
Fuel pressure
tm ed When the fuel pump is 3.8 … 4.2 bar (55 …
ho ns
active 61 psi)
e
» If the specification is not reached:

h@ Lic
– Check that the fuel line is clear.

– Change the fuel filter. ( p. 128)
fo r |
– Change the fuel pump. ( p. 127)

sh fü
400928-01
– Finish the actuator test.
rt
ta rt
– Remove the special tools.

at ie
M ns
– Thoroughly clean the plug-in connection of the fuel line using

compressed air.
h, ze
Li
Info
t
or
– Join the fuel hose connection 1.

hf
as
G04488-10
ew
th
at
M
126
12.10 Changing the fuel pump
Danger
Warning
72
04
0
/0
57
04
0
,0
l.c r:
ai fo
Preparatory work
om
– Remove the passenger seat. (
tm ed p. 118)
ho ns

e

h@ Lic
– Drain the fuel from the fuel tank into a suitable container.
fo r |
Main work
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04486-10
t
or
– Pull out the fuel pump.

hf
– Position the new fuel pump with the gasket in the fuel tank.
as
ew
th
at
M
G04487-10
127

Guideline
Screw, fuel pump M6 6 Nm (4.4 lbf ft)
G04486-10
Finishing work
72
04
12.11 Changing the fuel filter
0
/0
57
Danger
04
0
,0
l.c r:
ai fo
om
–
tm ed
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
ho ns
e

h@ Lic
Warning
fo r |

sh fü

rt
ta rt

at ie

M ns
h, ze
Li

t
or
Preparatory work
hf

as

ew

th
– Drain the fuel from the fuel tank into a suitable container.
at
M
128
Main work
G04486-10
– Pull out the fuel pump.
72
004
/0
G04487-10
57
– Push clamps 2 outward.
04
– Take off the fuel filter housing.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
306644-10
– Remove gasket 3.
fo r |
– Take off fuel pipe 4.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
306645-10
– Detach connectors 5 and 6.

t
or
hf
as
ew
th
at
M
306646-10
129
306647-10
72
0 04
/0
306648-10
57
– Remove retaining brackets 9 and bk.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
306649-10
– Remove plastic housing bl with the distance sleeves.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
306650-10
– Take the fuel pump out of the fuel pump cover.

t
or
hf
as
ew
th
at
M
306651-10
130
– Take off sealing element bm.
306652-10
– Remove fuel filter.

– Mount the new fuel filter.
72
0 04
/0
306653-10
57
– Release latch bn.
04
– Pull off the outer fuel filter housing.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
306654-10
– Take off fuel filter bo.

fo r |
– Mount the new fuel filter.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
306655-10
– Mount the outer fuel filter housing.

t
or
Locking mechanism bn engages in the fuel filter housing.

hf
as
ew
th
at
M
306654-10
131
– Mount sealing element bm.
306652-10
– Position the fuel pump in the fuel pump cover.
72
0 04
/0
306651-10
57
– Mount plastic housing bl with the distance sleeves.
04
The holding lugs of the plastic housing engage in the
0
holes of the fuel pump cover.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
306650-10
– Mount retaining brackets 9 and bk.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
306649-10

t
or
hf
as
ew
th
at
M
306648-10
132
– Mount and tighten screw 7 with the washer.
306647-10
– Plug in connectors 5 and 6.
72
0 04
/0
306646-10
57
– Mount gasket 3.
04
– Mount fuel pipe 4.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
306645-10
– Mount the fuel filter housing.

fo r |
Clamps 2 must engage.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
306644-11
– Position the fuel pump with the gasket in the fuel tank.
t
or
hf
as
ew
th
at
M
G04487-10
133

Guideline
G04486-10
Finishing work
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
134
MASK, FENDER, DECAL 13
13.1 Removing front fender

– Take off the fender.
Info
Pay attention to the brake lines.
G04495-10
13.2 Installing front fender

– Position the fender.
72
Info
04
Pay attention to where the brake lines are placed.
0
/0
57
Guideline
04
Screw, trim M5 3.5 Nm
0
(2.58 lbf ft)
,0
l.c r:
G04495-10
–
ai fo
Mount and tighten screws 2.
om
Guideline tm ed
ho ns
chassis
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
135
14 WHEELS
14.1 Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
– Remove the protection cap.

– Check the tire pressure when the tires are cold.
Tire pressure when solo
front: with cold tires 2.5 bar (36 psi)
rear: with cold tires 2.5 bar (36 psi)
Tire pressure with passenger / full payload

400695-01
72
04
» If the tire pressure does not meet specifications:
0
– Correct the tire pressure.
/0
– Mount the protection cap.
57
0 04
14.2 Checking the tire condition
,0
l.c r:
ai fo
om
Warning tm ed
Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable.
ho ns
– Ensure that damaged or worn tires are replaced immediately.
e
h@ Lic
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
fo r |
teristic.
sh fü
Different tire tread patterns can make the vehicle significantly more difficult to control.
rt
ta rt
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
at ie
M ns
Warning
h, ze
Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character-
Li
istic.
– Only use tires/wheels approved by KTM with the corresponding speed index.
t
Warning
or
Danger of accidents New tires have reduced road grip.

hf
The contact surface on new tires is not yet roughened.

as
– Run in new tires with moderate riding at alternating angles.

ew
Running-in phase 200 km (124 mi)

th
at
Info
M
Tire type, tire condition, and tire pressure influence the braking and handling characteristics of the vehi-
cle.
Worn tires are particularly unfavorable on wet surfaces.
136
WHEELS 14
– Check front and rear tires for cuts, run-in objects, and other
damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check tread depth.
Info
Observe the minimum profile depth required by
400602-10 national law.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum tread depth:
– Check tire age.
72
Info
04
The tire date of manufacture is usually contained in the
0
tire label and is indicated by the last four digits of the
/0
DOT number. The first two digits indicate the week of
57
manufacture and the last two digits the year of manu-
04
facture.
KTM recommends that the tires be changed after 5
0
,0
years at the latest, regardless of the actual state of
l.c r:
H01144-01
ai fo
wear.
om
»
tm ed
If the tires are more than 5 years old:
ho ns
e
h@ Lic
14.3 Checking the brake discs

fo r |
sh fü
Warning
rt
ta rt
Danger of accidents Worn-out brake discs reduce the braking effect.

at ie
– Make sure that worn-out brake discs are replaced immediately.

M ns
h, ze
– Check the front and rear brake disc thickness at multiple

Li
points for the dimension . A

Info
t
Wear will reduce the thickness of the brake disc at con-

or
tact surface1 of the brake linings.

hf
as
Brake discs - wear limit

ew
front 4.5 mm (0.177 in)

100135-10
rear 4.5 mm (0.177 in)
th
at
» If the brake disc thickness is less than the specified value:

M
– Change the front brake discs. ( p. 142)

– Change the rear brake disc. ( p. 148)
– Check the front and rear brake discs for damage, cracking, and
deformation.
137
14 WHEELS
» If the brake disc exhibits damage, cracking, or deforma-

tion:
– Change the front brake discs. ( p. 142)
– Change the rear brake disc. ( p. 148)
14.4 Checking the wheel bearings

Preparatory work
Main work
– Move the front wheel from side to side.
Info
Hold the fork leg to check it.
72
04
0
/0
57
R01909-10
04
0
– Move the rear wheel from side to side.
,0
l.c r:
ai fo
om
Info
tm ed Hold the link fork to check it.
ho ns

e

h@ Lic
R01912-10
fo r |
Finishing work
sh fü

rt
ta rt
( p. 18)
at ie
M ns
h, ze
14.5 Changing the tire pressure sensor (EU/US)

Li
Info
The following steps are the same for the front and rear wheel.
t
or
hf
Condition
Tire has been removed.
as
Main work
ew
– Remove nut 1.
th
– Take off valve 2 and tire pressure sensor 3.

at
M
D03965-10
138
WHEELS 14
– Note the ID number A of the new tire pressure sensor.

Info
The ID number is used to program the tire pressure
sensor.
D03966-10
– Grease O-ring 4 slightly.

Thinned tire mounting paste
– Position valve 2 in the hole on the rim.
The valve points towards the rim tape.
–
72
Position new tire pressure sensor 3 with nut 1 on the valve.
The tire pressure sensor points backward in the direction
04
of travel.
0
/0
D03968-10 – Tighten nut 1.
57
Guideline
04
Nut, valve M8 6 Nm (4.4 lbf ft)
0
,0
Finishing work
l.c r:
– Mount and balance tires.
ai fo
om
tm ed
ho ns
14.6 Programming the tire pressure sensor (EU/US)
e
Condition
h@ Lic

fo r |
Alternative 1
– Execute "Tire pressure monitor" > "Functions" > "Program-
sh fü
ming the tire air pressure sensor" > "Select the wheel".
rt
ta rt
at ie
Info
M ns
The instructions must be followed precisely.

h, ze
Alternative 2
Li
– Execute "Tire pressure monitor" > "Functions" >

H02627-01 "Tire air pressure sensor activation via TPMS tool" >
"Select the wheel".
t
or
hf
Info
as
A TPMS tool is required for this function.

The instructions must be followed precisely.
ew
– Clear the fault memory using the KTM diagnostics tool.

th
» Take a test ride.

at
– Read out the fault memory using the KTM diagnostics

M
tool.
139
14 WHEELS
14.7 Front wheel
14.7.1 Removing the front wheel

Preparatory work
Main work
– Remove screws 1 from both brake calipers.
– Press back the brake linings by slightly tilting the brake
calipers laterally on the brake disc. Pull the brake calipers
carefully back from the brake discs and hang to the side.
Info
Do not operate the hand brake lever if the brake
calipers have been removed.
72
S03926-10
04
– Loosen screw 2 and screws 3.
0
– Unscrew screw 2 about six turns and press your hand on the
/0
screw to push the wheel spindle out of the axle clamp. Remove
57
screw 2
.
0 04
Warning
,0
l.c r:
Danger of accidents Damaged brake discs reduce the
ai fo
om
braking effect.
R01778-10
tm ed – Always lay the wheel down in such a way that the
ho ns
brake discs are not damaged.
e
h@ Lic
– Hold the front wheel and remove the wheel spindle. Take the
front wheel out of the fork.
fo r |
– Remove spacers 4.
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
S03928-10
t
or
hf
14.7.2 Installing the front wheel

as

ew

th
– Clean and grease shaft seal rings 1 and contact surfaces A

at
of the spacers.
M
S03928-11
140
WHEELS 14
– Insert wide spacer 2 on the left in the direction of travel.

Info
Arrow B indicates the direction of travel of the front
wheel.
The wheel speed sensor wheel is on the left viewed in
the direction of travel.
– Insert the narrow spacer on the right in the direction of travel.

S03929-10
Warning
72
essary.
0 04
/0
S03930-10 – Clean screw3 and wheel spindle 4.
57
– Grease wheel spindle 4 lightly.
04
0
,0
l.c r:
ai fo
wheel spindle.
om
– Mount and tighten screw
tm ed 3.
Guideline
ho ns

e

h@ Lic
– Position brake calipers and check that the brake linings are
fo r |
seated correctly.
sh fü
– Mount screws 5 on both brake calipers but do not tighten

rt
ta rt
yet.
at ie
M ns
h, ze
point. Secure the hand brake lever in the activated position.

Li

S03926-11 – Tighten screws 5 on both brake calipers.
Guideline
t
or

hf

as

–
ew
Take the motorcycle off the front lifting gear. ( p. 15)

th
( p. 19)
at
M
141
14 WHEELS
firmly.
Guideline
S03927-10
14.7.3 Changing the front brake discs
Info
If the brake discs are changed, the brake linings must also be changed.
72
Preparatory work
04
0
/0
– Remove the front wheel. ( p. 140)
57
Right-hand side
04
0
– Take off the brake disc.
,0
l.c r:
– Clean the contact surface of the brake disc.
ai fo
om
– Position the brake disc with the label facing outward.
tm ed
ho ns
Guideline
e

h@ Lic
G04490-10
brake disc Loctite®2701™
fo r |
Left-hand side
sh fü
rt
ta rt
– Take off wheel speed sensor wheel 3.

at ie

M ns

h, ze
– Position the brake disc with the label facing outward.

Li
– Position wheel speed sensor wheel 3.

G04489-10
Guideline
t
or

hf

as
Finishing work
ew
– Install the front wheel. ( p. 140)

th
at
14.7.4 Changing the front wheel bearing

M
Preparatory work
– Remove the front wheel. ( p. 140)
142
WHEELS 14
Main work
– Remove right radial shaft seal ring 1.
– Remove left radial shaft seal ring 2.
T00267-10
72
0 04
/0
202979-10
57
– Press out right wheel bearing 4 with a suitable tool.
04
Info
0
,0
l.c r:
Spacing tube 5 can be pushed aside.
ai fo
om
– Remove the spacing tube.
tm ed
ho ns
e
h@ Lic
T00268-10
– Press out the left wheel bearing 6 with a suitable tool.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
T00269-10
– Press in the new left wheel bearing 6 all the way with a suit-
t
or
able tool.
hf
as
Info
ew

th
pressed in.
at
– Mount lock ring 3.

M
T00270-10
143
14 WHEELS
– Clean, grease, and mount spacing tube 5.

– Press in the new right wheel bearing 4 all the way using a
suitable tool.
Info
T00271-10
pressed in.
– Grease new left radial shaft seal ring 2 and press it in until it
is flush.
– Grease new right radial shaft seal ring 1 and press it in until
it is flush.
72
0 04
/0
57
T00267-11
Finishing work
04
– Install the front wheel. ( p. 140)
0
,0
l.c r:
ai fo
om
14.8 Rear wheel tm ed
ho ns
14.8.1 Removing the rear wheel with the work stand
e
Preparatory work
h@ Lic

fo r |
Main work
sh fü
– Remove the inside locking wire 1.

rt
ta rt
– 2.
at ie
Remove the outside locking wire

M ns
h, ze
Li
t
S03931-10
or

hf

as
ew
th
at
M
S03932-10
144
WHEELS 14
G04511-10
14.8.2 Installing the rear wheel with the work stand
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
72
– Clean the brake discs with brake cleaner when necessary.
04
Warning
0
/0
Danger of accidents There is no braking effect to start with at the rear brake after installing the rear
57
wheel.
04
– Actuate the foot brake several times before going on a ride until you can feel a firm pressure point.
0
,0
l.c r:
Main work
ai fo
om
» tm ed
If the rear wheel bearing is damaged or worn:
–
ho ns
Change the rear wheel bearing. ( p. 176)
e
h@ Lic

fo r |
sh fü
S03933-10 1 engage in drilled holes A of the rim.

Driving pins
rt
ta rt
– Mount washer 2 and nut 3.

at ie

M ns
– Tighten nut 3.
h, ze
Guideline
Li

Thread greased/lock
t
or
varnish
hf
S03932-11
as
– Mount outside locking wire4.

ew
– Mount inside locking wire 5.

th
the wheel axle.

at
M
S03931-11
145
14 WHEELS
Finishing work
( p. 18)
14.8.3 Removing the rear wheel

Preparatory work
Main work
– Remove inside locking wire 1.
– Remove outside locking wire 2.
72
0 04
/0
57
S03931-10
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
S03932-10
sh fü
14.8.4 Installing the rear wheel

rt
ta rt
at ie
Warning
M ns
h, ze

Li
Main work
t
or

hf
» If the rear wheel bearing is damaged or worn:

as

–
ew
Clean and grease the threads of the wheel axle and axle nut.
th
at

M
S03933-10 Driving pins 1 engage in drilled holes A of the rim.

146
WHEELS 14

– Tighten nut 3.
Guideline
Thread greased/lock
varnish
S03932-11

the wheel axle.
72
0 04
/0
S03931-11
57
Finishing work
04
( p. 19)
0
,0
l.c r:
ai fo
om
tm ed
14.8.5 Checking that the rear wheel nut (right side) is tightened to the specified torque
ho ns
Preparatory work
e

h@ Lic
Main work
fo r |
– Remove the inside locking wire 1.

sh fü
– Remove the outside locking wire 2.

rt
ta rt
at ie
M ns
h, ze
Li
S03931-10

t
or

hf
as

ew

th

at
– Tighten nut 3.
M
S03932-10
Guideline
Thread greased/lock
varnish
147
14 WHEELS

the wheel axle.
S03931-10
Finishing work
( p. 18)
14.8.6 Changing the rear brake disc
72
04
Info
If the brake discs are changed, the brake linings must also be changed.
0
/0
57
Preparatory work
04
–
0
Remove main silencer. ( p. 97)
,0
l.c r:
ai fo
om
– Remove the rear sprocket carrier. ( p. 153)
tm ed
Main work
ho ns
e
– Hang the brake caliper to the side.

h@ Lic
Info
fo r |

sh fü
Do not operate the foot brake when the brake caliper is

rt
removed.
ta rt
at ie
203038-10
M ns
– Remove axle 2 from the hub housing.

h, ze
Li
t
or
hf
as
ew
203039-10
th
at
M
148
WHEELS 14
– Take off wheel speed sensor wheel 4.
203040-10

– Position new brake disc with the label facing the contact sur-
face.
– Position wheel speed sensor wheel 4.
72
Guideline
04
0
/0
T00261-10
– Clean and grease pivot point A of the axle.
57
04
0
– Clean and grease radial shaft seal rings 5 and contact sur-
,0
l.c r:
face B of the spacer ring.
ai fo
om
Long-life grease (
tm ed p. 448)
ho ns
e
h@ Lic
fo r |
T00262-10
sh fü
– Position axle 2 in the bearing seat of the hub housing.

rt
ta rt
at ie
M ns
h, ze
Li
t
or
203039-10
hf

as
Guideline
ew

th
at
– Operate the foot brake lever repeatedly until the brake lin-
M
point.
203038-10
149
14 WHEELS
Finishing work
– Install the rear sprocket carrier. ( p. 154)
– Install the rear wheel with the work stand. ( p. 145)
( p. 18)
14.8.7 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
72
wheel bearings wear more quickly. Some components may break if overloaded.
04
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
0
/0
– Check the chain tension regularly.
57
– Set the chain tension in accordance with the specification.
0 04
Preparatory work
,0
l.c r:
ai fo
om
Main work
tm ed
ho ns
– At the chain sliding guard in the area of markings and A B,
e
push the chain upward and determine the chain tension.

h@ Lic
Info
fo r |
The lower chain section must be taut.

sh fü
Chain wear is not always even, so you should repeat

rt
this measurement at different chain positions.

ta rt
S03918-10
at ie
The upper edge of the chain is located between

M ns
markings A and B .
h, ze
» If the chain tension does not meet the specification:

Li

– Check protection caps 1 for damage and tightness.
t
or
» If the protection caps are damaged or loose:

hf
– Replace the protection caps.

as
Link fork protection cap (61304041100)

ew
th
at
M
H00380-11
Finishing work
( p. 19)
150
WHEELS 14
14.8.8 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
– Check the chain tension. ( p. 150)
72
Main work
– Loosen screw 1.
04
– Set the chain tension by turning the hub housing.
0
/0
Holding wrench (61329085000) ( p. 460)
57
0 04
Info
,0
l.c r:
Turn clockwise to increase the chain tension; turn
ai fo
om
S03919-10
counterclockwise to reduce the chain tension.
tm ed
The tool required is in the tool set.
ho ns

e
The chain tension matches the specified value.

h@ Lic
Info
fo r |

sh fü

rt
ta rt
–
at ie
Tighten screw 1.
M ns
Guideline
h, ze
Screw, eccentric M16 70 Nm (51.6 lbf ft)

Li

( p. 19)
t
or
14.8.9 Checking the chain, rear sprocket, engine sprocket, and chain guide
hf
as
Preparatory work
ew
th
at
M
151
14 WHEELS
Main work
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or motor sprocket is worn:
– Change the drivetrain kit. ( p. 156)
Info
The engine sprocket, the rear sprocket, and the
chain should always be replaced together.
100132-10

– Pull on the top section of the chain with the specified
weight A.
Guideline
Weight, chain wear measure- 15 kg (33 lb.)
72
ment
04
– Measure distance B of 18 chain rollers in the upper chain
section.
0
/0
57
Info
04
0
,0
l.c r:
ai fo
Maximum distance Bfrom 272 mm (10.71 in)
om
18 chain rollers at the
tm ed
longest chain section
ho ns
» If distance B is greater than the specified measurement:

e
–
h@ Lic
S03949-10 Change the drivetrain kit. ( p. 156)
Info
fo r |
When a new chain is mounted, the rear sprocket

sh fü
and the engine sprocket should also be

rt
ta rt
changed.
at ie
New chains wear out faster on an old, worn rear

M ns
sprocket or engine sprocket.

h, ze
For safety reasons, the chain has no chain joint.

Li
– Check the chain sliding guard for wear.

» If the chain sliding guard shows a lot of wear:
–
t
Change the chain sliding guard.

or
– Check that the chain sliding guard is firmly seated.

hf
» If the chain sliding guard is loose:

as
– Tighten screws on the chain sliding guard.

ew
Guideline
th
Screw, chain slid- M5 5 Nm (3.7 lbf ft)

S04102-01
ing guard
at
M
152
WHEELS 14
– Check the chain sliding piece for wear.

» If the lower edge of the chain is in 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 screw on the chain sliding piece.
Guideline
Remaining screws, M8 25 Nm
chassis (18.4 lbf ft)
72
0 04
/0
S04103-01
57
Finishing work
04
( p. 19)
0
,0
l.c r:
ai fo
om
14.8.10 Removing the rear sprocket carrier tm ed
Preparatory work
ho ns

e
–
h@ Lic

fo r |
Main work
sh fü
– Remove locking wire 1.

rt
ta rt

at ie
– Loosen nut 2.
M ns
h, ze
Li
B04174-10
t
or
– Loosen screw 3.
hf

as
Holding wrench (61329085000) ( p. 460)

ew

th

at
M
R01847-10
153
14 WHEELS
– Protect the components against damage by covering them.

– Remove the chain from the rear sprocket.
B04175-10
– Remove nut 2 with washer 5.
72
0 04
/0
B04176-10
57
– Remove the rear sprocket carrier with the rear sprocket.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
B04177-10
fo r |
14.8.11 Installing the rear sprocket carrier

sh fü
Main work
rt
– Position the rear sprocket carrier with the rear sprocket.

ta rt
at ie
M ns
h, ze
Li
t
or
B04177-10
hf

as
– Mount and tighten nut 1 with washer 2.

Guideline
ew
Nut, rear axle, M35x1.5 200 Nm (147.5 lbf ft)

th
shock absorber Loctite® 262™/lock the

at
side locking wire with locking

M
varnish
B04176-11
154
WHEELS 14
– Position the chain on the rear sprocket.

The center of the wheel axle bearing is above the center of
the hub housing.
B04175-10
– Mount locking wire 3.

The pin of the locking wire engages in one of the drilled
holes of the axle.
72
0 04
/0
B04174-11
57
Finishing work
04
0
,0
l.c r:
ai fo
om
( p. 18)
– tm ed
Install the main silencer. ( p. 97)
ho ns
e
h@ Lic
14.8.12 Opening the chain

fo r |
– Mount mandrel A with the larger diameter in the spindle of

sh fü
the special tool. Turn the spindle counterclockwise.

rt
ta rt
Chain rivet tool (60029020000) ( p. 455)

at ie
–
M ns
Make the connecting link of the chain accessible. Fret the riv-
eting point.
h, ze
– Position the special tool with the mandrel on one of the 2 pins
Li
of the connecting link of the chain.
203065-10
Locking screw B points upwards.
–
t
Position retaining clampC of the special tool on the chain

or
from the rear.

hf
Markings A and B point upwards.

as
– Slide retaining clamp C of the special tool into the pressing

ew
tool.
The arrow of marking A points to locking screw B.
th
– Screw the locking screw hand-tight as far as it will go.

at
M
The retaining clamp is fixed.

– Hold the special tool and screw in the spindle.
The chain pin is pressed out through the retaining clamp
drill hole.
– Unscrew the locking screw and remove the special tool.
155
14 WHEELS
– Repeat the process on the second pin of the chain link.
14.8.13 Riveting the chain

– Grease new connecting link 1 and position an X-ring 2 on
each pin.
– Connect the chain ends with a connecting link.
– Position another X-ring 2 on each pin.
203075-10
– Mount pressing tool A with the smaller diameter in the spin-
72
dle of the special tool. Turn the spindle counterclockwise.
04
0
– Position press plate B of the special tool on the press drift.
/0
–
57
Position chain joint plate 3 in the press plate.
0 04
,0
l.c r:
203077-10
ai fo
om
– Position the special tool on the chain.
tm ed
Locking screw C points upwards.
ho ns
– D of the special tool on the chain
Position retaining clamp
e
from the rear.

h@ Lic
Markings A and B point upwards.

– Slide retaining clamp D of the special tool into the pressing
fo r |
tool.
sh fü
The arrow of marking A points to locking screw C.

rt
ta rt
203078-10
– Screw the locking screw hand-tight as far as it will go.
at ie
M ns
The retaining clamp is fixed.

– Hold the special tool and screw in the spindle.
h, ze
Press tool A of the special tool presses against the cen-

Li
ter of the chain joint plate 3 .

The chain joint plate is pressed on.
t
– Unscrew the locking screw and remove the special tool.

or
– Rivet the two pins of the connecting link with special tool.
hf
as

ew
th
14.8.14 Changing the drivetrain kit

at
Preparatory work
M

156
WHEELS 14
Main work
– Remove screw 1 and screw 2. Take off the engine sprocket
cover.
– Bend up lock washer 3.
– Remove the nut with the lock washer.
R01914-10
– Loosen screw 4.
Holding wrench (61329085000) ( p. 460)
72
– Open the chain. ( p. 155)
0 04
/0
B04170-10
57
– Remove the chain.
04
Info
0
,0
l.c r:
ai fo
om
– Remove the engine sprocket.
tm ed
ho ns
e
h@ Lic
R01915-10

fo r |
– Remove nuts 6 and take off the screws. Remove the rear
sh fü
sprocket.
rt
ta rt
– Position the new rear sprocket with the screws. Mount and
at ie
tighten the nuts.

M ns
Guideline
h, ze
Nut, rear sprocket M8 36 Nm (26.6 lbf ft)

Li
B04171-10
– Mount new engine sprocket.

t
or
– Mount new chain.

hf

as
the hub housing.

ew
th
at
M
R01915-10
157
14 WHEELS

– Mount and tighten the nut with lock washer 3.
Guideline
Nut of engine M20x1.5 100 Nm (73.8 lbf ft)
sprocket Loctite®243™
– Secure the nut with a lock washer.

– Position the engine sprocket cover and clamp with the outlet
hose.
R01916-10
Guideline
Screw, engine M6x30 10 Nm (7.4 lbf ft)
sprocket cover
Guideline
72
04
sprocket cover
0
/0
57
Guideline
04
0
sprocket cover
,0
l.c r:
ai fo
om
Finishing work
tm ed
ho ns
( p. 18)
e
h@ Lic
14.8.15 Cleaning the chain

fo r |
sh fü
Warning
rt
ta rt
Danger of accidents Lubricants on the tires reduces the road grip.

at ie
– Remove lubricants from the tires using a suitable cleaning agent.

M ns
h, ze
Warning
Li
t
or
Note
hf

as
ew
th
Info
at
The service life of the chain depends largely on its maintenance.

M
Regular cleaning increases the service life of the chain.
Preparatory work
158
WHEELS 14
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 448)
– After drying, apply chain spray.
Street chain spray ( p. 449)
400725-01
Finishing work
( p. 19)
14.8.16 Checking/changing the rear hub shock absorbers of the rear sprocket carrier
72
04
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rear hub shock absorbers.
0
/0
The rear hub shock absorbers wear out during operation. If the rear hub shock absorbers are not changed
57
in time, the rear sprocket carrier and rear hub shock absorber carrier will become damaged.
04
Preparatory work
0
,0
Condition
l.c r:
– The link fork is relieved of weight.
ai fo
om
Main work tm ed
ho ns

e
–
h@ Lic
Remove nut 2 with washer 3.

fo r |
sh fü
rt
ta rt
at ie
L01466-10
M ns
– Remove nuts 4.
h, ze
– Take off rear hub shock absorber carrier 5.

Li
t
or
hf
as
L01467-10
ew
th
at
M
159
14 WHEELS
– Remove rear hub shock absorbers 6 of the rear sprocket car-

rier.
L01468-10
– Check the rear hub shock absorbers of the rear sprocket carrier
on both sides for damage and wear.
» If the rear hub shock absorbers of the rear sprocket carrier
are damaged or worn:
– Install new rear hub shock absorbers.
72
0 04
/0
L01477-01
57
– Position rear hub shock absorbers 6 of the rear sprocket car-
04
rier.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
L01468-10
– Position rear hub shock absorbers 5.

fo r |
– Mount nuts 4 and tighten in a crisscross pattern.

sh fü
Guideline
rt
ta rt
Nut, rear hub M10x1.25 45 Nm (33.2 lbf ft)

at ie

M ns
carrier
h, ze
Li
L01467-10
– Mount nut 2 with washer 3.

t
or

hf
– Tighten nut 2.
as
Guideline
ew

th

at
varnish
M
L01466-10
holes of the axle.
160
WHEELS 14
14.8.17 Removing the rear hub

Preparatory work
Main work
Info
removed.
72
203038-10
04
– Remove axle 2 from the hub housing.
0
/0
57
0 04
,0
l.c r:
ai fo
om
203039-10
tm ed
ho ns

e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
203043-12
Li
– Remove washer 4 and O-ring 5.

t
or
hf
as
ew
th
203044-12
at
M
161
14 WHEELS
– Take off brake caliper bracket 6. Remove O-ring 7.

– Hang the brake caliper bracket to the side.
203045-12
72
004
/0
203046-12
57
– Remove hub housing 9 from the link fork.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
203047-12
fo r |
14.8.18 Installing the rear hub

sh fü
Main work
rt
– Position hub housing 1 in the link fork.

ta rt
at ie

M ns
the hub housing.

h, ze
Li
t
or
203047-11
hf
– Position washer 2.
as
ew
th
at
M
203046-11
162
WHEELS 14
– Mount and grease O-ring 3 in the brake caliper bracket 4.

– Position the brake caliper bracket on the link fork.
Pin A engages in slotted hole B.
203045-11
– Mount and grease O-ring 5 in the brake caliper bracket.

– Position washer 6.
72
0 04
/0
203048-10
57
04
The lock ring engages audibly.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
203043-11
– Clean and grease the shaft seal rings 8 and contact sur-
fo r |
face A of the spacer ring.

sh fü

rt
ta rt
at ie
M ns
h, ze
Li
203042-11

t
or
hf
as
ew
th
at
M
203039-12
163
14 WHEELS
– Position the brake caliper. Mount and tighten screws bk.

Guideline
point.
203038-12
Finishing work
( p. 18)
72
04
0
/0
57
14.8.19 Measuring the rear wheel bearing clearance
04
Preparatory work
0
,0
l.c r:
ai fo
om
Main work
– Produce the special tool.
tm ed
ho ns
Hex collar screw (61310021000)
e
– Drill the hole and cut the thread.

h@ Lic
Guideline
A
Diameter M6
fo r |
sh fü
Depth B 20 mm (0.79 in)

rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
309926-10
ew
th
at
M
164
WHEELS 14
72
0 04
/0
309927-10
57
04
– Remove screw 1.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04530-10
fo r |
–
sh fü
Mount and tighten special tool 2.

rt
Guideline
ta rt
at ie

M ns
h, ze
Li
t
G04531-10
or
– Position special tool 3.

hf
–
as
Mount and tighten screw 4.

Guideline
ew

th
chassis
at
M
G04532-10
165
14 WHEELS
– Mount the dial gage with the dial gage support.
G04533-10
Info
Measure the wheel bearing play when cold.
Values measured while the bearing or wheel axle is
warm are implausible.
72
04
Wheel bearing play on the ≤ 0.30 mm (≤ 0.0118 in)
rim ring
0
/0
G04534-10
» If the specified value is not reached:
57
04
– Change the rear wheel axle.
0
–
,0
Remove screw 4.
l.c r:
ai fo
–
om
Take off special tool 3.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04532-10
rt
– Remove special tool 2.

ta rt
at ie
M ns
h, ze
Li
t
or
G04531-10
hf
– 1.
as
Mount and tighten screw

Guideline
ew

th
at
M
G04530-10
166
WHEELS 14
Finishing work
( p. 18)
( p. 19)
14.8.20 Greasing rear wheel bearing

Preliminary work
Main work
72
04
0
/0
Info
57
04
0
removed.
,0
l.c r:
ai fo
203038-10
om
– Remove axle tm ed
2 from the hub housing.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
203039-10
M ns

h, ze

Li

– Clean and grease the shaft seal rings 3 and contact sur-
face Aof the spacer ring.
t
or
– Clean and grease the contact surfaces 4 of the bearing.

hf
– Grease the needle bearing 5.

as
D01012-10 Long-life grease ( p. 448)

ew
th
at
M
167
14 WHEELS
– Clean axle and grease in area B.

D01015-10

– Turn the axle and check for smooth operation.
» If the axle is stiff:
72
0 04
/0
203039-10
57
04
Guideline
0
,0
l.c r:
ai fo
om
tm ed
ho ns
point.
e
h@ Lic
203038-10
Final steps
fo r |

sh fü

rt
ta rt

at ie

M ns
( p. 18)
h, ze

Li

t
or
14.8.21 Measuring the wheel bearing play and greasing the rear hub
hf
Preliminary work
– Raise motorcycle with the work stand (inserted). (
as
p. 17)
ew
th
at
M
168
WHEELS 14
Main work
Hex collar screw (61310021000)
– Drill the hole and cut the thread.
Guideline
A
Diameter M6
Depth B 20 mm (0.79 in)
72
004
/0
309926-10
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
309927-10
t

or
hf
– Remove screw 1.
as
ew
th
at
M
G04530-10
169
14 WHEELS
– Mount and tighten special tool 2.

Guideline
G04531-10
– Position special tool 3.

Guideline
chassis
72
0 04
/0
G04532-10
57
– Mount the dial gauge with the dial gage support.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04533-10

fo r |
sh fü
Info
rt
ta rt
Measure the wheel bearing play when cold.

at ie
Values measured while the bearing or wheel axle is

M ns
warm are implausible.

h, ze
Wheel bearing play at rim ≤ 0.30 mm (≤ 0.0118 in)

Li
flange
G04534-10
» If the specified value is not reached:
–
t
Change the rear wheel bearing. ( p. 176)

or
– Change the rear wheel axle.

hf
– 4.
as
Remove screw
– Take off special tool 3.
ew
th
at
M
G04532-10
170
WHEELS 14
G04531-10

Guideline
72
0 04
/0
G04530-10
57
04
0
– Loosen nut 6.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
312294-10
– Loosen screw 1.
fo r |

sh fü
rt
Holding wrench (61329085000) ( p. 460)

ta rt
at ie

M ns

h, ze
Li
312295-10
t
Info
or
Protect the components against damage by covering them.

hf
as

ew
th
at
M
B04175-10
171
14 WHEELS
– Remove nut 6 with washer 8.
312296-10
– Remove the rear sprocket carrier with the rear sprocket.
72
0 04
/0
B04177-10
57
04
0
,0
l.c r:
Info
ai fo
om
tm ed Do not operate the foot brake when the brake caliper is
removed.
ho ns
e
h@ Lic
312297-10
– Remove axle bk from the hub housing.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
312298-10
– Remove lock ring bl.

t
or
hf
as
ew
th
at
M
312299-10
172
WHEELS 14
– Remove washer bm and O-ring bn.
312300-10
– Take off brake caliper bracket bo. Remove O-ring bp.

– Hang the brake caliper bracket to the side.
72
0 04
/0
312301-10
57
– Remove washer bq.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
312303-10
– Remove hub housing 7 from the link fork.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
312304-10
– Clean and grease hub.

t
or

hf
as
ew
th
at
M
312305-10
173
14 WHEELS
– Position hub housing 7 in the link fork.

the hub housing.
312304-10
– Position washer bq.
72
004
/0
312303-10
57
– Mount and grease O-ring bp in the brake caliper bracket bo.
04
0
,0
–
l.c r:
Position the brake caliper bracket on the link fork.
ai fo
om
Pin C engages in slotted hole D.
tm ed
ho ns
e
h@ Lic
312302-10
– Mount and grease O-ring bn in the brake caliper bracket.

fo r |
sh fü

rt
–
ta rt
Position washer bm.

at ie
M ns
h, ze
Li
312300-10
– Mount lock ring bl.

t
or

hf
as
ew
th
at
M
312299-10
174
WHEELS 14

– Clean and grease the shaft seal rings br and contact sur-
face Eof the spacer ring.
– Clean and grease the contact surfaces bs of the bearing.
– Grease the needle bearing bt.
312306-10 Long-life grease ( p. 448)
– Clean axle and grease in area F.

72
0 04
/0
312307-10
57
– Position axle bk in the bearing seat of the hub housing.
04
– Turn the axle and check for smooth operation.
0
» If the axle is stiff:
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
312298-10

fo r |
Guideline
sh fü

rt
ta rt

at ie
M ns
h, ze
point.
Li
312297-10
– Position the sprocket wheel support with the rear sprocket.

t
or
hf
as
ew
th
at
M
B04177-10
175
14 WHEELS

– Mount and tighten nut 6 with washer 8.
Guideline
varnish
312296-10
– Position the chain on the rear sprocket.

the hub housing.
72
0 04
/0
B04175-10
57
04
0
holes of the axle.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
312308-10
Final steps
fo r |

sh fü

rt
ta rt

at ie
( p. 18)
M ns

h, ze

Li

( p. 19)
t
or
14.8.22 Changing the rear wheel bearing

hf
as
Preparatory work
ew

th

at

M
– Remove the rear hub. ( p. 161)

176
WHEELS 14
Main work
– Remove spacer ring 1.
203054-10
– Remove radial shaft seal ring 2.

72
004
/0
203055-10
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
203056-10
– Press out bearings 6 from the inside to the outside.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
203057-10
– Press out bearing 7 from the inside to the outside.

t
or
hf
as
ew
th
at
M
203058-10
177
14 WHEELS
– Press in new bearing 7 from the outside all the way to the
inside.
Info
pressed in.
203059-10
– Press in new bearings 6 from the outside all the way to the
inside.
Info
Only press the bearings in via the outer bearing race
72
pressed in.
0 04
/0
203060-10
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
203056-10
– Grease new radial shaft seal ring 2 and press it in until it is

fo r |
flush.
sh fü
– Grease new radial shaft seal ring 3 and press it in until it is

rt
ta rt
flush.
at ie
M ns

h, ze
Li
203055-10
– Clean, grease, and mount spacer ring 1.

t
or

hf
as
ew
th
at
M
203054-10
Finishing work
178
WHEELS 14

( p. 18)
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
179
15 WIRING HARNESS, BATTERY
15.1 Removing the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep 12 V batteries out of the reach of children.
– Avoid contact with battery acid and battery gases.
– Keep sparks or open flames away from the 12 V battery.
– Only charge 12 V batteries in well-ventilated rooms.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Caution
72
04
charged or missing.
0
/0
57
Preparatory work
04
0
,0
l.c r:
Main work
ai fo
om
– Remove control unit 1 and hang to the side.
–
tm ed
Disconnect negative cable 2 from the 12-V battery.
ho ns
– Remove positive terminal cover 3 and disconnect the posi-
e
tive cable from the 12-V battery.

h@ Lic
fo r |
sh fü
S03934-10
rt
ta rt
– Disconnect connector 4.
at ie
–
M ns
Remove screw 5 and take off the battery cover.

– 6 out of the battery compartment.
h, ze
Take the 12-V battery

Li
t
or
hf
S03935-10
as
ew
th
at
M
180
WIRING HARNESS, BATTERY 15
15.2 Installing the 12-V battery
Warning
Caution
72
04
charged or missing.
0
/0
57
Main work
04
– Insert 12-V battery 1 into the battery compartment.
0
12-V battery (YTX14-BS) ( p. 407)
,0
l.c r:
ai fo
– Position the battery cover, mount screw 2, and tighten.
om
Guideline tm ed
ho ns
chassis
e
h@ Lic
S03936-10 – Join connector 3.

– Position the positive cable and mount and tighten the screw.
fo r |
Guideline
sh fü
Screw, battery termi- M6 4.5 Nm

rt
ta rt
nal (3.32 lbf ft)

at ie
M ns
– Mount positive terminal cover 4.

–
h, ze
Position negative cable 5 and mount and tighten the screw.

Li
Guideline
S03937-10 Screw, battery termi- M6 4.5 Nm
nal (3.32 lbf ft)
t
or
– Position control unit 6.

hf
Finishing work
as

ew
– Set time and date.

th
at
M
181
15.3 Disconnecting the negative cable of the 12-V battery
Warning
Caution
72
04
charged or missing.
0
/0
57
Preparatory work
04
– Switch off ignition – to do this, briefly press the RACE-ON but-
ton (maximum of 1 second) with the ignition switched on.
0
,0
l.c r:
ai fo
om
tm ed
Main work
– Remove control unit
ho ns
1 and hang to the side.
– Disconnect negative cable 2 from the 12-V battery.
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
S04104-10
M ns
h, ze
15.4 Connecting the negative cable of the 12-V battery

Li
Warning
t
or

hf

as

ew

th
at
M

182
Caution
charged or missing.
Main work
– Position negative cable 1 and mount and tighten the screw.
Guideline
Screw, battery termi- M6 4.5 Nm
nal (3.32 lbf ft)
S04105-10
72
Finishing work
04
0
/0
57
04
15.5 Charging the 12-V battery
0
,0
l.c r:
ai fo
om
Warning
tm ed
ho ns
e
h@ Lic

fo r |

sh fü
rt
ta rt
at ie

M ns
Note
h, ze
Environmental hazard 12 V batteries contain environmentally hazardous materials.

Li
– Do not dispose of 12 V batteries as household waste.

– Dispose of 12 V batteries at a collection point for used batteries.
t
or
Note
hf

as
ew
th
at
M
183
Info
Even when there is no load on the 12-V battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the 12-V battery will be
destroyed.
If the 12-V battery is depleted from starting the vehicle repeatedly, the battery must be charged immedi-
ately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
72
04
– Disconnect the negative cable of the 12-V battery. ( p. 182)
0
/0
Main work
– Connect the battery charger to the 12-V battery. Adjust the
57
battery charger.
04
EU battery charger XCharge‑professional (00029095050)
0
,0
l.c r:
( p. 450)
ai fo
om
Alternative 1
tm ed US battery charger XCharge‑professional
ho ns
(00029095051) ( p. 451)
311910-10
e
Alternative 2
h@ Lic
UK battery charger XCharge‑professional

(00029095052) ( p. 451)
fo r |
Alternative 3
sh fü
CH battery charger XCharge‑professional

rt
ta rt
(00029095053) ( p. 451)
at ie
M ns
Info
h, ze
Follow the instructions of the charger and the manual.

Li
– Disconnect the battery charger after charging the 12-V battery.

Guideline
t
or
The charging current, charging voltage, and charging time

hf
must not be exceeded.

as
Recharge the 12-V battery 3 months

regularly when the motorcy-
ew
cle is not being used

th
Finishing work
at
– Connect the negative cable of the 12-V battery. ( p. 182)

M

184
15.6 Changing the main fuse
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Preparatory work
Main work
– Take off protection cap 1.
72
0 04
/0
57
S03939-10
04
– Remove faulty main fuse 2.
0
,0
l.c r:
Info
ai fo
om
A faulty fuse has a burned-out fuse wire
tm ed A .
A spare fuse 3 is located in the starter relay.
ho ns
The main fuse protects all power consumers of the
e
vehicle.
h@ Lic
– Insert a new main fuse.

fo r |
S03940-10
Fuse (58011109130) ( p. 407)
sh fü
– Check that the electrical system is functioning properly.

rt
ta rt
– Mount protection caps 1.

at ie
M ns
Tip
h, ze
Insert a new spare fuse into the starter relay to have it

Li
available when needed.
Finishing work
– Mount the front rider's seat. (
t
p. 118)
or

hf

as
ew
th
at
M
185
15.7 Changing the fuses in the fuse box
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
72
Main work
– Open fuse box cover 1.
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
S03941-10
– tm ed
Check the fuses.
ho ns
Info
e
h@ Lic
A faulty fuse has a burned-out fuse wire A.

– Remove the faulty fuse.
fo r |
Guideline
sh fü
Fuse 1 - 10 A - power supply for control units and compo-

rt
ta rt
nents
at ie
S03942-10
Fuse 2 - 10 A - ACC1
M ns
Fuse 3 - 10 A - license plate lamp, tail light

h, ze
Fuse 4 - 10 A - permanent positive for headlight

Li
Fuse 5 - 10 A - control unit

Fuse 6 - 25 A - ABS return pump
t
Fuse 7 - 10 A - ABS hydraulic unit

or
Fuse 8 - 10 A - ACC2, USB socket

hf
as
Fuse 9 - not assigned

Fuse 10 - not assigned
ew
Fuse res - 10 A - spare fuses

th
Fuse res - 15 A - spare fuse

at
Fuse res - 25 A - spare fuse

M
– Insert the spare fuse with the correct rating.

Fuse (58011109110) ( p. 407)
Fuse (58011109115) ( p. 407)
Fuse (58011109125) ( p. 407)
186
Tip
Insert a spare fuse so that it is available if needed.
– Check that the power consumer is functioning properly.

– Close the fuse box cover 1.
Finishing work
15.8 Checking the charging voltage

Condition
The 12-V battery must be fully functional and completely charged.
Preparatory work
72
04
0
Main work
/0
– Remove control unit 1 and hang to the side.
57
– Remove positive terminal cover 2.
04
– Start the motorcycle to check the function. ( p. 20)
0
,0
l.c r:
ai fo
om
tm ed
ho ns
P00289-10
e
– Measure the voltage between the specified points.

h@ Lic
Measuring point plus (+) – Measuring point Ground (−)

fo r |
Charging voltage
sh fü
5,000 rpm 13.5 … 15.0 V

rt
ta rt
» If the displayed value is greater than the specified value:

at ie
– Change voltage regulator.

M ns
h, ze
P00291-10
Li
– Mount positive terminal cover 3.

t
or
hf
as
ew
th
P00290-10
at
M
Finishing work
187
15.9 Changing the RACE-ON key battery
Warning
Risk of injury Button cells may burst if misused.
Swallowing button cells leads to severe chemical burning and may result in death.
– Keep the button cell and the RACE-ON key out of the reach of children.
– Make sure the button cells can never be swallowed or ingested.
– Seek medical attention immediately if button cells are swallowed or ingested.
– Do not expose button cells to extreme temperatures or mechanical loads.
Permissible temperature −20 … 50 °C (−4 … 122 °F)
– Do not use the RACE-ON key if the battery compartment cannot be closed.
– Replace the RACE-ON key battery with the type specified only.
72
– Fold out the key bit of the RACE-ON key.
–
04
Push lower half of the RACE-ON key in the direction of the
arrow and take off.
0
/0
57
0 04
,0
l.c r:
ai fo
om
S01740-10
–
tm ed
Remove battery cover 1.
ho ns
– Remove RACE-ON key battery 2.
e
– Insert new the RACE-ON key battery with label facing upward.
h@ Lic
RACE-ON key battery (CR 2032) ( p. 407)

fo r |
– Mount battery cover 1.

sh fü
rt
ta rt
at ie
S01739-10
M ns
– Fit lower half of the RACE-ON key and snap into place in the
h, ze
direction of the arrow.

Li
t
or
hf
as
S01740-11
ew
th
at
M
188
BRAKE SYSTEM 16
16.1 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately.
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a
consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.
– Check all brake linings on both brake calipers to ensure they

have the minimum thickness A.
72
Minimum thickness A ≥ 1 mm (≥ 0.04 in)
04
» If the minimum thickness is less than specified:
0
/0
– Change the front brake linings. ( p. 189)
57
– Check all brake linings on both brake calipers for damage and
cracking.
04
» If there is damage or cracking:
0
S03923-10
,0
l.c r:
– Change the front brake linings. ( p. 189)
ai fo
om
tm ed
16.2 Changing the front brake linings
ho ns
e
h@ Lic
Warning
fo r |

sh fü

rt
ta rt
at ie

M ns
h, ze
Li
with the eyes.

t
Warning
or
Danger of accidents Old brake fluid reduces the braking effect.

hf
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
as
schedule.
ew
Warning
th
at

M

189
16 BRAKE SYSTEM
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Info
72
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
04
designed for DOT 5 brake fluid.
0
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
/0
Only use clean brake fluid from a sealed container.
57
04
– Move the brake reservoir mounted on the handlebar to a hori-
zontal position.
0
,0
l.c r:
– Cover painted parts.
ai fo
om
–
tm ed
Take off cover 2 with the membrane.
ho ns
e
h@ Lic
G04510-10
fo r |
sh fü
– Expose the cable of the wheel speed sensor.

rt
ta rt
– Take off the brake caliper.

at ie
M ns
h, ze
Li
G04509-10
t
or
– Press the brake piston back into the basic position and ensure
hf
that brake fluid does not flow out of the brake fluid reservoir;
as
extract some if necessary.

– Push the brake linings away from pistons 4 and remove.
ew
– Remove the retaining bracket.

th
– Clean the brake caliper.

at
M
203104-10
190
BRAKE SYSTEM 16
– Position retaining bracket 5.

Arrow A faces in the direction of travel.
203105-10
– Position brake linings and push in the direction of pistons 4.

Info
Always change the brake linings in sets and on both
sides.
72
0 04
/0
203104-10
57
– Position the brake caliper. Mount screws 3 but do not
04
tighten yet.
0
Guideline
,0
l.c r:
ai fo
om
–
tm ed
Repeat these steps on the opposite side.
ho ns
e
h@ Lic
G04509-10
point. Fix the hand brake lever in the activated position.
fo r |
– Tighten screws 3 on both brake calipers.

sh fü
Guideline
rt
ta rt

at ie

M ns
– Route the cable of the wheel speed sensor so it is not under

h, ze
tension and secure with a cable tie.

Li

– Fill brake fluid up to the MAX marking.
t
Brake fluid DOT 4 / DOT 5.1 ( p. 446)

or
hf
– Position the cover with the membrane. Mount and tighten the
as
screws.
ew
Info
Clean up overflowed or spilled brake fluid immediately
th
with water.
at
M
191
16 BRAKE SYSTEM
16.3 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are
worn down.
– Check the brake system and do not continue riding until the problem is eliminated.
Warning
schedule.
72
zontal position.
–
04
Check the brake fluid level in brake fluid reservoir 1.
0
» If the brake fluid level has dropped below
/0
MIN marking A :
57
– Add front brake fluid. ( p. 192)
0 04
,0
l.c r:
S03921-10
ai fo
om
16.4 Adding front brake fluid tm ed
ho ns
Warning
e
h@ Lic
fo r |
worn down.
sh fü
rt
ta rt
at ie
Warning
M ns

h, ze

Li

t
or
hf
as
with the eyes.

ew
Warning
th
at

M
schedule.
192
BRAKE SYSTEM 16
Note
Info
Preparatory work
– Check the front brake linings. ( p. 189)
Main work
72
zontal position.
04
0
– Take off cover 2 with membrane 3.
/0
–
57
Add brake fluid up to MAX marking A.
04
0
– 2 with membrane 3.
Position cover
,0
S03922-10
l.c r:
–
ai fo
om
Info
tm ed
ho ns
e
with water.
h@ Lic
fo r |
16.5 Changing the front brake fluid

sh fü
rt
ta rt
at ie
Warning
M ns

–
h, ze
Keep brake fluid out of the reach of children.

Li
t
–
or
Rinse the affected area with plenty of water in the event of contact with the skin.
–
hf
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
as

ew
Note
th

at
M

193
16 BRAKE SYSTEM
Info

zontal position.
– Take off cover 2 with the membrane.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 452)
G04510-10
72
04
– Mount the corresponding bleeder cover 3 from the special
0
tool set.
/0
57
Bleeder cover (00029013023) ( p. 450)
04
– Connect the bleeding device.
0
Bleeding device (00029013100) ( p. 450)
,0
l.c r:
ai fo
om
tm ed
R01751-10
ho ns
– Open shut-off valve 4.

e
h@ Lic
Info
fo r |
Follow the instructions in the Owner's Manual of the

bleeding device.
sh fü
rt
ta rt
– Ensure that the inflation pressure is set on pressure gauge A .

at ie
Correct the inflation pressure on pressure regulator B if nec-

M ns
essary.
h, ze
201494-10
Guideline
Li
Inflation pressure 2 … 2.5 bar (29 … 36 psi)
– Pull protection cap 5 off of the bleeder screw of the left

brake caliper. Connect the bleeder bottle hose.
t
or

hf
as
– Open bleeder screw 6 by approx. one half turn.

ew
Info
th
Drain until fresh brake fluid emerges in the bleeder bot-

at
tle hose without bubbles.

R01752-10
M
– Tighten the bleeder screw. Remove the bleeder bottle hose.

Attach the protection cap.
194
BRAKE SYSTEM 16
– Pull protection cap 7off the bleeder screw of the right brake
caliper. Connect the bleeder bottle hose.
Info
R01753-10
– Tighten the bleeder screw.

– Close shut-off valve 4.
– Open the bleeder screw again until brake fluid stops emerging.
Overfilling the brake fluid reservoir is prevented.
72
– Disconnect the bleeding device. Remove the bleeder cover.
04
– Remove the protection cap of the hand brake cylinder bleeder
0
/0
screw. Connect the bleeder bottle hose.
57
– Open bleeder screw 9
by approx. one half turn. Operate the
04
hand brake lever repeatedly until fresh brake fluid emerges
from the hose of the bleeder bottle without bubbles. Tighten
0
,0
the bleeder screw.
l.c r:
ai fo
– Remove the bleeder bottle hose. Attach the protection cap.
om
tm ed
ho ns
R01754-10
– Correct the brake fluid to the MAX marking.

e
h@ Lic

fo r |
– Position the cover with the membrane. Mount and tighten the
sh fü
screws.
rt
ta rt
Info
at ie

M ns
with water.
h, ze
R01755-10
– Check the hand brake lever for a firm pressure point.
Li
16.6 Bleeding the brake system

t
or
hf
Warning
as

ew

–
th
Wear suitable protective clothing and safety glasses.

–
at
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
M

with the eyes.
195
16 BRAKE SYSTEM
Note
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Condition
– Execute "Brake electronics" > "Functions" > "Bleed brake sys-
tem".
– Follow the instructions in the diagnostics tool.
72
0 04
/0
57
04
401898-01
0
16.7 Adjusting the basic position of the hand brake lever
,0
l.c r:
ai fo
om
– Push the hand brake lever forward.
–
tm ed
Adjust the basic position of the hand brake lever to your hand
ho ns
size by turning adjusting screw 1 .
e
Info
h@ Lic
Turn the adjusting screw clockwise to increase the

fo r |
distance between the hand brake lever and the han-

dlebar.
sh fü
Turn the adjusting screw counterclockwise to decrease

rt
ta rt
S03892-10
the distance between the hand brake lever and the han-
at ie
dlebar.
M ns

h, ze
Only turn the adjusting screw by hand, and do not use

force.
Li
Do not make any adjustments while riding.

t
or
16.8 Checking the brake linings of the rear brake

hf
as
Warning
ew
Danger of accidents Worn-out brake linings reduce the braking effect.

th
– Ensure that worn-out brake linings are replaced immediately.

at
M
196
BRAKE SYSTEM 16
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a
consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.
– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:

– Change the rear brake linings. ( p. 197)
– Check the brake linings for damage and cracking.
– Change the rear brake linings. ( p. 197)
72
500320-10
04
16.9 Changing the rear brake linings
0
/0
57
Warning
04
0
,0
l.c r:
ai fo
om
–
tm ed
Consult a doctor immediately if brake fluid has been swallowed.
ho ns
e
h@ Lic
with the eyes.

fo r |
sh fü
Warning
rt
ta rt

at ie
M ns
schedule.
h, ze
Warning
Li
t

or
hf
Warning
as
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
ew
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
th
If brake linings are used that differ from the original equipment, compliance with the original homologa-
at
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
M
manufacturer warranty shall be void.

– Only use brake linings approved and recommended by KTM.
197
16 BRAKE SYSTEM
Note
Info
– Stand the vehicle upright.

– Remove screw cap 1 with the washer and the membrane.
72
0 04
/0
57
G04516-10
04
0
,0
l.c r:
– Take off the brake caliper and pull the brake line out of the
ai fo
om
holders.
– tm ed
Press the brake piston back into the basic position and ensure
that brake fluid does not flow out of the brake fluid reservoir;
ho ns
extract some if necessary.

e
h@ Lic
fo r |
G04517-10
sh fü

rt
ta rt
at ie
M ns
h, ze
Li
t
203100-10
or
–
hf
Remove pin 4.
as
ew
th
at
M
203101-10
198
BRAKE SYSTEM 16
– Remove brake linings 6.

– Clean the brake caliper.
203102-10
– Position the new brake linings and spring 5.

Info
Always change the brake linings in pairs.
– Mount pin 4.
72
0 04
/0
203101-10
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
203100-10
– Position the brake caliper.

fo r |

sh fü
Guideline
rt
ta rt

at ie

M ns
– Attach the brake line to the holders.

h, ze
Li
G04517-10
t
or
hf
point.
as
– Correct the brake fluid level to the MAX marking.

ew

– 1 with the shim and the mem-
th
Mount and tighten screw cap

brane.
at
M
G04516-10
Info
with water.
199
16 BRAKE SYSTEM
16.10 Checking the rear brake fluid level
Warning
worn down.
Warning
schedule.
– Stand the vehicle upright.
72
– Check the brake fluid level in brake fluid reservoir 1.
04
» If the fluid level reaches the MIN marking A:
0
– Add rear brake fluid. ( p. 200)
/0
57
0 04
,0
l.c r:
S03924-10
ai fo
om
16.11 Adding rear brake fluid tm ed
ho ns
Warning
e
h@ Lic
fo r |
worn down.
sh fü
rt
ta rt
at ie
Warning
M ns

h, ze

Li

t
or
hf
as
with the eyes.

ew
Warning
th
at

M
schedule.
200
BRAKE SYSTEM 16
Note
Info
Preparatory work
– Check the brake linings of the rear brake. ( p. 196)
Main work
– Position the vehicle upright.
72
– Remove screw 1 with the screw cap lock.
0 04
Info
/0
Make sure that the reservoir stays vertical and no brake
57
fluid runs out.
04
– Remove screw cap 2 with the washer and membrane 3.
0
,0
l.c r:
– Add brake fluid up to the MAX marking A.
ai fo
om
tm ed
– Mount and tighten screw cap 2 with the shim and mem-
ho ns
brane 3
.
e
– Position the screw cap lock and mount and tighten screw 1.
h@ Lic
Guideline
fo r |
Screw, brake M5 3.5 Nm (2.58 lbf ft)

sh fü
fluid reservoir, Loctite®243™

rear brake
rt
ta rt
S03925-10
at ie
Info
M ns
Use water to immediately clean up any brake fluid that

h, ze
has overflowed or spilled.

Li
t
16.12 Changing the rear brake fluid

or
hf
Warning
as

ew

th

at
M

with the eyes.
201
16 BRAKE SYSTEM
Note
Info

– Remove screw cap 1 with the washer and the membrane.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
72
Syringe (50329050000) ( p. 452)
04
0
/0
57
R01757-10
04
– Mount bleeder cover 2.
0
,0
l.c r:
Bleeder cover (00029013004) ( p. 450)
ai fo
om
– Connect the bleeding device.
tm ed
ho ns
e
h@ Lic
fo r |
R01758-10
sh fü
– Open shut-off valve 3.

rt
ta rt
at ie
Info
M ns
Follow the instructions in the Owner's Manual of the

bleeding device.
h, ze
Li
– Ensure that the inflation pressure is set on pressure gauge A .

Correct the inflation pressure on pressure regulator B if nec-
essary.
t
201494-11
or
Guideline
hf
Inflation pressure 2 … 2.5 bar (29 … 36 psi)

as
– Pull off protection cap 4 of the bleeder screw. Connect the

ew
bleeder bottle hose.

th

at

M
Info
R01759-10
– Tighten the bleeder screw.

– Close shut-off valve 3.
202
BRAKE SYSTEM 16
– Open the bleeder screw again until brake fluid stops emerging.
Overfilling the brake fluid reservoir is prevented.
– Disconnect the bleeding device. Remove the bleeder cover.
– Correct the brake fluid to the MAX marking.
– Mount and tighten the screw cap with the shim and the mem-
brane.
Info
with water.
R01756-10
– Check the foot brake lever for a firm pressure point.
72
004
16.13 Setting the step plate of the foot brake lever
/0
57
– Loosen screw 1.
04
– Turn the step plate of the foot brake lever to the desired posi-
tion.
0
,0
l.c r:
Guideline
ai fo
om
Standard Step plate positioned to the
tm ed front
ho ns
Info
e
h@ Lic
S03894-10 The step plate of the foot brake lever can be freely
rotated through 360 °.
fo r |
The basic position of the foot brake lever is set at the

factory and does not need to be changed.
sh fü
rt
ta rt
at ie
Guideline
M ns
Screw, step plate for M6 10 Nm (7.4 lbf ft)

h, ze
foot brake lever

Li
16.14 Adjusting the basic position of the foot brake lever

t
or
– Loosen nut 1.
hf
– 2
as
Press the foot brake lever down to be able to turn push rod
more easily.
ew
– Turn the push rod until the foot brake lever is in the desired
position.
th
at
Info
M

S03893-10 The screw must be screwed into the ball joint by at
least five turns.
– Lock nut 1.
203
16 BRAKE SYSTEM
16.15 Checking the wheel speed sensor distance
Info
The following work steps apply to the front and rear wheel speed sensors.
– Check the distance between wheel speed sensor 1 and wheel

speed sensor wheel 2with the special tool.
Guideline
Wheel speed sensor distance 0.5 … 1.8 mm (0.02 …
0.071 in)
Feeler gauge (59029041100) ( p. 453)

» If the distance does not meet specifications:
203133-10 – Mount the spacing plate under the wheel speed sensor.
72
Spacer plate (61342023000)
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
204
LIGHTING SYSTEM, INSTRUMENTS 17
17.1 Programming the ignition key
Info
If an ignition key is lost or replaced, all ignition keys must be reactivated. This will also prevent the vehicle
from being operated without authorization with the lost ignition key.
You can activate up to four ignition keys. All ignition keys not programmed during the activation procedure
are invalid, but can be reprogrammed in a further activation procedure.
An enabling code is required to activate the ignition keys.
Programming additional keys:

Condition
– Position black KTM ignition key in area A.
– Switch on ignition – to do this, briefly press the RACE-
ON button (maximum of 1 second) with the ignition
72
switched off.
04
– Select "CU diagnostics" > "Immobilizer" > "ECU".
– "Functions" > "Program key" > "Select".
0
/0
57
Info
04
The instructions in the diagnostics tool must be
followed precisely.
0
,0
l.c r:
– Select "Request enabling code".
ai fo
om
– Select "Start programming".
tm ed
Info
ho ns

e
P00279-10
h@ Lic
followed precisely.

fo r |
– Switch off ignition for 5 seconds.

sh fü
– Read out the fault memory using the KTM diagnostics tool.
rt
ta rt
» If an error is still present:

at ie
–
M ns
Repeat procedure.
h, ze
If no or one Race-on key is present:

Condition
Li
Ignition is switched off and diagnostics tool is connected to

external power supply for VCI and running.
t
or

hf
as
Info
ew
H02098-01
followed precisely.
th

at

M
Info
followed precisely.
205
17 LIGHTING SYSTEM, INSTRUMENTS
– Place Race-on key in the radio range of area A.

switched off.
P00277-10
– Repeat procedure.
If only the black KTM ignition key is present:
Condition
– Position black KTM ignition key in area A.
72
switched off.
04
0
/0
57
Info
04
0
followed precisely.
,0
l.c r:
ai fo
om
tm ed
ho ns
Info
e

h@ Lic
P00278-10
followed precisely.
fo r |

sh fü

rt
ta rt
at ie

M ns
– Repeat procedure.
h, ze
Li
17.2 Checking the headlight setting

–
t
Park the vehicle on a horizontal surface in front of a light-

or
colored wall and make a mark at the height of the center of

hf
the low beam headlight.

as
– Make another mark at a distance B under the first marking.

ew
Guideline
Distance B 5 cm (2 in)
th
at
– Position the vehicle perpendicular to the wall at a distance A

M
from the wall and switch on the low beam.

400726-10
Guideline
Distance A 5 m (16 ft)
– The rider now mounts the motorcycle with luggage and passen-
ger if applicable.
– Check the headlight setting.
206
The light-dark boundary must be exactly on the lower mark-

ing when the motorcycle is ready to be operated with the
rider mounted along with any luggage and a passenger if
applicable.
» If the boundary between light and dark does not meet
specifications:
17.3 Adjusting the headlight range

Preparatory work
– Check the headlight setting. ( p. 206)
Main work
– Turn adjusting screw 1 to adjust the headlight range.
72
Info
04
Turn clockwise to increase the headlight range; turn
0
/0
counterclockwise to reduce the headlight range.
57
If you have a payload, you may have to correct the
headlight range.
04
Screw 1 also secures the headlight. Ensure the screw
0
S03951-10
is always screwed in far enough.
,0
l.c r:
ai fo
om
– Set the headlight to marking B.
Guideline
tm ed
ho ns
The light-dark boundary must lie exactly on lower mark-
B
e
ing when the motorcycle is ready to operate with the

h@ Lic
rider mounted along with any luggage and a passenger if

applicable.
fo r |
sh fü
rt
ta rt
400726-11
at ie
M ns
17.4 Changing the turn signal bulb (US)

h, ze
Note
Li
Damage to reflector Grease on the reflector reduces the light intensity.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
t
or
– Clean and degrease the bulbs before mounting.

hf
– Do not touch the bulbs with your bare hands.

as
– Remove the screw on the front of the turn signal housing.

ew
– Carefully remove turn signal glass 1.

th
– Press bulb 2carefully into the socket, turn it counterclock-

at
wise by about 30°, and take it out of the socket.

M
Info
Do not touch the reflector with your fingers and keep it
free from grease.
M01489-10
207
17 LIGHTING SYSTEM, INSTRUMENTS
– Push the new bulb gently into the socket and turn it clockwise
all the way in.
Turn signal (RY10W / socket BAU15s) ( p. 408)
– Check that the turn signal is functioning properly.
– Position the turn signal glass.
Info
Insert holding lug A into cut-out B.
– Insert the screw and first turn counterclockwise until it
engages in the thread with a small jerk. Tighten the screw
lightly.
17.5 Resetting the service display using the KTM diagnostic tool
72
04
Info
The steps for adjusting the service display are the same for units Km and Meilen.
0
/0
57
Condition
04
0
– Select "Combination instrument" > "Functions" > "Service inter-
,0
l.c r:
val".
ai fo
om
– Enter the distance until the next service is due.
–
tm ed
Select the unit for the distance.
ho ns
– Quit the process using "Execute".
e
h@ Lic
fo r |
H02627-01
sh fü
rt
ta rt
17.6 Steering lock (antenna)

at ie
On this vehicle, the ignition/steering lock is replaced by a remote

M ns
key with transponder (RACE-ON key).

h, ze
In order to activate the steering lock, the handlebar must be

Li
turned fully to the left.

The steering is locked and unlocked electromechanically via the
RACE-ON button .
t
If the battery voltage of the RACE-ON key is too low, place either
or
the RACE-ON key or the black ignition key in area A and repeat
hf
starting.
as
S03885-10
Info
ew
Store the ignition key safely again as soon as the engine

th
has been started.

at
Possible states
M
• Ignition off, steering locked – In this operating mode, the

ignition circuit is interrupted and the steering locked.
• Ignition off, steering unlocked – In this operating mode, the
ignition circuit is interrupted and the steering unlocked.
208
• Ignition on, steering unlocked – In this operating mode, the

ignition circuit is closed and the steering unlocked.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
209
18 COMBINATION INSTRUMENT
18.1 Combination instrument
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
S03758-10
The combination instrument is attached in front of the handlebar.

tm ed
The combination instrument is divided into two function areas.
ho ns
1 indicator lamps
e
Display 2
h@ Lic
18.2 Activation and test

fo r |
sh fü
Activation
The combination instrument is activated when the ignition is
rt
ta rt
switched on.
at ie
M ns
Info
h, ze
The brightness of the displays is controlled by an ambient

light sensor in the combination instrument.
Li
Test
The welcome sequence appears on the display and the indicator
t
S03842-01
or
lamps are briefly activated for a function check.

hf
as
ew
th
at
M
210
COMBINATION INSTRUMENT 18
Info
The malfunction indicator lamp always lights up as long as
the engine is not running. If the engine is running and the
malfunction indicator lamp lights up, stop (taking care not
to endanger yourself or other road users in the process) and
contact an authorized KTM workshop.
The oil pressure warning lamp always lights up as long as
the engine is not running. If the engine is running and the
oil pressure warning lamp lights up, stop immediately (tak-
ing care not to endanger yourself or other road users in the
process) and switch off the engine.
The ABS warning lamp and TC indicator lamp light up until
a speed of approx. 6 km/h (approx. 4 mph) or more has
been reached.
72
18.3 Day-night mode
04
Day mode is shown in a bright color.
0
/0
57
0 04
,0
l.c r:
ai fo
om
S03748-01
tm ed
ho ns
Night mode is shown in a dark color.

e
h@ Lic
Info
The ambient light sensor in the combination instrument
fo r |
measures the brightness of the environment and automat-

sh fü
ically switches the display to day or night mode. The dis-

rt
ta rt
play is brightened, darkened or switched to the other mode

at ie
depending on the brightness measured by the ambient light

M ns
sensor.
S03749-01 In the Display Theme menu, the display mode can be
h, ze
changed manually between AUTOMATICand NIGHT.

Li
18.4 Warnings
t
or
If the general warning lamp lights up among the

hf
indicator lamps, the corresponding message appears in the

as
display. The SET button is used to confirm receipt of the

information and the message is cleared.
ew
All the existing warnings are displayed in the Warning menu until
they are no longer active.
th
at
M
S00001-01
211
18.5 Menu
Info
Press the SET button 1
to open the menu.
Navigate through the menu using the UP button 2or
the DOWN button 3 .
Press the BACK button 4 to close the current menu or the
menu overview.
S03759-10
18.5.1 KTM MY RIDE (optional)

Condition
• Function KTM MY RIDE (optional) activated.
72
• Bluetooth® is activated.
04
– Press the RIGHT button when the menu is closed.
0
– Press the UP or DOWN button until KTM MY RIDE is marked.
/0
Press the RIGHT button to open the menu.
57
In KTM MY RIDE, an appropriate cellphone or headset can be
04
paired with the combination instrument via Bluetooth® and the
0
S03789-01 navigation function can be configured.
,0
l.c r:
ai fo
om
Info
tm ed
Not every cellphone and headset is suitable for pairing with
the combination instrument.
ho ns
The standard Bluetooth® 2.1 must be supported.

e
h@ Lic
18.5.2 Audio (optional)

fo r |
Condition
sh fü

rt
ta rt
• Function Bluetooth® (optional) activated.

at ie
• The combination instrument is connected to a suitable cell-

M ns
phone.
h, ze
• The combination instrument is connected to a suitable Blue-

Li
tooth® headset.
• The cellphone music player is open.
S03790-01 – Press the RIGHT button when the menu is closed.
t
or

hf

as
Warning
ew
Danger of accidents Headphone volume which is too

th
high distracts attention from traffic activity.

at
– Always select headphone volume which is low

M
enough for you to still clearly hear acoustic signals.
– Press the UP or DOWN button until Audio is marked.

Press the UP button to increase the audio volume.
212
Press the DOWN button to reduce the audio volume.

Press the RIGHT button change to the next audio track.
Briefly pressing the LEFT button twice changes to the pre-
vious audio title or plays the current audio title from the
start, depending on the cellphone model.
Press the ENTER button to play or pause the audio track.
Tip
When using a wired headset, the volume cannot be con-
trolled via the combination instrument.
With some cellphones, the audio player needs to be
started before playback is possible.
For easier operation, the Audio function can be
assigned to the C1 or C2 button.
72
18.5.3 Navigation (optional)
04
Condition
0
/0
• The KTM MY RIDE app (optional) is installed and opened on a
57
suitable cellphone (Android devices Version 6.0 and higher,
04
iOS devices Version 10 and higher).
0
,0
l.c r:
ai fo
om
phone.
S03791-01 • tm ed
The GPS function is activated on the connected cellphone.
• For voice navigation: The combination instrument is connected
ho ns
to a suitable headset and an appropriate language package has

e
been downloaded in the KTM MY RIDE app.

h@ Lic

fo r |

sh fü

rt
– Press the UP or DOWN button until Navigation is marked.

ta rt
at ie
Press the RIGHT button to confirm the selection.

M ns
You can access navigation information and adjust the volume in

h, ze
the menu Navigation.

Li
Info
The route guidance is displayed in the small and large NAV-
IGATION widget.
t
or
The Audio function can be used with the navigation func-

hf
tion at the same time.

An incoming call is visualized in a small window at the top
as
of the combination instrument display when the navigation

ew
function is active.
When the navigation function is switched on and the device
th
is connected, the GPS symbol appears in the display of the

at
combination instrument.
M
213
18.5.4 Navigation information (optional)

Condition
phone.
S03793-01 • The GPS function is activated on the connected cellphone.
72
04
– Press the UP or DOWN button until Navigation Information is
marked.
0
/0
57
Info
04
Arrival Time shows the estimated arrival time of the
0
,0
l.c r:
cellphone.
ai fo
Distance to Target shows the distance to the destination.
om
tm ed
Information on the current navigation can be viewed in the NAVI-
GATION widget.
ho ns
e
18.5.5 Volume (optional)

h@ Lic
Condition
fo r |

sh fü

rt

ta rt

at ie
M ns

h, ze
phone.
Li
S03792-01 • The GPS function is activated on the connected cellphone.

• For voice navigation: The combination instrument is connected
to a suitable Bluetooth headset and an appropriate language
t
or
package has been downloaded in the KTM MY RIDE app.

hf

as

ew

th

at
M
214
Warning
– Press the UP or DOWN button until Volume is marked.

– Press and hold the UP button in order to increase the volume.
– Press and hold the DOWN button in order to reduce the vol-
ume.
The volume of the navigation can be set in the
large NAVIGATION widget.
72
18.5.6 Pairing (optional)
04
Condition
• The motorcycle is stationary.
0
/0
57
04
• The Bluetooth® function should also be activated in the device
0
to be paired.
,0
l.c r:
ai fo
om
S03795-01
tm ed
ho ns
– Press the UP or DOWN button until Pairing is marked.
e

h@ Lic
– Press the UP or DOWN button until the desired menu

item Phone or Headset is marked.
fo r |
A suitable cellphone can be paired with the combination

sh fü
instrument in the Phone submenu.

rt
ta rt
A suitable headset can be paired with the combination instru-

at ie
ment in the Headset submenu.

M ns

h, ze
Info
Li
Two cellphones can never be paired simultaneously

with the combination instrument. Only one cellphone
and one headset per submenu item can be paired with
t
or
the combination instrument at the same time.

hf
If the headset type is set for a wired headset, no Blue-

as
tooth®headset can be used.

ew
– Press the UP or DOWN button until Pairing is marked.

– Press the RIGHT button to confirm the Pairing submenu item.
th
at
M
215
Info
When pairing the combination instrument to a
cellphone: A message appears on the combination
instrument indicating that this is now ready for pairing.
The pairing is completed successfully by confirming
the Passkey on the cellphone and on the combination
instrument using the ENTER button.
When pairing the combination instrument to a headset:
The registered trademark of the headset appears on the
combination instrument. By pressing the ENTER button
the device is selected, and confirmed with Confirm by
pressing the ENTER button again. The pairing of a head-
set with the combination instrument is now completed
at this point.
Info
72
When a suitable device has been successfully paired,
the name of the paired cellphone or headset appears in
04
each case in the Phone or Headset menu.
0
Not every cellphone or headset is suitable for pairing
/0
with the combination instrument.
57
04
– If the device is in the range of the combination instrument and
has not been deleted previously while the Bluetooth® function
0
,0
is active:
l.c r:
ai fo
The device is automatically paired with the combination
om
tm ed instrument.
If the device is not automatically paired with the combina-
ho ns
tion instrument after approx. 30 seconds:

e
– Restart combination instrument or Pairing repeat pro-

h@ Lic
cedure.
– To delete a paired device, press the UP or button DOWN until
fo r |
the paired device is highlighted.

sh fü
– Open the delete Pairing menu by pressing the RIGHT button

rt
ta rt
and confirm with the ENTER button.

at ie
M ns
18.5.7 Telephony (optional)

h, ze
Condition
Li

t
or
phone.
hf
• The combination instrument is connected to a suitable head-

as
set.
ew
S03796-01 Warning
th

at

M

– Press the RIGHT button to accept an incoming call.

– Press the LEFT button to reject an incoming call.
– Press and hold the UP button in order to increase the volume.
216
– Press and hold the DOWN button in order to reduce the vol-
ume.
– Press the BACK button briefly to reduce the telephony display.
Info
The call duration and contact are displayed. Depend-
ing on the cellphone settings, the contact is shown by
name.
When the telephony display is activated and reduced in
size, a small window is displayed at the top edge of the
combination instrument display.
An incoming call is visualized in a small window at the
top of the combination instrument display when the
navigation function is active.
18.5.8 Trip 1
72
04
– Press the UP or DOWN button until Trips/Data is marked.
0
/0
57
– Press the UP or DOWN button until Trip 1 is marked.
04
0
Trip 1 shows the distance since the last reset, such as between two
,0
l.c r:
refueling stops. Trip 1 is running and counts up to 9999.
ai fo
om
ØFuelCons1 indicates the average fuel consumption based
S03798-01 on Trip 1. tm ed
ØSpeed1 indicates the average speed based on Trip 1
ho ns
and Trip Time1.
e
Trip Time1 shows the journey time on the basis of Trip 1 and runs
h@ Lic
as soon as a speed signal is received.

Fuel Range indicates the possible distance you can cover with the
fo r |
fuel reserve.
sh fü
Press and All the entries in the Trip 1 menu are reset.
rt
ta rt
hold the
at ie
ENTER button
M ns
for 3-5
h, ze
seconds.
Li
18.5.9 Trip 2
t
or

hf

as
– Press the UP or DOWN button until Trip 2 is marked.

ew
Trip 2 shows the distance since the last reset, such as between two
th
refueling stops. Trip 2 is running and counts up to 9999.

at
ØFuelCons2 indicates the average fuel consumption based

M
S03800-01 on Trip 2.
ØSpeed2 indicates the average speed based on Trip 2
and Trip Time2.
Trip Time2 shows the journey time on the basis of Trip 2 and runs
as soon as a speed signal is received.
217
Fuel Range indicates the possible distance you can cover with the
fuel reserve.
Press and All the entries in the Trip 2 menu are reset.
hold the
ENTER button
for 3-5
seconds.
18.5.10 General Info

– Press the UP or DOWN button until General Info is marked.
72
Date shows the date.
ODO shows the total distance covered.
04
Battery indicates the battery voltage.
0
Oil Temp indicates the engine oil temperature.
/0
S03797-01
57
18.5.11 TPMS
04
Condition
0
,0
• Model with TPMS.
l.c r:
ai fo
om
– tm ed
Press the UP or DOWN button until Trips/Data is marked.
ho ns
e
Warning
h@ Lic
Danger of accidents The tire pressure monitoring sys-

fo r |
S03801-01 tem does not eliminate the necessity to check the tires
before going on a ride.
sh fü
rt
To avoid false alarms, the tire pressure values are

ta rt
evaluated over a period of several minutes.

at ie
M ns
– Check the tire pressure before every ride.

–
h, ze
Correct the tire pressure if the tire pressure devi-

ates from the specified value.
Li
– Even if the tire pressure values are correct, stop

the vehicle immediately if its behavior indicates a
loss of pressure in the tires.
t
or
hf
– Press the UP or DOWN button until TIRE AIR PRESSURE is

as
marked.
Guideline
ew

th

at

M

The TIRE AIR PRESSURE menu displays the tire pressure of the
front and rear tires.
PRESS FRONT indicates the tire pressure at the front.
PRESS REAR indicates the tire pressure at the rear.
218
18.5.12 Warnings
Condition
• Message or warning is present.
– Press the UP or DOWN button until Warnings is marked.
– Use the UP or DOWN button to navigate through the warnings.
S03802-01
All the warnings that have occurred are displayed in the Warnings
menu.
18.5.13 Service
72
04
0
– Press the UP or DOWN button until Service is marked.
/0
57
The next service due is shown in the Service menu.
0 04
,0
l.c r:
S03803-01
ai fo
om
18.5.14 Extra Functions tm ed
ho ns
–
e
Press the UP or DOWN button until Trips/Data is marked.

h@ Lic

– Press the UP or DOWN button until Extra Functions is marked.
fo r |

sh fü
– Use the UP or DOWN button to navigate through the extra func-

rt
ta rt
tions.
at ie
The optional extra functions are listed in Extra Functions.

M ns
S03804-01
h, ze
Info
Li
The current KTM PowerParts and available software are

listed on the KTM website.
t
or
18.5.15 Ride Mode

hf

as
– Press the UP or DOWN button until the Ride Mode menu is

marked on the display.
ew
Press RIGHT button to open the menu.

th
– Use the UP or DOWN button to navigate through the menu.

at
– Press the ENTER button to select engine and motorcycle trac-

M
tion control settings that are coordinated with each other.

Guideline
S03808-01
Do not open the throttle during the selection.
219
TRACK - Optional setting available with homologated per-

formance and extremely direct response. The motorcycle
traction control and the characteristic map of the throttle
response can be individually set.
PERFORMANCE - Optional setting available with homolo-
gated performance and extremely direct response. The
motorcycle traction control and the characteristic map of
the throttle response can be individually set. Combines
the functions of TRACK mode with standard modes.
SPORT - Homologated performance with very direct
response; the motorcycle traction control allows greater
slip on the rear wheel.
STREET - Homologated performance with balanced
response; the motorcycle traction control allows normal
slip on the rear wheel.
RAIN - Reduced homologated performance with soft
72
response for improved rideability; the motorcycle traction
04
control allows normal slip on the rear wheel.
0
/0
18.5.16 Track (optional)
57
Condition
04
• The drive mode TRACK (optional) is activated.
0
,0
l.c r:
– Press the UP or DOWN button until TRACK is marked.
ai fo
om
tm ed
ho ns
Info
TRACK allows settings to be made for TRACK and PER-
e
h@ Lic
S03825-01
FORMANCE mode.
The respective riding mode is ended via LEAVE TRACK
fo r |
or LEAVE PERFORMANCE when the throttle grip is closed

sh fü
and automatically switched to the driving mode STREET.

rt
ta rt
at ie
18.5.17 Throttle Response (optional)

M ns
Condition
h, ze
• The riding mode TRACK (optional) or PERFORMANCE (optional)

is activated.
Li
• Cruise control system function deactivated.

t
–
or
Press the UP or DOWN button until TRACK is marked.

hf

as
– Press the UP or DOWN button until Throttle Response is marked.

S03830-01 Press the RIGHT button to open the menu.
ew
– Press the UP or DOWN button until the required mode is

th
marked.
at
– Press the ENTER button to confirm a mode.

M
TRACK-Homologated performance with extremely direct

response.
SPORT - Homologated performance with direct response.
STREET - Homologated performance with balanced
response.
– Press the BACK button to close the Throttle Response menu.
220
18.5.18 Anti Wheelie Mode (optional)

Condition
is activated.
– Press the UP or DOWN button until Anti Wheelie Mode is
marked.
S03827-01 Press the RIGHT button to open the menu.
Warning
Danger of accidents When Anti Wheelie Mode is dis-
abled, the motorcycle traction control no longer coun-
72
teracts the raising of the front wheel.
– Only switch off the Anti Wheelie Mode if you have
04
the appropriate experience.
0
/0
57
– Press the UP or DOWN button until Anti Wheelie ModeOFF or ON
is marked.
04
– Confirm the selection using the ENTER button.
0
,0
l.c r:
18.5.19 Launch Control (optional)
ai fo
om
Condition tm ed
ho ns
is activated.
e

h@ Lic

fo r |
– Press the UP or DOWN button until Launch Control is marked.

sh fü

rt
ta rt
at ie
S03826-01
Warning
M ns
Danger of accidents Launch control enables very pow-

h, ze
erful acceleration which may ask too much of a novice

Li
rider.
– Only use the launch control if you have the appro-
priate experience.
t
or
– Do not use launch control on public roads.

hf
as
– Press the UP or DOWN button until Launch ControlOFF or ON is

marked.
ew
– Press the ENTER button to confirm the selection.

th
at
M
221
18.5.20 Motorcycle
– Press the UP or DOWN button until Motorcycle is marked.
Motorcycle allows settings to be made for ABS, traction control
and extra functions.
S03805-01
18.5.21 Heated Grips (optional)

Condition
• The Heated Grips menu activated.
72
04
0
/0
– Press the UP or DOWN button until Heated Grips is marked.
57
04
– Press the UP or DOWN button to select the heating level or OFF.
0
S03806-01
,0
l.c r:
ai fo
om
Info
tm ed The heated grip can also be adjusted in the HEATING
widget.
ho ns
e
h@ Lic
18.5.22 Heated Seat (optional)

Condition
fo r |
• The Heated Seat menu activated.

sh fü

rt
ta rt

at ie

M ns
– Press the UP or DOWN button until Heated Seat is marked.

h, ze

Li
– Press the UP or DOWN button to select the heating level or OFF.

S03807-01
t
or
Info
hf
The seat heating can also be adjusted in the HEATING

as
widget.
ew
th
at
M
222
18.5.23 MTC+MSR (optional)

Condition
• Cruise control system function deactivated.
– Press the UP or DOWN button until MTC+MSR is marked.
– Press the UP or DOWN button until MTC+MSROFF or ON is
S03809-01 marked.
Info
When riding mode Track or ABS mode Supermoto is
72
active, the MSR is not active.
After the ignition is switched on, the motorcycle
04
traction control and engine traction torque control are
0
enabled again.
/0
57
18.5.24 ABS
04
Condition
0
,0
l.c r:
ai fo
om
– tm ed
Press the UP or DOWN button until Motorcycle is marked.
ho ns
– Press the UP or DOWN button until ABS is marked.

e
h@ Lic

– Press the UP or DOWN button to select the desired ABS mode.
fo r |
S03810-01
sh fü
rt
Info
ta rt
at ie
When the ABS mode Road is active, ABS controls both

M ns
wheels.
If the ABS mode Supermoto is active, the ABS only con-
h, ze
trols the front wheel and the MSR is not active. The rear
Li
wheel is not controlled by ABS and may lock during

braking maneuvers.
t
or
18.5.25 Quickshifter + (optional)

hf

as

ew

– Press the UP or DOWN button until Quickshifter + is marked.
th

at
M
– Press the UP or DOWN button until Quickshifter +OFF or ON is

marked.
S03824-01
223
18.5.26 Settings
Condition
– Press the UP or DOWN button until Settings is marked.
The combination instrument display can be configured in Settings.
Settings can be made for units or various values. Several functions
can be enabled or disabled.
S03811-01
18.5.27 C1 and C2 buttons

Condition
72
04
– Press the UP or DOWN button until Settings is marked. Press
the RIGHT button to open the menu.
0
/0
– Press the UP or DOWN button until Custom Switch 1 or Cus-
57
tom Switch 2 is marked.
04
–
0
S03812-01 Press the UP or DOWN button to select the desired button and
,0
l.c r:
press the ENTER button to confirm.
ai fo
om
tm ed Info
In the menu Custom Switches, the C1 and C2 buttons
ho ns
can be assigned different quick accesses, e.g.

e
ABSand MTC+MSR.
h@ Lic
The C1 switch is used to access the menu defined

in Custom Switch 1.
fo r |
The C2 switch is used to access the menu defined

sh fü
in Custom Switch 2.
rt
ta rt
at ie
18.5.28 Bluetooth (optional)

M ns
Condition
h, ze

Li

t
or
– Press the UP or DOWN button until Bluetooth® is marked.

hf

as
– Press the UP or DOWN button until Bluetooth®OFF or ON is

S03794-01 marked.
ew

th
at
M
224
Info
The Bluetooth® function can only be used in conjunction
with KTM MY RIDE (optional).
When the Bluetooth® function is switched on, cellphone
and helmet symbols appear in the KTM MY RIDE widget. As
soon as there is a connection between the cellphone and or
a headset, the symbols are displayed filled in. The signal
strength and the battery status of the cellphone are also
displayed.
Not every cellphone and headset is suitable for pairing with
the combination instrument.
18.5.29 Headset Type

72
04
– Press the UP or DOWN button until Headset Type is marked.
0
/0
57
– Press the UP or DOWN button until BT HEADSET
or CORDED HEADSET is marked.
04
0
,0
S03831-01
l.c r:
Info
ai fo
om
In the Headset Type menu, you can configure whether
tm ed
a Bluetooth® headset or a wired headset is used.
ho ns
With a wired headset, the volume cannot be controlled
via the combination instrument.
e
h@ Lic
18.5.30 Display Theme

fo r |

sh fü

rt
ta rt

at ie
M ns
– Press the UP or DOWN button until Display Theme is marked.

h, ze
– Press the UP or DOWN button until AUTOMATIC or NIGHT is

Li
marked.
S03832-01
t
or
Info
hf
In AUTOMATIC mode, the combination instrument auto-

as
matically switches to day or night mode depending on

the brightness.
ew
In NIGHT mode, the combination instrument remains

th
permanently in night mode.

at
M
225
18.5.31 Button Illumination

– Press the UP or DOWN button until Button Illumination is
marked.
– Press the UP or DOWN button until the desired menu
item BRIGHT, MEDIUM,DARK, or OFF is marked.
S03833-01 – Press the ENTER button to confirm the selection.
Info
The brightness of the button lighting can be configured
in the Button Illumination menu.
72
04
18.5.32 Shift Light
0
Condition
/0
57
• ODO > 1,000 km (621 mi).
04
0
– Press the UP or DOWN button until Settings is marked. Press
,0
l.c r:
the RIGHT button to open the menu.
ai fo
om
– Press the UP or DOWN button until Shift Light is marked.
tm edPress the RIGHT button to open the menu.
ho ns
S03813-01 – Press the UP or DOWN button to select the desired menu
e
subitems.
h@ Lic

– Press the UP or DOWN button to adjust the value for RPM1 and
fo r |
RPM2 and press the ENTER button to confirm.

sh fü
rt
ta rt
Info
at ie
If the engine speed does not reach RPM1, the first

M ns
value set, the engine speed display flashes slowly.

If the engine speed does not reach RPM2, the second
h, ze
value set, the engine speed display flashes quickly.

Li
– Switch the shift warning light off or on using the menu

subitems OFF or ON.
t
or
18.5.33 Daytime Runn. Light

hf
Condition
as

ew

th
at

M
S03823-01
226
Warning
Danger of accidents When visibility is poor, the day-
time running light is not a substitute for the low beam.
Automatic switching between the daytime running
light and low beam may only be partially available
when visibility is significantly impaired due to fog,
snow or rain.
– Ensure that the appropriate type of lighting is
always selected.
– If necessary switch off the daytime running lights
using the menu before going on a ride or when
stopped so that the low beam is switched on per-
manently.
– Note the legal regulations regarding the daytime
72
running light.
04
– Press the UP or DOWN button until Daytime Runn. Light is
0
marked.
/0
57
– Press the UP or DOWN button until Daytime Runn. LightOFF or ON
04
is marked.
0
,0
–
l.c r:
Press the ENTER button to switch the daytime running light on
ai fo
or off.
om
18.5.34 Setting the time and date
tm ed
ho ns
Condition
e
The motorcycle is stationary.

h@ Lic
– Press RIGHT button when the menu is closed.

fo r |

sh fü

rt
– Press the UP or DOWN button until Clock/Date is marked.

ta rt
at ie

M ns
h, ze
Li
S03821-01
Setting the clock

t
– Press the UP or DOWN button until the time is marked.

or
– Press the ENTER button.

hf
The hour next to Clock flashes.

as
– Press the UP or DOWN button until the current hour is set.

ew
– Press the RIGHT button.

th
The minute next to Clock flashes.

–
at
Press the UP or DOWN button until the current minute is

M
S03820-01 set.
The time is stored.
227
Setting the date

– Press the UP or DOWN button until the date is marked.
The day next to Date flashes.
– Press the UP or DOWN button until the current day is set.
The month next to Date flashes.
– Press the UP or DOWN button until the current month is
S03822-01 set.
The year next to Date flashes.
– Press the UP or DOWN button until the current year is set.
The date is stored.
72
04
18.5.35 Programming the cruise control system
0
/0
– Switch on ignition; to do this, briefly press the RACE-ON but-
57
ton (maximum of 1 second).
04
The cruise control system indicator lamp flashes.
– Press and hold the cruise control system button for
0
,0
l.c r:
three seconds.
ai fo
om
– Press and hold button RES/+ for three seconds.
– tm ed
Press and hold button SET/‑ for three seconds.
– Turn the throttle grip forward, past the basic position.
ho ns
The cruise control system indicator lamp goes out.

e
h@ Lic

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04688-10
18.5.36 Units
t
or
Condition
hf
• The vehicle is stationary.

–
as
Press the RIGHT button when the menu is closed.

ew

th
– Press the UP or DOWN button until Units is marked.

at

M
Units allows settings to be made for units or various values.

S03814-01
228
18.5.37 Distance
Condition
– Press the UP or DOWN button until Distance is marked.
S03815-01
– Activate the menu item using the UP or DOWN button.
– Press the ENTER button to confirm the desired unit.
18.5.38 Temperature
72
Condition
04
0
/0
57
04
0
,0
l.c r:
ai fo
– Press the UP or DOWN button until Temperature is marked.
om
S03816-01
tm ed
ho ns

e
h@ Lic
18.5.39 Pressure
fo r |
Condition
sh fü

rt
ta rt

at ie
M ns

h, ze

Li
– Press UP or DOWNbutton until Pressure is marked.

S03817-01
t

or

hf
as
ew
th
at
M
229
18.5.40 Consumption
Condition
– Press UP or DOWNbutton until Consumption is marked.
S03818-01
18.5.41 Language
72
Condition
04
0
/0
57
04
0
,0
l.c r:
ai fo
– Press the UP or DOWN button until Language is marked.
om
S03819-01
tm edPress the RIGHT button to open the menu.
ho ns
– Press the ENTER button to confirm the desired language.

e
The menu languages are US English, UK English, German, Italian,

h@ Lic
French, and Spanish.

fo r |
18.5.42 Heated Grips (optional)

sh fü
Condition
rt
ta rt

at ie

M ns

h, ze

Li
– Press the UP or DOWN button until Heated Grips is marked.

t
– Press the UP or DOWN button until NOT AVAILABLE or AVAILABLE

or
S03828-01 is marked.
hf

as
Info
ew
The heated grip is activated or deactivated in the

th
Settings menu. The heated grip is controlled in the

at
Motorcycle menu, in submenu Heated Grips or in

M
the HEATING widget.

230
18.5.43 Heated Seat (optional)

Condition
– Press the UP or DOWN button until Heated Seat is marked.
– Press the UP or DOWN button until Heated SeatNOT AVAILABLE
S03829-01 or AVAILABLE is marked.
Info
The seat heating is activated or deactivated in the
72
Settings menu. The seat heating is controlled in the
Motorcycle menu, in Heated Seat submenu or in the
04
widget HEATING.
0
/0
57
18.5.44 Small widget
04
– Press the UP button once when the menu is closed.
0
– Use the LEFTor RIGHT button to change between the informa-
,0
l.c r:
tion displays.
ai fo
om
Info tm ed
In the small widget you can switch between the individ-
ho ns
ual widgets.
e
All widgets dependent on optional menus and func-

h@ Lic
tions are only available if the corresponding option is

S03787-01
installed in the vehicle.
fo r |
sh fü
18.5.45 Large widget

rt
ta rt
at ie
– Press the UP button twice when the menu is closed.

M ns
The widget is large and displays all the information of the

respective information display.
h, ze
Li
Info
All widgets dependent on optional menus and func-
tions are only available if the corresponding option is
t
or
installed in the vehicle.

hf
S03788-01
as
ew
th
at
M
231
18.5.46 KTM MY RIDE widget

– Use the LEFTor RIGHT button to switch between the information
displays until the KTM MY RIDE widget is displayed.
– Press the ENTER button to open the large widget.
The KTM MY RIDE widget displays various status information
on the cellphone battery status, cellphone reception and the
Bluetooth® connection to the headset.
Info
When the symbols are filled in, there is a connection
between the combination instrument and the terminal
device.
When the symbols are not filled in, there is no connec-
tion between the combination instrument and the ter-
72
minal device.
0 04
/0
57
S03834-10
0 04
18.5.47 NAVIGATION widget
,0
l.c r:
–
ai fo
Press the UP button once when the menu is closed.
om
tm ed
displays until the NAVIGATION widget is displayed.
ho ns

e
h@ Lic
Info
The NAVIGATION widget is only available if the naviga-
fo r |
tion app is active and the TRACKmode is deactivated.

sh fü
The large NAVIGATION widget shows the direction arrow,

rt
the distance to the next waypoint, the road name, the

ta rt
at ie
arrival time and the distance to the destination.

M ns
The volume of the navigation can be controlled with

the UP or DOWN button.
h, ze
Li
t
or
hf
S03836-10
as
ew
th
at
M
232
18.5.48 FAVORITES widget

tion displays until the FAVORITES widget is displayed.
Info
In the large FAVORITES widget, up to four areas with
different information types can be configured.
– Use the LEFTor RIGHT button to change between the individual

areas until the desired area is highlighted.
– Press the UP or DOWN button to select the desired information
type.
72
Info
The selection is accepted after a few seconds.
04
An area can be added using the selection
0
item Item Add.
/0
An area can be removed using the selection
57
S03837-10 item Item Add.
04
Up to four areas can be selected and configured.
0
The areas one to four are also the information displays
,0
l.c r:
in the small FAVORITES widget.
ai fo
om
18.5.49 Widget INFO
tm ed
ho ns
e

h@ Lic
tion displays until the INFO widget is displayed.

fo r |
sh fü
Info
rt
ta rt
The small INFO widget displays the fuel level indicator,

at ie
the coolant temperature indicator and the remaining

M ns
range.
The large INFO widget also displays the total mileage,
h, ze
the ambient air temperature and the oil temperature.

Li
t
or
hf
as
ew
S03838-10
th
at
M
233
18.5.50 HEATING widget

displays until the widget HEATING is displayed.
– Press the LEFT or RIGHT button to select the heating level or
the heated grip.
– Press the UP or DOWN button to select the desired heating
intensity.
Info
The HEATING widget is only available if it has been acti-
vated in the menu SETTINGS.
A selection can be made between heating intensities
OFF, MAX, MED or MIN.
72
The heating intensity is displayed in bars in the large
04
widget. The more bars displayed, the higher the heating
intensity.
0
/0
57
S03839-10
0 04
18.5.51 MUSIC widget
,0
l.c r:
–
ai fo
Press the UP button once when the menu is closed.
om
tm ed
tion displays until the MUSIC widget is displayed.
ho ns
e
Warning
h@ Lic

fo r |

sh fü

rt
ta rt
at ie

M ns
– Press the UP button to increase the volume.

h, ze
– Press the DOWN button to reduce the volume.

Li
– Press the RIGHT button briefly to change to the next audio

track.
– Depending on the cellphone model, press the LEFT button
t
or
briefly or twice to change to the previous audio track or to play

hf
the current audio track from the start.

S03840-10
as
– Press the ENTER button to change between playback and

pause.
ew
Tip
th
The MUSIC widget is only available if a cellphone and a

at
headset are connected via Bluetooth® with the motorcy-

M
cle.
With some cellphones, the cellphone's audio player
needs to be started before playback is possible. For
easier operation, the MUSIC function can be added to
the C1 or C2 switch.
234
ENGINE 19
19.1 Removing the engine

Preparatory work
– Disconnect the negative cable of the 12-V battery. ( p. 182)
Info
Only disassemble the right-hand side.
– Drain the coolant. ( p. 356)

–
72
04
– Remove the manifold. ( p. 101)
0
/0
57
– Remove the air filter box. ( p. 114)
04
– Remove the throttle valve body. ( p. 396)
0
Main work
,0
l.c r:
– Loosen hose clips 1.
ai fo
om
– Remove the radiator hose on the right.
tm ed
ho ns
e
h@ Lic
fo r |
G04620-10
sh fü
– Loosen hose clips 2.

rt
ta rt
– Pull off the radiator hoses from the radiator on the left.
at ie
M ns
h, ze
Li
t
or
G04621-10
hf
as
– Pull hoses 4 out of the bracket.

ew
th
at
M
G04622-10
235
19 ENGINE
– Remove screw 5.
– Remove screw 6.
– Detach the radiator on both sides.
Info
Pay attention to the cooling fins.
G04623-10
– Disconnect plug-in connectors 7.

– Remove the radiator sideways.
72
0 04
/0
G04624-10
57
– Remove screw 8.
04
– Remove screws 9. Take off the footrest bracket.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04636-10
– Remove screws bk. Hang the footrest bracket to the side.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04637-10
– Screw the holder of the special tool all the way into the upper
t
or
drill holes of the footrest brackets. Select the right height and
hf

as
Guideline
Mount the special tool with the open side pointing forward.
ew
Work stand (62529055200) ( p. 461)

th
at

M
R01958-10
Info
236
ENGINE 19
– Pull the activated carbon filter forward and off.

– Take off bracket.
72
0 04
/0
G04631-10
57
– Remove nut bm.
04
– Hang the positive cable of the starter motor to the side.
0
– Detach connector bn.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04625-10
– Remove screw bo.

fo r |
– Hang the ground wire to the side.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04626-10
–
t
Remove screws bp.

or
– Pull off the secondary air system cover and hang it to the side.
hf
as
ew
th
at
M
G04627-10
237
19 ENGINE
– Remove screws bq.

– Hang the SAS valve to the side.
G04639-10
– Disconnect plug-in connector br of the shift shaft sensor.
72
0 04
/0
G04640-10
57
– Remove screws bs from the ignition coils.
04
– Disconnect connectors bt of the ignition coils.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04628-10
– Remove screws ck.

fo r |

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04629-10
– Disconnect plug-in connectors cl.

t
or

hf
as
ew
th
at
M
G04630-10
238
ENGINE 19

– Open the plug box.
72
0 04
/0
G04632-10
57
– Disconnect plug-in connectors cm.
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04633-10
t
– Remove screws cn.

or
– Take off the slave cylinder of the clutch and hang to the side.
hf
as
Info
ew

of the clutch is removed.
th
Do not kink the clutch line.

at
– Remove the spacer with sleeves.

M
G04634-10
– Remove screws co.
– Take off the engine sprocket cover.
239
19 ENGINE
– Remove screw cp.

– Remove the chain securing guide with the spacer.
G04635-10
– Bend up the lock washer.

– Loosen nut cq.
72
004
/0
G04638-10
57
– Remove screws cr.
04
– Remove the side stand.
0
– Remove screws cs.
,0
l.c r:
– Remove the side stand bracket.
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04641-10
–
t
Loosen screw ct.

or
– Turn hub housing dk clockwise.

hf
as
Holding wrench (61329085000) ( p. 460)

ew

th
at
M
G04643-10
240
ENGINE 19
Info
R01977-10
– Remove nut dl with the lock washer.

– Remove the engine sprocket.
72
0 04
/0
G04642-10
57
– Remove screw dm with the washer.
04
– Take off the shift shaft deflector.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04644-10
– Position the scissor jack.

fo r |
sh fü
Info
rt
ta rt
It is a good idea to have assistance when carrying out

at ie
the following steps.

M ns
h, ze
Li
G04645-10
– Remove nut dn.

t
or
– Pull the swingarm pivot out far enough to release the engine.
hf
as
ew
th
at
M
G04646-10
241
19 ENGINE
– Remove the plug in the frame.

– Remove screws do.
G04647-10
– Remove the plug in the frame.

– Remove screws dp.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04648-10
– Pull the engine forward slightly and lower carefully.

fo r |
sh fü
Info
rt
ta rt
The help of an assistant is useful in this step.

at ie
M ns
h, ze
Li
G04649-10
t
or
19.2 Installing the engine

hf
Preparatory work
as
– Prepare the engine for installation. ( p. 251)

ew
th
at
M
242
ENGINE 19
Main work
– Position the engine on a scissor jack under the vehicle.
Info
It is a good idea to have assistance when carrying out
the following steps.
G04649-10
– Position the engine in the frame.

– Mount screws 1, but do not tighten yet.
Guideline
Screw, engine M10 45 Nm (33.2 lbf ft)
bearer Loctite®243™
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04648-11
– Mount screws 2, but do not tighten yet.

fo r |
Guideline
sh fü
Screw, engine M10 45 Nm (33.2 lbf ft)

rt
ta rt
at ie
M ns
h, ze
Li
G04647-11
– Mount the swingarm pivot.

t
or

hf
Guideline
as

ew
Thread greased
–
th
Tighten screws 1.
at
Guideline
M
G04646-11 Screw, engine M10 45 Nm (33.2 lbf ft)

243
19 ENGINE
– Remove the scissor jack.
G04645-10
– Position the shift shaft deflector.

– Mount and tighten screw 4 with the washer.
Guideline
Screw, shift M6 18 Nm (13.3 lbf ft)
shaft deflector Loctite®243™
72
on shift shaft
0 04
/0
G04644-11
57
– Mount the engine sprocket.
04
– Lay a chain over the engine sprocket.
0
,0
l.c r:
the hub housing.
ai fo
om
– Mount nut 5 with the lock washer, but do not tighten yet.
tm ed
Guideline
ho ns
e
h@ Lic
G04642-11
– Position the side stand bracket.

fo r |

sh fü
Guideline
rt
ta rt
Screw, side M8 25 Nm (18.4 lbf ft)

at ie
stand bracket Loctite®243™

M ns
– 7.
h, ze
Mount and tighten screws

Guideline
Li

t
or
hf
as
ew
th
at
M
G04641-11
244
ENGINE 19
– Lay a chain over the rear sprocket.

the hub housing.
– Tighten nut 5.
Guideline
G04638-11
– Secure the nut with lock washer 8.
– Mount the chain securing guide with the spacer.
Guideline
chassis
72
0 04
/0
G04635-11
57
04
– Mount and tighten screw bk.
0
,0
l.c r:
Guideline
ai fo
om
tm ed
sprocket cover
ho ns
– Mount the clutch slave cylinder with the spacer and sleeves.
– Route the clutch line without kinks.
e
h@ Lic
G04634-11
Guideline
fo r |

sh fü
screw
rt
ta rt
at ie
– Join plug-in connectors bm.

M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
G04633-11
245
19 ENGINE
– Route the cables without tension.

– Secure the cable with cable ties.
– Close the plug box.
72
0 04
/0
G04632-10
57
– Join plug-in connectors bn.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04630-11

fo r |
– Mount and tighten screws bo.

sh fü
Guideline
rt
ta rt

at ie
M ns
chassis
h, ze
Li
G04629-11
–
t
Plug in connectorsbp of the ignition coils.

or
– Mount and tighten screws bq of the ignition coil.

hf
as
ew
th
at
M
G04628-11
246
ENGINE 19

– Join the plug-in connector br of the shift shaft sensor.
G04640-10
– Mount and tighten screws bs of the SAS valve.
72
0 04
/0
G04639-11
57
– Position the two secondary air system covers.
04
– Mount and tighten screws bt.
0
Guideline
,0
l.c r:
ai fo
om
engine
tm ed
ho ns
e
h@ Lic
G04627-11
– Position the ground wire.

fo r |
– Mount and tighten screw ck.

sh fü
Guideline
rt
ta rt
Screw, starter motor M6 10 Nm (7.4 lbf ft)

at ie
M ns
h, ze
Li
G04626-11
– Position the positive cable on the starter motor.

t
or
– Mount and tighten nut cl.

hf
Guideline
as
Nut, cable on starter M6 6 Nm (4.4 lbf ft)

ew
motor
–
th
Plug in both plugs cm.

at
M
G04625-11
247
19 ENGINE
– Mount the bracket.

– Mount and tighten screw cn.
Guideline
chassis
– Mount active carbon filter.
72
0 04
/0
G04631-11
57
04
side stand.
0
,0
l.c r:
Work stand (62529055200) ( p. 461)
ai fo
om
tm ed
ho ns
e
h@ Lic
R01958-10
– Position the footrest bracket. Mount and tighten screws co.

fo r |
Guideline
sh fü

rt
ta rt

at ie
bracket
M ns
h, ze
Li
G04637-11
–
t
Position the footrest bracket. Mount and tighten screws cp.

or
Guideline
hf

as

ew
bracket
–
th
Position the shift rod. Mount and tighten screw cq.

at
Guideline
M
G04636-11
Loctite®243™
248
ENGINE 19
– Position the radiator.

– Join plug-in connectors cr.
G04624-11
– Insert the radiator on both sides.

– Mount and tighten screws cs and ct.
Guideline
chassis
72
0 04
/0
G04623-11
57
– Mount hoses dk in the bracket.
04
– Plug in connector dl.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04622-11
– Mount the radiator hoses.

fo r |
– Position and tighten hose clips dm.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04621-11
– Mount the radiator hose.

t
or
– Position and tighten hose clips dn.

hf
as
ew
th
at
M
G04620-11
249
19 ENGINE
– Have the entire filling quantity available.

Engine oil 3.50 l Engine oil
Ambient (3.7 qt.) (SAE 10W/50)
temperature: ≥ 0 °C ( p. 446)
(≥ 32 °F)
Engine oil Engine oil (SAE
Ambient 5W/40) ( p. 447)
temperature: < 0 °C
G04650-10
(< 32 °F)
– Remove filler plug do with the O-ring, and fill up with the first
partial quantity.
Engine oil (1st par- 3.0 l (3.2 qt.) Engine oil
tial quantity) approx. (SAE 10W/50)
Ambient ( p. 446)
temperature: ≥ 0 °C
72
(≥ 32 °F)
04
Engine oil (1st par- Engine oil (SAE
0
tial quantity) approx. 5W/40) ( p. 447)
/0
Ambient
57
04
(< 32 °F)
0
– Mount filler plug do with the O-ring.
,0
l.c r:
ai fo
Finishing work
om
– Install the throttle valve body. (
tm ed p. 397)
– Install the lower part of the air filter box. ( p. 115)
ho ns

e
– Install the manifold. ( p. 103)

h@ Lic

–
fo r |
Check the throttle cable tension of the exhaust valve con-

troller. ( p. 109)
sh fü

rt
ta rt

at ie
M ns
– Connect the negative cable of the 12-V battery. ( p. 182)

h, ze

Li

t
– Add the coolant/bleed the cooling system. ( p. 357)

or

hf
as
Danger
ew
Danger of poisoning Exhaust gases are toxic and inhal-

ing them may result in unconsciousness and death.
th
– Always make sure there is sufficient ventilation

at
when running the engine.

M
– Use effective exhaust extraction when starting or

running the engine in an enclosed space.
– Start the engine and check for leaks.

– Switch off the engine.
250
ENGINE 19
– Remove the filler plug with the O-ring and add the second par-
tial quantity up to the upper marking on the engine oil level
viewer.
Engine oil (2nd par- 0.50 l Engine oil
tial quantity) approx. (0.53 qt.) (SAE 10W/50)
Ambient ( p. 446)
(≥ 32 °F)
Engine oil (2nd par- Engine oil (SAE
Ambient
(< 32 °F)
– Mount the filler plug with the O-ring.
– Perform the initialization run. ( p. 399)
72
– Check the lubrication system for leaks.
04
– Check the cooling system for leaks.
0
/0
– Program the shift shaft sensor. ( p. 354)
57
– Go for a short test ride.
04
0
– Check the engine oil level. ( p. 377)
,0
l.c r:
ai fo
– Check the coolant level in the compensating tank. ( p. 355)
om
tm ed
ho ns
19.3 Preparing the engine for installation

e
h@ Lic
– Position both radiator hoses. Position and tighten the hose

clips.
fo r |
– Position the bleeder hoses.

sh fü
– Position SAS hose and mount hose clamps.

rt
ta rt
at ie
M ns
h, ze
Li
G04700-10
19.4 Preparing the engine for clamping in the engine assembly stand
t
or
– Remove the hose clips.

hf
– Remove both radiator hoses.

as
– Remove the vent hose.

– Remove the SAS hose.
ew
th
at
M
G04700-10
251
19 ENGINE
19.5 Setting the engine to ignition top dead center of the rear cylinder
Condition
The valve cover has been removed.
– Remove screw 1 of the alternator cover.
R01891-10
– Turn the crankshaft counterclockwise until markings A are

flush with the edge of the cylinder head.
72
0 04
/0
57
0 04
,0
l.c r:
R01892-10
ai fo
om
– Remove screw 2.
–
tm ed
Look through the hole to check that the position notch of the
ho ns
crankshaft is visible.
– Screw in special tool 3.
e
h@ Lic
Locking screw (61229015000) ( p. 457)

fo r |
sh fü
rt
ta rt
G04689-11
at ie
M ns
19.6 Setting the engine to ignition top dead center of the front cylinder
h, ze
Condition
Li
The engine is positioned at ignition top dead center of the rear

cylinder.
– Loosen special tool 1 by several turns.
t
or
Locking screw (61229015000) ( p. 457)

hf
as
ew
th
at
M
G04699-10
252
ENGINE 19
– Keep turning the crankshaft counterclockwise until

markings A are flush with the edge of the cylinder head.
– Screw special tool 1 back in.
R01893-10
19.7 Engine disassembly
19.7.1 Clamping engine into the engine work stand

Preparatory work
– Prepare the engine for clamping in the engine assembly stand.
72
( p. 251)
04
Main work
0
– Mount special tool 1 on engine work stand 2.
/0
57
Engine work stand (61229001000) ( p. 456)
Engine bracket for engine work stand (61729002000)
04
( p. 461)
0
,0
l.c r:
– Mount the engine on special tool 1.
ai fo
om
Info tm ed
G04351-10
Work with an assistant or a motorized hoist.
ho ns
e
h@ Lic
19.7.2 Removing the engine bearer

fo r |
– Remove screws 1 and take off the engine bearer.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04352-10
t
or
– Remove screws 2 and take off the engine bearer.

hf
as
ew
th
at
M
G04353-10
253
19 ENGINE
19.7.3 Draining the engine oil

– Remove oil drain plug 1 with the magnet, O-rings and oil
screen.
– Completely drain the engine oil.
72
0 04
/0
57
G04354-10
0 04
19.7.4 Removing the front resonator
,0
l.c r:
–
ai fo
Remove screws 1.
om
– Take off resonator with O-rings.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04355-10
rt
ta rt
at ie
19.7.5 Removing the rear resonator

M ns
h, ze
– Take off resonator with O-rings.

Li
t
or
hf
as
ew
G04356-10
th
at
M
254
ENGINE 19
19.7.6 Removing the front valve cover

– Remove ignition coils 1.
– Remove screws 2 with gaskets.
– Take off the valve cover with the valve cover seal.
– Remove the spark plugs using the special tool.
Spark plug wrench with link (77229172000) ( p. 462)
G04357-10
19.7.7 Removing the rear valve cover

– Remove screws 2 with gaskets.
72
– Take off the valve cover with the valve cover seal.
04
– Remove the spark plugs using the special tool.
0
/0
57
0 04
G04358-10
,0
l.c r:
ai fo
om
19.7.8 Setting the engine to ignition top dead center of the rear cylinder
–
tm ed
Remove screw plug 1 with O-ring.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
G04359-10
M ns
– Turn the crankshaft counterclockwise until markings A of the

h, ze
rear camshafts are flush with the edge of the cylinder head.
Li
t
or
hf
as
G04360-10
ew
th
at
M
255
19 ENGINE

– Look through the hole to check that the position notch of the
crankshaft is visible.
Locking screw (61229015000) ( p. 457)
G04361-10
19.7.9 Removing the starter motor

– Take off the starter motor.
72
0 04
/0
57
G04362-10
0 04
19.7.10 Removing the oil filler neck
,0
l.c r:
ai fo
om
– Remove the oil filler neck with the O-ring.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04363-10
rt
ta rt
at ie
19.7.11 Removing the heat exchanger

M ns
– Remove screws 1 of heat exchanger 2.

h, ze
– Remove the heat exchanger.

Li
t
or
hf
as
ew
G04364-10
th
at
M
256
ENGINE 19
– 3 and sleeves 4.
Remove O-rings
– Remove seal 5.
G04365-10
19.7.12 Removing the rear timing chain tensioner

– Remove screw 1 with O-ring 2.
– Remove timing chain tensioner3 with O-ring 4.
72
0 04
/0
57
G04366-10
0 04
19.7.13 Removing the rear camshafts
,0
l.c r:
ai fo
– Remove the spark plug shaft insert 1 with the gasket.
om
– tm ed
Loosen and remove screws 2 from the outside to the inside.
ho ns
Info
e
The cams should not activate the valves.

h@ Lic
– Remove the camshaft bearing support.

fo r |
sh fü
G04367-10
rt
ta rt
at ie
– Raise the camshafts at the rear and take the timing chain off
M ns
of the rear sprocket. Remove the camshafts.

h, ze
Li
t
or
hf
G04368-10
as
ew
th
at
M
257
19 ENGINE
19.7.14 Removing the rear cylinder head

– Remove nuts 1 with the washers.
– Alternately loosen screws 2 and remove them.
– Take off the cylinder head.
72
0 04
/0
57
G04369-10
04
– Remove cylinder head gasket 3.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
G04370-10
sh fü
19.7.15 Removing the rear piston

rt
ta rt
–
at ie
Push the cylinder up.

M ns
Info
h, ze
Push the cylinder up until the piston pin can be

Li
removed.
Make sure that the two pins remain in place.
t
or
hf
G04371-10
as
– Remove piston pin retainer 1.

ew
– Remove the piston pin.

th
– Remove the cylinder with the piston.

at
– Push the piston upward out of the cylinder.

M
Info
If no additional work needs to be performed on the
cylinder and piston, the piston can remain in the cylin-
G04372-10 der.
258
ENGINE 19
– Remove cylinder base gasket 2.
G04373-10
19.7.16 Setting the engine to ignition top dead center of the front cylinder
– Loosen special tool 1 by several turns.
Locking screw (61229015000) ( p. 457)
– Keep the timing chain taut. Hold the connecting rod in the
72
center of the drill hole.
04
– Keep turning the crankshaft counterclockwise until
markings A of the front camshafts are flush with the edge of
0
/0
the cylinder head.
57
– Screw special tool 1 back in.
G04374-10
0 04
,0
l.c r:
19.7.17 Removing the front timing chain tensioner
ai fo
om
– Remove screw 1 with O-ring 2.
–
tm ed
Take off timing chain tensioner 3 with O-ring 4.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
G04375-10
at ie
M ns
19.7.18 Removing the front camshafts

h, ze
– Remove the spark plug shaft insert 1 with the gasket.

Li
– Loosen and remove screws 2 from the outside to the inside.

Info
t
or

hf

as
ew
G04376-10
th
at
M
259
19 ENGINE
– Raise the camshafts at the rear and take the timing chain off
of the rear sprocket. Remove the camshafts.
G04377-10
19.7.19 Removing the front cylinder head

– Remove nuts 1 with washers.
– Loosen screws 2 in a crisscross pattern and remove them.
– Remove the cylinder head.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
G04378-10
sh fü
– Remove cylinder head gasket 3.

rt
ta rt
at ie
M ns
h, ze
Li
t
or
G04379-10
hf
19.7.20 Removing the front piston

as
– Push the cylinder upward.

ew
Info
th
Only push the cylinder as far up as necessary to take

at
the piston pin out.

M
Make sure that the two pins remain in place.

G04380-10
260
ENGINE 19
– Remove piston ring lock 1.

– Remove the piston pin.
– Take off the cylinder and piston.
– Push the piston upward out of the cylinder.
Info
If no further work is to be performed on the cylinder
and piston, the piston can remain in the cylinder.
G04381-10
– Remove cylinder base gasket 2.
72
0 04
/0
G04382-10
57
19.7.21 Removing the alternator cover
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
G04383-10
sh fü
– Screw in special tool 2 and pull off the alternator cover.

rt
ta rt
Puller (61229010000) ( p. 457)

at ie
M ns
Info
h, ze
Strike the alternator cover lightly with a rubber mallet

Li
to prevent strain.
– Take off the alternator cover seal. Take off the dowels.
t
or
G04384-10
hf
19.7.22 Removing the crankshaft speed sensor

as
– Remove the screws of crankshaft speed sensor 1.

ew
– Pull rubber grommet 2out of the engine case. Take off the
th
crankshaft speed sensor.

at
M
G04385-10
261
19 ENGINE
19.7.23 Removing the torque limiter and the intermediate gear

– 1.
Take off torque limiter
– Remove intermediate gear 2 with the washers and needle
bearing.
Info
The intermediate gear has one washer at the front and
one at the rear; the front washer usually sticks to the
alternator cover.
G04386-10
19.7.24 Removing the rotor

– Remove the screws and take off starter wheel guide 1.
– Loosen and remove screw 2 of the rotor.
72
04
Info
0
The crankshaft must be blocked.
/0
57
0 04
G04387-10
,0
l.c r:
ai fo
– Screw special tool 3 into the crankshaft.
om
tm ed
Pressing tool (61229008100) ( p. 457)
ho ns
– Mount special tool 4 on the rotor, apply counterpressure,
e
and pull off the rotor by screwing in the screw.

h@ Lic
Puller (75029021000) ( p. 461)

fo r |

sh fü
rt
G04388-10
ta rt
at ie
– Take freewheel gear 5 from rotor 6.

M ns
h, ze
Li
t
or
hf
307036-10
as
ew
th
at
M
262
ENGINE 19
19.7.25 Removing the intermediate gear and the timing chain on the left
– Take off intermediate gear 1 with washer 2.
G04389-10
– Remove the timing chain, needle bearing 3 and the washer

lying behind it.
Info
72
If the timing chain is to be used again, mark on it the
04
direction of travel and the cylinder to which it belongs.
0
/0
57
G04390-10
0 04
19.7.26 Removing the oil filter
,0
l.c r:
– 1. Take off oil filter cover 2 with the O-
ai fo
Remove screws
om
ring.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04391-10
rt
ta rt
– Pull oil filter 3 out of the oil filter housing.

at ie
M ns
Lock ring plier (51012011000) ( p. 452)

h, ze
Li
t
or
hf
G04392-10
as
ew
th
at
M
263
19 ENGINE
19.7.27 Removing the balancer shaft

– Remove balancer shaft 1 with washer 2.
– Mount the needle bearing and the rear washer.
G04393-10
19.7.28 Removing the drive gear wheel of the balancer shaft

– Remove drive gear wheel 1 of the balancer shaft with special
tool23, and 4 .
72
Puller (78029033100) ( p. 462)
04
Pressing tool (61229018000) ( p. 458)
0
Arms for puller (61229017000) ( p. 458)
/0
57
0 04
G04394-10
,0
l.c r:
ai fo
om
19.7.29 Removing the gear position sensor
–
tm ed
Remove screws 1.
ho ns
– Take off gear position sensor 2.
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
G04395-10
M ns
h, ze
19.7.30 Removing the left suction pump

Li
t
or
hf
as
ew
th
G04396-10
at
M
264
ENGINE 19
– Screw suitable screws into the oil pump cover.

– Remove the oil pump cover by screwing in the screws.
– Remove oil pump cover 2.
72
0 04
/0
G04397-10
57
– Remove external rotor 4 and internal rotor 5.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04398-10
– Remove pin 6.
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04399-10
t
or
19.7.31 Removing the water pump wheel

hf
as
– Take off the water pump cover.

ew
th
at
M
G04400-10
265
19 ENGINE
– Remove dowels2.
– Remove screw 3. Take off the water pump wheel with the
washer below it.
G04401-10
19.7.32 Removing shift shaft sensor

– Take off the shift shaft sensor 2.
72
0 04
/0
57
G04402-10
0 04
19.7.33 Removing the clutch cover
,0
l.c r:
ai fo
– Loosen screws1 of the outer clutch cover.
om
– tm ed
Remove screws 2.
– Take off the clutch cover.
ho ns
e
h@ Lic
fo r |
sh fü
G04403-10
rt
ta rt
at ie
– Take off dowels3. Remove the clutch cover gasket.

M ns
– Remove return valve 4.

h, ze
– Take water pump sleeve 5 off the intermediate gear.

Li
t
or
hf
G04404-10
as
ew
th
at
M
266
ENGINE 19
19.7.34 Removing the clutch discs

– Take off clutch center 2 and the springs.
G04405-10
– Remove clutch pressure cap 3.
72
0 04
/0
57
G04406-10
04
– Remove clutch push rod 4.
0
,0
–
l.c r:
Remove clutch discs 5 , support ring, and pretension ring.
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
G04407-10
sh fü
19.7.35 Removing the clutch basket

rt
ta rt
– Hold the inner clutch hub with the special tool.

at ie
M ns
Holding wrench (51129003000) ( p. 452)

h, ze
– Remove nut 1 with the washer.

Li
t
or
hf
G04408-10
as
– Take off inner clutch hub 2 and washer 3.

ew
Info
th
The washer usually sticks to the inner clutch hub.

at
M
– Take off clutch basket 4.
G04409-10
267
19 ENGINE
– Remove needle bearing 5 and washer 6.
G04410-10
19.7.36 Removing the intermediate gear and the timing chain on the right
– Take off intermediate gear 1.
– Take off the timing chain.
Info
72
If the timing chain is to be used again, mark on it the
04
direction of travel and the cylinder to which it belongs.
0
/0
57
G04411-10
0 04
19.7.37 Removing the primary gear wheel
,0
l.c r:
ai fo
– Remove nut 1 of primary gear 2 with the washer.
om
tm ed Info
ho ns
LH thread!
e
Make sure that the crankshaft is blocked.

h@ Lic
fo r |
sh fü
G04412-10
rt
ta rt
at ie
– Remove the primary gear wheel with special tool 3, 4

M ns
and 5 .
h, ze
Puller (78029033100) ( p. 462)

Li
Pressing tool (61229018000) ( p. 458)

Arms for puller (61229017000) ( p. 458)
t
or
hf
G04413-10
as

ew
Locking screw (61229015000) ( p. 457)

th
at
M
G04414-10
268
ENGINE 19
19.7.38 Removing the force pump

– Remove lock washer 1 and washer 2.
– Take off oil pump gear wheel 3.
G04415-10
– Remove pin 4 and washer 5.

– Remove the oil pump cover.
72
0 04
/0
57
G04416-10
04
– Remove external rotor 7 and internal rotor 8.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
G04417-10
sh fü
– Remove pin 9.
rt
ta rt
at ie
M ns
h, ze
Li
t
G04418-10
or
hf
19.7.39 Removing the shift shaft

as
– Push sliding plate1 away from shift drum locating unit 2.

ew
Remove shift shaft3 with washer.

th
at
M
G04419-10
269
19 ENGINE
19.7.40 Removing the shift drum locating

– Remove screw 1.
– Press locking lever 2 away from shift drum locating 3 and
take off the shift drum locating.
– Release the locking lever.
G04420-10
19.7.41 Removing the locking lever

– Remove screw 1.
– Take off locking lever 2 with the sleeve and spring.
72
0 04
/0
57
0 04
G04421-10
,0
l.c r:
ai fo
om
19.7.42 Removing the left engine case
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
G04422-10

th
– Swing the left section of the engine case upward. Remove screw 3.
at
– Loosen the left section of the engine case by striking it lightly with a plastic hammer and remove it.
M
270
ENGINE 19
– Remove dowels4.
– Remove dowel 5.
G04423-10
19.7.43 Removing the crankshaft

– Remove crankshaft.
72
004
/0
57
G04424-10
0 04
19.7.44 Removing the middle suction pump
,0
l.c r:
ai fo
– Take off oil pump shaft 1 with internal rotor 2.
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
G04425-10
rt
ta rt
at ie
– Remove internal rotor 2 and pin 3 from the oil pump

M ns
shaft1 .
–
h, ze
Remove external rotor 4.

Li
t
or
hf
G04426-10
as
ew
th
at
M
271
19 ENGINE
19.7.45 Removing the transmission shaft

– Remove shift rails 1 with the springs.
G04427-10
– Swing shift forks 2 to one side.

Info
Make sure not to misplace shift rollers 3.
72
– Remove shift drum 4.
0 04
/0
57
G04428-10
04
– Remove shift forks 2.
0
,0
l.c r:
Info
ai fo
om
tm ed Make sure not to misplace the shift rollers.
ho ns
e
h@ Lic
fo r |
G04429-10
sh fü
– Place the engine in an upright position.

rt
– 5 and the stop disk.

ta rt
Remove lock ring

at ie
M ns
h, ze
Li
t
G04430-10
or
– Pull both transmission shafts out of the bearing seats together.

hf
as
ew
th
at
M
G04431-10
272
ENGINE 19
19.7.46 Removing the oil spray tube

– Remove oil spray tube 1. Remove O-rings 2.
G04432-10
19.7.47 Removing the timing chain rails of the right section of the engine case
– Remove screw 1. Remove guide rail 2.
– Remove screw 3. Remove tensioning rail 4.
72
004
/0
57
0 04
G04433-10
,0
l.c r:
ai fo
om
19.7.48 Removing the timing chain rails of the left section of the engine case
– Remove screw
tm ed
1. Remove guide rail 2.
ho ns
– Remove screw 3. Remove tensioning rail 4.
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
G04442-10
M ns
h, ze
19.8 Working on individual parts

Li
19.8.1 Working on the right section of the engine case

– Remove studs 1.
t
or
hf
as
ew
th
at
M
G04434-10
273
19 ENGINE
– Remove regulating nozzle 2.

– Remove oil nozzles 3.
72
0 04
/0
G04435-10
57
– Remove bearing retainers 4.
04
– Remove the dowels.
0
– Remove any remnants of the sealing compound and clean the
,0
l.c r:
section of the engine case thoroughly.
ai fo
om
– Warm the section of the engine case in an oven.
tm ed
Guideline
ho ns
130 °C (266 °F)

e
– Knock the section of the engine case against a level wooden

h@ Lic
G04436-10
board. This will cause the bearings to drop out of the bearing
seats.
fo r |
sh fü
Info
rt
ta rt
Any bearings that remain in the section of the engine

at ie
case must be removed using a suitable tool.

M ns
– Warm the section of the engine case again.

h, ze
Guideline
Li
130 °C (266 °F)

– Insert the new cold bearings into the bearing seats of the hot
t
section of the engine case and, if necessary, use a suitable

or
press tool to push the bearings from the inside to the outside,
hf
all the way to the stop or until flush.

as
Info
ew
When pressing in, ensure that the section of the engine

th
case lies flat in order to prevent damage.

at
Only press the bearings in using the outer bearing race;

M
otherwise, the bearings will be damaged when they are

pressed in.
– After the section of the engine case has cooled, check that the
bearings are firmly seated.
274
ENGINE 19
Info
If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.
– Mount and tighten bearing retainers 4.

Guideline
Screw, bearing M5 5 Nm (3.7 lbf ft)
retainer Loctite®243™
– Mount and tighten regulating nozzle 2.

Guideline
Nozzle 100 M6x0.75 4 Nm (3 lbf ft)
Loctite®243™
– Mount and tighten oil nozzles 3.
72
Guideline
04
Oil nozzle M5 2 Nm (1.5 lbf ft)
0
Loctite®243™
/0
57
– Mount the dowels.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04435-10
–
fo r |
Mount studs 1.
sh fü
Guideline
rt
Stud, timing chain M6 8 Nm (5.9 lbf ft)

ta rt
at ie
shaft
M ns
– Blow compressed air through all oil channels and check that
h, ze
they are clear.

Li
G04434-10
t
or
19.8.2 Removing the right main bearing

hf
– Remove the screws and take off bearing shell bracket 1.

as
ew
th
at
M
G04437-10
275
19 ENGINE
– Mark face A of the main bearing shells as shown in the fig-

ure.
G04438-10
– Place the engine case section on special tool 2.

Pressing tool (61229045000) ( p. 459)
– Place special tool 3 with the smaller diameter on the bearing
shells and press from the inside to the outside.
72
Pressing tool (61229044000) ( p. 459)
0 04
/0
D01192-10
57
19.8.3 Selecting the main bearing shells
04
New crankshaft
0
,0
– Select the new bearing shells according to color mark-
l.c r:
ai fo
ing 1 .
om
tm ed Info
ho ns
Color marking 2 refers to the conrod bearing.
e
h@ Lic
Used crankshaft
– Measure both pivot points and select the new bearing
shells accordingly.
fo r |
sh fü
Guideline
rt
Crankshaft - main bearing diameter

ta rt
at ie
Yellow 52.965 … 52.975 mm

M ns
(2.08523 … 2.08563 in)

Blue 52.976 … 52.985 mm
h, ze
(2.08567 … 2.08602 in)

Li
Red 52.986 … 52.995 mm

(2.08606 … 2.08641 in)
t
or
310639-10
hf
19.8.4 Installing the right main bearing

as
Preparatory work
ew
– Select the main bearing shells. ( p. 276)

th
at
M
276
ENGINE 19
Main work
– Center the new main bearing shells 1 using special tool 2.
Pressing tool (61229044000) ( p. 459)
200439-10
– Place the inside of the section of the engine case on special

tool 3 .
Pressing tool (61229045000) ( p. 459)
– Align the joint of the new bearing shells with the mark made
during disassembly.
72
– Press the bearing shells with the stepped side of special
04
tool 4 through sleeve 2 from the outside to the inside, all
the way.
0
/0
D01193-10
Pressing tool (61229044000) ( p. 459)
57
–
04
Position bearing shell holding plate 5. Mount and tighten the
screws.
0
,0
l.c r:
Guideline
ai fo
om
retainer tm ed Loctite®243™
ho ns
e
h@ Lic
G04437-11
fo r |
19.8.5 Working on the left section of the engine case

sh fü
rt
– 1.
ta rt
Remove studs
at ie
M ns
h, ze
Li
t
or
G04443-10
hf
as
ew
th
at
M
277
19 ENGINE

– Remove oil nozzle 3.
– Remove oil nozzles 4.
72
0 04
/0
D01194-10
57
– Remove radial shaft seal rings5.
04
– Remove radial shaft seal ring 6 of the clutch push rod.
0
– Remove any remnants of the sealing compound and clean the
,0
l.c r:
section of the engine case thoroughly.
ai fo
om
– Warm the section of the engine case in an oven.
tm ed
Guideline
ho ns
130 °C (266 °F)

e
–
h@ Lic
G04444-10 Knock the section of the engine case against a level wooden
board. This will cause the bearings to drop out of the bearing
fo r |
seats.
sh fü
Info
rt
ta rt
Any bearings that remain in the section of the engine

at ie
case must be removed using a suitable tool.

M ns
– Warm the section of the engine case again.

h, ze
Guideline
Li
130 °C (266 °F)

– Insert the new cold bearings into the bearing seats of the hot
t
or
section of the engine case and, if necessary, use a suitable

press tool to push the bearings from the inside to the outside,
hf
all the way to the stop or until flush.

as
ew
Info
When pressing in, ensure that the section of the engine
th
case lies flat in order to prevent damage.

at
Only press the bearings in using the outer bearing race;

M
otherwise, the bearings will be damaged when they are

pressed in.
– After the section of the engine case has cooled, check that the
bearings are firmly seated.
278
ENGINE 19
Info
If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.
– Mount oil nozzles 4.

Guideline
Loctite®243™
– Mount oil nozzle 3.
Guideline
Oil nozzle for clutch M6x0.75 4 Nm (3 lbf ft)
lubrication
72
Guideline
04
Screw plug, clutch M10x1 8 Nm (5.9 lbf ft)
0
lubrication
/0
57
0 04
,0
l.c r:
ai fo
om
D01195-10
–
tm ed
Press in radial shaft seal rings 5 flush.
ho ns
– Press in the radial shaft seal ring of clutch push rod 6.
e
Pressing tool (61229013000) ( p. 457)

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
D01196-11
M ns
– Mount studs 1.
h, ze
Guideline
Li
Stud, timing chain M6 8 Nm (5.9 lbf ft)

shaft
t
– Blow compressed air through all oil channels and check that
or
they are clear.

hf
as
G04443-10
ew
th
at
M
279
19 ENGINE
19.8.6 Removing the left main bearing

– Remove the screws and take off bearing shell bracket 1.
G04445-10
– Mark joint A of the main bearing shells as shown in the fig-

ure.
72
0 04
/0
57
G04446-10
04
– Place the engine case section on special tool 2.
0
,0
l.c r:
Pressing tool (61229045000) ( p. 459)
ai fo
om
– Place special tool 3 with the smaller diameter on the bearing
tm ed
shells and press from the inside to the outside.
ho ns
Pressing tool (61229044000) ( p. 459)

e
h@ Lic
fo r |
309392-10
sh fü
19.8.7 Installing the left main bearing

rt
ta rt
Preparatory work
at ie
– Select the main bearing shells. ( p. 276)

M ns
Main work
h, ze
– Center the new main bearing shells 1 using special tool 2.

Li
Pressing tool (61229044000) ( p. 459)

t
or
hf
as
ew
200439-10
th
at
M
280
ENGINE 19
– Place the inside of the section of the engine case on special

tool3 .
Pressing tool (61229045000) ( p. 459)
– Align the joint of the new bearing shells with the mark made
during disassembly.
– Press the bearing shells with the stepped side of special
tool4 through sleeve 2
from the outside to the inside, all
the way.
D01198-10
Pressing tool (61229044000) ( p. 459)
– Position bearing shell holding plate 5. Mount and tighten the

screws.
Guideline
retainer Loctite®243™
72
0 04
/0
57
D01197-11
04
19.8.8 Changing the conrod bearing
0
,0
l.c r:
Info
ai fo
om
Perform this step on both connecting rods.
tm ed
ho ns
– Clamp each connecting rod individually.
Guideline
e
h@ Lic
Use soft jaws.

fo r |
sh fü
Multi-tooth wrench socket (60029075000) ( p. 455)

rt
ta rt
– Take off the bearing cap and connecting rod. Remove the bear-
at ie
ing shells.
M ns
Info
h, ze
Mark the conrod bearing cover and connecting rod to

Li
ensure that each conrod bearing cover is mounted on

the same connecting rod.
t
or
hf
as
ew
B04832-10
th
at
M
281
19 ENGINE
New crankshaft
– Select the new bearing shells according to color
coding 2 .
Info
Color coding 3 refers to the crankshaft bearing.
72
0 04
/0
310640-10
57
Used crankshaft
04
– Measure the crank pin diameter and select the new bearing
shells accordingly.
0
,0
l.c r:
Guideline
ai fo
om
Crankshaft - crank pin diameter
tm ed Yellow 41.978 … 41.989 mm
ho ns
(1.65267 … 1.65311 in)
Blue 41.990 … 42.000 mm
e
h@ Lic
310637-10 (1.65315 … 1.65354 in)

Red 42.001 … 42.011 mm
fo r |
(1.65358 … 1.65397 in)

sh fü
– Check the radial clearance of the bottom connecting rod bear-

rt
ta rt
ing. ( p. 285)
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
282
ENGINE 19
– Oil the bearing shells.

– Position the conrod bearing cover according to the markings
made during disassembly. Mount the new connecting rod
screws and tighten them using the special tool.
Guideline
Screw, conrod bear- M10x1 Step 1
ing 25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Multi-tooth wrench socket (60029075000) ( p. 455)

Angle disc (60029010000) ( p. 454)
Info
72
The conrod bearing shells are positioned laterally off-
04
set in the connecting rod to make space for radius A
of the crank shaft. If mounted in reverse, the bear-
0
/0
310638-10 ing shells push on the radius and the connecting rods
57
block.
0 04
,0
l.c r:
19.8.9 Working on the clutch cover
ai fo
om
– Remove screw 1 with the bushing.
tm ed
– Remove the damping plate.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
G04439-10
at ie
M ns

h, ze
Li
t
or
hf
as
G04440-10
ew
th
at
M
283
19 ENGINE
– Remove bearing bush 3.

Bearing puller (15112017000) ( p. 451)
Internal bearing puller (15112018100) ( p. 452)
– Press in the new bearing bush until it is flush using a suitable
press tool.
– Change the support bearing of the crankshaft. ( p. 284)
G04441-10
– Grease radial shaft seal ring 2 and press in with the open
side flush and facing outward.
72
0 04
/0
G04440-10
57
– Position the damping plate.
04
– Mount and tighten screw 1 with the bushing.
0
Guideline
,0
l.c r:
Screw, damping EJOT ALtracs® 10 Nm (7.4 lbf ft)
ai fo
om
plate M6x14 Loctite®243™
tm ed
ho ns
e
h@ Lic
G04439-10
fo r |
19.8.10 Changing the support bearing of the crankshaft

sh fü
– Mark the position of bearing joint 1.

rt
ta rt
at ie
M ns
h, ze
Li
t
or
G04455-10
hf
– Pull out support bearing shells 2 with the special tool.

as
Bearing puller (15112017000) ( p. 451)

ew
Internal bearing puller (60029018000) ( p. 454)

th
at
M
G04456-10
284
ENGINE 19
– Center the new support bearing shells 2 with the special

tool.
Pressing tool (60029046128) ( p. 455)
305478-10
– Support the clutch cover directly under the support bearing.

Press in the support bearing shells using the special tool until
they are flush.
Pressing tool (60029046128) ( p. 455)
72
0 04
/0
G04458-10
57
19.8.11 Checking the radial clearance of the bottom connecting rod bearing
0 04
Info
,0
l.c r:
Perform the operation on both connecting rods.
ai fo
om
–
tm ed
Position the bearing shells. Insert the Plastigauge measuring
ho ns
strips 1 offset by 90° from the bearing joint.
e
Plastigauge clearance gauge (60029012000) ( p. 454)

h@ Lic
– Position the connecting rod bearing cap. Mount and tighten

fo r |
the screws.
sh fü
Guideline
rt
Screw, conrod bear- M10x1 Step 1

ta rt
25 Nm (18.4 lbf ft)

at ie
ing
Step 2
M ns
30 Nm (22.1 lbf ft)

h, ze
Step 3
Li
90°
Info
t
Do not twist the connecting rod.

or
hf
– Remove the connecting rod bearing cap again. Compare the

as
Plastigauge measuring strip with the specifications on the

packaging.
ew
310648-10
Guideline
th
Connecting rod - radial clearance of lower conrod bearing

at
New condition 0.030 … 0.060 mm

M
(0.00118 … 0.00236 in)

Wear limit 0.080 mm (0.00315 in)
285
19 ENGINE
Info
The width of the Plastigauge measuring strips indicates
the bearing play.
– Clean the parts.
19.8.12 Checking/measuring the cylinder

– Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
– Change the cylinder and piston.
– Measure the bore diameter at several locations of the contact
surface on the ‑ and
X ‑axes using a micrometer to iden-
Y
tify oval wear.
Guideline
72
Cylinder - bore diameter
04
305435-10
Size I 108.000 … 108.012 mm
0
(4.25196 … 4.25243 in)
/0
57
Size II 108.013 … 108.025 mm
(4.25247 … 4.25294 in)
0 04
– The cylinder size 1 is marked on the side of the cylinder.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
310650-10
sh fü
– Using a straightedge and the special tool, check the sealing

rt
ta rt
surface of the cylinder head for distortion.

at ie
Feeler gauge (59029041100) ( p. 453)

M ns
h, ze
Cylinder/cylinder head - seal- ≤ 0.05 mm (≤ 0.002 in)

ing area distortion
Li
» If the measured value does not meet specifications:

– Change the cylinder.
t
or
305418-10
hf
19.8.13 Checking/measuring the piston

as
– Check the piston bearing surface for damage.

ew
» If the piston bearing surface is damaged:

th
– Change the piston and, if necessary, the cylinder.

at
– Check that the piston rings can move easily in the piston ring
M
grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.
310651-10
286
ENGINE 19
Tip
Use an old piston ring to clean the piston ring
groove.
– Check the piston rings for damage.

» If the piston ring is damaged:
Info
Mount the piston ring with the marking facing
upward.
– Use the special tool to measure clearance A of the piston

rings in the piston ring groove.
Guideline
72
Piston ring - groove clearance
04
First ring (rectangular ≤ 0.08 mm (≤ 0.0031 in)
ring)
0
/0
Second ring (lower com- ≤ 0.08 mm (≤ 0.0031 in)
57
pression ring)
04
400484-10
Oil scraper ring ≤ 0.06 mm (≤ 0.0024 in)
0
,0
Feeler gauge (59029041100) ( p. 453)
l.c r:
ai fo
om
» If clearance A is larger than the specified value:
– tm ed
Change the piston and piston rings.
ho ns
– Check/measure the cylinder. ( p. 286)
– Check the piston pin for discoloration or signs of wear.
e
h@ Lic
» If the piston pin has strong discoloration/signs of wear:

– Change the piston pin.
fo r |
– Insert the piston pin into the connecting rod and check the
sh fü
bearing for play.

rt
ta rt
» If the piston pin bearing has too much play:

at ie
– Change the connecting rod and the piston pin.

M ns
– Measure the piston at the piston skirt, at right angles to the

h, ze
piston pin, at a distance . B

Li
Guideline
Piston - diameter
t
Size I 107.940 … 107.950 mm

or
(4.2496 … 4.24999 in)

hf
Size II 107.950 … 107.960 mm

as
(4.24999 … 4.25039 in)

ew
B04836-10
Distance B 6 mm (0.24 in)
th
at
M
287
19 ENGINE
– Piston size 1 is marked on the piston head.
310652-10
19.8.14 Checking the piston ring end gap

– Remove the piston ring from the piston.
– Place the piston ring in the cylinder and align it with the pis-
ton.
Guideline
72
Under the upper edge of the 10 mm (0.39 in)
04
cylinder
0
/0
– Measure the end gap with special tool A.
57
Guideline
200477-10
04
Piston ring end gap
0
First ring (rectangular ≤ 0.50 mm (≤ 0.0197 in)
,0
l.c r:
ring)
ai fo
om
Second ring (lower com- ≤ 0.60 mm (≤ 0.0236 in)
tm ed pression ring)
ho ns
e
Feeler gauge (59029041100) ( p. 453)

h@ Lic
» If the end gap is greater than the specified value:

fo r |

sh fü
» If the cylinder wear is within the tolerance range:

rt
ta rt

at ie
– Mount the piston ring with the marking facing toward the pis-
M ns
ton head.
h, ze
Li
19.8.15 Checking the piston/cylinder mounting clearance

t
or
– Check/measure the piston. ( p. 286)

hf
– The smallest piston/cylinder mounting clearance is the result

as
of the smallest cylinder bore diameter minus the largest piston

diameter. The largest piston/cylinder mounting clearance is the
ew
result of the largest cylinder bore diameter minus the smallest

piston diameter.
th
at
M
B04837-10
288
ENGINE 19
Guideline
Piston/cylinder - mounting clearance
Size I 0.05 … 0.072 mm (0.002
… 0.00283 in)
Size II 0.053 … 0.075 mm
(0.00209 … 0.00295 in)
19.8.16 Working on the cylinder head
Info
The following work steps apply to both cylinder heads.
– Remove oil pressure sensor 1 with O-ring.
72
04
Info
0
This only applies to the front cylinder head!
/0
57
– Remove O-rings 2.
04
– Remove vacuum connections 3.
0
– Remove screws.
,0
l.c r:
– Remove thermostat case 4 and the thermostat.
ai fo
om
– Remove coolant temperature sensor 5 with the O-ring.
tm ed
ho ns
Info
e

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
B04838-10
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
289
19 ENGINE
– Remove the SAS diaphragm valve A.

– Remove screw plugs 6 with the O-rings.
– Pull out cam lever shafts 7 with a suitable M5 screw and
remove the cam lever.
72
0 04
/0
D01229-10
57
– Remove shims 8 and label according to their normal built-in
04
position.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
D01203-10
– Tension the valve spring with a special tool.

fo r |
sh fü
Valve spring mounter (59029019000) ( p. 453)

rt
Insert for valve spring lever (78029060000) ( p. 463)

ta rt
at ie
– Remove valve collets 9 and release the valve spring.

M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
B04839-10
290
ENGINE 19
– Remove valve spring retainer bk

, the valve spring, valve stem
seals bland valve spring seats bm .
Info
Place the valves in a box according to their normal
built-in position and label them.
– Check the cylinder head. ( p. 293)

– Mount valve spring seatsbm and new valve stem seals bl.
305420-10
– Mount valve spring and valve spring retainer bk.
The tight winding of the valve spring is at the bottom.
– Tension the valve spring with a special tool.
Valve spring mounter (59029019000) ( p. 453)
Insert for valve spring lever (78029060000) ( p. 463)
72
– Mount valve collets 9. Release the tension on the valve
04
spring.
0
/0
Info
57
When mounting the valve collets, check they are seated
properly; preferably use a little grease to secure the
04
valve collets on the valve.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
B04839-10
sh fü
– Place shims 8 into the valve spring retainer according to

rt
ta rt
their normal built-in position.

at ie
M ns
h, ze
Li
t
or
D01203-10
hf
as
ew
th
at
M
291
19 ENGINE
– Position the cam lever and mount cam lever shafts 7.

– Mount screw plugs 6 with new O-rings.
Guideline
Screw plug, cam M10x1 12 Nm (8.9 lbf ft)
lever axis
– Mount the SAS membrane valve A.
The SAS membrane valve is positioned flush in the cylin-
der.
72
0 04
/0
D01230-10
57
– Mount coolant temperature sensor 5 with the new O-ring.
04
Guideline
0
Coolant temperature M12x1.5 12 Nm (8.9 lbf ft)
,0
l.c r:
sensor
ai fo
om
tm ed Info
ho ns
e
–
h@ Lic
Mount thermostats and thermostat case 4.

– Mount and tighten the screws.
fo r |
Guideline
sh fü
Screw, thermo- M6 10 Nm (7.4 lbf ft)

rt
ta rt
stat case Loctite®243™

at ie
– Mount vacuum connections 3.

M ns
Guideline
h, ze
Vacuum connec- M6 5 Nm (3.7 lbf ft)

Li
tion Loctite®243™
B04838-10
– Mount and grease O-rings 2.
t
– 1 with new O-ring.

or
Mount oil pressure sensor

hf
Guideline
as
Oil pressure sensor M10x1 10 Nm (7.4 lbf ft)

ew
Info
th

at
M
292
ENGINE 19
19.8.17 Checking the cylinder head

– Check the sealing surface of the spark plug thread and the
valve seats for damage and cracking.
– Change the cylinder head.
– Check the valve guides using the special tool.
Limit plug gauge (59029026006) ( p. 453)
Valve guide - diameter

305433-10 New condition 6.004 … 6.016 mm
(0.23638 … 0.23685 in)
» If the special tool is easy to insert into the valve guide:
– Change the valve guide and valve.
72
– Check sealing seat A of the valves.
04
Valve - sealing seat width
0
/0
Intake: New condition 0.90 mm (0.0354 in)
57
Intake: Wear limit 1.5 mm (0.059 in)
04
Exhaust: New condition 1.0 mm (0.039 in)
0
Exhaust: Wear limit 2.0 mm (0.079 in)
,0
l.c r:
ai fo
om
302808-10 – Machine the valve seat.
tm ed
–
ho ns
Check the sealing surface of the cylinder for distortion using a
straightedge and the special tool.
e
h@ Lic
Feeler gauge (59029041100) ( p. 453)

fo r |
Cylinder/cylinder head - seal- ≤ 0.05 mm (≤ 0.002 in)

ing area distortion
sh fü
rt

ta rt
at ie
– Change the cylinder head.

M ns
305419-10 – Check the pivot points of the camshafts in the cylinder head
h, ze
and in the camshaft bearing bridge for damage and wear.

Li

– Change the cylinder head with the camshaft bearing
support.
t
or
– Check valve 1 for damage and wear.

hf

as
– Change the valve.

– Check the valve for run-out.
ew
Valve - run-out
th
Intake: on the valve plate ≤ 0.1 mm (≤ 0.004 in)

at
Exhaust: on the valve ≤ 0.1 mm (≤ 0.004 in)

M
200471-10
plate
– Check the valve stem diameter.
293
19 ENGINE
Valve – valve stem diameter

Exhaust 5.956 … 5.970 mm
(0.23449 … 0.23504 in)
Intake 5.966 … 5.980 mm
(0.23488 … 0.23543 in)
– Check valve spring 2 for damage and wear.
– Change the valve spring.
– Measure the length of the valve springs.
Valve spring - length
New condition 42.70 mm (1.6811 in)
72
04
0
– Change the valve springs.
/0
– Check cam lever 3 for damage and wear.
57
04
– Change the cam lever.
0
–
,0
Check cam lever shaft 4 for damage and wear.
l.c r:
ai fo
om
tm ed – Change the cam lever shaft.
– Check valve spring seat 5 for damage and wear.
ho ns

e
h@ Lic
– Change the valve spring seat.

– Check valve spring retainer 6 for damage and wear.
fo r |

sh fü
– Change the valve spring retainer.

rt
ta rt
at ie
M ns
19.8.18 Working on the right intermediate gear

h, ze
– Remove bushing 1.
Li
– Mount new O-ring 2.
t
– Mount the new bushing 1.

or
hf
as
ew
310814-10
th
at
M
294
ENGINE 19
19.8.19 Checking the timing assembly
72
004
/0
57
307121-10
04
– Clean all parts well.
0
–
,0
Check intermediate gear 1 for damage and wear.
l.c r:
ai fo
om
– Change the intermediate gear. tm ed
– Check tensioning rail 2 for damage and wear.
ho ns

e
h@ Lic
– Change the tensioning rail.

– Check guide rail 3 for damage and wear.
fo r |

sh fü
– Change the guide rail.

rt
ta rt
– Check camshaft 4 for damage and wear.

at ie

M ns
– Change the camshaft.

h, ze
– If the surface of the cams is damaged, check the oil supply to the camshaft and cam lever.
Li
– Check timing chain 5 for damage and wear.

t
– Change the timing chain.

or
– Check the timing chain links for smooth operation. Let the timing chain hang down freely.
hf
» The chain links no longer align in a straight line:

as
– Change the timing chain.

ew
– Check guide rail 6 for damage and wear.

th

at
– Change the guide rail.

M
295
19 ENGINE
19.8.20 Preparing the timing chain tensioner for installation

– Fully compress the timing chain tensioner.
Info
This requires considerable force since the oil has to be
pressed out.
– Release the timing chain tensioner.

Without pressure, the timing chain tensioner expands
fully.
200171-10
– Place two compensating disks or similar aids next to the

timing chain tensioner piston. This should ensure that when
pushed down, the piston does not fully withdraw.
Guideline
72
Thickness of the compensat- 2 … 2.5 mm (0.08 …
04
ing disks 0.098 in)
0
– Release the timing chain tensioner.
/0
The latching system locks and the piston stops moving.
57
200172-10
04
End position of piston 3 mm (0.12 in)
after latching
0
,0
l.c r:
ai fo
Info
om
tm ed This position is necessary for installation.
If the timing chain tensioner is now pressed in once
ho ns
more (while it is installed) and then pulled out no more
e
than halfway (preventing it from coming out fully), the

h@ Lic
latching system locks and the timing chain tensioner

can no longer be compacted; this function is necessary
fo r |
to ensure sufficient tension of the timing chain, even at

sh fü
low oil pressure.

rt
ta rt
at ie
M ns
19.8.21 Checking the oil pressure control valve

h, ze
– Remove supporting plate 1 and spring 2.

Li
– Measure the length of spring 2.

Oil pressure regulator valve - 39 mm (1.54 in)
t
minimum length spring

or
hf
» If the measured length is less than the specified value:

as
– Change the spring.

– Check control piston 3 for damage and wear.
ew
305421-10 » If there is damage or wear:

th
– Change the control piston.

at
– Check the control piston bore in oil pump cover 4 for dam-
M
age and wear.

– Change the oil pump cover.
296
ENGINE 19
– Thoroughly oil control piston 3 and spring 2 and mount

them.
– Mount supporting plate 1.
19.8.22 Checking the lubrication system
Info
The following operations apply to all three oil pumps.
– Check the clearance between internal rotor 1

and external
rotor 2
and between the external rotor and the engine case.
Oil pumps
Clearance between exter- 0.20 … 0.40 mm (0.0079
nal rotor and engine case … 0.0157 in)
72
Clearance between exter- 0.10 … 0.25 mm (0.0039
04
nal rotor and internal … 0.0098 in)
0
rotor
/0
D01187-10
Axial clearance 0.04 … 0.25 mm (0.0016
57
… 0.0098 in)
04
» If the clearance exceeds the specifications:
0
,0
l.c r:
– Change the oil pump and, if necessary, the engine
ai fo
case.
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
305434-10
– Check the internal rotor and external rotor of oil pumps 3 for damage and wear.
th

at
– Change the oil pumps.

M
– Check oil pump shaft 4 for damage and wear.

– Change the oil pump shaft.
– Check the oil pump cover for damage and wear.
297
19 ENGINE

– Change the oil pump cover.
19.8.23 Checking the clutch
72
04
0
/0
57
0 04
,0
l.c r:
ai fo
om
307122-10
– Check clutch throw-out 1 for damage and wear.

tm ed
ho ns
e
– Change the clutch push rod.

h@ Lic
– Place the clutch push rod 2 on a flat surface and check for run-out.
» If there is run-out:
fo r |
– Change the clutch push rod.

sh fü
– 3 for damage and wear.

rt
Check axial bearing

ta rt
at ie

M ns
– Change the axial bearing.

–
h, ze
Check the length of clutch springs 4.

Li
Clutch spring - length ≥ 44.7 mm (≥ 1.76 in)

» If the clutch spring length is shorter than specified:
– Change all clutch springs.
t
or
– Check the contact surface of clutch pressure cap 5 for damage and wear.
hf

as
– Change the clutch pressure cap.

ew
– Check the thrust surfaces of the clutch facing discs in clutch basket 6 for damage and wear.
th

at
– Change the clutch disc pack and the clutch basket.

M
– Check needle bearing 7 for damage and wear.

– Change the needle bearing.
– Check intermediate clutch discs 8 for damage and wear.
» If the intermediate clutch discs are not level and are pitted:
– Change the clutch disc pack.
298
ENGINE 19
– Check clutch facing discs 9 for discoloration and scoring.

» If there is discoloration or scoring:
– Check the thickness of the clutch disc pack.
Clutch disc pack - thickness
New condition 48.00 … 47.2 mm (1.8898 … 1.858 in)
» If the clutch disc pack does not meet the specified value:
– Check pretension ring bk and support ring bl for damage and wear.
– Change the pretension ring and support ring.
– Check inner clutch hub bm for damage and wear.
72
04
– Change the inner clutch hub.
–
0
Check springs bn of the clutch basket for damage and wear.
/0
» If there is damage, wear or play in the direction of rotation:
57
– Change the clutch basket.
04
– Check damper bo for damage and wear.
0
,0
l.c r:
Info
ai fo
om
If the clutch pressure cap can be mounted without resistance from the damper, the dampers are too
hard and are worn out.
tm ed
ho ns

e
– Change the damper.

h@ Lic
fo r |
19.8.24 Checking the shift mechanism

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
D01209-10
– Check shift forks 1 at leaf A for wear.
299
19 ENGINE
Shift fork
Thickness at plate 4.85 … 4.95 mm (0.1909 … 0.1949 in)
Clearance in the sliding gear groove: New condi- 0.35 … 0.55 mm (0.0138 … 0.0217 in)
tion
Clearance in the sliding gear groove: Wear limit 0.70 mm (0.0276 in)
» If the measured value does not equal the specified value:
– Change the shift fork and gear wheel pair.
– Check shift grooves B of shift drum 2 for wear.
» If the shift groove is worn:
– Change the shift drum.
– Check the seat of the shift drum in bearings 3.
» If the shift drum is not seated correctly:
– Change the shift drum and/or the bearing.
72
– Check bearing 3 for stiffness and wear.
04
» If the bearings do not move freely or are worn:
– Change the bearings.
0
/0
– Check shift drums 4 for ovality, surface damage and cracking.
57
» If the shift drum is oval, or shows signs of surface damage or cracks:
04
– Change the shift drum.
0
– Check springs 5 of the shift rails for damage and wear.
,0
l.c r:
ai fo
» If the spring is broken or worn:
om
– Change the spring of the shift rail. tm ed
– Check the shift rails 6 on a flat surface for run-out.
ho ns
» If there is run-out:
e
–
h@ Lic
Change the shift rail.

– Check shift rails for scoring, signs of corrosion and stiffness in the shift fork.
fo r |
» If there is scoring or corrosion, or if the shift fork is stiff:

sh fü
– Change the shift rail.

rt
ta rt
– Check sliding plate 7 in contact areas C for wear.

at ie
» If the sliding plate is worn:

M ns
– Change the sliding plate.

h, ze
– Check return surface D on the sliding plate for wear.

Li
» If deep notches are present:

– Check guide pin E for looseness and wear.
t
or
» If the guide pin is loose and/or worn:

hf

as
ew
th
at
M
300
ENGINE 19
19.8.25 Preassembling shift shaft

– Mount sliding plate 1 with the guide pin facing downward
and put the guide pin on the shift quadrant.
– Mount pressure spring 2.
– Slide on spring guide 3, push return spring 4, with the off-
set end facing upward, over the spring guide and lift the offset
end over abutment bolt 5.
– Mount stop disk 6.
D01210-10
19.8.26 Removing magnetic holder

– Raise the locking hooks1 slightly.
– Take off magnet holder 2.
72
0 04
/0
57
0 04
D01207-10
,0
l.c r:
ai fo
om
19.8.27 Installing magnet holder
–
tm ed
Position magnet holder 1.
ho ns
Guide A engages in the recess B of the shift shaft.
e
Retaining clips 2 engage on the slip ring.

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
D01208-10
th
at
M
301
19 ENGINE
19.8.28 Disassembling the main shaft
72
04
0
/0
57
310820-10
04
– Secure the main shaft with the toothed end facing downward in the bench vise.
0
,0
Guideline
l.c r:
ai fo
Use soft jaws.
om
– Remove stop disk tm ed
1 and second-gear fixed gear 2.
ho ns
– Remove sixth-gear idler gear 3.
–
e
Remove needle bearing 4 and stop disk 5.

h@ Lic
– Remove third/fourth-gear sliding gear 6.

fo r |
sh fü
– Remove stop disk 8 and fifth-gear idler gear 9.

rt
–
ta rt
Remove needle bearing bk.

at ie
– Remove needle bushing bl with a suitable tool.

M ns
h, ze
Info
Only needs to be removed in case of wear.
Li
t
or
hf
as
ew
th
at
M
302
ENGINE 19
19.8.29 Disassembling the countershaft
72
004
/0
57
D01212-10
04
– Secure the countershaft in the bench vise with the toothed end facing downward.
0
,0
Guideline
l.c r:
ai fo
Use soft jaws.
om
– Remove stop disk 1 and first-gear idler gear 2. tm ed
ho ns
– Remove needle bearing 3 and stop disk 4.
–
e
Remove the fifth-gear sliding gear 5 and lock ring 6.

h@ Lic
– Remove stop disk 7 and fourth-gear idler gear 8.

– Remove needle bearing 9 and third-gear idler gear bk.
fo r |
sh fü
– Remove needle bearing bl and stop disk bm.

rt
–
ta rt
Remove lock ring bn and sixth-gear sliding gear bo.

at ie
– Remove lock ring bp and stop disk bq.

M ns
– Remove second-gear idler gear br and needle bearing bs.

h, ze
Li
t
or
hf
as
ew
th
at
M
303
19 ENGINE
19.8.30 Checking the transmission
72
0 04
/0
57
D01211-10
04
– Check needle bearings 1 for damage and wear.
0
,0
l.c r:
ai fo
om
– Check the pivot points of main shaft tm ed
2 and countershaft 3 for damage and wear.
ho ns
– Change the main shaft and/or countershaft.

e
h@ Lic
– Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
fo r |
– Change the main shaft and/or countershaft.

sh fü
– Check the pivot points of idler gears 4 for damage and wear.
rt
ta rt

at ie
– Change the gear wheel pair.

M ns
– Check the shift dogs of idler gears 4 and sliding gears 5 for damage and wear.
h, ze

Li

– Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
t

or

hf
–
as
Check the tooth profiles of sliding gears 5 for damage and wear.
ew

th
– Check sliding gear 5 for smooth operation in the profile of main shaft 2.
at
» If the solid gear does not move freely:

M
– Change the sliding gear or the main shaft.

– Check sliding gears 5 for smooth operation in the profile of countershaft 3.
» If the solid gear does not move freely:
– Change the sliding gear or the countershaft.
– Check stop disks 7 for damage and wear.
304
ENGINE 19

– Change the stop disks.
– Use new lock rings8 with every repair.
– Check stop disks 9 for damage and wear.
– Change the needle bushing.
19.8.31 Assembling the main shaft
Info
Use new lock rings with every repair.
Preparatory work
– Carefully lubricate all parts before assembling.
72
– Check the transmission. ( p. 304)
004
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
D01213-10
Li
Main work
– Secure the main shaft in the vise with the gear teeth facing downward.
Guideline
t
or
Use soft jaws.

hf
– If removed, mount the new needle bushing 1 with suitable tools.

as
– Mount needle bearing 2 and mount fifth-gear idler gear 3 with the shift dogs facing up.
ew
– Mount stop disk 4 and new lock ring 5.

th
– Mount third/fourth-gear sliding gear 6 with the small gear wheel facing up.
at
– Attach stop disk 7 and needle bearing 8.

M
– Attach sixth gear idler gear 9 with the shift dog facing downward.
– Attach second-gear fixed gear bk with the collar facing downward and stop disk bl.
– Finally, check all the gear wheels for smooth operation.
305
19 ENGINE
19.8.32 Assembling the countershaft
Info
Use new lock rings with every repair.
Preparatory work
– Carefully lubricate all parts before assembling.
– Check the transmission. ( p. 304)
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
D01214-10
h@ Lic
Main work
– Secure the countershaft in the bench vise with the toothed end facing downward.
fo r |
Guideline
sh fü
Use soft jaws.

rt
ta rt
– 1 and second-gear idler gear 2 onto the countershaft with the protruding collar fac-
at ie
Mount needle bearing

M ns
ing downward.
– Mount stop disk 3 and new lock ring 4.
h, ze
– Mount the sixth-gear sliding gear 5 with the shift groove facing up.
Li
– Mount the new lock ring 6 and stop disk 7.

– Mount needle bearing 8 and the third-gear idler gear 9 with the collar facing up.
t
or
– Mount needle bearing bk and the fourth-gear idler gear bl with the collar facing down.
hf
– Mount stop disk bm and new lock ring bn.

as
– Mount the fifth-gear sliding gear bo with the shift groove facing down and stop disk bp.
ew
– Mount needle bearing bq, first-gear idler gear br with the recess facing down, and stop disk bs.
– Finally, check all the gear wheels for smooth operation.
th
at
M
306
ENGINE 19
19.8.33 Measuring the main shaft axial play

– Mount transmission in the right section of the engine case.
Info
Do not forget the dowels.
– Mount the left section of the engine case.

Guideline
Screw, engine case M8 18 Nm (13.3 lbf ft)
312035-10
– Mount the dial gauge support on the engine case and measure
and note down the main shaft axial play.
Guideline
72
Main shaft axial clearance 0.05 … 0.15 mm (0.002 …
0.0059 in)
0 04
/0
– Calculate the thickness of the stop disk.
57
– Remove screws and take off section of the engine case.
04
– Mount corresponding stop disk on the main shaft.
0
,0
l.c r:
ai fo
om
19.8.34 Checking the electric starter drive
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
305432-10
– Check the gear teeth and bearing of starter intermediate gear 1 for damage and wear.
th

at
M
– Change the starter intermediate gear.

– Check the gear teeth and the bearing of torque limiter 2 for damage and wear.
– Change torque limiter.
– Check gear mesh and bearing of freewheel gear 3 for damage and wear.
307
19 ENGINE

– Change freewheel gear or bearing.
– Check freewheel 4 for damage and wear.
– Change freewheel.
– Check gear teeth of starter motor 5 for damage and wear.
– Change starter motor.
– Change O-ring 6 of the starter motor.
– Connect negative cable of a 12-volt power supply to the housing of the starter motor. Connect positive cable
of the power supply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is closed:
– Change starter motor.
72
04
19.8.35 Checking the freewheel
0
– Insert freewheel gear 1into the freewheel hub while turning
/0
the freewheel gear counterclockwise; do not wedge it.
57
– Check the locking action of freewheel gear 1.
04
» The freewheel gear cannot be turned counterclockwise and
0
does not block clockwise:
,0
l.c r:
ai fo
– Change freewheel.
om
tm ed
ho ns
305469-10
e
h@ Lic
19.9 Engine assembly

fo r |
19.9.1 Installing the timing chain rails of the left section of the engine case
sh fü
– Position guide rail 1. Mount and tighten screw 2.

rt
ta rt
Guideline
at ie
Screw, guide M8 15 Nm (11.1 lbf ft)

M ns
rail Loctite®243™
h, ze
Li
Info
Ensure that there is no thread locker on the collar of
the screw; otherwise, the guide rail may lock and break.
t
or
G04442-11
– Position tensioning rail 3. Mount and tighten screw 4.
hf
Guideline
as
Screw, tension- M8 15 Nm (11.1 lbf ft)

ew
ing rail Loctite®243™

th
Info
at

M
the screw; otherwise, the tensioning rail may lock and

break.
– Check both timing chain rails for freedom of movement.

308
ENGINE 19
19.9.2 Installing the timing chain rails of the right section of the engine case
– Position guide rail 1. Mount and tighten screw 2.
Guideline
Screw, guide M8 15 Nm (11.1 lbf ft)
rail Loctite®243™
Info
the screw; otherwise, the guide rail may lock and break.
G04433-11
– Position tensioning rail 3. Mount and tighten screw 4.
Guideline
Screw, tension- M8 15 Nm (11.1 lbf ft)
ing rail Loctite®243™
72
Info
04
0
the screw; otherwise, the tensioning rail may lock and
/0
break.
57
04
– Check both timing chain rails for freedom of movement.
0
,0
l.c r:
ai fo
om
19.9.3 Installing the oil spray tube
–
tm ed
Mount new O-rings 1 on oil spray tube 2.
ho ns
– Mount the oil spray tube.
e
Pin 3 must engage in recess 4.

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
G04432-11
M ns
h, ze
19.9.4 Installing the transmission shafts

Li
– Clamp the right section of the engine case.

Engine work stand (61229001000) ( p. 456)
Engine bracket for engine work stand (61729002000)
t
or
( p. 461)
hf
– Join the two transmission shafts and slide them into the bear-
as
ing seats together.

ew
th
G04431-10
at
M
309
19 ENGINE
– Mount stop disk 1 and lock ring 2 of the countershaft.
G04430-11
– Tilt the engine.

– Mount shift forks 3 with shift rollers 4.
Info
Use a small amount of grease to fix the shift rollers to
the shift forks.
72
0 04
/0
G04429-11
57
– Tilt shift forks 3 to the side.
04
Info
0
,0
l.c r:
Watch out for shift rollers 4.
ai fo
om
– Insert shift drum
tm ed 5 into the bearing seat.
– Let the shift forks engage in the shift grooves.
ho ns
e
h@ Lic
G04428-11
– Mount shift rails 6 with the springs.

fo r |
sh fü
Info
rt
ta rt
Fix the springs in the shift rails with grease.

at ie
M ns
– Check the transmission for smooth operation.

h, ze
Li
G04427-11
t
19.9.5 Installing middle suction pump

or
hf
– Mount external rotor 1.

as
The rounded side of the external rotor must face the

engine case.
ew
– Mount pin 2 into the third hole of oil pump shaft 3 after
th
shaft keyway 4.
at
– Slide internal rotor 5 over the pin.

M
G04426-11
310
ENGINE 19
– Mount oil pump shaft 3 with internal rotor 5.

– Oil the parts.
G04425-11
19.9.6 Installing the crankshaft

– Oil the bearing shells.
– Slide the crankshaft into the bearing seat.
Info
72
Position the connecting rods as shown.
0 04
/0
57
G04424-10
0 04
19.9.7 Installing the left engine case
,0
l.c r:
ai fo
– Mount dowels 1.
om
– tm ed
Check that dowel 2 is correctly seated.
ho ns
e
h@ Lic
fo r |
sh fü
G04423-11
rt
ta rt
at ie
– Degrease the sealing surface and coat thinly with Sealing com-
M ns
pound.
h, ze
Loctite® 5910
Li
Info
Only coat the sealing surface around the outside (see
t
illustration).
or
hf
G04654-10
as
ew
th
at
M
311
19 ENGINE
72
04
0
/0
G04422-11
57
– Attach the left engine case, using a plastic hammer if necessary to seat it properly.
04
Info
0
,0
l.c r:
Do not use the screws to pull the two sections of the engine case together.
ai fo
om
Guideline
tm ed
ho ns

e
–
h@ Lic

Guideline
fo r |
Screw, engine case M6x60 10 Nm (7.4 lbf ft)

sh fü

rt
ta rt
Guideline
at ie
M ns

–
h, ze

Li
Guideline
t
or
Info
hf
6 must always be replaced with new screws.

Screws
as
– Mount screw 7.
ew
th
at
M
312
ENGINE 19
19.9.8 Installing the locking lever

– 1 with sleeve 2 and spring 3.
Position locking lever
Guideline
Screw, locking M6 10 Nm (7.4 lbf ft)
lever Loctite®243™
G04421-11
19.9.9 Installing the shift drum locating

– Press locking lever 1 down and position shift drum locat-
ing2 .
72
Info
04
The flat surfaces of the shift drum locating unit are not
0
/0
symmetric.
57
– Release the locking lever.
04
0
G04420-11
Guideline
,0
l.c r:
ai fo
Screw, shift M6 – 12.9 18 Nm (13.3 lbf ft)
om
drum locating
tm ed Loctite®243™
ho ns
e
19.9.10 Installing the shift shaft

h@ Lic
– On the engine case, check whether the holding bracket for

fo r |
shift shaft A is present or B

is not present.
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
M01823-10
t
or
hf
as
ew
th
at
M
313
19 ENGINE
– Slide shift shaft 1 with the washer into the bearing seat.
Guideline
Condition
Engine case with holding bracket for shift shaft
Use shift shaft 61434005044 without holding lug.
Condition
Engine case without holding bracket for shift shaft
Use shift shaft 61734005044 with holding lug C.

– Push sliding plate 2 away from shift drum locating unit 3.
– Insert the shift shaft all the way.
– Let the sliding plate engage in the shift drum locating unit.
– Shift through the transmission.
72
0 04
/0
D07167-10
57
19.9.11 Installing the force pump
04
–
0
Mount pin 1.
,0
l.c r:
ai fo
om
Info
tm ed Ensure that pins 2 are seated correctly.
ho ns
e
h@ Lic
fo r |
G04418-11
sh fü
– Mount internal rotor 3 and external rotor 4.

rt
ta rt

at ie
engine case.
M ns
– Oil the parts.

h, ze
Li
t
or
G04417-11
hf
– Position the oil pump cover. Mount and tighten screws 5.

as
Guideline
ew
Screw, oil pump M6 10 Nm (7.4 lbf ft)

cover Loctite®243™
th
– Mount washer 6 and pin 7.

at
M
G04416-11
314
ENGINE 19
– Mount oil pump gear wheel 8, washer 9 and lock

washer bk .
G04415-11
19.9.12 Installing the left suction pump

– Mount pin 1.
72
0 04
/0
57
G04399-11
04
– Mount internal rotor 2 and external rotor 3.
0
,0
l.c r:
ai fo
om
engine case.
– Oil the parts.tm ed
ho ns
e
h@ Lic
fo r |
G04398-11
sh fü
– Insert new gasket 4 into the oil pump cover.

rt
ta rt
– Position the oil pump cover 5.

at ie
M ns
h, ze
Li
t
or
G04397-11
hf

as
Guideline
Screw, oil pump M6 10 Nm (7.4 lbf ft)
ew
cover Loctite®243™
th
– Turn the oil pump gear wheel and ensure the oil pump moves
at
easily.
M
G04396-11
315
19 ENGINE
19.9.13 Setting the engine to ignition top dead center of the rear cylinder
– Set the crankshaft to top dead center of the rear cylinder.
The position notch of the crankshaft is visible in the hole.
Locking screw (61229015000) ( p. 457)
G04414-11
19.9.14 Installing the primary gear wheel

– Ensure that the woodruff key is seated properly.
– Mount primary gear wheel 1.
72
– Mount the washer and nut 2 and tighten the nut.
04
Guideline
0
Nut, primary M33LHx1.5 130 Nm (95.9 lbf ft)
/0
gear wheel Loctite®243™
57
0 04
G04412-11
,0
l.c r:
ai fo
om
19.9.15 Installing the intermediate gear and the timing chain on the right
–
tm ed
Position timing chain 1 according to the direction of travel.
ho ns
– Place the timing chain over the gear teeth of intermediate
gear 2 . Align markings A and B .
e
h@ Lic
– Slide on the intermediate gear.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
G04447-10
th
at
M
316
ENGINE 19
19.9.16 Installing the clutch basket

– Mount washer 1 and needle bearing 2.
G04410-11
– Mount clutch basket 3 and washer 4.

Info
Turn the clutch basket and the oil pump gear wheel
72
backwards and forwards slightly to help them mesh
04
more easily.
0
/0
57
G04409-11
04
– Mount inner clutch hub 5.
0
,0
–
l.c r:
Mount nut 6 with the washer.
ai fo
om
– Tighten the nut, holding the inner clutch hub with a special
tool. tm ed
Guideline
ho ns
Nut, inner M22x1.5 130 Nm (95.9 lbf ft)

e
Loctite®243™
h@ Lic
clutch hub
Holding wrench (51129003000) ( p. 452)

fo r |
G04408-11
sh fü
rt
ta rt
19.9.17 Installing the clutch discs

at ie
M ns
– Mount support ring 1 and pretension ring 2.

h, ze
The pretension ring rests against the support ring on the

inside and the outside faces away from the support ring.
Li
t
or
hf
as
307126-10
ew
th
at
M
317
19 ENGINE
– Thoroughly oil the clutch facing discs.

– Mount a clutch facing disc 3 with a larger inside diameter.
– Alternately mount 8 intermediate clutch discs 4 and 7 of the
same clutch facing discs 5.
– Alternately mount 2 clutch facing discs 3 and an intermedi-
ate clutch disc 6 with a larger inside diameter.
– The outer clutch facing disc must be mounted offset by one
mesh.
307127-10
– Mount clutch push rod 7.
72
0 04
/0
G04407-11
57
– Mount damper 8 in the clutch pressure cap 9.
04
Info
0
,0
l.c r:
When changing the clutch discs, always renew the
ai fo
om
damper.
tm ed
ho ns
e
h@ Lic
307128-10
– Position clutch pressure cap 9.

fo r |
The teeth of the outer intermediate clutch disc engages in

sh fü
the clutch pressure cap.

rt
ta rt
The clutch pressure cap rests flush against the outer lin-
at ie
ing disc.
M ns
h, ze
Li
G04406-11
– bk and the springs.

Position clutch center
t
or

hf
Guideline
as
Screw, clutch spring M6 12 Nm (8.9 lbf ft)

ew
th
at
M
G04405-11
318
ENGINE 19
19.9.18 Installing the clutch cover

– Mount dowels 1 and position the clutch cover gasket.
– Mount return valve 2.
G04404-11
– Mount water pump impeller 3.
72
0 04
/0
57
G04655-10
04
– Mount the clutch cover. Mount and tighten screws 4
0
5
,0
and .
l.c r:
ai fo
Guideline
om
Screw, clutch cover
tm ed M6 10 Nm (7.4 lbf ft)
–
ho ns
Push water pump sleeve 3 all the way.
e
Water pump sleeve 3 is flush with the recess of the

h@ Lic
water pump shaft.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
G04403-11
hf
19.9.19 Installing the shift shaft sensor

as
– Position the shift shaft sensor 1.

ew

th
Guideline
at

M
shaft sensor Loctite®243™
G04402-11
319
19 ENGINE
19.9.20 Installing the water pump wheel

– Mount the washer and water pump wheel.
Guideline
Screw, water M6 10 Nm (7.4 lbf ft)
pump wheel Loctite®243™
– Mount dowels 2.
– Replace the seal.
G04401-11
– Mount the water pump cover.

Guideline
Screw, water pump M6 10 Nm (7.4 lbf ft)
72
cover
0 04
/0
57
G04400-11
0 04
19.9.21 Installing the gear position sensor
,0
l.c r:
– 1.
ai fo
Position gear position sensor
om
– Mount and tighten screws
tm ed 2.
Guideline
ho ns
Screw, gear M5 5 Nm (3.7 lbf ft)

e
position sensor Loctite®243™

h@ Lic
fo r |
sh fü
G04395-11
rt
ta rt
at ie
19.9.22 Installing the drive gear wheel of the balancer shaft

M ns
– Warm up the drive gear wheel of the balancer shaft.

h, ze
Guideline
Li
200 °C (392 °F)

– Ensure that the woodruff key is seated properly. Mount the
drive gear wheel of the balancer shaft with the beveled edge
t
or
facing forward.
hf
Pressing tool (61229016000) ( p. 458)

as
G04449-10 The markings are visible after mounting.

ew
th
at
M
320
ENGINE 19
19.9.23 Installing the balancer shaft

– Mount the rear washer and needle bearing.
– 1.
Mount balancer shaft
Markings A and B are aligned.
– Mount washer 2.
72
0 04
/0
57
G04393-11
0 04
19.9.24 Installing the intermediate gear and the timing chain on the left
,0
l.c r:
–
ai fo
Mount the rear washer.
om
– Mount intermediate gear
tm ed 1 with timing chain 2 in accor-
dance with the direction of travel.
ho ns
Markings A and B are aligned.

e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
G04389-11
as
– Mount needle bearing 3.

ew
– Mount washer 4.
th
at
M
D01128-10
321
19 ENGINE
19.9.25 Installing the oil filter

– Tilt the engine sideways and fill the oil filter housing to about
⅓ full with engine oil.
– Insert oil filter 1.
G04392-11
– Lubricate the O-ring of oil filter cover 2. Mount the oil filter
cover.
Guideline
72
Remaining engine M5 6 Nm (4.4 lbf ft)
04
screws
0
/0
57
G04391-11
0 04
19.9.26 Installing the rotor
,0
l.c r:
– 1 counterclockwise and mount it in
ai fo
Turn the freewheel gear
om
rotor
tm ed 2 .
ho ns
e
h@ Lic
fo r |
sh fü
307036-11
rt
ta rt
– Mount the rotor with the freewheel gear.

at ie
M ns
Info
h, ze
Ensure that the woodruff key is seated properly.

Li
– Mount and tighten rotor screw 3.

Guideline
t
or
Rotor screw M12x1.5 115 Nm

(84.8 lbf ft)
hf
G04387-11
as
– Position starter wheel guide 4. Mount and tighten the

screws.
ew
Guideline
th
Screw, starter M6 10 Nm (7.4 lbf ft)

at
wheel guide Loctite®243™

M
322
ENGINE 19
19.9.27 Installing the torque limiter and the intermediate gear

– Mount the rear washer, needle bearing, intermediate gear 1
and front washer.
– Mount torque limiter 2 with the rear washer.
G04386-11
19.9.28 Installing the crankshaft speed sensor

– Position crankshaft speed sensor 1.
72
Guideline
04
Screw, M5 6 Nm (4.4 lbf ft)
0
crankshaft Loctite®243™
/0
speed sensor
57
– Position the cable, thinly coat rubber grommet 2 with the
04
sealing compound and insert it in the engine case.
0
G04385-10
,0
l.c r:
Loctite® 5910
ai fo
om
– Check the distance between the crankshaft speed sensor and
rotor. tm ed
ho ns
Guideline
Crankshaft speed 0.50 mm (0.0197 in)
e
h@ Lic
sensor/rotor – distance
fo r |
sh fü
19.9.29 Installing the alternator cover

rt
ta rt
– Mount the new alternator cover seal and dowels.

at ie
– Position the alternator cover.

M ns

h, ze
Guideline
Li

screws
t
or
hf
G04383-10
as
ew
th
at
M
323
19 ENGINE
19.9.30 Assembling the rear piston

– Oil the cylinder and piston.
– Shift the gap of the piston rings by 120°.
– Mount special tool 1 on the piston.
Piston ring compressor (60029015000) ( p. 454)
– Clamp the piston rings together using the special tool.
G03325-10
– Position the piston with the special tool on the cylinder.

– Tap lightly on the piston ring compressor from the top with a
plastic hammer so that it lies flush with the cylinder.
72
Info
04
The special tool must press the piston rings together
properly and lie flush with the cylinder.
0
/0
– Drive the piston into the cylinder by striking it carefully with
57
G03326-10 the hammer handle.
0 04
Info
,0
l.c r:
The piston rings should not catch or they will be dam-
ai fo
om
aged.
tm ed
– Place new cylinder base gasket 2 in position.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
G03329-10
h, ze
– Ensure that piston marking 3 faces the exhaust side.

Li
t
or
hf
as
ew
G03327-10
th
at
M
324
ENGINE 19
– Cover the engine case opening with a cloth. Thread the timing
chain through the timing chain shaft. Mount the piston pin.
G04372-11
– Position the new piston ring lock.
Info
For purposes of illustration, the following operations are
shown on the removed piston.
72
– Insert the special tool and press it with force towards the pis-
ton.
04
– Turn the special tool counterclockwise and, in doing so, press
0
/0
the piston ring lock into the groove.
57
Insertion for piston ring lock (75029035000) ( p. 461)
04
– Ensure that the piston ring lock is in the correct position on
0
both sides.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
B04818-01
–
Li
Remove the cloth.

– Keep the timing chain taut. Press the cylinder down carefully
and bring dowel pins into contact.
t
or
hf
as
ew
th
G04371-10
at
M
325
19 ENGINE
19.9.31 Installing rear cylinder head

– Fit the new cylinder head gasket 1.
G04370-11
– Position the cylinder head and mount and tighten the new
cylinder head screws 2 with washers.
Guideline
Cylinder head M11x1.5 Tightening sequence:
72
screw Using a crisscross pat-
04
tern
Step 1
0
/0
15 Nm (11.1 lbf ft)
57
Step 2
30 Nm (22.1 lbf ft)
04
Step 3
0
90°
,0
l.c r:
Step 4
ai fo
om
90°
tm ed Lubricated with engine
oil
ho ns
– Mount and tighten nuts 3 with the washers.

e
h@ Lic
Guideline
Nut, cylinder head M6 8 Nm (5.9 lbf ft)
fo r |
G04369-11
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
326
ENGINE 19
19.9.32 Installing the rear camshafts

– Pull up the timing chain and insert intake camshaft 1.
Info
The intake camshaft is marked INRE.
– Place the timing chain over the rear sprocket of the intake
camshaft.
Marking 2 is aligned.
– Ensure that bleeder A is positioned properly.
– Slip in exhaust camshaft 3.
Info
The exhaust camshaft is marked EXRE.
72
– Place the timing chain over the rear sprocket and position the
04
camshaft in the bearing seat.
0
/0
57
G04450-10
04
– Clean all oil nozzles thoroughly and blow out with compressed
0
,0
air.
l.c r:
ai fo
– Mount the camshaft bearing support.
om
– Mount screws tm ed
5 and tighten them from the inside to the out-
side.
ho ns
Guideline
e
M6 – 10.9
h@ Lic
Screw, camshaft 10 Nm (7.4 lbf ft)

bearing support
fo r |
G04367-11
Screw, camshaft M8 – 10.9 Step 1
sh fü
bearing support 10 Nm (7.4 lbf ft)

Step 2
rt
ta rt
18 Nm (13.3 lbf ft)

at ie
–
M ns
Grease the O-rings and mount spark plug shaft insert 6 with
gasket.
h, ze
Li
19.9.33 Installing the rear timing chain tensioner

–
t
Position timing chain tensioner 1 and insert it with new O-

or
ring 2 .
hf
– Mount and tighten screw plug 3 with the O-ring 4.

as
Guideline
ew
Plug, timing-chain M24x1.5 25 Nm (18.4 lbf ft)

tensioner
th
at
M
G04366-11
327
19 ENGINE
– Remove screw 5 with O-ring and use the special tool to push
the timing chain tensioner toward the timing chain.
Release device for timing chain tensioner (61229021000)
( p. 458)
The timing chain tensioner unlocks.
– Mount and tighten screw 5 with new O-ring.
Guideline
G04457-10 Screw, unlocking of M10x1 8 Nm (5.9 lbf ft)
timing chain ten-
sioner
19.9.34 Setting the engine to ignition top dead center of the front cylinder
72
– Keep the timing chain tensioned.
04
– Turn the crankshaft counterclockwise by the specified value.
0
/0
Guideline
57
1 turn
0 04
,0
l.c r:
ai fo
G04451-10
om
– Turn the crankshaft counterclockwise by the specified
tm ed
value A .
ho ns
Guideline
e
75°
h@ Lic
The position notch of the crankshaft is visible in the hole.

fo r |

sh fü
Locking screw (61229015000) ( p. 457)

rt
ta rt
at ie
G04454-10
M ns
19.9.35 Installing the front piston

h, ze
– Oil the cylinder and piston.

Li
– Shift the gap of the piston rings by 120°.

– Mount special tool 1 on the piston.
t
or
Piston ring compressor (60029015000) ( p. 454)

hf
– Clamp the piston rings together using the special tool.

as
ew
G03325-10
th
at
M
328
ENGINE 19
– Position the piston with the special tool on the cylinder.

– Tap lightly on the piston ring compressor from the top with a
plastic hammer so that it lies flush with the cylinder.
Info
The special tool must press the piston rings together
properly and lie flush with the cylinder.
– Drive the piston into the cylinder by striking it carefully with

G03326-10 the hammer handle.
Info
The piston rings should not catch or they will be dam-
aged.
– Place new cylinder base gasket 2 in position.
72
0 04
/0
57
0 04
,0
l.c r:
G03328-10
ai fo
om
– Ensure that piston marking 3 faces the exhaust side.
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
G03327-10
at ie
– Cover the engine case opening with a cloth. Thread the timing
M ns
chain through the timing chain shaft. Mount the piston pin.
h, ze
Li
t
or
hf
as
G04381-11
ew
th
at
M
329
19 ENGINE
– Position the new piston ring lock.
Info
For purposes of illustration, the following operations are
shown on the removed piston.
– Insert the special tool and press it with force towards the pis-
ton.
– Turn the special tool counterclockwise and, in doing so, press
the piston ring lock into the groove.
Insertion for piston ring lock (75029035000) ( p. 461)
– Ensure that the piston ring lock is in the correct position on
both sides.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
B04818-01
tm ed
ho ns
– Remove the cloth.

e
–
h@ Lic
Keep the timing chain taut. Press the cylinder down carefully
and bring dowel pins into contact.
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
G04380-10
Li
19.9.36 Installing the front cylinder head

– Fit the new cylinder head gasket 1.
t
or
hf
as
ew
th
at
G04379-11
M
330
ENGINE 19
– Put the cylinder head in place. Mount and tighten the new
cylinder head screws 2 with washers.
Guideline
Cylinder head M11x1.5 Tightening sequence:
screw Using a crisscross pat-
tern
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Step 4
90°
Lubricated with engine
oil
72
– Mount and tighten nuts 3 with the washers.
04
Guideline
0
/0
G04378-11
57
04
19.9.37 Installing the front camshafts
0
–
,0
1.
l.c r:
Pull up the timing chain and insert intake camshaft
ai fo
om
Info tm ed
The intake camshaft is marked INFR.
ho ns
e
h@ Lic
camshaft.
fo r |

sh fü
rt
ta rt
Info
at ie
The exhaust camshaft is marked EXFR.

M ns
– Place the timing chain over the rear sprocket and position the
h, ze
camshaft in the bearing seat.

Li
t
or
G04453-10
hf
as
– Clean all oil nozzles thoroughly and blow out with compressed
air.
ew

th
– Mount screws 5 and tighten them from the inside to the out-
at
side.
M
G04376-11
331
19 ENGINE
Guideline
Screw, camshaft M6 – 10.9 10 Nm (7.4 lbf ft)
bearing support
Step 2
18 Nm (13.3 lbf ft)
– Grease the O-rings and mount spark plug shaft insert 6 with
gasket.
19.9.38 Installing the front timing chain tensioner

– Position timing chain tensioner 1 and insert it with new O-
ring 2 .
– Mount and tighten screw plug 3 with new O-ring 4.
72
Guideline
04
Plug, timing-chain M24x1.5 25 Nm (18.4 lbf ft)
0
tensioner
/0
57
04
G04375-11
0
,0
–
l.c r:
Remove screw 5 with O-ring and use the special tool to push
ai fo
the timing chain tensioner toward the timing chain.
om
tm ed
( p. 458)
ho ns
The timing chain tensioner is unlocked.

e
h@ Lic
– Mount and tighten screw 5 with the O-ring.

Guideline
fo r |
Screw, unlocking of M10x1 8 Nm (5.9 lbf ft)

sh fü
B04806-10
timing chain ten-
rt
ta rt
sioner
at ie
M ns
h, ze
19.9.39 Installing the heat exchanger

Li
– Oil and mount O-rings 1.

– Mount sleeves 2.
t
– 3.
or
Mount gasket
hf
as
ew
th
G04365-11
at
M
332
ENGINE 19
– Position the heat exchanger.

Guideline
screws
Guideline
G04364-11 Screw, heat M8 15 Nm (11.1 lbf ft)
exchanger
19.9.40 Installing the starter motor

– Grease the O-ring. Position the starter motor.
72
04
Info
0
/0
The screws are mounted only in the vehicle.
57
0 04
,0
G04362-10
l.c r:
ai fo
om
19.9.41 Checking the rear valve clearance
tm ed
ho ns
Locking screw (61229015000) ( p. 457)

e
h@ Lic
– Crank the engine several times.

– Set the engine to ignition top dead center of the rear cylinder.
fo r |
( p. 255)
sh fü
rt
ta rt
at ie
M ns
310488-10
– On all valves, check the valve clearance between the camshaft

h, ze
and cam lever.

Li
Guideline
Valve clearance
t
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039

or
… 0.0059 in)
hf
Exhaust at: 20 °C 0.25 … 0.30 mm (0.0098

as
(68 °F) … 0.0118 in)

ew
T00523-10
Feeler gauge (59029041100) ( p. 453)
th
» If valve clearance does not meet specifications:

at
– Adjust the rear valve clearance. ( p. 333)

M
19.9.42 Adjusting the rear valve clearance

– Remove the rear timing chain tensioner. ( p. 257)
– Remove the rear camshafts. ( p. 257)
333
19 ENGINE
– Swing up cam lever 1.

– Remove shims 2 and set them down according to the instal-
lation position.
– Correct the shims as indicated by the results of the valve clear-
ance check.
– Insert suitable shims.
– Install the rear camshaft. ( p. 327)
– Install the rear timing chain tensioner. ( p. 327)
B04810-10
– Check the rear valve clearance. ( p. 333)
19.9.43 Checking the front valve clearance

– Remove the special tool.
Locking screw (61229015000) ( p. 457)
72
– Crank the engine several times.
04
– Set the engine to ignition top dead center of the front cylinder.
0
( p. 259)
/0
– Check the valve clearance between the camshaft and cam
57
lever on all valves.
04
Guideline
0
B04790-10
,0
Valve clearance
l.c r:
ai fo
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039
om
tm ed … 0.0059 in)
Exhaust at: 20 °C 0.25 … 0.30 mm (0.0098
ho ns
(68 °F) … 0.0118 in)

e
h@ Lic
Feeler gauge (59029041100) ( p. 453)

» If the valve clearance does not meet specifications:
fo r |
– Adjust the front valve clearance. ( p. 334)

sh fü
rt
ta rt
at ie
19.9.44 Adjusting the front valve clearance

M ns
– Remove the front timing chain tensioner. ( p. 259)

h, ze
– Remove the front camshafts. ( p. 259)

Li
– Swing up cam lever 1.

t
lation position.
or
– Correct the shims based on the results of the valve clearance

hf
check.
as
– Insert suitable shims.

ew
– Install the front camshafts. ( p. 331)

–
th
Install the front timing chain tensioner. ( p. 332)

B04809-10
at
– Check the front valve clearance. ( p. 334)

M
334
ENGINE 19
– Mount and tighten screw plug 3 with the O-ring.

Guideline
Screw plug, alterna- M24x1.5 8 Nm (5.9 lbf ft)
tor cover
G04359-11
– Remove special tool 4. Mount and tighten screw 5 with the

washer.
Guideline
Crankshaft locking M8 12 Nm (8.9 lbf ft)
bolt
72
0 04
/0
G04361-11
57
19.9.45 Installing the oil filler neck
04
– Mount the oil filler neck with the O-ring.
0
,0
l.c r:
ai fo
om
Guideline
tm ed
ho ns
screws
e
h@ Lic
fo r |
G04363-10
sh fü
19.9.46 Installing the front valve cover

rt
ta rt
at ie
– Clean and degrease the valve cover seal.

M ns
– Apply a thin layer of sealing compound to area A.

h, ze
Loctite® 5910
Li
Info
The front valve cover is not equipped with a connector
t
or
for the engine vent.

hf
R01991-11
as
– Position the valve cover with the gasket.

ew
– Mount and tighten screws 1 with the gaskets.

th
Guideline
at
Screw, valve cover M6 10 Nm (7.4 lbf ft)

M
– Mount and tighten the spark plugs using the special tool.
Guideline
Spark plug M12x1.5 18 Nm (13.3 lbf ft)
Spark plug M10x1 11 Nm (8.1 lbf ft)
G04357-11
335
19 ENGINE

– Mount ignition coils 2.
19.9.47 Installing the rear valve cover

Loctite® 5910
Info
The rear valve cover is equipped with a connector for
the engine vent.
R01992-10
72
– Position the valve cover with the gasket.
04
– Mount and tighten screws 1 with the gaskets.
0
/0
Guideline
57
04
– Mount and tighten the spark plugs using the special tool.
0
Guideline
,0
l.c r:
ai fo
om
G04358-11 Spark plug M10x1 11 Nm (8.1 lbf ft)
tm ed
ho ns
– 2.
e
Mount ignition coils

h@ Lic
fo r |
19.9.48 Installing the oil drain plug

sh fü
– Mount the new O-rings.

rt
ta rt
– Mount and tighten oil drain plug 1 with the magnet, O-rings
at ie
and oil screen.

M ns
Guideline
h, ze
Oil drain plug M20x1.5 20 Nm (14.8 lbf ft)

Li
t
or
G04459-10
hf
19.9.49 Installing the rear resonator

as
– Oil and mount both O-rings 1.

ew
th
at
M
B04780-10
336
ENGINE 19
– Position resonator on the cylinder head.

Guideline
Screw, resonator M5 8 Nm (5.9 lbf ft)
Loctite®243™
G04356-11
19.9.50 Installing the front resonator

– Oil and mount both O-rings 1.
72
0 04
/0
57
B04780-10
04
– Position resonator on the cylinder head.
0
,0
l.c r:
ai fo
om
Guideline
tm ed
Loctite®243™
ho ns
e
h@ Lic
fo r |
G04355-11
sh fü
19.9.51 Mounting the engine bearer

rt
ta rt
at ie
– Position the engine bearer.

M ns

h, ze
Guideline
Li
Screw, engine bearer M10 45 Nm (33.2 lbf ft)

t
or
hf
G04353-11
as
– Position the engine bearer.

ew

th
Guideline
at

M
G04352-11
337
19 ENGINE
19.9.52 Removing the engine from the engine work stand

– Remove the fittings.
– Remove the engine from the engine work stand.
Info
Work with an assistant or a motorized hoist.
G04351-11
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
338
SECONDARY AIR SYSTEM SAS 20
20.1 Changing the SAS membrane

– Pull off the cover and hang it to one side.
G04461-10
– Remove SAS membrane 2.

– Mount the new SAS membrane.
The SAS membrane is positioned flush in the cylinder.
72
0 04
/0
57
G04462-10
04
0
,0
l.c r:
ai fo
om
Guideline
tm ed
ho ns
engine
e
h@ Lic
fo r |
G04461-10
sh fü
rt
ta rt
– Pull off the cover and hang it to one side.

at ie
M ns
h, ze
Li
t
or
G04463-10
hf
– Remove SAS membrane 4.

as
– Mount the new SAS membrane.

The SAS membrane is positioned flush in the cylinder.
ew
th
at
M
G04464-10
339
20 SECONDARY AIR SYSTEM SAS

Guideline
engine
G04463-10
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
340
CLUTCH 21
21.1 Checking/correcting the fluid level of the hydraulic clutch
Warning
with the eyes.
Note
72
04
0
/0
57
Info
04
The fluid level rises with increasing wear of the clutch facing discs.
0
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
,0
l.c r:
ai fo
om
Only use clean brake fluid from a sealed container. tm ed
ho ns
– Move the clutch fluid reservoir mounted on the handlebar to a

e
horizontal position.
h@ Lic
– Check the fluid level.

fo r |
The fluid level must be between MIN and MAX markings.

sh fü
» If the fluid level does not meet specifications:

rt
ta rt
– Remove screw cap 1 with membrane 2 and the

at ie
shim.
M ns
– Correct the fluid level of the hydraulic clutch.

h, ze

Li
– Mount and tighten screw cap 1 with membrane 2

and the shim.
t
or
Info
hf
Clean up overflowed or spilled brake fluid

as
immediately with water.

ew
th
S03920-10
at
M
341
21 CLUTCH
21.2 Changing the hydraulic clutch fluid
Warning
with the eyes.
Note
72
04
0
/0
57
Info
04
The fluid level rises with increasing wear of the clutch facing discs.
0
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
,0
l.c r:
ai fo
om
tm ed
ho ns
– Move the clutch fluid reservoir mounted on the handlebar to a

e
horizontal position.
h@ Lic
– Remove screw cap 1 with membrane and shim.

fo r |
sh fü
rt
ta rt
at ie
M ns
R01760-10
h, ze
– Fill bleeding syringe 2 with the appropriate hydraulic fluid.

Li
Syringe (50329050000) ( p. 452)

t
or
– On the slave cylinder, remove bleeder screw and mount bleed-

hf
ing syringe 2 .
as
ew
R01761-10
th
at
M
342
CLUTCH 21
– Now press the fluid into the system until it emerges from
hole 3 of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir
to prevent overflow.
– Remove bleeding syringe. Mount and tighten screws bleeder
screw.
– Correct fluid level.
Guideline
R01762-10 The fluid level must be between MIN and MAX markings.

– Mount and tighten screw cap with membrane and shim.
21.3 Checking the clutch
72
04
Warning
0
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
/0
– Wear suitable protective clothing and safety gloves.
57
– In the event of scalding, rinse the area affected immediately with lukewarm water.
0 04
Note
,0
l.c r:
ai fo
om
the applicable regulations. tm ed
ho ns
Main work
e
– Place an appropriate container under the engine.

h@ Lic
fo r |
– Take off the outer clutch cover.

sh fü
rt
ta rt
at ie
M ns
h, ze
G04690-10
Li
– Take off clutch center 3 and the springs.
t
or
hf
as
ew
th
G04691-10
at
M
343
21 CLUTCH
– Take off clutch pressure cap 4.
G04692-10
– Remove clutch discs 5, support ring, and pretension ring.
72
0 04
/0
G04693-10
57
– Hold the inner clutch hub with the special tool.
04
Holding wrench (51129003000) ( p. 452)
0
–
,0
6 with the washer.
l.c r:
Remove nut
ai fo
om
tm ed
ho ns
e
h@ Lic
G04694-10
– Take off inner clutch hub 7 and washer 8.

fo r |
sh fü
Info
rt
ta rt
The washer usually sticks to the inner clutch hub.

at ie
M ns
h, ze
Li
G04695-10
– Remove clutch basket 9 with oil pump drive gear.

t
or
hf
as
ew
th
at
M
G04696-10
344
CLUTCH 21
– Remove needle bearing bk and washer bl.
R01788-10
72
004
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
R01789-10
– Check axial bearing bm for damage and wear.

fo r |

sh fü
– Change the axial bearing.

rt
ta rt
–
at ie
Check the length of clutch springs bn.

M ns

h, ze
» If the clutch spring length is shorter than specified:

Li
– Change all clutch springs.

– Check the contact surface of clutch pressure cap 4 for damage and wear.
t
or
– Change the clutch pressure cap.

hf
– Check the thrust surfaces of the clutch facing discs in clutch basket 9 for wear.
as
Clutch basket - thrust surface of clutch facing discs

ew

th
» If the thrust surface exhibits excessive wear:

at
– Change the clutch disc pack and the clutch basket.

M
– Check needle bearing bk for damage and wear.

– Check intermediate clutch discs bo for damage and wear.
345
21 CLUTCH
» If the intermediate clutch discs are not level and are pitted:
– Check clutch facing discs bp for discoloration and scoring.
» If there is discoloration or scoring:
– Check the thickness of the clutch disc pack.
Clutch disc pack - thickness
» If the clutch disc pack does not meet the specified value:
– Check pretension ring bq and support ring br for damage and wear.
72
– Change the pretension ring and support ring.
04
– Check inner clutch hub 7 for damage and wear.
0
/0
– Change the inner clutch hub.
57
– Check springs bs of the clutch basket for damage and wear.
04
» If there is damage, wear or play in the direction of rotation:
0
– Change the clutch basket.
,0
l.c r:
ai fo
– Check damper bt for damage and wear.
om
Info
tm ed
ho ns
If the clutch pressure cap can be mounted without resistance from the damper, the dampers are too
e
hard and are worn out.

h@ Lic

fo r |
– Change the damper.

sh fü
– Mount washer bl and needle bearing bk.

rt
ta rt
at ie
M ns
h, ze
Li
t
or
R01788-10
hf
– Mount clutch basket 9 with oil pump drive gear.

as
Info
ew
Turn the clutch basket and the oil pump gear wheel
th
backwards and forwards slightly to help them mesh

at
more easily.
M
G04696-10
346
CLUTCH 21
– Mount washer 8.
– Mount inner clutch hub 7.
G04695-10
– Mount nut 6 with the washer.

– Hold the inner clutch hub with the special tool and tighten the
nut.
Guideline
Nut, inner M22x1.5 130 Nm (95.9 lbf ft)
72
clutch hub Loctite®243™
04
Holding wrench (51129003000) ( p. 452)
0
/0
G04694-10
57
– Mount support ring br and pretension ring bq.
04
The pretension ring rests against the support ring on the
0
inside and the outside faces away from the support ring.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
R01790-10
– Thoroughly oil the clutch facing discs.

fo r |
– Mount a clutch facing disc ck with a larger inside diameter.

sh fü
– Alternately mount 8 intermediate clutch discs bo and 7 of the

rt
ta rt
same clutch facing discs bp.

at ie
– Alternately mount 2 clutch facing discs cl and an intermedi-

M ns
ate clutch disc cm with a larger inside diameter.

h, ze
– Mount the outer clutch facing disc offset by one mesh.

Li
R01791-10
– Mount damper bt in the clutch pressure cap 4.

t
or
hf
Info
as
When changing the clutch discs, always renew the

damper.
ew
th
at
M
R01792-10
347
21 CLUTCH
– Position clutch pressure cap 4.

The teeth of the outer intermediate clutch disc engages in
the clutch pressure cap.
The clutch pressure cap rests flush against the outer lin-
ing disc.
G04692-10
– 3 and the springs.

Position clutch center
Guideline
72
0 04
/0
G04691-10
57
– Position the outer clutch cover.
04
– Mount screws 1 and tighten in a crisscross pattern.
0
Guideline
,0
l.c r:
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
ai fo
om
tm ed
ho ns
e
h@ Lic
G04690-10
Finishing work
fo r |

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
348
SHIFT MECHANISM 22
22.1 Adjusting the basic position of the shift lever

– Loosen nut 1, holding threaded rod 2.
Info
Nut1 has a left-handed thread.
– Loosen nut 3, holding threaded rod 2.
– Turn threaded rod 2 to adjust the shift lever.
S03895-10
Info
The shift lever must not come into contact with any
other vehicle components during the shift procedure.
– Tighten nut 3 while holding threaded rod 2.
72
Guideline
04
Nut, shift rod M8 12 Nm (8.9 lbf ft)
0
–
/0
Tighten nut 1 while holding threaded rod 2.
57
Guideline
04
Nut, shift rod M8LH 12 Nm (8.9 lbf ft)
0
,0
l.c r:
ai fo
om
22.2 Changing the gear position sensor
tm ed
Preparatory work
ho ns
e

h@ Lic

fo r |
Main work
sh fü
–
rt
Take off the engine sprocket cover.

ta rt
at ie
M ns
– Take off the slave cylinder of the clutch and hang to the side.
h, ze
Info
Li

G04553-10 of the clutch is removed.
Do not kink the clutch line.
t
or
–
hf
Remove screws 4.
as

ew
th
at
M
G04554-10
349
22 SHIFT MECHANISM
– Disconnect plug-in connectors 5 and 6.

– Remove the cable tie.
G04555-10
– Remove the side stand.
72
0 04
/0
G04556-10
57
04
– Loosen screw 9.
0
– Hang the side stand bracket to the side.
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04557-10
– Remove screws bk.

fo r |
– Take off the gear position sensor.

sh fü
– Position a new gear position sensor.

rt
ta rt
– Mount and tighten screws bk.

at ie
M ns
Guideline
Screw, gear M5 5 Nm (3.7 lbf ft)
h, ze
position sensor Loctite®243™

Li
G04558-10
– Position the side stand bracket.

t
or

hf
Guideline
as

ew
–
th
Tighten screw 9.
at
Guideline
M
G04557-10 Screw, side M10 45 Nm (33.2 lbf ft)

350
SHIFT MECHANISM 22
– Position the side stand.

Guideline
stand Loctite®243™
G04556-10
– Join plug-in connectors 5 and 6.

– Route the cable without tension and secure it with a cable tie.
72
0 04
/0
G04555-10
57
04
0
Guideline
,0
l.c r:
ai fo
om
screws
tm ed
ho ns
e
h@ Lic
G04554-10
– Position the clutch slave cylinder.

fo r |

sh fü
Guideline
rt
ta rt

at ie
screw
M ns

h, ze

Li
G04553-10 Guideline
t
sprocket cover
or
hf
Finishing work
as

ew
troller. ( p. 109)
th

at

M

( p. 19)
351
22 SHIFT MECHANISM
22.3 Programming the gear position sensor

Condition
– Execute "Engine electronics" > "Functions" >
"Program the gear position sensor".
– Switch the ignition off and on again.
The green idle indicator lamp N lights up.
H02627-01
22.4 Changing the shift shaft sensor
72
Main work
04
0
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
R03375-10
h, ze

Li

t
or
hf
as
ew
R03377-10
th
at
M
352
SHIFT MECHANISM 22
– Take off shift shaft sensor 3.
– Position new shift shaft sensor 3.
Guideline
shaft sensor Loctite®243™
R03378-10

72
0 04
/0
R03377-10
57
– Secure the cable with cable ties.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
R03376-10
Finishing work
t
or
– Program the shift shaft sensor. ( p. 354)

hf
as
ew
th
at
M
353
22 SHIFT MECHANISM
22.5 Programming the shift shaft sensor

Condition
– Execute "Engine electronics" > "Functions" > "Quick Shift teach-
in procedure".
H02627-01
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
354
WATER PUMP, COOLING SYSTEM 23
23.1 Checking the coolant level in the compensating tank
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
72
– Consult a doctor immediately if coolant is swallowed.
04
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
0
/0
– Change clothing if coolant spills onto your clothing.
57
04
Condition
The engine is cold.
0
,0
l.c r:
The radiator is completely full.
ai fo
om
– Park the motorcycle on a horizontal surface.
–
tm ed
Check the coolant level in the compensating tank 1.
ho ns
The coolant level must be between MIN and MAX.

e
» If there is no coolant in the compensating tank:

h@ Lic

fo r |
Info
sh fü
Do not start up the motorcycle!

rt
ta rt
S03955-10
at ie

M ns
» If the coolant in the compensating tank is not at the

h, ze
required level, but the tank is not empty:

Li
– Correct the coolant level in the compensating tank.

( p. 361)
t
or
23.2 Checking the coolant fill level and antifreeze

hf
as
Warning
ew
th
at

M
355
23 WATER PUMP, COOLING SYSTEM
Warning
Condition
The engine is cold.
– Park the motorcycle on a horizontal surface.
– Check the coolant level in compensating tank 1.
72
04
» If there is no coolant in the compensating tank:
0
/0
57
Info
04
Do not start up the motorcycle!
0
S03955-10
,0
l.c r:
ai fo
om
» If the coolant level in the compensating tank is not at the
tm ed required level, but the tank is not empty:
ho ns
– Correct the coolant level in the compensating tank.
( p. 361)
e
h@ Lic
– Remove cover 2 of the compensating tank.

– Check the antifreeze in the coolant.
fo r |
sh fü
−25 … −45 °C (−13 … −49 °F)

rt
ta rt
» If the antifreeze in the coolant does not match the speci-

at ie
fied value:
M ns
– Correct the antifreeze in the coolant.

h, ze
– Mount the cover of the compensating tank.

Li
G04593-11 – Mount the compensating tank.

t
23.3 Draining the coolant

or
hf
Warning
as
ew
th

at
M

356
Warning
Condition
The engine is cold.
Preparatory work
Info
72
0 04
Main work
/0
57
– Remove screw 1.
04
– Take off radiator cap 2.
0
– Completely drain the coolant.
,0
l.c r:
ai fo
– Mount and tighten screw 1 with a new seal ring.
om
Guideline tm ed
ho ns
G04589-10
cover
e
h@ Lic
fo r |
23.4 Adding the coolant/bleeding the cooling system

sh fü
rt
ta rt
Warning
at ie

M ns

h, ze
Li

t
or

hf
as
Preparatory work
ew
th
at
M
357
Main work
– Move the vehicle into the position shown and secure it against
rolling away. Height difference A must be reached.
Guideline
Height difference A 50 cm (19.7 in)
400677-10
– Remove radiator cap 1 and bleeder screw 2 of the radiator.
72
0 04
/0
G04590-10
57
– Remove bleeder screws 3 of the cylinder heads.
04
– Add coolant until it exits from the vent holes without bubbles.
0
Coolant 3.20 l Coolant ( p. 446)
,0
l.c r:
(3.38 qt.)
ai fo
om
– tm ed
Mount and tighten bleeder screws 2 and 3 with the new
seal ring.
ho ns
Guideline
e

h@ Lic
screws
fo r |

sh fü
chassis
rt
ta rt
at ie
M ns
h, ze
Li
G04591-10
– Completely fill the radiator with coolant and close it with radia-
t
or
tor cap1 .
hf
as
ew
th
at
M
G04592-10
358
– Park the vehicle on a level surface.

– Pull off the compensating tank toward the bottom and maneu-
ver it out.
– Add coolant to the compensating tank until the coolant
reaches the specified level.
Guideline
G04593-10
– Mount the compensating tank.
Finishing work
72
23.5 Changing the coolant
0 04
Warning
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
Warning
ho ns

e
h@ Lic

fo r |

sh fü
rt
ta rt
at ie

M ns
h, ze
Condition
Li
The engine is cold.

Main work
t
or
Info
hf

as
ew
th
at
M
359

– Remove screw 1 with the seal ring.
– Take off radiator cap 2.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
G04589-10
cover
– Move the vehicle into the position shown and secure it against
rolling away. Height difference A must be reached.
Guideline
Height difference A 50 cm (19.7 in)
72
0 04
/0
400677-10
57
– Remove bleeder screw 3 of the radiator.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04594-10
– Remove bleeder screws 4 of the cylinder heads.

fo r |
– Add coolant until it exits from the vent holes without bubbles.
sh fü
rt
Coolant 3.20 l Coolant ( p. 446)

ta rt
(3.38 qt.)
at ie
M ns
– Mount and tighten bleeder screws 3 and 4 with the new

h, ze
seal ring.
Li
Guideline
screws
t

or
chassis
hf
as
ew
th
at
M
G04591-11
360
– Completely fill the radiator with coolant and close it with radia-
tor cap 2 .
G04592-11
– Park the vehicle on a level surface.

– Pull off the compensating tank toward the bottom and maneu-
ver it out.
– Add coolant to the compensating tank until the coolant
72
reaches the specified level.
Guideline
04
0
/0
G04593-12
57
– Mount the compensating tank.
0 04
Danger
,0
l.c r:
ai fo
om
–
tm ed
Always make sure there is sufficient ventilation
ho ns
–
e
Use effective exhaust extraction when starting or

h@ Lic

fo r |
– Start the engine and allow it to warm up.

sh fü
– Stop the engine and allow it to cool down.

rt
ta rt
– After the engine has cooled down, check the coolant level in
at ie
the radiator and in the compensating tank again and add more
M ns
coolant if necessary.
h, ze
Finishing work
Li

t
23.6 Correcting the coolant level in the compensating tank

or
hf
Warning
as
ew
th

at
M

361
Warning
Condition
The engine is cold.
Preparatory work
– Check the coolant level in the compensating tank. ( p. 355)
72
Main work
04
– Add coolant to the MAX marking.
0
/0
Coolant ( p. 446)
57
– Mount cover 1 of the compensating tank.
0 04
,0
l.c r:
ai fo
om
S03956-10
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
362
CYLINDER HEAD 24
24.1 Checking the valve clearance

Preparatory work
Main work
– Detach connector 1 of the ignition coil.
72
0 04
/0
G04608-10
57
– Remove screw 2.
04
– Remove ignition coil 3.
0
– Remove the spark plug using the special tool.
,0
l.c r:
ai fo
Spark plug wrench (75029172000) ( p. 462)
om
tm ed
ho ns
e
h@ Lic
G04609-10
fo r |
– Take off the valve cover with the gasket.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04610-10
t
or
hf
as
ew
th
at
M
G04611-10
363
24 CYLINDER HEAD
– Detach connector 6 of the ignition coil.
G04612-10
– Remove screw 7.
– Remove ignition coil 8.
– Remove the spark plug using the special tool.
72
0 04
/0
G04613-10
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04614-10
– Remove gasket bk.

fo r |
sh fü
( p. 252)
rt
ta rt
at ie
M ns
h, ze
Li
G04615-10

t
or
and cam lever with special tool .bl

hf
Guideline
as
Valve clearance
ew
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039

… 0.0059 in)
th
Exhaust at: 20 °C 0.25 … 0.30 mm (0.0098

at
(68 °F) … 0.0118 in)

M
G04617-10
Feeler gauge (59029041100) ( p. 453)
– Set the valve clearance of the rear cylinder.
( p. 371)
364
CYLINDER HEAD 24
( p. 252)
and cam lever with special tool .bl
Guideline
Valve clearance
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039
… 0.0059 in)
Exhaust at: 20 °C 0.25 … 0.30 mm (0.0098
(68 °F) … 0.0118 in)
G04616-10
Feeler gauge (59029041100) ( p. 453)
– Set the valve clearance of the front cylinder.
( p. 371)
72
– Remove special tool bm.
04
– Crank the engine several times. Check the valve clearance and
0
/0
correct it if necessary.
57
– Remove special tool bm and mount and tighten screw bn.
04
Guideline
0
,0
l.c r:
bolt
ai fo
om
G04689-10 tm ed
–
ho ns
Mount and tighten screw bo of the alternator cover.
Guideline
e
h@ Lic

tor cover
fo r |
sh fü
rt
ta rt
at ie
M ns
R01900-10
h, ze
– Mount gasket bk.

Li
t
or
hf
as
ew
G04615-10
th
at
M
365
24 CYLINDER HEAD

Loctite® 5910
Info
the engine vent.
R01992-10 for the engine vent.
– Put the valve cover in place with the gasket. Mount and
tighten screws 9.
Guideline
– Mount and tighten the spark plug using the special tool.
72
04
0
/0
G04614-10
57
– Mount ignition coil 8.
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04613-10
fo r |
– Plug in connector 6 of the ignition coil.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04612-10
t
–
or
Position gasket 5.
hf
as
ew
th
at
M
G04611-10
366
CYLINDER HEAD 24

– Apply a thin layer of sealing compound to area B.
Loctite® 5910
Info
the engine vent.
tighten screws 4
.
Guideline
– Mount and tighten the spark plug using the special tool.
72
04
0
/0
G04610-10
57
– Mount ignition coil 3.
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04609-10
fo r |
– Plug in connector 1 of the ignition coil.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04608-10
t
or
Finishing work
hf

as

ew

th

at

M
367
24 CYLINDER HEAD
24.2 Checking the valve clearance (air filter and spark plugs removed)
Condition
The air filter and spark plugs are removed.
G04614-11
72
0 04
/0
57
0 04
,0
l.c r:
G04615-11
ai fo
om
–
tm ed
Take off the valve cover with the gasket.
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
G04610-11
at ie
M ns
h, ze
( p. 252)
Li
t
or
hf
as
G04611-11

ew
and cam lever with special tool 5 .

th
Guideline
at
Valve clearance
M
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039

… 0.0059 in)
Exhaust at: 20 °C 0.25 … 0.30 mm (0.0098
(68 °F) … 0.0118 in)
G04617-11
368
CYLINDER HEAD 24
Feeler gauge (59029041100) ( p. 453)

– Set the valve clearance of the rear cylinder.
( p. 371)
( p. 252)
and cam lever with special tool .5
Guideline
Valve clearance
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039
… 0.0059 in)
Exhaust at: 20 °C 0.25 … 0.30 mm (0.0098
(68 °F) … 0.0118 in)
72
G04616-11
Feeler gauge (59029041100) ( p. 453)
04
0
/0
– Set the valve clearance of the front cylinder.
57
( p. 371)
04
0
– Crank the engine several times. Check the valve clearance and
,0
l.c r:
correct it if necessary.
ai fo
om
– Remove special tool
tm ed 6 and mount and tighten screw 7.
Guideline
ho ns

e
bolt
h@ Lic
G04618-10
fo r |
– Mount and tighten screw 8 of the alternator cover.

sh fü
rt
Guideline
ta rt
at ie

M ns
tor cover
h, ze
Li
G04619-10
t
or
– Mount gasket 4.
hf
as
ew
th
at
M
G04611-11
369
24 CYLINDER HEAD

Loctite® 5910
Info
the engine vent.
tighten screws .3
Guideline
72
0 04
/0
G04610-11
57
– Position gasket 2.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04615-11
fo r |

sh fü
– Apply a thin layer of sealing compound to area B.

rt
ta rt
Loctite® 5910
at ie
M ns
Info
h, ze

Li
the engine vent.

t
or
hf
tighten screws .1
as
Guideline
ew

th
at
M
G04614-11
370
CYLINDER HEAD 24
24.3 Setting the valve clearance of the rear cylinder
Info
For purposes of illustration, the following operations are shown with the engine deinstalled.
Removal is not necessary.
Condition
cylinder
Preparatory work
– Disassemble the camshafts of the rear cylinder. ( p. 372)
Main work
– Lift cam lever1.
lation position.
72
– Correct and insert the shims as indicated by the results of the
04
valve clearance check.
0
/0
57
306995-10
04
Finishing work
0
– Install the camshafts of the rear cylinder. (
,0
p. 372)
l.c r:
ai fo
om
tm ed
24.4 Setting the valve clearance of the front cylinder
ho ns
e
Info
h@ Lic
For purposes of illustration, the following operations are shown with the engine deinstalled.
Removal is not necessary.
fo r |
sh fü
Condition
rt
ta rt
The engine is positioned at ignition top dead center of the front

at ie
cylinder
M ns
Preparatory work
– Disassemble the camshafts of the front cylinder. ( p. 373)
h, ze
Li
Main work
– Lift cam lever1.
t
or
lation position.
–
hf
Correct and insert the shims as indicated by the results of the

valve clearance check.
as
ew
th
307093-10
at
Finishing work
M
– Install the camshafts of the front cylinder. ( p. 374)

371
24 CYLINDER HEAD
24.5 Disassembling the camshafts of the rear cylinder

Condition
cylinder
– Pull out timing chain tensioner 2.
R01894-10
– Remove the spark plug shaft insert 3.
72
0 04
Info
/0
57
04
0
– Remove the timing chain from the rear sprocket. Remove the
,0
l.c r:
camshafts.
ai fo
R01896-10
om
tm ed
ho ns
24.6 Installing the camshafts of the rear cylinder
e
– Pull up the timing chain and insert intake camshaft 1.

h@ Lic
Info
fo r |
The intake camshaft is marked INRE.

sh fü
rt
–
ta rt
Place the timing chain over the rear sprocket of the intake
at ie
camshaft.
M ns
– Ensure that the bleeder is seated correctly.

h, ze

Li
Info
The exhaust camshaft is marked EXRE.
t
or
– Lay the timing chain over the rear sprocket and the camshaft
hf
in the bearing seat.

as
Markings B must be flush with the edge of the cylinder

head.
ew

th
– Mount screws 3 and tighten them from the inside to the out-
at
R01897-10
side.
M
372
CYLINDER HEAD 24
Guideline
bearing support
Step 2
18 Nm (13.3 lbf ft)
bearing support 8.5 Nm (6.27 lbf ft)
Step 2
14.5 Nm (10.7 lbf ft)
Only applies when
using:
Hexagon socket bit
(61229025000)
( p. 459)
72
Hexagon socket bit (61229025000) ( p. 459)
04
– Grease O-rings and mount spark plug shaft insert.
0
/0
– Prepare the timing chain tensioner for installation. ( p. 296)
57
– After it has been positioned in the installation location, insert
04
timing chain tensioner 4 with a new O-ring.
0
– Mount and tighten screw plug 5 with a new seal ring.
,0
l.c r:
Guideline
ai fo
om
Plug, timing-chain
tm ed M24x1.5 25 Nm (18.4 lbf ft)
tensioner
ho ns
e
h@ Lic
R01895-10
– Remove screw 6 and use a special tool to push the timing

fo r |
chain tensioner toward the timing chain.

sh fü
rt

ta rt
( p. 458)
at ie
M ns
The timing chain tensioner unlocks.

h, ze

Li
Guideline
R01899-10 Screw, unlocking of M10x1 8 Nm (5.9 lbf ft)
timing chain ten-
t
sioner
or
hf
as
24.7 Disassembling the camshafts of the front cylinder

ew
Condition
th
The engine is positioned at ignition top dead center of the front

at
cylinder
M
373
24 CYLINDER HEAD

– Pull out timing chain tensioner 2.
309460-10
– Remove the spark plug shaft insert 3.

Info
72
04
– Remove the timing chain from the rear sprocket. Remove the
0
camshafts.
/0
309461-10
57
04
24.8 Installing the camshafts of the front cylinder
0
,0
–
l.c r:
Pull up the timing chain and insert intake camshaft 1.
ai fo
om
tm ed Info
The intake camshaft is marked INFR.
ho ns
e
h@ Lic
camshaft.
fo r |
sh fü
Info
rt
ta rt
The exhaust camshaft is marked EXFR.

at ie
– Lay the timing chain over the rear sprocket and the camshaft
M ns
in the bearing seat.

h, ze
Markings A must be flush with the edge of the cylinder

Li
head.
– 3 and tighten them from the inside to the out-
t
Mount screws
or
side.
hf
R01898-10
as
ew
th
at
M
374
CYLINDER HEAD 24
Guideline
bearing support
Step 2
18 Nm (13.3 lbf ft)
bearing support 8.5 Nm (6.27 lbf ft)
Step 2
14.5 Nm (10.7 lbf ft)
Only applies when
using:
Hexagon socket bit
(61229025000)
( p. 459)
72
Hexagon socket bit (61229025000) ( p. 459)
04
– Grease O-rings and mount spark plug shaft insert.
0
/0
– Prepare the timing chain tensioner for installation. ( p. 296)
57
– After it has been positioned in the installation location, insert
04
timing chain tensioner 4 with a new O-ring.
0
– Mount and tighten screw plug 5 with a new seal ring.
,0
l.c r:
Guideline
ai fo
om
Plug, timing-chain
tm ed M24x1.5 25 Nm (18.4 lbf ft)
tensioner
ho ns
e
h@ Lic
309463-10
– Remove screw 6 and use a special tool to push the timing

fo r |
chain tensioner toward the timing chain.

sh fü
rt

ta rt
( p. 458)
at ie
M ns
The timing chain tensioner is unlocked.

h, ze

Li
Guideline
309464-10 Screw, unlocking of M10x1 8 Nm (5.9 lbf ft)
timing chain ten-
t
sioner
or
hf
as
ew
th
at
M
375
25 LUBRICATION SYSTEM
25.1 Oil circuit
72
04
0
/0
57
004
,0
l.c r:
ai fo
om
402650-60
Oil circuit of middle suction pump tm ed

1 Oil screen of oil drain plug in gearbox
ho ns
2 Middle suction pump

e
3 Heat exchanger
h@ Lic
4 Oil exit in oil tank

fo r |
Oil circuit of left suction pump

sh fü
5 Crankcase
rt
ta rt
6 Left suction pump

at ie
7 Lubricating slots in gearbox

M ns
Oil circuit of force pump

h, ze
8 Oil screen of oil drain plug in oil tank

Li
9 Force pump
bk Oil pressure control valve
t
bl Bypass valve
or
bm Oil filter
hf
bn Crankshaft
as
bo Oil nozzle for alternator cooling

ew
bp Timing chain tensioner

th
bq Camshaft lubrication/oil nozzles for valve gear lubrication

at
br Oil nozzles for piston cooling

M
bs Oil spray tube

bt Oil nozzle for clutch lubrication
ck Clutch
376
LUBRICATION SYSTEM 25
25.2 Checking the engine oil level
Info
Oil consumption depends on the riding style and the operating conditions.
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Check the engine oil level in the engine oil level viewer.
Info
After switching off the engine, wait one minute before
checking the level.
72
04
The engine oil level should be in the upper area B of the
engine oil level viewer.
0
/0
S03957-10
» When the engine oil level is in area A of the engine oil
57
level viewer:
04
– Do not add engine oil.
0
» B of the engine oil
,0
When the engine oil level is in area
l.c r:
ai fo
level viewer:
om
– Engine oil can be added.
tm ed
» When the engine oil level is in area C of the engine oil
ho ns
level viewer:
e
– Add engine oil. ( p. 380)

h@ Lic
fo r |
25.3 Changing the engine oil and oil filter, cleaning the oil screens
sh fü
rt
ta rt
Warning
at ie
M ns
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
h, ze
Li
Note
t
or
hf

as
Main work
ew
– Place the motorcycle on a horizontal surface using the side

stand.
th

at
M
– In order to prevent oil from running over the exhaust system,

use a mouldable funnel if necessary.
– Remove oil drain plugs 1 with the magnets, the O-rings, and
the oil screens.
S03958-10
377
– Remove screws 2. Take off oil filter cover 3 with the O-

ring.
S03959-10
– Pull oil filter 4 out of the oil filter housing.

Lock ring plier (51012011000) ( p. 452)
– Allow the engine oil to drain completely.
– Thoroughly clean the parts and the sealing surfaces.
72
0 04
/0
S03960-10
57
– Insert new oil filter 4.
04
Info
0
,0
l.c r:
Only insert the oil filter by hand.
ai fo
om
– Oil the O-ring of the oil filter cover. Mount oil filter cover
tm ed 3.
ho ns
e
h@ Lic
S03961-10

fo r |
Guideline
sh fü

rt
ta rt
screws
at ie
M ns
h, ze
Li
S03959-11
– Thoroughly clean magnets A and oil screens B of the oil

t
or
drain plugs.
hf
as
ew
th
at
M
100773-12
378
– Mount and tighten oil drain plugs 1 with magnets, O-rings,

and oil screens.
Guideline
S03958-10
– Have the entire filling quantity available.

Engine oil 3.50 l Engine oil
Ambient (3.7 qt.) (SAE 10W/50)
temperature: ≥ 0 °C ( p. 446)
(≥ 32 °F)
72
Engine oil Engine oil (SAE
Ambient 5W/40) ( p. 447)
04
0
(< 32 °F)
/0
S03962-10
57
– Add the oil quantity in two steps.
–
04
Remove filler plug 5 with the O-ring, and fill up with the first
partial quantity.
0
,0
l.c r:
Engine oil (1st par- 3.0 l (3.2 qt.) Engine oil
ai fo
om
tial quantity) approx. (SAE 10W/50)
Ambient tm ed ( p. 446)
ho ns
(≥ 32 °F)
e
Engine oil (1st par- Engine oil (SAE

h@ Lic

Ambient
fo r |
sh fü
(< 32 °F)
rt
ta rt
– Mount filler plug 5 with the O-ring.

at ie
M ns
Danger
h, ze

Li

t
or

hf

as
– Start the engine and check for tightness.

ew

th
at
M
379
– Remove the filler plug with the O-ring and add the second par-
tial quantity up to the upper marking Con the engine oil
level viewer.
Engine oil (2nd par- 0.50 l Engine oil
tial quantity) approx. (0.53 qt.) (SAE 10W/50)
Ambient ( p. 446)
(≥ 32 °F)
S03957-11 Engine oil (2nd par- Engine oil (SAE
Ambient
(< 32 °F)
72
Danger
04
0
/0
57
04
0
,0
l.c r:
ai fo
om
– Start the engine and check for tightness.
tm ed
Finishing work
ho ns
e
h@ Lic
25.4 Adding engine oil

fo r |
sh fü
Info
rt
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ta rt
The engine may be damaged if the engine oil level is too high.
at ie
M ns
Condition
h, ze
The engine is at operating temperature.

Li
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
t
or
Main work
hf
– Remove filler plug 1 with the O-ring.

as
ew
th
at
M
S03962-11
380
– Add engine oil to upper marking A on the engine oil level

viewer.
Condition
Ambient temperature: ≥ 0 °C (≥ 32 °F)
Engine oil (SAE 10W/50) ( p. 446)
Condition
Ambient temperature: < 0 °C (< 32 °F)
S03957-12
Engine oil (SAE 5W/40) ( p. 447)
Info
In order to achieve optimal engine oil performance, it is
not advisable to mix different engine oils.
KTM recommends changing the engine oil.
72
04
Danger
0
/0
57
04
0
,0
l.c r:
ai fo
om
–
tm ed
Start the engine and check for tightness.
ho ns
Finishing work
– Check the engine oil level. (
e
p. 377)
h@ Lic
fo r |
25.5 Checking the oil pressure

sh fü

rt
ta rt
– 1
at ie
Remove screw .
M ns
h, ze
Li
t
or
R01775-10
hf
– Mount and tighten special tool 2.

as
Guideline
ew
Oil pressure adapter M10x1 10 Nm (7.4 lbf ft)

th
Oil pressure adapter (77329006000) ( p. 462)

at
–
M
Connect pressure tester 3 without the t-plate on the special

tool.
Pressure testing tool (61029094000) ( p. 456)
R01776-10
381
Danger
– Start the engine and allow it to warm up.

– Check the oil pressure.
Oil pressure
Coolant temperature: 1.8 … 4.5 bar (26 …
≥ 60 °C (≥ 140 °F) 65 psi)
Idle speed
72
04
– Check the oil pumps for wear. Check that all oil holes
0
are clear.
/0
57
04
Warning
0
Danger of burns Some vehicle components get very
,0
l.c r:
hot when the machine is driven.
ai fo
om
tm ed – Wear appropriate protective clothing and safety
gloves. In case of burns, rinse immediately with
ho ns
lukewarm water.
e
h@ Lic

fo r |
Guideline
sh fü
rt
Screw, unlocking of M10x1 8 Nm (5.9 lbf ft)

ta rt
timing chain ten-

at ie
sioner
M ns
h, ze
Li
R01775-10
t
or
25.6 Removing the oil nozzle for the clutch lubrication

hf
– Remove screw 1.
as
– Remove screw 2.
ew
– Take off the engine sprocket cover.

th
at
M
G04553-11
382
– Remove screw plug 3 with O-ring.
T00534-10
– Remove oil nozzle 4.

Mounting tool (61229035000) ( p. 459)
72
0 04
/0
T00535-10
57
25.7 Checking/cleaning the oil nozzle for clutch lubrication
0 04
Preparatory work
,0
l.c r:
– Remove the oil nozzle for the clutch lubrication. ( p. 382)
ai fo
om
Main work
tm ed
– Check that the oil nozzle for clutch lubrication is not blocked.
ho ns
» If the oil nozzle is blocked:
– Clean the oil nozzle and change as necessary.
e
h@ Lic
fo r |
sh fü
rt
ta rt
301428-10
at ie
Finishing work
M ns
– Install the oil nozzle for the clutch lubrication. ( p. 383)

h, ze
Li
25.8 Installing the oil nozzle for the clutch lubrication

– 1.
t
Mount and tighten oil nozzle

or
Guideline
hf
Oil nozzle for clutch M6x0.75 4 Nm (3 lbf ft)

as
lubrication
ew
Mounting tool (61229035000) ( p. 459)

th
at
M
R01769-11
383
– Mount and tighten screw plug 2 with the O-ring.

Guideline
Screw plug, clutch M10x1 8 Nm (5.9 lbf ft)
lubrication
R01768-10

Guideline
sprocket cover
72
04
Guideline
0
/0
G04553-12
sprocket cover
57
– 3.
04
Tighten screw
Guideline
0
,0
l.c r:
ai fo
om
sprocket cover
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
384
IGNITION SYSTEM 26
26.1 Alternator - checking the stator winding

Condition
The stator is disconnected.
Stator winding measurement I - check the resistance.
– Measure the resistance between the specified points.
Stator, connector HQ pin 1 – Stator, connector HQ pin 2
Alternator
Stator winding resistance 0.15 … 0.30 Ω
at: 20 °C (68 °F)
» If the indicated value does not correspond to the setpoint
value:
P00012-01
– Change the stator.
Stator winding measurement II - check the resistance.
–
72
Measure the resistance between the specified points.
0 04
Alternator
/0
57
at: 20 °C (68 °F)
04
0
value:
,0
l.c r:
ai fo
om
Stator winding measurement III - check resistance.
tm ed
ho ns
e
Alternator
h@ Lic

at: 20 °C (68 °F)
fo r |
sh fü

rt
value:
ta rt
at ie

M ns
h, ze
Li
t
or
hf
as
P00012-01 P00291-10
ew
Stator winding I - check short circuit to ground (terminal 31).

th

Stator, connector HQ pin 1 – Measuring point Ground (−)
at
M
Resistance ∞Ω
» If the indicated value does not correspond to the setpoint value:
385
26 IGNITION SYSTEM
P00012-01 P00291-10
Stator winding II - check short circuit to ground (terminal 31).

Resistance ∞Ω
72
04
0
/0
57
0 04
,0
l.c r:
ai fo
om
P00012-01
tm ed P00291-10
ho ns
Stator winding III - check short circuit to ground (terminal 31).

e

h@ Lic

fo r |
Resistance ∞Ω
sh fü

rt
ta rt

at ie
– Start the motorcycle to check the function. ( p. 20)

M ns
Stator winding measurement I - check voltage.

h, ze

Li
Info
t
or
The results of the measurements on the individual coils

hf
must not deviate significantly from one another.

as
Alternator
ew
P00012-01
Alternating voltage stator ≥ 50 V
winding at 4000 rpm:
th
20 °C (68 °F)
at
M

value:
386
IGNITION SYSTEM 26
Stator winding measurement II - check voltage.

Info
Alternator
Alternating voltage stator ≥ 50 V
20 °C (68 °F)
value:
72
Stator winding measurement III - check voltage.
04
0
/0
57
Info
04
0
,0
l.c r:
Alternator
ai fo
om
Alternating voltage stator
tm ed ≥ 50 V
ho ns
20 °C (68 °F)
e

h@ Lic
value:
fo r |
sh fü
rt
ta rt
26.2 Changing the spark plugs

at ie
M ns
Preparatory work
h, ze

Li

t

or

hf
as
Main work
– Unplug connectors 1 and 2 of the ignition coils.
ew
th
at
M
G04595-10
387
26 IGNITION SYSTEM
– Remove screw 3.
G04596-10
– Remove the spark plug with special tool 5.

– Mount and tighten a new spark plug using a special tool.
Guideline
72
0 04
/0
G04597-10
57
– Remove the spark plug with special tool 5.
04
0
,0
–
l.c r:
Mount and tighten a new spark plug using a special tool.
ai fo
om
Guideline
tm ed
ho ns
e
h@ Lic
G04598-10

fo r |

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04596-10
– Plug in connectors 2 and 1 of the ignition coils.

t
or
hf
as
ew
th
at
M
G04595-10
388
IGNITION SYSTEM 26
– Unplug connectors 6 and 7 of the ignition coils.
G04599-10
– Remove screw 8.
72
0 04
/0
G04600-10
57
– Remove the spark plug with special tool bk.
04
0
,0
–
l.c r:
ai fo
om
Guideline
Spark plug tm ed M12x1.5 18 Nm (13.3 lbf ft)
ho ns
e
h@ Lic
G04601-10
– Remove the spark plug with special tool bk.

fo r |
sh fü

rt
–
ta rt

at ie
Guideline
M ns

h, ze
Li
G04602-10

t
or

hf
as
ew
th
at
M
G04600-10
389
26 IGNITION SYSTEM
– Plug in connectors 7 and 6 of the ignition coils.
G04599-10
Finishing work
–
72
Mount the front rider's seat. ( p. 118)
0 04
/0
57
26.3 Changing the spark plugs (air filter removed)
04
Condition
0
The air filter is removed.
,0
l.c r:
– 1.
Unplug connector
ai fo
om
tm ed
– Disconnect fuel connection 3.
ho ns
– Take off the fuel line.

e
h@ Lic
Info
fo r |

sh fü
Info
rt
ta rt
Remaining fuel may flow out of the fuel line.

at ie
M ns
h, ze
Li
t
or
hf
G04492-12
as
ew
– Remove the intake trumpet.

th
at
M
G04482-11
390
IGNITION SYSTEM 26
– Remove spring band clamp 5.

– Detach the SAS hose.
G04491-12

– Lift the lower part of the air filter box carefully.
72
0 04
/0
G04493-12
57
– Remove the lower part of the air filter box with O-rings 8.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04494-12
– Unplug connectors 9 and bk of the ignition coils.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04595-11

t
or
– Remove ignition coils bm.

hf
as
ew
th
at
M
G04596-11
391
26 IGNITION SYSTEM
– Remove the spark plug with special tool bn.

Guideline
G04597-11
– Remove the spark plug with special tool bn.

Guideline
72
0 04
/0
G04598-11
57
– Mount ignition coils bm.
04
– Mount and tighten screw bl.
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04596-11
– Plug in connectors bk and 9 of the ignition coils.

fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04595-11
– Unplug connectors bo and bp of the ignition coils.

t
or
hf
as
ew
th
at
M
G04599-11
392
IGNITION SYSTEM 26
– Remove screw bq.

– Remove ignition coils br.
G04600-11
– Remove the spark plug with special tool bs.

Guideline
72
0 04
/0
G04601-11
57
– Remove the spark plug with special tool bs.
04
0
,0
–
l.c r:
ai fo
om
Guideline
Spark plug tm ed M10x1 11 Nm (8.1 lbf ft)
ho ns
e
h@ Lic
G04602-11
– Mount ignition coils br.

fo r |
– Mount and tighten screw bq.

sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04600-11
– Plug in connectors bp and bo of the ignition coils.

t
or
hf
as
ew
th
at
M
G04599-11
393
26 IGNITION SYSTEM
– Position the base of the air filter box with O-rings 8 in the
frame.
– Push intake snorkel A onto intake channel B.
Info
Ensure that the intake snorkels and O-rings are posi-
tioned correctly.
72
0 04
/0
G04494-13
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04493-12
– Mount the SAS hose.

fo r |
– Mount spring band clamp 5.

sh fü
rt

ta rt
at ie
M ns
h, ze
Li
G04491-12
– Position the intake trumpet.

t
or

hf
Guideline
as

ew
chassis
th
at
M
G04482-11
394
IGNITION SYSTEM 26
– Position the fuel line and injection valves.

– Join fuel connection 3.
– Join connector 1.
72
004
/0
G04492-13
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
395
27 THROTTLE VALVE BODY
27.1 Removing the throttle valve body

Preparatory work
Main work
– Detach connector 1.
72
004
/0
G04502-10
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04503-10
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04504-10
– Loosen clamp 4.
t
or
hf
as
ew
th
at
M
G04505-10
396
THROTTLE VALVE BODY 27
– Loosen clamp 5.
G04506-10
– Lift the throttle valve body.

– Detach connectors 6 and remove the throttle valve body.
72
0 04
/0
G04507-10
57
– Cover the intake duct with a cloth.
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04508-10
fo r |
27.2 Installing the throttle valve body

sh fü
Main work
rt
ta rt
– Remove the cloth from the intake duct.

at ie
M ns
h, ze
Li
t
or
R01879-10
hf
as
– Position the throttle valve body.

ew
th
at
M
G04507-11
397
– Position and tighten clamp 2.

Guideline
Hose clip, intake M4 1.5 Nm
flange (1.11 lbf ft)
G04506-11
– Position and tighten clamp 3.

Guideline
Hose clip, intake M4 1.5 Nm
flange (1.11 lbf ft)
72
0 04
/0
G04505-11
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
G04504-11
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
G04503-11
– Plug in connectors 6.
t
or
hf
as
ew
th
at
M
G04502-11
Finishing work

398
THROTTLE VALVE BODY 27

– Perform the initialization run. ( p. 399)
27.3 Performing the initialization run

Condition
"Clear adaptation values".
The adaptation values are deleted.
– Switch off the ignition.
– Disconnect the diagnostics tool.
72
Danger
04
0
401897-01
/0
57
04
0
,0
l.c r:
ai fo
om
– Start the engine without operating the throttle grip.
Guideline tm ed
ho ns
Coolant temperature < 25 °C (< 77 °F)
e
– Let the engine run at idle speed for at least 10 minutes (600
h@ Lic
seconds).
fo r |
Info
sh fü
Do not operate the throttle grip during the initialization

rt
process.
ta rt
at ie
– Switch off the ignition after 10 minutes (600 seconds).

M ns
h, ze
Info
Li
If initialization is not completed or if the initialization

process was interrupted, the entire process must be
restarted.
t
or
hf
as
27.4 Resetting the engine electronics control unit

ew
Condition
th
at
M
399
Main work
"Clear adaptation values".
401898-01
Final steps
72
04
0
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
400
TECHNICAL DATA 28
28.1 Engine
Design 2-cylinder 4-stroke Otto engine, 75° V arrangement,
water-cooled
Displacement 1,301 cm³ (79.39 cu in)
Stroke 71 mm (2.8 in)
Bore 108 mm (4.25 in)
Compression ratio 13.5:1
Idle speed 1,400 … 1,600 rpm
Control DOHC, 4 valves per cylinder, chain-driven
Valve - valve plate diameter
Intake 42 mm (1.65 in)
Exhaust 34 mm (1.34 in)
Valve clearance
72
Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.0039 … 0.0059 in)
04
Exhaust at: 20 °C (68 °F) 0.25 … 0.30 mm (0.0098 … 0.0118 in)
0
Crankshaft bearing Sleeve bearing
/0
57
Conrod bearing Sleeve bearing
Piston pin bearing No bearing bush - DLC coated piston pin
04
Piston Forged light alloy
0
,0
l.c r:
Piston ring 1 upper compression (rectangular) ring, 1 lower com-
ai fo
om
pression ring, 1 oil scraper ring
Engine lubrication tm ed
Dry sump lubrication system with 3 trochoidal pumps
ho ns
Primary transmission 40:76
Clutch Antihopping clutch in oil bath/hydraulically operated
e
h@ Lic
Transmission 6-gear transmission, claw shifted

Transmission ratio
fo r |
1st gear 12:35

sh fü
2nd gear 15:32

rt
ta rt
3rd gear 18:30

at ie
4th gear 20:27

M ns
5th gear 24:27

h, ze
6th gear 27:26

Li
Mixture preparation Electronic fuel injection

Ignition system Contactless controlled fully electronic ignition with
t
digital ignition adjustment

or
Alternator 12 V, 450 W
hf
Spark plug
as
Inside spark plug NGK LKAR9BI‑10

ew
Outside spark plug NGK LMAR7DI‑10

th
Electrode gap, spark plug 1 mm (0.04 in)

at
Cooling Water cooling, permanent circulation of coolant by

M
water pump
Cold start device Starter motor
401
28 TECHNICAL DATA
28.2 Tolerance, engine wear limits

Camshaft bearing - radial clearance
Valve guide - diameter
Valve - sealing seat width
Intake: New condition 0.90 mm (0.0354 in)
Intake: Wear limit 1.5 mm (0.059 in)
Exhaust: New condition 1.0 mm (0.039 in)
Exhaust: Wear limit 2.0 mm (0.079 in)
Valve - run-out
72
Intake: on the valve plate ≤ 0.1 mm (≤ 0.004 in)
04
Exhaust: on the valve plate ≤ 0.1 mm (≤ 0.004 in)
0
/0
Valve – valve stem diameter
57
Exhaust 5.956 … 5.970 mm (0.23449 … 0.23504 in)
04
Intake 5.966 … 5.980 mm (0.23488 … 0.23543 in)
0
Valve spring - length
,0
l.c r:
New condition 42.70 mm (1.6811 in)
ai fo
om
Cylinder head - bearing hole of camshaft
tm ed
24.000 … 24.021 mm (0.94488 … 0.94571 in)
ho ns
Cylinder/cylinder head - sealing area distortion ≤ 0.05 mm (≤ 0.002 in)
e
Cylinder - bore diameter

h@ Lic
Size I 108.000 … 108.012 mm (4.25196 … 4.25243 in)

Size II 108.013 … 108.025 mm (4.25247 … 4.25294 in)
fo r |
sh fü
Piston - diameter
rt
Size I 107.940 … 107.950 mm (4.2496 … 4.24999 in)

ta rt
at ie
Size II 107.950 … 107.960 mm (4.24999 … 4.25039 in)

M ns
Piston/cylinder - mounting clearance

h, ze
Size I 0.05 … 0.072 mm (0.002 … 0.00283 in)

Li
Size II 0.053 … 0.075 mm (0.00209 … 0.00295 in)

Piston - piston pin hole diameter 20.004 … 20.008 mm (0.78756 … 0.78771 in)
t
or
Piston ring
hf
Width, first ring (rectangular ring) 0.797 … 0.800 mm (0.03138 … 0.0315 in)
as
Width, second ring (lower compression ring) 0.797 … 0.800 mm (0.03138 … 0.0315 in)
Width, oil scraper ring 1.970 … 1.990 mm (0.07756 … 0.07835 in)
ew
Piston ring - groove clearance

th
First ring (rectangular ring) ≤ 0.08 mm (≤ 0.0031 in)

at
Second ring (lower compression ring) ≤ 0.08 mm (≤ 0.0031 in)

M

Piston ring end gap
First ring (rectangular ring) ≤ 0.50 mm (≤ 0.0197 in)
≤ 0.60 mm (≤ 0.0236 in)
Second ring (lower compression ring)
402
TECHNICAL DATA 28

Piston pin - diameter 19.995 … 20.000 mm (0.7872 … 0.7874 in)
Connecting rod - diameter of upper conrod eye 20.007 … 20.013 mm (0.78768 … 0.78791 in)
Connecting rod - axial clearance of lower conrod bearing
Connecting rod - radial clearance of lower conrod bearing
Connecting rod - width of conrod eye 20.950 … 21.000 mm (0.8248 … 0.82677 in)
Crankshaft - axial clearance
72
Crankshaft - crank pin width 42.100 … 42.150 mm (1.65748 … 1.65945 in)
Crankshaft - crank pin diameter
04
Yellow 41.978 … 41.989 mm (1.65267 … 1.65311 in)
0
/0
Blue 41.990 … 42.000 mm (1.65315 … 1.65354 in)
57
Red 42.001 … 42.011 mm (1.65358 … 1.65397 in)
04
Crankshaft - main bearing diameter
0
Yellow 52.965 … 52.975 mm (2.08523 … 2.08563 in)
,0
l.c r:
Blue 52.976 … 52.985 mm (2.08567 … 2.08602 in)
ai fo
om
Red 52.986 … 52.995 mm (2.08606 … 2.08641 in)
tm ed
Crankshaft - radial clearance of main bearing
ho ns

e

h@ Lic
Crankshaft - step bearing diameter 27.985 … 28.000 mm (1.10177 … 1.10236 in)

fo r |
Crankshaft - radial clearance of step bearing

sh fü

rt
ta rt

at ie
Clutch discs - thickness of total package

M ns

h, ze

Li

Clutch basket - thrust surface of clutch facing discs
t
or
Oil pressure regulator valve - minimum length spring 39 mm (1.54 in)

hf
Oil pumps
as
Clearance between external rotor and engine case 0.20 … 0.40 mm (0.0079 … 0.0157 in)
ew
Clearance between external rotor and internal rotor 0.10 … 0.25 mm (0.0039 … 0.0098 in)
Axial clearance 0.04 … 0.25 mm (0.0016 … 0.0098 in)
th
at
Oil pressure
M
Coolant temperature: ≥ 60 °C (≥ 140 °F) 1.8 … 4.5 bar (26 … 65 psi)

Idle speed
Oil consumption
403
28 TECHNICAL DATA
After the vehicle is run-in ≤ 0.4 l/1.000 km (≤ 0.4 qt./600 mi)
Info
Oil consumption depends on the riding style
and the operating conditions.
Shift fork
Thickness at plate 4.85 … 4.95 mm (0.1909 … 0.1949 in)
Clearance in the sliding gear groove: New condi- 0.35 … 0.55 mm (0.0138 … 0.0217 in)
tion
Clearance in the sliding gear groove: Wear limit 0.70 mm (0.0276 in)
Shift shaft - play in sliding plate/shift quadrant 0.40 … 0.80 mm (0.0157 … 0.0315 in)
Sliding gear - width of shift fork groove 5.30 … 5.40 mm (0.2087 … 0.2126 in)
Main shaft axial clearance 0.05 … 0.15 mm (0.002 … 0.0059 in)
72
28.3 Engine tightening torques
04
Screw, damping plate EJOT ALtracs® M6x14 10 Nm (7.4 lbf ft)
0
/0
Loctite®243™
57
Screw, retaining bracket, valve EJOT ALtracs® M6x10 10 Nm (7.4 lbf ft)
04
cover, rear
Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft)
0
,0
l.c r:
ai fo
om
Loctite®243™
Remaining engine screws M5 tm ed 6 Nm (4.4 lbf ft)
Screw, bearing retainer M5 5 Nm (3.7 lbf ft)
ho ns
Loctite®243™
e
h@ Lic
Screw, bearing shells retaining M5 6 Nm (4.4 lbf ft)

bracket Loctite®243™
fo r |
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)

sh fü
Loctite®243™
rt
Screw, engine oil level viewer M5 4 Nm (3 lbf ft)

ta rt
at ie
Screw, gear position sensor M5 5 Nm (3.7 lbf ft)

M ns
Loctite®243™
h, ze
Loctite®243™
Li
Bleeder screw, water pump cover M6 10 Nm (7.4 lbf ft)

Coolant connection screw on the M6 8 Nm (5.9 lbf ft)
cylinder head Loctite®243™
t
or
Freewheel ring bolt M6 – 10.9 15 Nm (11.1 lbf ft)

hf
Loctite® 648™
as

ew
Remaining engine screws M6 10 Nm (7.4 lbf ft)

Screw, camshaft bearing support M6 – 10.9 10 Nm (7.4 lbf ft)
th
Screw, clutch cover M6 10 Nm (7.4 lbf ft)

at
M

404
TECHNICAL DATA 28
Screw, locking lever M6 10 Nm (7.4 lbf ft)

Loctite®243™
Screw, oil pump cover M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift drum locating M6 – 12.9 18 Nm (13.3 lbf ft)
Loctite®243™
Screw, shift lever M6 18 Nm (13.3 lbf ft)
Screw, starter motor M6 10 Nm (7.4 lbf ft)
Screw, starter wheel guide M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, stator M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
Screw, water pump wheel M6 10 Nm (7.4 lbf ft)
72
Loctite®243™
04
Stud, timing chain shaft M6 8 Nm (5.9 lbf ft)
0
Vacuum connection M6 5 Nm (3.7 lbf ft)
/0
Loctite®243™
57
Nozzle 100 M6x0.75 3 Nm (2.2 lbf ft)
04
Loctite®243™
0
Crankshaft locking bolt M8 12 Nm (8.9 lbf ft)
,0
l.c r:
ai fo
Screw, camshaft bearing support M8 – 10.9 Step 1
om
10 Nm (7.4 lbf ft)
tm ed
Step 2
ho ns
18 Nm (13.3 lbf ft)
Screw, camshaft bearing support M8 – 10.9 Step 1
e
h@ Lic
8.5 Nm (6.27 lbf ft)

Step 2
fo r |
14.5 Nm (10.7 lbf ft)

Only applies when using:
sh fü
Hexagon socket bit

rt
ta rt
(61229025000) ( p. 459)
at ie

M ns
Screw, guide rail M8 15 Nm (11.1 lbf ft)

h, ze
Loctite®243™
Li
Screw, tensioning rail M8 15 Nm (11.1 lbf ft)

Loctite®243™
Stud, exhaust flange M8 10 Nm (7.4 lbf ft)
t
or

hf
Oil pressure sensor M10x1 10 Nm (7.4 lbf ft)

as
Screw plug, cam lever axis M10x1 12 Nm (8.9 lbf ft)

ew
Screw plug, clutch lubrication M10x1 8 Nm (5.9 lbf ft)

Screw plug, spreading transmis- M10x1 12 Nm (8.9 lbf ft)
th
sion lock
at
Screw, conrod bearing M10x1 Step 1

M
25 Nm (18.4 lbf ft)

Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
405
28 TECHNICAL DATA
Screw, unlocking of timing chain M10x1 8 Nm (5.9 lbf ft)

tensioner
Cylinder head screw M11x1.5 Tightening sequence:
Using a crisscross pattern
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Step 4
90°
Lubricated with engine oil
Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft)
Rotor screw M12x1.5 115 Nm (84.8 lbf ft)
72
04
Nut of engine sprocket M20x1.5 100 Nm (73.8 lbf ft)
0
Loctite®243™
/0
57
Nut, inner clutch hub M22x1.5 130 Nm (95.9 lbf ft)
04
Loctite®243™
0
Plug, timing-chain tensioner M24x1.5 25 Nm (18.4 lbf ft)
,0
l.c r:
ai fo
Screw plug, alternator cover M24x1.5 8 Nm (5.9 lbf ft)
om
Nut, primary gear wheel M33LHx1.5 tm ed 130 Nm (95.9 lbf ft)
Loctite®243™
ho ns
e
28.4 Capacities
h@ Lic
28.4.1 Engine oil

fo r |
sh fü
Engine oil 3.50 l (3.7 qt.) Engine oil (SAE 10W/50)

Ambient temperature: ≥ 0 °C
rt
( p. 446)
ta rt
(≥ 32 °F)
at ie
M ns
Engine oil Engine oil (SAE 5W/40) ( p. 447)

Ambient temperature: < 0 °C
h, ze
(< 32 °F)
Li
28.4.2 Coolant
t
Coolant 3.20 l (3.38 qt.) Coolant ( p. 446)

or
hf
28.4.3 Fuel
as
Total fuel tank capacity, approx. 16 l (4.2 US gal) Super unleaded (ROZ 95)
ew
( p. 447)
th
Fuel reserve, approx. 3.5 l (3.7 qt.)

at
M
406
TECHNICAL DATA 28
28.5 Chassis
Frame Lattice frame made of chrome molybdenum steel tub-
ing, powder-coated
Fork WP SuspensionAPEX 5548
Shock absorber WP SuspensionAPEX 5746
Suspension travel
front 125 mm (4.92 in)
rear 140 mm (5.51 in)
Brake system
front Double disc brake with radially mounted four-piston
brake calipers, floating brake discs
rear Single disc brake with dual-piston brake caliper, fixed
brake disc
72
Brake discs - diameter
04
front 320 mm (12.6 in)
0
rear 240 mm (9.45 in)
/0
Brake discs - wear limit
57
front 4.5 mm (0.177 in)
04
rear 4.5 mm (0.177 in)
0
,0
l.c r:
ai fo
om
tm ed
Secondary drive ratio 17:38
ho ns
Chain 5/8 x 5/16” (525) X‑ring

e
h@ Lic
Steering head angle 64.8°

Wheelbase 1,497 mm (58.94 in)
fo r |
Seat height unloaded 835 mm (32.87 in)

sh fü
Ground clearance unloaded 160 mm (6.3 in)

rt
ta rt
Weight without fuel approx. 198 kg (437 lb.)

at ie
Maximum permissible front axle load 165 kg (364 lb.)

M ns
Maximum permissible rear axle load 260 kg (573 lb.)

h, ze
Maximum permissible overall weight 425 kg (937 lb.)

Li
28.6 Electrical system

t
or
12-V battery YTX14-BS Battery voltage: 12 V

hf
Nominal capacity: 12 Ah
Maintenance-free
as
RACE-ON key battery CR 2032 3V

ew
Fuse 58011109110 10 A
th
Fuse 58011109115 15 A
at
Fuse 58011109125 25 A
M
Fuse 58011109130 30 A
Low beam/high beam LED
Daytime running light/position light LED
407
28 TECHNICAL DATA
Combination instrument lighting LED

and indicator lamps
Turn signal (Super Duke R EU/JP) LED
Turn signal (US) RY10W / socket BAU15s 12 V
10 W
Tail light LED
Brake light LED
License plate lamp LED
28.6.1 Diagnostics connector

Diagnostics connector 1 is located under the front rider's seat.
72
0 04
/0
57
H01949-01
0 04
28.6.2 Front ACC1 and ACC2
,0
l.c r:
Installation location
ai fo
om
– Front power supplies ACC1 1 and ACC2 2 are located
tm ed
behind the fuel tank spoiler on the left between the triple
clamps.
ho ns
e
h@ Lic
fo r |
sh fü
S04081-10
rt
ta rt
at ie
28.6.3 ACC1 and ACC2 rear

M ns
Installation location
h, ze
– Power supplies ACC1 1 and ACC2 2 rear are located under

Li
the seat.
t
or
hf
as
S03954-10
ew
th
at
M
408
TECHNICAL DATA 28
28.7 Tires
Front tire Rear tire
120/70 ZR 17 M/C (58W) TL 200/55 ZR 17 M/C (75W) TL
Bridgestone Battlax Hypersport S22 F Bridgestone Battlax Hypersport S22 R
The tires specified represent one of the possible series production tires. Additional information is available in
the Service section under:
http://www.ktm.com
28.8 Fork
Fork article number 14.18.8T.22
Fork WP SuspensionAPEX 5548
Compression damping
Comfort 21 clicks
72
Standard 15 clicks
04
Sport 7 clicks
0
/0
57
Rebound damping
04
Comfort 21 clicks
Standard 15 clicks
0
,0
l.c r:
Sport 7 clicks
ai fo
om
Spring length with preload spacer(s)
tm ed
303 mm (11.93 in)
ho ns
Spring rate
e
Soft 8.5 N/mm (48.5 lb/in)

h@ Lic
Medium (standard) 9 N/mm (51 lb/in)

Hard 9.5 N/mm (54.2 lb/in)
fo r |
Air chamber length 110 mm (4.33 in)

sh fü
+ 10 + 0.39
− 30 − 1.18
rt
Fork length 753 mm (29.65 in)

ta rt
at ie
Fork oil per fork leg 615 ± 15 ml (20.79 Fork oil (SAE 4) (48601166S1)
M ns
± 0.51 fl. oz.) ( p. 447)

h, ze
Li
28.9 Shock absorber

Shock absorber article number 15.18.7T.22
t
Shock absorber WP SuspensionAPEX 5746

or

hf
as
Comfort 21 clicks
Standard 12 clicks
ew
Sport 7 clicks
th

at

M
Comfort 1.5 turns

Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
409
28 TECHNICAL DATA
Rebound damping
Comfort 21 clicks
Standard 15 clicks
Sport 10 clicks
Spring preload
Standard 8 mm (0.31 in)
Info
Corresponds to position 0 on the preload
adjuster.
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 75 N/mm (428 lb/in)
72
04
Spring length 195 mm (7.68 in)
0
/0
57
Static sag 20 mm (0.79 in)
04
Riding sag 45 mm (1.77 in)
Fitted length 356 mm (14.02 in)
0
,0
l.c r:
Shock absorber fluid ( p. 447) SAE 2.5
ai fo
om
28.10 Chassis tightening torques
tm ed
ho ns
Remaining screws, chassis EJOT PT® K45x12 1 Nm (0.7 lbf ft)

e
h@ Lic

fo r |

sh fü

rt
ta rt
Screw, air filter box cover EJOT PT® K60 2 Nm (1.5 lbf ft)
at ie
Screw, exhaust valve cover fasten- EJOT SF® M4x6‑K 4 Nm (3 lbf ft)
M ns
ing
h, ze
Screw, quick release nipple of fuel EJOT PT® K60 2 Nm (1.5 lbf ft)
Li
tank cover
Screw, tail light EJOT PT® K50x14 2.5 Nm (1.84 lbf ft)
Screw, exhaust valve cover M4 4 Nm (3 lbf ft)
t
or
Screw, fixed grip, left M4 2 Nm (1.5 lbf ft)

hf
Screw, side stand sensor M4 2 Nm (1.5 lbf ft)

as
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)

ew
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)

Screw for throttle grip M5 3.5 Nm (2.58 lbf ft)
th
screw, absorbing element, combi- M5 2 Nm (1.5 lbf ft)

at
nation instrument Loctite®243™

M
Screw, brake fluid reservoir, rear M5 3.5 Nm (2.58 lbf ft)

brake Loctite®243™
Screw, cable channel M5 5 Nm (3.7 lbf ft)
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft)
410
TECHNICAL DATA 28
Screw, combination instrument M5 2.5 Nm (1.84 lbf ft)

Screw, combination switch, left M5 5 Nm (3.7 lbf ft)
Screw, combination switch, right M5 5 Nm (3.7 lbf ft)
Screw, front turn signal bracket M5 3.5 Nm (2.58 lbf ft)
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft)
Screw, fuel tank filler cap M5 3 Nm (2.2 lbf ft)
Screw, rear turn signal bracket M5 3.5 Nm (2.58 lbf ft)
Screw, shock absorber adjusting M5 5 Nm (3.7 lbf ft)
ring
Screw, trim M5 3.5 Nm (2.58 lbf ft)
Cable disk nut, exhaust valve con- M6 14 Nm (10.3 lbf ft)
trol unit
Ground fitting on frame M6 10 Nm (7.4 lbf ft)
Lock nut, exhaust valve throttle M6 5 Nm (3.7 lbf ft)
72
cable
04
Nut, cable on starter motor M6 6 Nm (4.4 lbf ft)
0
/0
57
Screw, ABS module fastening M6 5 Nm (3.7 lbf ft)
04
Screw, angle sensor cover M6 6 Nm (4.4 lbf ft)
0
,0
Loctite®243™
l.c r:
ai fo
Screw, ball joint of push rod on M6 5 Nm (3.7 lbf ft)
om
foot brake cylinder tm ed Loctite®243™
Screw, battery terminal M6 4.5 Nm (3.32 lbf ft)
ho ns
Screw, clutch assembly M6 5 Nm (3.7 lbf ft)

e
Loctite®243™
h@ Lic
Screw, connecting piece, rear M6 10 Nm (7.4 lbf ft)

brake line Loctite®243™
fo r |
sh fü
Screw, cooler retaining bracket M6 5 Nm (3.7 lbf ft)

rt
Screw, exhaust clamp on main M6 8 Nm (5.9 lbf ft)

ta rt
silencer
at ie
M ns
Screw, exhaust clamp on manifold M6 8 Nm (5.9 lbf ft)

Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft)
h, ze
Loctite®243™
Li
Screw, front wheel speed sensor M6 4 Nm (3 lbf ft)

t
Screw, instrument support M6 2 Nm (1.5 lbf ft)

or
Screw, license plate holder on M6 8 Nm (5.9 lbf ft)

hf
lower rear panel

as
Screw, presilencer exhaust clamp M6 8 Nm (5.9 lbf ft)

ew
Copper paste
Screw, radiator hose clip M6 3 Nm (2.2 lbf ft)
th
Screw, rear wheel speed sensor M6 4 Nm (3 lbf ft)

at
M
Screw, shift lever stub M6 10 Nm (7.4 lbf ft)

Loctite®243™
Screw, shift shaft deflector on shift M6 18 Nm (13.3 lbf ft)
shaft Loctite®243™
411
28 TECHNICAL DATA
Screw, side stand stub M6 6 Nm (4.4 lbf ft)

Loctite®243™
Screw, steering damper bracket on M6 8 Nm (5.9 lbf ft)
frame Loctite®243™
Screw, step plate for foot brake M6 10 Nm (7.4 lbf ft)
lever
Nut, exhaust valve throttle cable M6x1 5 Nm (3.7 lbf ft)
Cable disk nut, exhaust valve M8 7 Nm (5.2 lbf ft)
Nut, manifold on cylinder head M8 Tightening sequence:
Tighten the nuts evenly. Do not
warp the metal plate.
25 Nm (18.4 lbf ft)
Nut, rear sprocket M8 36 Nm (26.6 lbf ft)
Nut, shift rod M8 12 Nm (8.9 lbf ft)
Nut, shift rod M8LH 12 Nm (8.9 lbf ft)
72
Nut, valve (EU/US) M8 6 Nm (4.4 lbf ft)
04
Nut, valve (JP) M8 4 Nm (3 lbf ft)
0
/0
57
04
0
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft)
,0
l.c r:
Screw, foot brake lever M8 20 Nm (14.8 lbf ft)
ai fo
om
Loctite®243™
Screw, front brake disc M8
tm ed
28 Nm (20.7 lbf ft)
Loctite®2701™
ho ns
Screw, front rider footrest bracket M8 25 Nm (18.4 lbf ft)

e
h@ Lic
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
fo r |
Screw, ignition lock (tamper-proof M8 25 Nm (18.4 lbf ft)

sh fü
screw)
rt
ta rt
Screw, rear brake caliper M8 25 Nm (18.4 lbf ft)

at ie
Loctite®2701™
M ns
Screw, rear brake disc M8 28 Nm (20.7 lbf ft)

Loctite®243™
h, ze
Screw, shift lever on footrest M8 20 Nm (14.8 lbf ft)

Li
bracket Loctite®243™
Screw, shift shaft deflector on M8 10 Nm (7.4 lbf ft)
Loctite®243™
t
frame
or
Screw, side stand bracket M8 25 Nm (18.4 lbf ft)

hf
Loctite®243™
as
Screw, side stand spring M8 15 Nm (11.1 lbf ft)

Loctite®2701™
ew
Screw, steering damper on holder M8 8 Nm (5.9 lbf ft)

th
Loctite®243™
at
Screw, steering damper on triple M8 8 Nm (5.9 lbf ft)

M
clamp Loctite®243™
Screw, steering stem clamp M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp M8 18 Nm (13.3 lbf ft)
412
TECHNICAL DATA 28

Loctite®243™
Screw, front brake caliper M10 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Loctite®243™
Screw, side stand M10 40 Nm (29.5 lbf ft)
Loctite®243™
Loctite®243™
Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft)
72
Banjo bolt, brake line, connecting M10x1 25 Nm (18.4 lbf ft)
04
piece, rear
0
Nut, rear hub shock absorber car- M10x1.25 45 Nm (33.2 lbf ft)
/0
rier Loctite®243™
57
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft)
04
Screw, bottom shock absorber M14x1.5 80 Nm (59 lbf ft)
0
Loctite®243™
,0
l.c r:
ai fo
Screw, top shock absorber M14x1.5 80 Nm (59 lbf ft)
om
Loctite®243™
Screw, eccentric M16
tm ed
70 Nm (51.6 lbf ft)
ho ns

e
Thread greased
h@ Lic
Screw, steering head, top M20x1.5 12 Nm (8.9 lbf ft)

Nut, seat lock M22x1.5 4 Nm (3 lbf ft)
fo r |
Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft)

sh fü
Thread greased
rt
ta rt
Nut, rear axle, shock absorber side M35x1.5 200 Nm (147.5 lbf ft)
at ie
Loctite® 262™/lock the locking wire

M ns
with locking varnish

h, ze

Li
Thread greased/lock locking wire

with locking varnish
t
or
hf
as
ew
th
at
M
413
29 CLEANING/PROTECTIVE TREATMENT
29.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
72
04
Info
0
Clean the motorcycle regularly to maintain its value and appearance over a long period.
/0
Avoid direct sunshine when cleaning the motorcycle.
57
04
– Close off exhaust system to keep water from entering.
–
0
Remove the coarse dirt particles with a gentle water jet.
,0
l.c r:
– Spray the heavily soiled parts with a normal commercial motor-
ai fo
om
cycle cleaner and clean using a brush.
tm ed
Motorcycle cleaner ( p. 448)
ho ns
Info
e
h@ Lic
Use warm water containing normal motorcycle cleaner

401061-01
and a soft sponge.
fo r |
Never apply motorcycle cleaner to a dry vehicle; always

sh fü
rinse the vehicle with water first.

rt
If the vehicle has been used on salted roads, use cold

ta rt
water for cleaning after riding. Warm water enhances

at ie
the corrosive effects of salt.

M ns
h, ze
– After rinsing the motorcycle with a gentle spray of water, allow

it to dry thoroughly.
Li
– Remove the closure of the exhaust system.

t
Warning
or
Danger of accidents Moisture and dirt impair the

hf
brake system.
as
– Brake carefully several times to dry out and remove

ew
dirt from the brake linings and the brake discs.

th
– After cleaning, ride the vehicle a short distance until the

at
engine warms up.

M
Info
The heat produced causes water at inaccessible loca-
tions in the engine and on the brake system to evapo-
rate.
414
CLEANING/PROTECTIVE TREATMENT 29
– After the motorcycle has cooled down, lubricate all moving

parts and pivot points.
– Clean the chain. ( p. 158)
– Treat bare metal (except for brake discs and the exhaust sys-
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 449)
– Treat the painted parts with a mild paint polish.
Perfect finish and high gloss polish for paints ( p. 449)
Info
Do not polish parts that were matte when delivered as
this would strongly impair the material quality.
– Treat the plastic parts and powder-coated parts with a mild
72
cleaning agent and care product.
04
Special cleaner for glossy and matte paint finishes, metal
0
/0
and plastic surfaces ( p. 449)
57
– Oil steering lock and seat lock.
04
Universal oil spray ( p. 449)
0
,0
l.c r:
ai fo
om
29.2 Checks and maintenance steps for winter operation tm ed
ho ns
Info
e
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precau-
h@ Lic
tions against aggressive road salt.

If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water
fo r |
enhances the corrosive effects of salt.

sh fü
rt
–
ta rt
Clean the motorcycle. ( p. 414)

at ie
– Clean the brakes.

M ns
Info
h, ze
After EVERY trip on salted roads, thoroughly clean the

Li
brake calipers and brake linings, after they have cooled

down and without removing them, with cold water and
dry them carefully.
t
or
After riding on salted roads, thoroughly clean the

401060-01
hf
motorcycle with cold water and dry it well.

as
– Treat the engine, the link fork, and all other bare or zinc-plated
ew
parts (except the brake discs) with a wax-based corrosion

inhibitor.
th
at
Info
M
Corrosion inhibitor must not come into contact with

the brake discs. This would severely lower the braking
effect.
– Clean the chain. ( p. 158)

415
30 STORAGE
30.1 Storage
Info
If the motorcycle is not being used for an extended length of time, additional measures are recommended.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements
are necessary, you should do this during the storage period (less workshop overload). This allows you to
avoid long waiting periods when the next season starts.
– When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Fuel additive ( p. 448)
– Refuel.
– Clean the motorcycle. ( p. 414)
– Change the engine oil and the oil filter, clean the oil screens.
72
( p. 377)
–
04
Check the coolant fill level and antifreeze. ( p. 355)
401058-01
– Check tire pressure. ( p. 136)
0
/0
– Remove the 12-V battery. ( p. 180)
57
Guideline
04
Storage temperature of the 0 … 35 °C (32 … 95 °F)
0
12-V battery without direct
,0
l.c r:
sunlight
ai fo
om
– Charge the 12-V battery.
–
tm ed
Store the vehicle in a dry location that is not subject to large
ho ns
fluctuations in temperature.
e
h@ Lic
Info
KTM recommends jacking up the motorcycle.
fo r |

sh fü

rt
ta rt
– Cover the motorcycle with a tarp or cover that is permeable to

at ie
air.
M ns
h, ze
Info
Li
Do not use non-porous materials since they prevent

humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since
t
the engine cannot warm up properly, the water vapor

or
produced during combustion condenses and causes

hf
valves and the exhaust system to rust.

as
ew
th
at
M
416
STORAGE 30
30.2 Preparing for use after storage

– Take the motorcycle off the front lifting gear. ( p. 15)
( p. 19)
– Install the 12-V battery. ( p. 181)
Info
If the 12-V battery was removed, the time and date
must be set.
401059-01
– Perform checks and maintenance measures when preparing for
use.
– Take a test ride.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
417
31 SERVICE SCHEDULE
31.1 Additional information

Any further work that results from the compulsory work or from the recommended work must be ordered sepa-
rately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.
31.2 Required work

every 24 months
every 12 months
every 30,000 km (18,600 mi)
every 15,000 km (9,300 mi)
after 1,000 km (620 mi)
72
Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ●
04
Check the exhaust valve control unit with the KTM diagnostics tool. ● ● ● ●
0
/0
Check that the electrical system is functioning properly. ○ ● ● ● ●
57
Change the engine oil and the oil filter, clean the oil screens. ( p. 377) ○ ● ● ● ●
04
Check the front brake linings. ( p. 189) ○ ● ● ● ●
○ ● ● ● ●
0
Check the brake linings of the rear brake. ( p. 196)
,0
l.c r:
Check the brake discs. ( p. 137) ○ ● ● ● ●
ai fo
om
Check the brake lines for damage and leakage. ○ ● ● ● ●
Change the front brake fluid. ( p. 193)
tm ed ●
ho ns
Change the rear brake fluid. ( p. 201) ●
e
Change hydraulic clutch fluid. ( p. 342) ●

h@ Lic
Check the front brake fluid level. ( p. 192) ○ ● ● ●

Check the rear brake fluid level. ( p. 200) ○ ● ● ●
fo r |
● ● ●
sh fü
Check/correct the fluid level of the hydraulic clutch. ( p. 341)

rt
Check the shock absorber and fork for leaks. Perform service as needed and depending ○ ● ● ● ●
ta rt
on how the vehicle is used.

at ie
M ns
Clean dust boots of the fork legs. ( p. 23) ● ●

Check steering head bearing play. ( p. 36) ○ ● ● ● ●
h, ze
Check tire condition. ( p. 136) ○ ● ● ● ●

Li
Check tire pressure. ( p. 136) ○ ● ● ● ●

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 151) ● ● ● ●
t
or
Check the chain tension. ( p. 150) ○ ● ● ● ●

hf
Measure the wheel bearing play and grease the rear hub. ( p. 168) ●
as
Check that the rear wheel nut (right side) is tightened to the specified torque. ○ ● ● ● ●
Change the spark plugs (air filter removed). ( p. 390) ●
ew
Check the valve clearance (air filter and spark plugs removed). ( p. 368) ●
th
Change the SAS membrane. ( p. 339) ●

at
Check the cables for damage and routing without sharp bends (fuel tank removed). ● ● ● ●
M
Check the coolant level in the compensating tank. ( p. 355) ○ ● ● ● ●

Change the air filter, clean the air filter box. ( p. 112) ● ●
Check the fuel pressure. ( p. 125) ● ● ● ●
Check the headlight setting. ( p. 206) ○ ● ●
418
SERVICE SCHEDULE 31
every 24 months
every 12 months
every 30,000 km (18,600 mi)
every 15,000 km (9,300 mi)
after 1,000 km (620 mi)
Check that the radiator fan is functioning properly. ○ ● ● ● ●
Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ●
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ●
Reset the service display using the KTM diagnostic tool. ○ ● ● ● ●
Make a service entry in KTM Dealer.net. ○ ● ● ● ●
○ One-time interval
● Periodic interval
31.3 Recommended work
72
04
every 48 months
0
every 12 months
/0
every 30,000 km (18,600 mi)
57
every 15,000 km (9,300 mi)
04
after 1,000 km (620 mi)
0
●
,0
Check the frame. ( p. 56)
l.c r:
ai fo
Check the link fork. ( p. 87) ●
om
Check/clean the oil nozzle for clutch lubrication. ( p. 383) tm ed ○ ● ●
Check the fork bearing. ( p. 87) ● ●
ho ns
Check the wheel bearings. ( p. 138) ● ●

e
h@ Lic
Check the shock absorber linkage for play. ● ●

Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth ○ ● ● ● ●
fo r |
operation.
sh fü
Empty the drainage hoses. ○ ● ● ● ●

rt
ta rt
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, ● ● ● ●
at ie
leaks, and incorrect routing.

M ns
Check the antifreeze. ○ ● ● ●

h, ze
Check the tightness of the safety-relevant screws and nuts which are easily accessible. ○ ● ● ● ●
Li
Change the coolant. ( p. 359) ●

○ One-time interval
● Periodic interval
t
or
hf
as
ew
th
at
M
419
420
32.1
M
at
th
32 WIRING DIAGRAM
ew
Page 1 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00365-01
72
WIRING DIAGRAM 32
Components:
A10 MCU
F1 Fuse
F2 Fuse
F8 Fuse
G10 12-V battery
G20 Alternator
K10 Starter relay with main fuse
M10 Electric starter system
T20 Voltage regulator
X270 Connector for accessory ground (terminal 31) ACC 1 (not assigned)
X271 Connector for accessory plus (terminal 30) ACC 1 (not assigned)
72
X291 Connector for accessory ground (terminal 31) ACC 1
04
X292 Connector for accessory plus (terminal 30) ACC 1
0
/0
57
X296 USB charging plug
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
421
422
32.2
M
at
th
32 WIRING DIAGRAM
ew
Page 2 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00366-01
72
WIRING DIAGRAM 32
Components:
A10 MCU
E60 License plate lamp
F3 Fuse
K31 Relay for auxiliary equipmentACC 2
M14 Radiator fan
P36 Brake/tail light
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
72
0 04
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
423
424
32.3
M
at
th
32 WIRING DIAGRAM
ew
Page 3 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00367-01
72
F4
S12
E75
A10
X295
Components:
Fuse
MCU
M
Headlight unit
KTM RACE ON
at
th
Diagnostics connector
ew
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
425
57
/0
0 04
72
WIRING DIAGRAM 32

426
32.4
M
at
th
32 WIRING DIAGRAM
ew
Page 4 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00368-01
72
WIRING DIAGRAM 32
Components:
A10 MCU
A11 Engine electronics control unit
F5 Fuse
K30 Power relay
S31 Emergency OFF switch, electric starter button, hazard warning flasher switch, Race‑on button
S32 Combination switch, left side
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
427
428
32.5
M
at
th
32 WIRING DIAGRAM
ew
Page 5 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00369-01
72
WIRING DIAGRAM 32
Components:
A10 MCU
A50 Alarm system (optional)
B25 Ambient air temperature sensor
B36 Alarm system switch (optional)
B85 Tire pressure sensor (optional)
B86 Lean angle sensor
P10 Combination instrument
72
0 04
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
429
430
32.6
M
at
th
32 WIRING DIAGRAM
ew
Page 6 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00370-01
72
F7
F6
A30
B71
B70
Components:
ABS fuse
ABS fuse
M
ABS control unit
at
th
Rear wheel speed sensor
ew
Front wheel speed sensor
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
431
57
/0
0 04
72
WIRING DIAGRAM 32

432
32.7
M
at
th
32 WIRING DIAGRAM
ew
Page 7 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00371-01
72
WIRING DIAGRAM 32
Components:
A10 MCU
B32 Fuel level sensor
B76 Front brake light switch
B77 Rear brake light switch
E80 Seat heater (optional)
E82 Heated grip (optional)
M13 Fuel pump
P15 Horn
72
0 04
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
433
434
32.8
M
at
th
32 WIRING DIAGRAM
ew
Page 8 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00372-01
72
P10
A41
M78
Components:
M
Connectivity unit
at
th
Combination instrument
ew
Exhaust valve control unit
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
435
57
/0
0 04
72
WIRING DIAGRAM 32

436
32.9
M
at
th
32 WIRING DIAGRAM
ew
Page 9 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00373-01
72
A11
A10
Components:
MCU
M
at
th
ew
Engine electronics control unit
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
437
57
/0
0 04
72
WIRING DIAGRAM 32

438
32.10
M
at
th
32 WIRING DIAGRAM
ew
Page 10 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00374-01
72
WIRING DIAGRAM 32
Components:
B35 Oil pressure sensor
B46 Oil level and temperature sensor
B51 Lambda sensor, cylinder 1
B52 Lambda sensor, cylinder 2
B53 Lambda sensor after catalytic converter
M20 Evaporate emission control valve
M21 Secondary air system valve
72
0 04
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
439
440
32.11
M
at
th
32 WIRING DIAGRAM
ew
Page 11 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00375-01
72
WIRING DIAGRAM 32
Components:
B80 Throttle grip
M60 Throttle valve actuator and throttle valve position sensor
R51/1 Ignition coil 1, cylinder 1
72
0 04
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
441
442
32.12
M
at
th
32 WIRING DIAGRAM
ew
Page 12 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00376-01
72
WIRING DIAGRAM 32
Components:
B13 Ambient air pressure sensor
B21 Coolant temperature sensor, cylinder 1
B27 Shift shaft sensor
B30 Side stand sensor
B34 Gear position sensor
B41 Induction manifold pressure sensor, cylinder 1
B42 Induction manifold pressure sensor, cylinder 2
72
0 04
/0
57
04
0
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
443
444
32.13
M
at
th
32 WIRING DIAGRAM
ew
Page 13 of 13
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
57
/0
0 04
Y00377-01
72
WIRING DIAGRAM 32
Components:
B12 Intake air temperature sensor
B37 Crankshaft speed sensor
B38 Clutch switch
M51/1 Injection valve 1, cylinder 1
Cable colors:
bl Black
br Brown
bu Blue
gn Green
72
gr Gray
04
lbu Light blue
0
or Orange
/0
57
pk Pink
04
pu Violet
rd Red
0
,0
l.c r:
wh White
ai fo
om
ye Yellow
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
445
33 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade
72
and unsuitable antifreeze causes corrosion, deposits and frothing.
04
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec-
0
tion and lubrication properties.
/0
– Only use coolant that complies with the requirements stated (see specifications on the container) and that
57
has the relevant properties.
04
Antifreeze protection to at least −25 °C (−13 °F)
0
,0
l.c r:
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs
ai fo
om
to be diluted.
tm ed
The use of premixed coolant is recommended.
ho ns
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
e
h@ Lic
with other coolants.
fo r |
MOTOREX®
sh fü
– COOLANT M3.0
rt
ta rt
at ie
Engine oil (SAE 10W/50)

M ns
h, ze
– JASO T903 MA2 ( p. 469)

–
Li
SAE ( p. 469) (SAE 10W/50)

Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
t
possess the corresponding properties.

or
Fully synthetic engine oil

hf
as
MOTOREX®
ew
– Power Synt 4T
th
at
M
446
SUBSTANCES 33
Engine oil (SAE 5W/40)

– JASO T903 MA2 ( p. 469)
– SAE ( p. 469) (SAE 5W/40)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
Fully synthetic engine oil
MOTOREX®
– Power Synt 4T
Fork oil (SAE 4) (48601166S1)

72
– SAE ( p. 469) (SAE 4)
04
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
0
/0
the corresponding properties.
57
Shock absorber fluid (SAE 2.5) (50180751S1)
04
0
,0
l.c r:
– SAE ( p. 469) (SAE 2.5)
ai fo
om
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
tm ed
the corresponding properties.
ho ns
e
Super unleaded (ROZ 95)

h@ Lic
– DIN EN 228 (ROZ 95)
fo r |
Guideline
sh fü
– Only use super unleaded fuel that matches or is equivalent to the specified standard.
rt
ta rt
– Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.

at ie
M ns
Info
h, ze
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15,
E25, E85, E100).
Li
t
or
hf
as
ew
th
at
M
447
34 AUXILIARY SUBSTANCES
Chain cleaner
MOTOREX®
– Chain Clean
Fuel additive
MOTOREX®
– Fuel Stabilizer
High viscosity grease

SKF®
– LGHB 2
72
Long-life grease
04
0
MOTOREX®
/0
– Bike Grease 2000
57
04
Lubricant (T14034)
0
,0
l.c r:
WP Performance Systems
ai fo
om
– WP Racing Grease IPR 2
tm ed
Lubricant (T158)
ho ns
e
h@ Lic
Lubcon®
– Turmogrease® PP 300
fo r |
Lubricant (T625)
sh fü
rt
ta rt
Molykote®
at ie
– 33 Medium
M ns
h, ze
Lubricant (T159)
Li
Bel‑Ray®
– MC‑11®
t
or
Motorcycle cleaner
hf
as
MOTOREX®
ew
– Moto Clean
th
at
M
448
AUXILIARY SUBSTANCES 34
Perfect finish and high gloss polish for paints

MOTOREX®
– Moto Shine
Preserving materials for paints, metal and rubber

MOTOREX®
– Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
MOTOREX®
– Quick Cleaner
72
Street chain spray
04
Guideline
0
/0
MOTOREX®
57
– Chainlube Road Strong
0 04
Universal oil spray
,0
l.c r:
ai fo
om
MOTOREX®
– Joker 440 Synthetic tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
449
35 SPECIAL TOOLS
Bleeder cover
Art. no.: 00029013004
H00503-01
Bleeder cover
Art. no.: 00029013023
72
04
0
/0
57
0 04
H02850-01
,0
l.c r:
ai fo
om
Bleeding device
tm ed
Art. no.: 00029013100
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00518-01
M ns
h, ze
EU battery charger XCharge‑professional

Li
Art. no.: 00029095050

Feature
EU safety plug
t
or
Nominal voltage 230 V

hf
Mains fuse 16 A
as
Power cable length 5 m (16 ft)

ew
approx.
Charger cable length 5 m (16 ft)
th
H01065-01
approx.
at
M
450
SPECIAL TOOLS 35
US battery charger XCharge‑professional

Art. no.: 00029095051
Feature
US plug
Mains fuse 32 A
approx.
H01065-01
approx.
UK battery charger XCharge‑professional

Art. no.: 00029095052
72
Feature
UK safety plug
04
0
/0
Mains fuse 16 A
57
04
approx.
0
,0
l.c r:
H01065-01
approx.
ai fo
om
CH battery charger XCharge‑professional
tm ed
ho ns
Art. no.: 00029095053
e
Feature
h@ Lic
CH plug
fo r |
sh fü
Mains fuse 16 A
rt

ta rt
approx.
at ie
M ns

H01065-01
approx.
h, ze
Li
Bearing puller
Art. no.: 15112017000
t
or
hf
as
ew
th
at
M
H00520-01
451
35 SPECIAL TOOLS
Internal bearing puller

Art. no.: 15112018100
Feature
18 … 23 mm (0.71 … 0.91 in)
H00522-01
Syringe
Art. no.: 50329050000
72
04
0
/0
57
0 04
500689-01
,0
l.c r:
ai fo
om
Lock ring plier
tm ed
Art. no.: 51012011000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00572-01
M ns
h, ze
Holding wrench
Li
Art. no.: 51129003000

t
or
hf
as
ew
th
H00575-01
at
M
452
SPECIAL TOOLS 35
Valve spring mounter

Art. no.: 59029019000
H00610-01
Limit plug gauge

Art. no.: 59029026006
Feature
72
Diameter 6.05 mm (0.2382 in)
004
/0
57
0 04
H00612-01
,0
l.c r:
ai fo
om
Feeler gauge
tm ed
Art. no.: 59029041100
ho ns
Feature
e
5 piece 0.10 … 0.25 mm (0.0039 …

h@ Lic
0.0098 in)
fo r |
sh fü
rt
ta rt
at ie
H00616-01
M ns
h, ze
Handle for holding wrench

Li
Art. no.: 60012060000

t
or
hf
as
ew
th
H00951-01
at
M
453
35 SPECIAL TOOLS
Angle disc
Art. no.: 60029010000
Feature
Driver system / tip 1/2 in
H00625-01
Plastigauge clearance gauge

Art. no.: 60029012000
Feature
72
0.025 … 0.175 mm (0.00098 … 0.00689 in)
0 04
/0
57
0 04
H00627-01
,0
l.c r:
ai fo
om
Piston ring compressor
tm ed
Art. no.: 60029015000
ho ns
Feature
e
Height 80 mm (3.15 in)

h@ Lic
Diameter 57 … 125 mm (2.24 … 4.92 in)

fo r |
sh fü
rt
ta rt
at ie
H00628-01
M ns
h, ze
Internal bearing puller

Li
Art. no.: 60029018000

Feature
23 … 28 mm (0.91 … 1.1 in)
t
or
hf
as
ew
th
H00630-01
at
M
454
SPECIAL TOOLS 35
Chain rivet tool

Art. no.: 60029020000
H00631-01
Pressing tool
Art. no.: 60029046128
72
004
/0
57
0 04
H01087-01
,0
l.c r:
ai fo
om
Spring band clamps plier
tm ed
Art. no.: 60029057100
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00651-01
M ns
h, ze
Multi-tooth wrench socket

Li
Art. no.: 60029075000

Feature
Drive 1/2 in
t
or
Diameter 10 mm (0.39 in)

hf
as
ew
th
H00654-01
at
M
455
35 SPECIAL TOOLS
Testing hose
Art. no.: 61029093000
H00659-01
Pressure testing tool

Art. no.: 61029094000
72
04
0
/0
57
0 04
H00660-01
,0
l.c r:
ai fo
om
Front wheel work stand, small
tm ed
Art. no.: 61129965000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H01865-01
M ns
h, ze
Engine work stand

Li
Art. no.: 61229001000

t
or
hf
as
ew
th
H00662-01
at
M
456
SPECIAL TOOLS 35
Pressing tool
Art. no.: 61229008100
H00667-01
Puller
Art. no.: 61229010000
72
0 04
/0
57
04
0
H00668-01
,0
l.c r:
ai fo
om
Pressing tool
tm ed
Art. no.: 61229013000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00669-01
M ns
h, ze
Locking screw
Li
Art. no.: 61229015000

t
or
hf
as
ew
th
H00670-01
at
M
457
35 SPECIAL TOOLS
Pressing tool
Art. no.: 61229016000
H00671-01
Arms for puller

Art. no.: 61229017000
72
04
0
/0
57
0 04
H00672-01
,0
l.c r:
ai fo
om
Pressing tool
tm ed
Art. no.: 61229018000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00673-01
M ns
h, ze
Release device for timing chain tensioner

Li
Art. no.: 61229021000

t
or
hf
as
ew
th
H00675-01
at
M
458
SPECIAL TOOLS 35
Hexagon socket bit

Art. no.: 61229025000
Feature
Hexagon socket 5 mm (0.2 in)
Drive 1/4 in
H00676-01
Mounting tool
Art. no.: 61229035000
72
004
/0
57
0 04
H00678-01
,0
l.c r:
ai fo
om
Pressing tool
tm ed
Art. no.: 61229044000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00679-01
M ns
h, ze
Pressing tool
Li
Art. no.: 61229045000

t
or
hf
as
ew
th
H00680-01
at
M
459
35 SPECIAL TOOLS
Pressing tool
Art. no.: 61329004100
H00685-01
Pressing tool
Art. no.: 61329004200
72
04
0
/0
57
0 04
H00686-01
,0
l.c r:
ai fo
om
Holding wrench
tm ed
Art. no.: 61329085000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H01811-01
M ns
h, ze
Rear wheel work stand for single-sided swing arm

Li
Art. no.: 61329955000

t
or
hf
as
ew
th
H00979-01
at
M
460
SPECIAL TOOLS 35
Engine bracket for engine work stand

Art. no.: 61729002000
500812-01
Work stand
Art. no.: 62529055200
72
0 04
/0
57
04
0
H02865-01
,0
l.c r:
ai fo
om
Puller
tm ed
Art. no.: 75029021000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00707-01
M ns
h, ze
Insertion for piston ring lock

Li
Art. no.: 75029035000

t
or
hf
as
ew
th
H00710-01
at
M
461
35 SPECIAL TOOLS
Spark plug wrench

Art. no.: 75029172000
Feature
Drive 1/2 in
Hexagonal part 14 mm (0.55 in)
Length 85 mm (3.35 in)
H00729-01
Spark plug wrench with link

Art. no.: 77229172000
Feature
72
Drive 3/8 in
04
0
Length 130 mm (5.12 in)
/0
57
0 04
H00761-01
,0
l.c r:
ai fo
om
Oil pressure adapter
tm ed
Art. no.: 77329006000
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00764-01
M ns
h, ze
Puller
Li
Art. no.: 78029033100

t
or
hf
as
ew
th
H00788-01
at
M
462
SPECIAL TOOLS 35
Insert for valve spring lever

Art. no.: 78029060000
H00795-01
Depth micrometer
Art. no.: T107S
72
004
/0
57
0 04
H00842-01
,0
l.c r:
ai fo
om
Drift
Art. no.: T120
tm ed
ho ns
Feature
e

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00844-01
M ns
h, ze
Clamping stand
Li
Art. no.: T1202S

Feature
t
or

hf
as
ew
th
H01149-01
at
M
463
35 SPECIAL TOOLS
Mounting sleeve
Art. no.: T1204
Feature
Diameter 25.5 … 30.5 mm (1.004 … 1.201 in)
H00878-01
Pressing tool
Art. no.: T1206
Feature
72
Diameter 15 … 30 mm (0.59 … 1.18 in)
0 04
/0
57
0 04
H00880-01
,0
l.c r:
ai fo
om
Pressing tool
tm ed
Art. no.: T1207S
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00881-01
M ns
h, ze
Filling adapter
Li
Art. no.: T12128

t
or
hf
as
ew
th
Z00747-10
at
M
464
SPECIAL TOOLS 35
Vacuum pump
Art. no.: T1240S
H00890-01
Filling adapter
Art. no.: T1245S
72
004
/0
57
0 04
Z00731-10
,0
l.c r:
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om
Protecting sleeve
Art. no.: T1401
tm ed
ho ns
Feature
e

h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H00894-01
M ns
h, ze
Clamping stand
Li
Art. no.: T14015S

Feature
t
or
hf
as
ew
th
H01035-01
at
M
465
35 SPECIAL TOOLS
Clamping stand
Art. no.: T14016S
Feature
H01036-01
Ring wrench
Art. no.: T14017
Feature
72
04
0
/0
57
0 04
H00904-01
,0
l.c r:
ai fo
om
Clamping stand
tm ed
Art. no.: T1403S
ho ns
Feature
e

h@ Lic

fo r |
sh fü
rt
ta rt
at ie
H00896-01
M ns
h, ze
Mounting tool
Li
Art. no.: T14040S

Feature
t
or
hf
as
ew
th
H00922-01
at
M
466
SPECIAL TOOLS 35
Spring compressor
Art. no.: T14050S
H00925-01
Mounting tool
Art. no.: T146
72
0 04
/0
57
04
0
H03355-01
,0
l.c r:
ai fo
om
Clamping bush
Art. no.: T147
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
H03390-01
M ns
h, ze
Filling adapter
Li
Art. no.: T1565

t
or
hf
as
ew
th
H02354-01
at
M
467
35 SPECIAL TOOLS
Socket
Art. no.: T17002S
Feature
Pin diameter 3 mm (0.12 in)
H03003-01
Filling tool
Art. no.: T170S1
72
04
0
/0
57
0 04
H00855-01
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
or
hf
as
ew
th
at
M
468
STANDARDS 36
JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2
standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor-
cycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high
performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils
according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
at ie
M ns
h, ze
Li
t
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hf
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ew
th
at
M
469
37 GLOSSARY OF TECHNICAL TERMS
ABS Anti-lock braking system Safety system that prevents locking of the wheels
when driving straight ahead without the influence of
lateral forces
PA Preload adjuster Device on the suspension components that enables
the adjustment of the spring preload
TPMS Tire pressure monitoring system A safety system that monitors the tire pressure with
the assistance of sensors in the tires and displays it to
the rider
72
0 04
/0
57
0 04
,0
l.c r:
ai fo
om
tm ed
ho ns
e
h@ Lic
fo r |
sh fü
rt
ta rt
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M ns
h, ze
Li
t
or
hf
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ew
th
at
M
470
cf.
ca.
no.
i.a.
e.g.
etc.
poss.
Art. no.
circa
M
number
possibly
compare
et cetera
inter alia
for example
at
th
Article number
ew
as
hf
or Li
th, ze
M ns
at ie
ta rt
sh fü
fo r |
rt
h@ Lic
e
ho ns
tm ed
ai fo
l.c r:
om
,0
0 04
471
57
/0
0 04
72
LIST OF ABBREVIATIONS 38

INDEX
Brake fluid level

INDEX
1 front brake, checking . . . . . . . . . . . . . . . . 192

12-V battery rear brake, checking . . . . . . . . . . . . . . . . . 200
charging . . . ... . . . . . . . . . . . . . . . . . . . 183 Brake linings
connecting . ... . . . . . . . . . . . . . . . . . . . 182 front brake, changing . . . . . . . . . . . . . . . . 189
disconnecting .. . . . . . . . . . . . . . . . . . . . 182 front brake, checking . . . . . . . . . . . . . . . . 189
installing . . . ... . . . . . . . . . . . . . . . . . . . 181 of rear brake, changing . . . . . . . . . . . . . . . 197
removing . . . ... . . . . . . . . . . . . . . . . . . . 180 rear brake, checking . . . . . . . . . . . . . . . . . 196
A Brake system
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 195
ACC1
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 C
rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 Camshafts
ACC2 of the front cylinder, disassembling . . . . . . . 373
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 of the front cylinder, installing . . . . . . . . . . 374
rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 of the rear cylinder, disassembling . . . . . . . 372
72
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 of the rear cylinder, installing . . . . . . . . . . . 372
04
Air filter Capacity
0
/0
changing . . . . . . . . . . . . . . . . . . . . . . . . . 112 Coolant . . . . . . . . . . . . . . . . . . 358, 360, 406
57
engine oil . . . . . . . . . . . . . . . . 250, 379, 406
Alternator
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
04
stator winding, checking . . . . . . . . . . . . . . 385
Chain
0
Antifreeze
,0
l.c r:
checking . . . . . . . . . . . . . . . . . . . . . . . . . 151
checking . . . . . . . . . . . . . . . . . . . . . . . . . 355
ai fo
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 158
om
Assembling the engine opening . . . . . . . . . . . . . . . . . . . . . . . . . . 155
alternator cover, installing . . . . . . . . . . . . .
tm ed 323 riveting . . . . . . . . . . . . . . . . . . . . . . . . . . 156
ho ns
balancer shaft, installing . . . . . . . . . . . . . . 321
Chain guide
heat exchanger, installing . . . . . . . . . . . . . 332
e
checking . . . . . . . . . . . . . . . . . . . . . . . . . 151
h@ Lic
ignition top dead center of the front cylinder,

setting . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 151
fo r |
ignition top dead center of the rear cylinder,

checking . . . . . . . . . . . . . . . . . . . . . . . . . 150
sh fü
setting . . . . . . . . . . . . . . . . . . . . . . . . . . 316
locking lever, installing . . . . . . . . . . . . . . . 313
rt
Charging voltage
ta rt
oil drain plug, installing . . . . . . . . . . . . . . . 336 checking . . . . . . . . . . . . . . . . . . . . . . . . . 187

at ie
oil filter, installing . . . . . . . . . . . . . . . . . . 322

M ns
Clutch
oil spray tube, installing . . . . . . . . . . . . . . 309 fluid level, checking/correcting . . . . . . . . . . 341
h, ze
rear valve clearance, adjusting . . . . . . . . . . 333 fluid, changing . . . . . . . . . . . . . . . . . . . . . 342

Li
rear valve clearance, checking . . . . . . . . . . 333

Clutch lever
shift drum locating, installing . . . . . . . . . . . 313
basic position, adjusting . . . . . . . . . . . . . . . 50
starter motor, installing . . . . . . . . . . . . . . . 333
t
water pump wheel, installing . . . . . . . . . . . Combination instrument

or
320
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
hf
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . 11
activation and test . . . . . . . . . . . . . . . . . . 210
as
B Anti Wheelie Mode . . . . . . . . . . . . . . . . . . . 221

Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
ew
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . 137 Bluetooth . . . . . . . . . . . . . . . . . . . . . . . . . 224
th
of front brake, changing . . . . . . . . . . . . . . 142 Button Illumination . . . . . . . . . . . . . . . . . . . 226

at
of the rear brake, changing . . . . . . . . . . . . 148 C1 and C2 buttons . . . . . . . . . . . . . . . . . . 224

M
Consumption . . . . . . . . . . . . . . . . . . . . . . . 230
Brake fluid
day-night mode . . . . . . . . . . . . . . . . . . . . 211
front brake, adding . . . . . . . . . . . . . . . . . . 192
Daytime Runn. Light . . . . . . . . . . . . . . . . . . 226
front brake, changing . . . . . . . . . . . . . . . . 193
Display Theme . . . . . . . . . . . . . . . . . . . . . . 225
of rear brake, adding . . . . . . . . . . . . . . . . . 200
Distance . . . . . . . . . . . . . . . . . . . . . . . . . 229
of rear brake, changing . . . . . . . . . . . . . . . 201
472
INDEX
Extra Functions . . . . . . . . . . . . . . . . . .... 219 Cooling system

FAVORITES widget . . . . . . . . . . . . . . .... 233 bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 357
General Info . . . . . . . . . . . . . . . . . . . .... 218 Cruise control system
Headset Type . . . . . . . . . . . . . . . . . . .... 225 programming . . . . . . . . . . . . . . . . . . . . . . 228
Heated Grips (optional) . . . . . . . . . . . . 222, 230
Heated Seat (optional) . . . . . . . . . . . . 222, 231 D
HEATING widget . . . . . . . . . . . . . . . .... 234 Date
KTM MY RIDE widget . . . . . . . . . . . . .... 232 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 227
KTM MY RIDE . . . . . . . . . . . . . . . . . . .... 212 Diagnostics connector . . . . . . . . . . . . . . . . . . . 408
Language . . . . . . . . . . . . . . . . . . . . . .... 230
Disassembling the engine
large widget . . . . . . . . . . . . . . . . . . . .... 231
alternator cover, removing . . . . . . . . . . . . . 261
Launch Control . . . . . . . . . . . . . . . . . .... 221
balancer shaft, removing . . . . . . . . . . . . . . 264
menu . . . . . . . . . . . . . . . . . . . . . . . .... 212
clutch basket, removing . . . . . . . . . . . . . . . 267
Motorcycle . . . . . . . . . . . . . . . . . . . . .... 222
engine oil, draining . . . . . . . . . . . . . . . . . . 254
MTC+MSR (optional) . . . . . . . . . . . . . .... 223
heat exchanger, removing . . . . . . . . . . . . . 256
MUSIC widget . . . . . . . . . . . . . . . . . .... 234
72
navigation . . . . . . . . . . . . . . . . . . . . .... 213
setting . . . . . . . . . . . . . . . . . . . . . . . . . . 259
04
navigation information . . . . . . . . . . . . .... 214
left suction pump, removing . . . . . . . . . . . . 264
0
NAVIGATION widget . . . . . . . . . . . . . .... 232
/0
locking lever, removing . . . . . . . . . . . . . . . 270
overview . . . . . . . . . . . . . . . . . . . . . .... 210
57
middle suction pump, removing . . . . . . . . . 271
Pairing . . . . . . . . . . . . . . . . . . . . . . .... 215
oil filter, removing . . . . . . . . . . . . . . . . . . 263
04
Pressure . . . . . . . . . . . . . . . . . . . . . .... 229
oil spray tube, removing . . . . . . . . . . . . . . 273
0
Quickshifter + (optional) . . . . . . . . . . . .... 223
rear cylinder head, removing . . . . . . . . . . . 258
,0
l.c r:
Ride Mode . . . . . . . . . . . . . . . . . . . . .... 219
rear piston, removing . . . . . . . . . . . . . . . . 258
ai fo
om
Service . . . . . . . . . . . . . . . . . . . . . . .... 219
rear timing chain tensioner, removing . . . . . 257
Settings . . . . . . . . . . . . . . . . . . . . . . .... 224 tm ed
shift drum locating, removing . . . . . . . . . . . 270
small widget . . . . . . . . . . . . . . . . . . .... 231
ho ns
starter motor, removing . . . . . . . . . . . . . . . 256
telephony . . . . . . . . . . . . . . . . . . . . .... 216
transmission shaft, removing . . . . . . . . . . . 272
e
Temperature . . . . . . . . . . . . . . . . . . . .... 229

h@ Lic
water pump wheel, removing . . . . . . . . . . . 265

Throttle Response . . . . . . . . . . . . . . . .... 220
TPMS . . . . . . . . . . . . . . . . . . . . . . . .... 218 Drivetrain kit
fo r |
Track . . . . . . . . . . . . . . . . . . . . . . . .... 220 changing . . . . . . . . . . . . . . . . . . . . . . . . . 156

sh fü
Trip 1 . . . . . . . . . . . . . . . . . . . . . . . .... 217 E

rt
ta rt
Trip 2 . . . . . . . . . . . . . . . . . . . . . . . .... 217

Engine
at ie
Units . . . . . . . . . . . . . . . . . . . . . . . . .... 228

M ns
volume . . . . . . . . . . . . . . . . . . . . . . .... 214

setting . . . . . . . . . . . . . . . . . . . . . . . . . . 252
h, ze
warnings . . . . . . . . . . . . . . . . . . . . . 211, 219

widget INFO . . . . . . . . . . . . . . . . . . .... 233
Li
setting . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Combination switch installation, preparing for . . . . . . . . . . . . . . 251
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 54 installing . . . . . . . . . . . . . . . . . . . . . . . . . 242
t
preparing for clamping in the engine assembly

or
Compression adjuster
assembling . . . . . . . . . . . . . . . . . . . . . . . . 74 stand . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
hf
disassembling . . . . . . . . . . . . . . . . . . . . . . 68 removing . . . . . . . . . . . . . . . . . . . . . . . . . 235

as
Coolant Engine - Work on individual parts

ew
changing . . . . . . . . . . . . . . . . . . . . . . . . . 359 left main bearing, removing . . . . . . . . . . . . 280

draining . . . . . . . . . . . . . . . . . . . . . . . . . 356 main bearing shells, selecting . . . . . . . . . . 276
th
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 357 main bearing, right, removing . . . . . . . . . . . 275

at
main shaft, disassembling . . . . . . . . . . . . . 302

M
Coolant level
piston ring end gap, checking . . . . . . . . . . . 288
checking . . . . . . . . . . . . . . . . . . . . . . . . . 355
piston, checking/measuring . . . . . . . . . . . . 286
compensating tank, checking . . . . . . . . . . . 355
piston/cylinder mounting clearance, checking 288
correcting in the compensating tank . . . . . . 361
radial clearance of the bottom connecting rod
bearing, checking . . . . . . . . . . . . . . . . . . . 285
473
INDEX
shift mechanism, checking . . . . . . . . . . . . 299 left engine case, installing . . . . . . . . . . . . . 311

timing chain tensioner for installation, prepar- left suction pump, installing . . . . . . . . . . . 315
ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 magnet holder, installing . . . . . . . . . . . . . . 301
transmission, checking . . . . . . . . . . . . . . . 304 middle suction pump, installing . . . . . . . . . 310
Engine – work on the individual parts oil filler neck, installing . . . . . . . . . . . . . . . 335
crankshaft, support bearing, changing . . . . . 284 primary gear wheel, installing . . . . . . . . . . . 316
rear camshafts, installing . . . . . . . . . . . . . . 327
Engine - working on the individual parts
rear cylinder head, installing . . . . . . . . . . . 326
electric starter drive, checking . . . . . . . . . . 307
rear piston, assembling . . . . . . . . . . . . . . . 324
left main bearing, installing . . . . . . . . . . . . 280
rear resonator, installing . . . . . . . . . . . . . . 336
right main bearing, installing . . . . . . . . . . . 276
rear timing chain tensioner, installing . . . . . 327
timing assembly, checking . . . . . . . . . . . . . 295
rear valve cover, installing . . . . . . . . . . . . . 336
Engine – working on the individual parts rotor, installing . . . . . . . . . . . . . . . . . . . . . 322
checking the cylinder head . . . . . . . . .... 293 shift shaft sensor, installing . . . . . . . . . . . . 319
clutch cover . . . . . . . . . . . . . . . . . . . .... 283 shift shaft, installing . . . . . . . . . . . . . . . . . 313
clutch, checking . . . . . . . . . . . . . . . . 298, 343 timing chain rails of the left section of the
72
conrod bearing . . . . . . . . . . . . . . . . . .... 281 engine case, installing . . . . . . . . . . . . . . . . 308
04
countershaft, assembling . . . . . . . . . . .... 306 timing chain rails of the right section of the
countershaft, disassembling . . . . . . . . .... 303
0
engine case, installing . . . . . . . . . . . . . . . . 309
/0
cylinder head . . . . . . . . . . . . . . . . . . .... 289 torque limiter and intermediate gear, installing 323
57
cylinder, checking/measuring . . . . . . . .... 286 transmission shafts, installing . . . . . . . . . . 309
04
freewheel, checking . . . . . . . . . . . . . .... 308
Engine disassembly
intermediate gear, right . . . . . . . . . . . .... 294
0
clutch cover, removing . . . . . . . . . . . . . . . 266
,0
lubrication system, checking . . . . . . . .... 297
l.c r:
crankshaft speed sensor, removing . . . . . . . 261
ai fo
main shaft axial play, measuring . . . . . .... 307
om
crankshaft, removing . . . . . . . . . . . . . . . . . 271
main shaft, assembling . . . . . . . . . . .
tm ed .... 305
drive gear wheel of the balancer shaft,
oil pressure control valve, checking . . . .... 296
removing . . . . . . . . . . . . . . . . . . . . . . . . . 264
ho ns
section of the engine case, left . . . . . . .... 277
engine bearer, removing . . . . . . . . . . . . . . 253
e
section of the engine case, right . . . . . .... 273

engine, clamping into the engine work stand 253
h@ Lic
shift shaft, preassembling . . . . . . . . . .... 301

force pump, removing . . . . . . . . . . . . . . . . 269
Engine assembly front camshafts, removing . . . . . . . . . . . . . 259
fo r |
clutch basket, installing . . . . . . . . . . . . . . 317 front cylinder head, removing . . . . . . . . . . . 260

sh fü
clutch cover, installing . . . . . . . . . . . . . . . 319 front piston, removing . . . . . . . . . . . . . . . . 260

rt
ta rt
clutch discs, installing . . . . . . . . . . . . . . . 317 front resonator, removing . . . . . . . . . . . . . . 254

at ie
crankshaft speed sensor, installing . . . . . . . 323 front timing chain tensioner, removing . . . . . 259
M ns
crankshaft, installing . . . . . . . . . . . . . . . . . 311 front valve cover, removing . . . . . . . . . . . . . 255

h, ze
drive gear wheel of the balancer shaft, gear position sensor, removing . . . . . . . . . . 264
installing . . . . . . . . . . . . . . . . . . . . . . . . . 320
Li

engine bearer, mounting . . . . . . . . . . . . . . 337 setting the engine . . . . . . . . . . . . . . . . . . . 255
engine, removing from the engine work stand 338 intermediate gear and timing chain on the left,
force pump, installing . . . . . . . . . . . . . . . . 314
t
removing . . . . . . . . . . . . . . . . . . . . . . . . . 263
or
front camshafts, installing . . . . . . . . . . . . . 331 intermediate gear and timing chain on the
hf
front cylinder head, installing . . . . . . . . . . . 330 right, removing . . . . . . . . . . . . . . . . . . . . . 268

as
front piston, installing . . . . . . . . . . . . . . . . 328 left engine case, removing . . . . . . . . . . . . . 270

front resonator, installing . . . . . . . . . . . . . . 337 oil filler neck, removing . . . . . . . . . . . . . . . 256
ew
front timing chain tensioner, installing . . . . . 332 primary gear wheel, removing . . . . . . . . . . . 268
th
front valve clearance, adjusting . . . . . . . . . 334 rear camshafts, removing . . . . . . . . . . . . . . 257

at
front valve clearance, checking . . . . . . . . . . 334 rear resonator, removing . . . . . . . . . . . . . . 254

M
front valve cover, installing . . . . . . . . . . . . 335 removing magnetic holder . . . . . . . . . . . . . 301

gear position sensor, installing . . . . . . . . . . 320 removing the clutch discs . . . . . . . . . . . . . 267
intermediate gear and the timing chain on the Removing the rear valve cover . . . . . . . . . . 255
right, installing . . . . . . . . . . . . . . . . . . . . . 316 rotor, removing . . . . . . . . . . . . . . . . . . . . . 262
intermediate gear and timing chain on left, shift shaft sensor, removing . . . . . . . . . . . . 266
installing . . . . . . . . . . . . . . . . . . . . . . . . . 321
474
INDEX
shift shaft, removing . . . . . . . . . . . . . . . . . 269 Fuel filter

timing chain rails of the left section of the changing . . . . . . . . . . . . . . . . . . . . . . . . . 128
engine case, removing . . . . . . . . . . . . . . . . 273 Fuel pressure
timing chain rails of the right section of the checking . . . . . . . . . . . . . . . . . . . . . . . . . 125
engine case, removing . . . . . . . . . . . . . . . . 273
Fuel pump
torque limiter and intermediate gear, removing 262
changing . . . . . . . . . . . . . . . . . . . . . . . . . 127
Engine electronics control unit
Fuel tank
resetting . . . . . . . . . . . . . . . . . . . . . . . . . 399
installing . . . . . . . . . . . . . . . . . . . . . . . . . 123
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 13 removing . . . . . . . . . . . . . . . . . . . . . . . . . 121
Engine oil Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . 11
adding . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Fuses
changing . . . . . . . . . . . . . . . . . . . . . . . . . 377
in fuse box, changing . . . . . . . . . . . . . . . . 186
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . 377 G
Engine sprocket Gear position sensor
72
checking . . . . . . . . . . . . . . . . . . . . . . . . . 151 changing . . . . . . . . . . . . . . . . . . . . . . . . . 349
04
programming . . . . . . . . . . . . . . . . . . . . . . 352
Exhaust valve actuator
0
installing . . . . . . . . . . . . . . . . . . . . . . . . . 106 H
/0
57
removing . . . . . . . . . . . . . . . . . . . . . . . . . 104 Hand brake lever
04
F basic position, adjusting . . . . . . . . . . . . . . 196
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
0
Handlebar position
,0
l.c r:
Foot brake lever adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ai fo
om
basic position, adjusting . . . . . . . . . . . . . . 203 Headlight
setting the step plate . . . . . . . . . . . . . . . . 203 tm ed range, adjusting . . . . . . . . . . . . . . . . . . . . 207
ho ns
Fork Headlight setting
compression damping, adjusting . . . . . . . . . . 22 checking . . . . . . . . . . . . . . . . . . . . . . . . . 206
e
h@ Lic
rebound, adjusting . . . . . . . . . . . . . . . . . . . 22
I
Fork bearing
Ignition key
fo r |
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 87
programming . . . . . . . . . . . . . . . . . . . . . . 205
sh fü
Fork legs
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . 11
rt
ta rt
assembling . . . . . . . . . . . . . . . . . . . . . . . . 32
at ie
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Initialization run

M ns
disassembling . . . . . . . . . . . . . . . . . . . . . . 27 performing . . . . . . . . . . . . . . . . . . . . . . . . 399

h, ze
dust boots, cleaning . . . . . . . . . . . . . . . . . . 23 K

fork, servicing . . . . . . . . . . . . . . . . . . . . . . 27
Li
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 24
L
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Link fork
t
Fork part number . . . . . . . . . . . . . . . . . . . . . . . 13

or
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Frame
hf
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 90
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 56
as
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Front fender
Link fork bearing
ew
installing . . . . . . . . . . . . . . . . . . . . . . . . . 135
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 93
removing . . . . . . . . . . . . . . . . . . . . . . . . . 135
th
Lower part of the air filter box

at
Front rider’s seat

installing . . . . . . . . . . . . . . . . . . . . . . . . . 115
M
mounting . . . . . . . . . . . . . . . . . . . . . . . . 118
removing . . . . . . . . . . . . . . . . . . . . . . . . . 114
removing . . . . . . . . . . . . . . . . . . . . . . . . . 118
Lower triple clamp
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 42
installing . . . . . . . . . . . . . . . . . . . . . . . . . 140
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 38
removing . . . . . . . . . . . . . . . . . . . . . . . . . 140
475
INDEX
M Rear hub shock absorbers of the rear sprocket carrier

checking . . . . . . . . . . . . . . . . . . . . . . . . . 159
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . 185 Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . 151
Main silencer
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Rear sprocket carrier
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 97 installing . . . . . . . . . . . . . . . . . . . . . . . . . 154
removing . . . . . . . . . . . . . . . . . . . . . . . . . 153
Manifold
installing . . . . . . . . . . . . . . . . . . . . . . . . . 103 Rear wheel
removing . . . . . . . . . . . . . . . . . . . . . . . . . 101 installing . . . . . . . . . . . . . . . . . . . . . . 145-146
removing . . . . . . . . . . . . . . . . . . . . . 144, 146
Manufacturer warranty . . . . . . . . . . . . . . . . . . . . 11
Rear wheel bearing clearance
Motorcycle
measuring . . . . . . . . . . . . . . . . . . . . . . . . 164
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 414
lifting with front lifting gear . . . . . . . . . . . . . 15 Rear wheel nut (right side)
lifting with rear lifting gear . . . . . . . . . . . . . . 18 torque, checking . . . . . . . . . . . . . . . . . . . 147
72
raising with work stand (inserted) . . . . . . . . . 17 S
raising with work stand (screw-in type) . . . . . . 15
04
SAS membranes
removing from the work stand (inserted) . . . . 18
0
changing . . . . . . . . . . . . . . . . . . . . . . . . . 339
/0
removing from the work stand (screw-in type) . 16
Service schedule . . . . . . . . . . . . . . . . . . . 418-419
57
removing the rear from the lifting gear . . . . . . 19
taking off front lifting gear . . . . . . . . . . . . . . 15 Servicing the fork . . . . . . . . . . . . . . . . . . . . . . . 27
04
Servicing the shock absorber . . . . . . . . . . . . . . . 62
O
0
Shift lever
,0
l.c r:
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
basic position, adjusting . . . . . . . . . . . . . . 349
ai fo
om
Oil filter
tm ed Shift shaft sensor
changing . . . . . . . . . . . . . . . . . . . . . . . . . 377
changing . . . . . . . . . . . . . . . . . . . . . . . . . 352
ho ns
Oil nozzle for clutch lubrication programming . . . . . . . . . . . . . . . . . . . . . . 354
checking/cleaning . . . . . . . . . . . . . . . . . . . 383
e
Shock absorber
h@ Lic
installing . . . . . . . . . . . . . . . . . . . . . . . . . 383
assembling the seal ring retainer . . . . . . . . . . 73
removing . . . . . . . . . . . . . . . . . . . . . . . . . 382
bleeding and filling . . . . . . . . . . . . . . . . . . . 81
fo r |
Oil pressure damper, assembling . . . . . . . . . . . . . . . . . . 78

sh fü
checking . . . . . . . . . . . . . . . . . . . . . . . . . 381 damper, checking . . . . . . . . . . . . . . . . . . . . 70

rt
ta rt
Oil screens damper, disassembling . . . . . . . . . . . . . . . . 64

at ie
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 377 damper, filling with nitrogen . . . . . . . . . . . . 85

M ns
P disassembling the seal ring retainer . . . . . . . 69

h, ze
heim joint, changing . . . . . . . . . . . . . . . . . . 72

Passenger seat high-speed compression damping, adjusting . . 57
Li
mounting . . . . . . . . . . . . . . . . . . . . . . . . 119 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60

removing . . . . . . . . . . . . . . . . . . . . . . . . . 118 low-speed compression damping, adjusting . . 57
Preparing for use piston rod, assembling . . . . . . . . . . . . . . . . 77
t
or
after storage . . . . . . . . . . . . . . . . . . . . . . 417 piston rod, disassembling . . . . . . . . . . . . . . 65

hf
Presilencer rebound adjuster, assembling . . . . . . . . . . . . 76

as
installing . . . . . . . . . . . . . . . . . . . . . . . . . 100 rebound adjuster, disassembling . . . . . . . . . . 67

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 98 rebound damping, adjusting . . . . . . . . . . . . . 58
ew
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 59
R
th
shock absorber, servicing . . . . . . . . . . . . . . . 62

at
RACE-ON key spring preload, adjusting . . . . . . . . . . . . . . . 59

M
RACE-ON key battery, changing . . . . . . . . . 188 spring, installing . . . . . . . . . . . . . . . . . . . . 86

Rear hub spring, removing . . . . . . . . . . . . . . . . . . . . . 63
installing . . . . . . . . . . . . . . . . . . . . . . . . . 162 Shock absorber article number . . . . . . . . . . . . . . 13
removing . . . . . . . . . . . . . . . . . . . . . . . . . 161 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
476
INDEX
Spark plugs Tire pressure sensor

changing . . . . . . . . . . . . . . . . . . . . . 387, 390 programming . . . . . . . . . . . . . . . . . . . . . . 139
Spoiler tire pressure sensor, changing . . . . . . . . . . 138
installing . . . . . . . . . . . . . . . . . . . . . . . . . 120 Turn signal bulb
removing . . . . . . . . . . . . . . . . . . . . . . . . . 119 changing . . . . . . . . . . . . . . . . . . . . . . . . . 207
Spring Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 31 U
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Upper part of the air filter box
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
installing . . . . . . . . . . . . . . . . . . . . . . . . . 113
for checking the function . . . . . . . . . . . . . . . 20
removing . . . . . . . . . . . . . . . . . . . . . . . . . 112
Steering damper
V
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering damper article number . . . . . . . . . . . . . . 14 Valve clearance
checking . . . . . . . . . . . . . . . . . . . . . . . . . 363
Steering head bearing
checking (air filter and spark plugs removed) 368
72
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 48
of the front cylinder, setting . . . . . . . . . . . . 371
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 38
04
of the rear cylinder, setting . . . . . . . . . . . . 371
Steering head bearing play
0
Vehicle identification number . . . . . . . . . . . . . . . 12
/0
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 37
57
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 36 W
04
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . 208 Wheel bearing
checking . . . . . . . . . . . . . . . . . . . . . . . . . 138
0
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
,0
l.c r:
measuring the wheel bearing play and greasing
T
ai fo
om
the rear hub . . . . . . . . . . . . . . . . . . . . . . . 168
Technical data tm edof the front wheel, changing . . . . . . . . . . . . 142
capacities . . . . . . . . . . . . . . . . . . . . . . . . 406 of the rear wheel, changing . . . . . . . . . . . . 176
ho ns
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 407 rear wheel, greasing . . . . . . . . . . . . . . . . . 167
e
chassis tightening torques . . . . . . . . . . . . . 410

Wheel speed sensor distance
h@ Lic
electrical system . . . . . . . . . . . . . . . . . . . 407

checking . . . . . . . . . . . . . . . . . . . . . . . . . 204
engine . . . . . . . . . . . . . . . . . . . . . . . . . . 401
fo r |
engine – tolerance, wear limits . . . . . . . . . . 402 Winter operation

sh fü
engine tightening torques . . . . . . . . . . . . . 404 checks and maintenance steps . . . . . . . . . . 415

rt
Wiring diagram .. ................. 420-445

ta rt
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
at ie
shock absorber . . . . . . . . . . . . . . . . . . . . . 409 Page 01 of 13 ................. . . . . 420

M ns
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Page 02 of 13 ................. . . . . 422

Page 03 of 13 ................. . . . . 424
h, ze
Throttle cable tension of the exhaust flap control

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 110 Page 04 of 13 ................. . . . . 426
Li
checking . . . . . . . . . . . . . . . . . . . . . . . . . 109 Page 05 of 13 ................. . . . . 428

Page 06 of 13 ................. . . . . 430
Throttle cables, exhaust valve controller
Page 07 of 13 ................. . . . . 432
t
changing . . . . . . . . . . . . . . . . . . . . . . . . . 108
or
Page 08 of 13 ................. . . . . 434

Throttle grip
hf
Page 09 of 13 ................. . . . . 436

changing . . . . . . . . . . . . . . . . . . . . . . . . . . 51
as
Page 10 of 13 ................. . . . . 438

Throttle valve body Page 11 of 13 ................. . . . . 440
ew
installing . . . . . . . . . . . . . . . . . . . . . . . . . 397 Page 12 of 13 ................. . . . . 442

removing . . . . . . . . . . . . . . . . . . . . . . . . . 396 Page 13 of 13 ................. . . . . 444
th
at
Time Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

M
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 227
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . 136
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . 136
477
*3206404en*
3206404en
07/2020
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KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM
http://www.ktm.com

Manuale Officina Superduke 3.0

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Manuale Officina Superduke 3.0

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Matthew ashforth, Mattashforth@hotmail.com,

© 2020 KTM Sportmotorcycle GmbH, Mattighofen Austria

This document is valid for the following models:

1290 Super Duke R JP (F9986T2)

1290 Super Duke R US (F9975T2, F9975T9)

Matthew ashforth, Mattashforth@hotmail.com,

6.6 Servicing the fork............................. 27

1 MEANS OF REPRESENTATION ...................... 9

lifting gear ...................................... 15 9.1 Adjusting the low-speed

lifting gear ...................................... 15 absorber.......................................... 57

stand (screw-in type) ........................ 15 compression damping of the shock

5.4 Removing the motorcycle from the absorber.......................................... 57

work stand (screw-in type) ................ 16

9.3 Adjusting the rebound damping of

stand (inserted) ............................... 17 9.4 Adjusting the spring preload of the

work stand (inserted)........................ 18 9.5 Removing the shock absorber ............ 59

from the lifting gear ......................... 19

9.9 Disassembling the damper ................ 64

function .......................................... 20 adjuster .......................................... 67

6 FORK, TRIPLE CLAMP ................................ 22 9.12 Disassembling the compression

of the fork ....................................... 22 retainer ........................................... 69

9.14 Checking the damper ....................... 70

6.5 Installing the fork legs ...................... 24

14.8.7 Checking the chain tension......... 150

air filter box................................... 112 14.8.10 Removing the rear sprocket

11.3 Installing the upper part of the air

filter box ....................................... 113 14.8.11 Installing the rear sprocket

11.4 Removing the air filter box .............. 114

filter box ....................................... 115 14.8.13 Riveting the chain...................... 156

14.8.14 Changing the drivetrain kit.......... 156

shock absorbers of the rear

12.2 Mounting the front rider's seat......... 118

12.3 Removing the passenger seat .......... 118

14.8.20 Greasing rear wheel bearing ........ 167

14.8.21 Measuring the wheel bearing

play and greasing the rear hub .... 168

foot brake lever.............................. 203 18.5.35 Programming the cruise control

16.15 Checking the wheel speed sensor system ...................................... 228

18.5.36 Units ........................................ 228

17 LIGHTING SYSTEM, INSTRUMENTS .......... 205 18.5.37 Distance ................................... 229

(US) ............................................. 207

18.5.43 Heated Seat (optional) ............... 231

18.5.44 Small widget ............................. 231

18.5.45 Large widget.............................. 231

18 COMBINATION INSTRUMENT ................... 210 18.5.47 NAVIGATION widget .................. 232

18.1 Combination instrument ................. 210

18.2 Activation and test ......................... 210

18.3 Day-night mode ............................. 211

19.2 Installing the engine....................... 242

19.7.16 Setting the engine to ignition

tensioner................................... 259 bearing ..................................... 275

19.7.18 Removing the front camshafts..... 259

19.7.19 Removing the front cylinder shells ....................................... 276

head......................................... 260 19.8.4 Installing the right main

19.7.20 Removing the front piston........... 260 bearing ..................................... 276

19.7.22 Removing the crankshaft speed

the intermediate gear ................. 262

19.7.27 Removing the balancer shaft....... 264

of the balancer shaft .................. 264 19.8.12 Checking/measuring the

cylinder .................................... 286

mounting clearance.................... 288

case ......................................... 308 head......................................... 330