REPAIR MANUAL 2019 790 Adventure Art, no. 3206372enRead this repair manual carefully and thoroughly before beginning work. The vehicle will only be able to meet the demands placed on it ifthe specified service work is performed regularly ‘and properly. This repair manval was written to cortespond tothe latest state of this model series. We reserve the right to make changes inthe interest of technical advancement without updating this repair manual atthe same time. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. Iti assumed that the repair work will be performed by a fully trained mechanic Al 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 natice and without specifying reasons, to adapt these to local congitions, as well as to stop produc- tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig- Lures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply. © 2019 KTM Sportmotorcycle GmbH, Mattighoten Austria All nghts reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner, TW Uefined int Ue ISO 9001 internalivnal qualily iaragennent standard. Issued by: TUV Management Service This document is valid for the following models: 790 Adventure EU (F9603S1, F9603S2) 790 Adventure US (F9675S1, F9675S2) {NMA 2206372en 02/2019MEANS OF REPRESENTATION... LL SyMbOIS USE sannsnnnesnnesns 1.2 Formats used. SAFETY ADVICI 24 IMPORTANT NOTES. Repair Manual wsneserne Safety advice.... gat Dogrcos of risk and symbols. Work rues.. 3.1 Manufacturer and implied warranty... 10 3.2 Fuel, auxiliary substances nnrninsee 10 3.3 Spare parts, accessories 3.4 Figures ‘SERIAL NUMBERS... .u 4.1 Vehicle identification number. u 4.2 Type labsl 4.3 Key number 4.4 Engine number.. 4.5 Fork part number 4.6 Shock absorber article number... 4.7 Steering damper article number... MOTORCYCLE... 14 5.1 Lifting the motorcycle with the tront liting gear od 5.2 Taking the motoreyce of the front lifting gear sve V4 5.3 Raising the motoreycle with rear lifting gear 15 5.4 Removing the rear of the motel from the lifting gear. we 15 5.5 Raising the motoreyle atthe rea using the work stand 16 5.6 Removing the motorcycle from the work stand at the 1€2Fccnenniie 16 5.7 Reiing the matoreyele at the front Using the work $tand .avrnnnnnnnee 17 5.8 Removing the motorcycle from the Work stand at the front nnnnnnne 18 5.9 Starting the vehicle... 18 5.10 Starting the motoreyele to check the Function svn 19 FORK, TRIPLE CLAMP... a 21 61 62 63 64 65 66 67 Cleaning the dust boots of the fork legs Removing the fork legs. Installing the fork legs. Servicing the fork.. Disassembling the fork legs. Removing the spring... Checking the fork legs. 10 rt Installing the spring. 6.9 Assembling the fork legs.. 5.10 Checking the steering heed bearing, play... 6.11 Adjusting the steering head bearing play 6.12 Lubricating the steering head bearing, . sens 36 6.13 Removing the loner triple lamp... 36 6.14 Installing the lower triple clamp... 37 6.15 Changing the steering head bearing... 42 6.16 Changing the steering damper nnn. 43 HANDLEBAR, CONTROLS.. aa ‘Adjusting the basic position of the CLULCH IOVEr enmetenminneemnnee A 7.2 Checking the free travel of the clutch lever. 7.3. Setting the free travel of the clutch lever: 45 7.4 — Adjusting the handlebar position ...... 45 7.5. Changing the throttle grip. 46 FRAME &.1 Checking the frame. 49 SHOCK ABSORBER, LINK FORK. 60 9.1 Adjusting the spring preload of the shock absorber 50 9.2 Checking the heim joint for play...... 50 9.3. Removing the shack absorber 51 9.4 Installing the shock absorber........ 52 9.5. Changing the heim joint. 54 9.6 Removing the spring. 56 9.7 Installing the spring .. 56 9.8 Removing the heim joint. 58. 9.9. Installing the heim join 59 9.10 Checking the link fork 89 9.11 Checking the fork bearing for play .... 60 9.12 Removing the link ork, =) 9.13 Changing the link fork beating wnnme- 62 9.14 Installing the link fork EXHAUST SYSTEM .. 10.1 _ Removing the main silencer... 10.2 Installing the main silencer. 10.3 Removing the exhaust system, 10.4 Installing the exhaust eyatem AIR FILTER .. 111 Removing the air ier, 11.2 Installing the air iter. 11.3 Changing te ai iter, cleaning the air tilter box.12 FUEL TANK, SEAT, TRIM 13 4 12.1 Opening the fuel tank filler cap... 12.2 Closing the fuel tank filler cap. 12.3 Removing the passenger seat ...nnuu 83 12.4 Mounting the passenger seat 83 12.5 Removing the front rider's seat ...e. 83 12.6 Mounting the front rider's seat. 12.7 Removing the fucl tonk. 12.8 Installing the fuel tank 12,9 Checking the fuel pressure... 412.10. Changing the tue! level sensor 12.11 Changing the fuel pump 12,12 Changing the fue! filter... 12.13. RefUeling een MASK, FENDER, DECAL.. 101 13.1 Removing the left side Cover .arnnee LOL 13.2 _ Installing the lett side cove 101 13.3 Removing the right side cover nance LOL 13.4 Installing the right side cover ree 102 13.5 Removing the battery cover. 102 13.6 Installing the battery COVE cee. 103 13.7 Removing left fuel tank spoiler..nc. 103 13.8 Installing the left fuel tank spoiler... 104 13.9 Removing right fuel tank spoiler... 105 13.10 Installing the right fuel tank spoiler 106 13.11 Removing left fuel tank COVE onus LOT 13.12 Installing the left fuel tank cover..... 108 13.13. Removing right fuel tank cover....... 108 13.14 Installing the right fuel tank cover... 109, 13.15. Removing engine guard . 109 15.16 Installing Ue engi yuatd 110 13.17, Removing the front fender 11 13.18. Installing the front fender.. M1 13.19 Removing the windshiel4.. U2 13.20. Installing the windshield. 12 WHEELS 1s 14,1 Checking tire pressure... 113 14.2 Checking the tire condition ua 14.3 Checking the rim run-out. 14 14.4 Checking the whee bearing for lay er soe IS 14,5 Tubeless tire system: 116 14.6 Checking spoke tension.. 6 14.7 Checking brake discs... 17 14.8 Programming the tire pressure ‘sensor (Option: With TPMS) uz 14,9 Front whee! 18 14.9.1 Removing the front wheel wavs LLB 14.9.2 Installing the front wheel cece 119 14.9.3 Changing the front whee! bearing. 120 15 16 14.9.4 Changing the front brake discs... 14.9.5 Changing the front tubeless sealing profile. . 14.9.6 Changing the front ire oressure sensor (Option: With TPMS)}.. 14.10. Rear wheel. 14.10.1 Removing the rear wheel. 14.10.2 Installing the rear Wheel nm. 414.10.3 Removing the rear wheel (work stand).. Installing the rear wee! (work stand) ‘Changing the rear wheel bearing... 14.10.4 14.10.5 14.10.6 sprocket carrer. (Changing the rear brake disc... Changing the rear tubeless sealing profile. 14.10.7 14.108 14.10. sensor (Option: With TPMS)... 14.10.10 Checking the chain tension. 14.10.11 Adjusting the chain tension 14.10.12 Checking the chain, rear sprocket, engine sprocket, and chain guide 14.10.13 Cleaning the chain... 14.10.14 Opening the chain... 14.10.15 Riveting the chain 14.10.16 Checking the rear hub daing rubber pieces .. 14.10.17 Changing all the damping ‘ubber pieces of the rear hub 14.10.18 Changing the crivetrain kit WIRING HARNESS, BATTERY.. 15.1 Removing the 12-V battery. 15.2 Installing the 12-V battery 15.3 _Disconnecting the negative cable of the 12-V battery. 15.4 Connecting the negative cable of the 12-V battery. . 18 Charging the 12-V hattery 15.6 Changing the main fuse.. 15.7 Changing the fuses of individual ower consumers 15.8 Checking the charging voltage... 15.9. Checking the open-circuit current BRAKE SYSTEM . 16.1 Checking the front brake linings... 16.2 Changing the front brake linings... 16.3. Checking the front brake fluid level 16.4 Adding the front brake fluid... 16.5 Changing the front brake fluid, Changing the bearing of the rear Changing the rear tie pressure 122 123 126 127 127 128 129 130 132 134 135 136 138 139 120 aan 143 144 144 145 146 147 150 150 151 153 153 1a 156 157 158 158 160 160 160 162 163 164W 18 16.6 16.7 168 16.9 16.10 16.11 16.12 16.13, 16.14 16.15 Adjusting the basic position of the hand brake lever... CChacking the roar brake linings Changing the brake pads of the rear wheel brake .. Checking the free travel ofthe fot brake lever Adjusting the basic postion ofthe foot brake lever... Adjusting foot brake lever stub Checking the rear brake fluid level : Adding rear brake fui. Changing the rear brake fluid Bleeding the brake system LIGHTING SYSTEM, INSTRUMENTS...... a. 72 173 A 175 176 COMBINATION INSTRUMENT .. 18.1 18.2 183 184 18.5 18.6 18.7 188 18.9 18.10 18.11 18.12 18.13 18.14 18.15 18.16 18.17 18.18 18.19 18.20 18.21 18.22 13.23 18.24 18.25 18.2.1 KTM MY RIDE (optional) Programming the ignition key. Removing the headlight mask with the headlight. Installing the headlight mask with the headlight. Changing the turn signal bulb (us) Checking the headlight setting Adjusting the headlight range. Combination instrument Activation and tes... Day-night mode Warnings. Toe warning Indicator lamos Display ... RALLY display (optional. Spoce.. Shift warning light Speedometer. Cruise control indicator (optional) Ride display ABS display MTC display... Coolant temperature indicator... Fuel level display. Ambient air temperature indicator. Tie see Favorites display Quick Selector 1 display... Quick Selector 2 display... Navigation display (optional) Setting the service interval display. Meni 166 166 167 169 170 wv im 172 173 175 176 176 176 178 179 179 180 182 182 182 182 183 183 184 185 186 1g? 187 187 188 188 188 188 189 189 190 190 190 190 191 1h 191 192 192 19 18.25.2 Audio (optional. 192 18.25.3 Navigation (optional. 193 18.25.4 Navigation Setup (optional) ne. 194 18.25.5 Volume (optional)... 194 18.25.6 Pairing (optional) 195 418.25./-_ Phone (optional). Ay 18,25.8 Headset (optional). 196 18.25.9 Telephony (optional). 197 18.25.10 TripsData 198 18.25.11 General Info 198 18.95.12 Trin 198 18.25.13 Trip 18.25.14 TPMS.... 18.25.15 Warning, 200 18.25.16 Ride Mode... 201 18.25.17 Ride Mode 201 18.25.18 Rally (optional 202 18,25.19 Throttle Response (optional) ...... 202 18.25.20 Leave Rally (optional). 202 18.25.21 Motorcycle 203 18.25.22 MTC 18.25.23 ABS 18.25.24 ABS, 18.25.25 Quick Shifts (optional. 204 18.25.26 Settings. 205 18.25.27 Favorites. 205 18.25.28 Quick Selector 1 205 18.25.29 Quick Selector 2. 18,25.30 Bluetooth (optional. 206 18.25.31 Display Theme. 206, 18,25.32 Shift Light . 18.25.33 Lights up 207 18.25.34 Flashes. 207 18.25.35 Shift Light 208, 18.25.36 Setting the time and date 208 18.25.37 DRL 209 18.25.38 Units... 210 18.25.39 Distance 210 18.25.40 Temperature. 210 18.25.41 Fuel Cons. 210 18.25.42 Language aun 18,25.43 Service aul 18.25.44 Extra Functions... au. ENGINE 212 19.1 Removing the engine... 212 19.2 Installing the engine. 220 19.3. Engine disassembly. 229, 19.3.1 Clamping the engine into the engine assembly stana . 229 19.3.2 Draining the engine oil. 230 19.3.3 Removing the oil filter. 230 19.3.4 Removing the starter motor....... 231 19,35 Removing the valve Cover sce 23119.3.6 Removing shift shaft sensor nee 232 19.3.7. Removing the ger positon sensor. 232 19.3.8 Removing the spacer.. 233 19.3.9 Removing the alternator cover..... 233 19.3.10 Reinoving the torque limiter arid starter idler gear. 193.11 Removing the crankshaft speed sensor. 234 193.12 Removing the heat exchanger... 235 19.3.13 Removing the thermostat 235 19.3.14 Removing the water pump impeller . 236 19.3.15 Removing the clutch Cover ne. 236 19.3.16 Removing the clutch dises 237 193.17 Removing the clutch basket....... 238 193.1R Removing Ineking lover 23a 193.19 Removing the shift shaft... 239 19.3.20 Removing the spark plugs.. 240 19.3.21 Removing the camshatts.cnunne 240 19.3.22 Removing the cylinder head....ne 242 193.23. Removing te timing chain rails. os 283 19.3.24 Removing the rotor. 243 19.3.25 Removing the oll pa vennnnnn 28 19.3.26 Removing the oil pump unit... 245 19.3.27 Removing the engine case downwards 246 19.3.28 Removing the transmission shalts.. soe 247 193.29 Removing ol spray tube 249) 19,3.30 Removing the piston ae) 19.4 Working on individual pars. 261 19.4.1 Checking the radial clearance of crankshaft bearings. 281 19.4.2 Changing the main bearing ACIS 250, 19.4.3 Checking the Balancer shaft... 253 19.4.4 Working on the upper section of he engine vase 19.4.5 Working onthe lower section of the engine case 256 WA: Setiettesmn being shells 256 19.4.7 Installing the primary gear whet. et 19.4.8 Changing the shaft seal ring of the water pump . 287 19.4.9 Checking the radial clesrance of lower conrod bearing. weve 269 19.4.10. Changing the conrod bearing... 259 19.4.1 Cylinder - Nikasil® coating... 261 194.12. Checking/measuring the evlinder wn. 261 19.4.13 Checkinglmeasuring the piston.... 262 194.14 194.15 194.16 19.4.17 Checking the piston ring end 2p. 1» 263 Determining tha pistoreylinder mounting clearance.. snes 263 Removing the ot! pumps... 264 Checking the oil pumps for wear 1 265 19.4.18 Checking the oil pressure control valve. nes 266 194.19 Installing the oll PUMPS.nrenrsnne 267 194.20 Preparing timing chain tensioner {or installation... 268 194.21 Checking the timing assembly... 269 194.22 Working on the camshaft bearing bridge . -. 270 194.23 Working onthe cylinder head... 271 194.24 Checking the cylinder Nead.n..u 276 19.4.25 Checking the clutch 278 19.4,26 Removing the shift drum locating unit. 279 194.27 Checking the shift mechanism ... 280 19.4.28 Preassembling the shift shaft... 281 19.4.29 Installing the shift drum locating unit... 1. 282 19,4.30 Disassembling the main shaft... 283, 194.31 Disassembling the countershatt.. snes 284 194.32 Checking the transmission neu. 285 19.4.33 Assembling the main shaft... 286 194.34 Assembling the countershaft...... 287 19.4.35 Checking the electric starter drive... 289 194.36 Checking the freewheel suns 290 194.37 Working on the alternator cover... 290 19.5. Engine assembly wnnrmnsnnnnines 291 19.5.1 Installing the piston 291 19.5.2 Installing the oil spray tubo........ 293 19.5.3 Installing the transmission shafts.. ~. 293 19.5.4 Installing the lower engine C898 crnnrtnnnntnennenee 295) 19.5.5 Installing the oil PUMP UNI... 298 19.5.6 Installing Ue ll Pat vssnnonns 298 19.5.7 Installing the 100 snrnnnnnins 299 19.5.8 Installing the timing chain rails... 300 19.5.9 Installing the cylinder head........ 300 19.5.10 Installing the camshatts .nwuene 302 19.5.1 Checking the valve clearance... 305 19.5.12 Adjusting the valve clearance... 306 19.5.13 Installing the spark plugs.. 307 19.6.4 Installing tha shift shaft. 207 19.5.15 Installing the locking lever nnn 308 19.5.16 Installing the clutch basket....... 308 19.5.17 Installing the clutch alscs. 309 19.5.18 Installing the clutch cover 21020 2 22 23 24 19.5.19 Mounting the water pump cover. 3u1 195.20. Installing the thermottat.ecvou. 311 19.5.21 Installing the heat exchanger... 312 195.22, Instalng the crankshaft speed sensor. a2 19,5.23 Installing toraue limiter and starter idler geat neeneneeeee 313 19.5.24 Installing the alternator cover... 213 19.5.25 Installing the spacerneeeene 314 19.5.26 Installing the gear position sensor. 314 19.5.27 Installing the shift shaft sensor... 315 19.5,28 Installing the valve cover wwe 316 19.5.29 Installing the starter motor. 317 19.5.30 Installing the oll filter... 317 1951 Installing the oil drain plug 318 19.5.32 Removing the engine from the ‘engine assembly stand .. 318 CLUTCH. 319 20.1 Adjusting the clutch release lever... 319 20.2 Checking tne cluteh 319 SHIFT MECHANISM... 328 21.1 Checking the basic position of the shift lever. 228 21.2 Aajstng the base poston ofthe shift lever... . 328 21.3 Changing the gear position sensor... 328 21.4 Programming the gear position sensor. 330 21.5 Changing the sift shat sensor... 331 21.6 Programming the shift shaft sensor. 332 WATER PUMP, COOLING SYSTEM 333) 22.1. Checking the coolant fill level and antifreeze, ss 333 22.2 Checking the coolant level in the compensating tank 334 22.3. Draining the coolant. 336 22.4 Tilling/bleeding the cooling system 336 22.5 Changing the coolant... 337 22.6 Comecting he coolant level In he compensating tank 339 CYLINDER HEAD 340 23.1 Checking the valve clearance 240 23.2 Adjusting the valve clearance 347 LUBRICATION SYSTEM. . 348 24.1 Oil circuit. 24.2 Checking the engine oil level 24.3 Checking the oll pressure. . 248. 248, 349 25 26 27 28 29 30. 31 24.4 Changing the engine oil and oil filter, cleaning the oil screens Adging engine ol. Checkingjcleaning the oil nozzle for clutch lubrication. 24.5 24.6 352 IGNITION S¥STEM, 25.1 _Allernator - checking the stator winding 25.2 Ignition coll - checking the primary winding... 25.3 Gnanging ine spark plugs. THROTTLE VALVE BODY .. 26.1 Performing the initialization run... 26.2 Adjusting service display with KTM 365 diagnosties 100... TECHNICAL DATA. 27.1 Engine 27.2 Tolerence, engine wear limits 368 27.3 Engine honing torques 369 27.4 Capacities. 372 27.4.1 Engine ol 372 27.4.2 Coolant. 372 27.8.3 Fuel 372 27.5 Chassis. 372 27.6 Electrical system, 373 27.6.1 Diagnostics connector 373 27.6.2 Front ACC1 and ACC2 373 27.6.3 RCCL and ACC2 rear 374 27.7 Tires. 374 278 Fotki 374 27.9 Shock absoroer 374 27.10 Chassis tightening torques... CLEANING/PROTECTIVE TREATMEN’ 28.1 Cleaning the motorcycle 28.2 Checks and maintenance steps for Winter operation nnn STORAGE. 29,1 Storage... 29.2 Preparing for use after storage 375 379 379, SERVICE SCHEDULE 30.1 Adgitional information. 30.2 Required work 30.3 Recommended work... WIRING DIAGRAM 311 31.2 31.3 314 Page 1 of 12 (EU), Page 2 of 12 (EU).. Page 3 of 12 (EU), Page 4 of 12 (EU)..31.5 Page 5 of 12 (EU) 31.6 Page 6 of 12 (EU) 31.7 Page 7 of 12 (CU). 31.8 Page 8 of 12 (EU} 31.9 Page 9 of 12 (EU) BL1U Page 10 of 12 (EU). 31.11 Page 11 of 12 (EU) 392 394, 396 398, 400 402 404 31.12 Page 12 of 12 (EU) 406 31.13 Page 1 of 12 (US). 408 31.14 Page 2 of 12 (US). 410 3118 Page 3 of 19 (US) 419 31.16 Page 4 of 12 (US) 414 31.17 Page 5 of 12 (US) 416 31.18 Page 6 of 12 (US). 418 31.19 Page 7 of 12 (US) 420 31.20 Page 8 of 12 (US) 422 31.21 Page 9 of 12 (US) 424 31.22 Page 10 of 12 (US)... 426 31.23 Page 11 of 12 (US), 428 31.24 Page 12 of 12 (US), 430 32. SUBSTANCES .. 33 AUXILIARY SUBSTANCES .. 434 34 SPECIAL TOOLS 436 35) STANDARDS vinssnnnnnnnnnannnnnnn 53 36 INDEX OF SPECIAL TERMS 454 37. LIST OF ABBREVIATIONS. sve 455 38 LIST OF SYMBOLS. 456 38.1 Red symbols. 486 38.2 _Yollow and orange SyMbOI5.....00e 456 38.3. Green and blue symbals 458 INDEX 467The meaning of epacific symbole 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). Jv x Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips. Indicates the result ofa testing step. wi Indicates a voltage measurement. A Indicates a current measurement. a Indicates a resistance measurement Indicates the end of an activity including potential rework. ‘The typographical formats used in this dacument are explained below. Proprietary name Indicates a proprietary name. Name® Indicates a protected name. Brand™ Indicates a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.Read this Repair Manual carefully and thoroughly before beginning work, It contains useful information and tipe 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. ‘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 and may therefore be injured, Warning Identifies @ danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. A auton Identifies 2 danger that may lead to minor injuries if the appropriate measures are not taken, Note Identitias a danger that wll lead to considerable machine and matarial damage ifthe appropriate measures are not taken. Note Indicates a danger that will lead to environmental damage if the appropriate measures are not taken. ‘Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (16112017000) During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals, sealing rings, O-rings, pins, and lock wasters). In the case of certain screws, a screw adhesive (e.g, Loctte®) is required. Observe the manufacturer's instruc~ tions. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged ‘or worn parts, Alter completing a repair or service work, check the operating safety ofthe vehicle,‘The work cpacified in the carvice echedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Watranty Booklet and in the KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle is not covered by the manufacturer warranty ‘Additional information on the manufacturer or manufacturer warranty and the procedures involved can be found In the Service & Warranty Booklet. Note Environmental hazard Improper handling of fuel is a danger to the enviranment. = Donat allow fuel to enter the groundwater, the soll, or the sewage system, Use the operating and auxiliary substances (such as fuel and lubricants) specified in the manual. Only use spare parts and accessories approved andior recommended by KIM. KIM accepts no liability tor other products and any resulting damage or loss. The current KTM PowerParts fur your velivle Gat! be four un ne KTM website. International KTM Website: ttp:/Avwww-ktm.com ‘The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at al. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions inthe text.The vehicle identification number @ is stamped on the right side ofthe steering head eu ‘The type label @ is located on the frame on the ltt The type label for Australi @ is located on the frame on the right. (us) “Te USA type label @) is located onthe fame on the let The Canada type abel @ is located onthe fame onthe ight. "The key number @ can be found on the KEVEODECARD © Info Hou need the key number to order a spare key. Keep ‘the KEYCODECARD in @ safe place. L o “e ‘S (e Hore] The engine number @ is stamped onto the engine case atthe top. The fork part murmher @ is tamper onthe inner sie ofthe fork stub. Shock absorber article number @ is on the lett side of the shock absorber.Steering demper eticle number @) is embossed onthe underside of the stering damper.Note Danger of damage The parked vehicle can rall away or fall over. Park the vehicle on a firm and level eurface. Proparatory work = aise motorycle with ear iting pea. (© p. 15) work = Remnuesereus = Toke off retaining bracket @ “= Move the handlebar to the straight-ahead position. — Attach the front lifting gear with the adapters on the steering stem. Mounting pin (69329965040) (™ p. 445) Front wheel work stand, large (69329965100) (1 p. 445) — Align the front lifting gear with the fork legs. Into T Aivays raise the motorcycle at the rear first. = Lift the motoreycle at the front. < Note Danger of damage The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface. AB @) — Secure the motorcycle against falling over. — Remove the front lifting gear. “4~ Position retaining bracket @. = Mount and tighten scens @. Guidetine Remaining screws, | M6 10 Nm (7.4 TBF) chassis « Note Danger of damage The parked vehicle can roll away or fall over. ~ Park the vehicle on a firm and level surface, = Mount retaining adapter on the link fork. = Insert adapter in the rear lifting gear. Retaining adapter (61029955144) (™ p. 441) Rear wheel work stand (69329955000) (™ p. 445) = Stand motoreycle upright, align lifting gear to the link fork with the adapters, and raise motorcycle. < a vee Danger of damage The parked vehicle can roll away or fall over. pa tak avalcaan in alone Seu mao ap ing oe weno e tea gter een eee e [Ww a ‘ aN © KSNote Danger of damage The parked vehicle can rall away or fall over. Park the vehicle on a firm and level eurface. Propartary work = Remove the main silencer. (2 p. 69) work = Remove nit = Take off footrest rubber and holder. = Mount special tot @ [Work stand atachments (75029036000) (= p. 446) ] ~ Repeat these stepson the oppesite sie. ~ Mount special tot © [Work stand (o2s290562001(— 9.448) «id = Position motorcycle upright, align special tool, and raise ‘motorcycle. Note Danger of damage The parked vehicle can roll away or fal over. = Park the vehicle on a firm and level surface, Main work = Serute the motoreycle against falling over ~ Remove special too! @ and @. Work stand (62525055200) (= p. 443) Work stand attachments (75029036000) (= p. 446)= Position footrest rubber with holder. = Mount and tigen nut @ Guideline Remaining nuts, | M6 10 Nm (7.4 TOFD chassis = Repeat these steps on the opposite side. ishing work = Install the main silencer. (© p. 69) Note Danger of damage The parked vehicle can roll away or fall over. = Park the vahicle on a firm and level surface Preparatory work = Remove the passenger seat. (2 p. 83) = Remove the front rider's seat. (© p. 83) = Remove the left side cover. (! p. 101) = Remove the battery cover, (© p. 102) Remove left fuel tank spoiter. (22 p, 103) = Kemove the rignt side cover. (2° p. 101) = Remove right fuel tank spoiler. (* p, 105) = Remove engine guard (88 p. 199) — Remove the fuel tank. (=! p. 84) Main work = Remove the cable tes = Remove screws @, ‘Mount the special tool. Work stand (62529086200) (© p. 443) Stand the motorcycle upright, align the special tool, and raise the motorcycle. 7Note Danger of damage The parked vehicle can rall away or fall over. Park the vehicle on a firm and level eurface. ‘Main work = Secure the motorcycle agalnst falling over. = Remove the special tool Work stand (62525086200) (™ p. 443) ~ Mount and tighten screws @. Guideline Remaining screws, | MB 25 Nm (184 IFA) chassis = Mount the eable ties. Finishing work = Install the fuel tank. (© p. 87) Install the engine guard. (©* p. 110) Install the right fuel tank spoiler. (© p. 106) Install the right side cover. (& p. 102) Install the left fuel tank spoiler, (== p. 104) Install the battery cover. (= p. 103) Install the left side cover. (* p. 101) Mount the front rider's seat. (= p. 84) Mount the passenger seat. (=* p. 83) (59 Starfingthe vehicle Danger Danger of poisoning Exhaust gases are toxic and inhaling therm may result in unconsciousness andi death. = Always make sure there is sufficient ventilation when running the engine. Use effective exhaust extraction when staring or running the engine in an enclosed spac Note Engine damage High rewing speed with a cold engine negatively impacts the lifespan of the engine. Always run the engine warm at a low speed. 18= Take the motorcycle off the side stand and sit on the matorey- cle, = Make sure that the emergency OFT switch/electric starter but- tom is in the middle position O. = Switch on the ignition by turning the ignition key to the posi- ton ©. After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check wn of the combination instrument is run at the same time. oY The ABS warning lamp lights up and goes back out after, starting off. = Shift the transmission into neutral The green idle indicator lamp W lights up. — Turn emergency OFF switchielectric starter button to the lower position ©. © Info To not press the emergency off switch/electric starter bouton into the fower position © until Une combination instrument function check has been completed When starting, DO NOT open the thrattle. If you open the trottle during the starting procedure, tue isnot injected by the engine management system and the engine cannot start Press the emergency OFF switchielectric starter button into the lower position © for @ maximum of 5 seconds Wait tora least 5 seconds before trying again. This motorcycle is equipped with a safety starting sys- tem. You can only start the engine ifthe transmission is in neutral or ifthe clutch lever is pulled when a gear is engaged. If the side stand is folded out and you shift into gear and release the clutch lever, the engine stops. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death, ‘= Always make sure there is sufficient ventilation when running the engine. Use effective exhaust extraction when starting or running the engine in an enclosed space. Info Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.‘Make sure that the emergency OFF switchielectric starter but- tom is in the middle position ©. Sitch on the ignition by turing the ignition key to the posi tion ©, Shift the transmission into neutral I. Turn emergency OFF switch/electric starter button to the lower position © Info only press the emergency off switchielectrc starter but ton into the lower position ® when the combination instrument function check has been completed. \When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start. 20Proparatory work = Raise motorcycle with rear lifting gear. (£2 p. 15) = Lift the motoreyele with the front lifting gear. (= p. 14) = Remove the front fender. (5% p. 111) Main work = Push dust boots @) of both fark logs downward. Info The dust boots remove cust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumu- late behind the dust boots. If this dirt is not removed, the oll seals behind can start to leak. A Wearing Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oil and grease. = Clean the brake discs with brake cleaner when nec- essary. = Clean and oil the dust boots and inner fork tubes of both fork legs. Universal oil spray ( p. 435) — Press the dust boots back into the installation position — Remove the excess oil Finishing work = Install the front fender. (#8 p. 111) = Take the motorcycle off the front lifting gear. (= p. 14) = Remove the rear of the motorcycle from the lifting gear. (p15) « Preparatory work = Remove the main silencer. (* p. 69) = Raise the motorcycle at the rear using the work stand. (8p. 16) = Place a load on the rear of the vehicle, The front whee! is nat in contact with the ground. = Remove the front fender. (© p. 111) 2Main work = Remove screw @. ~ Hang the wheel speed sensor tote side. = Remove screus @. ~ ress back the brake lnines by light tine the brake calipers laterally ont the brake diss, Pull the bake calipers caretlly back from the brake dacs and nang to the sce © Info Do not operate the hand brake lever if the brake calipers have bees reimured. ~ Loosen screw @ by several rotations. = Loosen screws @ — Press on screw @ to push the wheel spindle out of the axle clamp. Remove screw @. Warning Danger of accidents Damaged brake discs reduce the braking effec. = Always lay the wheel down in such a way thatthe brake discs are not damaged. = Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork. = Loosen serous @ = Take the brake lines out of the clamps and hang to the side, 2= Loosen screws @. = Remove the fork legs downwards. A Waring Danger of acci tic, = Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. mts. Modifications to the suspension setting may seriously alter tne handling characteris- Main work = Push the fork logs into the triple clamps. = Align the fork legs inthe requited position using the fork rings. = Tighten screws @. Guideline Screw, top triple | MB 15 Nm (11.1 IBFD) clamp Screw, bottom triple | MB 12 Nm (8.9 bff) clamp 23Postion the brake line in the clamps. Tighten screws @ Guideline ‘Screw, brake line | M5 T Nm (0.7 Toff holder on link fork Check the wheel bearing for damage and wear. > Hi the wheel bering is damaged of worn = Change front wheel bearing, (© p. 120) Remove the spacers. Clean and grease shat seal rings @ and contact suraces @ ff the spacers Long-life grease ("= p. 434) Insort wide spacer on the lett in the direction of travel Insert narrow spacer on the right in the direction of travel. T Arcow © indicates the direction of travel ofthe front whee ‘The ABS sensor whee ison the lft viewed inthe diec- tion of travel A Waring anger of accidents i or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oll and grease, = Clean the brake discs with brake cleaner when nec~ essary. Clean screw @ and the wheel spindle Grease wheel spindle lightly Long-life grease (=" p. 434) Jack up the front wheel into the fork, postion i, and insert the noe! spinal Mount and tighten screw @. uidetne Screw front. [M25x1.5 | 45Nm (33.2 br) wheel spindle ‘Thread greased= Position brake calipers. The brake linings are correctly positioned, — Mount screws @, but do nat tighten yet. Guidetine Scraw, front | MI0x.25 | 45Nm (33.2 tA) brake caliper Loctte®24a™ = Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. Secure the hand brake lever in the activated position. The brake calipers straighten. = Tighten screns ©. Guideline Screw, front [MI0x1.25 | 45 Nm (83.2 Ibi A) brake caliper Loctite®24a™ = Postion te whee speed sensor inthe hole. = Mount and tighten screw @ SEM cuidoine Remaining screws, | M6 10 Nm (7.4 Ib ft) chassis ~ Remove the locking piece ofthe hand brake lever. = Remove the loed from the rer ofthe vehicle. = Operate the front brake and compress the fork few times fitmiy. (7 Th or ge site, = Tighten screns @. Guideline Seren, fork stub [WB TENT wD Finishing work = Install the front fender. (9! p. 111) = Remove the motorcycle from the work stand at the rear p.1A) = Install the main silencer. (© p. 69) « Condition The fork legs have been removed. 25— Disassemble the fork legs. (82 p. 26) ° = Remove the spring, (@ p. 28) — Gheck the fork legs. (& p. 25) = Install the spring. (28 p. 30) = Assemble the fork legs. (© p. 30) © Info TH The operation are the same on beth fork logs. Condition The fork legs nave been removed. ~ Clamp fork leg in the area of the upper triple clamp, Guideline Distance @ 25 mm (0.98 in} (Er Glamping stand (16125) (= p. 452) 0 = Loosen screw cap @. Ring wrench (T14017) (E= p. 451) Into the screw cover cannot be removed yet. = Unclamp tte fork teg. = Drain the fork ot S—vww}y OE 10i = Unclamp the fork leg with the axle clamp. Guideline Use Soft jaws: = Remove screw @ with the washer. © Info Place @ collecting container underneath as some oil will ‘usually stil run out, = Remove the cartridge, — Remove dust boot ©. Remove fork protector ring @. Info I The tork protector ring does not necessarily need to be removed for repair work. = Remove lek ing @. Info T The lock ring has a beveled end where a screwdriver can be applied. — Warm up the outside fork tube in area @ of the lower sliding, bushing, Guideline 50°C 227 = Pull the outside fork tube off the inside fork tube with a jerk Info Dower sting bushing @ must be drawn from its bear. ing seat~ Remove upper sliding bushing ®. = Info Without using @ ool, pull the stack slightly apart by hana, = Take off lower sliding bushing @. = Takeoff support ring @ ~ Take off seal ring @. = Take of lock ring @ ~ Takeoff dust boct @ ~ Take off lit indicator @. = Unclamp the fork leg. Info I The operations are the same on both fork legs. Preparatory work = Disassemble the fork legs. (2 p. 26) Main work = Clamp the cartridge into a bench vise, Clamping stand (T14015S) (© p. 450) — Pull the spring downward and slide the special tool onto the hhexagonal part. Open end wrench (714032) (~ p. 451) — Hold nut @ and remove screw cop @. Ring wench (114017) (© p. 451) = Remove the special tools ‘Open end wrench (114032) (= p. 451) Ring wrench (T14017) (© p. 451) ~ Remove spring with preload spacers @ Into T The upper pretoad spacer usually becomes stuck in the screw cap. = Unclamp the cartridge 28Condition The fork legs have been disassembled, = Check the inside fork tube and the axle clamp for damage. » If damage is found: = Change the inside fork tube. — Measure the outside diameter of the inside fork tube at several places. Outside diameter ofthe | 42,975... 43,005 mm inside fork tube (1.69193 ... 1.69311 in) » Ifthe measured value is less than the specified value = Change the inside fork tube [atsee2.10, = Measure the run-out of the inside fork tube Rurvout of the inside fork | $0.20 mm (= 0.0079 in) tube + If the measured value is greater than the specified value: = Change the inside fork tube. — Check the outside fork tube for damage, » If damage is found: = Change the outside fork tube. = Check the surface ofthe sling bushings. + tthe dark layer @ is worn aft = Change the slicing bushings 20151710cine sinh Guideline ae » If the measured value is less than the specified value: © Into T The operations are the same on both fork legs. — Clamp the cartridge into a bench vise. Clamping stand (T140158) (= p. 450) ° = Position spring with preload spacers @). = Mount the spacial too ‘Open end wrench (714032) (= p. 451) — Mount serew cap @ all the way. = Counternold screw cap @ and tighten nut @. Guideline Nut, piston rod on | MI2x1 "30 Nm (22.1 If ft) screw cap ‘Open end wrench (114032) (= p. 451) Ring wrench (T14017) (= p. 451) Info Tine operations are tne same on both tork legs. Preparatory work = Check the fork legs. ( p.29)Main work = Clamp the inside fork tube using an axle clamp, Guidetine Use soft jaws. = Mount the special thal Protecting sleeve (1512) (= p. 451) = Position litt indicator @. = Grease end push on dust boot @ Lubricant (714034) (> p. 434) Info ‘Always change the dust boot, seal ring, lock ring, and support ring, ‘Mount the sealing lip at the bottom. ~ Pus on lock ring @. ~ Grease an push on seat rng @ Lubricant (114034) (© p. 434) 7 The sealing lip paints downward, the open sida upward = Remove the special too. Push on support rine @. = Sand edges of the sliding bushings with 600 grit sandpaper; then clean and grease the bushings. Fork oil (SAE 4) (4860116681) (= p. 433) ~ Pusn en lower slicing bushing @. — Mount upper sliding bushing @. Info Without using a tool, pull the stack slightly apart by hand. — Warm up the outside fork tube in area @ of the lower sliding bushings. Guidetine 50°C (22°F = Hulu the lower sliding bushing wilt longer side of the special tol Mounting tool (T5288) (© p. 452) = Slide on the outside fork tube. = Press the sliding bushing all the way into the outside fork tube. a1d v. fos026.1 = Position the support ring. = Hold the seal ring with shorter side of the special tool Mounting tool (T5285) (= p. 452) = Press the seal ring and support ring all the way into the out- side fork tube. = Mount look vine @ / The lock ring engages audibly. — Mount cust boot @. Mount fork protector ring @. = Assemble the individual components that belong together. Info T compression damping side: cartridge with additional cil holes @ fork fit withthe hile for wheel speed Rebound damping side: carvidge without addtional i holes. = Slide the cartridge into the inside fork tube. 32~ Mount and tighten screw @ with the washer. Guidetine Screw, cariridge | MI0x1.25 [25 Nm (18.4 IFT) = Clamp the left fork les upright. Guidetine Use soft jaws: = Fill with fork ol Fork oil per fork leg [4802 5mi | Fork ol (SAE 4) ez (a8euLLe6s1) £017 02) | (5 p. 439) Info TH Atter approx. half the ol capacity has been filled, close the serew cap of the outside fork tube, unelamp the fork and bounce a number of times so that the car- tridge fills with oil. Then add the remaining amount. = Clamp fork leg in the area of the upper triple clamp. Guideline & Distance © 25 mm (0.98 i Clamping stand (T6125) (= p. 452) oO = Grease the O-ring of the screw cover. Lubricant (T158) (= p. 434) SSF ccs] - Terence Guidetine Screw caponthe —|MSIx1.5 | 40 Nm (29.5 Ibr fi) outside fork tube Ring wrench (T14017) (H5 p. 451) A Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic end dam- ‘ages components. = Correct incorrect steering head bearing play immediately Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the beerings and the bearing seats in the frame can become damaged over time, 33Preparatory work — Remove the main silencer. (%2 p. 69) Raise the motoreycle at the reer using the work stand, (2 p.19 ‘Main work = Place a load on the rear of the vehicle. ‘7 The front wheel is notin contact with the ground. ‘Move the handlebar to the atraight ahead position. Move the fork legs back and forth in the direction of travel Play should nat be detectable on the steering head bearing. > If there is detectable play: — Adjust the steering head bearing play. (= p. 34) — Move the handlebar back and forth over the entire steering, range. TU mUSI Be pOSSIDIE lo move the handlebar easily over he entre steering range. There should be no detectable detent positions. > If detent positions are detected: = Adjust the steering head bearing play. (© p. 34) = Check the steering head bearing and adjust it neces- sary Finishing work = Remove the motorcycle from the work stand at the rear. (p16) = Install the main silencer. (© p. 69) Preparatory work = Remove the main silencer. (% p. 69) = Raise the motorcycle at the rear using the work stand. (2p. 16) = Place a load on the rear of the vehicle. J The front wheel is not in contact with the ground, in work. — Remove screus @. Take off the handlebor clamps, Take off the handlebar and place it at the front. Cover the components to protect them against damage, Do not kink the cables and lines.= Loosen screws @. = Remove screw @. = Loosen anc retighten screw @ Guideline Suen, steainy head [2HI5 [18 Nw OSS wT — Using a plastic hammer, tap lightly on the upper triple clamp to aold stresses, = Tigtenscrens @. Guideline Screw, topple | MB 15 Nm (11.1 #9 clamp — Mount and tighten screw @. Guideline Screw, steoring | MB 20 Nm (14.8 stem Loctte"24a™ = Position the handlebar. Info T Make sure the cables and wiring are positioned cor rectly ~ Position the handlebar clamps. Mount screws, but do not tighten tham yt Y Markings @ face backwards. Y The horizontal markinz @ on the handlebar scale is aligned withthe center of the handlebar clamp. Y The vertical markings @ on the handlebar scale are lige eqully on Lot Sides. — Tighten screws @ evenly. Giidtine Seren, handlsbar | MB 20 Nm (14.8 FF clamp Finishing wark = Check the steering head bearing play. (=* p. 33) — Remove the motorcycle from the work stand at the rear. (9.10) = Install the main silencer. (= p. 69) 350000) 000) ~ Remove the lower triple clamp. (8! p. 36) = Install the lower triple clamp, (= p. 37) Preparatory work = Remove the main silencer. (2 p. 69) Raise the motorcycle at the rear using the work stand, (2 p. 16) Place 2 load on the rear af the vehicle. ‘7 The front wheel is notin contact with the ground. Remove the front fender. (© p. 111) — Remove the fork legs. (© p. 21) Main work = Renve screws @. — Take off the retaining bracket. ~ Remove screw @ = Hang the brake ne to the side, ~ Remove screw @. 36= Remove screws @. = Take off the handlebar clamps. — Take off the handlebar and place it at the front. Info Cover the components to protect them against damage. Do not kink the cables and lines. = Rema cine @) = Remove screw @ with the washer. ~ Loosen the upper triple clamp and plac it to one side Info Hold the tower triole clam, ~ Remove protective ring @ = Remove the lower tripe clamp with steering stem, ~ Remove seal rng retainer @. = Remove upper staring head bearing © Main work = Grease the bearing, clean the sealing elamente, and check for damage. High viscosity grease ("" p. 434) = Inger the lover triple clamp with te steering stem. = Mount upper steering head bearing @. = Mount seal rng retainer @).Mount protective ring @ Position the upper triple clamp. ~ Mount screw @ with the washer, but do not tighten yet Guideline Screw, steering head | M25x1.5 18 Nm (13.3 bff) Position the steering damper. Mount and tighten screw @. Guideline Serew, steering [MB damper on triple clamp 8 Nm 6.9 IF AD Loctite®243r™ Position the brake line, Mount and tighten screw @ Guideline Remaining screws, | M6 chassis 10 Nm (7-4 tbe #8) Position the brake line and the retaining bracket. Mount and tighten screws @. 38~ Push the fork eg into the triple clamp. Align the fork legs inthe required postion using the fork rings. — Highton screws @ ot the lier tripe clamp. Guideline Serow, bottom tpl | MB 12 Nm (G9 FRY clamp = Tighten screw @. Guietine Screw, steering head | M25x1.5 18 Nm (13.3 Ib) Using 2 plastic hammer, tap lightly on the upper triple clamp to avoid stresses, = Tighten screws @ ofthe upper triple clam. Guideline Sere, top ple | WB HR OTIER] clomp = Mount and tighten serew @ Guideline Seren, steering | WB 20 Win AAD stem Lectte®249™ 38Position the handlebar = nfo Make sure the cables and witing ar positioned cor- rectly. Position the handlebar clamps. Mount screws, but do nat tighten ther yet. Markings @ face backwares. The horizontal marking @ on the handlebar scale is aligned with the center of the handlebar lamp. ‘The vertical markings @ on the handlebar scale are aligned equelly on both sides. Tighten screws €® evenly. Guideline ‘Screw, handlebar | MB 20 Nm (14.8 16F A clamp Check the wheel bearing for damage and wear. = I the wheel bearing is damaged or wor: — Change front whee! bearing. (© p. 120) Remove the spacers. Clean and grease shaft seal rings @® and contact surfaces @ of the spacers. Long-life grease ("= p. 434) Insert wide spacer on the left in the direction of travel. Insert narrow spacer on the right in the alrection of travel Info Tiron @ iniaes tne eto of tort ofthe ont wheel. ‘The ABS sensor wheel is on the left viewed in the direc- tion of travel A Waring Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake dises free of oll and grease. = Clean tha brake dizes with brake cleaner whan nec- essary. Clean serew (Band the wheel spindle Grease wheel spindle itl. angie grease (= p. 434),= Jack up the front wheel into the fork, position it, and insert the wheel spindle. = Mount and tighten screw @®. Guideline Screw. front | M25x1.5 | 45Nm(33.2 bff) wheel spindle ‘Thread greased — Position brake calipers. The brake linings are correctly positioned Mount screws @®, but do not tighten yet Guideline Screw, front | MI0x1.25 | 45 Nm (33.2 bff) brake caliper Loctite"24g™ = Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. Secure the hand brake lever in the activated position. The brake calipers straighten. Tighten sorows @. Guideline Screw, front [MI0x1.25 | 45 Nm (33.2 bf) brake caliper Loctte”24g™ Position the wheel speed sensor in the hol, = Mount and tighten screw (®. Guidetine Remaining screws, | MG 10 Nm (7.4 [BFAD chassis = Remove the locking piece of the hand brake lever. = Remove the load fram the rear of the vehicle. = Operate the front brake and compress the fork a few times firmly. J The fork legs straighten. = Tighten screws ®. Guideline Screw, fork stub MB 15 Nm (11.1 IBFD ing work = Install the front fender. (8! p. 111) = Check the steering head bearing play. (°* p. 33) = Remove the motorcycle from the work stand at the rear (p16) = Install the main silencer. (© p. 69) aLS 00371710] SSN i Ae Apo Proparatory work ~ Remove the main silencer. (© p. 69) ~ Raise the motorcycle at the rear using the work stand, p. 16) = Place a load on the rear of the vehicle, The front wheel is not in contact with the ground, Remove the front fender. (© p. 111) = Remove the fork legs. (© p. 21) = Remove the lower triple clamp. (8 p. 36) ‘Main work = Remove lower bearing ring @) using a a = Press in the new bearing ring all the way using a suitable tool. ~ Remove upper bearing ring @ using a suitable tool. ~ Press in the new bearing ring all the way using a suitable tool.~ Remove lower steering head bearing @. Remove the seal ring. Grease and mount the new seal ring, Mount a new bearing. Finishing work = Install the lower triple clamp. (°* p. 37) Install the front fender. (22 p. 111) Crock Une steering hea beating play. (2 ps 88) Remove the motorcycle from the work stand at the reat: (=p. 16) Install the main silencer. (° p. 69) = Remove screw @. ~ Remove screws @ = Take ott bracket @ with the steering camper = Position the bracket withthe new steering damper. = Mount and Highten the serous, Guidetine Screw, steer] MB Bim GOI ing damper on Loctte2z93" holder = Mount and tighten screw @. Guidetine Screw, steering | MB Nm (5.9 1bF Ay damper on triple Loctite®2aa™ clamp 43Note — Push clutch lever forward = Adjust the basic position of the clutch lever to your hand size by tuning adusting screw @ Info T wren the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar. When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. ‘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, Clutch damage If there isn free travel by the clutch lever, the clutch will begin to slip. = Check the tree travel of the clutch lever each time before using the motorcycle Adjust the free travel of the cluteh lever when necessary in accordance with the specification, = Check the clutch ever for smooth operation = Move the handlebar othe staight-ahead postion = Pull the clutch lever until resistance is perceptible, and deter rine the tee travel @ Free travel Qofcuich | Smm(O.2im lever > If the free travel ofthe clutch lever does not meet specifi- cations: = Set the free travel of the clutch lever. (=! p. 45) ~ Move the nandlebar to ana tro over the entire steering range, The free travel of the cluteh lever must not change. > I the tree travel of the clutch lever changes: = Check the routing of the clutch cable.— Move the handlabar tothe etraight-ahead postion. = Loosen lack nut @. — Adiust the free travel @ by turning adiustine screw @. Guidetine Free travel @ of clutch ‘5mm (0.2 in) lever = Tigten tock nut @ Warning Danger of accidents A repaired handlebar poses a safety risk. Ifthe handlebar i bent or straightened, the material becomes fatigued. The handlebar may break as a result. = Change the handlebar if the handlebars damaged or bent. ~ Remove screws @. Take off the handlebar clamps @. Posi- ttion the handlebar so that screws @ are accessible. Info Hover the components to protect ther against damage. Do nat kink the cables and lines Remove screws @. Take off handlebar supports @ = Move the handlebar supports into the desired position @, @ or ®. Mount and tighten screws @. Guideline ‘Mount the left and right handlebar supports in the came position ‘Shrew, andi] MIO GA Nim (389 Int A bar support Loctite?24a™ = Position the handlebar. Info T Make sure the cables and wiring are positioned cor rectly. 45~ Position handlebar clamp. Mount screws @ and tighten evenly Guideline Screw, handlebar | MB 20 Nm (14.8 Ibf ft) clamp Preparatory work ‘Switch off the ignition by turning the ignition key to the posi tion 2, Remove the headlight mask with the headlight. (*" p. 176) in work. = Remove the cable ties. = Remnun plugin enanertor @ frm the holrer and disconnect ~ Loosen serow @. Push the hand guard slightly tothe side= Remove screws @. = Take off cover @. = Take off the throttle grip with the sensor unit. = Position @ new throttle grip with a sensor uni Holding ig @ engages in evess ©. Position cover @. = Mount and tighten screws @. Guideline Remaining screws, | M5 5 Nm (3.7 Ibt chassi 47Position hand guard Tighten screw @. Guideline Hand guard screw | MB 25 Nm (18.4 1bF Ininplgsin eonnectar @. and position inthe hirer Route the cables without tension and secure with cable ties. Finishing work Install the headlight mask with the headlight. (©2 p. 178) Check the headlight setting. ( p.179)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. 49(8.1 Adjusting the spring preload ofthe shock absorber A Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris tic = Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Info I The spring preload defines the initial status ofthe spring operation on the shock absorber. ‘The best spring preload setting is achieved when itis set forthe weight ofthe rider and that of any lug- ‘age and a passenger, thus ensuring an ideal compromise between handling and stability — Adjust the spring preload by turning adjusting ring @ using the hook wrench fram the toolset Guideline Spring preload ‘Standard Belicks Fall payload 10 clicks © Into ‘The spring preload can be set to 10 different positions. < Preparatory work = Remove the main silencer. (#2 p. 69) = Raise the motorcycle at the rear using the work stand. 2p. 16) = Place 2 load on the front of the vehicle. 7 The rear wheel is not in contact with the ground. Main work = Move link fork up and down. > If there is detectable play: = Change the heim joint. (© p. $4) Porro Finishing work = Remove the motoreycle from the work stand at the rear. (2p. 16) = Install the main silencer. (© p. 69) 50Proparatory work — Remove the main silencer. (= p. 69) = Raise the matoreycle at the rer using the work stand (p16) ain work = Remoue covering can @ = Loosen screw @, but do not remove it yet. = Loosen screw @. but do not remove it vet. = Loosen adjusting screw @. Info LH thread stRaise the rear wheel Remove screw @ Remove screw @. Remove the shock absorber toward the ear. Remove the serew and the splash protector. & = Mut and een he sow 52= Position the shock absorber inthe frame = Mount screw @, but donot tighten yet. Guideline Screw, top M12 80 Nm (59 Ibf ft) shock absorber Loctte®2701™ = Raise the rear wheel and mount the screw @ but donot tighten ityt Guideline Sere, bation | WIZ 80 Nim (59 TF shock sbsorber tocttoe27017" A = Tighten adjusting screw @. Guietine ‘Adjusting screw, | M2OLH1.6 | 10 Nm (7.4 Ibf A) swingarm = Tishtenserew @. Guideline ‘Screw, bottom | MIZ ‘BO Nm (69 Tbr He) shock absorber Loctite®2701™ = Tighten screw @ Guideline Screw, top wi 80 Nm (69 Ib? #) shock absorber Loctiter2701"™ 53= Mount covering cap @. Finishing work = Remove the motorcycle from the work stand at the rear. (2p. 16) Install the main silencer. (© p. 69) < © Info I The operations are the same forthe top and bottom heim joints. Preparatory work — Remove the main silencer. (28 p. 69) = Raise the motoreycle at the rear using the work stand. (p16) = Remove the shock absorber. (2 p. 51) ‘Main work = Clamp the shack absorber into the vise eo Guideline Use soft jaws. = Remove bath collar bushings @ ofthe heim jin with a dit. [Danze a SSSCSCS~S~S ~ Remove seal rings @ on both sides. 0801810 £~ Press heim joint @ to the side. Pressing tool (112075) 450) A The heim joint rests against a lock ring. = Remove second lock ring @. = Place sperial ont @) underneath and preset the helm jint witha special toot @. Pressing tool (112075) (= p. 450) = Push in the new heim joint to the lock ring using special Pressing tool (T1206) (© p. 450) Info Tush in the new heim joint with the rounded side fac- ing nware = Mount second lock ing @. = Mount and grease seal rings @ on both sides. Lubricant (7158) (© p. 434) = Press in both collar bushings @ of the heim joint. Finishing work = Install the shock absorber. (/ p. 52) = Remove the motorcycle from the work stand at the rear (p16) 55= Install the main silencer. (© p. 69) i} &° & os? es” » oso1es Condition The shock absorber has been removed. = Clamp the shock absorber into the vise. Guideline Use soft jaws. ~ Note the position of the spring preload. — Loosen adjusting ring @ using the special tool. Hook wrench (T1068) (= p. 449) = Clamp the shock absorber into the special tool. ‘Spring compressor (T140808) (™p. 481) Info Use the suitable ring of the special tool with the small est possible inside diameter. = Compress the spring. — Remove spring retainer @. = Release the spring. Remove the shack absorber fram the epe- cial tool, = Remove washer @. — Remove the spring. = Mount the spring The tight col ofthe spring's mounted in the installation position a the bottom, = Position washer @.ay = Clamp the shock absorber into the special tool Spring compressor (T140505) (= p. 451) © Info Iza the suitable ring of the special tonl with the ) > If there is detectable play: = Change the link fork bearing. (© p. 62) Finishing work = Remove the motorcycle from the work stand at the rear. (ep. 16) = Install the main silencer. (© p. 69) < Preparatory work — Remove the passenger seal. (= p. 83) = Remove the front rider's seat. (-* p. 83) Remove the let side cover. (= p. 101) = Remove the battery cover. (® p. 102) — Remove left fuel tank spoiler, (28 p. 103) — Remove the right side cover. (® p. 101) ~ Remove right fuel tank spoiler. (= p. 105) ~ Remove engine guard. (= p. 103) = Remove the fuel tank. (5! p. 84) = Raise the motoreycle at the front using the work stand. (p.17) = Place a load on the front of the vehicle. Ine rear whee! is not in contact with the ground. = Remove rear wheel (work stand). (© p. 129) work = Take the brake line and cable out of the holders.= Take the brake caliper out of the guide and hang it to the side. = Info Cover the components to protect them against damage. = Remoue screws @ ~ Take off the chain guard. — Remove fitting @. ~ Remove screw @. = Hang the chain guide with chain to the side — Remove screw @ with the washer. Place the shift ro te the side. = Remove seeus @ = Takeoff the engine sprocket cover. = Loosen screw @ but do not remove it yet.~ Loosen adjusting screw @. = Info LH thread = Lift the fink fork, ~ Remove screw @ — Lower the link fork, ~ Remove screw @. Remove swingarm pivot @ = Take off the link fork. Proparatory work = Remove the passenger seat. (= p. 83) — Remove the front rider's seat (2 p. 83) — Remove the left side cover. (22 p. 101) ~ Remove the battery cover. (-* p. 102) ~ Remove left fuel tank spoiler. (= p. 103) = Remove the right side cover. (© p. 101) = Remove right fuel tank spoiler. (© p. 105) = Remove engine guard. (-* p. 108) — Remove the fuel tank. (5! p. 84) = Reise the niotureycle a the fruit using the work ste. (p.17) = Place a load on the front of the vehicle. 7 The rear wheel is not in contact with the ground, — Remove rear wheel (work stand). (©! p. 129) = Remove tie lnk fork. (= p, 60) 62SHOCK ABSORBER, LINK FORK 9 Left fork bearing = Remove collar bushings @. = Remove bushing @. — Remove shaft sea rings @ using a suitable too. = Remove stop disks @. ~ Press out bearing @ using a suitable too = Using 2 suitable tool, press in new bearing @. = Position the stop disks @. — Press in shaft seal rings @. = Mount busting @. 63oF iO = Grease the shaft seal rings. Long-life grease (2 p. 434) ~ Position the collar bushings @ with the shoulder facing. inward, Right fork bearing — Remove colar bushings @ = Remove bushing @.7s = Remove shat seal rings @ using suitable too = ress out bearing @ using a suitable too = Using suitable tol, press in new bering @) ~ ress in shat sel rings @, = Meu nine @ — Grease the shatt seal rings, wea 0p 454) ~ Postion the collar bushings @ wit the shoulder facing inward, Finishing work 1 Install the link fork, (= p. 66) Install rear wheel (work stand). (-* p. 130) Check the chain tension. (© p, 198) Remove the motorcycle from the work stand at the front. (p18) Install the fuel tank. (© p. 87) Install the engine guard. (= p. 110) Install the ight fuel tank spoiler, = p. 106) Install the right side cover. (© p. 102) Install the left uel tank spoiler. (§ p. 104) Install the battery cover. (= p. 103) Install the left side cover. (&2 p. 101) 65= Mount the front rider's seat. (5 p. 84) = Mount the passenger seat. (© p, 83) work = Position the tink fork, = Mount swingarm pivot @. = Mount and tighten screw @, Guideline ‘Screw, swingarm | M12 100 Nm pivot (73.8 tof A) —_ Lift the link fork end position the shock absorber. ~ Mount screw @, but do not tighten yet. Guideline ‘Screw, bottom | M12 ‘80 Nm (69 IFAD shock absorber Loctite®2701™ ~ Tighten adjusting screw @. Guideline ‘Adjusting screw, M2OLHXLS | 10 Nm (7.4 If fo swingarm = Tighten screw @. Guideline ‘Screw, bottom | M12 80 Nm (59 Ibf ft) shock absorber Loctite®2701™ 66Position the engine sprocket cove. Mount and tigen screws @. Guideline Screw, engine | M5 sprocket cover 5 New (3.7 Wot A) Loctite»24g™ Position the shift lever. Mount and tighten serew @. Guideline Screw, shift rod | M6 10 Nm (7.2 IF FD Loctite™24g™ Position the chain guide, Guideline Mount serew @, but do not tighten yt. Remaining screws, | M6 chassis 10 Nm (7.4 IBF TD) ‘Mount and tighten fitting Guideline Fitting, chain guide | M6 10 Nm (7.4 Tot ft) Tiehten screw @. Guideline Remaining serews, | ME chassis YO Nm (7-4 IBF FE Position the chain guard. Mount and tighten scens @. Guideline Remaining screws, | M5 chassis 5 Nm (3.7 Wi AD Position the brake caliper in the guide.= Secure the brake line and cable in the halders. Finishing work = Install rear wheel (work stand). (°° p. 130) ~ Check the chain tension. (&2 p. 139) = Remove Ure milorcycle fr the murk shane al Ute fri (=p. 18) ~ Install the fuel tank. (© p. 87) = Install the engine guard. (© p. 110) — Install the right fuel tank spoiler. (2 p. 108) = Ista Une righ side cover. (© p. 102) — Install the left fuel tank spoiler, (== p. 104) Install the battery cover. (=# p. 103) ~ Install the left side cover. (© p. 101) = Mount the front rider's seat. (= p. 84) ~ Mount the passenger seat. (=* p. 83) 68— Remove screw @. = Remove the clamp. = Remove screw @ withthe washer. = Take of tne main siencer. — Position the main silencer with the gasket. — Mount screw @ with the washer, but do not tighten yet. Guideline Screw, exhaust wa 25 Nm (18.4 IDF ft) clamp = Position te etamp. = Mount and tighten screw @ Guideline Screw, pres | MG Nm (5.9 IBF AY lencer exhaust Copper paste clamp = Tighten screw @. Guideline Screw, exhaust MB 25 Nm (184 BR clampProparatory work = Remove the main silencer. (22 p. 69) Raise motorcycle with rear lifting gear. (© p. 15) Remove the passenger seat. (= p. 83) Remove the front rider's seat. (© p. 83) — Remove the lett side cover. (°° p. 101) Remove the battery cover, (8 p. 102) Remove left fuel tank spoiler. (= p. 103) Remove the right side cover. ("2 p. 101) Remove right fuel tank spoiler. (= p. 105) = Remove engine guard. (2 p. 109) Remove the fuel tank. (=p. 84) Main work Remove screws @. Take off the engine guard connection. = Remove the cable ties. Disconnect plug-in connector @. — Expose the cable. ~ Remove te cable ts. ~ Pullff and cisconnect plug-in connector @ fom the holder, = tapose ne cadte. 70~ Remove nuts @. = Info To not misplace spacers @. = Remove sin @ = Take off the exhaust clam, — Remove manifold with gasket. = Remove exhaust gaskets @. = Remove screw @ with the washers. Hang the bel crank with the shit linkage to the side. = Remove screws @. — Take off the engine sprocket cover n= Loosen screw @. = Remove serous ® = Remove screw = Remove screw @® with the bushing, ~ Take off the side stand bracket and allow it to hang tension- free to the side, = Remove screus ® Take off the presilencer in a downward direction. 2Main work — Position the presilencer. = Mount screws @, but do not tighten yet. Guideline Screw, presi- | MB 25 Nm (18.4 Ibi ft) lencor on frame netite® aa = Position exhaust gaskets @. = Position the manifold with the gasket. — Position the clamp. Mount screw @, but do not tighten yet. Guideline Screw, manifold | M6 8 Nem (5.9 IDI Tt) clamp Copper paste Position spacers @. = Mount nuts @, but donot tighten yt Guideline Nut, manifold | MB Tighten the nute evenly. on cylinder head Do not bend the metal 20 Nm (14.8 Ib ft) Copper paste 3= Position the main silencer with the gasket. ~ Mount screw @ with the washer, but donot ihten yet. Guideline Screw, malnslencer | WB Tem TT IW fastening = Position the clamp. Mexint screw @, bit oat tighten yok Guideline Screw, presi: | M6 8 Nm 6.9 Tbr f) lencer exhaust Copper paste clamp ~ Tighten nuts @ evenly. Guideline Nt, manifold | MB Tighten the nuts evenly on cylinder head Do not bend the metal 20. Nm (14.8 IDF Tt) Copper paste Info First, tighten the nuts on the bushings. = Tighten screws @ and @ evenly Guideline Screw, presi- | M6 8Nm (5.9 Ibt ft) lencer exhaust Copper paste clamp ‘Screw, manifold | M6 8 Nm 6.9 lor A) clamp Copper paste 4Tighten screw @. Guidetine Screw, main silencer | MB 15 Nm (11.1 WF FD) fastening Tiehten srens @ Guideline Screw, presi | MB 25 Nm (18.4 Ibi f) lencer on frame Loctteezagi™ Position the side stand bracket. Mount and tigten screw @ wih the busing Guideline Sere, front | M100] 45 Nm (G32 oT 1D footrest bracket Lotte®24a7 Mount and tighten screw @ Guideline Sere, front | WIOG5 | 45 Nm (G32 Tot f footrest bracket Loctite*243™ Mount and tignten sren Guideline Geren, front] WIOGO | 45 Nm WBE TOT HD footrest bracket totite®24a7 15~ Tighten screw @. Guideline ‘Screw, swingarm | MI2 100 Nm Pivot (73.8 1bt 1) ~ Position the engine sorocket cove. ~ Mount and tighten screws @. Guideline Screw, engine | MB sprocket cover Nm (3.7 [oF TD) Loctite®243™" — Position the bell crank. © Info ‘The shift lever must not come into contact with any ‘other vehicle components during the shift procedut ~ Locate an tighten serew @ with the washers. Guideline Serew, shift | M6 14 Nm (20.3 Ibf #0) lever Loctite®24a™ = Route the cable without tension. = Join plug-in connector @ and position it in the holder. ~ Mount the cable ties. Route tine cable witout tension. ~Join plug-in connector @. = Mount the cable tes 6= Poston the engine guard connection = Mount and tigten screws Guideline Remaining screws, | MB 25 Nm (18.4 WF A) chassis Finishing work = Install the fuel tank. (© p. 87) Install the engine guard. (22 p. 110) = Inst Une igh fuel tank spoiler, p, 106) = Install the right side cover. (%8 p. 102) Install the left fuel tank spoiler. (* p. 104) Install the battery cover. (= p. 103) = Install the left side cover. (&8 p. 101) = Mount the tront rider's seat. (© p. 84) = Mount the passenger seat, (© p. 83) = Remove the rear of the motorcycle from the lifting gear. (p15)Preparatory work ~ Remove the passenger seat. (© p. 83) = Remove the front riders seat. (© p. 83) Main work = Remove screus @. = Remove the air filter box ld, loosening the wiring harness from the holder atthe same time. ~ Remove air filter clamping wedge @ upwards. ~ Remove ai fiter ame @ withthe air filter, = Remove the ar filter from the ar filter frame.> iain wort = Position ait filter in the air filter frame. = Clean the air filter box Position air titer rame @ with air titer. “ Mount air filter clamping wedge @. 7 The open side of the air filter clamping wedge faces down- wars: Guide rails @ engage in recesses ®. = Positioning air filter box ta wv Wiring harness is attached with the holder. = Mount and tighten serens © Guideline Seren, arte box [MB hm PRR Finishing work = Mount the front rider's seat. (= p. 84) 73Mount the passenger seat. (= p. 83) Proparatory work — Remove the passenger seat. (82 p. 83) = Remove the front riders sea. (=p. 83) Main work ~ Remove screus @. Remove the ar filter ox lid, loosening the wiring harneaa from the holder at the same time. ~ Remove air filter clamping wedge @ upwards. ~ Remove air filter frame @ with the air filter — Remove the ar filter from the air filter frame. = Position the new air filter in the air filter frame,~ Position air filter frame @ with the air filter. — Mosinee tarmpiner weg The open sid of the air iter clamping wedge faces down- ward Y Guide rails @ engoze in recesses @. = Positioning air filter box li. Wiring harness is attached with the holder. = Mount and tighten screws @. Guideline Screw, air filter bax | MB 2 Nm (2.2 16D Finishing work = Mount the front rider's seat (© p. 84) = Mount the passenger seat. (© p. 83)% Danger Fire hazard Fuel is highly flammable, “The fuel In the fuel tank expands when warm andi can escape if overiled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling. ~ Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. = If any uel is spilled, wipe it off immediately. = Observe the specifications for refueling. Warning Danger of poisoning Fuel is poisonous and a health hazed. — Avoid skin, eye and clothing contact with fuel, — Immediately consult @ doctor if you swallow fuel. = Do not inhale fuel vapors. In cace of ckin contac Rinse the eyes thoroughly with water, and consulta doctor in case of fuel contact with the eyes. = Change your clothing in case of fuel spills on ther. = Keep fuels correctly in a sultable canister, and out of the each of children, nse the affected area with plenty of water. 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, Lift cover @ of the fuel tank filler cap and insert the ignition key into the lock. Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced, — Push down on the fuel tank filler cap to take pressure off the ignition key. = Turn the ignition key 90° clockwise. Lift the fuel tank filler cap. ~ Fold down the fuel tank filler cap, = Turn the ignition key 90° clockwise. — Push down the fuel tank filler cap and turn the ignition key ‘counterclockwise until the luck closes, 82highly flammable, toxic and a = Check that the fuel tank filler cap is locked cor- rectly after closing. = Change your clothing if fuel spills on them. = Rinse the affected area immediately with olenty of water in the event of contact with the skin. = Remove the ignition key and close the cover. Insert the ignition key in seat lock and turn it clockwise. = Raise the front of the passenger seat, pull it toward the tank, and take off from above, Remove the ignition key trom the seat lock. — Hook holding lugs of the passenger seat into the bushings on ‘the subframe, lower the front, and simultaneously push back- ward, = Insert locking pin @ into the lock housing and push down the ‘ont of the passenger seat until the locking pin engages with an auaible click. Warning. Danger of accidents The seat can come loose from the anchoring if itis not mounted correctly. = After assembly, check whether the seat is correctly locked and cannot be pulled up, Finally, check that the passenger seat is correctly mounted. « Preparatory work = Remove the passenger seat. (* p. 83) 83Main work — Lift the rider's seat back and unhook in the @ area. Main work = Attach the recesses on the front rider's seat to the fuel tank at the desired seat position @) or @, and push the front rider's seat fonware while lowering it atthe rear. = Finally, check that the front rider's seat is correctly mounted. Finishing work = Mount the passenger seat. (-* p. 83) A ‘Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel. = Immediately consult a dactor if you swallow fuel. Do not inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. se 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. Preparatory work ~ Remove the passenger seat. (= p. 83) ~ Remove the front rider's seat. (= p. 83) ~ Remove the lett side cover. (© p. 101) Remove the battery cover. (#8 p. 102)= Remove left fuel tank spoiler. (8 p. 103) = Remove the right side cover. (2 p. 101) = Remove right tue! tank spoiler. (© p. 105) = Remove engine guard. (#2 p, 109) Main work = Remove fuel tank cover @). = Pull off vent hoses @ and @. = Thoroughly clean the plug-in connection of the fue! line using compressed air, Info Unser no circumstances should dirt enter into the fuel line, Dirt in the fuel tine clogs te Injection valet = Disconnect fuel nose connection @. Info Remaining fuel may flow out of the fuel hose. 85~ Unplug connector @, 5} = Close fuel cocks @, = Push back hose clips @ and pull off fut lines @ Info A residue of fuel may run out of the fuel lines. = Unplug connector © Remove screws @with bearing sleeves and rubber bushings. = Take nff the fuel tankDanger Fire hazard Fuel is highly flammable. “The tue In the fuel tank expands when warm and can escape i overilea. = Do not refuel the vehicle in the veinity af open flames or it cigarettes. Switch off the engine for retueling. = Make sure that no fue is spilled; particularly not on hot pars ofthe vehicle = Hf any fuels spilled, wipe it off immesiately = Observe the specifications for refueling. A Waring Danger of poisoning Fuel is poisonous and a health hazard, = Avoid skin, eye and clothing contact with fuel. = Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors. ~ Incase of skin contact, rinse the affected area with plonty 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 spill on them, = Keep fuels correctly in a suitable canister, and out of the reach of children. Main work = Position the fuel tank. = Check rubber bushings @are seated properly= Mount and tighten screws @ with the bearing sleeves and the rubber bushings Guideline ‘Screw, fuel tank Me 10 Nm (7-4 Ibe i) ~ Plug in connector @. = Mount fuel ines @ = Position hase clips @. ~ open tue cocks @. — Plug in connector @. = Thoroughly clean the plug-in pannertinn af the fuel line sing compressed air. = Info Under no circumstances should ditt enter into the fuel line. Dirt in the fuel line clogs the injection valve! ~Join fuel hose connection @. 88= Mount vent hoses @ and @. = Mun uel tank ever Finishing work = Install the engine guard. (© p, 110) Install the right fuel tank spoiler, (© p. 106) Install the right side cover. (&8 p. 102) = Install the lett tue! tank spotter. (= p. Lua) = Install the battery cover. (* p. 103) = Intall the left side cover (58 101) = Mount the front rider's seat. (5 p. 84) = Mount the passenger seat, (© p. 83) ‘Danger fie hazard Fuel is highly flammable. “The fuel in the fuel tank expands when warm and can escape if overfilled. ‘= Do not refuel the vehicle in the vicinity of open flames or it cigarettes. = 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. ‘= Observe the specifications for refueling,A Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel. = Immediately consult a doctor if you swallow fuel. Do not inhale fuel vopers, = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes = Change your clothing in case of fuel spills on them. = Keep fuels correctly in a suitable canister, and out of the reach of children. Condition The fuel tank is completely full. Ensure that the battery voltage does not drop below 12.5 V. The ignition is off The diagnostic tool is connected. Preparatory work = Remove the passenger seat. (© p. 83) = Remove the front rider's seat. (*! p. 83) — Remove the left side cover. (28 p. 101) ~ Remove the battery cover. (°* p. 102) ~ Remove left fuel tank spoiler. (= p. 103) Main work = Thoroughly clan the plug-in connection of the fuel line using ‘compressed air. Into T Under no circumstances should dirt enter into the fuel lie, Dirt inthe fuel line clogs the injection valve! ~ Disconnect fuel hose connection @. into Remaining fuel may flow out ofthe fuel hose. = Remove ose clamp @. = Remove angle piece @.Remove hose clip @. Pressure testing tool (61029094000) (5 p. 441) Remove the hose, Mont spacial onl @ andl secure with hose clin Pressure testing tool (61029094000) ("* p. 441) Mount zpscial tol @ with neste code 1,0; “esting hose (61028093000) =p. 440) Position the hose end in a fuel can. Guidetine Minimum size, uel can 101(2.6 US gal) Connect the diagnostic tool and start it. Execute "Engine Electronics" > "Actuator Test" > “Function test of fuel pump controler". Check the fuel pressure with the fuel tank filler cap closed. Fuel pressure When the fuel pumpis 3.8... 4.2 bar (55 active 61 psi) '» Ifthe specification is not reached: = Open the fuel tank filler cap. — Check the fuel tank breather. Check the fuel pressure with the fuel tank filler cap open, Fuel pressure When the fuel pump is [3.8... 4.2 bar (55... active 61 psi) » If the specification is not reached: = Check that the fuel line is clear. = Change the fue! filler. (© p. 94) = Change the fuel pump. (= p. 93) Finish the actuator test Remove the special tools~ Mount angle piece @. = Mount hese clamp @. Hose clamp plier (60029057000) (= p. 440) = nin fet hone connection @ Finishing work = Install the left fuel tank spoiler. (© p. 104) Install the battery cover. (© p. 103) Install the left side cover. (© p. 101) Mount the tront nder’s seat. ("2 p. 84) Mount the passenger seat. (© p. 83) 1 ree The fuel in the fuel tank expands when warm and can escape i overfiled. = Do not refuel the vehicle in the vicinity of open flames or it cigarettes. = Switch off the engine for reveling. Make sure that no fuel is spilled; particularly not on hot parts ofthe vehicle. = Ifany fuel is spilled, wipe it off immediatly = Observe the specifications for refueling, A Worn Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel. — Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes = Ghange your clotning in case of tue spllis on them. = Keep fuels correctly in a suitable canister, and out of the reach of children. Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged. 92In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. = Retvel only with clean tuel trat meets tne specitied standards, Note RE niromenat art imoropertancngot tel 3 dog te enorent = Dono alo ul entre rund, thei othesovage ion. Proparatory work = Remove right fuel tank cover. (2% p. 108) Drain the fuel from the fuel ink into a suitable container Main work ~ Unplug connector @. = Remove screws = Remove the fuel level sensor with gasket. = Position the refuel level sensor with gasket. ~ Mount ane tighten screns @ Guideline See lise TS Shim G2 = Plug in connector @. Finishing work = Install the right fuel tank cover. (£2 p. 109) Danger Fire hazard Fuel is highly flammable. “The fuel in the fuel tank expands when warm and can escape if overfilled. = Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switeh off the engine for refueling '~ Make sure that no fuel is spilled; particularly not on hot parts of the vehicle, = any fuel is spilled, wipe it off immediately. = Observe the specifications for refueling. A Warning Danger of polsoning Fuel is poisonous and a health hazard, = Avoid skin, eye and clothing contact with fuel. = Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes, = Change your clothing in case of fuel spills on them, = Keep fuels correctly in a suitable canister, and out of the reach of children. Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged. 93In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. — Retuel only witn clean tuel that meets the specitied standards. Note Environmental nazard Improper nandiing of fuel Is a danger to the environment. = Do not allow fuel to enter the groundwater, the soil, or the sewage system, Preparatory work ~ Remove left fuel tank cover. (5 p. 107) Drain the fuel from the fuel tank into a suitable container. work = Unlug connector @ = Remove hose clamp @ and pul off the fuel hose ~ Remove screws @. = Remove the fuel pump withthe gasket Info Do erating ue nay tow otf te fe tank Place an appropriate container under the engine. Position the new fuel pump withthe gasket ~ Mount and tighten serevs © Guiaetine ‘Screw, fuel pump M6 6 Nm (4.4 Ibf ft) = Mount fel hse. = Mount nose clamp @. Tze lamp pir (60025087000) © p A70) ~ Plug in connector @. nishing work Install the left fuel tank cover. (8 p. 108) Danger Fire hazard Fuel is highly flammable. ‘The fuel in the fuel tank expands when warm and can escape if overfilled. = Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. = Sutton of he engine tor retueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. = Hfany fuel is spilled, wipe it off immediately. = Observe the specifications for refueling,A Warning Danger of poisoning Fuel is poisonous and a health hazard. Note ‘Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. De not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult 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. ‘Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged. longue counties au regions, the available [uel yualily aid cleanliness may sot be sufficient. This will result it problems with the fuel syste. = Refvel only with clean fuel that meets the specified standards, 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, Preyaratury woth = Remove left fuel tank cover, (®! p. 107) = Drain the fuel from the fuel tank into a suitable container. Main work = Unplug connector @ — Remove hose clamp @ and pull off the fuel hose. — Remove screws @, Remove the fuel pump with the gasket. © Info Remaining uel may tlow out of the Tuel tank Place an appropriate container under the engine. ~ Detach connectors @ and © 9512 FUEL TANK, SEAT, TRIM a ‘Yl v i Remove screus @. Take off the cables. Remove retaining washer @ Remove pressure contr! vale @ with O-ring Disengage locking mechanisms @ on all sides in area @. © fa T The housing halves are damaged in this step and are contained inthe filter se. Disengage housing halves.= ~ Remove O-rings @. = Pull fet 1 @ cit te = Pull fuel pump @ out of the fuel pump housing. = Remove O-ring ® and mount new Ong. — Mount fuel pump @) in new fuel pump housing.oo5e48.10 ~ Mount new fuel filter @ on the fuel pum. = Mount new ings @ = Join housing halves and allow to click into place, ~ Mount pressure contol vive @ with new Oxing. = Position retaining waster @ with the collar facing downward. 98= Poston the ground wt = Mount and tighten screns @. © «> = Phig in connectors @ and Position the fuel pump with the gasket Mount and tighten serene @. Guideline Serea, fuel pomp [M6 ENm(aa I = Mount fuel hose — Mount nose clamp @ Hose clamp plier (60025057000) (=p. 440) Plug in connector @. Finishing work Install the left fuel tank cover. (2 p. 108) Danger Fire nazard Fuel is highly tlammable. ‘The fuel in the fuel tank expands when warm and can escape if overfilled. = Donot refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switch off the engine for refueling. ‘= Make sure that no fuel is spilled; perticularly not on hot parts of the vehicle. = Hany fuel is spilled, wipe it off immediately. = Observe the specifications for refueling.Note Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel. = Immediately consult a doctor if you swallow fuel. Do not inhale fuel vopers, = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes = Change your clothing in case of fuel spills on them. Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged. In some countries and regions, the available fuel quality and cleantiness may not be sufficient. This will result in problems with the fuel system. = Refuel only with clean fuel that meets the specified standards. Note Environmental hazard Improper handling of fuel is a danger to the environment. = Do nat allow fuel to enter the groundwater, the soil, or the sewage system, ~ Switch off the engine. Open tne fut tank ler cap. CE p, 82) ~ Fill the fuel tank with fuel up tothe lower edge @ of the filler neck, Total fuel tank 201 Super unleaded capacity, approx. | (5.3 US gal) | (ROZ 95/RON S5/FON 91) (= p. 433) = Close the fuel tank filler cap. (© p. 82)Preparatory work — Remove the passenger seat. (22 p. 83) = Remove the front rider's seat. (® p. 83) Main work = Remove left side cover from the rubber bushings in the areas @ and = Pull off the left side cover sideways and remove it toward the front. « Main work: = Position the left side cover withholding lug @ on busting @ and push backward. ~ The left side cover engages under the tail part. ~ Press the left side cover in area @ into rubber bushing @ and press into rubber bushing @ in area @. Finishing work = Mount the front rider's seat (© p. 84) = Mount the passenger seat, (© p. 83) Preparatory work = Remove the passenger seat. (2 p. 83) = Remove the front rider's seat. (1° p. 83) 101