REPAIR MANUAL 2011 |) VAIMIANMIKGLO 990 Supermoto R EU 990 Supermoto R FR 990 Supermoto R AUS/UK 990 Supermoto R USA Art, no, 3206108enINTRODUCTION 1 Read this repair manual carefully and thoroughly before beginning work The vehicle will only be able to meet the demands placed on it If the specified service work is performed regularly and properly, This repair manual was written to correspond to the latest state ofthis series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this manual We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified here, tis assumed that the repair work will be performed by a fully trained mechanic, Al specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica- tions, prices, color, forms, materials, services, designs, equipment, etc., without prior natice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular madel without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. Thre models portrayed partly contain spe- cial equipment that does not belong to the regular scope of supply. © 2013 KTM-Sportmotorcycle AG, Mattighofen Austria Al rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright & Iso 9001(12 100 6061) ‘According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead TOV'S to the maximum possible quality of the products. Issued by: TUV Management Service KTM-Sportmotorcyele AG 5230 Mattighofen, AustriaTABLE OF CONTENTS 1 MEANS OF REPRESENTATION 1.1 Symbols used 1,2 Formats used... 2 SAFETY ADVICE, 2.1, Repair Manual 22 — Safely advice. 2.3 Degrees of risk and symbols .n 2. — Work rules. 3 IMPORTANT INFORMATION 3.1 Guarantee, warranty 3.2 Operating and auxiliary substances. 3.3 Spare parts, accessories 34 Figures 4 SERIAL NUMBERS 4.1 Chassis numberftype label 42 Key number. 4.3. Engine number... 4.4 Fork part number 4.5 Shock absorber part number 5 MOTORCYCLE 5.1 Raising the motorcycle with the rear wheel stand 5.2. Taking the motorcycle off ofthe rear whee! stand 5.3 Raising the motorcycle with the front wheel stand 5.4 Taking the motorcycle off ofthe front wheel stand... 5.5 Lifting te motoreyle withthe It stand. 5.6 Removing the motorcycle from the work stand 5.7 Starting, 5.8 Starting the motoreycle to make checks 6 FORK, TRIPLE CLAMP sn 6.1 Adjusting the compression damping ofthe fork 6.2 Adjusting the reboune damping of the fork. 6.3 Bleeding the fork legs. 6.4 Cleaning the dust boots ofthe fork legs. 6.5 Removing fork legs.. 6.6 Installing the fork legs 6.7 Servicing the fork. 6.8 Disassembling the fork legs. 6.9 Checking the fork legs. 6.10 Assembling the fork legs. 6.11 Checking the steering head bearing play. 6.12 Removing the lower triple clamp, 6.13 Installing the lower triple clamp 6.14 Lubricating the steering head bearing 6.15 Adjusting the steering head bearing play 7 HANDLEBAR, CONTROLS... se 7.1 Adjusting the basic postion of the clutch 7.2 Checking the play in the throttle cable. 7.3 Checking the throttle cable routing... 7.4 Adjusting the play in the throttle cable. 8 SHOCK ABSORBER, SWINGARM 8.1 Adjusting the high-speed compression damping of the shock absorber... 8.2 Adjusting the low-speed compression damping. of the shock absorber. 8.3 Adjusting the rebound damping of the shock absorber. 34 35 10 12 13 8.4 Adjusting the spring preload of the shock absorber. 8.5 Removing the shock absorber 8.6 Installing the shock absorber. 8.7 Servicing the shock absorber. 8.8 Removing the soring. 8.9 Disassembling the damper. 8.10 Disassembling the piston rod 8.11 Disassembling the seal ring retainer. 8.12 Changing the pilot bushing 8.13 Checking the damper 8.14 Removing the heim joint. 8.15 _ Installing the heim joint 8.16 Assembling the seal ring retainer 8.17 Assembling the piston rod. 8.18 Assembling the damper 8.19 Bleeding and filling the damper 8.20 Filling the damper with nitrogen 8.21 _ Installing the spring EXHAUST. 9.1 Removing the exhaust manifold 9.2 Installing exhaust manifold 9.3. Removing the main silencer with the distributor pipe. 9.4 Installing the main silencer with the distributor Pipe. AIR FILTER .. 10.1 Removing te ait fier 10.2 Installing the air filter. 10.3 Removing the air filter box. 10.4 Installing the air filter box. FUEL TANK, SEAT, TRIM 11.1 Opening the filler cap. 11.2 Closing the filler cap 11,3 Removing the seat 11.4 Mounting the seat 11.5 Reinstalling the fuel tank 11,6 Positioning the fuel tank. 11,7 Removing the fuel tank. 11.8 Installing the fuel tank 11.9 Changing the fuel filter. 11,10 Changing the fuel pump 11.11 Checking the fuel pressure MASK, FENDER, TRIM 12.1 Removing the front fender 12,2 Removing the front fender 12.3 Removing the front splash protector. 12.4 Installing the front splash protector WHEELS... 13.1 Checking the tite air pressure 13.2 Checking the tire condition 13.3 Front wheel 13.3.1 Removing the front whee! 13.3.2 Installing the front whee! 13.3.3 Checking the front brake discs 13.3.4 Removing the front brake discs 13.3.5 Installing the front brake dises 13.4 Rear whee! 13.4.1 — Removing the rear wheel 13.4.2. Installing the rear wheel 13.4.3. Chocking the rear brake disc. 13.4.4 — Removing the brake disc of the rear brake 35 36 36 37 37 38 39. 40 41 42 42 43 44 44 45 47 50 50 52 52 87 58 58 59 60. 6 63. 63 63 63 64 64 64. 65 66 67 72 73 % A 5 78 15 76 76 76 7 7 77 78 79 79 79 79 80 al alTABLE OF CONTENTS 4 15 16 Vv 13.4.5 Installing the brake disc of the rear brake. 18.4.6 Checking the chain tension... 13.4.7 Adjusting the chain tension 13.4.8 Checking the chain, rear sprocket, engine sprocket and chain guide 13.4.9 Cleaning the chain. : 134.10 Checking the rear nub rubber dampers 13.4.1 Changing the rear hub shock absorbers WIRING HARNESS, BATTERY. 14,1 Removing the battery . 14.2 Installing the battery 14,3 Disconnecting the battery 14,4 Connecting the battery . 14.5. Recharging the battery 14.6 Changing the main fuse. 14.7 Changing the fuses of ncvicusl power 14.8 grition curve plug-in connector. 14.9 Adjusting the ignition curve to the fuel quality. BRAKE SYSTEM 15.1. Checking the front brake linings. 15.2 Changing the front brake linings. 15.3 Adjusting the basic position of the hand brake lever es 15.4 Checking the front brake flu level 15.5 Adding front brake fluid 15.6 Changing the front brake fluid... 15,7 Checking the rear brake linings. 15.8 Changing the rear brake linings 15.9 Checking the free travel ofthe foot brake lever 15.10 Adjusting the basic position ofthe foot brake lever 15.11 Checking the rear brake fluid level 15.12 Adding rear brake fluid. 15.13 Changing the rear brake fluid LIGHTING SYSTEM, INSTRUMENTS 16.1 Setting kilometers or miles. 16,2 Setting the clock 16.3 Setting/esetting display TRIP I. 16.4 Setting/resetting display TRIP 2 16.5 Combination instrument - setting the wheel circumference 16.6 Removing the headlight mask with the headlig 16.7 Refitting the headlight mask with the headlight. 16.8 Checking the headlight setting 16.9 Adjusting the headlight range. 16.10. Changing the headlight bulb .. 16.11 Changing the parking light bulb. 16.12 Changing the turn signal bulb 16.13 Changing the brake light bulb... 16.14 Changing the taillight bulbs 16.1 Changing the license plate lamp. 16.16 Activating/deactivating the ignition key 16.17 Activating the immobilizer control unit. ENGINE 17.1 Removing the engine 17.2 _ Installing the engine. 17,3 _ Engine disassembly 17.3.1 Clamping the engine into the engine assembly stand 81 81 82 83 83 84 84 86 ~ 86 86 87 87 87 88 89 90 90 91 91 91 “93. 93 93, 94 96 96 98 98 98 99) 99 102 102 102 102 103 108 104 17.3.2 17.33 173.4 17.3.5 17.3.6 17.37 17.3.8 Preparing the engine for disassembly. Removing the starter motor. Removing the ignition coils. Remaving the valve cover of eylinder 2. Removing the valve cover of cylinder 1 Removing the spark plugs. Setting the engine to ignition top dead center of cylinder 1 Removing the camshafts of cylinder 2 Removing the timing chain tensioner of cylinder 1 Removing the timing gears of cylinder 1 Removing the cylinder head of cylinder 1 with cylinder Setting the engine to ignition top dead center of cylinder 2. Removing the camshafts of cylinder 2. Removing the timing chain tensioner of cylinder 2 Removing the timing gears of cylinder 2 Removing the cylinder head of cylinder 2 with cylinger Remaving the water pump impeller. Removing the clutch cover Removing the clutch discs. Remaving the clutch basket Removing the spread transmission Removing the primary gear Removing the timing chain of cylinder 1 Removing the oil pump gear wheel Removing the shit shatt. Removing the shift drum locating Removing the locking lever Removing the gear position sensor. Removing the alternator cover: Removing the rotor Remaving the timing chain of cylinder 2 Removing the oil filter Removing the left engine case, Removing the crankshaft Removing the transmission shafts. Removing the oi pumps: Work on individual parts ‘Work on the lett section of the engine ‘Work on the right section of the engine case Remaving the left main bearing. Removing the right main bearing, Selecting main bearing shells, Installing the left main bearing Installing the right main bearing. ‘Changing the conrod bearing Checking the radial clearance of lower ‘conrad bearing ‘Changing the support bearing of the crankshatt.. ‘Changing the water pump bearing Remaving the cylinder head from the cylinder Checking the oil pressure regulator valve. (Checking the oil pumps. Cylinder - Nikasil coating 1739 173.10 Waal 173.12 173.13 17.814 173.15 178.16 173.17 178.18 17.3.19 17.3,20 173.21 173.22 17.3.23 173.24 173.25 17.38.26 17.3.27 173.28 173.28 17.330 173.31 173.32 173.33 17.3.34 173.35 17.3.36 17.337 74 W741 1742 1743 W744 1745 1746 W747 17.48 1748 174.10 V4 W74l2 174.13 74a 174.5TABLE OF CONTENTS 174.16 174,17 174.18, 174.19 174.20 Work on the cylinder head Checking the cylinder head... CChecking/measuring the cylinder Checking/measuring the piston Gheckng he steiner mounting learance vn Checking the piston ring end gap. Installing the piston Mounting the cylinder head on the ylinder 7 Checking the timing assembly reassembling the spread transmission Checking the clutch. Checking the shift mechanism Preassembling the shift shaft Disassembling the main shaft... Dismantling the countershaft Checking the transmission ‘Assemling the main shaft. Assembling the countersheatt.. Work on the alternator cover. Checking the electric starter drive Checking the freewheel 17.4.37 Removing the freewheel . 17.4.38 Installing the freewheel 17.5 Assembling the engine 174.21 17.4.2 174.23 17.4.24 17.4.28 174.26 174.27 17.4.28 174.29 174,30, 17.431 17.432 17.433, 17.434, 17.4.35 174.36 17.5.1 Installing the oil pumps... 17.5.2 Installing the transmission shafts 17.5.3 Installing the crankshaft 17.5.4 Installing the left engine case 17.5.5 Installing the ol fit 17.5.6 Installing the timing chain of cylinder 2 17.5.7 Installing the rotor 17.5.8 Installing the alternator cover. 17.5.9 Installing the gear position sensor 17.5.10 Installing the locking lever. 17.5.1 Installing the shift drum locating, 17.5.12 Installing the shift shaft 17.5.13 Removing te cil pump gear wheel. 17.5.14 Installing the timing chain of eylinder 1 17.5.15 Installing the primary gear 17.5.16 Installing the spread transmission 17.5.17 Installing the clutch basket. 17.5.18 Installing the clutch dises. 17.5.19 Installing the clutch cover ee 17.5.20 Installing the water pump impeller. 175.21 Installing cylinder 1 with the cylinder eas 17.5.2 Installing the timing gears of cylinder 1. 17.5.23 Installing the timing chain tensioner of cylinder 1 17.5.24 Installing the camshafts of cylinder 1 17.5.25 Setting the engine to ignition top dead center of cylinder 2 17.5.26 Installing cylinder 2 with the eylincer head 17.5.27 Installing the timing gears of eyliner 2 17.5.28 Installing the timing chain tensioner of cylinder 2 17.5.29 Installing the camshafts of cylinder 2 17,5.30 Checking the valve clearance of cylinder 1 161 161 162 162 163 63 164 193 195 195 196 96 197 199 199 199 18 19 20 28. 178.31 178.32 Setting the valve clearance of cylinder 1 Setting the engine to ignition top dead center of cylinder 2. Checking the valve clearance of cylinder 2 5.34 Setting the valve clearance of cylinder 2 17.5.35 Installing the spark plugs. 17.5.36 Installing the valve cover of eylinder 2 17.5.37 Installing the valve cover of cylinder 2 17.5.38 Installing the ignition coils, 17.5.39 Installing the starter motor, 17.8.4 Preparing the engine for installation 17.5.41 Removing the engine from the engine assembly stand 175.33 CLUTCH. 18.1 Checking/rectifying the fluid level of the hycraulie clutch 18.2. Changing the hydraulic clutch fluid WATER PUMP, COOLING SYSTEM 19.1 Draining the coolant 19.2 _Filling/bleeding the cooling system 19.3 Checking the antifreeze and coolant level 19.4 Checking the coolant level in the compensating tank. LUBRICATION SYSTEM. 20.1 Oil circuit, 20.2 Checking the engine ol level 20.3 Changing the engine oil and filter, cleaning the oll screens. 20.4 Draining the engine oil and filter, cleaning the oll sereens.. 20.5 Draining the engine oil 20.6 Filling up with engine oil 20.7 20.8 20.9 Adding engine ol Checking the engine oil pressure Checking the oll jat for the cluteh lubrication. THROTTLE VALVE BODY 21.1 Throttle position sensor circuit A - check in zero position Throttle position sensor circuit A adjusting the position 21,3 Removing the throttle valve body, 21.4 Installing the throttle valve body. IMMOBILIZER BLINK CODE TECHNICAL DATA... 23,1 Engine... 212 23.2 Engine tolerance, wear limits 23.3. engine tightening torques 23.4 Capacities. 23.4.1. Engine oil 23.4.2 Coolant. 23.4.3 Fuel. 23.5 chassis. 23.6 Electrical system. 23.7 Tires 23.8 fork. 23.9 Shock absorber. 23.10 chassis tightening torques. CLEANING/CONSERVATION 24.1 Cleaning motorcycle 24.2 Checks and maintenance measures for winter operation. 200 200 200 201 201 201 202 203 208 208 205 206 206 206 207 207 . 207 208 209 ail 212 220 221 221 222 231 231 2al 233 235 235 238 235 235 236 236 237 237 238 240 240 241TABLE OF CONTENTS 25 STORAGE. 25,1 Storage 25.2 Preparing for use after storage. 26 SERVICE SCHEDULE 26.1 Service schedule, 27, WIRING DIAGRAM 27.1 Page 1 of 10 27.2 Page 2 of 10 27.3 Page 3 of 10 27.4 Page 4 of 10 27.5 Page S of 10 27.6 Page 6 of 10 27.7 Page 7 of 10 27.8 Page 8 of 10 27.9 Page 9 of 10 27.10 Page 10 of 10.. 28 SUBSTANCES 29 AUXILIARY SUBSTANCES 30 SPECIAL TOOLS 31 STANDARDS. INDEX 242, 242 242 243, 243 246 246 248, 250 252 254 256 258 260 262 264 266 268 270 284 2851 MEANS OF REPRESENTATION 6 ‘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 funtion). Indicates a page reference (more information is provided on the specified page). axS ' Indicates information with more details or tips » Indicates the result of a testing step. wi Denotes a voltage measurement, A Denotes a current measurement, a Denotes @ resistance measurement, The typographical formats used in this document are explained below. Proprietary name Identifies @ proprietary name. Name? Identifies a protected name, Brand™ Identifies a trademark,2 SAFETY ADVICE 2A Repair Manat Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. ‘This manual assumes that the necessary special KTM toals and KTM workplace and workshop equipment are available. ‘A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. © Info The vehicle has various information and warning labels at prominent locations. Do not remove informationiwarning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury ifthe appropriate measures are not taken, Warning. Identifies a danger that is likely to lead to fatal or serious injury ifthe appropriate measures are not taken. Caution Ba entities a canger that may load to minor injuries ithe appropriate measures are not taken Note Identifies a danger that will ead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies 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 nat contained in the vehicle but can be ordered under the number in paren- theses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (e.g, sel-locking screws and ruts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts, In some instances, a thread locker (eg. Lectite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check tham for damage and wear. Change damaged or worn parts. After you complete the repair or service work, check the operating safety of the vehicle.3 = IMPORTANT INFORMATION 8 BA Guarantee, warranty ‘The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be vord. No warranty claims can be consi¢- ered for damage resulting from manipulations andior alterations to the vehicle, Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet. Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. Only use spare parts and accessories approved andior recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss ‘The current KTM PowerParts for your vehicle can be found on the KTM website, International KTM Website: http:/imww.ktm,com ‘The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all Iti not always necessary to dis- assemble the component to perform the activity in question. Please follow the instructions in the text.4 — SERIAL NUMBERS 9 Chassis number @ is embossed in the steering head at the right. 101093-10 (Supermoto R EWFR/AUS/UK) ‘Type label @ is applied to the right frame tube (Supermoto R USA) ‘Type label USA @ is applied to the right frame tube, (Supermoto R USA) ‘Type label Canada @ is applied to the left frame tube. ‘The Code number @ key number can be found on the KEYCODECARD. © Info T You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.4 — SERIAL NUMBERS 10 ‘The engine number @ is stamped on the left side of the engine under the engine sprocket. ‘The fork part number @ is stamped on the inner side of the fork stub ‘The shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring on the engine side.5 MOTORCYCLE " Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on @ firm and even surface. = Mount the lifting bushings on the swingarm. = Insert the adapter in the rear wheel stand. ‘Adapter (61029055120) (* p. 278) Rear wheel stand (61029085400) (* p. 279) = Stand the motoreycle upright, align the wheel stand with the swingarm and the adapters, and lift the motorcycle, Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface. ‘Secure the motorcycle against falling over. — Remove the rear wheel stand and lean the vehicle on the side stand, = Remove the lifting bushings from the swingarin Note Danger of damage The parked vehicle may roll away or fall over = Always place the vehicle on 2 firm and even surface. Preparatory work = Raise the motorcycle with the rear wheel stand. (© p. 11) Main work = Move the handlebar to the straight-ahead position. Align the front wheel stand with the fork legs using the adapters Front wheel stand (61029055300) (* p. 278) Info T Alvays raise the rear of the motorcycle first. Raise the front of the motorcycle. Note Danger of damage The parked vehicle may roll away or fall over = Always place the vehicle on a firm and even surface. = Secure the motorcycle against falling over — Remove the front wheel stand.5 MOTORCYCLE 2 (55 __Liting the motoreycle with thei stand Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on @ firm and even surface. = Remove nut @, = Take off the footrest rubber and holder. = Mount special tool @ ‘Work stand adapter (75029036000) (* p. 280) Repeat the operation on the opposite side. = Mount special tool @. Work stand (62529055000) (= p. 280) Place the motoreyele in a vertical position, align the special tool and lft the matar- cycle, 0885210] Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface. = Secure the motoreycle against falling over. = Remove the special tool @ and @. Work stand (62529055000) (* p. 280) ‘Work staid adapter (75029036000) (* p. 280) = Position the footrest rubber with the holder. = Mount nut @, Guideline Remaining chassis nuts Me TONm (7.4 TFA Repeat the operation on the opposite side5 MOTORCYCLE 13 87 stating Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death, ~ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system, Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged. ~ Never operate the vehicle with a discharged battery or without a battery, Note Engine falure High engine speeds in cold engines have a negative effect on the service life of the engine. = Always warm up the engine at low engine speeds. Press the emergency OFF switch into the position © Switch on the ignition by turning the ignition key to the ON © position. After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function test of the combination instrument is run at the same time. Shift the transmission to neutral % The green idling speed indicator lamp N @ lights up. — Press the electric starter button ©. Info Do not press the electric starter button until the function test of the combi- ration instrument is finished. ‘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 Press the starter for a maximum of § seconds. Wait for a least § seconds before tying again ‘This motorcycle is equipped with a safety starting system. You can only start the engine ifthe transmission is in neutral or ifthe clutch lever is pulled when a gear is engaged. Ifthe side stand is folded out and you shift into ‘gear and release the clutch lever, the engine stops. Take the weight off the side stand and swing it upwards with your foot as far as it will go. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. © Info Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again5 MOTORCYCLE 4 Press the emergency OFF switch into the position ©. Shift the transmission to neutral. The green idling speed indicator lamp N @ lights up. Switch on the ignition. ~ Press the electric starter button ©. = Info Do not open the throttle6 FORK, TRIPLE CLAMP 15 (G41 Adjustng the compression damping ofthe fork Info The hydraulic compression damping determines the fork suspension behavior. {An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when the load shifts very fast. It gives the rider good feedback about the road conditions. = Tum adjusting screws @ clockwise al the way. Info TThe adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. = Tur back counterclockwise by the number of clicks corresponding to the fork type Guiana Compresen damping Cantor Wale Standard Tees Stor To cen Full aoa TD ceks Info Turn chcose to increase damping, try counterclockwise to recuce com ine (62 Adjusting the rebound damping of thefork Info T The tydraulic rebound damping determines the fork rebound behavior. ‘An optimally adjusted rebound damping brakes the springing energy and enables 2 fast, vibration-fre resetting of the fork to the zero position. Tum adjusting screws @ clockwise until they stop. = Info ‘The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. = Turn back counterclockwise by the number of clicks corresponding to the fork type, Guideline Rebound damping outie-t0 Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload TO clicks © Info I Tur clockwise to increase suspension damping; turn counterclockwise to reduce damping.6 FORK, TRIPLE CLAMP 16 63 Bleeding the fork eps Preparatory work = Lean the motoreycle on the side stand, ‘Main work = Remove bleeder screws @ riety. 7 Any excess pressure escapes from the interior ofthe fork, = Mount and tighten the bleeder screws. = Info T cary out this operation on both fork legs. Preparatory work = Remove the front splash protector. (9. 75) ‘Main work = Push dust boots @ of both fork legs downwards, ® Info TThe dust boots should remove dust and coarse dit particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dit is not removed, the oil seals behind can start to leak. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake dises, Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary. Clean and oil the dust boots and inner fork tube of beth fork legs. Uni sal oil spray (Fp. 269) Press the dust boats back into their normal position. Remove excess all. Finishing work = Install the front splash protector. (** p. 75) Preparatory work = Lift the motoreycle with the lift stand. (* p. 12) = Clamp down the rear of the vehicle. = Remove the front splash protector. (* 9. 75) ‘Main work = Remove the screws @ from both brake calipers. Press back the brake linings with a light lateral tilting ofthe brake calipers on the brake dise. Pull the brake caliper carefully back from the brake discs and hang it to the side, = Info To not pull the hand brake lever when the brake calipers are removed.6 FORK, TRIPLE CLAMP 7 = Loosen screws @ and @, = Unscrew screw @ about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw @. Warning BD acer ot accidents Reduced baking eticiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not damages: = Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork = Remove screws @, Hang the wheel speed sensor to the side, = Unscrew screw ©, Remove the fork legs downward, 6.6 __Installing the fork legs Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior = Following modifications, ride slowly at first to get the feel of the new ride behavior. Main work = Push the fork legs into the triple clamps. = Align the fork leg in the desired position by means of the fork rings. 304067-10 = Tighten screws @, Guideline Screw, top tiple clamp we 20 Nm (24.8 bef) = Fully tighten screws @ Guideline Screw, bottom triple clamp we 15 Nm 1.1 br6 FORK, TRIPLE CLAMP 18 30285211 = Position the wheel speed sensor. Mount and tighten screws @ Guideline Screw, wheel speed sensor | M4 2Nm Toctite® 243% (1.5 bt Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: = Replace the wheel bearing. Clean and grease the shaft seal rings @ and mating surfaces @ of the spacers. Longrlife grease (* p. 268) = Insert the wide spacer on the left-hand side ® {when looking in the direction of travel. Insert the narrow spacer on the right-hand side (when viewed in the direction of travel). Clean screw @ and the wheel spindle. = Lift the front wheel into the fork, position it, and insert the wheel spindle, Y The arrow on the spoke points in the direction of motion. = Mount and tighten screw @. Guideline Bolt, front axle M25x1 5 45 Nm (33.2 Ibe ft = Position the brake calipers and check that the brake linings are seated correctly. = Mount screws @ on both brake calipers but do not tighten them yet. = Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in the acti- vated position, The brake calipers straighten. = Tighten the screws @ on both brake calipers. Guideline Screw, front brake caliper [M10x1.25 [45 Nm octte® 243%" (33.2 Ibf A) Release the fixation of the hand brake lever. — Release the rear of the vehicle. Remove the motorcycle from the work stand, ( p. 12)6 FORK, TRIPLE CLAMP 19 = Pull the front brake and compress the fork powerfully a few times. The fork legs straighten, = Tighten screws @. Guideline Screw, fork stub ve 15Nm (12.1 Ibe ft Finishing work = Install the front splash protector. (#* p. 75) © Info ‘These operations are the same on both fork legs. Condition ‘The fork legs have been removed. = Disassemble the fork legs. (* p. 19) — Check the fork legs. (& p. 22) = Assemble the fork legs. (% p. 24) 8 er So ° So So a © Info ‘These operations are the same on both fork legs, Condition ‘The fork legs have been removed. ~Daterine and rete down the eurant sting of rebound damping @ and compres. sion damping \ = Completely open the adjusting elements of the rebound and compression damping, = Determine and note down the current setting of spring preload @ Rin) - completely open the adjusting elements of the spring preload. 20121610]6 FORK, TRIPLE CLAMP 20 Clamp the fork leg in the area of Clamping stand (114038) (* p, 282) 3 lower triple clamp. Release Preload Adjuster © © Gm The Preload Adjuster cannot be removed yet, = Unclamp the fork log and clamp it with the axle clamp. ‘© Info Use soft jaws. 2oraie10 = Slide the outer tube down, = Pull the spring downwards, Mount the special tool on the hexagonal piece. Open-end wrench (714032) (* p, 282) O—® x ‘Info f The preload spacers @ should be above the special = Clamp the special tool in the vise. Release Preload Adjuster ©. 200647-12 Remove Preload Adjuster = Remove adjusting tube @. with preload spacers ©. coin6 FORK, TRIPLE CLAMP We| = 20065091 “ee 200663-01, Pe 2o06se-12 a Pull the spring downwards. Remove the special tool Remove the spring. Drain the fork cil ® Info TPuttout and pusi in the piston rod a few times to empty the cartridge Clamp the fork log with the axle clamp. = Remove screws @ of the axle clamp. Loosen screw @ of the cartridge and remove it with the sealing ring. = Info Place a container underneath to catch any oil that may run out, Remove the cartridge. Remove valve @ of the rebound damping with the spring from the cartridge.6 FORK, TRIPLE CLAMP 2 2o06ss-12 20065612 = 2o1a2e10| ‘ @ 20065812 20065912 Remove dust boot @. Remave lock ring . ® Info I Tre lock ring has a beveled end where a screwdriver can be applied. = Heat up the outer tube in area @ of the lower sliding bushing. Guideline 50°C 22) Pull the fork outer tube with a jerk from the inner tube. Info TThe lower sling bushing @ must be pulled from its bearing seat. Remove the upper sliding bushing @. ® Info Without using a tool, carefully pull the stack apart by hand, = Take off the lower sliding bushing ®, Toke off support ring ®. Toke off seal ring ®, = Take off lock ring ®, = Take off dust boot ©. Condition ‘The fork legs must be disassembled6 FORK, TRIPLE CLAMP 2a 2orase0| 20066610] Check the inner tube and axle clamp for damage. » If there is damage = Change the inner tube. Measure the outside diameter at several locations on the inner tube. ‘47.375... 88.005 mm (188878... 1.88996 in} ‘Outside diameter of nner tube » If the measured value is less than the specified value: = Change the inner tube. = Measure the run-out of the inner tube. Run-out of inner tube 0.20 mm (S 0.0079 in) » Ifthe measured value is greater than the specified value: = Change the inner tube. Check the outer tube for damage, > If there is damage: = Change the outer tube. Check the surface of the sliding bushings. » If the bronze-colored layer @ under the sliding layer @ is visible: Replace the sliding bushings. Check the spring length, Guideline Spring lenath with preload spaceris) | 886 mm (15.2 in) > Ifthe measured value is greater than the specified value: Reduce the thickness of the preload spacer, + Ifthe measured value is less than the specified value: = Increase the thickness of the preload spacer.6 FORK, TRIPLE CLAMP 24 6.10 Assembling the fork legs These operations are the same on both fork logs. 200670-10 Preparatory work Check the fork legs. ( p. 22) Main work = Clamp the inner tube with the axle clamp. Install the special tool Protecting sleeve (T1401) (* p. 282) ©. Grease and push on dust bor Di p. 268) Lubricant (75) Info I Always replace the dust boot, seal ring, lock ring, and support rng tall the dust boot withthe sealing lip and spring expander facing down- = Push on lock ring @. = Grease and push on seal ring @. Lubricant (TS11) (+ p. 268) © Info Seating ring downward, open side upward, = Push on support ring @. Remove the special tool = Sand the edges ofthe sliding bushes with 600-grain sandpaper, then clean and srease them, Fork oll (SAE 4) (4860116681) (* 6. 267) = Push on the lower sliding bushing @, = Mount the upper sliding bushing @. Info T without using a tool, carefully pull the stack apart by hand. Heat up the outer tube in area @ of the lower sliding bushings. Guideline 50°C (122 °F) = Slide the outer tube onto the inner tube. Hole the lower sliding bushing wi [Assembly tool (T1402) (p28) s—~—<“C~*~s~sSCSYS - Push t the longer side of the special sliding bushing all the way into the outer tube.6 FORK, TRIPLE CLAMP \ fo 200656-11 25 Position the support ring. Hold the seal ring with the shorter side of the special tool ‘Assombly tool (T14028) (* p. 282) Push the seal ring and support ring all the way into the outer tube Mount lock ring @. = Info ‘The lock ring must engage audibly. Install dust boot ©. Grease the O-ring of valve @ of the rebound damping, Labricant (1758) (* p. 269) — Mount valve @ of the rebound damping with the spring on adjusting tube @. Mount valve @ of the rebound damping from below in cartridge ®, The adjusting tube protrudes 6 mm (0.197 in) from the cartridge and can be pressed in against the resistance of the spring 2€ The adjusting tube protrudes more than 7 mm (0.275 in) from the cartridge and cannot be pressed in against the resistance of the spring. Screw on fluid barrier @ as far as it will go © Info ‘The fluid barrier must be tightened as much as possible. Do not use tools. Install the special tool on the cartridge Support tool (T14026) (* p. 282) Info ‘The special tool must be used to prevent the adjusting tube from being raised, which would cause oil to enter into the piston rod.6 FORK, TRIPLE CLAMP 26 7 = Pull the rebound valve @ out of the cartridge until it hits the stop. 201227-10] Push the cartridge with the spring seat and preload spacer into the inner tube. = Mount screw @ of the cartridge with the seal ring and tighten it Guideline Screw, cartridge Mizx1 25 Nm (18.4 Ibe ft) 201326-10] = Grease and mount screws ® of the axle clamp but do not tighten. Lobricant (T7152) (* p. 263) = Clamp the fork veticaly. = Add fork oil Fork oil per fork 750 ml Fork oil (SAE 4) (4860116681) log (25.36 tloz) | ( p.267) Info Tut out the piston rod and push back in a number of times to bleed the car- ‘ridge. = Remove pin @ of the special too. Support tool (T14026) (* p. 282) Pull out the piston rod. Mount the spring. Mount the spring again. Guideline Spring vate Medium (standard) 7-5 Ninny (42.8 Tain o067e12 — Pull the spring downwards, Mount the special tool on the hexagonal piece, Sf- ‘Open-end wrench (714032) (+ p. 282) ~ Remove the special too Support tool (T14026) (* p. 282) 20067210]6 FORK, TRIPLE CLAMP 20064611 Clamp the special tool in the vise. = Lubricate the thread of the piston rod Lubricant (T7158) (* p. 269) = Lubricate the upper edge of the piston rod t icant (7158) (* p. 269) 21 Screw the Preload Adjuster with the preload spacers onto the piston rod. TThe Pretoad adjuster must reach the stop before the piston rod begins turn- ing as well. If the piston rod thread is stiff, the rod must be held to prevent it from turning. Ifthe Preload Adjuster is not screwed in all the way, the rebound adjustment will not function properly. ‘Tighten Preload Adjuster Guideline ‘Screw cover an piston rod Mi2xi 25 Nm as ft) = Release the special tool, Pull the spring downward and take off the special tool. Push the outer tube upward. = Clamp the fork in the area of the lower triple clamp. Clamping stand (T14038) (* p. 282) Lubricate the O-ring of the Preload Adjuster. Lubricant (TS11) (* p. 268) = Screw on the load Adjuster and tighten. Guideline ‘Screw cover on outer tube W5IK1S 50 Nm (36.9 bt Alternative 1 Tur the adjusting screw of rebound damping ® and the adjusting screw of compression damping @ clockwise as far as possible = Tur back counterclockwise by the number of clicks corresponding to the fork leg type. . Guideline Rebound damping Comfort 20 clicks 20181611 Standard TS clicks Sport 10 clicks Full payload TO licks Compression damping Comfort 20 clicks Standard TS clicks Sport 10 clicks Full payload TO clicks = Turn spring preload @ clockwise all the way.6 FORK, TRIPLE CLAMP 28 — Turn back counterclockwise by the number of turns corresponding to the fork leg type. Guideline ‘Spring preload - Preload Adjuster Comfort Siumns Standard Bruns Sport Bums Full payload Stuns Alternative 2 Warning Danger of accidents Mocifications to the suspension settings can seri- ously alter the vehicle's ride behavior. Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling character's- ties and overload some components, = Only make adjustments within the recommended range. = After making adjustments, ride slowly at first to get the feel of the new ride behavior. = Return the adjusting screws to the position determined when the unit was dis- assembled 6.11 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. — Adjust the steering head bearing play without delay. © Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and subsequently the bearing seats in the frame are camaged. Preparatory work = Lift the motoreycle with the lift stand, (#* p. 12) Main work = Move the handlebar to the stralght-ahead position. Move the fork legs back and forth in the direction of travel Play should not be detectable on the steering head bearing. » If there is no detectable play: Adjust the steering head bearing play. (7 9. 31) Move the handlebar to and fro over the entire steering range. Te must be possible to move the handlebar easily over the entire steering range ‘There should be no detectable detent positions » If detent positions are detected: Adjust the steering head bearing play. (%* p. 31) = Check the steering head bearing and adjust it necessary, Finishing work = Remove the motorcycle from the work stand. ( p. 12)6 6.12 303877-10 FORK, TRIPLE CLAMP 29 Removing the lower triple clamp Preparatory work Lift the motoreyele with the lft stand. (F p. 12) Clamp down the rear of the vehicle. Remove the front splash protector. (%* p. 75) Remove the fork legs. (# p. 16) Remave the front fender. (% p. 75) Remove the headlight mask with the headlight. (7 p, 104) Main work Remove screws @. Take off the headlight mask holder. Hang the brake lines carefully to the side. Info Do not damage the brake lines, Remove screw @, Release screw @, remove the upper triple clamp with the han- dlebar and set aside. © Info Protect the motorcycle and attachments against damage by covering them. o not kink cables and lines. Remove protective ring @. 6.13 Installing the lower triple cl Remove O-ring @. Take out the lower triple clamp with the steering stem. ‘Take out the upper steering head bearing. lamp Main work ‘Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (* p. 268) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. Check that the upper steering head seal @ is posit Slide on O-ring @, ned correctly "8890-106 FORK, TRIPLE CLAMP 20 = Mount protective ring @. = Position the upper triple clamp with the handlebar. A Holding lugs @ engage in the drilled hole. Info Ensure that the throttle cable, the other cables, and the lines are correctly routed, Mount and tighten screw @. Guideline Screw, steering head 20x15 T2 Nm (89 FR Position the brake lines and headlight mask holder. Mount and tighten screws @, Guideline Remaining chassis screws Me 10 Nm 7.4 BA Install the fork legs. (* p. 17) Tighten screw @, Guideline ‘Screw, steering stem Me 20.Nm (24.8 tbe AY) 308891-10 Finishing work = Check that the wiring hamess, cables, and brake and clutch lines are free to move and correctly routed, Check the steering head bearing play. (** p. 28) Remove the matoreycle from the work stand. (* p. 12) Remove the front fender. (* 9. 75) Refit the headlight mask with the headlight, (& p, 104) Check that the lighting is functioning properly. Check the headlight setting. (** p. 105)6 FORK, TRIPLE CLAMP a (6.14 Lubricating the steering head beating So oS @ @ o® = Remove the lower triple clamp. (* p. 29) = Install the lower triple clamp. (* p. 29) Preparatory work = Lift the motoreycle with the lift stand. (** p. 12) ‘Main work = Loasen screws @ and @, Loosen and retighten screw @, Guideline Screw, steering head M20x1-5 T2Nm 9 FR) = Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. — Tighten screws ©. Guideline Screw, top triple clamp Ma 20 Nm (14.8 Ibe ft Tighten screw @, Guideline ‘Sorew, steering stem Me 20 Nm (14.8 Ibe ft Finishing work = Check the steering head bearing play. (* p. 28) = Remove the motorcycle from the work stand, (* p. 12)7 HANDLEBAR, CONTROLS 2 TA Adjusting the basic postion of the clutch lever 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 handlebar, The range of adjustment is limited. ‘Turn the adjusting screw by hand only, and do nat apply any force. Do not make any adjustments while riding! = Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw @. 101166410 = Check the throttle grip for smooth operation. Move the handlebar to the straight-ahead position, Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throtle cable 3. 5mm (0.12...02 in) » If the throttle cable play does not meet specifications: = Adjust the play in the throttle cable. (** p. 33) Danger 400192310 Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. = When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an ‘ffective exhaust extraction system, = Start the engine and let it rum idle. Move the handlebar to and fro over the entire steering range. ‘The idle speed must not change, » If the idle speed changes: Adjust the play in the throttle cable, ( p. 33) Preparatory work = Remove the seat, (* p, 63) = Remove the fuel tank. (** p. 65) = Remove the air filter. (7 p. 58) ‘Main work = Loosen screws @. Info T The screws stay in the intake flange. = Remove the intake snorkel.7 HANDLEBAR, CONTROLS 2 30«a77-10] Check the throttle cable routing. Both throttle cables must be routed side by side, downward in front of the han the specied value is ot veacheds = Charge the piston od = Measure the run-out of he piston ro Piston od 20102710 Run-out 0.03 mm (0.0012 m) » Ifthe measured value is greater than the specified value: = Change the piston rod, ~ Check the piston rod for damage and wear » there is damage or wear: = Change the piston rod info T The operations are the same for the upper and lower heim joints. Condition ‘The shock absorber has been removed. = Clamp the shock absorber into the vice with soft jaws. Remove both collar bushings @ of the heim joint with a drift. Pin (7120) (* p. 281) = Remove seal rings @ on both sides. 200907-10|8 SHOCK ABSORBER, SWINGARM a = Press heim joint @ aside. fs Pressing tool (112078) (* p. 281) 7 The heim joint is resting against one lock ring. Remove the other lock ring ®. 20090810 = Place special tool @ underneath and push out the heim joint with special tool @. Pressing tool (112078) (* p. 281) 200809-10] Info The operations are the same for the upper and lower helm joints = Place special tool @ underneath and press in the heim joint as far as the lock ring. using special tool @. Pressing tool (112078) (* p. 281) Pressing tool (11206) (* p. 281) 200911-10] = Mount the second lock ring @. = Mount and grease seal rings @ on both sides. Lubricant (1758) (* p. 269) 20091210] Push in both collar bushings of the heim joint.8 SHOCK ABSORBER, SWINGARM = Position washer @. e = Grease and mount seal ring @. Lubricant (1511) (* p. 268) Cda® | — Womtwastere. e\¢ i 200084-10| Mount centering disk ©. = Mount rebound rubber @. oe 200885-10| = Grease the nut of the O- 1. Lubricant (T7158) (¥ p. 269) = Mount the O-ring @. Grease the sealing li of the dust boot Lubricant (1625) (* p. 269) = Install dust boot @. 200981-11 Preparatory work Assemble the seal ring retainer. (Fp. £4) ‘Main work = Clamp the piston rod with the fork in a vise, Mount rubber buffer plug @ and locking cap @. Position special tool on the piston rod Mounting sleove (T1515) (* p. 283) Grease the dust boot and push seal ring retainer @ on to the piston rod. Labricant (1625) (* p. 269) Remove the special tool = Mount rebound washer @ with cut-out @ facing down. = Mount compression shim stack @ with the smaller shims at the bottom.8 SHOCK ABSORBER, SWINGARM ~ ° @° 2o.0a1-10| 201032410] 9032-10] £ = Sand both sides of piston @ on a surface plate using grain 1200 sandpaper. = Clean the piston. = Mount the piston. Guideline View © Piston from above View @ Piston from below Mount rebound shim stack @ with the smaller shims at the top. Mount supporting plate = Mount and tighten nut ©. Guideline Nat, piston rod Mi2x1 40 Nm (29.5 lof ft) = Mount washer ®. = Mount and tighten screw ®. Guideline ¢ 20103410] Screw, piston rod M6x0.5 6 Nm Toctite® 2701 (4.4 tbr A Preparatory work Assemble the seal ring retainer. ( p. 44) = Assemble the piston rod. (* p. 44) ‘Main work =" Slide the spring and piston onto the compression adjuster @. = Lubricate the O-rings. Lbricant (1758) (* p. 269) Lubricate the thread, Lbricant (1759) (* p. 269) = Mount and tighten the compression adjuster. Guideline ‘Compression adjuster Maint 50Nm (36.9 Ibe ft)8 SHOCK ABSORBER, SWINGARM v ‘ 20101910 o &: T » » as, Mount screw @ but do net tighten yet = Lubricate O-ring ofthe seal ring Lubricant (1758) (* p. 269) = Fill the damper cartridge about halt full ‘Shock absorber oil (SAE 2.5) (5018034281) (* p. 267) = Carefully mount the piston rod. = Mount seal ring retainer @ and slide it under the ring groove, Mount lock ring ©. Info Do not scratch the inside surface. = Pull out the piston rod until the seal ring retainer rests against the lock ring, = Mount locking cap @ of the damper cartridge, = Bleed and fill the damper, (* p. 47) Fill the damper with nitrogen. (%* p. 50) = Mount rubber cap @ of the reservoir, ative 1 = Turn adjusting screw @ clockwise up to the last perceptible click. Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard TS clicks Sport TO clicks Full payload TO elicks8 SHOCK ABSORBER, SWINGARM a Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click. = Turn back counterclockwise by the number of clicks corresponding to the shack absorber type, Guideline ‘Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload TS clicks — Tum adjusting screw @ clockwise all the way using a socket wrench. = Turn back counterclockwise by the number of turns corresponding to the shock absorber type, Guideline ‘Compression damping, high-speed Comfort 2iums Standard 1.5 tums Sport Tin Full payload Tum Alternative 2 Warning Danger of accidents Mocifications to the suspension settings can seri- ‘ously alter the vehicle's ride behavior. = Extreme modifications to the adjustment of the suspension compo rents can cause a serious deterioration in the handling characteris tics and overload some components. Only make adjustments within the recmmended range. = Atter making adjustments, ride slowly at first to get the feel of the new ride behavior = Tum adjusting screws @, sembly. and @ to the position determined during disas- Info TH Before working with the vacuum pump, carefully read the operating manual included with the vacuum pump. Completely open the adjusting elements of the rebound and compression damping. Remove the filling port screw. Mount adapter @ on the damper. © Info Do tand ighten only without using a tool. Connect adapter @ to connecter @ of the vacuum pump. Vacuum pump (112408) (* p. 281) Clamp the damper with soft jaws or hold it as shown in the photo 20103810] © Info TD clamp the damper only lightly, The filling part must be located at the highest position. ‘The piston rod moves in and out during filing; do not immobilize it by hold- ing it with your hand,8 SHOCK ABSORBER, SWINGARM Position the control lever as shown in the photo. External tank @ is set to Closed, Damper © is set to Vacuum ang ir @ is set to Vacuum, Activate On/Off switch ©. The suction process begins. Pressure gauge @ drops to the required value. =O bar Vacuum gauge @ drops to the required value 2a103010] 200267-10| 200268-10] ‘mbar Determine distance @ between the floating piston and reservoir hole with the spe ial tool, Depth micrometer (T1078) (* p. 280) A The floating piston is positioned all the way at the bottom. ‘When the vacuum gauge reaches the required value, turn control lever Ol reser- voir © to Equalize pressure. Guideline “4 mbar 7 The pressure gauge increases to the required value. O bar ‘When the pressure gauge reaches the req to Pressure. ed value, tutn control lever Damper @ Guideline ‘O bar Y Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar When the pressure gauge reaches the required valve, turn contol lever Damper © to Vacuum, Guideline 3 bar 7 The pressure gauge drops to the required value. Obar ‘the pressure gauge reaches the voir @ to Vacuum. Guideline squired value, turn control lever Oil reser- 0 bar 7 The vacuum gauge drops to the required value. & mbar8 SHOCK ABSORBER, SWINGARM 49 = When the vacuum gauge reaches the required value, turn control lever Oil reser voir © to Equalize Pressure. Guideline ‘Bmbar 7 The pressure gauge drops to the required value, O bar When the pressure gauge reaches the required value, turn control lever Damper © to Pressure, Guideline ‘bar Oil is pumped into the damper. 7 The pressure gauge increases to the required value, 3 bar = When the prossure gauge reaches the required value, turn control lever Damper © to Vacuum, Guideline ‘3 bar The pressure gauge drops to the required valve. O bar When the pressure gauge reaches the required valve, actwvate the On/Off switch. 20026210] Guideline ‘O bar The vacuum pump is switched off = Slide O-ring @ to the end of the special tool by the specified value (distance @ ° § E minus spectied value). Guieline i Yi ¥ To mm 7 Depth micrometer T1078) (* p. 280) Oo o : Push the floating piston inte the reservoir tothe distance described above using the special 00, a mf 20104010 info Twnen the piston rod is fully extended, the floating piston must be at pre- cisely this position; otherwise, damage will occur when the shock absorber ‘compresses and rebounds. = Remove the special tool = Remove adapter @ from connector @ of the vacuum pump. 9 ® Info Hold the damper so that the filling port is at the highest point. = Remove the adapter AY — Mount and tighten screw @. Guideline Screw, filling port Ml0x1 14 Nm 201041-10] (10.3 Ibe ft)8 SHOCK ABSORBER, SWINGARM r 20104210] 201043.10| ‘Serew in screw @ by approx. 2 turns but do not tighten. Info, TThe piston rod is fully extended, Fix the special tool in the vise, Nitrogen filling tool (117081) (* p. 283) Connect the special tool to the pressure regulator ofthe filling cylinder. Filling gas - nitrogen Adjust the pressure regulator. Guideline Gas pressure 10 bar (145 psi) Position the damper in the special too. The hexagonal part of the tap handle filing port screw. Open filer tap ©. Fill the damper for at least 1 seconds. Guideline @ engages in the hexagon socket of the Gas pressure 10 bar (145 psi) Into T watch the pressure regulator dial Ensure that the damper is filed to Tighten the filing port screw. Guideline the specified pressure, Close the filling port screw using tap handle @. Close tap @ and take the damper out of the special tool ‘Screw filing port, reservoir M5 35 Nm (2.58 Ibe ft) poioi2-11 Screw on retaining ring @ and adjusting ring @ with the washer. Measure the overall spring length without Position the spring. Guideline load. Spring rate Medium (standard) 140 Nimm (799 Tavin) Mount washer @ and spring retainer @.8 SHOCK ABSORBER, SWINGARM 31 e.’ =e ative 1 = Tension the spring by turning the adjusting ring to the prescribed value Guideline Spring preload Comfort 11 mm (0.43 in) Standard TI mm (0.43 in) Sport 11 mm (0.43 in) Full payload TS mm (51m) Hook wrench (T1578) (* p. 283) native 2 Warning Danger of accidents Mocifications to the suspension settings can seri- ously alter the vehicle's ride behavior Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling character's- tics and overload some components. = Only make adjustments within the recommended range. = Aiter making adjustments, ride slowly at frst to get the feel of the new ride behavior. Adjust the spring to the value determined wren it was removed by turning the adjusting ring Hook wrench (T1578) ( p. 283) Hold adjusting ring @ and tighten retaining ring @. Hook wrench (T1578) (* p. 283)9 EXHAUST 52 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. = Allow the exhaust system to cool down. Do not touch hol components. Preparatory work = Lift the motoreycle with the lift stand. (* p. 12) — Remove the seal, (* p, 63) = Remove the fuel tank, (% p. 68) ‘Main work = Remove screws ©, Remove the cover. Disconnect plug Expose the lambda sensor cable. Disconnect plug = Remove screws ©, = Remove the cover. =. Disconnect plug @.9 EXHAUST 53 = Remove screws @. = Remove nut @, Expose the cables of the lambda sensor and the side stand, — Remove the side stand bracket. Release the exhaust clam = Release exhaust clamp @. Remove nuts ©. — Remove distance sleeve ®. = Remove nuts ®. Remove the distance sleeve. — Remove fitting ®, Take off the exhaust manifold9 EXHAUST ‘Main work Position the exhaust manifold. Mount fitting @ but do not tighten yet. Guideline Remaining chassis screws we 25Nm (18.4 Ibe ft Mount the distance sleeve Mount nuts @ but do not tighten them yet. Guideline Nat, manifold on eylinder head ve Tightening, sequence: Tighten the nuts uniformly, Do net bend the metal Mount the distance sleeve Mount and tighten nuts @, Guideline ‘Nut, manifold on eylinder head ve Tightening sequence: Tighten the nuts uniformly. Do not bend the metal, Tighten nuts @. Guideline Nat, manifold on cylinder head we Tightening: sequence: Tighten the nuts uniformly. Do not bend the metal Position and tighten exhaust clamp @. Guideline Remaining chassis screws Ms 25 Nm (18.4 Ibe ft Position and tighten exhaust clamp ®. Guideline Screw, exhaust clamp on distributor | MB 35 Nm pipe (25.8 Ibe ft) Tighten fitting @, Guideline Remaining chassis screws Me 25 Nm (18.4 Ibe ft9 EXHAUST 55 — Position the lambda sensor cable. = Position the side stand bracket. = Mount and tighten screws @. Guideline ‘Screw, side stand bracket] MIO 45 Nm Toctte® 24" (33.2 Ibt A) = Mount and tighten the nut @. Guideline Screw connection, engine mounting | M10 45 Nm bracket (33.2 Ibe ft = Position the side stand cable. = Plug in connector ©. Position the cover, = Mount and tighten screws . Guideline Remaining chassis screws Me TO Nm (7-4 BA = Plug in connector @. = Attach the cables of the lambda sensor and the side stand with cable binders. 30890011 Position the lambda sensor cable, = Plug in connector . = Attach the lambda sensor cable with cable binders. Position the cover = Mount and tighten screws @. Guideline Remaining chassis screws Me TO Nm (7a BofA9 EXHAUST 56 Finishing work = Install the fuel tank. (* p. 66) = Mount the seat, (* p, 64) = Remove the motorcycle from the work stand. (© p. 12) 9.3 Removing the main silencer with the distributor pipe Warning Danger of burns The exhaust system gets very hot when the vehicle is driven, = Allow the exhaust system to cool down, Do not touch hat components, Release nuts @. Fold both turn signals down, 308867-10 Remove screws @. Remove the retaining bracket and exhaust clamp. Remove screws @. Loosen screw ©. ‘Take off the main silencer with the distributor pipe.9 EXHAUST 87 308866-11 Position the main silencer with the distributor pipe. Mount the exhaust clamp and retaining bracket. Mount screws @ but do not tighten them yet Guideline Screw, exhaust clamp on main silencer | MB 20 Nm (14.8 Ibe ft Mount screws @ but do not tighten them yet. Guideline Remaining chassis screws Me 25 Nm (18.4 Ibe ft) Position and tighten exhaust clamp @. Guideline Screw, exhaust clamp on distributor | MB 35 Nm Pipe (25.8 Ibe ft) Tighten screws @ Guideline Screw, exhaust clamp on main silencer | MB 20 Nm (14.8 Ibe ft) Fully tighten screws @. Guideline Remaining chassis screws Ms 25 Nm (18.4 Ibe ft Position the turn signal. Mount and tighten nuts @,10 AIR FILTER se 10.1 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Preparatory work = Remove the seat. (* p. 63) = Remove the fuel lank, (* p. 65) Main work Push back spring band clamps @, Pliers for spring band clamp (60029057100) (* p. 277) Pull off engine breather hoses and remove the spring band clamps. = Remove the cable binder and detach connector @. \ 30497210 = Remove screws @, © Info ‘The screws stay in the air filter box lid Take off air filter box i ‘© Info Pay attention to the engine breather hoses. soea7et0 Tur intake trumpet © counterclockwise and remove it. = Remove air filter ® = Clean the air filter box. 3044761010 AIR FILTER 59 10.2 __ Installing the air filter Main work = Position air filter @. 30ea76-1 Mount intake trumpet @. Position the air filter box lic = Tighten screws @. aoea7a0 = Plug in connector @ and secure with a cable binder. = Mount the engine breather hoses with hose clips @. Pliers for spring band clamp (60029057100) (* p. 277) 304972411 Finishing work = Install the fuel tank. (* p. 66) = Mount the seat. (* p. 64)10 AIR FILTER 60 10.9 Removing the airfter Box Preparatory work = Remove the seat. (* p. 63) = Remove the fuel tank. (** p. 65) = Remove the air filter. ( p. 58) ‘Main work = Loosen screws @ Info T The screws stay in the intake snorkel. = Remove the intake flange. = Pull manifold absolute pressure sensor @ from the holder and hang to one side. = Remove screws @, = Remove the side panel = Pull connector @ off of the holder and disconnect it. Pull manifold absolute pressure sensor @ from the holder and hang to one side. = Remove screws @. = Remove the side panel. = Push spring band clamp @ back. Pliers for spring band clamp (60029057100) (* p. 27) Pull off the fuel hose and remove the spring band clamp, = Pull secondary ar valve @ off ofthe holder.10 AIR FILTER 6 Loosen screws @. Lift the air filter box slightly. Detach hose @. Pull fuel hose ® downward out of the air filter box. Pull the air filter box upward with the throttle valve body. Remove the air filter box. Raise the throttle valve body at the front and fix it on the handlebar, © Info Protect the vehicle and attachments against damage by covering them Cover the intake duct with a cloth. Position rubber sleeves @. Position the air filter box. Push on hose @. Mount the throttle valve body. Position and tighten clamps @.10 AIR FILTER = Mount secondary air valve @ on the holder. Mount the fuel hose with spring band clamp ©. Pliers for spring band clamp (60029057100) (* p. 277) = Position the side panel = Mount and tighten screws @. = Plug in connector @ and mount on the holder. = Mount manifold absolute pressure sensor @ on the holder. — Position the side panel. = Mount and tighten screws @, = Mount manifold absolute pressure sensor @ on the holder. = Position the intake snorkel = Tighten screws @. ing work = Install the air filter, (& p. 59) Install the fuel tank. (* p, 66) = Mount the seat. ( p. 64)11. FUEL TANK, SEAT, TRIM 6 MA Opening the fer ep Danger Fire hazard Fuel is highly flammable. ~ Never refuel the vehicle near open flames or burning cigareties, and always switch off the engine first. 8e careful thal no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately — The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling, Warning Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel ‘Store fuel properly in a suitable canister and keep away from children, Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. = Lift the cover of the filler cap @ and insert the ignition key. Note Danger of damage Ignition key breakage. = To take pressure off of the ignition key, push down an the filler cap. Damages ignition keys must be replaced, Turn the ignition key 90° counterclockwise and remove the filler cap. 1o1101-10| zine TThe tiller cap has 2 tank ar vent system. Put the filler cap back on and turn the ignition key 90° clockwise. = Remove the ignition key and fold down the cover. p, ~ 10110291, Insert the ignition key in the seat lock @ and turn it clockwise, = Raise the rear of the seat, push it towards the rear, and remove it upwards. Remove the ignition key from the seat lock, 1011041011. FUEL TANK, SEAT, TRIM 6 (14 —Mountingthe seat = Position front recesses @ of the seat on the oval head screws of the fuel tank, lower the rear and simultaneously push it forward. Both lugs @ must hook into the frame and locking bolt © must be inserted into the lock housing, The seat engages with an audible click. Finally, check that the seat is correctly mounted, Preparatory work = Remove the seat. (* p. 63) ‘Main work = Remove screws @ and the spoller on both sides. = Remave screw @ on both sides. © Info The fuel hoses do not need to be disconnected, Remove screw @, Carefully push the fuel tank back. ‘Main work = Carefully push the fuel tank forward, = Mount and tighten screw @ with the collar bushing. Guideline Remaining chassis screws Me TONm (7-4 Toft)11. FUEL TANK, SEAT, TRIM 6s = Install and tighten screw @ with the bearing sleeve and rubber bushing on both sides. Guideline Remaining chassis screws ws 25 Nm (18.4 1bF A) Check the routing ofthe fuel lines. = Position the spoilers on bath sides. Mount and tighten screws @, Guideline Screw, spoiler Me 33 Nm (2.43 tbe f) Finishing work = Mount the seat. (* p. 64) 11.7 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. — Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine f fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately — The fuel in the fuel tank expands when warm and may emerge if overilled, Follow the instructions on refueling, t. Be careful that no Warning Danger of poisoning Fuel is poisonous and a health azar, — Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. f contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water, If fuel is swallowed, contact a physician immediately, Change clothing that is contaminated with fuel. ‘Store fuel properly in a suitable canister and keep away fram children, Preparatory work = Remove the seat. (* p. 63) Main work = Close fuel cocks @. = Push back the hose clips and detach the fuel hoses. = Press down the metal plate and disconnect the fuel hase connection @. © Info Remaining fuel may run out of the fuel hose. — Disconnect plug @. — Pulloff vent hose @, = Remove screw ,11. FUEL TANK, SEAT, TRIM Remove screws @ and spoilers on both sides. Remove screw @ on both sides. = Pull off vent hose ©. ‘Take off the fuel tank. 30889610 11.8 Installing the fuel tank 66 Danger Fire hazard Fuel is highly flammable. Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. he fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling, Warning Danger of poisoning Fuel is poisonous and a health hazard. = Fuel must not come into contact with the skin, eyes, or clothing, Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and Keep away from children. Main work = Position the fuel tank. — Mount vent hose ©11. FUEL TANK, SEAT, TRIM 67 = Install and tighten screw @ with the bearing sleeve and rubber bushing on both sides. Guideline Remaining chassis screws ws 25 Nm (18.4 1bF A) — Position the spoiler on both sides. Mount and tighten screws @, Guideline Screw, spoiler Me 33 Nm (2.43 toe f) = Mount vent hose © Mount and tighten screw @ with the collar bushing Guideline Remaining chassis screws i TO Nm (7-4 Taf ft) 30889210 = Plug in connector @. = Mount the fuel hoses with hose clips. = Connect fue! hose connector @ with the new O-ring, = Open fuel cocks ©. Finishing work = Mount the seat. ( p. 64) 11.9 Changing the fuel filter Danger Fire hazard Fuel is highly flammable. Be careful that no — Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine f fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately ~The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling, Warning Danger of poisoning Fuel is poisonous and a health hazara. = Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors, f contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately, Change clothing thal is contaminated with fuel. ‘Store fuel properly in a suitable canister and keep away trom children, Warning Environmental hazard Improper handling of fuel is a danger to the environment, = Do not allow fuel to get into the ground water, the ground, or the sewage system.11. FUEL TANK, SEAT, TRIM Preparatory work = Drain the fuel from the fuel tank into a suitable container. = Remove the seat, (* p, 63) = Remove the fuel tank. (** p. 65) Main work = Remove screws @. = Pull out the fuel pump. Push clamps @ outward, = Take off the fuel filter housing, = Remove gasket @. Take off fuel pipe ©. = Detach connectors @ and @. Remove screw @ with the washer.1 FUEL TANK, SEAT, TRIM Remove screws @. = Remove retaining brackets @ and ®, = Remove plastic housing @ with the distance sleeves, Take the fuel pump cut of the fuel pump cover. = Take off sealing element ®. = Remove fuel filter. = Mount the new fuel filter.1 FUEL TANK, SEAT, TRIM 1 Release latch @. Pull off the outer fue! filter housing. Toke off fuel filter ®, = Mount the new fuel filter. = Mount the outer fuel filter housing. Locking mechanism @ engages in the fuel filter housing, = Mount sealing element @. Position the fuel pump in the fuel pump cover. = Mount plastic housing ® with the distance sleeves. 7 The lugs of the plastic housing engage in the holes of the fuel pump cover,11. FUEL TANK, SEAT, TRIM n = Mount retaining brackets @ and @. = Mount and tighten screws ©. Guideline ‘Screw, retal ig bracket on fuel pump [MS 4 Nm (3 Ibt FD = Mount and tighten screw @ with the washer. Plug in connectors @ and @. = Mount gasket @. Mount fuel pipe @. = Mount fuel filter housing, % Clamps @ must engage.11. FUEL TANK, SEAT, TRIM n = Position the fuel pump. = Mount and tighten screws @. Guideline Screw, fuel pump We G Nm (6.4 AD 30896410] Finishing work = Install the fuel tank. ( p. 66) = Mount the seat, (© p. 64) Danger Fite hazard Fuel is highly flammable. ~ Never refuel the vehicle near open flames or burning cigarettes, and always suitch off the engine fist. Be careful that no fuels spilt, especially on hot vehicle components. Clean up spitt fuel immediatly. ~The fuel in the fuel tank expands when warm and may emerge if overiled, Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard — Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. if contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel ‘Store fuel properly in a suitable canister and keep away from children, ymental hazard Improper handling of fuel is a danger to the environment, = Do not allow fuel to get into the ground water, the ground, or the sewage system, Preparatory work Drain the fuel from the fuel tank into a sultable container. Remave the seat, ( p. 63), Remove the fuel tank, (* p. 65) ‘Main work = Remove screws @, = Pull out the fuel pump. Position the new fuel pump into the fuel tank. = Mount and tighten screws @. Guideline Screw, fuel pump Me 6 Nm (4-4 tof) 20896210] Finishing work = Install the fuel tank. (* p. 66) = Mount the seat. ( p, 64)11. FUEL TANK, SEAT, TRIM a MAL Checking the fuel pressure Danger Fire hazard Fuel is highly flammable. ~ Never refuel the vehicle near open flames or burning cigareties, and always switch off the engine first. 8e careful thal no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately — The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling, Warning Danger of poisoning Fuel is poisonous and a health hazard. ~ Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water, If fuel is swallowed, contact a physician immediately, Change clothing that is contaminated with fuel. ‘Store fuel properly in a suitable canister and keep away from children, Condition ‘The fuel tank is completely full, Ensure that the battery voltage does not drop below 12.5 V. The ignition is oft ‘The diagnostic tool is connected. = Press down the metal plate and disconnect the fuel hose connection @. Info T Remaining fuel may run out ofthe fuel hose. = Mount special tool @ Pressure testing tool (61029094000) (* p. 279), = Mount special tool @ with nozzle code 1,05. Testing hose (61029093000) (* p. 279) > = Tet the hose ed in a fel cai Ge Guang Minima Seo Tal eaier [TOTES OS aa dse6s0 Switch on the ignition = Perform the “Actuator Test" > “Function test of fuel pump contro”. Guideline Maximum duration of astuatortest___[ 3 min Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active 33. 37 bar 8... 64 paid > Tf the specified value isnot achieved — Open the filler cap. (* p. 63) . he tank ai * Gi ‘Check the tank air vent sytem 0927-0111. FUEL TANK, SEAT, TRIM 1” Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 33. 37 bar (48... 64 psid » If the specified value is not achieved Check that the fuel lines are free of blockages. Change the fuel filter, (% p. 67) Change the fuel pump. (* p. 72) "Function test of fuel pump control” actuator test by pressing the "Quit* but- Remave the special tools Connect the fuel hose connection.12 MASK, FENDER, TRIM 8 303849-10| = Remove screws @. Remove the front fender. Ensure that the spacers remain in place. Ensure that the spacers are mounted in tne fender. Position the front fender. Mount and tighten screws @, Guideline Remaining chassis screws Me TONm (7-4 Toff Info Tnsure thatthe holding lugs engage inthe headlight mask Remove screws @. Take off the front splash protector. = Position the front splash protector. Mount and tighten screws @. Guideline Screw, splash protector 6 Nm (4.4 tot A) Toctte® 243"13. WHEELS 1% © Info Low tire air pressure leads to abnormal wear and overheating ofthe tire. Cortect tir air pressure ensures optimal riding comfort and maximum tire service life. Remove the protection cap, Check the tire air pressure when the tres are cold, Tire air pressure, s0l0 Front 2.2 bar (32 psd) Rear 22 bar (32 psi) Tire air pressure with passenger/full payload Front 2.4 bar (5 psd Rear 25 bar (36 psi) > If the tire pressure does not meet specifications: Correct the tie pressure, = Mount the protection cap. Info TThe rubber seal in the protection cap prevents air from leaking out of the tire if the valve is faulty. Warning Danger of accidents Uncontrollale vehicle handling in the event ofa flat tre, = Inthe interest of safety, replace damaged or worn tres immediately Wa Danger of crashing Poor vehicle handling due to different tre tread patterns on front and rear wheels. = The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tireswhects, — Only tresiwheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. — New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in, Info The type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle. Worn tires have a negative effect on vehicle handling, especially on wet surfaces. o> Ff eset eis rinse tha aomeg Gans he tres ~ check ie depth te ead we y T Note focal national regulations concerning the minimum tread depth. AY 400602410] Minimum tread depth 2mm (0.08 in)13. WHEELS n » If the tread depth is less than the minimum permissible depth: Change the tires. = Check the age of the tires. Info T The tre's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking, The first two digits refer to the week of manufacture and last two digits refer to the year of manufac- ture. KTM recommends that the tires be changed after 5 years atthe latest, regardless of the actual state of wear. » Ifa tire is more than five years ol Change the tires. 13.3.1 Removing the front whe Preparatory work = Raise the motoreycle with the rear wheel stand. (* p. 11) — Raise the matoreyole with the front wheel stand. (# p. 11) Main work = Remove the screws @ from beth brake calipers. = Press back the brake linings with alight lateral tilting of the brake calipers on the brake disc. Pull the brake calipers carefully back from the brake discs and hang them to one side. Info To not pull the hand brake lever when the brake calipers are removed = Loosen screws @ and @, = Unscrew screw @ about six turns and press your hand on the serew to push the wheel spindle out of the axle clamp. Remove screw Warning Danger of accidents Reduced braking efficiency due to damaged brake discs. Always lay down the wheel in such a way that the brake discs are not damages. = Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork 13.3.2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to cl or grease on the brake discs, = Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.13. WHEELS n Check the wheel bearing for damage and wear. » If the wheel bearing is broken or worn: = Replace the whee! bearing, = Grease and mount the left and right spacers and the shaft seal rings. Longelife grease (¥ p. 268) Glean screw @ and wheel spindle @. = Lift the front wheel into the fork, position it, and insert the wheel spindle, The arrow on the spoke points in the direction of motion. = Mount and tighten screw @. Guideline Bok, front axle M25R1.5 45 Nm (33.2 Ibe ft) = Position the brake calipers and check that the brake linings are seated correctly. = Mount screws @ on both brake calipers but do nat tighten yet = Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point. Fix the hand brake lever in its engaged position. The brake calipers straighten. = Tighten screws @ on both brake calipers. Guideline Screw, front brake caliper [M10x1.25 [45 Nm Toctite® 243" (33.2 Ibf A) Remove the fixation of the hand brake lever. Take the motorcycle off of the front wheel stand. (%* p. 11) = Take the motorcycle off of the rear wheel stand, (** p. 11) Pull the front brake and compress the fork powerfully a few times. The fork legs straighten, = Fully tighten screws @. Guideline Serew, fork stub 8 15 Nm aL bef 13.3.3. Checking the front brake di Warning Danger of accidents Reduces braking efficiency due to worn brake cists). = Change the worn brake diss) without delay. = Check the thickness ofthe brake cic in several places to ste i it conforms to mea- Al] surement ! © Info T Wear reduces the thickness of the brake discs in area @ of the brake discs. Broke dies - wear limit o Front Znm O17 mM co1s61013. WHEELS 1 » I the brake dise thickness is less than the specified valve: Change the brake dises. CCheck the brake discs for damage, cracking and deformation » If the brake discs exhibit damage, cracking or deformation: = Change the brake dises. 13.3.4 Removing the front brake discs Preparatory work = Raise the motorcycle with the rear wheel stand, (Fp. 11) = Raise the motorcycle with the front wheel stand. (* p. 11) Remove the front wheel. ( p. 77) in work = Remove screws @, Take off the brake disc. Repeat the operation on the opposite side 308847-10 13.3.5 _ Installing the front brake discs Main work = Clean the contact surface of the brake dis, = Position the brake disc with the label facing outward. Mount and tighten screws @. Guideline Screw, font brake dise | MB 30 Nm Toetite® 243 (22.1 tof f) Repeat the operation an the opposite side 308847-10 Finishing work = Install the front wheel. (* p. 77) 13.4 Rear wheel 13.4.1 Removing the rear wheel Preparatory work = Raise the motorcycle with the rear wheel stand. (© p. 11) Main work = Remove nut @, Remove chain adjuster @, = Pull out wheel spindle @ to the paint where the chain adjuster is no longer in con- tact with the adjusting screw. = Push the rear wheel forward as far as possible and take the chain off the rear sprocket, Withdraw the wheel spindle. Pull the rear wheel back until the brake caliper suppor is suspended freely between the brake dise and rim.13 WHEELS 20 Warning Danger of accidents Reduced braking efficiency due to damaged brake ‘Always lay down the wines! in such a way that the brake dises are not damaged: Take the rear wheel carefully 0 brake disc. of the swingarm without damaging the rim and/or Info Do not operate the foot brake when the rear wheel is removed. 13.4.2 Installing the rear whee! Warning Danger of accidents Reduced braking efficiency due ta oll or grease on the brake dises, = Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake, = After installing the rear wheel, always operate the foot brake until the pressure point is reached Main work = Check the rear hub rubber dampers. (* p. 84) Check the wheel bearing for damage and wear. > If the wheel bearing is broken or worn: = Replace the wheel bearing, Remove spacer @, Clean and grease the mating surfaces of the spacers and the shaft seal rings. Ton je grease (7 p. 268) = Install the spacer. = Clean and grease the thread of the wheel spindle and nut, Longelife grease ( p. 268) = Clean the fixing locations on the brake caliper support and swingarm, Engage the thrust bearing of the brake caliper support @ and the swingarm. Care- fully lift the rear wheel into the swingarm and engage the brake disc. Lay the chain ‘on the rear sprocket an mount the wheel spindle. = Mount chain adjuster @ and nut @. © Info Mount the left and right chain adjusters in the same position = Push the rear wheel forward so that the chain adjusters are in contact with the adjusting screws, and tighten the nut Guideline Th order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks ©, Nut, rear wheel spindle [M25x1.5 [30 Nm Thread greased (66.4 Ibt 1) = Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there isa pressure point, Finishing work = Take the motorcycle off of the rear wheel stand. (* p. 11) Check the chain tension, (* p. 81)13. WHEELS a 13.4.3 Checking the rear brake disc Waring Danger of accidents Reduced braking efficiency due to worn brake disc(s) — Change the worn brake dise(s) without delay, Check the thickness of the brake disc in several places to see if it conforms to mea- surement @. ‘© Info ‘Wear reduces the thickness of the brake disc in area @ of the brake dise. ‘wear Timit 25mm (0.177 in) aooaseio > If the brake dise thickness is less than the specified valve: = Change the brake disc Check the brake disc for damage, cracking and deformation, » If damage, cracks or deformation are visible on the brake dise: = Change the brake dises. 13.4.4 Removing the brake disc of the rear brake Preparatory work = Raise the motorcycle with the rear wheel stand, (* p. 11) Remove the rear wheel, (* p, 79) Main work = Remove screws @, Take off the brake disc, sosete10 13.4.5 Installing the brake disc of the rear brake Clean the contact surface of the brake dis. — Position the brake dise with the label facing outward. Mount and tighten screws @. Guideline Screw, rear brake disc | MB 30Nm Toetite® 243" (22.1 bt) = Install the rear wheel. ( p. 80) 13.4.6 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension, = Ifthe chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fll off the engine sprocket ar rear spracket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary13. WHEELS 22 Preparatory work = Lean the mot Main work = Shift the transmission to neutral = Inthe area of chain sliding guard, press the chain upward toward the swingarm and determine chain tension ®. reycle on the side stand, Info The upper chain section @ must be taut Chain wear is not always even, so you should repeat this measurement at different chain positions, [Chain tension Timm 0.28 » If the chain tension does not meet specifications = Adjust the chain tension, ( p. 82) 13.4.7 Adjusting the chain tension, Warning Danger of accidents Danger caused by incorrect chain tension. — Ifthe chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershatt of the transmission to break in extreme cases. If the chain is too loose, however, it may fll off the engine sprocket or rear spracket and black the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary. Preparatory work — Lean the motoreycle on the side stand. Check the chain tension, (* p. 81) Remove the frame slider. Main work = Loosen nut ©, = Loosen nuts @, Adjust the chain tension by turning the adjusting screws @ on the left and right Guideline Chain tension T mm (0.28 in ‘Turn adjusting screws @ on the left and right so that the markings on the left ang right chain adjuster @ are in the same position in relation to reference marks @. The rear wheel is then correctly aligned, Info T_the upper ehain section must be taut, Chain wear is not always even, so you should check the setting at different chain positions. = Tighten nuts @. Make sure that chain adjusters @ are resting against adjusting screws @. = Tighten nut @ Guideline Nut, rear wheel spindle J M25x1.5 _)30Nm Thread greased (66.4 Ibt 1 = Info T The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary transmissions with the same chain length. Chain adjusters @ can be turned through 180°,13. WHEELS 13.4.8 Checking the chain, rear sprocket, engine sprocket and chain guide = Check the rear sprocket and engine sprocket for wear. 83 ue 100132-10 > If the rear sprocket or engine sprocket is worn: = Change the power set. © Info T The rear sprocket, engine sprocket and chain should always be changed togetn Shift the transmission to neutral Pull the lower chain section with specified weight @. Guideline ‘Weight, chain wear measurement 15 kg G3 Ib Measure the distance @ of 18 chain links in the lower chain section. Info. T chain wear is not always even, so you should repeat this measurement at different chain positions, 123 1617 18 700872.91 Maximum distance @ ai the longest | 272 mm (10-71 in) chain section » If distance @ is greater than the specified measurement: = Change the power set. ® Into Twhen the chain is replaces, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets For safety reasons, the chain has no chain joint. ‘Check the chain sliding guard for wear. » If there is no gap between the chain and the upper edge of the screw: = Change the chain sliding guard. Check the chain sliding guard for tightness, » If the chain sliding guard is loose: Tighten the chain sliding guard, Guideline Screw, chain shang] WS Nn ]= ued (3.7 be Screw chain shang | WO Nm] oette® 20a award tga br 13.4.9 Cleaning the chain Check the chain sliding piece for wear. » If the dril hole becomes visible on the chain sliding piece in area @: = Change the chain sliding piece. Check the chain sliding piece for tightness. » If the chain sliding piece is loose: = Tighten the chain sliding piece Guideline ‘Screw, chain sliding piece Elo PT 2Nm 60x20 (1.5 ter fo War 1 Danger of accidents Oil or grease on the tires reduces their grip. = Remove oil and grease with a suitable cleaning material.13. WHEELS a ay ene Danger of accidents Reduced braking efficiency due to oll or grease on the brake discs, = Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage, = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in apolicable regulations. Info The service life of the chain depends largely on its maintenance. lean the chain regulary Rinse off loose dirt with a soft jet of water. Remove old grease remains with chain cleaner, hain cleaner (* p. 268) = Alter drying, apply chain spray. ‘Ghain lube for road use (* p. 268) 4007, 13.4.10 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 5 rubber dampers. They eventually wear out during. ‘operation. Ifthe rubber dampers are nat changed in time, the rear sprocket carrier and the rear hub will be damaged, Preparatory work = Raise the motorcycle with the rear wheel stand. ( p. 11) — Remove the rear wheel. (* p. 79) Main work = Remove the rear sprocket carrier. Check the rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn = Change the rear hub shock absorber. (* p. 84) = Position the rear sprocket carrier, © Info A pin/rubber damper pair that is low in play increases the service life of the rubber damper. Finishing work = Install the rear wheel. (# p. 80) Take the motorcycle off of the rear wheel stand, (* p. 11) = Check the chain tension. (€ p. 81) 13.4.1 Changing the rear hub shock absorbers. © Info The steps are the same for all 5 rear hub shock absorbers. Always change the rear hub shock absorbers in pairs. Preparatory work = Raise the motorcycle with the rear wheel stand, (% p. 11) — Remove the rear wheel, (€ p. 79)13. WHEELS 20189210 85 Main work Remove rear sprocket carrier @. Remove screws @. Warm the hub. Guideline 50°C (22°F Remove the hub from the rim, Press out rear hub shock absorber @. ‘© Info ‘The hub has drill oles @ through which the rear hub shock absorbers are pressed out from the back using a suitable drift. Position the new rear hub shock absorber @ and press in all the way using the back of sleeve ©. Pressure damper tool (61029010000) (* p. 278) Warm the hub. Guideline 50°C 22 "A Position the hub on the rim, Mount and tighten screws @. Guideline Miox1.25 | 48.Nm Loctite® 243 (35.4 Ib) Mount the rear sprocket carrier Finishing work Install the rear wheel. (* p. 80) ‘Take the motorcycle off of the rear wheel stand. (** p. 11) Check the chain tension, (* p. 81)