REPAIR MANUAL 2013 85 SX 19/16 85 SX 17/14 Art. no. 3206141enINTRODUCTION ' 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 are not specified here. Its assumed that the repair work will be performed by a fully trained mechanic. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular madel without prior notice. KTM accepts no liability for delivery ‘options, deviations from illustrations and descriptions, as well as misprints and other erras. The models portrayed partly contain spe cial equipment that does nat 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 §so 9001112100 6061) GEA, Kectinato ite nterattoal uaiy management standard 180 9001, KTH ues qui asiance processes tht ead TOV to the maximum possible quality of the products Issued by: TOV Management Service TaN SprmotreleAG 520 Mati, AstiTABLE OF CONTENTS 1 MEANS OF REPRESENTATION... 1.1 Symbols used... 1.2 Formats used... 2 SAFETY ADVICE.. 2.1 Repair Manual 2.2 Salety advice. 2.3 Degrees of risk and symbols 2.4 — Work rules. 3. IMPORTANT NOTES. 3.1 Guarantee, warranty... son 3.2 Operating and auxiliary substances... 3.3 Spare parts, accessories 3.4 Figures . 4 SERIAL NUMBERS nn 4.1 Chassis number... 4.2 Type label . 4.3 Engine number.. 4.4 Fork part number 4.5 Shock absorber part number 5 MOTORCYCLE : 5.1 Raising the motorcycle withthe lift stand... 5.2 Removing the motorcycle from the lift stand 5.3 Startinginnnne 6 FORK, TRIPLE CLAMP 6.1. Adjusting the compression damping of the fork 6.2 Adjusting the rebound damping of the fork.. 6.3 Bleeding the fork legs. 6.4 Cleaning the dust boots of the fork legs. 6.5 Removing the fork protector.. 6.6 Installing the fork protector... 6.7 Removing the fork legs... 6.8 Installing the fork legs. 6.9 Performing a fork service. 6.10 Disassembling the fork legs... 6.11 _ Disassembling the cartridge 6.12 _ Disassembling the compression holder.. 6.13 Checking the fork legs... 6.14 Assembling the compression holder 6.15 Assembling the cartridge 6.16 Assembling the fork legs. 6.17 Greasing the steering head bearing. 6.18 Removing the lower triple clamp. 6.19 Installing the lower triple clamp... 6.20. Checking the play of the steering head bearing 6.21 _Aastng the play ofthe steering head bearing. 7 HANDLEBAR, CONTROLS... 7.1 Adjusting the basic position of the clutch lever . 7.2 Checking the routing ofthe throttle cable... 7.3 Checking the play in the throttle cable 7.4 Adjusting the play in the throttle cable. 7.8 Handlebar position. 7.6 Adjusting the handlebar position. 8 SHOCK ABSORBER, SWINGARM 8.1 Adjusting the high-speed compression ‘damping of the shock absorber... o 8.2 Adjusting the low-speed compression damping of the shock absorber 10 u 12 13 2 8.3 Adjusting the rebound damping of the shock absorber... 8.4 Measuring rear wheel sag unloaded... : 8.5 Checking the static sag ofthe shock absorber... 35 8.6 Checking the riding sag of the shock absorber.... 36 8.7 Adjusting the spring preload of the shock absorber... 8.8 Adjusting the riding sag. 8.9 Removing the shock absorber 8.10 _ Installing the shock absorber. ae 8.11 _ Performing a shack absorber service 38 8.12 Removing the spring. 8.13 _ Disassembling the damper 8.14 _ Disassembling the piston rod 8.15 _ Disassembling the seal ring retainer. 8.16 _ Disassembling the rebound adjuster. 8.17 Checking the damper . 8.18 Removing the heim joint 8.19 _ Installing the heim join 8.20. Assembling the rebound adjuster. 8.21 Assembling the seal rng retainer... 8.22 Assembling the piston rod... 8.23 Assembling the damper 8.24 Bleeding and filing the damper. 8.25 Filling the damper with nitrogen 8.26 _ Installing the spring . EXHAUST. 9.1 Removing the manifold 9.2 Installing the manifold .... 9.3. Removing the main silencer... 9.4 Installing the main silencer. 9:5 Changing heals fer yr filing of he main silencer... . AIR FILTER .. 10.1 Removing the ai filter box lid 10.2 Removing the ai filter... 10.3 Cleaning the ai filter and air filter box. 57 10.4 Installing the air filter. 10.5 Sealing the air filter box.. 10.6 _ Installing the air filter box lid FUEL TANK, SEAT, TRIM 11.1 Removing the seat 11.2 Mounting the seat. 113 Fuel tap. 11.4 Removing the fuel tank 11.5 _ Installing the fuel tank MASK, FENDER vs 12.1." Removing the font fender 12.2 _ Installing the front fender... 12.3 Removing the start number plate 12.4 _ Installing the start number plate. WHEELS 13.1 Checking the tire ai pressure .nnnnnnnnennne 68 13.2 Checking the tire condition 13.3 Checking the brake discs... ae 13.4 Checking the spoke tension 6a 13.5 Front whee! 6a, 13.5.1 Removing the front wheel. 6A, 13.5.2 Installing the front wheel 13.6 Rear wheel.. 13.6.1 Removing the rear wheel. . 66 13.6.2 Installing the rear wheelTABLE OF CONTENTS 4 15 13.6.3 13.6.4 13.6.5 13.66 13.6.7 13.68 BRAKE 141 142 143 44 145 146 147 4s 149 14.10 141 14.12 14.13 14.14 Checking for chain dirt accumulation. Cleaning the chain - Checking the chain tension.. Checking the chain, rear sprocket, engine sprocket, and chain guide. Adjusting the chain tension... Adjusting the chain guide SYSTEM Checking the free travel of the hand brake lever. Adjusting the free travel of the handbrake lever Checking front brake fluid level... ‘Adding front brake flud.. Changing the front brake fluid Checking the front brake linings. Changing the front brake linings... Checking the free travel of foot brake lever ‘Adjusting the basic position of the foot brake lever. os Checking the rear brake Tuid level. ‘Adding rear brake fluid Changing the rear brake fluid... Checking the rear brake linings... Changing the rear brake linings. ENGINE 15.1 15.2 15.3 15.3.1 15.3.2 15.3.3 15.3.4 15.3.5 15.3.6 15.3.7 15.3.8 15.3.9 153.10 153.11 153.12 15.313 153.14 153.15 153.16 153.17 153.18 153.19 153.20 153.21 15.3.2 15.3.23 15.3.24 15.3.25 15.3.26 183.27 15.3.28 153.29 Removing the engine, Installing the engine... Engine disassembly. Clamping the engine into the engine assembly stand... Removing the engine sprocket. Removing the clutch push rod.. Draining the gear ol... Removing the spark plug Removing the cylinder head Removing the alternator cover . Removing the kick starter... Removing the exhaust control Removing the cylinder Removing the piston Removing the rotor.. Removing the stator Removing the spacer... Removing the clutch cover. Removing the clutch basket Removing the primary gear. Removing the kick starter shat Removing the intermediate kick starter ear, Removing the shift shaft. : Removing the shift drum locating unit Removing the locking lever Removing the reed valve housing... Removing the left engine case section . Removing the shift rails. Removing the shift drum .. Removing the shift forks... Removing the transmission shaft Removing the crankshaft 67 .. 67 . 68 68. 70 n 72 72 72 72 73 B 78 78 7 78 78 79 .. 80 81 81 BA 87 90 1) 90 90 91 91 1 91 92, 92 92 1 93, 93 93 1 98 94 34 95: 96 96 96 7 97 97 97 98 98 1 9B - 98 99 3 15.4 Work on individual parts. 99 15.4.1 Working on the right section ofthe engine case 99 15.4.2 Work onthe left section of the engine case 100 15.4.3 Removing the crankshaft bearing inner race, 100 15.4.4 Installing the crankshaft bearing inner race. 101 15.4.5 Changing the connecting rod, conrod bearing, and crank pin . 101 18.4.6 Checking the crankshaft run-out atthe bearing pin. seosses 102, 15.4.7 Checking/measuring the cylinder. .. 103 15.4.8 Removing the exhaust control 103 15.4.9 Checking the exhaust control 105 15.4.10 Installing the exhaust contra. 1. 105 15.4.1 Checking/measuring the piston.. . 107 15.4.12 Checking the piston ring end gap . 107 eS clearance 1. 108 18.4.14 Checking the reed valve housing, reed valve, and intake flange.. eee 108, 15.4.1 Work on the clutch cover... 108 15.4.16 Checking the clutch 113 15.4.17 Checking the shift mechanism 114 15.4.18 Preassembling the shift shaft. 118 1.4.19 Disassembling the main shaft. ~. 116 15.4.20 Disassembling the countershaft 116 15.4.21 Checking the transmission 47 15.4.22 Assembling the main shaft. .. 18 1.4.23 Assembling the countershatt. 119 15.4.24 Checking the kick starter. . 120 15.4.25 Preassembling the kick starter shaft rosa. 120 15.5 Assembling the engine... 121 15.5.1 Installing the crankshatt. yz. 15.5.2 Installing the transmission shafts... 121 15.5.3 Installing the shift forks... 122 15.5.4 Installing the shift drum 122 15.5.5 Installing the shift rails .. eit] 15.5.6 Installing the left engine case section nue 123 15.5.7 Installing the reed valve housing .. 123 15.5.8 Installing the locking lever. 124 15.5.9 Installing the shift drum locating unit we 124 15.5.10 Installing the shift shaft sone 128, 15.5.11 Installing the intermediate kick starter gee. sess 124 155.12 Installing the kick starter shat. 1. 125 15.5.13 Installing the primary gear. 125 15.5.14 Installing the clutch discs. 126 15.5.15 Installing the clutch cover 1. 127 15.5.16 Installing the spacer... 1. 127 15.5.17 Installing the stator. . 128 155.18 Installing the rotor 128 15.5.19 Installing the piston ... 1. 128 15.5.20 Installing the cylinder... 129 155.21 Checking the X-distance 129 15.5.22 Adjusting the X-distance... . 130 15.5.23 Adjusting the ignition... .. 130 155.24 Adjusting the Z-distance. 130 15.5.25 Installing the kick starter... 132 15.5.26 Installing the alternator cover. 1. 132 15.5.27 Installing the cylinder head. . 132TABLE OF CONTENTS 15.58.28 15.5.29 15.5.30 15.5.31 18.5.32 Installing the spark plug... Installing the oil drain plug... Installing the clutch push rod Installing the engine sprocket Removing the engine from the engine assembly stand. 16 CARBURETOR 16.1 Removing the carburetor... 16.2 _ Installing the carburetor 16.3 _ Disassembling the carburetor 16.4 Assembling the carburetor = 16.5. Checking/setting the carburetor components. 16.6 Checking the jet needle. 16.7 Checking the throttle slide... 16.8 Checking the float needle valve 16.9 Checking the choke slide... 16.10. Checking/adjusting the float level 16.11 Carburetor - adjusting idle speed 16.12. Emptying the carburetor float chamber 17 CLUTCH... 17.1 Checking the fluid level ofthe yea clutch... Correcting the flid eve ofthe hydraulic clutch 17.3 Changing the hydraulic clutch fluid .. 18 WATER PUMP, COOLING SYSTEM 18.1 Draining the coolant... 18.2 Refilling coolant. 18.3 Checking the antifreeze and coolant level 18.4 Checking the coolant level 19. LUBRICATION SYSTEM. 19.1 Checking the gear oil level 19.2 Changing the gear oil 19.3 Draining the gear oil 19.4 Filling up with gear ol... 19.5 Adding gear oil 20 IGNITION SYSTEM... 20.1. Checking the ignition sytem. 20.2 Checking the kill switch... 20.3 Checking the ignition col. 20.4 Checking the ignition pulse generator... 20.5 Checking the spark plug connector 20.6 Checking the CDI controller 20.7 Checking the power supply 21 TECHNICAL DATA 21.1 Engine 21.2 Engine tolerance, wear limits... 21.3 _ Engine tightening torques... 21.4 Capacities... 21.8.1 Gear ol 21.4.2 Coolant.. 21.43 Fuel 21.5 Chassis. 21.6 Tires. 21.7 Fork... 21.8 Shock absorber. 21.9 Chassis tightening torques 21.10 Carburetor. 21.10.1 Carburetor tuning, 22 CLEANING, CARE... 22.1 Cleaning the motorcycle 72 156 161 162 132 133 133, 133 133, 134 134 135 136 138 139 140 140 140 140 141 441 142 143 143. 143. 143 145 145 145 146 146 148 148 148 14g, 14g 149 181 151 151 152 153, 153 184 154 156 156 187 157 . 187 187 . 187 158 158 159 159 160 160 162 4 23. STORAGE sn 163 23.1 Storage. 163 23.2 Preparing for use after storage 163 24 SERVICE SCHEDULE . 164 24.1 Service schedule, 164 25 WIRING DIAGRAM... 166 25.1 Page 1of 1 166 26 SUBSTANCES fennnnnnnnnnnne 168 27 AUXILIARY SUBSTANCES wvssnonssosronsnnonennee 170 28 SPECIAL TOOLS nnn fener 173) 29. STANDARDS, 181 INDEX 1821 MEANS OF REPRESENTATION 5 The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function) Indicates a page reference (more information is provided on the specified page). xX Indicates an unexpected reaction (e.g, of a work step or a function). 7 Indicates information with moce details o tips. » Indicates the result of a testing step. wi Denotes a voltage measurement. i Denotes @ current measurement. oa Denotes a resistance measurement, The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name. Name? Identities a protected name. Brand™ Identifies a trademark,2 + SAFETY ADVICE ° Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle, This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. ‘A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. © Info ‘The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they ate missing, you or others may not recognize dangers and may therefore be injured. Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal ar serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken, Wi e FRE ees a danger at wit to ervtonenta damage tthe appropriate messes nat ake ‘Special tools are necessary for certain tasks. The tools are not 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. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g, Lectite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them 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 NOTES 1 31 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 void. No warranty claims can be consid tered for damage resulting from manipulations and/or alterations to the vehicle. Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet Warning Environmental hazard Improper handling of fuel is @ danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's 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 PowerPars for your vehicle can be found on the KTM website International KTM Website: ntip/iww.ktm.com The figures contained in the manual may depict special equipment, Inthe interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis- assemble the component to perform the activity in question. Please follow the instructions in the text.4 — SERIAL NUMBERS 8 Chassis number @ is stamped on the right side of the steering head, ‘Type label @ is located on the front frame tube. Engine number @ is stamp into the engine case below the carburetor. Fork part number @ is stamped on the inner side of the axle clamp. Shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring on the engine side.5 MOTORCYCLE a ‘5.1 Raising the motorcycle with the itstand Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface. = Raise the motorcycle at the frame underneath the engine. Lift stand (59229055000) (* p. 17) 7 The wheels must no longer touch the ground. = Secure the motorcycle against falling over. L00036.10 Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface. = Remove the motorcycle from the lft stand. — Remove the lift stand. To park the motorcycle, insert plug dle, stand @ into the left side of the wheel spin- © Info T Remove the plugsin stand before riding. Lo0022-10 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andlor 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. Note Engine failure High engine speeds in cold engines have a negative effect on the service life ofthe engine. = Always warm up the engine at fow engine speeds. © Info Hr the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a lang time of standing, If the float chamber is filled with fresh fuel, the engine starts immediately. Engine has been out of use for more than 1 week Empty the carburetor float chamber. (© p. 142) ~ Turn tap handle @ on the fuel tap to the ON position. (Figure LO0035-10" p. 59) % Fuel can flow from the fuel tank to the carburetor. = Remove the motorcycle from the stand, = Shift gear to neutral5 MOTORCYCLE The engine is cold = Push the choke lever down all the way. = Forcefully step on the kick starter, pushing it all the way down, 10 © Info Do not open the throttle.6 FORK, TRIPLE CLAMP " © Info ‘The hydraulic compression damping determines the fork suspension behavior. = Remove protection caps @, = Turn adjusting screws @ clockwise all the way. © Info TAajusting screws @ are located atthe bottom end ofthe fork legs. Make the same adjustment on both fork legs. rs Turn counterclockwise by the number of clicks corresponding to the fork type. 7 Guideline Loddse.t0 ‘Compression damping Comfort Ta clicks Standard TB clicks Sport T2 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing, = Mount protection caps @. © Info ‘The hydraulic rebound damping determines the fork suspension behavior. ‘Turn adjusting screw @ clockwise all the way. Info TAdjusting screws @ are located at the top end of the fork legs. ‘Make the same adjustment on both fork legs. ‘Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort TB clicks Standard 1B clicks Sport T2 clicks ® Into TTurn clockwise to increase damping; tuin counterclockwise to reduce damp- ing. Preparatory work = Raise the motorcycle with the lift stand. (** p. 9) Main work = Release bleeder screws ©. Any excess pressure escapes from the interior of the fork, = Mount and tighten bleeder screws,6 FORK, TRIPLE CLAMP 2 Finishing work = Remove the motorcycle from the lft stand. (* p. 9) Preparatory work = Raise the motorcycle with the lift stand. (* p. 9) Main work = Push dust boots @ of both fork legs downwards. © Info ‘The dust boots remove dust and coarse dirt particles from the inside fork ‘tubes. Over time, dirt can penetrate behind the dust boots. If this dirt 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 discs. = Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary. Clean and ol the dust boots and inner fork tube of both fork legs. Universal oll spray (Fp. 172) Press the dust boots back into their normal position = Remove excess oll. Finishing work = Remove the motorcycle from the lft stand. (* p. 9) = Remove screws @, Take off the clamp. = Remove screws @ on the left fork leg. Take off the fork protector. Lovo46-11 = Remove screws @ on the right fork leg. Take off the fork protector, = Position the fork protection on the right fork leg. Mount and tighten screws @. Guideline Remaining screws, chassis Me 10 Nm (7.4 Ib ft)6 Lovo46.12 FORK, TRIPLE CLAMP 13 Position the fork protection on the left fork leg. Mount and tighten screws @. Guideline Remaining screws, chassis M6 TO Nm (7.4 TBF Position the brake line, wiring harness, and clamp. Mount and tighten screws @. Preparatory work Raise the motorcycle with the lift stand. ( p. 9) Remove the front wheel. ( p. 64) Main work Remove screws @ and take off the clamp, (85 sx 17714) Remove screws @ and take off the brake caliper. Allow the brake caliper and brake line to hang tension-free to the side. Info To not kink the brake line. Do not activate the hand brake lever when the brake caliper is removed (85 sx 19/16) Remove screws @ and spacers and take off the brake caliper. Allow the brake caliper and brake line to hang tension-free to the side. Info Do not kink the brake line. Do not activate the hand brake lever when the brake caliper is removed. Loosen screw @, Take out the left fork leg. Release screws @. Take out the right fork leg. Warning Danger of accidents. Modifications t 0 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 Position the fork legs. Info The second milled groove (from the top) must be flush with the top edge of the upper triple clamp. Position bleeder screws @ toward the front.6 FORK, TRIPLE CLAMP 14 = Tighten screws @. Guideline Screw, top triple clamp we 20Nm (4.8 Ib fo Tighten screws ©. Guideline Screw, bottom triple clamp we TSNm (Libr FO (85 sx 17/14) = Position brake caliper, and mount and tighten screws @. Guideline ‘Screw of brake caliper | MB 25 Nm Loctite® 243% (28.4 tbr A) = Position the brake line. Mount the clamp and screws @. (85 sx 19/16) = Position the brake caliper with spacers and fit and tighten screws @. Guidetine ‘Screw of brake caliper | MB 25 Nm Toctite® 243 (18.4 tbr A Position the brake line. Mount the clamp and screws Finishing work Install the front wheel. (* p. 65) = Remove the motorcycle from the lft stand. (* p. 9) COMTI OO em (Ge 0060 om 201467-01 Condition “The fork legs have been removed. = Disassemble the fork legs. (* p. 15) = Disassemble the cartridge. (* p. 17) = Disassemble the compression holder. ( p. 19) = Check the fork legs. (* p. 20) Assemble the compression holder. (%* p, 21) = Assemble the cartridge. ( p. 22) = Assemble the fork legs. (* p. 23)6 FORK, TRIPLE CLAMP 15 The operations are the same on both fork legs. 20142310) ae i , A ouse510| | 201426-10] 201827.10) CConiiton ‘The fork legs have been removed. Remove protection cap @. Note down the present state of rebound damping @ and compression damping @. ‘Completely open the adjusters of the rebound damping and compression damping, Clamp the fork leg in the area of the lower triple clamp. ‘Clamping stand (T6128) (* p. 180) = Loosen screw cap @. © Info The screw cap cannot be removed yet. Unclamp the fork leg and clamp it with the axle clamp. ‘e Info Tse sott jaws Push the outer tube down, Pull the spring downward. Place the special tool on the hexagonal part. Open-end wrench (114032) (* p. 179) © nfo I Pretoad spacers @ should be above the special tool.6 v4 20142810) 20142910) 201430410) 201431410) 20143310) FORK, TRIPLE CLAMP Clamp the special too! in the bench vise. Loosen screw cap ©. Remove screw cap @ with preload spacers @. Remove adjusting tube ©. Pll the spring downward. Remove the special tool Remove spring. Drain the fork oil, © Info Putt out the piston rod all the way and push it back in several times in order ‘to pump out the cartridge until itis empty. Clamp the fork lg with the axle clamp, Guideline Use soft jaws. Unscrew and remove compression holder @. Info T_ Pace a tluid collector beneath it, as usually some oil will drain out. Remove the cartridge.6 FORK, TRIPLE CLAMP 7 20143410) 20183510) c 201436-10) I | 201437.10) i 4° oe 3 1436-10) = Remove dust boot @, = Remove lock ring @. Info I The lock ring nas a specially finished end against which the screwdriver can be placed. = Warm up the outer tube in area @ of the lower sliding bushings. Guideline soc a22 "A Jerk the outer tube out of the inner tube. Info T The tower sling bushing @ must be pulled out of its bearing seat winen doing this. — Remove the upper sliding bushing ®, © Info T without using 2 toot, pull the stack apart by hand slightly Take off the loner sliding bushing @, = Take off support ring @. = Take off seal ring @. = Take off lock ring @, = Take off dust boot = Take out the fork leg ‘he steps are identical for both fork legs. ratory work Disassemble the fork legs. ( p. 15)6 FORK, TRIPLE CLAMP 18 20069310) | 200694-10 U e 200696-10] + Sas a 2 01462.10) Main work = Clamp the special tool in a bench vise, Pin (T605) (* p. 180) Hitch cartridge @ by using the drilled holes. Unscrew and remove screw sleeve @. Pull piston rod @ out of cartridge @. Clamp in the piston rod. Remove water excluder @. ‘Clamping stand (T14016S) (* p. 179) Remove screw sleeve @ with washer and spring seat from the cartridge. ~~ Degrease the piston rod. = Clamp the piston rod with the special tool. ‘Clamping stand (T140168) (* p. 179) = Remove nut ©. = Remove shim stack @ completely.6 FORK, TRIPLE CLAMP 19 v4 20146310) = Remove piston @. Remove shim stack @ completely. 200700.10) = Remove spring ©. = Loosen tap rebound ® and remove. = Remove spring ®. = Remove valve @ of the rebound damping together withthe spring = Take out the piston rod. © Info H The steps are identical for both fork legs. Preparatory work = Disassemble the fork legs. (* p. 15) Main work = Clamp the compression holder in a bench vise using soft jaws. = Remove nut — Remove the spring. = Remove washer @, = Remove piston @. = Remove shim stack @,6 20072610) FORK, TRIPLE CLAMP = Remove O-ring @ and seal ring @ from the compression holder. Extract the compression holder. Condition ‘The fork has been disassembled, = Check the inner tube and axle clamp for damage. » If there is damage: = Change the inner tube, = Measure the outside diameter ofthe inner tube at several locations. Outside diameter of the inner tube | 42,975... 43.005 mm (1.69193. 1.69311 in) » Ifthe measured value is less than the specified value: = Change the inner tube, — Measure the run-out of the inner tube. Inner tub run-out '§ 0.20 mm (5 0.0079 in} » If the 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.6 FORK, TRIPLE CLAMP 20146610) 200666.10 a (Check the surface of the sliding bushing, » Ifthe bronze-colored layer @ under sliding layer @ is visible: = Replace the sliding bushing. ‘Check the spring length. Guideline Spring length with preload spacer(s) | 438 mm (17.24 in) » If the measured value is greater than the specified value: = Reduce the thickness of the preload spacers. » If the measured value is less than the specified value: Increase the thickness of the preload spacers. Info ‘The steps are identical for both fork legs. Clamp the compression holder in a bench vise using soft jaws. Mount O-ring @ and seal ring @. Grease the O-ring Lubricant (7158) (* p. 170) Mount shim stack @ with the smaller shims facing downward. Mount pistons © with O-ring. Info T The side with the largest inside diameter @ faces upward. Grease the piston O-ring. Fork oil (SAE 4) (4860116681) (* p. 168) Mount washer ©, Mount spring @ with the tighter coil facing downward. Mount and tighten nut @. Guideline Nut, compression holder M6x0-5 Nm (2.2 Ibt ft) Info TH Washer @ must be free to move against the spring force, Secure the nut by locking. Extract the compression holder6 FORK, TRIPLE CLAMP © Info The steps are identical for both fork legs. 20071510) 20071810) @ ve : 1464-10) ~ |’ 201465.10) ———_— ee beeen 20069611 Clamp in the piston rod. ‘Clamping stand (T140168) (* p. 179) Mount valve @ of the rebound damping, with the spring and O-ring. Grease the O-ring. Lubricant (158) (* p. 170) Mount spring @. ‘Grease the O-ring of tap rebound @. Lubricant (T158) (* p. 170) Mount and tighten the tap rebound. Guideline “Tap rebound Moe 18.Nm Loctite® 2701 (23.3 Ibe fo Position spring @. Mount shim stack @ with the smaller shims facing downward Press the shim stack downward against the spring force. Info I The shim stack must be pressed downward over the collar. Mount piston @ with the piston ring © Info The side with the largest inside diameter faces downward. Mount shim stack @ Info TL Align the triangular plate exactiy with the piston opening. Mount and tighten nut @. Guideline Tap rebound nut M6x0.5 5 Nm (3.7 Iot f) Info TH ount the nut withthe collar facing downward. Secure the nut by locking Slide screw sleeve @ withthe washer and spring seat onto the cartridge.6 FORK, TRIPLE CLAMP Info to 2 tool i=] some Screw on water excluder @ to the stop. = Slide piston rod @ into cartridge ®. = Clamp the special tool in a bench vise. D.The note excuder mist be screwed on tity against the stop. Donat use Pin (T605) (* p. 180) 20069511 Guideline ° = Hitch cartridge @ by using the drilled holes. = Mount and tighten screw sleeve ©. Screw sleeve M29x1 46 Nm (33.9 Ibf ft) Loctite® 241 © Info ‘The operations are the same on bath fork legs. Preparatory work = Check the fork legs. ( p. 20) = Assemble the compression holder. (* p. 21) Assemble the cartridge. (* p. 22) Main work Guideline = Clamp the inner tube with the axle clamp. Use soft jaws: = Mount the special tool Protecting sleeve (T512) (* p. 180) Lubricate and mount dust boot @, Lubricant (TS1D) ( p. 170) Info = Slide on lock ring @. Lubricate and mount seal ring @. TAtways change the dust boot, lock ring, seal ring, and support ring ‘Mount the sealing lip with the spring expander facing downward. Lubricant (TS11) (* p. 170) Info I seating lip facing down, open side facing up.6 FORK, TRIPLE CLAMP m4 Push on support ring @. Remove the special too. = Sand the edges of the sliding bushes with 600-grit sandpaper, and then clean and ‘grease them. Fork oil (SAE 4) (48601 166S1) (* p. 168) cat Serer j = Mount the upper sliding bushing @. ay © Info T Without using a toot, pull the stack apart by hand slightly, 20144010) ~ Warm up the outer tube in area @ of the lower sliding bushings. Guideline 50°C (22°F) = Slide the outer tube onto the inner tube. = Hold the lower sliding bushing with the longer section of the special tool. Mounting tool (T5028) (* p. 180) Push the sliding bushing all the way into the outer tube. = Position support ring, = Hold seal ring with the shorter section of the special too. Mounting tool (T5028) (* p. 180) = Push the seal ring and support ring all the way into the outer tube. = Mount lock ring @. Info TH The tock ring must engage audibly. 20143511 Install dust boot @. 201434-116 FORK, TRIPLE CLAMP — f200725-11 2o144a-i0) 201445.10) Mount adjusting tube @ of the rebound damping in the cartridge. ‘7 The adjusting tube extends 5 mm out from the cartridge and can be pressed inward against the spring force 2X The adjusting tube extends more than 7 mm out from the cartridge and cannot be pressed inward against the spring force. Screw on water excluder @ to the stop. Info T The water exctuder must be screwed on tightly against the stop. Do not use tools. Mount the special tool on the cartridge. ‘Support tool (114026) (* p. 179) Info T The special tool must be used in order that the adjustment tube is not raised. Otherwise, oil will each the piston rod. Slide the cartridge into the inner tube. Mount and tighten compression holder @. Guideline ‘Compression holder W25x1 35Nm (25.8 Ib) Info Tr the cartridge turns as well, press the piston rod slightly to the side. Clamp the fork vertically. Refill wth fork ol, Fork oll per fork] 378 mi Fork oll (SAE 4) (860116681) leg 2.78 tL02) | (op. 168) © Info Tutt out and push in the piston rod several times to bleed air rom the car- tidge. Remove pin @ of the special tool ‘Support tool (114026) (* p. 179) Pull out the piston rod. Mount spring. Reinstall the pin. Guideline Spring rate ‘Weight of rider: < 45 kg (< 99 Ib.) Weight of rider: 45... 55 kg (99. 121 ib.) 3.2 Nimm (18.3 Ibfin) 3.4 Nimm (19.4 Iofin) 20144610) Weight of rider: > 55 ke © 121 Ib) Pull the spring down. Place the special tool on the hexagonal part. Open-end wrench (114032) (# p. 179) Remove the special tool, ‘Support tool (114026) (* p. 179) 3.6 Nimm (20.6 Ibfin)6 FORK, TRIPLE CLAMP 2o144e.10) = Clamp the special too! in the bench vise Grease the threads of the piston rod. Lubricant (T159) (* p. 171) Grease the upper edge @ of the piston rod. Lubricant (7158) (* p. 170) = Screw the screw cap with the preload spacers on to the piston rod. © Info I The screw cap must be screwed in all the way before the piston rod begins ‘to turn. In case of tight piston rod threads, it must be held to keep it from turning. If the screw cap is not screwed in all the way, the rebound adjust- ‘ment will not function properly = Tighten the screw cap. Guideline ‘Serew cap on piston rod Mi2x1 25 Nm (18.4 tbf FO = Release the special tool. Pull the spring downward and remove the special tool = Push the outer tube upward = Clamp the outer tube in the area of the lower triple clamp. ‘Clamping stand (T6128) (* p. 180) = Grease the screw cap O-ring Lubricant (1158) (* p. 170) = Screw on and tighten the screw cap, Guideline waéxt 50. Nm (36.9 Ibf FY) ‘Screw cap on outer tube Alternative 1 = Turn the adjusting screw of rebound damping @ and the adjusting screw of compression damping @ clockwise all the way. = Turn back counterclockwise by the number of clicks corresponding to the fork ¥ ‘type. Guidetine Rebound damping Qe Comfort Ta ciens 201449.10| Standard TS clicks Sport Ta chess ‘Compression damping Comfort TB clicks Standard TS clicks Sport T2 clicks6 FORK, TRIPLE CLAMP 2 Alternative 2 Warning Danger of accidents Modifications 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 recammended range. — After making adjustments, ride slowly at frst to get the feel of the new ride behavior. = Set the adjusting screws to the position determined before removal = Mount protection cap @. = Remove the loner triple clamp. (* p. 27) 8 = Install te lover triple clamp. (* p. 28) Preparatory work = Raise the motorcycle with the lft stand. (€ p. 9) = Remove the front wheel. (** p. 64) Remove the fork legs. (* p. 13) Remove the start number plate, (** p. 62) = Remove the front fender. (* p. 62) Main work = Remove fuel tank breather @, = Remove nut @. Remove screw @, take off the upper triple clamp with the handle- boar and set it aside. © Info I Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. Remove protective ring @. ‘Take out the lower triple clamp with the steering stem, ‘Take out the upper steering head bearing.6 FORK, TRIPLE CLAMP a Main work e = Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (** p. 170) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing o-2 e = Slide on O-ring @. Position protective rin oe Pr co0250.10 = Position the upper triple clamp with the steering. = Mount nut @, but do not tighten it yet. Position the fork legs. © Info The second milled groove (from the top) must be flush with the top edge of ‘the upper triple clamp. Position bleeder screws @ to the front, = Tighten screws ©. Guideline Screw, bottom triple clamp |6 FORK, TRIPLE CLAMP 2 Position the fuel tank breather. = Mount and tighten screw @. = Tighten nut ©. Guideline Nut, steering stem 20x15 TO Nm (7.4 TBF Guideline Screw, top triple clamp wa 20Nm (24.8 tof AD = Tighten screws @. Guideline Screw, top tiple clamp WB 20Nm (24.8 tof FO (@5 sx 17/14) = Position brake caliper, mount and tighten screws @. Guidetine ‘Screw of brake caliper | MB 25 Nm Toctite® 243 (18.4 tbr #0 = Position the brake line and clamp. Mount and tighten screws ®. (85 sx 19/16) = Position the brake caliper with spacers and fit and tighten screws @. Guideline Screw of brake caliper | MB 25 Nm Loctite® 243 (28.4 tbr f Position the brake line and clamp. Mount and tighten screws ®. ing work = Install the front fender. (% p. 62) = Install the start number plate, (** p. 62) = Check that the wiring harness, cables, and brake and clutch lines can move freely ‘and are routed correctly. = Install the front wheel. (* p. 65) = Check the play of the steering head bearing. (* p. 30) = Remove the motorcycle from the lft stand. (* p. 9)6 FORK, TRIPLE CLAMP 0 Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. = Adjust the steering head bearing play without delay. Info Hi the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. Preparatory work = Raise the motorcycle with the lft stand. (€ p. 9) Main work SA = Mave the handlebar to the straight-ahead position. Move the fork legs to and fro in a the direction of travel. = 2 No play should be noticeable in the steering head bearing. ws TA » there is noticeable play present: = Adjust the play of the steering head bearing. (* p. 30) (OJ = More te handlebar tan ro oe the enti tering range [| sconSts] [ie Raalbar usb ae To nove easly ove Te ene scan ange. No resting locations should be noticeable. » If click positions are noticeable: Adjust the play of the steering head bearing. (* p. 30) Cheek the steering head bearing and replace if required. ishing work = Remove the motorcycle from the lft stand. (© p. 9) Preparatory work = Raise the motorcycle with the lft stand. (€ p. 9) Main work = Remove fuel tank breather @, = Release screws @. = Loosen screw ©. = Loosen and retighten nut , Guideline Nat, steering stem M20x1-5 TO Nm (7.4 Tot = Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. = Tighten screw @, Guideline Screw, top triple clamp we 20Nm (24.8 tbr AD Tighten screws @. Guideline Screw, top triple clamp we 20Nm (4.8 tbr Position the fuel tank breather ®, ishing work = Check the play ofthe steering head bearing. (* p. 30) = Remove the motorcycle from the lft stand. (€ p. 9)7 HANDLEBAR, CONTROLS 3 7.1___Aajustingthe basic postion ofthe clutch lever Adjust the basic position ofthe clutch lever to the size of the rider's hand using adjusting screw @. © Info [Tur 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. ae Turn the adjusting screw by hand only, and do not apply force. Soret Do not make any adjustments while riding! Warning of injury The throttle cable can slip out of the guide; if this happens, the throttle slide can no longer be closed and the speed cannot be controled. = Always ensure that the throttle cable is correctly routed and check the throttle cable play. Preparatory work = Remove the seat. (* p, 59) = Remove the fuel tank, (* p. 60) Main work = Check the routing of the throttle cable. “The throttle cable must be routed to the carburetor on the left side above the fuel tank bracket. » If the throttle cable is not routed as specified: = Correct the routing of the throttle cable. ishing work = Install the fuel tank. ( p. 60) = Mount the seat. ( p. 59) ‘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 play @ in the throttle cable. Throttle cable play 2... 3 mm (0.08... 0.12 in) » If the throttle cable play does not meet specifications: = Adjust the play in the throttle cable. (* p. 32) = Start the engine. = Move the handlebar to and fro over the entire steering range. The engine speed should not change while doing so. » Ifthe engine speed changes: = Check the routing of the throttle cable. (#* p. 31) = Adjust the play in the throttle cable. ( p. 32) 400192-117 HANDLEBAR, CONTROLS 2 (74 Aejustingthe play in the throttle cable Preparatory work = Remove the seat. (* p, 59) = Remove the fuel tank, (** p. 60) = Check the routing of the throttle cable. (* p. 31) Main work 2 = Move the handlebar to the straight-ahead position. = Push back sleeve @. = Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster @, = Loosen nut @, 00273-10) = Turn adjusting screw @ in such a way there is throttle cable play @ in the throttle rip. Guideline Throttle cable play 2... 3mm (0.08... 0.12 in) = Tighten nut ©. = Slide on sleeve ©. 400192-11 Finishing work Install the fuel tank. (& p. 60) = Mount the seat. ( p. 59) = Check the play inthe throttle cable. (** p. 31) ‘On the upper triple clamp, there are two holes at a distance of @ to each other. Hole distance A 15 mm (0.59 in) ‘The holes on the handlebar support are placed at a distance of @ from the center w Hole distance B 3.5 mm (0.138 in) ra ‘The handlebar can be mounted in four different positions. In this way, the handlebar @ ‘can be mounted in the position that is most comfortable forthe rider. cove4e.10] Warning Danger of accidents Handlebar breakage. = Ifthe handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar, ~ Remove the four serews @, Remove the handlebar clamp. Remove the handlebar oo oO and lay it to one side. e- © Info < —e Protect the motoreycle and its attachments against damage by covering them, >) Do not bend the cables and lines. x = Remove the two screws @, Remove the handlebar support. SD e = Place the handlebar support in the required position. Fit and tighten the two D __cwoasoro] ~ Place tig7 HANDLEBAR, CONTROLS 33 Guidetine Screw, handlebar support | M10 20 Nm Tostite® 243 (29.5 lot f) Position the handlebar. © Info Make sure cables and wiring are positioned correctly. Position the handlebar clamps. Fit and evenly tighten the four screws @. Guidetine Screw, handlebar clamp ue 20Nm (4.8 bt Info Make sure the gap width is even.8 SHOCK ABSORBER, SWINGARM Ey Caution Danger of accidents Disassembly of pressurized parts can lead to injury. = The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info I The high-speed setting can be seen during the fast compression of the shock absorber. = Turn adjusting screw @ all the way clockwise with a socket wrench Info To not loosen fitting @. = Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideine Compression damping, highapeed Comfort Zune Standard 1.5 tn Sper urs Info Druin clocnse to increase damping; turn counterclockwise to reduce damp. ing 8.2 Adjusting the low-speed compression damping of the shock absorber = Caution Danger of accidents Disassembly of pressurized parts can lead to injury. = The shock absorber is filled with high density nitrogen. Adhere to the description provided. © Info ‘The low-speed setting can be seen during the slow to normal compression of the shock absorber. — Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click. Info To not loosen fitting @. = Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline ‘Compression damping, low-speed ‘Comfort TS clicks Standard 15 clicks Sport T2 clicks Info I Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing.8 SHOCK ABSORBER, SWINGARM 38 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. = The shock absorber is filled with high density nitrogen. Adhere to the description provided. — Turn adjusting screw @ clockwise up to the last perceptible click. = Turn back counterclocknise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort TB clicks Standard TB clicks Sport TZ clicks © Info I Tur clockwise to increase damping; turn counterclockwise to reduce damp- ing, 4a0988-10] Preparatory work = Raise the motorcycle with the lft stand. (* p. 9) Main work = Measure the distance — as vertically as possible — between the rear axle and a fixed point such as 2 mark on the side cover. = Make a note of the value as dimension @. ishing work = Remove the motorcycle from the lft stand. (* p. 9) — Measure distance @ of rear wheel unloaded. (* p. 35) = Hold the motorcycle upright with the aid of an assistant. = Measure the distance between the rear axle and the fixed point again. = Note down the value as dimension @. 400969.10] © Info The static sag is the difference between measurements @ and @, = Check the static sag. Static sag 30 mm (1.18 in) > Ifthe static sag is less or more than the specified value: Adjust the spring preload of the shock absorber. (*” p. 36)8 SHOCK ABSORBER, SWINGARM 6 (8.6 Checking the riding sag of the shock absorber Measure distance @ of rear wheel unloaded. (* p. 35) = With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up ‘and down a few times. 7 The rear wheel suspension levels out. = Another person now measures the distance between the rear axle and the fixed point = Note down the value as dimension @. Info The riding sag is the difference between measurements @ and @. = Check the riding sag. Riding sag 100 mm (3.94 in) 40099010] > Ifthe riding sag differs from the specified measurement: = Adjust the riding sag. (* p. 37) Caution Danger of accidents Disassembly of pressurized parts can lead to injury. = The shock absorber is filled with high density nitrogen. Adhere to the description provided. Preparatory work Raise the motorcycle with the lift stand. (#* p. 9) — Remove the shock absorber. (** p. 37) = After removing the shock absorber, clean it thoroughly Main work = Measure the full spring length while it is under tension and note down the value. = Loosen retaining ring @. ‘Turn adjusting ring @ until the spring is no longer under tension. ‘Combination wrench (50329080000) 40155110) Hook wrench (T1068) (* p. 17) = Measure the overall spring length while the spring is not under tension. = Tighten the spring by turning adjusting ring @ to measurement @. Guideline Spring preload Standard 10 mm (0.39 in) © Info I The spring preload isthe dierence between the relaxed spring length and ‘the tensioned spring length Depending on the static sag andor the riding sag, it may be necessary to increase or decrease the spring preload = Tighten screw Finishing work = Install the shock absorber. ( p. 37) = Remove the motorcycle from the lft stand. (* p. 9)8 SHOCK ABSORBER, SWINGARM a ratory work Raise the motorcycle with the lift stand. (#* p. 9) = Remove the shock absorber. (* p. 37) = After remaving the shack absorber, clean it thoroughly Main work = Choose and mount 2 suitable spring. Guideline Spring rate ‘Weight of rider: < 45 kg (< 99 1b.)_[ 30 Nimm (171 Iblin) Weight of rider: 45... 55 kg (99... | 35 Nimm (200 Ib/in) 121 iba Weight of rider: > 55 kg 40 Nimm (228 Iblin) 00292210 © 121 tb) Info TL The spring rate is shown on the outside of the spring. ‘Smaller weight differences can be compensated by changing the spring preload. Finishing work = Install the shack absorber. ( p. 37) Remove the motorcycle from the lft stand. (€ p. 9) = Check the static sag of the shock absorber. (** p. 35) = Check the riding sag of the shack absorber. ( p. 36) = Adjust the rebound damping of the shock absorber. ( p. 35) Preparatory work = Raise the motorcycle with the lft stand. (* p. 9) Main work = Remove screw @ and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Fix the rear wheel in this position, = Remove screw @, push splash protector @ to the side, and remove the shock absorber. Main work Push splash protector @ to the side and position the shock absorber. Mount and tighten screw @. Guideline ‘Screw, top shock absorber | M12 60. Nm Loctite® 243 (44.3 If fo) = Mount and tighten screw @. Guideline Screw, bottom shock Miz 60. Nm Tostite® 243 absorber (44.3 bor f) Finishing work = Remove the motorcycle from the lft stand. (* p. 9)8 SHOCK ABSORBER, SWINGARM 8 ‘8.11 Performing a shock absorber service Caution Danger of accidents Disassembly of pressurized parts can lead to injury. = The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been demounted. = Remove the spring. (%* p. 38) Disassemble the damper. (** p, 39) Disassemble the piston rod. (%* p. 40) a = Disassemble the seal rng retainer. (p41) e = check tne damper. (F p. 42) € = isassemble the rebound adjuster p42) 1 |= Remove the im joint. p. 43) | insta tne nei joint. (p44) ece ~ Assemble the rebound adjuster. (p45) g oy = Assemble the seal ring retainer. (* p. 45) ©, F | = Assemble the piston. (* p46) S * vp, Assemble the damper. (* p. 47) e © | — install the spring. (* p. 52) 2238.01 Condi ‘The shock absorber has been demounted. = Clamp the shock absorber in a bench vise using soft jaws. ‘ = Measure and note down the spring length in a preloaded state, = Loosen screw @. = Turn adjusting ring @ until the spring is no longer under tension. Hook wrench (T1068) (* p. 17) 20213610) = Remove spring retainer @ and washer @. Remove the spring. 20109610)8 SHOCK ABSORBER, SWINGARM 29 01100.10 SL _ 20110210 = Rotate adjusting ring @ with washer ® upward and remove. Preparatory work = Remove the spring. ( p. 38) Main work = Note down the present state of rebound damping @ and compression damping @. = Completely open the adjusters of the rebound damping and compression damping. = Remove protection cap @ of the reservoir. = Slowly unscrew screw ®. 7 The pressurized nitrogen is bled off. Remove screw ©, Drain the oll = Remove protection cap @. — Push in seal ring retainer @, = Remove lock ring @. Info To not scratch the inner surface.8 SHOCK ABSORBER, SWINGARM 40 EF 20110410) Remove the piston rod. Drain the remaining oil = Remove compression adjuster ®. Remove the spring and piston. 201105-10 p 9 I Preparatory work = Remove the spring. (* p. 38) = Disassemble the damper. (7 p. 39) Main work = Clamp the piston rod into a vise Guideline Use soft jaws. = Remove nut @. = Remove rebound shim stack @, Info Guide the rebound shim stack onto a screwdriver and put them aside together. = Remove piston @. = Remove compression shim stack @. © Info Tue the compression shim stack onto a screwdriver and put them aside together. Remove sleeve ©. — Remove rebound sim stack @, ‘© Info T Guide the rebound shim stack onto a screwdriver and put them aside together.8 SHOCK ABSORBER, SWINGARM a e 1 g ¢ 201067.10 20106810) = Remove piston @. = Remove compression shim stack © Info Guide the compression shim stack onto a screwdriver and put them aside ‘together. = Remove rebound washer ®. = Remove seal ring retainer = Remove protection cap @ and rubber butter ®. Preparatory work = Remove the spring. (%" p. 38) Disassemble the damper. (** p. 39) = Disassemble the piston rod. (* p. 40) Main work = Remove rebound rubber @, = Remove washer @. = Remove seal ring @. = Remove washer @ from seal ring ®.8 SHOCK ABSORBER, SWINGARM 2 = Remove washer ®. = Remove O-ring @. OD) — Remove dust boot ©. 200787-10) Preparatory work remove the spring. (* p. 38) = Disassemble the damper. (** p. 39) = Disassemble the piston rod. (* p. 40) Main work = Clamp the piston rod into a vise. = Remove piston rod adapter @, = Remove rebound needle @. — Remove rebound adjuster @, Regulative tension pin (T1218) (* p. 178) = Remove adjusting screw @. Condition ‘The damper has been disassembled. = Measure the inside diameter on both ends and in the middle of the damper car- ‘ridge. Damper cartridge Minimum diameter 46.10 mm (1.815 in) » If the measured value is greater than the specified value: = Replace the damper cartridge. = Check the damper cartridge for damage and wear. soiitio, » If there is damage or wear: Replace the damper cartridge. = Check the heim joint for damage and wear. » If there is damage or wear: = Replace the heim joint.8 2111210) 200813-10 SHOCK ABSORBER, SWINGARM — Measure the diameter of the piston rad. Fiston rod Diameter © 17.95 mm (= 0.7067 in} » If the specified value was not attained: Replace the piston rod. — Measure the run-out of the piston rod. Piston rod Run-out = 0.03 mm (s 0.0012 in} » If the measured value is greater than the specified value: = Replace the piston rod. Check the piston rod for damage and wear. » If there is damage or wear: = Replace the piston rod. = Check the piston rings for damage and wear. » If damage or a bronze-colored surface is visible: Replace the piston rings. The steps are identical on the upper and lower heim joints. 20111910) Condition ‘The shock absorber has been demounted, = Clamp the shock absorber in a bench vise using soft jaws. = Remove both collar bushings @ of the heim joint using a pin. = Remove seal rings @ on both sides.8 SHOCK ABSORBER, SWINGARM 44 Oo0c 201120:10) Press the heim joint against a lock ring using the special too. Pressing tool (112075) (* p. 178) Remove the second lock ring @. Place special tool @ underneath and press out heim joint @ using special tool @. Pressing tool (112075) (* p. 178) ‘The steps are identical on the upper and lower heim joints. 20191 Position the new heim joint @ and the special tool Pressing tool (11206) (* p. 178) Press in the heim joint al the way. Press the heim joint against the lock ring using the special tool Pressing tool (112078) (* p. 178) Mount the second lock ring @. Mount seal rings @ on both sides.8 SHOCK ABSORBER, SWINGARM 45 Position both collar bushings @ and press in. Lubricate the thread of adjusting screw @. Lubricant (T7152) (* p. 171) Screw in the adjusting screw by several full turns. Lubricate the O-ring of rebound adjuster @. Lubricant (1158) (* p. 170) Mount and tighten the rebound adjuster. Guideline Screw sleeve Wiad 1aNm (13.3 tbr FO Screw out the adjusting screw of the rebound adjuster all the way counterclockwise, Lubricate the lower end of the rebound needle, Lubricant (1158) (* p. 170) Slide rebound needle @ into the piston rod Mount and tighten piston rod adapter Guideline Piston rod adapter MBxI 30. Nm Loctite® 2701 (22.1 tof ft) Mount dust boot @ with the special tool. Mounting sleeve (T1204) (* p. 178) Grease the sealing lip of the dust boot. Lubricant (1625) ( p. 171) Grease the O-ring groove Lubricant (T7158) (* p. 170) Mount O-ring ©. Mount washer @,8 SHOCK ABSORBER, SWINGARM 48 A SB 201072-10) 20107310) Position washer @ on seal ring @. Grease the seal ring and mount with the washer facing downward, Lubricant (T511) (* p. 171) = Mount washer @. = Mount rebound rubber @. Preparatory work = Assemble the seal ring retainer. (© p. 45) = Assemble the rebound adjuster. (© p. 45) Main work = Clamp the piston rod into a vise Guideline Use soft jaws. = Mount rubber buffer @ and protection cap @. = Position the special tool on the piston rod. Mounting sleeve (T1515) (* p. 179) = Grease the dust boot and slide seal ring retainer @ onto the piston rod. Lubricant (1625) ( p. 171) = Remove the special too. = Mount rebound washer ©. = Mount compression shim stack @ with the smaller shims facing downward. = Grind piston @ on both sides, using 1200 grit sandpaper on a surfacing plate. = Clean the piston. = Mount the piston, Guideline View @ Top view of piston View @ Bottom view of piston8 SHOCK ABSORBER, SWINGARM a7 = Mount rebound shim stack @ with the smaller shims at the top, 2 — Mount sleeve ©, 4 20107410) = Mount compression shim stack @ with the smaller shims at the bottom. /—o 20107510) Grind piston @ on both sides on a surface plate using 1200 grit sandpaper. Clean the piston, ¥ 0 View @ Top view of piston & View @ Bottom view of piston Mount the lower rebound washer @ and washer ®. © Info T The washer centers the lower rebound washer. Mount the upper rebound washer @. = Mount and tighten nut ®. Guideline i Nat, piston rod Mi0x1 30Nm 201130101 (22.1 bt) Preparatory work = Assemble the seal ring retainer. (© p. 45) = Assemble the rebound adjuster. (€* p. 45) = Assemble the piston rod. (** p. 46) Main work = Slide the spring and piston onto compression adjuster @. Grease the O-ring, Lubricant (7158) (* p. 170) Grease the threads. Lubricant (T159) (* p. 170) ~ Mount and tighten compression adjuster @, 20107610} Guideline ‘Compression damping adjuster Wald 50Nm (36.9 tbr FO8 SHOCK ABSORBER, SWINGARM 201123:10) of 201124.10 2a112510) Mount screw @ but do not tighten yet. Grease the O-ring of the seal ring retainer. Lubricant (1158) (* p. 170) Fill the damper tube approximately half way. ‘Shock absorber oll (SAE 2.5) (5018084251) (* p. 169) = Carefully mount the piston rod = Mount seal ring retainer @ and slide it under the ring groove. = Mount lock ring @. ® Into To not scratch the inner surface. = Pull out the piston rod in order that the seal ring retainer fits closely against the lock ring. = Mount protection cap @ of the damper cartridge. = Bleed and fill the damper. (* p. 49) = Fill the damper with nitrogen. ( p. 51) = Mount protection cap @ of the reservoir Alternative 1 = Turn adjusting screw @ clockwise with a screwdriver up ta the last perceptible click. = Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping ‘Comfort 18 clicks Standard 15 clicks Sport 12 clicks Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click = Turm back counterclockuise by the number of clicks corresponding to the shock absorber type. Guideline ‘Compression damping, low-speed Comfort 18 clicks ‘Standard 16 clicks Sport 12 clicks = Turn adjusting screw @ clockwise with a socket wrench until it stops. = Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guidetine ‘Compression damping, high-speed Comfort 2 tums Standard 1.5 turns Sport Tituen8 SHOCK ABSORBER, SWINGARM 49 Alternative 2 Warning Danger of accidents Modifications 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 recommended range. — After making adjustments, ride slowly at first to get the feel of the new ride behavior. = Set adjusting screws @, @ and © in the positions determined when disassem- bling. Info I Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound damping and compression damping. Remove the screw from the filing port. Mount adapter @ on the damper. Info TH Hana-tignten only without using a tool. = Connect adapter @ to connector @ of the vacuum pump. ‘Vacuum pump (112408) (* p. 179) 20111510] — Clamp the damper with soft jaws or hold it as shown in the photo. Info TH ciamp the damper only lightly The filling port must be located at the highest point. The piston rod moves in and out during filling; do not immobilize it by hold ing it with your hand, Position the control lever as shown in the photo. ‘A Control lever External tank @ is set to Closed; Damper @ is set to Vacuum; and Oil reservoir @ is set to Vacuum. Activate On/OH switch ©. ‘The suction process begins. Pressure gauge @ drops to the required valu. <0 bar Vacuum gauge @ drops to the required valve. ‘4 mbar = Determine distance © between the floating piston and reservoir hole with the spe- Celt 7 The tating piston is postoned inthe lowermost poten : 20111610)8 SHOCK ABSORBER, SWINGARM 200267-10) 200268-10) ‘When the vacuum gauge reaches the required value, turn control lever Oil reser- voir © to Equalize pressure. Guideline ‘@mbar A The pressure gauge increases to the required value. Obar ‘When the pressure gauge reaches the required value, turn control lever Damper @ to Pressure, Guideline Obar A Oilis pumped into the damper. 7 The pressure gauge increases to the required value. 3 bar ‘When the pressure gauge reaches the required value, turn control lever Damper © to Vacuum, Guideline 3 bar 7 The pressure gauge drops to the required value. O bar ‘When the pressure gauge reaches the required value, turn control lever Oil reser- voir @ to Vacuum. Guideline Obar 7 The vacuum gauge drops to the requit value. ‘& mbar When the vacuum gauge reaches the required value, turn control lever Oil reser voir © to Equalize Pressure, Guideline ‘B mbar 7 The pressure gauge drops to the required value. Obar ‘When the pressure gauge reaches the required value, turn control lever Damper © to Pressure Guideline bar 7 Oil is pumped into the damper. 7 The pressure gauge increases to the required value. ‘3 bar8 SHOCK ABSORBER, SWINGARM st 200269-10) ‘When the pressure gauge reaches the required value, turn contrl lever Damper @ to Vacuum, Guideline bar A The pressure gauge drops to the required value. Obar ‘When the pressure gauge reaches the required value, activate the On/Off switch, Guideline zor1a10) Obar The vacuum pump is switched off Slide O-ring @ to the end of the special tool by the specified value (distance @ minus specified value) Guideline 10mm Depth micrometer (T1075) (+ p. 178) Push the floating piston into the reservoir to the distance described above using the special too. © Info I When 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. Info [Hold the damper so that the filing port is atthe highest point, Remove the adapter. Mount and tighten screw @, Guideline Screw, filing por MiOxi 14 Nm (10.3 thf FO Screw in screw @ approx. two turns, but do nat tighten. © Info The piston rod is completely extended. Keep the special tool in place in the bench vise. ‘ivogen filing tool (717081) (+p. 180) Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen ‘Adjust the pressure regulator Guideline Gas pressure 10 bar (145 psid Position the shock absorber in the special tool. The hexagonal part of tap handle @ engages in the hexagon socket of the screw of the filling por8 SHOCK ABSORBER, SWINGARM 82 — Open spigot ®. — Fill tne shock absorber for atleast 15 seconds. Guideline Gas pressure 10 bar (145 ps Info T waten the pressure regulator dia Ensure thatthe shock absorber has been filled to the specitied pressure. = Screw the filing port shut with tap handle = Close spigot @ and remove the damper from the special tool. = Tighten the screw of the filling port. Guideline Screw, filling pat for reservoir co 3Nm (2.2 Iot a i - oor i ve 202136-11 = Mount adjusting ring @ with washer @ and screw all the way down, = Measure the overall spring length when not under tension. = Position the spring, Guideline Spring rate Weight of rider: < 45 ka (< 99 1b.) 30 Nimm (171 Ibfin) Weight of rider: 45... 55 kg (99 121 Ib) ‘35 N/mm (200 Iblin) Weight of rider: > 55 kg (© 121 Ib) 40 Nimm (228 Iblin) = Mount washer @ and spring retainer @. Alternative 1 ‘= Tighten the spring by turning adjusting ring @ to the measurement. Guideline Spring preload Standard 10 mm (0.39 in) Hook wrench (T1068) (* p. 177) Alternative 2 Warning Danger of accidents Modifications 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 characteris- tics and overload some components. ~ Only make adjustments within the recommended range. After making adjustments, ride slowly at frst to get the feel of the new ride behavior. Tighten the spring by turning adjusting ring @ to the value measured when it was removed. Hook wrench (T1068) (* p. 177)8 SHOCK ABSORBER, SWINGARM Tighten screw @, Guidetine Screw, shock absorber adjusting ring MG 5 Nm (3.7 IF A) 539 EXHAUST “ 8.1 Removingthe manifolh 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 hot components. = Remove springs @. Spring hooks (60305017000) (* p. 175) 305295.10 = Remove screw @, = Loosen screw ©. = Remove screw ©, = Pull the manifold out of rubber sleeve ® and remove it. Grease the O-rings of the manifold. Longzlife grease (* p. 170) = Push the manifold into the rubber sleeve and position it. = Mount springs @ ‘Spring hooks (50305017000) (*" p. 175) = Mount and tighten screw @. Guideline Remaining screws, chassis We 10 Nm (7.4 Ibt = Tighten screw @. Guidetine Remaining screws, chassis od TO Nm (7.4 Tor9 EXHAUST 8 = Mount and tighten screws ©, Guideline Remaining screws, chassis M6 TO Nm (7.4 TBF 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 hot components. = Remove screw @, = Pull the main silencer off of the manifold at rubber sleeve @. Mount the main silencer with rubber sleeve @ = Mount and tighten screw @. Guideline Remaining screws, chassis M6 10 Nm (7.4 Tot Warning Danger of burns The exhaust system gets very hot when the vehicle is driven = Allow the exhaust system to cao! down. Do not touch hot components. Hover a period, the fibers ofthe glass fiber yarn vanish into the air, and the silencer "burns out. Not only is the noise level higher, the performance characteristic changes. Preparatory work = Remove the main silencer. (* p. 55)9 EXHAUST 40154410] Mai A Remove screws @. Take off silencer cap @ with O-ring @ and outer tube @. Pull glass fiber yarn filling @ from the inner tube. Clean the parts that are to be reinstalled. Mount new glass fiber yarn filling @ on the inner tube. Slide outer tube @ over the inner tube with the new glass fiber yarn filling. Insert protection cap @ with O-ring @ into the outer tube. Mount and tighten screws @ with toothed washers. Guidetine Remaining screws, chassis we TO Nm (7.4 Tot ishing work Install the main silencer. (€ p. 55)10 AIR FILTER 37 10.1 Removing the airfilterbox ti Ls Pull off the air filter box id in area @ sideways and remove it toward the front. fea0275-10) Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine, = Never ride the vehicle without an ar filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. = Gil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations, Preparatory work = Remove the air filter box lid. (7 p. 87) 7) Main work = Unhook air iter holder @ and swing it tothe side. Remove the air filter with the air filter support. ~ Remove the ai filter from the ar filter support. Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. © Info o not clean the air filter with fuel or petroleum since these substances attack the foam. Preparatory work = Remove the air filter box lid. (** p. 57) = Remove the air filter. (7 p. 87) Main work = Was the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner (* p. 170) eo, | Info Toniy squeeze te ai iter to dry it; never wring it out. = Oil the dry air filter with a high quality filter oil 800325.01 Oil for foam air filter (* p. 171)10 AIR FILTER Clean the air filter box ‘Check the intake flange for damage and looseness. ishing work Install the ar filter. (%* p, 58) Install the air filter box lid. (7p. 58) 301262210] — Loos 40182710) Main work = Mount the clean air filter onto the air filter support. = Apply grease to the air filter around area @. Longzlife grease (* p. 170) = Put in both parts together, position them and fix them with air filter holder @. The arrow of the UP marking points upward. Info Ts the air fitter is not correctly mounted, dust and dirt can enter the engine and cause damage. Finishing work Install the air filter box lid. (* p. 58) Seal the air filter box in marked area @, Insert the air filter box lid into rear area @ and clip it into front area @.11. FUEL TANK, SEAT, TRIM so ‘Mel Removing the seat Remove screw @. Lift up the seat at the rear, pull it back and then remove it from above. Lo0052.10 Hook in the front of the seat at the collar bushing of the fuel tank, lower it atthe rear and simultaneously push it forward, Make sure that the seat is correctly locked in. Mount and tighten screw @ of the seat fixing. Guideline Remaining screws, chassis Me 10 Nm (7.4 Ib ft) Lo0052.10 ‘The fuel tap is on the left of the fuel tank, ‘Tap handle @ on the fuel tap can be used to open or close the fuel supply to the car- buretor. Possible states ‘+ Fuel supply closed OFF ~ Fuel cannot flow from the fuel tank to the carburetor. ‘Fuel supply open ON — Fuel can flow from the fuel tank to the carburetor. The fuel tank empties fully L00035-1011. FUEL TANK, SEAT, TRIM 60 Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine frst. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. — The fuel in the fuel tank expands whien warm and may emerge if overflled, Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. Fuel must nat come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact accurs 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. Preparatory work = Remove the seat. (* p, 59) Main work = Close fuel tap. = Pull off fuel hose. Info T Remaining fuel may tlow out of the fuel hose. 4 = Remove seen @ = Remove the tube fom the fuel tank breather. L90059.10 = Remove screws @. = Remove the fuel tank from above. Danger Fire hazard Fuel is highly flammable. = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine frst. Be careful that no fuel is spilt, especialy on hot vehicle components. Clean up spilt fuel immediately = The fuel in the fuel tank expands when warm and may emerge if overflled. 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 accurs 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,11. FUEL TANK, SEAT, TRIM 6 Main work = Position the fuel tank. ese tht no cables ar goed or damaged Cameco uel ne eat ed tate seen @ Guiene q Feline chasse We ‘own 7a wT Lo0059.10 = Mount and tighten screws @. Guideline Remaining screws, chassis Me 10 Nm (7.4 Tb) = Position the fuel tank breather. ing work Mount the seat. (** p. 59)12 MASK, FENDER = Remove screws @, Remove the front fender. Ensure that the spacers are mounted in the fender. Position the front fender. Mount and tighten screws @. Guideline Remaining screws, chassis od 10 Nm (7.4 Tot 7 The holding lugs engage. = Remove screw @ and take off the clamp, = Remove screw @. Take off the start number plate. Position the start number plate. Mount and tighten screw @. Guideline Remaining screws, chassis we TO Nm (7.4 oF) The holding lugs engage. Position the brake line and clamp. Mount and tighten screw13. WHEELS 6 © Info Low tie air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life = Remove the protection cap. = Check the tire air pressure when the tires are cold. Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) » Ifthe tre pressure does not meet specifications: = Correct the tire pressure. = Mount the protection cap. © Info only mount ties approved andlor recommended by KTM. (the ties could nave o negative eect on hancling characteristic. Tho type, condition, and ar pressure af the tires all have amojor impact on the handling characteristics ofthe motorcycle The tes mounted on the font and rear wheels must havea simile rile. orn tires have @ negative effect on riding behave, especially on wet surfaces. ~ Check the front and rear tires for cuts, run-in objets, and other damage. ao I the tires exhibit cuts, ruin objects, or other damage: = Change the irs, ~ Check the dept of the tread - Info T Note toca national regulations concerning the minimum tread depth. AON Sr Sm 008 the ed depth than tena permissible deat = Change the tes = check the ag of th tits. Info I The tre's date of manufacture is usually pat ofthe tire markings and is indicated by the last four digits of the OT marking, The first two digits refer to the week of manufacture and last two digits refer to the year of manutac- ture, KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. > Ifa tire is more than 5 years ol Change the tire. Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). = Change the worn brake disc(s) without delay.13. WHEELS 64 Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement . Info Wear reduces the thickness of the brake disc around the area used by the brake linings. Brake discs - wear limit Front 2.5 mm (0.098 in) 400267.10) Rear 3.5 mm (0.138 in) » Ifthe brake disc thickness is less than the specified value: = Change the brake disc. = Check the front and rear brake discs for damage, cracking and deformation. » Ifthe brake disc shows signs of damage, cracking, or deformation = Change the brake disc. Warning Danger of accidents Instable handling due to incorrect spoke tension. Ensure that the spoke tension is correct. © Info ‘A Ioose spoke causes wheel imbalance and rapidly leads to more loose spokes. It the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. Briefly strike each spoke with the tip of a screwdriver. © Info I The tone frequency depends on the length of the spoke and the spoke diam eter. Ifyou hear different tone frequencies from diferent spokes of equal length and diameter, this is an indication of different spoke tension. You should hear a high nate, » If the spoke tension varies: = Correct the spoke tension. = Check the spoke torque Guideline ‘Spoke nipple MAS 5 Nm (3.7 It ft) ‘Torque wrench with various accessories in set (58429094000) (* p. 177) 13.5.1 Removing the front wheel Preparatory work = Raise the motorcycle with the lft stand. (* p. 9) Main work = Remove screw @, Release screws @.13. WHEELS 6s = Holding the front wheel, withdraw the wheel spindle, Take the front wheel out of the fork Info To not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not damn- aged. Lov092.10 13.5.2 _ Installing the front wh Warning 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, Main work = Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: = Change the whee! bearing, = Clean and grease shaft seal rings @ and bearing surface @ of the spacers. Longzlife grease (* p. 170) Insert the spacers. = Position the front wheel. ‘The brake linings are correctly positioned, = Insert wheel spindle. = Mount and tighten screw @. Guideline ‘Screw, front wheel spindle W20x1.5 35Nm (25.8 Ibf FO) = Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. = Remove the motorcycle from the lft stand. (% p. 9) = Pull the front wheel brake and push down hard on the fork several times to align the fork legs, = Tighten screws ©. Guideline Screw, fork stub we 18.Nm (21.1 tbr AD Finishing work = Remove the motorcycle from the lft stand. (* p. 9)13. WHEELS 6s 13.6.1 Removing the rear whee! Preparatory work = Raise the motorcycle with the lft stand. ( p. 9) Main work = Remove nut @. = Remove chain adjuster @. Withdraw wheel spindle © only enough to allow the rear ‘hee! to be pushed forward, = Push the rear wheel forward as far as possible. = Holding the rear wheel, withdraw the wheel spindle. Remove the chain from the rear sprocket. Take the rear wheel out of the swingarm. © Info To not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged. = Remove spacers @. 13.6.2 _ Installing the rear wheel ts 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, Main work = Check the wheel bearing for damage and wear. » Ifthe wheel bearing is damaged or worn: = Change the wheel bearing, = Clean and grease shaft seal rings @ and bearing surface @ of the spacers. Longzlife grease ( p. 170) = Insert the spacers = Lift the rear wheel into the swingarm, position it, and attach the chain, 7 The brake linings are correctly positioned. = Insert wheel spindle @,13. WHEELS 67 = Position chain adjuster @. Mount nut @, but do not tighten it yet Make sure that chain adjusters @ are fitted correctly on adjusting screws ©. = Check the chain tension. (** p. 68) = Tighten nut @. Guideline Nat, rear wheel spindle M20x1-5 80 Nm (59 lof ft) Info I The wide adjustment range of the chain adjusters enables different sec- ondary ratios with the same chain length. Chain adjusters @ can be turned by 180°. = Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. ishing work Remove the motorcycle from the lift stand. (* p. 9) 13.6.3 Checking for chain dirt accumulation = Check the chain for coarse dirt accumulation, @Q >If the chain is very diy = Clean the chain, (** p. 67) 400678-01 13.6.4 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. Remove oil and grease with a suitable cleaning materia Warning 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. = Gil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info I The service life of the chain depends largely on its maintenance.13. WHEELS ea = Clean the chain regularly and then treat with chain spray. ‘Chain cleaner (* p. 170) Off-road chain spray (* p. 171) 40072501 13.6.5 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. Ifthe chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary Preparatory work = Raise the motorcycle with the lft stand. (© p. 9) Main work = Push the chain at the end of the chain sliding component upwards to measure chain tension ©, Info Lower chain section @ must be taut Chain wear is not always even, so you should repeat this measurement at different chain positions. ‘Chain tension 55... 58 mm (2.17... 2.28 in) » Ifthe chain tension does not meet specifications: = Adjust the chain tension. (* p. 70) ishing work = Remove the motorcycle from the lft stand. (€ p. 9) 13.6.6 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work = Raise the motorcycle with the lft stand. (* p. 9) Main work —— = Shift gear to neutral COSIOSCIEO Cheek the rear sprocket and engine sprocket for wear » Ifthe rear sprocket and engine sprocket are worn: = Change the power set. Info I The engine sprocket, rear sprocket, and chain should always be changed together. 400227-0113. WHEELS 69 Pull on the upper part of the chain with specified weight @. COED 161718 400867-10 00255-01 £00256.01 Guidetine Weight, chain wear measurement 10... 15 kg (22... 33 1b) Measure distance @ of 18 chain links in the lower chain section. Info Thain wear is not always even, so you should repeat this measurement at different chain positions. ‘Maximum distance @ at the longest | 219 mm (8.62 in) chain section » If distance @ is greater than the specified measurement: = Change the power set Info When you replace the chain, you should also change the rear sprocket and engine sprocket ‘New chains wear out faster on old, worn sprockets. ‘Check the chain sliding guard for wear. » Ifthe lower edge of the chain pins is in line with or below the chain sliding uard: = Change the chain sliding guard, Check the chain sliding guard for tightness. » Ifthe chain sliding guard is loose: = Tighten the chain sliding guard. Guideline Remaining screws, chassis We 0Nm (7A Ibe tt) Check the chain sliding piece for wear. » Ifthe lower edge of the chain pins is in line with or below the chain sliding piece: = Change the chain sliding piece. Check the chain sliding piece for tightness. » Ifthe chain sliding piece is loose: Tighten the chain sliding piece. Guidetine ‘Screw, chain sliding piece we TS Nm (21.1 Ibs fe