2020 KTM 390 Adventure Repair Manual

Krzysztof Szczypka, kristofsx@gmail.
com,
Krzysztof Szczypka, kristofsx@gmail.com,
INTRODUCTION
This document is valid for the following models:

390 Adventure EU (F5303T5, F5303T6)
390 Adventure B.D. EU (F5303T7, F5303T8) 390
Adventure B.D. 2 EU (F5303T7L, F5303T8L) 390
Adventure AU (F5360T5, F5360T6)
390 Adventure JP (F5386T5, F5386T6)
390 Adventure US (F5375T5, F5375T6)
390 Adventure AR (F5342T5, F5342T6)

390 Adventure BR (F5340T5, F5340T6)
390 Adventure CN (F5387T5, F5387T6)
390 Adventure CO (F5341T5, F5341T6)
390 Adventure MY (F5389T5, F5389T6)
390 Adventure PH (F5382T5, F5382T6)
390 Adventure TH (F5383T5, F5383T6)
INDEX
7 HANDLEBAR, CONTROLS............................ 35
INDEX
1 MEANS OF REPRESENTATION ...................... 7

1.1 Symbols used .................................... 7 7.1 Checking the clutch lever play........... 35
1.2 Formats used..................................... 7 7.2 Adjusting play in the clutch lever....... 35
7.3 Changing the throttle grip ................. 36
2 SAFETY ADVICE............................................ 8
8 FRAME ...................................................... 41
2.1 Repair Manual ................................... 8
2.2 Safety advice..................................... 8 8.1 Changing the footrest bracket............ 41
2.3 Degrees of risk and symbols ................ 8 8.2 Checking the frame .......................... 45
2.4 Work rules......................................... 8
9 SHOCK ABSORBER, LINK FORK.................. 46
3 IMPORTANT NOTES...................................... 9
9.1 Measuring the dimension of the rear
3.1 Manufacturer warranty, implied wheel unloaded................................ 46
warranty............................................ 9 9.2 Checking the static sag of the shock
3.2 Fuel, auxiliary substances ................... 9 absorber.......................................... 46
3.3 Spare parts, accessories ..................... 9 9.3 Adjusting the spring preload of the
3.4 Figures ............................................. 9 shock absorber ................................ 46
9.4 Checking the heim joint for play ........ 47
4 SERIAL NUMBERS ..................................... 10 9.5 Removing the shock absorber ............ 47
4.1 Vehicle identification number............ 10 9.6 Installing the shock absorber............. 48
4.2 Type label ....................................... 10 9.7 Removing the spring......................... 50
4.3 Key number..................................... 11 9.8 Installing the spring ......................... 50
4.4 Engine number ................................ 11 9.9 Checking the link fork ...................... 52
9.10 Removing the link fork...................... 52
5 MOTORCYCLE ............................................ 12 9.11 Installing the link fork ...................... 54
5.1 Raising the motorcycle with rear 9.12 Checking the fork bearing for play ..... 57
lifting gear ...................................... 12 9.13 Changing the link fork bearing........... 57
5.2 Removing the rear of the motorcycle
10 EXHAUST SYSTEM ..................................... 61
from the lifting gear ......................... 12
5.3 Lifting the motorcycle with the front 10.1 Removing the exhaust system............ 61
lifting gear ...................................... 12 10.2 Installing the exhaust system ............ 62
5.4 Taking the motorcycle off the front 10.3 Removing the main silencer .............. 63
lifting gear ...................................... 13 10.4 Installing the main silencer............... 64
5.5 Raising the motorcycle with work
stand .............................................. 13 11 AIR FILTER ................................................ 65
5.6 Removing the motorcycle from the 11.1 Changing the air filter, cleaning the
work stand ...................................... 14 air filter box..................................... 65
5.7 Starting........................................... 15
5.8 Starting the motorcycle to make 12 FUEL TANK, SEAT, TRIM ............................ 67
checks ............................................ 16 12.1 Opening fuel tank filler cap............... 67
6 FORK, TRIPLE CLAMP ................................ 17 12.2 Closing the fuel tank filler cap........... 67
12.3 Removing the front rider's seat .......... 68
6.1 Cleaning the dust boots of the fork
12.4 Mounting the front rider's seat........... 68
legs ................................................ 17
12.5 Removing the passenger seat ............ 68
6.2 Removing the fork legs ..................... 17
12.6 Mounting the passenger seat............. 69
6.3 Installing the fork legs ...................... 18
12.7 Removing the fuel tank cover ............ 69
6.4 Disassembling the fork legs............... 20
12.8 Installing the fuel tank cover ............. 70
6.5 Checking the fork legs ...................... 22
12.9 Removing the fuel tank..................... 71
6.6 Assembling the fork legs................... 23
12.10 Installing the fuel tank ..................... 72
6.7 Removing the lower triple clamp........ 27
12.11 Removing motor guard...................... 74
6.8 Installing the lower triple clamp ........ 29
12.12 Installing the motor guard................. 74
6.9 Checking steering head bearing
play ................................................ 31 12.13 Removing front fender ...................... 75
6.10 Adjusting the steering head bearing 12.14 Installing the front fender ................. 75
play ................................................ 32 12.15 Checking the fuel pressure................ 76
6.11 Changing the steering head bearing ... 33 12.16 Changing the fuel filter..................... 78
2
INDEX
12.17 Changing the fuel pump ................... 79 15.6 Checking the rear brake linings ....... 120
12.18 Removing the engine guard retaining 15.7 Changing the rear brake linings ....... 120
bracket ........................................... 80 15.8 Checking the free travel of foot
12.19 Installing the engine guard retaining brake lever .................................... 123
bracket ........................................... 81 15.9 Adjusting the free travel of the foot
brake lever .................................... 123
13 WHEELS .................................................... 82
15.10 Checking the rear brake fluid
13.1 Checking tire pressure ...................... 82 level ............................................. 124
13.2 Checking the tire condition ............... 82 15.11 Adding rear brake fluid ................... 125
13.3 Checking the brake discs .................. 83 15.12 Changing the rear brake fluid .......... 126
13.4 Front wheel ..................................... 84
16 COMBINATION INSTRUMENT ................... 129
13.4.1 Removing the front wheel ............. 84
13.4.2 Installing the front wheel .............. 84 16.1 Combination instrument ................. 129
13.4.3 Changing the front brake disc ....... 85 16.2 Activation and test ......................... 129
13.4.4 Changing the front wheel 16.3 Day-Night mode............................. 129
bearing ....................................... 86 16.4 Warnings....................................... 130
13.4.5 Checking the wheel bearing for 16.5 Indicator lamps.............................. 130
play ............................................ 88 16.6 Display ......................................... 131
13.5 Rear wheel ...................................... 88 16.7 Speed ........................................... 132
13.5.1 Removing the rear wheel .............. 88 16.8 Shift warning light ......................... 132
13.5.2 Installing the rear wheel ............... 89 16.9 Speed ........................................... 133
13.5.3 Changing the rear brake disc......... 91 16.10 ODO display .................................. 133
13.5.4 Changing the rear wheel bearing.... 92 16.11 Coolant temperature indicator ......... 133
13.5.5 Checking the chain tension........... 96 16.12 Fuel level display ........................... 134
13.5.6 Adjusting the chain tension .......... 97 16.13 Time............................................. 134
13.5.7 Checking the chain, rear 16.14 Favourites display .......................... 134
sprocket, and engine sprocket ....... 97 16.15 Quick Selector 1 display ................. 135
13.5.8 Cleaning the chain ....................... 99 16.16 Quick Selector 2 display ................. 135
13.5.9 Checking the rear hub damping 16.17 Menu............................................ 135
rubber pieces ............................ 100
16.17.1 KTM MY RIDE (optional) ............ 135
13.5.10 Opening the chain ..................... 101
16.17.2 Trips/Data ................................. 136
13.5.11 Riveting the chain...................... 101
16.17.3 Motorcycle ................................ 136
13.5.12 Changing the drivetrain kit.......... 102
16.17.4 Settings .................................... 136
14 WIRING HARNESS, BATTERY.................... 105 16.17.5 Pairing (optional) ....................... 136
16.17.6 Phone (optional) ........................ 137
14.1 Removing the 12-V battery.............. 105
16.17.7 Headset (optional) ..................... 138
14.2 Installing the 12-V battery .............. 105
16.17.8 Audio (optional)......................... 139
14.3 Disconnecting the negative cable
16.17.9 Telephony (optional) .................. 140
of the 12-V battery......................... 106
16.17.10 General Info .............................. 140
14.4 Connecting the negative cable of
the 12-V battery............................. 106 16.17.11 Trip 1 ....................................... 140
14.5 Charging the 12-V battery ............... 107 16.17.12 Trip 2 ....................................... 141
14.6 Checking the charging voltage ......... 108 16.17.13 Warning .................................... 141
14.7 Checking the open-circuit current .... 109 16.17.14 ABS.......................................... 141
14.8 Changing the fuses of individual 16.17.15 Favourites ................................. 142
power consumers ........................... 109 16.17.16 Quick Selector 1........................ 142
14.9 Changing the ABS fuses ................. 111 16.17.17 Quick Selector 2........................ 142
16.17.18 Bluetooth (optional) ................... 143
15 BRAKE SYSTEM ....................................... 113
16.17.19 Shift Light ................................ 143
15.1 Checking the front brake linings ...... 113 16.17.20 Setting the time and date ........... 143
15.2 Changing the front brake linings ...... 113 16.17.21 Distance ................................... 144
15.3 Checking the front brake fluid 16.17.22 Temperature.............................. 145
level ............................................. 116 16.17.23 Fuel Cons.................................. 145
15.4 Adding the front brake fluid ............ 116 16.17.24 Language .................................. 145
15.5 Changing the front brake fluid ......... 118 16.17.25 Service ..................................... 145
3
INDEX
16.17.26 Extra Functions ......................... 146 18.3.34 Removing the balancer shaft....... 176
16.18 Setting the service interval 18.3.35 Removing the crankshaft ............ 176
display.......................................... 146 18.4 Working on individual parts............. 176
17 LIGHTING SYSTEM, INSTRUMENTS .......... 147 18.4.1 Working on the left section of
the engine case ......................... 176
17.1 Checking the headlight setting ........ 147 18.4.2 Working on the right section of
17.2 Adjusting the headlight range.......... 147 the engine case ......................... 178
18.4.3 Changing the radial shaft seal
18 ENGINE ................................................... 148
ring of the water pump ............... 179
18.1 Removing the engine...................... 148 18.4.4 Checking the radial clearance of
18.2 Installing the engine....................... 152 lower conrod bearing .................. 179
18.3 Engine disassembly........................ 157 18.4.5 Changing the conrod bearing....... 180
18.3.1 Preparations .............................. 157 18.4.6 Changing the balancer shaft
18.3.2 Draining the engine oil ............... 157 bearing ..................................... 183
18.3.3 Removing the chain securing 18.4.7 Working on the cylinder head ...... 183
guide ........................................ 158 18.4.8 Checking the cylinder head......... 184
18.3.4 Removing the valve cover............ 158 18.4.9 Checking the pivot points of the
18.3.5 Removing the spark plug ............ 159 camshafts ................................. 185
18.3.6 Removing the shift shaft 18.4.10 Checking/measuring the
sensor....................................... 159 cylinder .................................... 186
18.3.7 Removing the clutch cover.......... 159 18.4.11 Checking the piston ring end
gap........................................... 186
18.3.8 Positioning the engine at
ignition top dead center.............. 160 18.4.12 Checking/measuring the piston.... 187
18.3.9 Removing the timing chain 18.4.13 Checking the piston/cylinder
tensioner................................... 161 mounting clearance.................... 188
18.3.10 Removing the camshaft .............. 162 18.4.14 Checking the oil pump ............... 188
18.3.11 Removing the cylinder head ........ 162 18.4.15 Checking the oil pressure
control valve.............................. 189
18.3.12 Removing the piston .................. 163
18.4.16 Checking the clutch ................... 189
18.3.13 Removing the starter motor......... 164
18.4.17 Checking the shift mechanism .... 190
18.3.14 Removing the timing chain ......... 164
18.4.18 Preassembling the shift shaft ...... 191
18.3.15 Removing the water pump
wheel ....................................... 165 18.4.19 Disassembling the main shaft ..... 192
18.3.16 Removing the alternator cover ..... 165 18.4.20 Disassembling the
countershaft .............................. 193
18.3.17 rotor, removing .......................... 166
18.4.21 Checking the transmission .......... 193
18.3.18 Removing the starter drive .......... 166
18.4.22 Assembling the main shaft.......... 195
18.3.19 Removing the drive gear wheel
of the balancer shaft .................. 167 18.4.23 Assembling the countershaft ....... 195
18.3.20 Removing the gear position 18.4.24 Checking the timing assembly..... 197
sensor....................................... 167 18.4.25 Changing the stator.................... 198
18.3.21 Removing the suction pump........ 168 18.4.26 Checking the electric starter
18.3.22 Removing the clutch basket ........ 169 drive......................................... 199
18.3.23 Removing the primary gear 18.4.27 Checking the freewheel .............. 200
wheel ....................................... 170 18.5 Engine assembly ............................ 200
18.3.24 Removing the force pump........... 171 18.5.1 Installing the crankshaft ............. 200
18.3.25 Removing the shift shaft............. 172 18.5.2 Installing the balancer shaft........ 200
18.3.26 Removing the shift drum 18.5.3 Installing the transmission
locating .................................... 172 shafts ....................................... 201
18.3.27 Removing the locking lever ......... 173 18.5.4 Installing the shift forks.............. 201
18.3.28 Removing the oil filter ................ 173 18.5.5 Installing the shift drum ............. 201
18.3.29 Removing the left engine case..... 173 18.5.6 Installing the shift rails .............. 202
18.3.30 Removing the shift rails.............. 175 18.5.7 Installing the left engine case ..... 202
18.3.31 Removing the shift drum ............ 175 18.5.8 Installing the oil filter................. 204
18.3.32 Removing the shift forks............. 175 18.5.9 Installing the locking lever .......... 204
18.3.33 Removing the transmission 18.5.10 Installing the shift drum
shafts ....................................... 176 locating unit.............................. 205
4
INDEX
18.5.11 Installing the shift shaft ............. 205 22 CYLINDER HEAD ...................................... 243
18.5.12 Installing the oil pump ............... 205
22.1 Checking the valve clearance .......... 243
18.5.13 Installing the primary gear
22.2 Checking the valve clearance,
wheel ....................................... 207
changing the spark plug.................. 246
18.5.14 Installing the clutch basket......... 208
22.3 Adjusting the valve clearance .......... 250
18.5.15 Installing the spacer................... 210
22.4 Removing the camshafts................. 250
18.5.16 Installing the suction pump ........ 210
22.5 Installing the camshafts ................. 251
18.5.17 Installing the gear position
sensor....................................... 211 23 LUBRICATION SYSTEM............................. 253
18.5.18 Installing the drive gear wheel of
23.1 Oil circuit...................................... 253
the balancer shaft ...................... 212
23.2 Checking the engine oil level........... 253
18.5.19 Installing the starter drive........... 213
23.3 Checking the oil pressure................ 253
18.5.20 Installing the rotor ..................... 213
23.4 Changing the engine oil and oil
18.5.21 alternator cover, installing .......... 214
filter, cleaning the oil screens ......... 255
18.5.22 Installing the water pump
23.5 Adding engine oil ........................... 257
cover ........................................ 214
18.5.23 Installing the timing chain .......... 215 24 IGNITION SYSTEM.................................... 258
18.5.24 Installing the starter motor.......... 215
24.1 Alternator – checking the stator
18.5.25 Installing the piston ................... 215
winding......................................... 258
18.5.26 Installing the cylinder head......... 217
24.2 Changing the spark plug ................. 260
18.5.27 Installing the camshafts ............. 218
18.5.28 Installing the timing chain 25 THROTTLE VALVE BODY ........................... 262
tensioner................................... 219
25.1 Resetting the service display using
18.5.29 Checking the valve clearance ...... 219 the KTM diagnostic tool.................. 262
18.5.30 Adjusting the valve clearance ...... 220 25.2 Performing the initialization run ...... 262
18.5.31 Installing the clutch cover .......... 221
18.5.32 Installing the shift shaft sensor ... 222 26 TECHNICAL DATA..................................... 263
18.5.33 Installing the spark plug ............. 222 26.1 Engine .......................................... 263
18.5.34 Installing the valve cover ............ 223 26.2 Tolerance, engine wear limits .......... 264
18.5.35 Installing the chain securing 26.3 Engine tightening torques ............... 264
guide ........................................ 224
26.4 Capacities ..................................... 266
18.5.36 Installing the oil screen .............. 224
26.4.1 Engine oil ................................. 266
18.5.37 Removing the engine from the
26.4.2 Coolant ..................................... 266
engine work stand...................... 225
26.4.3 Fuel ......................................... 266
19 CLUTCH ................................................... 226 26.5 Chassis ......................................... 267
26.6 Electrical system............................ 267
19.1 Checking the clutch ....................... 226
26.6.1 Diagnostics connector ................ 268
20 SHIFT MECHANISM.................................. 233 26.6.2 Front ACC1 and ACC2 ................ 268
20.1 Adjusting the shift lever.................. 233 26.7 Tires ............................................. 268
20.2 Programming the gear position 26.8 Fork.............................................. 268
sensor........................................... 234 26.9 Shock absorber .............................. 269
20.3 Programming the shift shaft 26.10 Chassis tightening torques .............. 269
sensor........................................... 234
27 CLEANING/PROTECTIVE TREATMENT........ 273
20.4 Changing the shift shaft sensor ....... 234
27.1 Cleaning the motorcycle ................. 273
21 WATER PUMP, COOLING SYSTEM ............. 237
27.2 Checks and maintenance steps for
21.1 Draining the coolant ....................... 237 winter operation............................. 274
21.2 Filling/bleeding the cooling 28 STORAGE ................................................. 275
system .......................................... 237
21.3 Checking the antifreeze and 28.1 Storage ......................................... 275
coolant level .................................. 239 28.2 Preparing for use after storage......... 276
21.4 Checking the coolant level .............. 240
29 SERVICE SCHEDULE ................................ 277
21.5 Changing the coolant...................... 241
29.1 Additional information .................... 277
5
INDEX
29.2 Required work ............................... 277

29.3 Recommended work ....................... 278
30 WIRING DIAGRAM .................................... 280
30.1 Page 1 of 9 (EU/AU/JP/AR,
BR/CN/CO, MY/PH/TH) ................... 280
BR/CN/CO, MY/PH/TH) ................... 282
BR/CN/CO, MY/PH/TH) ................... 284
BR/CN/CO, MY/PH/TH) ................... 286
BR/CN/CO, MY/PH/TH) ................... 288
BR/CN/CO, MY/PH/TH) ................... 290
BR/CN/CO, MY/PH/TH) ................... 292
BR/CN/CO, MY/PH/TH) ................... 294
BR/CN/CO, MY/PH/TH) ................... 296
30.10 Page 1 of 9 (US)............................ 298
30.11 Page 2 of 9 (US)............................ 300
30.12 Page 3 of 9 (US)............................ 302
30.13 Page 4 of 9 (US)............................ 304
30.14 Page 5 of 9 (US)............................ 306
30.15 Page 6 of 9 (US)............................ 308
30.16 Page 7 of 9 (US)............................ 310
30.17 Page 8 of 9 (US)............................ 312
30.18 Page 9 of 9 (US)............................ 314
31 SUBSTANCES .......................................... 316
32 AUXILIARY SUBSTANCES ......................... 318
33 SPECIAL TOOLS ....................................... 320
34 STANDARDS ............................................ 334
35 GLOSSARY OF TECHNICAL TERMS............ 335
36 LIST OF ABBREVIATIONS.......................... 336
37 LIST OF SYMBOLS.................................... 337
37.1 Red symbols.................................. 337
37.2 Yellow and orange symbols.............. 337
37.3 Green and blue symbols.................. 337
INDEX ............................................................. 338
6
MEANS OF REPRESENTATION 1
1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name® Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
7
2 SAFETY ADVICE
2.1 Repair Manual

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

A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
2.3 Degrees of risk and symbols
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 or 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.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instruc-
tions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
8
IMPORTANT NOTES 3
3.1 Manufacturer warranty, implied warranty

The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con-
firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) specified in the manual.
3.3 Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other
products and any resulting damage or loss.
The latest news KTM PowerParts on your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
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. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
9
4 SERIAL NUMBERS
4.1 Vehicle identification number

The vehicle identification number 1 is stamped on the right side
of the steering head.
402408-10
4.2 Type label

(EU/JP/AR, BR/CN/CO, MY/PH/TH)
The type label 1 is on the right of the frame behind the
steering head.
402174-10
(AU)
The type label 1 is on the left of the frame behind the steer-
ing head.
402772-10
(US)
The type label USA 1 is located on the top frame on the
right.
402478-10
(US)
The Canada type label 2 is located on the bottom frame on
the left.
402477-10
10
SERIAL NUMBERS 4
4.3 Key number

The key number 1 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep
the KEYCODECARD in a safe place.
If at least one ignition key is still available, a spare key can
be produced. If an ignition key is no longer present, the
entire lock system must be replaced.
402245-10
4.4 Engine number

The engine number 1 is stamped on the left side of the engine
under the engine sprocket.
402486-10
11
5 MOTORCYCLE
5.1 Raising the motorcycle with rear lifting gear
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Mount the supports of the lifting gear.

– Insert the adapter in the rear lifting gear.
Retaining adapter (61029955244) ( p. 324)
Rear wheel work stand (69329955000) ( p. 326)
– Stand the motorcycle upright, align the lifting gear to the link
fork and the adapters, and raise the motorcycle.
402346-01
5.2 Removing the rear of the motorcycle from the lifting gear
Note
– Secure the motorcycle against falling over.

– Remove the rear lifting gear and lean the vehicle on side
stand 1 .
– Remove bushings kit.
402029-10
5.3 Lifting the motorcycle with the front lifting gear
Note
Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 12)
Condition
– Remove protection cap 1.
S04136-10
12
MOTORCYCLE 5
– Move the handlebar to the straight-ahead position. Position the

lifting gear.
Mounting pin (69329965030) ( p. 326)
Front wheel work stand, large (69329965100) ( p. 326)
Info
Always raise the motorcycle at the rear first.
402345-01 – Lift the motorcycle at the front.
5.4 Taking the motorcycle off the front lifting gear
Note
Main work
– Remove the front lifting gear.
402777-01
– Mount protection cap 1.
S04136-10
Finishing work
– Remove the rear of the motorcycle from the lifting gear.
( p. 12)
5.5 Raising the motorcycle with work stand
Note
13
5 MOTORCYCLE
– Remove screws 1.
– Take off the side cover.
G04656-10
G04668-10
– Screw in the special tool holder all the way. Select the right
height and width of the work stand.
Work stand (62529055200) ( p. 325)
– Raise the motorcycle.
Info
Check that the work stand is properly seated.
G04657-10
5.6 Removing the motorcycle from the work stand
Note

– Remove the special tool.
Work stand (62529055200) ( p. 325)
G04657-10
14
MOTORCYCLE 5
– Mount and tighten screws 1.

Guideline
Screw, engine bearer M8 22 Nm (16.2 lbf ft)
G04668-11
– Position the side cover.

G04656-11
5.7 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Caution
Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis-
charged or missing.
– Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
– Unlock the steering.

– Sit on the vehicle, take the weight off of the side stand, and
move it all the way up with your foot.
– Turn the emergency OFF switch to the position .
– Switch on the ignition by turning the ignition key to the posi-
tion .
After you switch on the ignition, you can hear the fuel
pump working for about two seconds. The function check
B00782-10 of the combination instrument is run at the same time.
– Shift the transmission into neutral.
15
5 MOTORCYCLE
The green idle indicator lamp N lights up.

The ABS indicator lamp lights up and goes back out after
starting off.
– Press start button .
Info
Do not press the start button until the combination
instrument function check has finished.
Do not open the throttle to start.
Press the starter for a maximum of 5 seconds. Wait for
a least 5 seconds before trying again.
This motorcycle is equipped with a safety starting sys-
tem. You can only start the engine if the transmission
is in neutral or if the clutch lever is pulled when a gear
is engaged. If the side stand is folded out and you shift
into gear and release the clutch lever, the engine stops.
5.8 Starting the motorcycle to make checks
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
– Turn the emergency OFF switch to the position .

– Switch on the ignition by turning the ignition key to the posi-
tion .
– Press start button .
Info
Do not open the throttle.
B00782-10
16
FORK, TRIPLE CLAMP 6
6.1 Cleaning the dust boots of the fork legs

Preparatory work
– Lift the motorcycle with the front lifting gear. ( p. 12)
– Remove front fender. ( p. 75)
Main work
– Push dust boots 1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles
from the inside fork tubes. Over time, dirt can accumu-
late behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
S04155-10
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when nec-
essary.
– Clean and oil the dust boots and inside fork tubes of both fork
legs.
Universal oil spray ( p. 319)
– Press the dust boots back into the installation position.
– Remove the excess oil.
Finishing work
– Install the front fender. ( p. 75)
– Take the motorcycle off the front lifting gear. ( p. 13)
( p. 12)
6.2 Removing the fork legs

Preparatory work
– Raise motorcycle with work stand. ( p. 13)
– Clamp down the rear of the vehicle.
Main work
– Remove screw 1.
– Remove the cable tie.
– Pull the wheel speed sensor out of the hole and hang to the
side.
G04669-10
17
6 FORK, TRIPLE CLAMP
– Press back the brake linings by slightly tilting the brake caliper
laterally on the brake disc.
– Pull the brake caliper with the spacers carefully back from the
brake disc and hang to the side.
Info
Do not operate the hand brake lever if the brake caliper
G04670-10
has been removed.
– Loosen screw 3 by several rotations.

– Loosen screws 4.
– Press on screw 3 to push the wheel spindle out of the axle
clamp.
– Remove screw 3.
Warning
Danger of accidents Damaged brake discs reduce the
G04671-10
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.
– Hold front wheel and remove wheel spindle. Take the front
wheel out of the fork.
– Loosen screws 5. Remove the fork legs downwards.
G04672-10
6.3 Installing the fork legs
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris-
tic.
– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
Main work
– Push the fork legs into the triple clamps.
– Align the fork legs in the required position using the fork rings.
G04676-10
18
– Tighten screws 1.
Guideline
Screw, top triple M8 15 Nm (11.1 lbf ft)
clamp
Guideline
Screw, bottom triple M8 12 Nm (8.9 lbf ft)
G04672-11
clamp
– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change front wheel bearing. ( p. 86)
– Remove the spacers.
– Clean and grease shaft seal rings 3 and contact surfaces A
of the spacers.
Long-life grease ( p. 318)
G04686-10 – Insert the spacers.
– Clean the thread of the wheel spindle and screw 4.

– Clean and grease wheel spindle.
– Position the front wheel and insert the wheel spindle.
– Mount and tighten screw 4.
Guideline
Screw, front wheel M8 25 Nm (18.4 lbf ft)
G04671-11 spindle
– Position the brake caliper with the spacers.
Info
Ensure that the brake linings are seated properly.
– Mount screws 5, but do not tighten yet.

Guideline
Screw, front M8x1 30 Nm (22.1 lbf ft)
brake caliper Loctite®243™
G04670-11
– Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point. Secure the hand brake lever in the activated position.
The brake caliper straightens.
Guideline
Screw, front M8x1 30 Nm (22.1 lbf ft)
brake caliper Loctite®243™
– Remove the locking piece of the hand brake lever.

19
– Position the wheel speed sensor in the hole.

Guideline
Screw, wheel speed M6 8 Nm (5.9 lbf ft)
sensor holder
– Route the cable and secure with a cable tie.
G04669-11
– Remove the load from the rear of the vehicle.

– Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
G04677-10
Finishing work
– Remove the motorcycle from the work stand. ( p. 14)
– Install the front fender. ( p. 75)
6.4 Disassembling the fork legs
Info
The operations are the same on both fork legs.
Condition
The fork legs have been removed.
– Make a note of the present state of rebound 1 and compres-
sion damping 2 .
– Open the adjusters of the rebound and compression damping
completely.
T03584-10
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) ( p. 333)
– Remove screw 3. Remove the adjuster.
– Loosen screw cap 4.
Ring wrench (T14091) ( p. 333)
Info
T03585-10
The screw cover cannot be removed yet.
20
– Unclamp the fork leg.

– Drain the fork oil.
Z01165-10
– Unclamp the fork leg with the axle clamp.

Guideline
Use soft jaws.
– Remove screw 5 with the washer.
Info
Place a collecting container underneath as some oil will
usually still run out.
Z01166-10
– Remove the cartridge.
Z01169-11
– Remove dust boot 6.

– Remove fork protector ring A.
Info
The fork protector ring does not necessarily need to be
removed for repair work.
T03590-10
– Remove lock ring 7.

Info
The lock ring has a beveled end where a screwdriver
can be applied.
T02344-10
21
– Warm up the outside fork tube in area B of the lower sliding

bushing.
Guideline
50 °C (122 °F)
– Pull the outside fork tube off the inside fork tube with a jerk.
Info
T03591-10
Lower sliding bushing 8 must be drawn from its bear-
ing seat.
– Remove upper sliding bushing 9.

Info
Without using a tool, pull the stack slightly apart by
hand.
– Take off lower sliding bushing 8.

– Take off support ring bk.
T03592-10
– Take off seal ring bl.
– Take off lock ring 7.
– Take off dust boot 6.
– Take off lift indicator bm.
– Unclamp the fork leg.
6.5 Checking the fork legs

Condition
The fork legs have been disassembled.
– Check the inside fork tube and the axle clamp for damage.
» If damage is found:
– Change the inside fork tube.
Z01167-11
– Measure the outside diameter of the inside fork tube at several

places.
Outside diameter of the 42.975 … 43.005 mm
inside fork tube (1.69193 … 1.69311 in)
» If the measured value is less than the specified value:
B03582-10
22
– Measure the run-out of the inside fork tube.

Run-out of the inside fork ≤ 0.20 mm (≤ 0.0079 in)
tube
» If the measured value is greater than the specified value:
B03583-10
– Check the outside fork tube for damage.

» If damage is found:
– Change the outside fork tube.
B04658-10
– Check the surface of the sliding bushings.

» If the dark layer A is worn off:
– Change the guiding bushes.
201517-10
– Check the spring length.

Guideline
Spring length with preload 399 mm (15.71 in)
spacer(s)
– Reduce the thickness of the preload spacers.
» If the measured value is less than the specified value:
– Increase the thickness of the preload spacers.
Z01088-10
6.6 Assembling the fork legs
Info
The operations are the same on both fork legs.
Preparatory work
– Check the fork legs. ( p. 22)
23
Main work
– Clamp the inside fork tube using an axle clamp.
Guideline
Use soft jaws.
– Mount the special tool.
Protecting sleeve (T512) ( p. 333)
– Position lift indicator 1.
T03594-10 – Grease and push on dust boot 2.
Lubricant (T14034) ( p. 318)
Info
Always change the dust boot, seal ring, lock ring, and
support ring.
Mount the sealing lip at the bottom.
– Push on lock ring 3.

– Grease and push on seal ring 4.
Lubricant (T14034) ( p. 318)
The sealing lip points downward, the open side upward.
– Push on support ring 5.
– Sand edges of the sliding bushings with 600 grit sandpaper;
then clean and grease the bushings.
Fork oil (SAE 4) (48601166S1) ( p. 317)
– 6.
Push on lower sliding bushing
– Mount upper sliding bushing 7.
T03593-10 Info
Without using a tool, pull the stack slightly apart by
hand.
– Warm up the outside fork tube in area A of the lower sliding

bushings.
Guideline
50 °C (122 °F)
– Hold the lower sliding bushing with the longer side of the spe-
cial tool.
Mounting tool (T528S) ( p. 333)
B05075-10 – Slide on the outside fork tube.
– Press the sliding bushing all the way into the outside fork
tube.
24
– Position the support ring.

– Hold the seal ring with shorter side of the special tool.
Mounting tool (T528S) ( p. 333)
– Press the seal ring and support ring all the way into the out-
side fork tube.
T03596-10
– Mount retaining ring 3.

The retaining ring engages audibly.
T03595-10
– Mount dust boot 2.

– Mount fork protection ring B.
T03590-11
– Assemble the individual components that belong together.
Info
Compression damping side: cartridge with upper oil
hole C , white adjuster, axle clamp with brake caliper
bracket.
Rebound damping side: cartridge with lower oil
hole D , red adjuster, axle clamp without brake caliper
bracket.
Z01168-11
– Slide the cartridge into the inside fork tube.
Z01169-11
25
– Mount and tighten screw 8 with the washer.

Guideline
Cartridge screw M10x1.5 25 Nm (18.4 lbf ft)
Z01166-11
– Clamp the fork leg vertically.

Guideline
Use soft jaws.
– Fill with fork oil.
Fork oil per fork leg 455 ± 5 ml Fork oil (SAE 4)
(15.38 (48601166S1)
± 0.17 fl. oz.) ( p. 317)
Z01161-10
Info
After approx. half the oil capacity has been filled, screw
in the screw cover of the outside fork tube, unclamp
the fork and bounce a number of times so that the car-
tridge fills with oil. Then add the remaining amount.
– Push the outside fork tube upward.

– Clamp the outside fork tube in the area of the lower triple
clamp.
Clamping stand (T612S) ( p. 333)
– Grease the O-ring of the screw cap.
Lubricant (T159) ( p. 318)
– Mount and tighten screw cap 9.
T03586-10
Guideline
Screw cap on the M47x1.5 40 Nm (29.5 lbf ft)
outside fork tube
Ring wrench (T14091) ( p. 333)

– Mount the adjuster.
– Mount and tighten screw bk.
Guideline
Adjuster M4x0.7 1.5 Nm
(1.11 lbf ft)
26
Alternative 1
– Turn the adjuster of the rebound bl
and the adjuster of
the compression damping bm
clockwise as far as possible.
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline
Rebound damping
Comfort 20 clicks
T03584-11 Standard 15 clicks
Sport 10 clicks
Full payload 15 clicks
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 10 clicks
Alternative 2
Warning
Danger of accident Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
characteristic and overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.
– Set the adjusters to the positions determined upon

removal.
6.7 Removing the lower triple clamp

Preparatory work
– Remove the fork legs. ( p. 17)
27
Main work
G04707-10
– Lift the headlight mask and swing forward.
G04708-10
– Unplug connector 3.
– Take off the headlight mask.
G04709-10
– Remove the cable ties and expose the cable.

– Disconnect the plug-in connections.
G04710-10
– Remove screw 6.
– Take off the upper triple clamp with the handlebar and hang
them to the side.
Info
Cover the components to protect them against damage.
G04711-10
28
– Remove nut 7.
Groove nut wrench (90129050100) ( p. 329)
G04712-10
– Take off washer 8.

– Remove steering head bearing 9.
– Remove the lower triple clamp with the steering stem.
G04713-10
6.8 Installing the lower triple clamp

Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 318)
– Mount upper steering head bearing 1.
– Mount washer 2 with the cut-out facing downward.
G04713-11
Alternative 1
A new steering head bearing is used.
– Insert the lower triple clamp with the steering stem.
– Mount and tighten nut 3.
Guideline
Nut, steering head M30x1 1st stage
45 Nm
(33.2 lbf ft)
G04712-11 2nd stage (loosen,
counterclockwise)
2 turns
3rd stage
5 Nm (3.7 lbf ft)

Alternative 2
The steering head bearing is used again.
– Insert the lower triple clamp with the steering stem.
29
Guideline
Nut, steering head M30x1 5 Nm (3.7 lbf ft)

– Position the upper triple clamp with the handlebar.
Guideline
Screw, steering head, M16x1.5 53 Nm (39.1 lbf ft)
top
G04711-11
– Connect the plug-in connections.

– Route the cables without tension and secure with the cable
ties.
G04710-10
– Plug in connector 5.
– Position the headlight mask.
G04709-11

Guideline
Remaining screws, M8 25 Nm (18.4 lbf ft)
chassis
G04708-11
30
– Mount and tighten screws 9 on both sides.

Guideline
chassis
– Install the fork legs. ( p. 18)
G04707-11
– Loosen screws bk.

– Using a plastic hammer, tap lightly on the upper triple clamp
to avoid stresses.
– Tighten screw 4.
Guideline
top
G04765-10
– Tighten screws bk.
Guideline
clamp
Finishing work
– Check that the wiring harness, throttle cables, and brake line
have the necessary freedom of movement and are correctly
routed.
– Check steering head bearing play. ( p. 31)
6.9 Checking steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ages components.
– Correct incorrect steering head bearing play immediately.
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
31
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play. ( p. 32)
– Move the handlebar to and fro over the entire steering range.
400738-11 It 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. 32)
– Check the steering head bearing and adjust if neces-
sary.
Finishing work
6.10 Adjusting the steering head bearing play

Preparatory work
Main work
G04678-10
– Loosen screw 2.
G04679-10
– Tighten nut 3 with the special tool until there is no play in

the steering head bearing.
Hook wrench (90129051000) ( p. 329)
G04680-10
32
– Using a plastic hammer, tap lightly on the upper triple clamp

to avoid stresses.
– Remove screw 2.
Guideline
top
G04679-10
Guideline
clamp
G04678-10
Finishing work
6.11 Changing the steering head bearing

Preparatory work
– Remove the fork legs. ( p. 17)
– Remove the lower triple clamp. ( p. 27)
Main work
– Remove lower bearing ring 1 using a suitable tool.
T00912-10
– Press in the new bearing ring all the way using a suitable tool.
T00913-10
33
– Remove upper bearing ring 2 using a suitable tool.
T00914-10
– Press in the new bearing ring all the way using a suitable tool.
T00915-10
– Remove lower steering head bearing 3.

– Remove the seal ring.
– Grease new seal ring and press on all the way with a suitable
tube.
– Mount a new bearing.
T00911-10
Finishing work
– Install the lower triple clamp. ( p. 29)
– Check that the wiring harness, throttle cables, and brake line
have the necessary freedom of movement and are correctly
routed.
34
HANDLEBAR, CONTROLS 7
7.1 Checking the clutch lever play
Note
Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.
– Check the free travel of the clutch lever each time before using the motorcycle.
– Adjust the free travel of the clutch lever when necessary in accordance with the specification.
– Check the clutch lever for smooth operation.

– Move the handlebar to the straight-ahead position.
– Pull the clutch lever until resistance is perceptible, and deter-
mine the play in the clutch lever A.
Clutch lever play A 1 … 3 mm (0.04 …

0.12 in)
» If the clutch lever play does not meet the specified value:
S04142-12
– Adjust play in the clutch lever. ( p. 35)
– Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
» If the clutch lever play changes:
– Check the routing of the clutch cable.
7.2 Adjusting play in the clutch lever

– Move the handlebar to the straight-ahead position.
– Push back sleeve1.
– Loosen lock nut 2.
– Adjust the play in the clutch level A by turning adjusting
screw .3
Guideline
Clutch lever play A 1 … 3 mm (0.04 …
0.12 in)
– Tighten lock nut 2.
– Position bellows 1.
S04175-10
35
7 HANDLEBAR, CONTROLS
7.3 Changing the throttle grip

G04707-10
– Lift the headlight mask slightly and pull forward.
G04708-10
– Detach connector 3.
– Take off the headlight mask.
G04739-10
– Remove the cable ties.
G04737-10
– Detach connector 4.
T00879-10
36
– Remove nuts 5.
– Loosen screw 6.
– Take off the hand guard.
G04738-10
– Remove screw 7.
– Remove screw 8.
T00882-10
– Pull the throttle grip and accelerator position sensor unit from
the handlebar.
T00883-10
– Remove the throttle grip.
Info
Push the accelerator position sensor slightly to the side.
T00884-10
37
– Position the new throttle grip.

– Latch holding lugs A into throttle grip driving hub B.
Info
Push the accelerator position sensor slightly to the side.
T00885-10
– Position the throttle grip and accelerator position sensor unit

on the handlebar.
Pin C engages in hole D.
T00886-10

Guideline
Screw for throttle M5 3.5 Nm
grip (2.58 lbf ft)
T00882-10
38
– Position the hand guard.

– Mount and tighten nuts 5.
Guideline
Remaining nuts, M6 15 Nm (11.1 lbf ft)
chassis
Guideline
Screw, handlebar M6 9 Nm (6.6 lbf ft)
weight
G04738-10
– Plug in connectors 4.
– Secure the cables with a cable tie.
T00879-10
– Secure the cable with cable ties.
G04737-10
G04739-10
39
– Position the headlight mask.

Guideline
Screw, headlight M6 8 Nm (5.9 lbf ft)
G04708-10
– Mount and tighten screws 1 on both sides.

Guideline
G04707-10
40
FRAME 8
8.1 Changing the footrest bracket

Preparatory work
– Remove motor guard. ( p. 74)
Main work
– Secure the engine and the link fork against turning using the
floor jack.
Info
G04715-10
– Remove screw 1 with the washers.

– Take off the shift lever and hang to the side.
G04716-10
– Remove all covers.
G04717-10
– Remove nut 3 with the washer.
G04718-10
41
8 FRAME
– Remove screw 4.
– Take off the footrest bracket.
G04719-10
– Remove nuts 5.
– Remove the side stand from the footrest bracket.
– Remove the pins.
– Mount the pins on the new footrest bracket and tighten.
Guideline
Threaded bolt, M10x1.25 27 Nm (19.9 lbf ft)
side stand Loctite®243™
bracket
G04720-10
– Position the side stand on the new footrest bracket.
– Mount and tighten nuts 5.
Guideline
Nut, side stand M10x1.25 35 Nm (25.8 lbf ft)
bracket
– Position the footrest bracket.

– Mount screw 4, but do not tighten yet.
G04719-10
– Adjust adjusting ring 6 with special tool A.

Guideline
Adjusting ring, link M22x1 Tighten and ensure
fork bearing that there is no
play
G04721-10 The adjusting ring is flush with the collar bushing.

42
FRAME 8
– Take the brake cylinder off the footrest bracket.
– Remove the spring.
– Remove screw 8 with the washers. Take off the foot brake
lever.
G04722-10
Procuring the tool (pin):

– Pin B .
Guideline
Length ≥ 300 mm (≥ 11.81 in)
Diameter 15 mm (0.59 in)
R00107-10
– Push pin B through hole C in the link fork.

Pin B replaces the swingarm pivot and stabilizes the
vehicle.
– Take off the footrest bracket.
– Position the new footrest bracket.
G04723-10
– Position the brake cylinder and foot brake lever on the new
footrest bracket.
Guideline
chassis
– Mount and tighten screw 8 with the washers.
G04722-10
Guideline
Screw, foot M8 16 Nm (11.8 lbf ft)
brake lever Loctite®243™
43
8 FRAME
– Mount and tighten fitting 4.

Guideline
Screw, front footrest M10x1.25 49 Nm (36.1 lbf ft)
bracket / engine
bearer
G04761-10
– Adjust the adjusting ring with special tool A.

Guideline
play
T00908-10 The adjusting ring is flush with the collar bushing.
– Mount the swingarm pivot with washer 9.

Recess D is aligned to the pin.
The tool (pin) is removed when the swingarm pivot is
mounted.
G04762-10
– Position the covers.

Guideline
chassis
G04717-10
44
FRAME 8
– Position the shift lever.

– Mount and tighten screw 1 with the washers.
Guideline
Screw, shift M8 16 Nm (11.8 lbf ft)
lever Loctite®243™
The step on the washers is in contact with the bearing.

– Mount and tighten nut 3 with the washer.
Guideline
Nut, swingarm pivot M14x1.5 100 Nm
(73.8 lbf ft)
Recess D is aligned to the pin.

– Remove the floor jack.
G04763-10
Finishing work
( p. 12)
– Install the motor guard. ( p. 74)
8.2 Checking the frame

– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a
mechanical impact:
– Change the frame.
Info
Always replace a frame that has been dam-
aged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
T00768-10
45
9 SHOCK ABSORBER, LINK FORK
9.1 Measuring the dimension of the rear wheel unloaded

Preparatory work
Main work
– Measure the distance – as vertical as possible – between the
rear axle and a fixed point, for example, a mark on the rear
fairing.
– Note the value as dimension A.
400988-10
Finishing work
9.2 Checking the static sag of the shock absorber

– Measure dimension A of rear wheel unloaded. ( p. 46)
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance between rear axle and fixed point again.
– Note the value as dimension B.
Info
The static sag is the difference between
measurements A and B .
– Check the static sag.

Guideline
Static sag 12 mm (0.47 in)
400989-10
9.3 Adjusting the spring preload of the shock absorber
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris-
tic.
– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
Info
The spring preload defines the initial status of the spring operation on the shock absorber.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any lug-
gage and a passenger, thus ensuring an ideal compromise between handling and stability.
46
SHOCK ABSORBER, LINK FORK 9
– Adjust the spring preload by turning adjusting ring 1.

Guideline
Spring preload
Comfort 3 clicks
Standard 3 clicks
Sport 3 clicks
S04134-10
Hook wrench, shock absorber (90529077000)
Extension for hook wrench (90129099025)
Info
The spring preload can be set to 10 different positions.
9.4 Checking the heim joint for play

Preparatory work
Main work
– Check the top and bottom heim joints.
– Move the link fork up and down.
– Change shock absorber.
H01902-01
Finishing work
9.5 Removing the shock absorber

Preparatory work
Main work
– Remove nut 1.
G04681-10
47
– Take off the cover.
G04682-10
– Remove screw 4 and 5.

– Remove the chain guard.
G04683-10
– Remove screw 6.
Info
Ensure that the chain and brake line are not damaged.
G04684-10
– Remove fitting 7.
– Remove the shock absorber 8 toward the rear.
G04685-10
9.6 Installing the shock absorber

Main work
– Position shock absorber 1.
– Mount fitting 2 , but do not tighten yet.
Guideline
Fitting, shock M10x1.25 50 Nm (36.9 lbf ft)
absorber, bot- Loctite®243™
tom
G04685-11
48
– Lift the link fork.

Guideline
Screw, top M10x1.25 50 Nm (36.9 lbf ft)
shock absorber Loctite®243™
– Tighten fitting 2.
Guideline
G04684-11 Fitting, shock M10x1.25 50 Nm (36.9 lbf ft)
tom
– Position the chain guard.

Guideline
chassis
Guideline
G04683-10 Screw, chain guard EJOT PT® 3 Nm (2.2 lbf ft)
K60x30
– Position the cover.

Guideline
chassis
G04682-11

Guideline
chassis
Guideline
G04681-11
chassis
Finishing work
49
9.7 Removing the spring

Condition
The shock absorber has been removed.
– Clamp the shock absorber into the vise.
Guideline
Use soft jaws.
– Note the position of the spring preload.
– Loosen adjusting ring A using the special tool.
Hook wrench (T106S) ( p. 332)
Z01170-10
– Clamp the shock absorber into the special tool.

Spring compressor (T14050S) ( p. 332)
Info
Use the suitable ring of the special tool with the small-
est possible inside diameter.
– Compress the spring.

Z01171-10 – Remove spring retainer 1.
– Release the spring. Remove the shock absorber from the spe-
cial tool.
– Remove washer 2.
– Remove spring seat 3.
– Remove the spring.
Z01172-10
9.8 Installing the spring

– Mount the spring.
– Position spring seat 1.
– Position washer 2.
Z01173-10
50
– Clamp the shock absorber into the special tool.

Spring compressor (T14050S) ( p. 332)
Info
Use the suitable ring of the special tool with the small-
est possible inside diameter.
– Mount spring retainer 3.

Z01171-11 The open end is opposite the spring end.
– Release the spring. Remove the shock absorber from the spe-
cial tool.
– Clamp the shock absorber into the vise.
Guideline
Use soft jaws.
Alternative 1
– Tension the spring to the prescribed position by turning
adjusting ring . A
Guideline
Spring preload
Comfort 3 clicks
Standard 3 clicks
Sport 3 clicks
Z01170-10
Hook wrench (T106S) ( p. 332)

Alternative 2
Warning
Danger of accident Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
characteristic and overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.
– Tension the spring to the position measured during dis-

mantling by turning adjusting ring A.
51
9.9 Checking the link fork

– Check the link fork for damage, cracking, and deformation.
» If the link fork shows signs of damage, cracking, or defor-
mation:
– Change the link fork.
Info
Always replace a damaged link fork. Repairing
the link fork is not authorized by KTM.
R01993-10
9.10 Removing the link fork

Preparatory work
Main work
– Secure the engine and the link fork against turning using the
floor jack.
Info
G04715-10
– Remove nut 1.
T00543-10
– Take off the cover.
G04682-10
52
– Remove screw 4 and 5.

– Remove the chain guard.
G04683-10
– Clamp down the front of the vehicle.

The rear wheel is not in contact with the ground.
– Remove screw 6 and pull wheel speed sensor 7 out of the
hole.
– Remove nut 8 with the washer. Take off chain adjuster 9.
– Hold the rear wheel and pull out wheel spindle bk with the
washer and chain adjuster bl .
– Push the rear wheel forward as far as possible and take the
chain off the rear sprocket.
G04724-10
– Expose cable bm and brake line bn.

– Remove the rear wheel.
Info
Do not operate the foot brake lever if the brake caliper
has been removed.
– Take off the brake caliper and hang to the side.
T00931-10 Info
– Hang chain bo to the side.
T00932-10
53
– Remove fitting bp.

– Push the link fork down and away from the shock absorber.
T00933-10
– Remove nut bq with the washer.

– Remove swingarm pivot br with the washer.
R03989-10
– Loosen adjusting rings bs using the special tool.

– Take off the link fork.
R03990-10
9.11 Installing the link fork

Main work
– Position the link fork.
– Adjust adjusting ring 1 with special tool.
Guideline
play
R03990-11
The adjusting ring is flush with the collar bushing.
54
– Mount swingarm pivot 2 with the washer.

Recess A is aligned to the pin.
Guideline
Nut, swingarm pivot M14x1.5 100 Nm
(73.8 lbf ft)
Recess A is aligned to the pin.
T00936-10
– Lift the link fork and position the shock absorber.

Guideline
Fitting, shock M10x1.25 50 Nm (36.9 lbf ft)
tom
– Position the chain.
T00933-11
– Position the brake caliper.

– Position the rear wheel and mount wheel spindle 5 with the
washer and chain adjuster .6
Info
Mount left and right chain adjusters 6 in the same
position.
– Mount nut 7 with the washer.

– Push the rear wheel forward so that the chain adjusters are in
contact with the screws, and tighten nut 7
.
Guideline
Nut, rear wheel spin- M14x1.5 100 Nm
dle (73.8 lbf ft)
In order for the rear wheel to be correctly aligned, the mark-

ings on the left and right chain adjusters must be in the
same position relative to reference markings B .
G04724-11 – Position wheel speed sensor 8 in the hole. Mount and

tighten screw 9 .
55
Guideline
sensor holder
– Remove load from the front of the vehicle.
– Secure cable bk and brake line bl in the bracket.
T00931-11

– Mount and tighten screw bm.
Guideline
chassis
– Mount and tighten screw bn.
Guideline
T00928-11 Screw, chain guard EJOT PT® 3 Nm (2.2 lbf ft)
K60x30

– Mount and tighten screws bo.
Guideline
chassis
G04725-10
– Mount and tighten screws bp.

Guideline
chassis
– Mount and tighten nut bq.
Guideline
T00543-12
chassis
56
– Remove the floor jack.
G04715-10
Finishing work
– Check the chain tension. ( p. 96)
9.12 Checking the fork bearing for play

Preparatory work
– Place a load on the front of the vehicle.
Main work
– Move the link fork up and down.
– Change the link fork bearing. ( p. 57)
– Move the link fork from one side to the other.
– Change the link fork bearing. ( p. 57)
H01903-01
Finishing work
9.13 Changing the link fork bearing

Preparatory work
– Remove the link fork. ( p. 52)
57
Left fork bearing

– Remove collar bushings 1.
R03807-10
– Remove bushing 2.
R03809-10
– Remove radial shaft seal rings 3 using a suitable tool.

– Remove stop disks 4 .
– Press out bearing 5 using a suitable tool.
– Using a suitable tool, press in new bearing 5.
– Position the stop disks 4.
– Press in radial shaft seal rings 3.
R03810-10
– Mount bushing 2.
R03809-10
58
– Grease the radial shaft seal rings.

– Position the collar bushings 1 with the shoulder facing
inward.
R03808-10
Right fork bearing

– Remove collar bushings 6.
R03811-10
– Remove bushing 7.
R03813-10
59
– Remove radial shaft seal rings 8 using a suitable tool.

– Using a suitable tool, press in new bearing 9.
– Press in radial shaft seal rings 8.
R03814-10
– Mount bushing 7.
R03813-10
– Grease the radial shaft seal rings.

– Position the collar bushings 6 with the shoulder facing
inward.
R03812-10
Finishing work
– Install the link fork. ( p. 54)
60
EXHAUST SYSTEM 10
10.1 Removing the exhaust system

Preparatory work
– Remove the main silencer. ( p. 63)
Main work
– Remove screw 1. Remove the clamp.
G04658-10
– Remove screws2.
– Remove screw 3.
– Take off the presilencer in a downward direction.
G04660-10
– Remove the cover.
– Hang ignition coil and cable to the side.
G04661-10
61
10 EXHAUST SYSTEM

– Expose and disconnect plug-in connector 5 of the lambda
sensor.
G04662-10
– Remove nuts 6.
– Take off the manifold in a forward direction.
G04663-10
10.2 Installing the exhaust system

Main work
– Position the manifold.
– Mount nuts 1, but do not tighten yet.
Guideline
Nut, exhaust flange M8 8 Nm (5.9 lbf ft)
G04663-11
– Join plug-in connector 2.

ties.
G04662-11
– Position the ignition coil.

– Mount and tighten screw 3 with the ground wire.
Guideline
chassis
G04661-11
62
EXHAUST SYSTEM 10
– Position the presilencer with a clamp.

Guideline
Screw, presilencer M6 12 Nm (8.9 lbf ft)
Guideline
Screw, presilencer M8 23 Nm (17 lbf ft)
G04660-11

Guideline
Exhaust clamp - 20 Nm (14.8 lbf ft)
– Tighten nuts 1.
Guideline
G04658-11
Guideline
Finishing work
– Install the main silencer. ( p. 64)
10.3 Removing the main silencer

– Remove screw 1. Remove the clamp.
G04664-10
63
10 EXHAUST SYSTEM
– Remove screw 2.
– Take off the main silencer.
G04665-10
10.4 Installing the main silencer

– Position the main silencer with the gasket.
Guideline
Screw, main silencer M8 23 Nm (17 lbf ft)
G04665-11
– Position the clamp. Mount and tighten screw 2.

Guideline
Guideline
G04664-11
64
AIR FILTER 11
11.1 Changing the air filter, cleaning the air filter box
Preparatory work
– Remove the passenger seat. ( p. 68)
– Remove the front rider's seat. ( p. 68)
Main work
– Take off the air filter box cover.
R03999-10
– Push the holding lugs forwards.

– Remove the air filter.
– Clean the air filter box.
R04000-10
– Position new air filter in the guides.
R04001-10
– Engage holding lugs to the rear.
R04002-10
65
11 AIR FILTER
– Mount the air filter box cover.
Info
Check that the air filter box cover is correctly seated.

Guideline
Screw, air filter box M6 3 Nm (2.2 lbf ft)
cover
R03999-10
Finishing work
– Mount the front rider's seat. ( p. 68)
– Mount the passenger seat. ( p. 69)
66
FUEL TANK, SEAT, TRIM 12
12.1 Opening fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
– Lift cover 1 of the fuel tank filler cap and insert the ignition
key into the lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
– Push down on the fuel tank filler cap to take pressure off
the ignition key.
S04127-10
– Turn the ignition key 90° clockwise.
– Lift the fuel tank filler cap.
12.2 Closing the fuel tank filler cap
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
– Check that the fuel tank filler cap is locked cor-
rectly after closing.
– Change your clothing if fuel spills on them.
– Rinse the affected area immediately with plenty of
A00705-10 water in the event of contact with the skin.
67
12 FUEL TANK, SEAT, TRIM
– Fold down the fuel tank filler cap.

– Turn the ignition key 90° clockwise.
– Push down the fuel tank filler cap and turn the ignition key
counterclockwise until the fuel tank filler cap lock engages.
– Remove the ignition key and close the cover.
12.3 Removing the front rider's seat

Preparatory work
Main work
– Raise the rear of the front rider's seat, pull it towards the rear,
and remove it upwards.
H01993-01
12.4 Mounting the front rider's seat

Main work
– Attach the front rider's seat in area A and lower at the rear.
– Finally, check that the front rider's seat is correctly mounted.
H01994-01
Finishing work
12.5 Removing the passenger seat

– Insert the ignition key in seat lock 1 and turn it clockwise.
– Raise the rear of the seat, push it towards the rear, and lift it
off.
– Remove the ignition key from the seat lock.
H01991-10
68
12.6 Mounting the passenger seat

– Attach hooks 1 on the passenger seat to seat mounting 2
on the subframe, and lower it at the rear while pushing for-
ward.
– Press passenger seat downward until it clicks into place.
Warning
Danger of accidents The seat can come loose from the
anchoring if it is not mounted correctly.
H01992-01 – After assembly, check whether the seat is correctly
locked and cannot be pulled up.
– Finally, check that the passenger seat is correctly mounted.
12.7 Removing the fuel tank cover
Danger
Warning
Note
Preparatory work
69
Main work
G04666-11
– Remove the spoiler to the rear.
G04667-10
12.8 Installing the fuel tank cover

Main work
– Position the trim.
Guideline
Screw, side cover M6 7 Nm (5.2 lbf ft)
Guideline
G04667-11 Screw, side cover M6 7 Nm (5.2 lbf ft)

Guideline
Screw, side cover M6 7 Nm (5.2 lbf ft)
G04666-12
Finishing work
70
12.9 Removing the fuel tank
Danger
Warning
Note
Preparatory work
– Remove the fuel tank cover. ( p. 69)
Main work
G04701-10
– Remove screw 2.
– Remove fuel tank cover 3.
G04702-10
71
– Push back hose clamps 4 and pull off the vent hoses.
Spring band clamps plier (60029057100) ( p. 324)
G04703-10
G04704-10
– Raise the fuel tank.

– Disconnect quick release couplings 7.
Info
Remaining fuel may flow out of the fuel hose.
– Take off the fuel tank.

G04705-10
12.10 Installing the fuel tank
Danger
Warning
72
Note
Main work
– Join quick release couplings 1.
G04705-11
G04704-11
– Mount spring band clamps 4.

G04703-10
– Mount fuel tank cover5.

Guideline
Screw, fuel tank M8 20 Nm (14.8 lbf ft)
G04702-11

Guideline
Screw, fuel tank trim M6 5 Nm (3.7 lbf ft)
G04701-11
73
Finishing work
– Install the fuel tank cover. ( p. 70)
12.11 Removing motor guard

– Take off the engine guard.
A00706-10
12.12 Installing the motor guard

– Position the engine guard, mount and tighten screws 1.
Guideline
Screw, engine M6 9 Nm (6.6 lbf ft)
guard Loctite®243™
A00706-10
74
12.13 Removing front fender

– Remove screws 1. Take off the front fender.
A00704-10
12.14 Installing the front fender

– Position the front fender. Mount and tighten screws 1.
Guideline
chassis
A00704-10
75
12.15 Checking the fuel pressure
Danger
Warning
Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The ignition is off.
The diagnostics tool is connected.
– Disconnect quick release coupling 1.
Info
Remaining fuel may flow out of the fuel hose.
G04714-10
– Remove connection 2 from the hose.

Pressure testing tool (61029094000) ( p. 324)
D02699-10
76
– Mount special tool 3.

Pressure testing tool (61029094000) ( p. 324)
– Mount special tool 4 with nozzle code 0,60.
Testing hose (61029093000) ( p. 324)
– Position the hose end in a fuel can.
Guideline
Minimum size, fuel can 10 l (2.6 US gal)
D00002-01
– Switch the ignition on.

– "Actuator test" > "Execute function test of fuel pump control".
– Check the fuel pressure with the fuel tank filler cap closed.
Fuel pressure
When the fuel pump is 3.2 … 3.7 bar (46 …
active 54 psi)
» If the specification is not reached:
– Open fuel tank filler cap. ( p. 67)
– Check the fuel tank breather.
400927-01
– Check the fuel pressure with the fuel tank filler cap open.
Fuel pressure
When the fuel pump is 3.2 … 3.7 bar (46 …
active 54 psi)
– Check that the fuel line is clear.
– Change the fuel filter. ( p. 78)
400928-01 – Change the fuel pump. ( p. 79)
– Stop the "Function test of fuel pump control" actuator test by
pressing the "Quit" button.
– Remove the special tools.
– Join quick release coupling 1.
G04714-10
77
12.16 Changing the fuel filter
Danger
Warning
Note
Preparatory work
– Remove the fuel tank. ( p. 71)
– Drain the fuel from the fuel tank into a suitable container.
Main work
– Take fuel filter 1 out of the holder.
– Remove quick-release coupling 2 and 3.
– Remove the fuel filter.
– Position the new fuel filter.
Arrow faces in the direction of travel.
– Join quick-release coupling 2 and 3.
– Position fuel filter 1 in the holder.
G04706-10
Finishing work
– Install the fuel tank. ( p. 72)
78
12.17 Changing the fuel pump
Danger
Warning
Note
Preparatory work
Main work
– Remove the fuel pump with the gasket.
T00856-10
79
– Mount the gasket 2 on the new fuel pump.
T00569-10
– Position the fuel pump with the gasket.

– Mount screws 1 and tighten in a crisscross pattern.
Guideline
Screw, fuel pump M6 10 Nm (7.4 lbf ft)
T00856-10
Finishing work
12.18 Removing the engine guard retaining bracket

Preparatory work
Main work
– Remove the engine guard retaining bracket.
A00691-10
80
12.19 Installing the engine guard retaining bracket

Main work
– Position the engine guard retaining bracket, mount and tighten
screws 1 .
Guideline
guard retaining Loctite®243™
bracket
A00691-10
Finishing work
81
13 WHEELS
13.1 Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
– Remove the protection cap.

– Check the tire pressure when the tires are cold.
Tire pressure when solo
front 2.0 bar (29 psi)
rear 2.0 bar (29 psi)
Tire pressure with passenger / full payload

400695-01
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the protection cap.
13.2 Checking the tire condition
Warning
Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable.
– Ensure that damaged or worn tires are replaced immediately.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
teristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character-
istic.
– Only use tires/wheels approved by KTM with the corresponding speed index.
Info
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the
motorcycle.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
82
WHEELS 13
– Check the front and rear tires for cuts, run-in objects, and
other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check the tread depth.
Info
Observe the minimum tread depth required by national
400602-10 law.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum tread depth:
– Check the tire age.
Info
The tire date of manufacture is usually contained in the
tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of
manufacture and the last two digits the year of manu-
facture.
KTM recommends that the tires be changed after 5
H01144-10 years at the latest, regardless of the actual state of
wear.
» If the tires are more than 5 years old:

13.3 Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately.
– Check the front and rear brake disc thickness at multiple

points for the dimension . A
Info
Wear will reduce the thickness of the brake disc at con-
tact surface1 of the brake linings.
Brake discs - wear limit

front 4.5 mm (0.177 in)
400480-10
rear 3.6 mm (0.142 in)
» If the brake disc thickness is less than the specified value.
– Change the front brake disc. ( p. 85)
– Change the rear brake disc. ( p. 91)
– Check the front and rear brake discs for damage, cracking, and
deformation.
83
13 WHEELS
» If the brake disc exhibits damage, cracking, or deforma-

tion:
– Change the front brake disc. ( p. 85)
– Change the rear brake disc. ( p. 91)
13.4 Front wheel
13.4.1 Removing the front wheel

Preparatory work
Main work
hole.
– Loosen screw 3 by several rotations.
– Press on screw 3 to push the wheel spindle out of the axle
clamp.
– Remove screw 3.
Warning
braking effect.
– Hold front wheel and remove wheel spindle. Take the front
wheel out of the fork.
S04157-10
Info
Do not actuate the hand brake lever when the front
wheel is removed.
13.4.2 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Clean the brake discs with brake cleaner when necessary.
84
WHEELS 13

of the spacers.
S04158-10 – Insert the spacers.
– Clean the thread of the wheel spindle and screw 2.

– Clean and grease the wheel spindle.
– Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
Guideline
Screw, front wheel M8 25 Nm (18.4 lbf ft)
spindle
– 3 in the hole.
Position wheel speed sensor
Guideline
sensor holder
– Operate the hand brake lever repeatedly until the brake lin-
S04157-11
point.
( p. 12)
– Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
Guideline
13.4.3 Changing the front brake disc
Info
If the brake discs are changed, the brake linings must also be changed.
Preparatory work
– Remove the front wheel. ( p. 84)
85
13 WHEELS
Main work
– Remove the wheel speed sensor wheel and the brake disc.
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward.
– Position the wheel speed sensor wheel.
Guideline
G04673-10
Screw, front M8 29 Nm (21.4 lbf ft)
brake disc Loctite®243™
Finishing work
– Install the front wheel. ( p. 84)
13.4.4 Changing the front wheel bearing

Preparatory work
– Remove the front wheel. ( p. 84)
Main work
– Remove spacer 1.
– Remove radial shaft seal ring 2.
R02037-10
R02038-10
R02040-10
86
WHEELS 13
– 6 using a suitable tool.

Press out bearing
– Remove spacing tube 7.
R02041-10

– Press in new bearing 8 all the way using a suitable tool.
Info
Only press the bearing in via the outer bearing race,
otherwise the bearing will be damaged when it is
pressed in.
R02039-10
– Clean, grease, and mount spacing tube 7.

– Press in new bearing 6 all the way using a suitable tool.
Info
pressed in.
R02042-10
– Grease new radial shaft seal ring 5 and press it in until it is

flush.
– Clean, grease, and mount the spacer 4.
R02043-10
– Mount lock ring 3.
R02038-10
87
13 WHEELS

flush.
– Clean, grease, and mount the spacer 1.
R02037-11
Finishing work
– Install the front wheel. ( p. 84)
13.4.5 Checking the wheel bearing for play

Preparatory work
– Place a load on the rear of the vehicle.
The front wheel is not in contact with the ground.
Main work
– Move the front wheel from side to side.
Info
Hold fork leg to check it.

H01901-01
– Place a load on the front of the vehicle.

– Move the rear wheel from side to side.
Info
Hold link fork to check it.

– Change the rear wheel bearing. ( p. 92)
H01900-01
Finishing work
13.5 Rear wheel
13.5.1 Removing the rear wheel

Preparatory work
88
WHEELS 13
Main work
– Remove screw 1.
S04164-10

hole.
– Remove nut 4 and washer.
– 5.
Take off chain adjuster
– Holding the rear wheel, withdraw wheel spindle 6 with the
washer and chain adjuster 5 .
– Push the rear wheel forward as far as possible and take the
chain off the rear sprocket.
– Push chain guard to the side.
Warning
braking effect.
– Pull the rear wheel back and take it out of the link fork.
F00861-11
Info
Do not operate the foot brake lever when the rear wheel
is removed.
13.5.2 Installing the rear wheel
Warning
Warning
Danger of accidents There is no braking effect to start with at the rear brake after installing the rear
wheel.
– Actuate the foot brake several times before going on a ride until you can feel a firm pressure point.
89
13 WHEELS
Main work
– Change the rear wheel bearing. ( p. 92)
of the spacers.
S04159-10
– Clean the thread of the wheel spindle and axle nut.
– Clean and grease wheel spindle.
– Clean the contact areas on the brake caliper bracket and link
fork.
– Mount the damping rubber and rear sprocket carrier on the
rear wheel.
– Insert the spacers.
– Position the rear wheel.
The brake linings are correctly positioned.
– Push the rear wheel forward as far as possible and lay the
chain on the rear sprocket.
– Pull the rear wheel back and mount wheel spindle 3 with the
washer and chain adjuster .4
Guideline
Mount left and right chain adjusters 4 in the same posi-
tion.
– Mount nut 2 and the washer.
– Push the rear wheel forward so that the chain adjusters are in
contact with the screws, and tighten nut .2
Guideline
same position relative to reference markings B .

dle (73.8 lbf ft)
– 5 in the hole.
Position wheel speed sensor
F00861-12
Guideline
sensor holder
90
WHEELS 13

Guideline
Screw, chain guard EJOT PT® 3 Nm (2.2 lbf ft)
K60x30
S04164-11
Finishing work
( p. 12)
13.5.3 Changing the rear brake disc
Info
If the brake discs are changed, the brake linings must also be changed.
Preparatory work
– Remove the rear wheel. ( p. 88)
Main work
– Take off the wheel speed sensor wheel.
G01070-10
– Take off the brake disc.
– Clean the contact surface of the brake disc and the wheel
speed sensor wheel.
– Position the brake disc with the label facing outward.
Guideline
Screw, rear M8 29 Nm (21.4 lbf ft)
G01071-10
brake disc Loctite®243™
91
13 WHEELS
– Position the wheel speed sensor wheel.

Guideline
Screw, rear M6 8 Nm (5.9 lbf ft)
wheel speed Loctite®243™
sensor
G01070-10
Finishing work
– Install the rear wheel. ( p. 89)
( p. 12)
13.5.4 Changing the rear wheel bearing

Preparatory work
Main work
– Remove rear sprocket carrier 1.
G01718-10
R02056-10
G01245-10
92
WHEELS 13
G01246-10
R02057-10
– 6 using a suitable tool.

Press out bearing
– Remove spacing tube 7.
R02058-10
R02059-10
R02060-10
93
13 WHEELS
– Remove radial shaft seal ring bk.
R02061-10
– Press out bearing bl using a suitable tool.

– Press in new bearing bl all the way.
Info
pressed in.
R02062-10
– Grease new radial shaft seal ring bk and press it in until it is

flush.
R02061-10
– Mount spacer 9.
R02060-10
– Press in new bearing 6 all the way.

Info
pressed in.
R05425-10
94
WHEELS 13
R02057-10
– Clean, grease, and mount spacing tube 7.

– Press in new bearing 8 all the way.
Info
pressed in.
R05424-10

flush.
G01246-10
– Mount spacer 3.
G01245-10
– Mount spacer 2.
R02056-10
95
13 WHEELS
– Ensure that the damping rubber pieces are correctly seated.

– Mount rear sprocket carriers 1.
G01718-10
Finishing work
( p. 12)
13.5.5 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
Main work
– In the area after the chain sliding guard, press the chain
upward toward the link fork and measure chain tension A.
Info
Top chain section B must be taut.
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
M00714-10
Chain tension 5 … 7 mm (0.2 … 0.28 in)

» If the chain tension does not meet the specification:
– Adjust the chain tension. ( p. 97)
( p. 12)
96
WHEELS 13
13.5.6 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 left
and right.
Guideline
Chain tension 5 … 7 mm (0.2 … 0.28 in)
Turn the adjusting screws 3 on the left and right so that
the markings on the left and right chain adjusters 4 are in
the same position relative to the reference marks A . The
rear wheel is then correctly aligned.
Info
The top chain section must be taut.
Chain wear is not always even, so you should check the
setting at different chain positions.
– Tighten nuts 2.
F00861-10
– Make sure that chain adjusters 4 are fitted correctly on
adjusting screws .3
– Tighten nut 1 .
Guideline
dle (73.8 lbf ft)
Finishing work
( p. 12)
13.5.7 Checking the chain, rear sprocket, and engine sprocket

Preparatory work
97
13 WHEELS
Main work
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the drivetrain kit. ( p. 102)
Info
The engine sprocket, rear sprocket, and chain
should always be replaced together.
100132-10

– Pull on the lower chain section with the specified weight A.
Guideline
Weight, chain wear measure- 15 kg (33 lb.)
ment
– Measure distance B of 20 chain rollers in the lower chain
section.
Info
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
Maximum distance Bfrom 301.6 mm (11.874 in)

20 chain rollers at the
longest chain section
» If distance B is greater than the specified measurement:
– Change the drivetrain kit. ( p. 102)
401288-10
Info
When a new chain is mounted, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on old, worn sprock-
ets.
98
WHEELS 13
– Check the chain sliding guard for wear.

» If screw 1 becomes visible in area C of the chain slid-
ing guard when viewed from above:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screw of the chain sliding guard.
Guideline
Screw, chain M5 7 Nm (5.2 lbf ft)
guard Loctite®243™
S04138-10
Finishing work
( p. 12)
13.5.8 Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.
Warning
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
99
13 WHEELS
Main work
– Clean the chain regularly.
– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
Chain cleaner ( p. 318)
– After drying, apply chain spray.
Street chain spray ( p. 319)
400725-01
Finishing work
( p. 12)
13.5.9 Checking the rear hub damping rubber pieces
Info
The engine power is transmitted from the rear sprocket to the rear wheel via the 6 damping rubber pieces.
They eventually wear out during operation. If the damping rubber pieces are not changed in time, the rear
sprocket carrier and the rear hub will be damaged.
Preparatory work
Main work
– Check bearing 1.
» If the bearing is damaged or worn:
– Change the bearing.
– Check the damping rubber pieces 2 of the rear hub for dam-
age and wear.
» If the damping rubber pieces of the rear hub are damaged
or worn:
S04160-10 – Change all the damping rubber pieces of the rear hub.
– Lay the rear wheel on a workbench with the rear sprocket fac-
ing upwards and insert the wheel spindle in the hub.
– To check play A , hold the rear wheel tight and try to rotate
the rear sprocket.
Info
Measure the play on the outside of the rear sprocket.
Play of damping rubber ≤ 5 mm (≤ 0.2 in)

S04161-10
pieces on rear wheel
» If clearance A is larger than the specified value:
– Change all the damping rubber pieces of the rear hub.
Finishing work
( p. 12)
100
WHEELS 13
13.5.10 Opening the chain

– Mount pressing tool A with the larger diameter in the spindle
of the special tool. Turn the spindle counterclockwise.
Chain rivet tool (60029020000) ( p. 323)
– Make the connecting link of the chain accessible. Fret the riv-
eting point.
– Position the special tool with the pressing tool on one of the 2
pins of the connecting link of the chain.
203065-10
Locking screw B points upwards.
– Position retaining clamp C of the special tool on the chain
from the rear.
Markings A and B point upwards.
– Slide retaining clamp C of the special tool into the pressing
tool.
The arrow of marking A points to locking screw B.
– Screw the locking screw hand-tight as far as it will go.
The retaining clamp is fixed.
– Hold the special tool and screw in the spindle.
The chain pin is pressed out through the retaining clamp
drill hole.
– Unscrew the locking screw and remove the special tool.
– Repeat the process on the second pin of the chain link.
13.5.11 Riveting the chain

– Grease new connecting link 1 and position an X-ring 2 on
each pin.
– Connect the chain ends with a connecting link.
– Position another X-ring 2 on each pin.
203075-10
– Mount pressing tool A with the smaller diameter in the spin-

dle of the special tool. Turn the spindle counterclockwise.
– Position press plate B of the special tool on the mandrel.
– Position chain joint plate3 in the press plate.
203077-10
101
13 WHEELS
– Position the special tool on the chain.

Locking screw C points upwards.
– Position retaining clamp D of the special tool on the chain
from the rear.
Markings A and B point upwards.
– Slide retaining clamp D of the special tool into the pressing
tool.
203078-10
The arrow of marking A points to locking screw C.
– Screw the locking screw hand-tight as far as it will go.
The retaining clamp is fixed.
– Hold the special tool and screw in the spindle.
Mandrel A of the special tool presses against the center
of chain joint plate 3 .
The chain joint plate is pressed on.
– Unscrew the locking screw and remove the special tool.
– Rivet the two pins of the connecting link with special tool.
13.5.12 Changing the drivetrain kit

Preparatory work
Main work
– Remove fittings 1. Take off the rear sprocket.
– Position the new rear sprocket.
– Mount and tighten the fittings.
Guideline
Nut, rear sprocket M8 38 Nm (28 lbf ft)
G04674-10
– Remove screws2.
– Remove screw 3 with the spacer.
– Remove the engine sprocket cover.
R04005-10
102
WHEELS 13
– Remove screws 4. Take off lock washer 5.
R04006-10
– Remove engine sprocket 6.

– Open the chain. ( p. 101)
– Take off the chain.
Info
Protect the components against damage by covering
them.
– Mount the new chain.

R04007-10
– Rivet the chain. ( p. 101)
– Position new engine sprocket 6 in the chain and mount on
the countershaft.
R04008-10
– Mount lock washer 5 and twist slightly.

The lock washer engages in the gear teeth of the counter-
shaft.
Guideline
Screw, lock M6 12 Nm (8.9 lbf ft)
washer, engine Loctite®243™
sprocket
R04009-10
– Position the engine sprocket cover.

Guideline
sprocket cover
– Mount and tighten screw 3 with spacer.
Guideline
R04005-10 Screw, engine M6 8 Nm (5.9 lbf ft)
sprocket cover
Finishing work
103
13 WHEELS

( p. 12)
104
WIRING HARNESS, BATTERY 14
14.1 Removing the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep 12 V batteries out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Avoid contact with battery acid and battery gases.
– Keep sparks or open flames away from the 12 V battery.
– Only charge 12 V batteries in well-ventilated rooms.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Preparatory work
Main work
– Remove screws 1 and take off the holding bracket.
– Disconnect negative cable 2 from the 12-V battery.
S04165-10
– Pull back positive terminal cover 3.

– 4 from the 12-V battery.
Disconnect positive cable
– Unhook rubber strap 5 and open rubber strap 6.
– Pull the 12-V battery upwards and out of the battery compart-
ment.
Info
Never operate the motorcycle with a discharged 12-V
S04166-10 battery or without a 12-V battery. In both cases, elec-
trical components and safety devices can be damaged.
The vehicle will therefore no longer be roadworthy.
14.2 Installing the 12-V battery

Main work
– Position the 12-V battery in the battery compartment.
12-V battery (ETZ‑9‑BS) ( p. 267)
– Close rubber strap 1 and attach rubber strap 2.
– Position positive cable 3 and mount and tighten the screw.
– Position positive terminal cover 4.
S04166-11
105
14 WIRING HARNESS, BATTERY
– Position negative cable 5 and mount and tighten the screw.

– Position the holding bracket, mount and tighten screws 6.
Guideline
Screw, cross connec- M6 15 Nm (11.1 lbf ft)
tor
S04165-11
Finishing work
– Set the time and date. ( p. 143)
14.3 Disconnecting the negative cable of the 12-V battery

Preparatory work
Main work
– Disconnect negative cable 1 of the 12-V battery.
S04165-12
14.4 Connecting the negative cable of the 12-V battery

Main work
– Connect negative cable 1 of the 12-V battery.
S04165-12
Finishing work
106
14.5 Charging the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep 12 V batteries out of the reach of children.
– Avoid contact with battery acid and battery gases.
– Keep sparks or open flames away from the 12 V battery.
– Only charge 12 V batteries in well-ventilated rooms.
– Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
Note
Info
Even if there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the
safety valves. This reduces the capacity of the 12-V battery.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.
Preparatory work
– Disconnect the negative cable of the 12-V battery. ( p. 106)
Main work
– Connect the battery charger to the 12-V battery. Adjust the
battery charger.
EU battery charger XCharge‑professional (00029095050)
( p. 320)
Alternative 1
US battery charger XCharge‑professional
(00029095051) ( p. 321)
311910-10
Alternative 2
UK battery charger XCharge‑professional
(00029095052) ( p. 321)
107
Alternative 3
CH battery charger XCharge‑professional
(00029095053) ( p. 321)
Info
Follow the instructions of the charger and the manual.
– Disconnect the battery charger after charging the 12-V battery.

Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery 3 months
regularly when the motorcy-
cle is not being used
Finishing work
– Connect the negative cable of the 12-V battery. ( p. 106)
14.6 Checking the charging voltage

Condition
The 12 V battery must be fully functional and completely charged.
Preparatory work
Main work
– Start the motorcycle to make checks. ( p. 16)
– Measure the voltage between the specified points.
Measuring point plus (+) – Measuring point Ground (−)
Charging voltage
5,000 rpm 13.5 … 15.0 V
» If the displayed value is less than the specified value:
– Check the cable from the alternator to the voltage regu-
lator.
P00296-10 – Check the cable from the voltage regulator to the wiring
harness.
– Check the stator winding of the alternator. ( p. 258)
» If the displayed value is greater than the specified value:
– Change the voltage regulator.
108
14.7 Checking the open-circuit current

Preparatory work
Main work
– Measure the current between the 12-V battery ground (−) and
the negative cable.
Info
The value of the open-circuit current only applies to
vehicles in their original state without additional power
consumers.
R04012-10 Maximum open-circuit cur- < 1.0 mA

rent
– Disconnect the voltage regulator from the wiring har-
ness and perform the measurement again.
Finishing work
14.8 Changing the fuses of individual power consumers
Info
The fuse box containing the fuses for the individual power consumers is located under the passenger seat.
Preparatory work
109
Main work
– Open fuse box cover 1.
– Remove the faulty fuse.
Guideline
Fuse 1 - not assigned
Fuse 2 - 10 A - combination instrument, fuel pump
Fuse 3 - 10 A - power relay
Fuse 4 - 15 A - ignition coil, start auxiliary relay
Fuse 5 - 15 A - radiator fan
Fuse 6 - 15 A - brake light, turn signal, high beam, low
beam, position light, tail light, license plate lamp
Fuse 7 - 10 A - engine electronics control unit, ABS control
unit
Fuse 8 - 10 A - emergency off
Fuse 9 - 10 A - permanent positive for auxiliary equipment
(ACC1 front)
Fuse 10 - 15 A - ignition positive for auxiliary equipment
A00699-10 (ACC2 front)
Fuse SPARE - 10 A/15 A/30 A - spare fuses
Info
A faulty fuse has a burned-out fuse wire A.
Warning
Fire hazard Incorrect fuses overload the electrical sys-
tem.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
– Insert the spare fuse with the correct rating.

Fuse (75011088010) ( p. 267)
Fuse (75011088015) ( p. 267)
Fuse (75011088030) ( p. 267)
Tip
Put a spare fuse in the fuse box so that it is available if
needed.
– Check that the power consumer is functioning properly.

– Close the fuse box cover 1.
Finishing work
110
14.9 Changing the ABS fuses
Warning
Fire hazard Incorrect fuses overload the electrical system.
Info
Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the
hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box.
Preparatory work
To change the fuse of the ABS hydraulic unit:
– Take off the protection cap and remove fuse 1.
Info
Warning
Fire hazard Incorrect fuses overload the electrical
A00700-10
system.

Fuse (75011088015) ( p. 267)
Tip
Insert spare fuse 2 in the fuse box so that it is
available if needed.

To change the fuse of the ABS return pump:
– Take off the protection cap and remove fuse 3.
Info
Warning
Fire hazard Incorrect fuses overload the electrical
A00700-11
system.

Fuse (90111088025) ( p. 267)
111
Tip
Insert spare fuse 4 in the fuse box so that it is
available if needed.

Finishing work
112
BRAKE SYSTEM 15
15.1 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately.
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a
consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.
– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:

– Change the front brake linings. ( p. 113)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the front brake linings. ( p. 113)
S04146-10
15.2 Changing the front brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally.
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
Warning
113
15 BRAKE SYSTEM
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
– Take off cover 2 with membrane 3.
G04768-10
T00804-10
– Remove pin 5.
– Take off spring 6.
T00805-10
114
BRAKE SYSTEM 15
– Remove brake linings 7.

– Clean the brake caliper.
T00806-10
– Press the brake piston back into the basic position and ensure
that brake fluid does not flow out of the brake fluid reservoir;
extract some if necessary.
Info
Protect the components against damage.
T00807-10
– Position the new brake linings 7.

Info
Always change the brake linings in pairs.
T00806-10
– Position spring 6.
The arrow on the spring points in the direction of travel.
– Mount pin 5.
Info
Make sure the springs are seated correctly.
T00805-10

– Operate the hand brake lever until you reach a firm pressure
point.
T00804-10
115
15 BRAKE SYSTEM
– Add brake fluid up to level A.

Guideline
Dimension A 5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 316)

– Position the cover with the membrane. Mount and tighten the
screws.
G04767-10 Info
Immediately clean up any brake fluid that has over-
flowed or spilled with water.
15.3 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are
worn down.
– Check the brake system and do not continue riding until the problem is eliminated.
Warning
schedule.
– Move the brake reservoir mounted on the handlebar into a hori-

zontal position.
– Check the brake fluid level in the level viewer 1.
» If the brake fluid level is below the MINmarking:
– Add the front brake fluid. ( p. 116)
S04144-10
15.4 Adding the front brake fluid
Warning
worn down.
116
BRAKE SYSTEM 15
Warning
with the eyes.
Warning
schedule.
Note
Info
Preparatory work
– Check the front brake linings. ( p. 113)
Main work
– Take off cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Dimension A 5 mm (0.2 in)
S04145-10

screws.
Info
117
15 BRAKE SYSTEM
15.5 Changing the front brake fluid
Warning
with the eyes.
Note
Info

– Cover the painted parts.
– Take off cover 2 with membrane.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 322)
G04787-10
– Mount bleeder cover 3.

Bleeder cover (00029013009) ( p. 320)
– Connect the bleeding device.
Bleeding device (00029013100) ( p. 320)
G04788-10
118
BRAKE SYSTEM 15
– Open shut-off valve 4.

Info
Follow the instructions in the Owner's Manual of the
bleeding device.
– Ensure that the inflation pressure is set at pressure gauge A .

Correct the inflation pressure on pressure regulator B if nec-
essary.
201494-10
Guideline
Inflation pressure 2 … 2.5 bar (29 … 36 psi)
– Pull off protection cap 5 of the brake caliper bleeder screw.

Connect the bleeder bottle hose.
– Open bleeder screw 6 by approximately one half turn.
Info
Drain until fresh brake fluid emerges in the bleeder bot-
tle hose without bubbles.
T00810-10
– Tighten the bleeder screw.

– Close shut-off valve 4.
– Open the bleeder screw again until brake fluid stops emerging.
Info
Overfilling the brake fluid reservoir is prevented.
– Tighten the bleeder screw. Remove the bleeder bottle hose.

Attach the protection cap.
– Disconnect the bleeding device. Remove the bleeder cover.
– Add brake fluid up to level C.
Guideline
Dimension C 5 mm (0.2 in)

screws.
G04789-10 Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.
– Check the hand brake lever for a firm pressure point.

119
15 BRAKE SYSTEM
15.6 Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately.
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a
consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.
– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:

– Change the rear brake linings. ( p. 120)
– Check the brake linings for damage and cracking.
– Change the rear brake linings. ( p. 120)
S04156-10
15.7 Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally.
Warning
with the eyes.
Warning
schedule.
Warning
120
BRAKE SYSTEM 15
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Info
Condition
The screw cap is locked.
– Remove screw 1 and take off the screw cap lock.
H01142-10
– Position the vehicle upright.

– Remove screw cap 2 with membrane 3.
– Manually press the brake caliper toward the brake disc to push
back the brake piston. Ensure that brake fluid does not flow
out of the brake fluid reservoir; extract some if necessary.
G04786-10
– Remove lock rings 4.

– Remove pin 5.
T00817-10
121
15 BRAKE SYSTEM
– Remove brake linings 6.

– Clean the brake caliper.
T00818-10
– Position the new brake linings 6.

Info
Always change the brake linings in pairs.
– Mount pin 5.
T00820-10
– Mount lock rings 4.
T00819-10
– Operate the foot brake lever repeatedly until the brake lin-
point.
– Adjust the brake fluid level to the MAX marking.
– Mount the screw cap with the membrane.
Info
G04786-11
Condition
– Position the screw cap lock and mount and tighten
screw 1 .
Guideline
Screw, compensat- M5 9 Nm (6.6 lbf ft)
ing tank cap lock,
rear brake
H01142-10
122
BRAKE SYSTEM 15
15.8 Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Disconnect spring 1.
– Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check
free travel A
.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not meet specifications:
– Adjust the free travel of the foot brake lever.
( p. 123)
– Reconnect spring 1.
S04147-10
15.9 Adjusting the free travel of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
123
15 BRAKE SYSTEM
– Detach spring1.
– Release nut 2 and use screw 3 to adjust the specified free
travel A.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
Info
The range of adjustment is limited.
– Hold screw 3 and tighten nut 2.

Guideline
chassis
– Attach spring 1.
A00708-10
15.10 Checking the rear brake fluid level
Warning
worn down.
Warning
schedule.
– Stand the vehicle upright.

– Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN marking 1:
– Add rear brake fluid. ( p. 125)
S04148-10
124
BRAKE SYSTEM 15
15.11 Adding rear brake fluid
Warning
worn down.
Warning
with the eyes.
Warning
schedule.
Note
Info
Preparatory work
– Check the rear brake linings. ( p. 120)
Main work
Condition
H01142-10
125
15 BRAKE SYSTEM

– Remove screw cap 2 with membrane 3.
– Add brake fluid up to the marking A.
– Mount the screw cap with the membrane.
Info
S04149-10 Immediately clean up any brake fluid that has over-
Condition
screw 1 .
Guideline
ing tank cap lock,
rear brake
H01142-10
15.12 Changing the rear brake fluid
Warning
with the eyes.
Note
Info
126
BRAKE SYSTEM 15
Condition
H01142-10
– Cover the painted parts.

– Take off screw cap 2 with the membrane.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 322)
G04769-10
– Mount bleeder cover 3.

Bleeder cover (00029013014) ( p. 320)
– Connect the bleeding device.
G04770-10
– Open shut-off valve 4.

Info
Follow the instructions in the Owner's Manual of the
bleeding device.
– Ensure that the inflation pressure is set at pressure gauge A .

Correct the inflation pressure on pressure regulator B if nec-
essary.
D01248-10
Guideline
Inflation pressure 2 … 2.5 bar (29 … 36 psi)
127
15 BRAKE SYSTEM
– Pull off protection cap 5 of the bleeder screw. Connect the

bleeder bottle hose.
– Open bleeder screw 6 by approximately one half turn.
Info
Drain until fresh brake fluid emerges in the bleeder bot-
tle hose without bubbles.
– Tighten the bleeder screw.

– Close shut-off valve 4.
– Open the bleeder screw again until brake fluid stops emerging.
Info
Overfilling the brake fluid reservoir is prevented.
– Tighten the bleeder screw. Remove the bleeder bottle hose.

Attach the protection cap.
T00815-10 – Disconnect the bleeding device. Remove the bleeder cover.
– Correct the brake fluid to marking C.
– Mount screw cap 2 with the membrane.
Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.
G04771-10
– Check the foot brake lever for a firm pressure point.

Condition
screw 1 .
Guideline
ing tank cap lock,
rear brake
H01142-10
128
COMBINATION INSTRUMENT 16
16.1 Combination instrument

The combination instrument is attached in front of the handlebar.
The combination instrument is divided into two function areas.
1 indicator lamps ( p. 130)
Display2
S04176-10
16.2 Activation and test

Activation
The combination instrument is activated when the ignition is
switched on.
Info
The brightness of the displays is controlled by an ambient
light sensor in the combination instrument.
Test
The welcome text appears on the display and the indicator lamps
S04177-10
are briefly activated for a function check.
16.3 Day-Night mode

Day mode is shown in a bright color.
M01578-01
Night mode is shown in a dark color.
Info
The ambient light sensor in the combination instrument
detects the brightness of the environment. Depending on
the amount of light detected by the ambient light sensor,
the display is brightened or dimmed, or switched to the
other mode depending on the setting.
The display mode can be configured in the Display Theme
M01579-01 menu. Here, you can select automatic day-night mode or
permanent night mode.
129
16 COMBINATION INSTRUMENT
16.4 Warnings
Warnings appear on the top and/or bottom edge of the display;
these are marked yellow or red depending on their relevance.
Yellow warnings 1 indicate malfunctions or information which
require prompt intervention or an adjustment to the riding style.
Red warnings 2 indicate malfunctions or information which
require immediate intervention.
Info
Warnings can be hidden by pressing any button.
F00904-10
All the existing warnings are displayed in the Warning menu
until they are no longer active.
16.5 Indicator lamps
S04178-01
The indicator lamps offer additional information about the operating state of the motorcycle.
When the ignition is switched on, all indicator lamps light up briefly.
Info
The malfunction indicator lamp always lights up as long as the engine is not running. If the engine is run-
ning and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road
users in the process) and contact an authorized KTM workshop.
The oil pressure warning lamp always lights up as long as the engine is not running. If the engine is run-
ning and the oil pressure warning lamp lights up, stop immediately (taking care not to endanger yourself or
other road users in the process) and switch off the engine.
The ABS warning lamp lights up until a speed of approx. 6 km/h (approx. 4 mph) or more has been
reached.
130
Possible states
The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn
signal is switched on.
Malfunction indicator lamp lights up yellow – The OBD has detected a malfunction in the
vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.
The ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS
warning lamp flashes if the ABS mode Super Moto is enabled.
TC indicator lamp lights up yellow – MTC is not enabled or is currently intervening. The TC
indicator lamp also lights up if a malfunction is detected. Contact an authorized KTM work-
shop. The TC indicator lamp flashes if MTC makes an active intervention.
The idle indicator lamp lights up green – The transmission is in neutral.
The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately,
taking care not to endanger yourself or other road users in the process, and switch off the
engine.
Alarm system indicator lamp flashes red – Status message on the alarm system (optional).
The high beam indicator lamp lights up blue – The high beam is switched on.
The general warning lamp lights up yellow – A note/warning note on operating safety has been
detected. This is shown in addition.
16.6 Display
S04179-01
1 Speed ( p. 132)
Shift warning light ( p. 132)
1 The shift warning light is integrated in the tachometer display.
2 Gear display
131
3 Unit for the speed display

4 Speed ( p. 133)
5 Unit for the speedometer
6 ODO display ( p. 133)
7 ABS mode
8 Coolant temperature indicator ( p. 133)
9 Fuel level display ( p. 134)
bk Bluetooth® (optional)
bl Time ( p. 134)
SET
bm Only shown where the menu overview is closed.
bn Favourites display ( p. 134)
16.7 Speed
The speed 1 is measured in revolutions per minute.
M01581-10
16.8 Shift warning light

The shift warning light is integrated in the tachometer display.
In the Shift Light menu, the engine speed for the shift warning
light can be set. The shift warning light is always active during the
running-in phase (up to 1,000 km / 621 mi). The shift warning
light can only be deactivated, and the values for RPM1 and RPM2
can only be adjusted after this. In RPM1 the shift warning light
flashes and in RPM2 it flashes and the color changes.
Info
F01772-01 In sixth gear, the shift warning light is deactivated when
the engine is warm after the first service.
Coolant temperature ≤ 35 °C (≤ 95 °F)

ODO < 1,000 km (< 620 mi)
The shift warning 6,500 rpm
light always flashes
at
Coolant temperature > 35 °C (> 95 °F)

ODO > 1,000 km (> 620 mi)
RPM1 shift warning flashes
light
RPM2 shift warning flashes and changes color
light
132
16.9 Speed
Speed 1 is shown in kilometers per hour km/h or in miles per
hour mph.
M01581-11
16.10 ODO display

The total distance covered ODO is shown in area 1 of the display.
Info
This value is retained, even if the 12-V battery is discon-
nected from the vehicle or the fuse blows.
M01581-12
16.11 Coolant temperature indicator

The coolant temperature indicator consists of bars. The more bars
that light up, the hotter the coolant.
Note
Engine failure Overheating damages the engine.
– If the coolant temperature warning is displayed, stop imme-
diately and take care not to endanger yourself or other traffic
participants in the process.
– Allow the engine and cooling system to cool down.
402808-01
– Check and, if necessary, correct the coolant level on the cool-
ing system while it is in a cooled state.
Info
When all the bars light up, the warning ENGINE TEMP HIGH
also appears.
If the cooling system overheats, the maximum engine
speed is limited.
Possible states
• The engine is cold – Up to three bars light up.
• Engine warm – Four to five bars light up.
• Engine hot – Six to eight bars light up.
• Engine very hot – All eight bars light up red.
133
16.12 Fuel level display

The fuel tank contents are shown in area 1 of the display.
The fuel level indicator consists of bars. The more bars are lit, the
more fuel is in the fuel tank.
Info
If the fuel level is getting low, the last segment flashes red
and the following warning also appears LOW FUEL.
The fuel level is displayed with a slight delay to prevent the
indicator from constantly moving while riding.
402807-10 The fuel level display is not updated while the side stand is
folded out or the emergency off switch is switched off.
Once the side stand is folded up and the emergency OFF
switch is switched on, the fuel level display is next updated
after 2 minutes.
The fuel level display flashes if the combination instrument
does not receive a signal from the fuel level sensor.
16.13 Time
The time is shown in area 1 of the display.
The time is displayed in 24 hour format in all languages except for
EN-US. The time is displayed in 12 hour format if the language is
set to EN-US.
The time can be configured in the Clock/Date menu.
Info
The time must be reset if the 12-V battery was discon-
nected from the vehicle or the fuse was removed.
M01581-13
16.14 Favourites display

Up to eight items of information are shown in the Favourites dis-
play.
The Favourites display can be freely configured in the
Favourites menu.
Info
One to four items of information selected are displayed on
two lines. Five to eight items of information selected are
displayed on a single line.
V01182-01
134
16.15 Quick Selector 1 display

When the menu is closed, the Quick Selector 1 menu is opened by
pressing the UP button.
Press the BACK button to close Quick Selector 1.
Info
The Quick Selector 1 can be configured in the Quick Selec-
tor 1 menu. Any information can be selected.
E01065-01
16.16 Quick Selector 2 display

pressing the DOWN button.
Press the BACK button to close Quick Selector 2.
Info
The Quick Selector 2 can be configured in the Quick Selec-
tor 2 menu. Any information can be selected.
E01066-01
16.17 Menu
Info
Press the SET button 1 in the start screen to open the
menu.
Navigate through the menu using the UP button 2 or
the DOWN button 3 .
Press the BACK button 4 to close the current menu or the
menu overview.
S04132-10
16.17.1 KTM MY RIDE (optional)

Condition
• The motorcycle is stationary.
• Function KTM MY RIDE (optional) activated.
• Function Bluetooth® (optional) activated.
– Press the SET button when the menu is closed.
– Press the UP or DOWN button until KTM MY RIDE is marked.
Press the SET button to open the menu.
A suitable cellphone or headset can be paired with the combina-
V01160-01 tion instrument via Bluetooth® in the KTM MY RIDE menu.
Info
Not every cellphone and headset is suitable for pairing with
the combination instrument.
The standard Bluetooth® 2.1 must be supported.
135
16.17.2 Trips/Data
– Press the UP or DOWN button until Trips/Data is marked. Press
the SET button to open the menu.
General information can be accessed in Trips/Data.
S04180-01
16.17.3 Motorcycle
– Press the UP or DOWN button until Motorcycle is marked. Press
The vehicle riding mode can be configured in Motorcycle.
V01162-01
16.17.4 Settings
Condition
– Press the UP or DOWN button until Settings is marked. Press
The combination instrument display can be configured in Settings.
Settings can be made for units or various values. Several functions
can be enabled or disabled. Favorites and quick selections can be
V01163-01
configured.
16.17.5 Pairing (optional)

Condition
– Press the UP or DOWN button until Pairing is marked. Press
F01958-01 the SET button to open the menu.
A suitable cellphone or headset can be paired with the combina-
tion instrument via Bluetooth® in the Pairing menu.
136
Info
The Bluetooth® function can only be used in conjunction
with KTM MY RIDE (optional).
When the Bluetooth® function is switched on and the device
is connected, the Bluetooth® symbol appears in the display
of the combination instrument.
Not every cellphone and headset is suitable for pairing with
the combination instrument.
16.17.6 Phone (optional)

Condition
• Function Bluetooth (optional) activated.
• The Bluetooth® function should also be activated in the device
to be paired.
F01959-01 Press the SET button to open the menu.
– Press the UP or DOWN button until Phone is marked. Press
Info
A suitable cellphone can be paired with the combina-
tion instrument in the Phone menu.
Two cellphones can never be paired simultaneously
with the combination instrument.

– The combination instrument starts searching for a suitable
cellphone. If the search was successful, the name of the cell-
phone is displayed in the Pairing menu. Press the SET button
to start the pairing.
Info
The cellphone must be visible via Bluetooth® for the
cellphone to be found by the combination instrument.
– A message appears on the combination instrument indicat-

ing that this is now ready for pairing. The pairing is completed
successfully by confirming the Passkey on the cellphone and
on the combination instrument.
137
Info
Once the pairing is completed, the registered trademark
of the paired cellphone is displayed in the Phone menu.
Press the UP or DOWN button until the paired device is
marked. The paired device can be deleted by pressing
the SET button.
Not every cellphone is suitable for pairing with the
combination instrument.
– Move the previously paired device into the range of the combi-
nation instrument while the Bluetooth® function is active.
The device is automatically paired with the combination
instrument.
If the device is not automatically paired with the combina-
tion instrument after approx. 30 seconds:
– Restart combination instrument or Pairing repeat pro-
cedure.
16.17.7 Headset (optional)

Condition
• Function Bluetooth (optional) activated.
to be paired.
F01960-01 Press the SET button to open the menu.
– Press the UP or DOWN button until Headset is marked. Press
– The combination instrument starts searching for a suitable
headset. If the search was successful, the name of the head-
set is displayed in the Pairing menu. Press the SET button to
select the device. If a PIN code is required for the headset,
this must be entered now. The pairing of a headset with the
combination instrument is now completed.
Info
The headset must be in pairing mode for the headset
to be found by the combination instrument. Follow the
instructions in the Owner's Manual of the headset.
Once the pairing is completed, the name of the paired
headset is displayed in the Headset menu.
Press the UP or DOWN button until the paired device is
marked. The paired device can be deleted by pressing
the SET button.
Not every headset is suitable for pairing with the com-
bination instrument.
138
– Move the previously paired device into the range of the combi-
nation instrument while the Bluetooth® function is active.
The device is automatically paired with the combination
instrument.
If the device is not automatically paired with the combina-
tion instrument after approx. 30 seconds:
– Restart combination instrument or Pairing repeat pro-
cedure.
16.17.8 Audio (optional)

Condition
to be paired.
V01165-01
Warning
Danger of accidents Headphone volume which is too
high distracts attention from traffic activity.
– Always select headphone volume which is low
enough for you to still clearly hear acoustic signals.
– Press the UP or DOWN button until Audio is marked. Press

– Press and hold the UP button to increase the audio volume.
– Press and hold the DOWN button to reduce the audio volume.
– Press the UP button briefly to change to the next audio track.
– Press the DOWN button briefly to change to the previous audio
track.
– Press the SET button to play or pause the audio track.
Info
The audio function can be added to Quick Selector 1 or
Quick Selector 2 for easier operation.
139
16.17.9 Telephony (optional)

Condition
• Function KTM MY RIDE activated (optional).
• Function Bluetooth® activated.
to be paired.
• Headset linked with appropriate cellphone.
Warning
Danger of accidents Headphone volume which is too
high distracts attention from traffic activity.
– Always select headphone volume which is low
enough for you to still clearly hear acoustic signals.
– Press the SET button to accept an incoming call.

– Press the BACK button to reject an incoming call.
Info
The call duration and contact are displayed. Depend-
V01183-01 ing on the cellphone settings, the contact is shown by
name.
16.17.10 General Info

– Press the UP or DOWN button until General Info is marked.
Date shows the date.
ODO shows the total distance covered.
Battery indicates the battery voltage.
V01166-01
16.17.11 Trip 1
– Press the UP or DOWN button until Trip 1 is marked. Press
Trip shows the distance since the last reset, such as between two
refueling stops. Trip is running and counts up to 9999.
ØCons indicates the average fuel consumption based on Trip.
ØSpeed indicates the average speed based on Trip and Trip Time.
E01062-01
Trip Time shows the journey time on the basis of Trip and runs as
soon as a speed signal is received.
Fuel Range indicates the possible distance you can cover with the
fuel reserve.
140
Press and All the entries in the Trip 1 menu are reset.
hold the SET
button for at
least 3 sec-
onds.
16.17.12 Trip 2
– Press the UP or DOWN button until Trip 2 is marked. Press
Trip shows the distance since the last reset, such as between two
refueling stops. Trip is running and counts up to 9999.
ØCons indicates the average fuel consumption based on Trip.
ØSpeed indicates the average speed based on Trip and Trip Time.
E01063-01
Trip Time shows the journey time on the basis of Trip and runs as
soon as a speed signal is received.
Fuel Range indicates the possible distance you can cover with the
fuel reserve.
Press and All the entries in the Trip 2 menu are reset.
hold the SET
button for at
least 3 sec-
onds.
16.17.13 Warning
Condition
• Message or warning is present.
– Press the UP or DOWN button until Warning is marked. Press
– Use the UP or DOWN button to navigate through the warnings.
V01167-01 All the warnings that have occurred are displayed and stored in
the Warning menu.
16.17.14 ABS
Condition
– Press the UP or DOWN button until Motorcycle is marked. Press
– Press the UP or DOWN button until ABS is marked. Press
– Activate menu item using the UP or DOWN button.
S04181-01 – Press the SET button to select between ABS modes.
141
Info
If the ABS mode Road is enabled, ABS controls both
wheels.
If the ABS mode Offroad is enabled, ABS only con-
trols the front wheel. The rear wheel is not controlled
by ABS and may lock during braking maneuvers. The
ABS warning lamp flashes slowly to remind you that
ABS mode Offroad is enabled.
16.17.15 Favourites
Condition
– Press the UP or DOWN button until Favourites is marked. Press
– Press the UP or DOWN button to activate the menu item and
V01168-01 select it with the SET button.
Up to eight items of information can be selected in the
Favourites menu.
16.17.16 Quick Selector 1

Condition
– Press the UP or DOWN button until Quick Selector 1 is marked.
Information can be selected in the Quick Selector 1 menu.
pressing the UP button.
16.17.17 Quick Selector 2

Condition
– Press the UP or DOWN button until Quick Selector 2 is marked.
Information can be selected in the Quick Selector 2 menu.
pressing the DOWN button.
142
16.17.18 Bluetooth (optional)

Condition
– Press the UP or DOWN button until Bluetooth is marked. Press
V01171-01 – Press the SET button to switch the Bluetooth® function on or
off.
Info
The Bluetooth® function can only be used in conjunction
with KTM MY RIDE (optional).
When the Bluetooth® function is switched on and the device
is connected, the Bluetooth® symbol appears in the display
of the combination instrument.
16.17.19 Shift Light

Condition
• ODO > 1,000 km (621 mi).
– Press the UP or DOWN button until Shift Light is marked. Press
– Switch the shift warning light on or off or set the engine speed
for the gear shift recommendation by pressing the SET button.
Info
When the engine speed reaches RPM 1, the engine
speed display flashes red.
When the engine speed reaches RPM 2, the engine
speed display flashes and the color changes.
V01186-01
16.17.20 Setting the time and date

Condition
The motorcycle is stationary.
143

– Press the UP or DOWN button until Preferences appears. Press
– Press the UP or DOWN button until Clock/Date is marked. Press
V01172-01
Setting the clock

– Press the UP or DOWN button until the time is marked.
– Press the SET button.
The hour flashes and is underlined.
– Press the UP or DOWN button until the current hour is set.
The minutes flash and are underlined.
– Press the UP or DOWN button until the current minute is
V01173-01 set.
The time is stored.
Setting the date
– Press the UP or DOWN button until the date is marked.
The day flashes and is underlined.
– Press the UP or DOWN button until the current day is set.
The month flashes and is underlined.
– Press the UP or DOWN button until the current month is
V01174-01 set.
The year flashes and is underlined.
– Press the UP or DOWN button until the current year is set.
The date is stored.
16.17.21 Distance
Condition
– Press the UP or DOWN button until Units is marked. Press
– Press the UP or DOWN button until Distance is marked. Press
V01176-01 the SET button to open the menu.
– Press SET button to confirm the desired unit.
144
16.17.22 Temperature
Condition
– Press the UP or DOWN button until Temperature is marked.
E01064-01 Press the SET button to open the menu.
16.17.23 Fuel Cons

Condition
– Press the UP or DOWN button until Fuel Cons is marked. Press
V01177-01 the SET button to open the menu.
16.17.24 Language
Condition
– Press the UP or DOWN button until Language is marked. Press
The menu languages are US English, UK English, German, Italian,
French, and Spanish.
16.17.25 Service
Condition
– Press the UP or DOWN button until Service is marked. Press
The next service due is shown in the Service menu.
S04182-01
145
16.17.26 Extra Functions

Condition
• Motorcycle with optional supplementary function.
– Press the UP or DOWN button until Extra Functions is marked.
S04183-01 – Use the UP or DOWN button to navigate through the extra func-
tions.
The optional extra functions are listed in Extra Functions.
Info
The current KTM PowerParts and the available software for
your vehicle can be found on the KTM website.
16.18 Setting the service interval display

Condition
The motorcycle is stationary.
– Press the UP or DOWN button until Preferences is marked.
– Press and hold the UP and DOWN buttons simultaneously for 3
seconds until the menu Service opens.
– Press the UP or DOWN button until the riding distance display
is marked. Press the SET button to increase the kilometers in
intervals of 500.
– Press the UP or DOWN button until the date display is marked.
S04182-01 Press the SET button to advance the date in intervals of one
month.
– Press the BACK button to close the current menu and save the
settings.
146
LIGHTING SYSTEM, INSTRUMENTS 17
17.1 Checking the headlight setting

– Park the vehicle on a horizontal surface in front of a light-
colored wall and make a mark at the height of the center of
the low beam headlight.
– Make another mark at a distance B under the first marking.
Guideline
Distance B 5 cm (2 in)
– Position the vehicle vertical to the wall at distance A from

the wall and switch on the low beam.
400726-10
Guideline
Distance A 5 m (16 ft)
– The rider now mounts the motorcycle with luggage and passen-
ger if applicable.
– Check the headlight setting.
The light-dark boundary must be exactly on the lower mark-
ing when the motorcycle is ready to be operated with the
rider mounted along with any luggage and a passenger if
applicable.
» If the boundary between light and dark does not meet
specifications:
– Adjust the headlight range. ( p. 147)
17.2 Adjusting the headlight range

Preparatory work
– Check the headlight setting. ( p. 147)
Main work
– Turn adjusting screw 1 to adjust the headlight range.
Info
Turn clockwise to increase the headlight range; turn
counterclockwise to reduce the headlight range.
If you have a payload, you may have to correct the
headlight range.
A00701-10
Screw 1 also secures the headlight. Ensure the screw
is always screwed in far enough.
– Set the headlight to marking B.

Guideline
The light-dark boundary must lie exactly on lower mark-
ingB when the motorcycle is ready to operate with the
rider mounted along with any luggage and a passenger if
applicable.
400726-11
147
18 ENGINE
18.1 Removing the engine

Preparatory work
– Drain the coolant. ( p. 237)
– Remove the main silencer. ( p. 63)
– Remove the exhaust system. ( p. 61)
Main work
– Push back protection cap.
– Remove nut 1 with the washers.
– Hang the cable to the side.
– Remove screw 2.
– Hang the cable to the side.
G04741-10
– Bend up lock washer 4.

– Detach the inner clutch cable and expose it.
G04742-10
148
ENGINE 18
– Disconnect spark plug connector 5.

– Push back hose clamps 6.
– Pull off the vent hoses.
– Disconnect plug-in connector 7.
G04743-10
– Remove screws8.
– Remove screw 9.
– Take off the engine sprocket cover.
G04744-10
– Remove screws bk and take off the lock washer.
G04745-10
– Remove nut bl with the washer.

– Take off chain adjuster bm.
– Push the rear wheel into the foremost position.
G04746-10
149
18 ENGINE
– Pull the engine sprocket off of the countershaft and remove it.
G04747-10
– Remove screw bn.

– Pull off the shift linkage and hang it to one side.
G04748-10
– Push back protection cap.

– Remove nut bo with the washer.
G04749-10

– Expose heat protector.
G04750-10
G04751-10
150
ENGINE 18
– Disconnect plug-in connectors bp and bq.

– Expose the cable.
G04752-10
– Loosen hose clip br.

– Push the throttle valve body upward out of the intake flange.
G04753-10
– Remove nuts bs with the washers.

– Remove screws bt along with the washers.
– Remove fitting ck.
– Remove both engine fixing arms.
G04754-10
– Push back hose clamp cl.

– Pull off the radiator hose.
G04755-10
– Remove screws cm.

– Pull off radiator pipe with O-ring and hang to the side.
G04756-10
151
18 ENGINE
– Position floor jack under the engine and secure using the spe-
cial tool.
Floor jack attachment (75029055000) ( p. 326)
G04757-10
– Remove fitting cn.

– Remove fitting co.
– Lower the engine.
Info
The help of an assistant is useful in this step.
Make sure that the motorcycle is sufficiently secured
against falling over.
G04758-10
18.2 Installing the engine

Preparatory work
– Lift the engine onto the special tool and secure it.
Main work
– Position the engine in the frame.
Info
The help of an assistant is useful in this step.
– Mount fitting 1, but do not tighten yet.

Guideline
G04758-11
Fitting, engine M10 49 Nm (36.1 lbf ft)
mounting bracket
– Mount fitting 2, but do not tighten yet.
Guideline
mounting bracket
– Remove the floor jack with the special tool.

G04757-10
152
ENGINE 18
– Mount the radiator pipe with the O-ring.

Guideline
chassis
G04756-11
– Mount the radiator hose.

– Position hose clamp 4.
G04755-11
– Position both engine fixing arms.

– Mount and tighten screws 5 with the washers.
Guideline
Guideline
G04754-11 mounting bracket
– Mount and tighten nuts 7 with the washer.
Guideline
Nut, radiator M6 5 Nm (3.7 lbf ft)
– Tighten fittings 1 and 2.
Guideline
mounting bracket
– Position the throttle valve body in the intake flange.

– Tighten hose clip 8.
G04753-11
153
18 ENGINE
– Join plug-in connectors 9 and bk.
G04752-11
ties.
G04751-10
– Position the heat protector and secure it with cable ties.
G04750-10
– Mount and tighten nut bl with the washer.

Guideline
Nut, oil pressure sen- M6 3 Nm (2.2 lbf ft)
sor
– Position the protection cap.
G04749-11
– Position the shift linkage.

– Mount and tighten screw bm.
Guideline
lever linkage Loctite®243™
G04748-11
154
ENGINE 18
– Position the engine sprocket in the chain and mount on the

countershaft.
G04747-10
– Pull the rear wheel back.

– Mount chain adjusterbn.
– Mount and tighten nut bo with the washer.
Guideline
same position relative to the reference markings.
G04746-11 Nut, rear wheel spin- M14x1.5 100 Nm

dle (73.8 lbf ft)
– Mount the lock washer and turn it slightly.

The lock washer engages in the gear teeth of the counter-
shaft.
– Mount and tighten screws bp.
Guideline
Screw, lock M6 12 Nm (8.9 lbf ft)
washer, engine Loctite®243™
sprocket
G04745-11
– Position the engine sprocket cover.

– Mount and tighten screw bq.
Guideline
chassis
– Mount and tighten screws br.
Guideline
G04744-11 Remaining screws, M6 9 Nm (6.6 lbf ft)
chassis
155
18 ENGINE
– Mount the vent hoses.

– Position the hose clamps bs.
– Join plug-in connector bt.
– Plug in spark plug connector ck.
G04743-11
– Attach the inner clutch cable.

– Secure the inner clutch cable with lock washer cl.
G04742-11
– Plug in connector cm.

– Position the ground wire.
– Mount and tighten screw cn.
Guideline
Screw, starter motor M6 12 Nm (8.9 lbf ft)
– Position the positive cable on the starter motor.
– Mount and tighten nut co with the washers.
G04741-11 Guideline
chassis
– Position the protection cap.
– Remove filler plug cp with the O-ring, and fill up with engine
oil.
Engine oil 1.7 l (1.8 qt.) Engine oil
(SAE 15W/50)
( p. 316)
– Mount and tighten the filler plug together with the O-ring.
G04759-10
156
ENGINE 18
Finishing work
( p. 12)
– Fill/bleed the cooling system. ( p. 237)
– Install the exhaust system. ( p. 62)
– Install the main silencer. ( p. 64)
– Read out the fault memory using the KTM diagnostics tool.
– Perform the initialization run. ( p. 262)
– Go for a short test ride.
– Check the engine for leak tightness.
– Check the engine oil level. ( p. 253)
– Check the coolant level. ( p. 240)
18.3 Engine disassembly
18.3.1 Preparations
– Mount special tool 1 and 2 on the engine work stand.
Holder and fitting for work stand (90129002000)
( p. 328)
Engine work stand (61229001000) ( p. 325)
– Mount the engine on the special tool.
Info
Work with an assistant or a motorized hoist.
R05415-10
18.3.2 Draining the engine oil

– Remove oil drain plug 1 with the O-ring.
311928-10
157
18 ENGINE
– Remove oil screen 2 with the O-ring.

– Completely drain the engine oil.
D01556-10
– Remove screw plug 3 with the O-ring and oil screen.
311930-10
18.3.3 Removing the chain securing guide

– Take off the chain securing guide.
R05416-10
18.3.4 Removing the valve cover

– Remove screws 1 with gaskets.
– Take off the valve cover with the valve cover seal.
R04043-10
– Take off gasket 2.
311933-10
158
ENGINE 18
– Remove the spark plug shaft insert 3.
311934-10
18.3.5 Removing the spark plug

– Remove the spark plug using special tool 1.
Spark plug wrench with link (77229172000) ( p. 327)
311936-10
18.3.6 Removing the shift shaft sensor

– Take off the shift shaft sensor with cover 2.
G04818-10
18.3.7 Removing the clutch cover

G04802-10
159
18 ENGINE
– Take off the clutch cover.
Info
Pull the clutch lever forward slightly.
G04803-10
– Remove dowels 2.
– Take off clutch cover gasket 3.
311938-10
18.3.8 Positioning the engine at ignition top dead center

– Remove screw plug 1 with the O-ring.
R05417-10
– Remove screw plug 2.
R05418-10
160
ENGINE 18
– Turn the crankshaft counterclockwise until markings A are

flush with the edge of the cylinder head.
Markings B and C align.
311941-10
– Remove screw 3.
311942-10

Locking screw (61229015000) ( p. 325)
311943-10
18.3.9 Removing the timing chain tensioner

– Remove screw 1 with the O-ring.
311946-10
161
18 ENGINE
– Turn the timing chain tensioner screw clockwise.

The timing chain tensioner is locked.
– Remove screw 2.
– Remove the timing chain tensioner with the gasket.
311947-10
18.3.10 Removing the camshaft

– Loosen and remove screws 1 from the outside to the inside.
– Take off the camshaft bearing support.
– Remove dowels.
311949-10
– Remove the intake camshaft 2.
311950-10
– Remove the exhaust camshaft 3.
311951-10
18.3.11 Removing the cylinder head

311953-10
162
ENGINE 18
– Loosen screws 2 in a crisscross pattern and remove them

with the washers.
– Take off the cylinder head.
311954-10
– Take off cylinder head gasket 3.

311955-10
– Remove guide rail 5.
311956-10
18.3.12 Removing the piston

– Push the cylinder upward.
Info
Only push the cylinder as far up as necessary to take
the piston pin out.
– Remove piston ring lock 1.

– Remove the piston pin.
– Take off the cylinder and piston.
311958-10
– Push the piston upward out of the cylinder.
Info
If no further work is to be performed on the cylinder
and piston, the piston can remain in the cylinder.
163
18 ENGINE
– Take off cylinder base gasket 2.

311959-10
18.3.13 Removing the starter motor

– Take off the starter motor.
311963-10
18.3.14 Removing the timing chain

– Slip out timing chain 1.
Info
If the timing chain is to be reused, mark the direction
of travel.
311977-10
– Remove screw 2.
– Take off the tensioning rail by lifting it upwards.
311978-10
164
ENGINE 18
18.3.15 Removing the water pump wheel

– Remove the water pump cover with the gasket.
311979-10
– Remove locating pins 2.
311980-10
– Remove nut 3 with washer.

– Take off the water pump impeller 4.
311981-10
18.3.16 Removing the alternator cover

– Take off the alternator cover.
311982-10
– Take off alternator cover gasket 3.
311983-10
165
18 ENGINE
18.3.17 rotor, removing

311984-10
– Position the special tool 2 in the crankshaft.

Pressing tool (90129020000) ( p. 328)
– Mount special tool 3 on the rotor.
Info
Left-handed thread!
– Hold it tight using the special tool and pull off the rotor by
311985-10 turning the screw in.
Puller (90229009000) ( p. 330)
– Remove the woodruff key.
18.3.18 Removing the starter drive

– 1.
Take off torque limiter
– Remove intermediate gear 2.
311986-10
– Remove screw 3.
– Take off the retaining bracket.
311987-10
166
ENGINE 18
– Remove freewheel gear 4.
311988-10
18.3.19 Removing the drive gear wheel of the balancer shaft

311989-10
– Remove balancer shaft gear wheel 2 with a wedge.
311990-10
– Remove nut 3 with washers.

– Take off the drive gear wheel of the balancer shaft.
– Remove the woodruff key.
311991-10
18.3.20 Removing the gear position sensor

– Take off the retaining bracket.
– Pull off the crankshaft speed sensor.
311995-10
167
18 ENGINE
– Take off the gear position sensor and the crankshaft speed
sensor with the cable.
311996-10
18.3.21 Removing the suction pump

– Take off the oil pump housing of the suction pump.
311997-10
311998-10
– Remove external rotor 3 and internal rotor 4.
311999-10
– Take off pin 5.
312000-10
168
ENGINE 18
18.3.22 Removing the clutch basket

– Remove pressure plate 2.
312442-10
– Remove springs 3.
– Take off clutch pressure cap 4.
312443-10
– Remove pull rod 5.

– Remove clutch disks 6.
312444-10
– Take off support ring and pretension ring 7.
312445-10
– Hold the clutch basket using the special tool.

Holding wrench (51129003000) ( p. 322)
– Remove nut 8 with washers.
Info
LH thread!
312446-10
169
18 ENGINE
– Take off inner clutch hub 9 and washer bk.

Info
The washer usually sticks to the inner clutch hub.
– Take off clutch basket bl.
312447-10
– Remove collar bushing bm.
312448-10
18.3.23 Removing the primary gear wheel

– Remove nut 1 with the washer.
312436-10
312437-10
– Remove the timing chain sprocket 3.
312438-10
170
ENGINE 18
– Remove primary gear wheel 4.
312439-10
– Remove woodruff key 5.
312440-10
18.3.24 Removing the force pump

– Remove lock ring1.
– Take off washer 2.
– Remove oil pump gear wheel 3.
312451-10
– Remove pin 4.
– Take off the washer.
312452-10
– Take off the pressure pump housing.
312453-10
171
18 ENGINE
312454-10
– Remove external rotor 7.

– Remove internal rotor 8.
312455-10
– Remove pin 9.
– Remove the oil pump shaft bk.
312456-10
18.3.25 Removing the shift shaft

– Push sliding plate1 away from shift drum locating unit 2.
Remove shift shaft3 with the washer.
312025-10
18.3.26 Removing the shift drum locating

– Remove screw 1.
– Press locking lever 2 away from shift drum locating 3 and
take off the shift drum locating.
– Release the locking lever.
312026-10
172
ENGINE 18
18.3.27 Removing the locking lever

– Remove screw 1.
– Take off locking lever 2 together with the washers and
spring.
312027-10
18.3.28 Removing the oil filter

– Remove oil filter cover 2 with the O-ring.
312457-10
– Pull oil filter 3 out of the oil filter housing.
312458-10
18.3.29 Removing the left engine case

– Remove special tool 1.
Locking screw (61229015000) ( p. 325)
312459-10
173
18 ENGINE
– Remove screw 2.
312460-10
312038-10
– Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm.

Pressing tool (90129020000) ( p. 328)
312039-10
– Mount special tool 5 with suitable screws.

Puller (90129048100) ( p. 329)
Info
Use the drill hole with marking 902.
– Pull off the section of the engine case by screwing in the

screw.
312040-10
174
ENGINE 18
Info
Do not tension the section of the engine case.
The washer of the main shaft usually sticks to the bear-
ing.
– Take off the left section of the engine case.

– Remove oil spray tube 7.
312041-10
18.3.30 Removing the shift rails

– Remove shift rail 1 together with upper spring and the lower
spring.
– Remove shift rail 2.
312042-10
18.3.31 Removing the shift drum

– Tilt shift forks 1 to the side.
– Remove shift drum 2.
312043-10
18.3.32 Removing the shift forks

– Remove shift forks 1.
312044-10
175
18 ENGINE
18.3.33 Removing the transmission shafts

– Pull both transmission shafts 1 out of the bearing seats
together.
312046-10
18.3.34 Removing the balancer shaft

– Remove screw 1.
– Take off the lock washer.
– Remove balancer shaft 2.
312047-10
18.3.35 Removing the crankshaft

– Remove crankshaft 1.
312048-10
18.4 Working on individual parts
18.4.1 Working on the left section of the engine case

– Remove spacer 1 of the countershaft.
312049-10
176
ENGINE 18
– Remove all dowels.

– Remove radial shaft seal ring 3 from the shift shaft and 4
from the countershaft.
– Remove oil nozzle 5.
– Remove any remnants of the sealing compound and clean the
section of the engine case thoroughly.
– Warm the section of the engine case in an oven.
Guideline
180 °C (356 °F)
– Knock the section of the engine case against a level wooden
board. This will cause the bearings to drop out of the bearing
seats.
Info
Any bearings that remain in the section of the engine
case must be removed using a suitable tool.
312050-10
– Insert the new cold bearings in the bearing seats of the heated
section of the engine case; if necessary, use a suitable press-
ing tool to push them all the way in and make them flush.
The closed side of the transmission output bearing points
towards the engine sprocket.
Info
When pressing in, ensure that the section of the engine
case lies flat in order to prevent damage.
Only press the bearings in using the outer bearing race;
otherwise, the bearings will be damaged when they are
pressed in.
– After the section of the engine case has cooled, check that the
bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.
– Mount the dowels.

– Press in radial shaft seal ring 3 of the shift shaft so it is
flush with the open side facing inward.
– Press in radial shaft seal ring 4 of the countershaft so it is
flush with the open side facing in.
– Mount and tighten oil nozzle 5.
Guideline
Oil nozzle M5 6 Nm (4.4 lbf ft)
Loctite®243™
– Blow out the oil channel with compressed air and check that it
is clear.
177
18 ENGINE
18.4.2 Working on the right section of the engine case

– Remove all dowels.
– Remove screws 1. Remove the bearing retainers.
– Remove any remnants of the sealing compound and clean the
section of the engine case thoroughly.
– Warm the section of the engine case in an oven.
Guideline
150 °C (302 °F)
– Knock the section of the engine case against a level wooden
board. This will cause the bearings to drop out of the bearing
seats.
Info
Any bearings that remain in the section of the engine
case must be removed using a suitable tool.
– Insert the new cold bearings in the bearing seats of the heated
section of the engine case; if necessary, use a suitable press-
ing tool to push them all the way in and make them flush.
312461-10
Info
When pressing in, ensure that the section of the engine
case lies flat in order to prevent damage.
Only press the bearings in using the outer bearing race;
otherwise, the bearings will be damaged when they are
pressed in.
– After the section of the engine case has cooled, check that the
bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.

– Position all bearing retainers.
Guideline
Screw, bearing M6 12 Nm (8.9 lbf ft)
retainer Loctite®243™
is clear.
178
ENGINE 18
18.4.3 Changing the radial shaft seal ring of the water pump
312462-10

– Grease new radial shaft seal ring 2 and push all the way in.
Pressing tool (93829043000) ( p. 330)
The radial shaft seal ring has 2 sealing lips.
312463-10
– Grease new radial shaft seal ring 1 and press all the way in
with the open side facing outwards.
Pressing tool (93829043000) ( p. 330)
312462-10
18.4.4 Checking the radial clearance of lower conrod bearing

Condition
Conrod bearing is removed.
– Clamp the connecting rod into the vise.
Guideline
Use soft jaws.
– Position the crankshaft.
– Position the bearing shells. Insert Plastigauge clearance
gage 1 90° offset to the bearing joint.
Plastigauge clearance gauge (60029012000) ( p. 323)
G03262-10
179
18 ENGINE
– Position the conrod bearing cover. Mount and tighten

screws 2 .
Guideline
Screw, conrod bear- M8x1 34 Nm (25.1 lbf ft)
ing
Multi-tooth wrench socket (63529075000) ( p. 325)
D06103-11
Info
Do not twist connecting rod.
– Remove the conrod bearing cover again. Compare

Plastigauge clearance gage with the data on the packaging.
Guideline
Connecting rod - radial play of lower conrod bearing
New condition 0.035 … 0.058 mm
(0.00138 … 0.00228 in)
Wear limit 0.080 mm (0.00315 in)
G03263-10
Info
The width of the Plastigauge clearance gauge indicates
the bearing play.
– Clean the parts.
18.4.5 Changing the conrod bearing

– Clamp the connecting rod into the vise.
Guideline
Use soft jaws.
– Take off the conrod bearing cover and crankshaft.
D06103-10
– Remove the bearing shells.
G03264-10
180
ENGINE 18
New crankshaft
– Select new bearing shells according to the crankshaft clas-
sification and connecting rod classification.
Guideline
Crankshaft – diameter, crank pin
Crankshaft classifica- 31.970 … 31.977 mm
tion A (1.25866 … 1.25893 in)
tion B (1.25897 … 1.25925 in)
Color coding for conrod bearing shell
Green Crankshaft classification B
and connecting rod classi-
fication 1
None Crankshaft classification B
fication 2
None Crankshaft classification A
D06105-10
fication 1
Blue Crankshaft classification A
fication 2
Info
The crankshaft classification is indicated by mark-
ing 2.
The connecting rod classification is indicated by
marking 3.
– Check the radial clearance of lower conrod bearing.

( p. 179)
Used crankshaft
– Measure the crank pin diameter and select the new bearing
shells according to the crankshaft classification and the
connecting rod classification.
D06106-10
181
18 ENGINE
Guideline
tion A (1.25866 … 1.25893 in)
tion B (1.25897 … 1.25925 in)
Color coding for conrod bearing shell
Green Crankshaft classification B
fication 1
None Crankshaft classification B
fication 2
None Crankshaft classification A
fication 1
Blue Crankshaft classification A
fication 2
Info
The crankshaft classification is indicated by mark-
ing 2 .
The connecting rod classification is indicated by
marking 3
.
– Check the radial clearance of lower conrod bearing.

( p. 179)
– Position and oil the bearing shells.
– Position the connecting rod and conrod bearing cover accord-
ing to markings 4
.
Guideline
Screw, conrod bear- M8x1 34 Nm (25.1 lbf ft)
ing
Info
Always replace the conrod bearing screws.
D06104-10
182
ENGINE 18
18.4.6 Changing the balancer shaft bearing

– Mount special tools 1.
Pressing tool (90129056000) ( p. 329)
312065-10
– Position the balancer shaft in the press using a suitable tool.

– Press out the bearing.
308071-10
– Press on the balancer shaft bearing with a suitable tool.

Pressing tool (90129056000) ( p. 329)
308072-10
18.4.7 Working on the cylinder head

– Fold cam lever1 up.
– Take the shims 2 out of the valve spring retainers and lay
them to one side according to their normal built-in position.
308104-01
– Tension the valve spring with a special tool.

Valve spring mounter (59029019000) ( p. 322)
Insert for valve spring lever (77029041200) ( p. 327)
308105-01
183
18 ENGINE
– Remove valve collets 3 and release the valve spring.

– Remove valve spring retainer 4.
– Remove valve spring, valve stem seal 5, and valve spring
seat 6.
Info
Place the valves in a box corresponding to their installa-
tion position and label them.
308103-01
– Check the cylinder head. ( p. 184)
– Mount valve spring seat 6 and the new valve stem seal 5.
– Mount the valve spring.
– Mount valve spring retainer 4.
– Tension the valve spring with a special tool.
Valve spring mounter (59029019000) ( p. 322)
Insert for valve spring lever (77029041200) ( p. 327)
– Mount valve collets. Release the tension on the valve spring.
Info
When mounting the valve collets, check they are seated
properly; preferably use a little grease to secure the
308105-01
valve collets on the valve.
– Place the shims in the valve spring retainers corresponding to

their installation position.
18.4.8 Checking the cylinder head

– Check valve guides 1 with the special tool.
Limit plug gauge (77029026000) ( p. 327)
» If the special tool is easy to insert into the valve guide:
– Change the valve guides and valves.
– Check the sealing area of the spark plug thread and the valve
seats for damage and tearing.
308100-01 – Change the cylinder head.
– Check the sealing area of the cylinder for distortion using a

straight edge and the special tool.
Feeler gauge (59029041100) ( p. 323)
Cylinder/cylinder head - dis- ≤ 0.10 mm (≤ 0.0039 in)

tortion of sealing area
» If the measured value does not equal the specified value:
– Change the cylinder head.
308101-01
184
ENGINE 18
– Check sealing seat A of the valves.

Valve - sealing seat width
Intake 0.90 … 1.10 mm (0.0354
… 0.0433 in)

Exhaust 0.90 … 1.10 mm (0.0354
… 0.0433 in)
302808-10
» If the measured value does not equal the specified value:
– Machine the valve seat.
– Blow compressed air through all oil holes and check that they
are clear.
18.4.9 Checking the pivot points of the camshafts

– Check the pivot points of the camshafts.
» If there is damage or wear:
– Change the cylinder head with the camshaft bearing
support.
308091-01
– Position the camshafts.

The valves are not actuated.
– Insert the Plastigauge clearance gage in area A.
Plastigauge clearance gauge (60029012000) ( p. 323)
312066-10
– Position camshaft bearing support 1.

– Mount the screws and tighten in a crisscross pattern from the
inside to the outside.
Guideline
Screw, camshaft M6 10 Nm (7.4 lbf ft)
bearing support
Info
312067-10 Make sure the cylindrical pins are seated correctly.
Do not twist the camshaft.
185
18 ENGINE
– Remove camshaft bearing support 1

again. Compare Plasti-
gauge clearance gauge with the data on the packaging.
Guideline
Camshaft bearing - slide bearing
Radial clearance 0.025 … 0.053 mm
(0.00098 … 0.00209 in)
312068-10
Info
The width of the Plastigauge clearance gauge indicates
the bearing play.
– Take off the camshafts and clean the parts.
18.4.10 Checking/measuring the cylinder

– Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
– Change the cylinder and piston.
– Measure the bore diameter at several locations on
the ‑ and
X ‑axes using a micrometer to identify oval wear.
Y
Guideline
Cylinder - bore diameter 88.982 … 88.998 mm
(3.50322 … 3.50385 in)
308078-10
– Using a straightedge and the special tool, check the sealing

surface of the cylinder head for distortion.
Feeler gauge (59029041100) ( p. 323)
Cylinder/cylinder head - dis- ≤ 0.10 mm (≤ 0.0039 in)

tortion of sealing area
» If the measured value does not meet specifications:
– Change the cylinder and piston.
308079-10
18.4.11 Checking the piston ring end gap

– Remove the piston ring from the piston.
– Place the piston ring in the cylinder and align it with the pis-
ton.
Guideline
Under the upper edge of the 20 mm (0.79 in)
cylinder
– Using special tool 1, measure the end gap.
Guideline
308080-10
Piston ring end gap
Compression ring ≤ 0.40 mm (≤ 0.0157 in)
Oil scraper ring ≤ 0.80 mm (≤ 0.0315 in)
Feeler gauge (59029041100) ( p. 323)

186
ENGINE 18
» If the end gap is more than the specified value:

– Check/measure the cylinder. ( p. 186)
» If the cylinder wear is within the tolerance range:
– Change the piston ring.
– Mount the piston ring with the marking facing toward the pis-
ton head.
18.4.12 Checking/measuring the piston

– Check the piston bearing surface for damage.
» If the piston bearing surface is damaged:
– Replace the piston and, if necessary, the cylinder.
– Check that the piston rings move easily in the piston ring
grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.
308081-01 Tip
An old piston ring can be used to clean the pis-
ton ring groove.
– Check the piston rings for damage.

» If the piston ring is damaged:
– Change the piston ring.
Info
Mount the piston ring with the marking facing
upward.
– Check the piston pins for discoloration or signs of wear.

» If the piston pin shows severe discoloration/signs of wear:
– Change the piston pin.
– Place the piston pin in the connecting rod and check the seat-
ing for play.
» If the piston pin seating has excessive play:
– Change the connecting rod and piston pin.
– Measure the piston at the piston skirt, at right angles to the
piston pin, at a distance . B
Guideline
Distance B 30 mm (1.18 in)
Piston - diameter 88.931 … 88.949 mm
(3.50121 … 3.50192 in)
308099-01
187
18 ENGINE
18.4.13 Checking the piston/cylinder mounting clearance

– Check/measure the cylinder. ( p. 186)
– Check/measure the piston. ( p. 187)
– The piston/cylinder mounting clearance is the result of the
cylinder bore diameter minus the piston diameter.
Guideline
Piston/cylinder - mounting clearance
New condition 0.033 … 0.067 mm
(0.0013 … 0.00264 in)
308081-01
18.4.14 Checking the oil pump
Info
The following operations apply to both oil pumps.
– With special tool 1

, check the play between the internal rotor
and external rotor and between the external rotor and the oil
pump housing.
Feeler gauge (59029041100) ( p. 323)
Oil pump
Play between external 0.10 … 0.20 mm (0.0039
rotor and internal rotor … 0.0079 in)
308082-01
Oil pump
Play between external 0.09 … 0.20 mm (0.0035
rotor and oil pump hous- … 0.0079 in)
ing
» If the play exceeds the specification:
– Change the oil pump and, if necessary, the oil pump
housing.
– Check axial play A of the oil pump.
Oil pump
Axial play 0.10 … 0.25 mm (0.0039
… 0.0098 in)
» If the play exceeds the specification:
– Change the oil pump and, if necessary, the oil pump
housing.
308083-01
188
ENGINE 18
18.4.15 Checking the oil pressure control valve

– Remove spring 2.
– Measure the length of spring 2.
Oil pressure regulator valve - 30.00 mm (1.1811 in)
minimum length spring
» If the measured length is less than the specified value:
– Change the spring.
308084-01 – Check control piston 3 for damage and wear.
– Change the control piston.
– Check the control piston for smooth operation in the pressure
pump housing.
» If the control piston is stiff:
– Change the control piston or the pressure pump hous-
ing.
– Check the control piston bore in the pressure pump hous-
ing 4for damage and wear.
– Change the pressure pump housing.
– Thoroughly oil control piston 3 and spring 2 and mount
them.
– Mount washer 1.
18.4.16 Checking the clutch
T02059-11
– Check collar bushing 1 for damage and wear.

– Change the collar bushing.
– Check the length of clutch springs 2.
189
18 ENGINE
Clutch spring - length ≥ 50 mm (≥ 1.97 in)

» If the clutch spring length is shorter than specified:
– Change all clutch springs.
– Check inner clutch hub 3 for damage and wear.
– Change the inner clutch hub.
– Check clutch pressure cap 4 for damage and wear.
– Change the clutch pressure cap.
– Check the thrust surfaces of the clutch facing discs in clutch basket 5 for wear.
Contact surface, clutch facing discs in clutch basket ≤ 0.5 mm (≤ 0.02 in)
» If the thrust surface exhibits excessive wear:
– Change the clutch facing discs and the clutch basket.
– Check clutch facing discs 6 for discoloration and scoring.
» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs 6 and intermediate discs 7.
Thickness of overall package ≥ 32.00 mm (≥ 1.2598 in)
» If the clutch facing discs do not meet specifications:
– Check intermediate discs 7 for damage and wear.
» If the intermediate discs are not flat or have punctiform outbreaks:
– Change all intermediate discs.
18.4.17 Checking the shift mechanism
312071-10
– Check shift forks 1 on plate A for damage and wear (visual check).
– Change the shift fork and gear wheel pair.
190
ENGINE 18
– Check shift grooves B of shift drum 2 for wear.

» If the shift groove is worn:
– Change the shift drum.
– Check the seat of shift drum in bearing 3.
» If the shift drum is not seated correctly:
– Change the shift drum and/or the bearing.
– Check bearing 3 for stiffness and wear.
» If the bearing is stiff or worn:
– Change the bearings.
– Check shift rail 4 for run-out on a flat surface.
» If there is run-out:
– Change the shift rail.
– Check the shift rails for scoring, wear and smooth operation in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
– Change the shift rail.
– Check sliding plate 5 in contact areas C for wear.
» If the sliding plate is worn:
– Change the shift shaft.
– Check return surface D on the sliding plate for wear.
» If deep notches are present:
– Check guide pin E for looseness and wear.
» If the guide pin is loose and/or worn:
– Check locking lever 6 for damage and wear.
» When the locking lever is damaged or worn:
– Change the locking lever.
– Preassemble the shift shaft. ( p. 191)

– Check clearance F between the sliding plate and the shift
quadrant.
Shift shaft – play in sliding 0.15 … 0.45 mm (0.0059
plate/shift quadrant … 0.0177 in)
» If the measured value does not meet specifications:
304514-10
18.4.18 Preassembling the shift shaft

– Fix the short end of the shift shaft in a vise.
Guideline
Use soft jaws.
– Mount sliding plate 1with the guide pin facing down and
attach the guide pin to the shift quadrant.
– Mount preload spring 2.
304512-10
191
18 ENGINE
– Push on spring guide 3 , push return spring4 over the

spring guide with the offset end facing upward and lift the off-
set end over abutment bolt 5 .
– Mount washer 6.
18.4.19 Disassembling the main shaft
308096-01
– Secure the main shaft in the vise with the gear teeth facing downward.
Guideline
Use soft jaws.
– Remove stop disk 1 and second-gear fixed gear 2.
– Remove sixth-gear idler gear 3.
– Remove collar bushing 4.
– Remove third/fourth-gear sliding gear 6.
– Remove fifth-gear idler gear 9.
192
ENGINE 18
18.4.20 Disassembling the countershaft
308094-01
– Secure the countershaft in the bench vise with the toothed end facing downward.
Guideline
Use soft jaws.
– Remove stop disk 1 and first-gear idler gear 2.
– Remove sixth-gear sliding gear 4.
– Remove third-gear idler gear 7.
– Remove fourth-gear idler gear 9.
– Remove fifth-gear sliding gear bk.
– Remove the second-gear idler gear bl.
– Remove collar bushing bm.
18.4.21 Checking the transmission

Condition
The transmission has been disassembled.
193
18 ENGINE
308098-01
– Check collar bushings 1 for damage and wear.

– Change the collar bushings.
– Check the pivot points of main shaft 2 and countershaft 3 for damage and wear.
– Change the main shaft and/or countershaft.
– Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
– Change the main shaft and/or countershaft.
– Check the pivot points of idler gears 4 for damage and wear.
– Change the gear wheel pair.
– Check the shift dogs of idler gears 4 and sliding gears 5 for damage and wear.
– Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
– Check the tooth profiles of sliding gears 5 for damage and wear.
– Check sliding gears 5 for smooth operation in the profile of main shaft 2.
» If the sliding gear does not move easily:
– Change the sliding gear or the main shaft.
– Check sliding gears 5 for smooth operation in the profile of countershaft 3.
» If the sliding gear does not move easily:
– Change the sliding gear or the countershaft.
– Check stop disks 7 for damage and wear.
– Change the stop disk.
194
ENGINE 18
– Use new lock rings 8 with every repair.
18.4.22 Assembling the main shaft
Info
Use new lock rings with every repair.
Preparatory work
– Carefully lubricate all parts before assembling.
– Check the transmission. ( p. 193)
308097-01
Main work
– Secure the main shaft in the vise with the gear teeth facing downward.
Guideline
Use soft jaws.
– Mount fifth-gear idler gear 1.
– Mount collar bushing 2.
– Mount third/fourth-gear sliding gear 4 with the small gear wheel facing downward.
– 7.
Mount sixth-gear idler gear
– Mount second-gear fixed gear 8 and stop disk 9.
– Finally, check all the gear wheels for smooth operation.
18.4.23 Assembling the countershaft
Info
Use new lock rings with every repair.
195
18 ENGINE
Preparatory work
– Carefully lubricate all parts before assembling.
– Check the transmission. ( p. 193)
308095-01
Main work
– Secure the countershaft in the bench vise with the toothed end facing downward.
Guideline
Use soft jaws.
– Mount second-gear idler gear 2.
– Mount fifth-gear sliding gear 3 with the shift groove facing up.
– Mount fourth-gear idler gear 4.
– Mount washer 5.
– Mount third-gear idler gear 6.
– Mount sixth-gear sliding gear 9 with the shift groove facing downward.
– Mount collar bushing bk.
– Mount first-gear idler gear bl.
– Mount stop disk bm.
– Replace O-ring bn of the countershaft.
– Finally, check all the gear wheels for smooth operation.
196
ENGINE 18
18.4.24 Checking the timing assembly
308087-01
– Check timing chain 1 for damage and wear.

– Change the timing chain.
– Check that the chain links of the timing chain can move easily.
» If the timing chain is stiff:
– Let the timing chain hang down freely. Check the timing chain links for smooth operation.
» The chain links no longer align in a straight line:
– Check guide rail 2 for damage and wear.
– Change the guide rail.
– Check tensioning rail 3 for damage and wear.
– Change the tensioning rail.
– Check timing chain sprocket 4 for damage and wear.
– Change the timing chain sprocket.
– Check camshaft gear wheels 5 for damage and wear.
– Change the camshaft gear wheels.
197
18 ENGINE
18.4.25 Changing the stator

– Remove the cable retainer.
312069-10
– Remove the stator.
– Position the new stator.
Guideline
Screw, stator M5 8 Nm (5.9 lbf ft)
Loctite®243™
312070-10
– Position the cable guide in the alternator cover.

– Position the cable retainer.
Guideline
Screw, retaining M5 8 Nm (5.9 lbf ft)
bracket, stator Loctite®243™
cable
312069-10
198
ENGINE 18
18.4.26 Checking the electric starter drive
304530-10
– Check the gear teeth and bearing of starter intermediate gear 1 for damage and wear.
– Change the starter intermediate gear.
– Check the gear teeth and bearing of torque limiter 2 for damage and wear.
– Change torque limiter.
– Check gear mesh and bearing of freewheel gear 3 for damage and wear.
– Change freewheel gear or bearing.
– Check gear teeth 4 of the starter motor for damage and wear.
– Change starter motor.
– Change O-ring 5 of the starter motor.
– Connect negative cable of a 12-volt power supply to the housing of the starter motor. Connect positive cable
of the power supply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is closed:
– Change starter motor.
199
18 ENGINE
18.4.27 Checking the freewheel

– Insert freewheel gear 1
into the freewheel hub, turning the
freewheel gear clockwise; do not wedge.
– Check the locking action of the freewheel gear.
» The freewheel gear cannot be turned clockwise and does
not block counterclockwise:
– Change the freewheel.
304255-10
18.5 Engine assembly
18.5.1 Installing the crankshaft

– Oil the bearing.
– Slide crankshaft 1 into the bearing seat.
312048-10
18.5.2 Installing the balancer shaft

Protection cap (90129005000) ( p. 328)
312060-10
– Mount balancer shaft 2 with the bearing.

Info
If necessary, heat the engine case.
– Position the retaining bracket.

Guideline
312047-11 Screw, bearing M6 12 Nm (8.9 lbf ft)
retainer Loctite®243™

Protection cap (90129005000) ( p. 328)
200
ENGINE 18
18.5.3 Installing the transmission shafts

– Oil the bearing.
– Slide both transmission shafts 1 into the bearing seats
together.
312046-10
18.5.4 Installing the shift forks

– Oil all parts carefully before assembling.
– Shift fork1 has a smaller inside diameter; mount it in the
shift groove of the main shaft.
– Mount shift fork 2 in the lower shift groove of the counter-
shaft.
– Mount shift fork 3 in the upper shift groove of the counter-
shaft.
308062-10
18.5.5 Installing the shift drum

– Slide shift drum 1 into the bearing seat.
– Hang shift forks 2 into the shift drum.
312043-11
201
18 ENGINE
18.5.6 Installing the shift rails

– Oil all parts carefully before assembling.
– Mount shift rail 1 together with upper spring and the lower
spring.
– Mount shift rail 2.
312042-10
18.5.7 Installing the left engine case

– Clean the sealing areas.
– Mount dowels 1.
312045-10
– Mount the new O-rings on oil spray tube 2.

– Mount the oil spray tube.
The holding lug A engages in the recess B.
– Apply sealing compound to the left section of the engine case.
Loctite® 5910
309199-10
202
ENGINE 18
312038-11
– Mount the section of the engine case. If necessary, tap lightly with a rubber mallet while turning the transmis-
sion shafts.
Info
Do not use the screws to pull the two sections of the engine case together.
– Mount screws 3, but do not tighten yet.

Guideline
Screw, engine case M6x75 12 Nm (8.9 lbf ft)
Loctite®243™
– Mount screws 4 and tighten all screws in a crisscross pattern.
Guideline
Loctite®243™
– Mount the screw cap of the engine fixing arm.

Guideline
312460-11
203
18 ENGINE
– Position crankshaft to TDC and lock with special tool 6.

Locking screw (61229015000) ( p. 325)
312459-11
18.5.8 Installing the oil filter

– Tilt the motorcycle to one side and fill the oil filter housing to
about ⅓ full with engine oil.
– Fill oil filter 1 with engine oil and place it in the oil filter
housing.
312458-11
– Oil the O-ring of the oil filter cover.

– Mount oil filter cover 2.
Guideline
Screw, oil filter cover M6 10 Nm (7.4 lbf ft)
312457-11
18.5.9 Installing the locking lever

– Mount locking lever1 with the sleeve, washers and spring.
Guideline
Screw, locking M6 12 Nm (8.9 lbf ft)
lever Loctite®243™
312027-11
204
ENGINE 18
18.5.10 Installing the shift drum locating unit

– Mount spacer ring 1 on the shift drum locating unit.
– Push away locking lever 2 from the shift drum locating unit
and position the shift drum locating unit 3.
The holding lugs A engage in the drill hole B.
– Relieve tension from the locking lever.
Guideline
drum locating Loctite®243™
308049-10
18.5.11 Installing the shift shaft

– Slide shift shaft1 with the washer into the bearing seat.
– Push sliding plate 2 away from the shift drum locating 3.
Insert the shift shaft all the way.
– Let the sliding plate engage in the shift drum locating.
– Shift through the transmission.
312025-11
18.5.12 Installing the oil pump

– Mount dowels 1.
312024-10
205
18 ENGINE
– Position pin 2 and internal rotor 3 on the oil pump shaft.
308042-10
– Position the oil pump shaft with the internal rotor in the pres-
sure pump housing.
– Position external rotor 4 in the pressure pump housing.
Markings A are visible after mounting.
308043-10
– Check that the oil holes are clear and fill with a small amount
of oil.
– Position the oil pump.
Guideline
Screw, oil pump M6 12 Nm (8.9 lbf ft)
Loctite®243™
312453-10
– Position the washer.

– Position pin 6.
312452-11
– Position oil pump gear wheel 7.

– Position washer 8.
– Crank the oil pump gear wheel to ensure that it can move eas-
ily.
312451-11
206
ENGINE 18
18.5.13 Installing the primary gear wheel

– Mount woodruff key 1.
312440-11
– Mount primary gear wheel 2.
312439-11
– Mount timing chain sprocket 3.
312438-10
– Mount washer 4.
312437-11

Guideline
Nut, primary M16x1.5 120 Nm (88.5 lbf ft)
gear Loctite®243™
wheel/timing
chain sprocket
312436-11
207
18 ENGINE
18.5.14 Installing the clutch basket

312448-11
– Slide clutch basket2 onto the main shaft.

– Turn the oil pump gear wheel 3 until the gearing of the
clutch basket meshes.
312449-10
– Slide on washer 4 and inner clutch hub 5.
312447-11
– Mount nut 6 with the washers. Hold the inner clutch hub
with the special tool and tighten the nut.
Guideline
Nut, inner M16LHx1.5 120 Nm (88.5 lbf ft)
clutch hub Loctite®243™
Holding wrench (51129003000) ( p. 322)
312446-11
– Mount support ring 7 and pretension ring 8.

The pretension ring rests against the support ring on the
inside and the outside faces away from the support ring.
308053-10
208
ENGINE 18
– Thoroughly oil the clutch facing discs.

– Mount the clutch facing disk 9 with the largest inside diame-
ter.
– Alternately mount all of the other intermediate clutch discs
and clutch facing discs.
– Mount the clutch facing disk bk with the largest inside diam-
eter.
310936-10
– Mount the clutch facing disk bl

with the largest inside diam-
eter on the clutch pressure cap.
– Mount the intermediate clutch disk bm with the largest inside
diameter on the clutch pressure cap.
T02058-11
– Mount pull rod bn.
312444-11
– Position clutch pressure cap bo with clutch disks.

The uppermost clutch facing disc is offset by one tooth.
– Position the springs bp.
312443-11
– Position pressure plate bq.

The marking A points outward.
– Mount and tighten screws br.
Guideline
Screw, clutch spring M6 10 Nm (7.4 lbf ft)
312450-10
209
18 ENGINE
18.5.15 Installing the spacer

– Grease the radial shaft seal ring of the countershaft before
mounting.
– Mount spacer 1.
312012-10
18.5.16 Installing the suction pump

– Position pin 1.
312000-11
– Mount internal rotor 2 and external rotor 3.

Marking A of the external rotor is not visible after assem-
bly.
312001-10
– Mount dowels 4.
311998-11
210
ENGINE 18
– Oil the oil pump.

– Position the oil pump housing.
Guideline
Loctite®243™
311997-11
18.5.17 Installing the gear position sensor

– Position gear position sensor 1.
The flat surface A of the shift drum engages in the flat
surface B of the gear position sensor.
312002-10

Guideline
Screw, gear sen- M5 6 Nm (4.4 lbf ft)
sor Loctite®243™
311996-11
– Position the cable guide in the engine case.

– Position the crankshaft speed sensor.
Guideline
Screw, M5 6 Nm (4.4 lbf ft)
crankshaft Loctite®243™
speed sensor
311995-11
Info
Ensure that the cable is correctly routed.

Guideline
bracket Loctite®243™
211
18 ENGINE
18.5.18 Installing the drive gear wheel of the balancer shaft

– Mount the woodruff key.
– Mount drive gear wheel 1 of the balancer shaft.
311992-10
– Mount washer 2.
The outer side of the washer is in contact with the drive
gear wheel and the inside faces away from the drive gear
wheel.
311993-10

Guideline
Nut, drive gear M28 60 Nm (44.3 lbf ft)
wheel for bal- Loctite®243™
ancer shaft
311991-10
– Position balancer shaft gear wheel 4.

MarkingsA and B align.
– Mount wedge 5.
311994-10

Guideline
Screw, balancer M8 40 Nm (29.5 lbf ft)
shaftgear wheel Loctite®243™
311989-11
212
ENGINE 18
18.5.19 Installing the starter drive

– Position freewheel gear 1.
311988-11

Guideline
Screw, M6 12 Nm (8.9 lbf ft)
freewheel Loctite®243™
gear retaining
bracket
311987-11
– Mount starter intermediate gear 3.

– Mount torque limiter 4 .
311986-11
18.5.20 Installing the rotor

– Mount the woodruff key.
– Mount the rotor.
Info
Turn the freewheel gear counterclockwise to simplify
assembly.

Guideline
310461-10
Screw, rotor M10 105 Nm (77.4 lbf ft)
Loctite®243™
213
18 ENGINE
18.5.21 alternator cover, installing

– Mount dowels 1.
– Seal the cable guide.
Loctite® 5910
– Position alternator cover gasket 2.
311983-11
is clear.
– Position the alternator cover.
– Mount screws 3 and tighten in a crisscross pattern.
Guideline
Screw, alternator M6 12 Nm (8.9 lbf ft)
cover
311982-11
18.5.22 Installing the water pump cover

– Mount water pump impeller 1.
Guideline
Nut, water M6 10 Nm (7.4 lbf ft)
pump impeller Loctite®243™
311981-11
– Mount locating pins 3.
311980-11
– Mount the water pump cover with the seal ring.

– Mount screws 4 and tighten them in a crisscross pattern.
Guideline
Screw, water pump M6 12 Nm (8.9 lbf ft)
cover
311979-11
214
ENGINE 18
18.5.23 Installing the timing chain

– Slip in the tensioning rail from the top.
Guideline
Screw, timing M6 12 Nm (8.9 lbf ft)
chain tensioning Loctite®243™
rail
311978-11
– Position timing chain 2 in the engine case according to the

direction of travel.
311977-11
18.5.24 Installing the starter motor

– Grease the O-ring. Position the starter motor.
Guideline
311963-10
18.5.25 Installing the piston

– Shift the gap of the piston rings by 120°.
– Place the special tool onto the oiled piston. Clamp the piston
rings together using the special tool.
Piston ring compressor (60029015000) ( p. 323)
The piston ring are squeezed together fully.
307992-10
215
18 ENGINE
– Position the piston on the cylinder with the special tool.

– Carefully slide the piston into the cylinder from the top.
Info
The piston rings should not catch or they will be dam-
aged.
307993-10
– Ensure that piston marking A faces the exhaust side.
307994-10
– Thinly apply sealing compound to area B.

Loctite® 5910
– Position the cylinder base gasket.
311962-10
– Mount dowels 1 and position cylinder base gasket 2.
311959-11
– Thread the timing chain through the timing chain shaft. Mount
piston pin 3 .
311958-11
216
ENGINE 18
– Cover the engine case opening with a cloth.

– Position piston ring lock 4.
12-o'clock position.
– Insert the special tool and press it with force towards the pis-
ton.
Insertion for piston ring lock (77329030100) ( p. 327)
– Turn the special tool clockwise, thereby pushing the piston
ring lock into the groove.
– Ensure that the piston ring lock is in the correct position on
both sides.
– Remove the cloth.
– Keep the timing chain taut. Push the cylinder down carefully
and let the dowels engage.
D06920-10
18.5.26 Installing the cylinder head

– Position guide rail 1.
The guide rail engages in recess A.
311957-10
– Mount dowels 2.
– Put on cylinder head gasket 3.
– Put the cylinder head in place.
311955-11
– Mount screws 4 with the washer and tighten in a crisscross

pattern.
Guideline
Screw, cylinder M10 1st stage
head 30 Nm (22.1 lbf ft)
2nd stage
60 Nm (44.3 lbf ft)
Thread is oiled, head
flat is greased
311954-11
217
18 ENGINE

Guideline
Cylinder head screw M6 12 Nm (8.9 lbf ft)
311953-11
18.5.27 Installing the camshafts

– Oil the camshafts and pivot points.
– Ensure that the crankshaft is blocked in the TDC position.
– Pull up the timing chain and insert the exhaust camshaft 1.
Info
The exhaust camshaft is marked EX.
– Slip in the intake camshaft.
Info
The intake camshaft is marked IN.
– Place the timing chain over the camshaft gear wheel of the
intake camshaft.
Markings A of the camshafts align with the edge of the
cylinder head.
311952-10
– Clean all oil nozzles thoroughly and blow out with compressed
air.
– Position the camshaft bearing support.
– Mount screws 2 and tighten them from the inside to the out-
side.
Guideline
311949-11 bearing support
218
ENGINE 18
18.5.28 Installing the timing chain tensioner

304804-10
– Holding it with the correct orientation, mount the timing chain

tensioner 1 with the gasket.
Guideline
Screw, timing chain M6 12 Nm (8.9 lbf ft)
tensioner
311948-10
– Unlock the timing chain tensioner screw counterclockwise.

– Check the timing chain tension.
311947-11
– Mount and tighten screw 3 with the O-ring.

Guideline
Screw, unlocking of M6 6 Nm (4.4 lbf ft)
timing chain ten-
sioner
311946-11
18.5.29 Checking the valve clearance

Locking screw (61229015000) ( p. 325)
– Crank the engine several times.
– Position the engine at ignition top dead center. ( p. 160)
– Check the valve clearance between the camshaft and cam
lever on all valves.
311944-10
219
18 ENGINE
Guideline
Valve clearance, exhaust, 0.15 … 0.20 mm (0.0059
cold … 0.0079 in)
Valve clearance, intake, cold 0.10 … 0.15 mm (0.0039
… 0.0059 in)
Feeler gauge (59029041100) ( p. 323)

» If the valve clearance does not meet specifications:
– Adjust the valve clearance. ( p. 220)
– Mount and tighten screw plug 1.
Guideline
Screw plug, alterna- M24x1.5 10 Nm (7.4 lbf ft)
tor cover
R05418-11
– Mount screw plug 2 with the O-ring and tighten hand-tight.
R05417-11
– Remove special tool 3.

Locking screw (61229015000) ( p. 325)
311943-11

Guideline
Screw plug M8 12 Nm (8.9 lbf ft)
Loctite®243™
311942-11
18.5.30 Adjusting the valve clearance

Preparatory work
– Remove the timing chain tensioner. ( p. 161)
– Remove the camshaft. ( p. 162)
220
ENGINE 18
Main work
– Swing up cam lever 1.
– Correct the shims 2 as indicated by the results of the valve
clearance check.
311945-10
Finishing work
– Install the camshafts. ( p. 218)
– Install the timing chain tensioner. ( p. 219)
– Check the valve clearance. ( p. 219)
18.5.31 Installing the clutch cover

– Mount dowel 1 and clutch cover gasket 2.
311938-11
– Position the clutch cover.
Info
Pivot the clutch lever.
G04803-10

Guideline
Screw, clutch cover M6 12 Nm (8.9 lbf ft)
G04802-11
221
18 ENGINE
18.5.32 Installing the shift shaft sensor

– Position shift shaft sensor 1.
The flat surface of inner clutch hub A engages in
groove B of the shift shaft sensor.
G04822-10

Guideline
shaft sensor Loctite®243™
G04817-11
18.5.33 Installing the spark plug

– Mount and tighten the spark plug using special tool 1.
Guideline
Spark plug M12 15 Nm (11.1 lbf ft)
311936-10
222
ENGINE 18
18.5.34 Installing the valve cover

– Grease the O-rings and mount spark plug shaft insert 1.
311934-11
– Mount gasket 2.
311933-10
– Degrease the sealing areas and thinly coat with sealing com-
pound in areas A
and B .
Loctite® 5910
– Position the gasket in the valve cover.
312059-10
– Position the valve cover with the gasket.

– Mount and tighten screws 3 with the gaskets.
Guideline
Screw, valve cover M6 12 Nm (8.9 lbf ft)
R04043-11
223
18 ENGINE
18.5.35 Installing the chain securing guide

– Position the chain securing guide.
Guideline
Screw, chain M6 10 Nm (7.4 lbf ft)
securing guide Loctite®243™
R05416-10
18.5.36 Installing the oil screen

– Mount and tighten screw plug 1 with the O-ring and oil
screen.
Guideline
Oil screen screw M17x1.5 12 Nm (8.9 lbf ft)
plug, small
311930-11
– Mount oil screen 2 with the O-ring.
311929-11
– Mount and tighten oil drain plug 3 with the O-ring.

Guideline
Oil drain plug M24x1.5 15 Nm (11.1 lbf ft)
311928-11
224
ENGINE 18
18.5.37 Removing the engine from the engine work stand

– Remove the fitting from special tool 1 and 2.
Holder and fitting for work stand (90129002000)
( p. 328)
– Remove the engine from the engine work stand.
Info
Work with an assistant or a motorized hoist.
R05415-10
225
19 CLUTCH
19.1 Checking the clutch
Danger
Warning
Main work
– Lay the vehicle on the side.
Info
Remaining fuel may flow out of the fuel tank.
G04760-10
– Take off the shift shaft sensor.
G04795-10
G04772-10
226
CLUTCH 19
– Take off the clutch cover with dowels and gasket.
Info
Pull the clutch lever forward slightly.
G04773-10
– Remove pressure plate 4.
G04774-10
– Remove springs 5.
– Take off clutch pressure cap 6.
G04775-10
– Remove pull rod 7.

– Remove clutch disks 8.
G04776-10
– Take off support ring and pretension ring 9.
G04777-10
227
19 CLUTCH
– Hold the clutch basket using the special tool.

Holding wrench (51129003000) ( p. 322)
– Remove nut bk.
Info
LH thread!
G04778-10
– Remove washers bl.
G04779-10
– Take off inner clutch hub bm and washer bn.

Info
The washer usually sticks to the inner clutch hub.
– Take off clutch basket bo.
G04780-10
– Remove collar sleeve bp.
G04781-10
228
CLUTCH 19
T02059-10
– Check collar sleeve bp for damage and wear.

– Change the collar sleeve.
– Check the length of clutch springs 5.
» If the clutch spring length is shorter than specified:
– Change all clutch springs.
– Check inner clutch hub bm for damage and wear.
– Change the inner clutch hub.
– Check clutch pressure cap 6 for damage and wear.
– Change the clutch pressure cap.
– Check the thrust surfaces of the clutch facing discs in clutch basket bo for wear.
Contact surface, clutch facing discs in clutch basket ≤ 0.5 mm (≤ 0.02 in)
» If the thrust surface exhibits excessive wear:
– Change the clutch facing discs and the clutch basket.
– Check clutch facing discs bq for discoloration and scoring.
» If there is discoloration or scoring:
– Check the thickness of clutch facing discs bq and intermediate discs br.
Thickness of overall package ≥ 32.00 mm (≥ 1.2598 in)
» If the clutch facing discs do not meet specifications:
– Check intermediate discs br for damage and wear.
» If the intermediate discs are not flat or have punctiform outbreaks:
– Change all intermediate discs.
229
19 CLUTCH
– Mount collar sleeve bp.
G04781-10
– Slide clutch basketbo onto the main shaft.

– Turn the oil pump gear wheel bs until the gearing of the
clutch basket meshes.
G04782-10
– Slide on washer bn and inner clutch hub bm.
G04783-10
– Mount washers bl.
G04779-10
– Mount nut bk. Hold the inner clutch hub with the special tool
and tighten the nut.
Guideline
Nut, inner M16LHx1.5 120 Nm (88.5 lbf ft)
clutch hub Loctite®243™
Holding wrench (51129003000) ( p. 322)
G04778-10
230
CLUTCH 19
– Mount support ring bt and pretension ring ck.

The pretension ring rests against the support ring on the
inside and the outside faces away from the support ring.
R02018-10
– Thoroughly oil the clutch facing discs.

– Mount the clutch facing disk cl with the largest inside diam-
eter.
– Alternately mount all of the other intermediate clutch discs
and clutch facing discs.
– Mount the clutch facing disk cm with the largest inside diam-
eter.
T02057-10
– Mount the clutch facing disk cnwith the largest inside diam-
eter on the clutch pressure cap.
– Mount the intermediate clutch disk co with the largest inside
diameter on the clutch pressure cap.
T02058-10
– Mount pull rod 7.
G04784-10
– Position clutch pressure cap 6 with clutch disks.

The uppermost clutch facing disc is offset by one tooth.
– Position the springs 5.
G04775-10
231
19 CLUTCH
– Position pressure plate 4.

The marking A points outward.
Guideline
G04785-10
– Position the clutch cover with dowels and new gasket.
Info
Pivot the clutch lever.
– Attach the inner clutch cable.
G04773-10

Guideline
G04772-10
– Position shift shaft sensor.

– Mount and tighten screws 1
G04795-10
– Place vehicle in upright position and lean on the side stand.
G04764-10
Finishing work
232
SHIFT MECHANISM 20
20.1 Adjusting the shift lever
Info
The adjustment range of the shift lever is limited.
– Loosen nuts 1.
– Adjust the shift lever by turning shift rod 2.
Guideline
Shift rod adjustment 83 … 85 mm (3.27 …
range A 3.35 in)
Make equal adjustments on both sides.
– Tighten nuts 1.
Guideline
Nut, shift rod M6 6 Nm (4.4 lbf ft)
Info
After the nuts have been tightened, the bearings of
the shift rod must be central and aligned identically
to each other in order to ensure freedom of movement
in the bearing shells.
A00709-10
– Loosen screw 3.
– Mount bell crank shift lever 4
on the shift shaft in the
required position and engage the gearing.
Info
The basic position of the marking on the shift shaft and
the shift bell crank is offset by two teeth.
Guideline
lever linkage Loctite®243™
– Check the shift lever to ensure it is functioning properly and

can move freely.
A00710-10
233
20 SHIFT MECHANISM
20.2 Programming the gear position sensor

Condition
The diagnostics tool is connected and running.
Preliminary work
– Clear adaptation values.
Main work
– Execute "Engine electronics" > "Functions" >
"Program the gear position sensor".
– Switch to the main menu.
– Switch the ignition off and on again.
Green idle indicator lamp N lights up.
H02627-01
20.3 Programming the shift shaft sensor

Condition
Preliminary work
– Clear adaptation values.
– Program the gear position sensor. ( p. 234)
Main work
– Execute "Engine electronics" > "Functions" > "Quick Shift teach-
in procedure".
H02627-01
20.4 Changing the shift shaft sensor

Main work
– Remove the cover of the shift shaft sensor.
G04796-10
234
SHIFT MECHANISM 20
G04797-10
– Disconnect plug-in connector 2.

– Remove the shift shaft sensor.
G04798-10
– Position the new shift shaft sensor.

The flat surface of inner clutch hub A engages in
groove B of the shift shaft sensor.
G04800-10
– Route the cable without tension.

– Mount the cable ties.
G04797-10
235
20 SHIFT MECHANISM
– Join plug-in connector 2.
G04798-10

Guideline
shaft sensor Loctite®243™
G04796-10
Finishing work
– Program the shift shaft sensor. ( p. 234)
236
WATER PUMP, COOLING SYSTEM 21
21.1 Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
Preparatory work
Main work
– Position the motorcycle upright.
– Position an appropriate container under the engine.
– Remove screw 1 with the seal ring.
– Remove the radiator cap.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
S04172-10
Screw plug, water M6 10 Nm (7.4 lbf ft)
pump drain hole
21.2 Filling/bleeding the cooling system
Warning
237
21 WATER PUMP, COOLING SYSTEM
Main work
– Remove screws 1 and take off the cover.
– Remove radiator cap 2.
S04173-11

– Loosen bleeder screw 4.
Guideline
3 turns
– Tilt the vehicle slightly to the right.
– Pour in the coolant until it emerges without bubbles at the
bleeder screw, and then mount and tighten the bleeder screw
S04174-10
immediately.
Coolant ( p. 316)
– Completely fill the radiator with coolant. Mount the radiator
cap.
– Rest the vehicle on the side stand.
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
– Start the engine and allow it to warm up.

– Stop the engine and allow it to cool down.
– When the engine is cool, check the coolant level in the radiator
and, if necessary, add coolant.
– Remove cap 5 of the compensating tank and top up the
coolant level to the upper marking.
– Mount the cap of the compensating tank.
– Position the cover, mount and tighten screws 1 and 3.
Guideline
S04170-11
chassis
Finishing work
238
21.3 Checking the antifreeze and coolant level
Warning
Warning
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove cap 1 of the compensating tank.
– Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the speci-
fied value:
– Correct the antifreeze in the coolant.
S04170-10 – Check the coolant level in the compensating tank.
The coolant level must be between the two markings.
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 316)
– Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the speci-
fied value:
– Correct the antifreeze in the coolant.
S04173-10 – Check the coolant level in the radiator.
The radiator must be filled completely.
– Check the coolant level and the reason for the loss.
239
Coolant ( p. 316)
» If you had to add more coolant than the specified amount:
> 0.20 l (> 0.21 qt.)
– Mount the radiator cap.
– Position the cover, mount and tighten screws 2.
Guideline
chassis
21.4 Checking the coolant level
Warning
Warning
Condition
The engine is cold.
– Check the coolant level in compensating tank 1.
The coolant level must be between the two markings.
– Correct the coolant level.
Coolant ( p. 316)
S04170-10
240

– Remove radiator cap 3 and check the coolant level in the
radiator.
The radiator must be filled completely.
– Check the coolant level and the reason for the loss.
» If you had to add more coolant than the specified amount:
S04173-10 > 0.20 l (> 0.21 qt.)
– Mount the radiator cap.
– Position the cover, mount and tighten screws 2.
Guideline
chassis
21.5 Changing the coolant
Warning
Warning
Condition
The engine is cold.
Preparatory work
Main work
– Position the motorcycle upright.
– Position an appropriate container under the engine.
– Remove screw 1 with the seal ring.
S04172-10
241

– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Screw plug, water M6 10 Nm (7.4 lbf ft)
pump drain hole
S04173-10

– Loosen bleeder screw 5.
Guideline
3 turns
– Tilt the vehicle slightly to the right.
– Pour in the coolant until it emerges without bubbles at the
bleeder screw, and then mount and tighten the bleeder screw
S04174-11
immediately.
Coolant ( p. 316)
– Completely fill the radiator with coolant. Mount the radiator
cap.
– Rest the vehicle on the side stand.
Danger
– Start the engine and allow it to warm up.

– Stop the engine and allow it to cool down.
– When the engine is cool, check the coolant level in the radiator
and, if necessary, add coolant.
– Remove cap 6 of the compensating tank and top up the
coolant level up to the MAX marking.
– Position the cover, mount and tighten screws 2 and 4.
Guideline
S04170-12
chassis
Finishing work
242
CYLINDER HEAD 22
22.1 Checking the valve clearance

Preparatory work
Main work
– Push back hose clamp 2.
– Pull off the vent hose.
– Remove cable tie and take off the fuel tank mounting rubbers.
G04726-10
– Remove the spark plug with special tool 3.

G04727-10
– Remove screws 4 and take off the valve cover.
G04728-10
– Remove gasket 5 and 6.
G04729-10
243
22 CYLINDER HEAD
G04730-10

– Stand the motorcycle upright, align the lifting gear with the
link fork and the adapters, and raise the motorcycle.
Note
G04731-10
Danger of damage The parked vehicle can roll away or fall
over.

– Engage the highest gear.
– Turn the rear wheel until markings A align with the edge of
the cylinder head.
G04732-10

Guideline
cold … 0.0079 in)
… 0.0059 in)
Feeler gauge (59029041100) ( p. 323)

G04733-10
244
CYLINDER HEAD 22

Note
over.

– Remove the lifting gear from the rear and lean the vehicle on
the side stand.
G04731-10
G04730-10
– Clean the sealing surfaces and thinly coat with sealing com-
pound in area D
.
Loctite® 5910
T00869-10
– Position gasket 5 and 6.
G04729-10

Guideline
G04728-10
245
22 CYLINDER HEAD
– Mount and tighten the spark plug with special tool 3.

Guideline
G04727-10
– Mount the vent hose and position hose clamp 2.

– Plug in spark plug connector 1.
– Mount the fuel tank mounting rubbers and secure with cable
ties.
G04726-10
Finishing work
22.2 Checking the valve clearance, changing the spark plug

Preparatory work
Main work
– Push back hose clamp 2.
– Pull off the vent hose.
– Remove cable tie and take off the fuel tank mounting rubbers.
G04726-10
246
CYLINDER HEAD 22
– Remove the spark plug with special tool 3.

G04727-10
– Remove screws 4 and take off the valve cover with the gas-
ket.
G04728-10
– Remove gasket 5 and 6.
G04729-10
G04730-10

– Stand the motorcycle upright, align the lifting gear with the
link fork and the adapters, and raise the motorcycle.
Note
G04731-10
over.

247
22 CYLINDER HEAD
– Engage the highest gear.

– Turn the rear wheel until markings A align with the edge of
the cylinder head.
G04732-10

Guideline
cold … 0.0079 in)
… 0.0059 in)
Feeler gauge (59029041100) ( p. 323)

G04733-10
Note
over.

– Remove the lifting gear from the rear and lean the vehicle on
the side stand.
G04731-10
G04730-10
248
CYLINDER HEAD 22
– Clean the sealing surfaces and thinly coat with sealing com-
pound in area D .
Loctite® 5910
T00869-10
– Position gasket 5 and 6.
G04729-10

Guideline
G04728-10
– Mount and tighten the new spark plug with special tool 3.
Guideline
G04727-10
– Mount the vent hose and position hose clamp 2.

– Mount the fuel tank mounting rubbers and secure with cable
ties.
G04726-10
Finishing work
249
22 CYLINDER HEAD
22.3 Adjusting the valve clearance
Info
For purposes of illustration, the following operations are shown with the engine removed.
Removal is not necessary.
Preparatory work
– Remove the camshafts. ( p. 250)
Main work
– Swing up cam lever 1.
– Correct the shims 2 as indicated by the results of the valve
clearance check.
311945-10
Finishing work
– Install the camshafts. ( p. 251)
22.4 Removing the camshafts

Condition
Engine is at ignition top dead center.
– Remove screw 1 with the O-ring.
– Remove screw 2.
– Remove the timing chain tensioner with the gasket.
G04735-10
250
CYLINDER HEAD 22
– Remove the spark plug shaft insert 3.

– Loosen and remove screws 4 from the outside to the inside.
– Take off the camshaft bearing support.
– Remove dowels.
– Remove the intake camshaft.
– Remove the exhaust camshaft.
G04734-11
22.5 Installing the camshafts

Main work
– Ensure that the marking A and B are flush.
Engine is at ignition top dead center.
T00873-10
– Pull up the timing chain and insert the exhaust camshaft.

– Place the timing chain over the camshaft gear wheel of the
intake camshaft.
Markings C of the camshafts align with the edge of the
cylinder head.
– Clean all oil nozzles thoroughly and blow out with compressed
air.
– Position the camshaft bearing support.
– Mount screws 1 and tighten them from the inside to the out-
side.
Guideline
bearing support
– Grease the O-rings and mount spark plug shaft insert 2.
G04736-10

304804-10
251
22 CYLINDER HEAD
– Holding it with the correct orientation, mount the timing chain

tensioner with the gasket.
Guideline
Screw, timing chain M6 12 Nm (8.9 lbf ft)
tensioner
– Unlock the timing chain tensioner screw counterclockwise.
– Check the timing chain tension.
G04735-11
– Mount screw 4 with the O-ring and tighten.
Guideline
Screw, unlocking of M6 6 Nm (4.4 lbf ft)
timing chain ten-
sioner
Finishing work
252
LUBRICATION SYSTEM 23
23.1 Oil circuit
1 Suction pump
2 Pressure pump
3 Oil filter
4 Oil pressure control valve
5 Oil nozzle for piston cooling
6 Oil spray tube
7 Oil nozzle for cam follower lubrication
308470-10
23.2 Checking the engine oil level

Condition
The engine is at operating temperature.
Preparatory work
Main work
– Check the engine oil level.
Info
After switching off the engine, wait one minute before
checking the level.
The engine oil must be between the A and B markings .

A00688-10
» When the engine oil level is below the A marking:
– Add engine oil. ( p. 257)
» When the engine oil level is above the B marking:
– Correct the engine oil level.
23.3 Checking the oil pressure
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
253
23 LUBRICATION SYSTEM
Note
Preparatory work
Main work
– Place an appropriate container under the engine.
– Remove screws 1. Remove the oil filter cover with the O-ring.
T00799-10
– Remove oil filter 2.

Lock ring plier (51012011000) ( p. 322)
T00800-10
– Position the special tool with the O-ring. Mount and tighten
the screws.
Guideline
Oil pressure adapter (90129094000) ( p. 330)

– Connect the pressure testing tool to the special tool without
the T-plate.
T00801-10 Pressure testing tool (61029094000) ( p. 324)
Danger
– Start the engine.

– Check the oil pressure.
Oil pressure
254
Coolant temperature: ≥ 0.7 bar (≥ 10 psi)

≥ 70 °C (≥ 158 °F)
Engine speed: Idle speed
Coolant temperature: ≥ 2.4 bar (≥ 35 psi)
≥ 70 °C (≥ 158 °F)
Engine speed:
5,000 rpm
– Check the oil pumps for wear. Check all oil channels
for free flow.
– Switch off the engine.
Warning
Danger of burns Some vehicle components get very
hot when the machine is driven.
– Wear appropriate protective clothing and safety
gloves. In case of burns, rinse immediately with
lukewarm water.

– Insert the new oil filter.
– Oil the O-ring of the oil filter cover. Mount the oil filter cover.
– Mount and tighten the screws.
Guideline
Finishing work
23.4 Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
Note
Info
Drain the engine oil while the engine is at operating temperature.
Preparatory work
– Remove the engine guard retaining bracket. ( p. 80)
255
23 LUBRICATION SYSTEM
– Place the motorcycle on a horizontal surface using the side

stand.
Main work
– Place an appropriate container under the engine.
– Remove oil drain plug 1 with the O-ring.
– Remove oil screen2 with the O-ring.
– Remove screw plug 3 with oil screen 4.
– Allow the engine oil to drain completely.
– Thoroughly clean the oil drain plugs and oil screens.
– Position oil screen 2
and mount and tighten oil drain
plug 1 with the O-ring.
Guideline
– Mount and tighten screw plug 3 with oil screen 4 and the
O-ring.
Guideline
Oil screen screw M17x1.5 12 Nm (8.9 lbf ft)
plug, small
A00693-10
– Remove screws 5. Take off oil filter cover 6 with the O-

ring.
– Pull oil filter 7 out of the oil filter housing.
– Allow the engine oil to drain completely.
– Thoroughly clean the parts and the sealing surface.
A00694-10
– Insert new oil filter 7.

– Oil the O-ring of the oil filter cover. Mount oil filter cover 6.
– Mount and tighten the screws.
Guideline
Info
Too little engine oil or poor-quality engine oil will result
A00695-10
in premature wear of the engine.
– Remove filler plug 8 with the O-ring, and fill up with engine
oil.
Engine oil 1.7 l (1.8 qt.) Engine oil
(SAE 15W/50)
( p. 316)
401955-12
256
Danger
– Start the engine and check for tightness.

Finishing work
– Install the engine guard retaining bracket. ( p. 81)
23.5 Adding engine oil
Info
Too little engine oil or poor-quality engine oil will result in premature wear of the engine.
Main work
– Remove filler plug 1 with the O-ring, and fill up with engine
oil.
Engine oil (SAE 15W/50) ( p. 316)
Info
In order to achieve optimal engine oil performance, it is
not advisable to mix different engine oils.
401955-10 We recommend changing the engine oil when neces-
sary.
Danger
– Start the engine and check for tightness.

Finishing work
257
24 IGNITION SYSTEM
24.1 Alternator – checking the stator winding

Stator winding measurement I – check the resistance.
– Measure the resistance between the specified points.
Stator, connector HB pin 1 – Stator, connector HB pin 2
Alternator
Resistance of stator ≤1Ω
winding at: 20 °C
(68 °F)
» If the indicated value does not correspond to the setpoint
L00082-10
value:
– Change the stator.
Stator winding measurement II – check the resistance.
Alternator
winding at: 20 °C
(68 °F)
value:
Stator winding measurement III – check the resistance.
Alternator
winding at: 20 °C
(68 °F)
value:
L00082-10 P00296-10
Stator winding I – check the short circuit to ground (terminal 31).

Stator, connector HB pin 1 – Measuring point Ground (−)
Resistance ∞Ω
» If the indicated value does not correspond to the setpoint value:
258
IGNITION SYSTEM 24
L00082-10 P00296-10
Stator winding II - check short circuit to ground (terminal 31).

Resistance ∞Ω
L00082-10 P00296-10
Stator winding III – check the short circuit to ground (terminal 31).
Resistance ∞Ω
– Start the motorcycle to make checks. ( p. 16)
Stator winding measurement I – check the voltage.
Info
The results of the measurements on the individual coils
must not deviate significantly from one another.
Alternator
L00082-10
Alternating voltage stator ≥ 50 V
winding at 4000 rpm:
20 °C (68 °F)
value:
259
24 IGNITION SYSTEM
Stator winding measurement II – check the voltage.

Info
Alternator
20 °C (68 °F)
value:
Stator winding measurement III – check the voltage.
Info
Alternator
20 °C (68 °F)
value:
24.2 Changing the spark plug

G04697-10
260
IGNITION SYSTEM 24
– Remove the spark plug using special tool 2.

– Mount and tighten a new spark plug using a special tool.
Guideline
G04698-10
G04697-10
261
25 THROTTLE VALVE BODY
25.1 Resetting the service display using the KTM diagnostic tool
Condition
– Select "Combination instrument" > "Functions" > "Service inter-
val".
– Enter the distance until the next service is due.
– Select the unit for the distance.
– Quit the process using "Execute".
H02627-01
25.2 Performing the initialization run

Condition
– Execute "Engine electronics" > "Functions" >
"Clear adaptation values".
The adaptation values are deleted.
– Program the gear position sensor. ( p. 234)
– Program the shift shaft sensor. ( p. 234)
– Switch off the ignition.
– Disconnect the diagnostics tool.
401897-01
Danger
– Start the engine without operating the throttle grip.

Guideline
Coolant temperature < 25 °C (< 77 °F)
– Let the engine run at idle speed for at least 10 minutes (600
seconds).
Info
Do not operate the throttle grip during the initialization
process.
– Switch off the ignition after 10 minutes (600 seconds).
Info
If initialization is not completed or if the initialization
process was interrupted, the entire process must be
restarted.
262
TECHNICAL DATA 26
26.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 373 cm³ (22.76 cu in)
Stroke 60 mm (2.36 in)
Bore 89 mm (3.5 in)
Compression ratio 12.6:1
Control DOHC, 4 valves controlled via cam lever, chain drive
Intake valve diameter 36 mm (1.42 in)
Exhaust valve diameter 29 mm (1.14 in)
Valve clearance, intake, cold 0.10 … 0.15 mm (0.0039 … 0.0059 in)
Valve clearance, exhaust, cold 0.15 … 0.20 mm (0.0059 … 0.0079 in)
Crankshaft bearing 2 slide bearings
Conrod bearing Sleeve bearing
Pistons Forged light alloy
Piston rings 1 compression ring, 1 tapered compression piston
ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with 2 trochoidal
pumps
Primary transmission 30:80
Clutch Slipper clutch in oil bath/mechanically operated
Transmission 6-gear transmission, claw shifted
Transmission ratio
1st gear 12:32
2nd gear 14:26
3rd gear 19:27
4th gear 21:24
5th gear 23:22
6th gear 25:21
Mixture preparation Electronic fuel injection
Ignition Contactless controlled fully electronic ignition with
digital ignition adjustment
Alternator 12 V, 230 W
Spark plug BOSCHVR6NEU
Spark plug electrode gap 1 mm (0.04 in)
Cooling Water cooling, permanent circulation of coolant by
water pump
Idle speed 1,680 ± 50 rpm
Starting aid Starter motor
263
26 TECHNICAL DATA
26.2 Tolerance, engine wear limits

Intake 0.90 … 1.10 mm (0.0354 … 0.0433 in)
Exhaust 0.90 … 1.10 mm (0.0354 … 0.0433 in)
Cylinder/cylinder head - distortion of sealing area ≤ 0.10 mm (≤ 0.0039 in)
Cylinder - bore diameter 88.982 … 88.998 mm (3.50322 … 3.50385 in)
Piston - diameter 88.931 … 88.949 mm (3.50121 … 3.50192 in)
Piston/cylinder - mounting clearance
New condition 0.033 … 0.067 mm (0.0013 … 0.00264 in)
Piston ring end gap
Compression ring ≤ 0.40 mm (≤ 0.0157 in)
Oil scraper ring ≤ 0.80 mm (≤ 0.0315 in)
Connecting rod - radial play of lower conrod bearing
New condition 0.035 … 0.058 mm (0.00138 … 0.00228 in)
Crankshaft classification A 31.970 … 31.977 mm (1.25866 … 1.25893 in)
Crankshaft classification B 31.978 … 31.985 mm (1.25897 … 1.25925 in)
Clutch facing discs – thickness of total package ≥ 21.30 mm (≥ 0.8386 in)
Oil pressure regulator valve - minimum length spring 30.00 mm (1.1811 in)
Oil pump
Play between external rotor and oil pump housing 0.09 … 0.20 mm (0.0035 … 0.0079 in)
Play between external rotor and internal rotor 0.10 … 0.20 mm (0.0039 … 0.0079 in)
Axial play 0.10 … 0.25 mm (0.0039 … 0.0098 in)
Shift shaft – play in sliding plate/shift quadrant 0.15 … 0.45 mm (0.0059 … 0.0177 in)
26.3 Engine tightening torques

Loctite®243™
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, gear sensor M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, retaining bracket M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, retaining bracket, stator M5 8 Nm (5.9 lbf ft)
cable Loctite®243™
Screw, stator M5 8 Nm (5.9 lbf ft)
Loctite®243™
Cylinder head screw M6 12 Nm (8.9 lbf ft)
Nut, oil pressure sensor M6 3 Nm (2.2 lbf ft)
Nut, water pump impeller M6 10 Nm (7.4 lbf ft)
Loctite®243™
264
TECHNICAL DATA 26

Loctite®243™
Screw plug, water pump drain hole M6 10 Nm (7.4 lbf ft)
Screw, alternator cover M6 12 Nm (8.9 lbf ft)
Screw, bearing retainer M6 12 Nm (8.9 lbf ft)
Loctite®243™
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
Screw, camshaft, decompression M6 10 Nm (7.4 lbf ft)
shaft Loctite®243™
Screw, chain securing guide M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch cable retaining M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, engine vent plate M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, freewheel gear retaining M6 12 Nm (8.9 lbf ft)
Screw, lock washer, engine M6 12 Nm (8.9 lbf ft)
sprocket Loctite®243™
Screw, locking lever M6 12 Nm (8.9 lbf ft)
Loctite®243™
Loctite®243™
Screw, retaining bracket M6 12 Nm (8.9 lbf ft)
Loctite®243™
Screw, retaining bracket, radial M6 12 Nm (8.9 lbf ft)
shaft seal ring, clutch cover Loctite®243™
Screw, shift drum locating M6 12 Nm (8.9 lbf ft)
Loctite®243™
Screw, timing chain tensioner M6 12 Nm (8.9 lbf ft)
Screw, timing chain tensioning rail M6 12 Nm (8.9 lbf ft)
Loctite®243™
Screw, unlocking of timing chain M6 6 Nm (4.4 lbf ft)
tensioner
Screw, water pump cover M6 12 Nm (8.9 lbf ft)
Screw plug M8 12 Nm (8.9 lbf ft)
Loctite®243™
Screw, balancer shaftgear wheel M8 40 Nm (29.5 lbf ft)
Loctite®243™
265
26 TECHNICAL DATA
Screw, spring thrust bearing of the M8 20 Nm (14.8 lbf ft)

shift shaft Loctite®243™
Stud, exhaust flange M8 22 Nm (16.2 lbf ft)
Screw, conrod bearing M8x1 34 Nm (25.1 lbf ft)
Coolant temperature sensor M10 14 Nm (10.3 lbf ft)
Oil pressure sensor M10 14 Nm (10.3 lbf ft)
Screw, camshaft gear wheel M10 36 Nm (26.6 lbf ft)
Loctite®243™
Screw, cylinder head M10 1st stage
30 Nm (22.1 lbf ft)
2nd stage
60 Nm (44.3 lbf ft)
Thread is oiled, head flat is greased
Screw, rotor M10 105 Nm (77.4 lbf ft)
Loctite®243™
Screw plug, cam lever axis M10x1 10 Nm (7.4 lbf ft)
Nut, inner clutch hub M16LHx1.5 120 Nm (88.5 lbf ft)
Loctite®243™
Nut, primary gear wheel/timing M16x1.5 120 Nm (88.5 lbf ft)
chain sprocket Loctite®243™
Oil screen screw plug, small M17x1.5 12 Nm (8.9 lbf ft)
Screw plug, alternator cover M18x1.5 10 Nm (7.4 lbf ft)
Screw plug, alternator cover M24x1.5 10 Nm (7.4 lbf ft)
Nut, drive gear wheel for balancer M28 60 Nm (44.3 lbf ft)
shaft Loctite®243™
26.4 Capacities
26.4.1 Engine oil

Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50)
( p. 316)
26.4.2 Coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 316)
26.4.3 Fuel
Total fuel tank capacity, approx. 14.5 l (3.83 US gal) Super unleaded (ROZ 95/RON
95/PON 91) ( p. 317)
(EU/AU/JP/US, AR/CN/CO, MY/PH)
Total fuel tank capacity, approx. Gasohol 95 E20 (RON 95)
( p. 317) (TH)
Total fuel tank capacity, approx. Super unleaded, type C (ROZ
95/RON 95/PON 91) ( p. 317)
(BR)
Fuel reserve, approx. 3.5 l (3.7 qt.)

266
TECHNICAL DATA 26
26.5 Chassis
Frame Lattice frame of steel tubes, powder-coated
Fork WP APEX 3343
Shock absorber WP APEX 3446
Brake system
front Disc brake with 4-piston brake caliper
rear Disc brake with single-pot brake caliper, floating
Suspension travel
front 170 mm (6.69 in)
rear 177 mm (6.97 in)
Brake discs - diameter
front 320 mm (12.6 in)
rear 230 mm (9.06 in)
Brake discs - wear limit
front 4.5 mm (0.177 in)
rear 3.6 mm (0.142 in)
Tire pressure when solo
Tire pressure with passenger / full payload
Secondary ratio 15:45
Chain 5/8 x 1/4” (520) X‑ring
Steering head angle 63.5°
Wheelbase 1,430 ± 15.5 mm (56.3 ± 0.61 in)
Seat height, unloaded 855 mm (33.66 in)
Ground clearance, unloaded 200 mm (7.87 in)
Weight without fuel, approx. 161 kg (355 lb.)
Maximum permissible front axle load 135 kg (298 lb.)
Maximum permissible rear axle load 275 kg (606 lb.)
Maximum permissible overall weight 375 kg (827 lb.)
26.6 Electrical system

12-V battery ETZ‑9‑BS Battery voltage: 12 V
Nominal capacity: 8 Ah
Maintenance-free
Fuse 75011088010 10 A
Fuse 75011088015 15 A
Fuse 90111088025 25 A
Fuse 75011088030 30 A
Headlight LED
Position light LED
Combination instrument lighting LED
and indicator lamps
267
26 TECHNICAL DATA
Turn signal (EU/AU/JP/AR, LED

BR/CN/CO, MY/PH/TH)
Turn signal (US) RY10W / socket BAU15s 12 V
10 W
Brake/tail light LED
License plate lamp LED
26.6.1 Diagnostics connector

Diagnostics connector 1 is located under the passenger seat.
A00702-10
26.6.2 Front ACC1 and ACC2

Installation location
– The front power supplies ACC1 1 and ACC2 2 are located
behind the headlight.
Info
The front power supplies ACC1 and ACC2 can be accessed
under the cable cover of the headlight mask.
S04169-10
26.7 Tires
Front tire Rear tire
110/70 R 17 M/C 54H TL 150/60 R 17 M/C 66H TL
Metzeler Sportec M5 Interact Metzeler Sportec M5 Interact
110/70 R 17 M/C 54H TL 150/60 R 17 M/C 66H TL
Michelin Pilot Street Radial Michelin Pilot Street Radial
The tires specified represent one of the possible series production tires. Additional information is available in
the Service section under:
http://www.ktm.com
26.8 Fork
Fork article number 05.58.8T.31
Fork WP APEX 3343
Fork length 797 mm (31.38 in)
Fork oil per fork leg 455 ± 5 ml (15.38 ± 0.17 fl. oz.) Fork oil (SAE 4) (48601166S1)
( p. 317)
268
TECHNICAL DATA 26
26.9 Shock absorber

Shock absorber article number 01.58.5T.31
Shock absorber WP APEX 3446
Spring preload
Comfort 3 clicks
Standard 3 clicks
Sport 3 clicks
Static sag 12 mm (0.47 in)
Riding sag 34 mm (1.34 in)
Inbuilt length 307 mm (12.09 in)
26.10 Chassis tightening torques

Screw, chain guard EJOT PT® K60x30 3 Nm (2.2 lbf ft)
Remaining screws, chassis M4 4 Nm (3 lbf ft)
Screw, tail light M4 2 Nm (1.5 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, chain guard M5 7 Nm (5.2 lbf ft)
Loctite®243™
Screw, compensating tank cap M5 9 Nm (6.6 lbf ft)
lock, rear brake
Screw, fuel tank cover M5 4 Nm (3 lbf ft)
Screw, outer clutch cable guide M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, side stand sensor M5 5 Nm (3.7 lbf ft)
Loctite®243™
Nut, foot brake lever adjustment M6 9 Nm (6.6 lbf ft)
Nut, radiator M6 5 Nm (3.7 lbf ft)
Screw, ABS hose clamp M6 7 Nm (5.2 lbf ft)
Screw, ABS module M6 10 Nm (7.4 lbf ft)
Screw, ABS module retaining M6 7 Nm (5.2 lbf ft)
bracket on frame
Screw, air filter box M6 6 Nm (4.4 lbf ft)
Screw, brake fluid reservoir for rear M6 8 Nm (5.9 lbf ft)
brake Loctite®243™
Screw, brake hose clamp M6 7 Nm (5.2 lbf ft)
Screw, chain sliding guard M6 7 Nm (5.2 lbf ft)
Screw, combination instrument M6 7 Nm (5.2 lbf ft)
Screw, compensating tank M6 5 Nm (3.7 lbf ft)
Screw, damper block M6 8 Nm (5.9 lbf ft)
Screw, engine sprocket cover M6 8 Nm (5.9 lbf ft)
269
26 TECHNICAL DATA
Screw, foot brake cylinder M6 9 Nm (6.6 lbf ft)

Loctite®243™
Screw, front fender M6 7 Nm (5.2 lbf ft)
Screw, front seat fixing M6 6 Nm (4.4 lbf ft)
Screw, front spoiler M6x13 9 Nm (6.6 lbf ft)
Screw, front spoiler rear M6x9 9 Nm (6.6 lbf ft)
Screw, fuel pump M6 10 Nm (7.4 lbf ft)
Screw, holder of fuel vapor valve M6 9 Nm (6.6 lbf ft)
Screw, ignition coil M6 8 Nm (5.9 lbf ft)
Screw, ignition lock (tamper-proof M6 13 Nm (9.6 lbf ft)
screw)
Screw, license plate holder M6 12 Nm (8.9 lbf ft)
Loctite®243™
Screw, lower rear panel M6 7 Nm (5.2 lbf ft)
Screw, magnetic holder on side M6 5 Nm (3.7 lbf ft)
stand Loctite®243™
Screw, main silencer M6 12 Nm (8.9 lbf ft)
Screw, main silencer retaining M6 9 Nm (6.6 lbf ft)
bracket
Screw, protective plate M6 8 Nm (5.9 lbf ft)
Screw, radiator holder M6 10 Nm (7.4 lbf ft)
Screw, radiator shield M6 7 Nm (5.2 lbf ft)
Screw, rear splash protector M6 9 Nm (6.6 lbf ft)
Screw, rear wheel speed sensor M6 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, shift lever linkage M6 11 Nm (8.1 lbf ft)
Loctite®243™
Screw, side stand sensor cable M6 9 Nm (6.6 lbf ft)
holder Loctite®243™
Screw, tilt sensor M6 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, wheel speed sensor holder M6 8 Nm (5.9 lbf ft)
Nut, rear sprocket M8 38 Nm (28 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, foot brake lever M8 16 Nm (11.8 lbf ft)
Loctite®243™
Screw, front brake disc M8 29 Nm (21.4 lbf ft)
Loctite®243™
Screw, front seat fixing M8 25 Nm (18.4 lbf ft)
Screw, front wheel spindle M8 25 Nm (18.4 lbf ft)
Screw, fuel tank M8 20 Nm (14.8 lbf ft)
270
TECHNICAL DATA 26
Screw, grab handle M8 22 Nm (16.2 lbf ft)

Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
Screw, horn M8 12 Nm (8.9 lbf ft)
Screw, passenger footrest unit M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, rear brake disc M8 29 Nm (21.4 lbf ft)
Loctite®243™
Screw, rear seat fixing M8 18 Nm (13.3 lbf ft)
Screw, seat support plate M8 18 Nm (13.3 lbf ft)
Screw, shift lever M8 16 Nm (11.8 lbf ft)
Loctite®243™
Screw, subframe M8 25 Nm (18.4 lbf ft)
Loctite® 620™
Screw, top triple clamp M8 15 Nm (11.1 lbf ft)
Screw, front brake caliper M8x1 30 Nm (22.1 lbf ft)
Loctite®243™
Banjo bolt, brake line M10 24 Nm (17.7 lbf ft)
Fitting side stand M10 35 Nm (25.8 lbf ft)
Loctite®243™
Fitting, engine mounting bracket M10 49 Nm (36.1 lbf ft)
Loctite®243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Fitting, shock absorber, bottom M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Nut, left rear mirror M10x1.25 16 Nm (11.8 lbf ft)
Nut, right rear mirror M10LHx1.25 16 Nm (11.8 lbf ft)
Nut, side stand bracket M10x1.25 35 Nm (25.8 lbf ft)
Screw, combination instrument M10x1.25 21 Nm (15.5 lbf ft)
bracket
Screw, front footrest bracket M10x1.25 44 Nm (32.5 lbf ft)
Loctite®243™
Screw, front footrest bracket / M10x1.25 49 Nm (36.1 lbf ft)
engine bearer
Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Stud, rear sprocket M10x1.25 50 Nm (36.9 lbf ft)
Threaded bolt, side stand bracket M10x1.25 27 Nm (19.9 lbf ft)
Loctite®243™
Nut, rear wheel spindle M14x1.5 100 Nm (73.8 lbf ft)
Nut, swingarm pivot M14x1.5 100 Nm (73.8 lbf ft)
Screw, steering head, top M16x1.5 53 Nm (39.1 lbf ft)
Lambda sensor M18x1.5 19 Nm (14 lbf ft)
Adjusting ring, link fork bearing M22x1 Tighten and ensure that there is no
play
271
26 TECHNICAL DATA
Nut, steering head M30x1 1st stage

45 Nm (33.2 lbf ft)
2nd stage (loosen, counterclock-
wise)
2 turns
3rd stage
5 Nm (3.7 lbf ft)
Nut, steering head M30x1 5 Nm (3.7 lbf ft)
272
CLEANING/PROTECTIVE TREATMENT 27
27.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
Info
Clean the motorcycle regularly to maintain its value and appearance over a long period.
Avoid direct sunshine when cleaning the motorcycle.
– Close off exhaust system to keep water from entering.

– Remove loose dirt first with a soft jet of water.
– Spray the heavily soiled parts with a normal commercial motor-
cycle cleaner and clean using a brush.
Motorcycle cleaner ( p. 318)
Info
Use warm water containing normal motorcycle cleaner
401061-01
and a soft sponge.
Never apply motorcycle cleaner to a dry motorcycle;
always rinse the vehicle with water first.
Clean the motorcycle with cold water if it has been
used on salted roads. Warm water enhances the cor-
rosive effects of salt.
– After rinsing the motorcycle with a gentle spray of water, allow

it to dry thoroughly.
– Remove the closure of the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the
brake system.
– Brake carefully several times to dry out and remove
dirt from the brake linings and the brake discs.
– After cleaning, ride the vehicle a short distance until the

engine warms up.
Info
The heat produced causes water at inaccessible loca-
tions in the engine and on the brake system to evapo-
rate.
273
27 CLEANING/PROTECTIVE TREATMENT
– Push back the sleeves of the handlebar controls to allow any

water that has penetrated to evaporate.
– After the motorcycle has cooled down, lubricate all moving
parts and pivot points.
– Clean the chain. ( p. 99)
– Treat bare metal (except for brake discs and the exhaust sys-
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 318)
– Treat all painted parts with a mild paint care product.
Perfect finish and high gloss polish for paints ( p. 318)
Info
Do not polish parts that were matte when delivered as
this would strongly impair the material quality.
– Treat all plastic parts and powder-coated parts with a mild

cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 319)
– Lubricate the ignition and steering lock.
Universal oil spray ( p. 319)
27.2 Checks and maintenance steps for winter operation
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precau-
tions against aggressive road salt.
Clean the motorcycle with cold water if it has been used on salted roads. Warm water enhances the corro-
sive effects of salt.
– Clean the motorcycle. ( p. 273)

– Clean the brakes.
Info
After EVERY trip on salted roads, thoroughly clean the
motorcycle and, in particular, the brake calipers and
brake linings, after they have cooled down and without
removing them, with cold water and dry carefully.
401060-01 – Treat the engine, the link fork, and all other bare or zinc-plated
parts (except the brake discs) with a wax-based corrosion
inhibitor.
Info
Corrosion inhibitor must not come in contact with the
brake discs as this would greatly reduce the braking
force.
– Clean the chain. ( p. 99)

274
STORAGE 28
28.1 Storage
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them per-
formed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements
are necessary, you should do this during the storage period (less workshop overload). In this way, you can
avoid long workshop waiting times at the start of the new season.
– When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Fuel additive ( p. 318)
– Refuel.
– Clean the motorcycle. ( p. 273)
– Change the engine oil and the oil filter, clean the oil screens.
( p. 255)
– Check the antifreeze and coolant level. ( p. 239)
401058-01
– Check tire pressure. ( p. 82)
– Remove the 12-V battery. ( p. 105)
– Charge the 12-V battery.
Guideline
Storage temperature of the 0 … 35 °C (32 … 95 °F)
12-V battery without direct
sunlight
– Store vehicle in a dry location that is not subject to large fluc-
tuations in temperature.
Info
KTM recommends jacking up the motorcycle.

– Cover the motorcycle with a tarp or cover that is permeable to
air.
Info
Do not use non-porous materials since they prevent
humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since
the engine cannot warm up properly, the water vapor
produced during combustion condenses and causes
valves and the exhaust system to rust.
275
28 STORAGE
28.2 Preparing for use after storage

( p. 12)
– Install the 12-V battery. ( p. 105)
– Perform checks and maintenance measures when preparing for
use.
– Take a test ride.
401059-01
276
SERVICE SCHEDULE 29
29.1 Additional information

Any further work that results from the compulsory work or from the recommended work must be ordered sepa-
rately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.
29.2 Required work

every 24 months
every 12 months
every 15,000 km (9,300 mi)
every 7,500 km (4,650 mi)
after 1,000 km (620 mi)
Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ●
Program the shift shaft sensor. (Option: Shift shaft sensor activated) ○ ● ●
Check that the electrical system is functioning properly. ○ ● ● ● ●
Change the engine oil and the oil filter, clean the oil screens. ( p. 255) ○ ● ● ● ●
Check the brake discs. ( p. 83) ○ ● ● ● ●
Check the front brake linings. ( p. 113) ○ ● ● ● ●
Check the rear brake linings. ( p. 120) ○ ● ● ● ●
Check the brake lines for damage and leakage. ○ ● ● ● ●
Check the front brake fluid level. ( p. 116) ○ ● ● ●
Check the rear brake fluid level. ( p. 124) ○ ● ● ●
Check the tire condition. ( p. 82) ○ ● ● ● ●
Check tire pressure. ( p. 82) ○ ● ● ● ●
Check the shock absorber and fork for leaks. ○ ● ● ● ●
Clean the dust boots of the fork legs. ( p. 17) ● ●
Check the chain, rear sprocket, and engine sprocket. ( p. 97) ● ● ● ●
Check the chain tension. ( p. 96) ○ ● ● ● ●
Check the coolant level. ( p. 240) ○ ● ● ● ●
Check that the radiator fan is functioning properly. ○ ● ● ● ●
Change the air filter, clean the air filter box. ( p. 65) ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set cor- ○ ● ● ● ●
rectly.
Check the cables for damage and routing without sharp bends. ○ ● ● ● ●
Check the valve clearance, change the spark plug. ( p. 246) ●
Change the front brake fluid. ( p. 118) ●
Change the rear brake fluid. ( p. 126) ●
Check steering head bearing play. ( p. 31) ○ ● ● ● ●
Check the headlight setting. ( p. 147) ○ ● ●
Set the service interval display. ( p. 146) ○ ● ● ● ●
Final check: Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● ●
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ●
Make a service entry in KTM Dealer.net. ○ ● ● ● ●
○ One-time interval
● Periodic interval
277
29 SERVICE SCHEDULE
29.3 Recommended work

every 48 months
every 12 months
every 30,000 km (18,600 mi)
every 7,500 km (4,650 mi)
after 1,000 km (620 mi)
Check the frame. ( p. 45) ●
Check the link fork. ( p. 52) ●
Checking the fork bearing for play. ( p. 57) ● ●
Check the wheel bearing for play. ( p. 88) ● ●
Check the antifreeze. ○ ● ● ●
Change the coolant. ( p. 241) ●
Empty the drainage hoses. ○ ● ● ● ●
Check all hoses (e.g. fuel, coolant, bleeder, drainage, etc.) and sleeves for cracking, ○ ● ● ● ●
leaks, and incorrect routing.
Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth ○ ● ● ● ●
operation.
Check the tightness of the safety-relevant screws and nuts which are easily accessible. ○ ● ● ● ●
○ One-time interval
● Periodic interval
278
279
SERVICE SCHEDULE 29

30 WIRING DIAGRAM
30.1 Page 1 of 9 (EU/AU/JP/AR, BR/CN/CO, MY/PH/TH)
Y00413-01
280
WIRING DIAGRAM 30
Components:
A11 Engine electronics control unit
F2 Fuse
F8 Fuse
F9 Fuse
G10 12-V battery
K10 Starter relay with main fuse
M10 Electric starter system
R15 Transil unit
S11 Ignition and steering lock
S27 Light switch, emergency OFF switch, start button
281
30 WIRING DIAGRAM
Y00414-01
282
WIRING DIAGRAM 30
Components:
F4 Fuse
F6 Fuse
F7 Fuse
F10 Fuse
K11 Start auxiliary relay
K40 Fuel pump relay
M13 Fuel pump
X272 Connector for accessory ground terminal 31 ACC 2, rear
X273 Connector for accessory plus terminal 15 ACC 2, rear
283
30 WIRING DIAGRAM
Y00415-01
284
WIRING DIAGRAM 30
Components:
E75 Headlight unit
G20 Alternator
K14 Low beam relay
P10 Combination instrument
T20 Voltage regulator
X270 Connector for accessory ground terminal 31 ACC 2, front
X271 Connector for accessory plus terminal 15 ACC 2, front
X290 12-V socket
285
30 WIRING DIAGRAM
Y00416-01
286
WIRING DIAGRAM 30
Components:
B41 Induction manifold pressure sensor
B44 Ambient air pressure sensor and intake air temperature sensor
B51 Lambda sensor
B86 Lean angle sensor
M51 Injection valve
M60 Throttle valve position sensor
287
30 WIRING DIAGRAM
Y00417-01
288
WIRING DIAGRAM 30
Components:
B27 Shift shaft sensor
B30 Side stand sensor
B34 Gear position sensor
B37 Crankshaft speed sensor
F5 Fuse
K50 Radiator fan relay
M14 Radiator fan
M15 Radiator fan
M20 Fuel vapor valve
R51 Ignition coil
289
30 WIRING DIAGRAM
Y00418-01
290
WIRING DIAGRAM 30
Components:
B76 Front brake light switch
B77 Rear brake light switch
E60 License plate lamp
P15 Horn
P36 Brake/tail light
S27 Light switch
S32 Combination switch
291
30 WIRING DIAGRAM
Y00419-01
292
WIRING DIAGRAM 30
Components:
B32 Fuel level sensor
B35 Oil pressure sensor
K20 Turn signal relay
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
293
30 WIRING DIAGRAM
Y00420-01
294
WIRING DIAGRAM 30
Components:
F3 Fuse
K30 Power relay
X295 Diagnostics connector
X296 USB charging plug
295
30 WIRING DIAGRAM
Y00421-01
296
WIRING DIAGRAM 30
Components:
A30 ABS control unit
B21 Coolant temperature sensor
B38 Clutch switch
B70 Front wheel speed sensor
B71 Rear wheel speed sensor
B80 Throttle grip
F21 ABS fuse
F22 ABS fuse
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
lbu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
297
30 WIRING DIAGRAM
30.10 Page 1 of 9 (US)
Y00440-01
298
WIRING DIAGRAM 30
Components:
F2 Fuse
F8 Fuse
F9 Fuse
G10 12-V battery
K10 Starter relay with main fuse
M10 Electric starter system
R15 Transil unit
S11 Ignition and steering lock
S27 Light switch, emergency OFF switch, start button
299
30 WIRING DIAGRAM
30.11 Page 2 of 9 (US)
Y00441-01
300
WIRING DIAGRAM 30
Components:
F4 Fuse
F6 Fuse
F7 Fuse
F10 Fuse
K11 Start auxiliary relay
K40 Fuel pump relay
M13 Fuel pump
301
30 WIRING DIAGRAM
30.12 Page 3 of 9 (US)
Y00442-01
302
WIRING DIAGRAM 30
Components:
E75 Headlight unit
G20 Alternator
K14 Low beam relay
T20 Voltage regulator
X290 12-V socket
303
30 WIRING DIAGRAM
30.13 Page 4 of 9 (US)
Y00443-01
304
WIRING DIAGRAM 30
Components:
B41 Induction manifold pressure sensor
B44 Ambient air pressure sensor and intake air temperature sensor
B51 Lambda sensor
B86 Lean angle sensor
M51 Injection valve
M60 Throttle valve position sensor
305
30 WIRING DIAGRAM
30.14 Page 5 of 9 (US)
Y00444-01
306
WIRING DIAGRAM 30
Components:
B27 Shift shaft sensor
B30 Side stand sensor
B34 Gear position sensor
B37 Crankshaft speed sensor
F5 Fuse
K50 Radiator fan relay
M14 Radiator fan
M15 Radiator fan
M20 Fuel vapor valve
R51 Ignition coil
307
30 WIRING DIAGRAM
30.15 Page 6 of 9 (US)
Y00445-01
308
WIRING DIAGRAM 30
Components:
B76 Front brake light switch
B77 Rear brake light switch
E60 License plate lamp
P15 Horn
P36 Brake/tail light
S27 Light switch
309
30 WIRING DIAGRAM
30.16 Page 7 of 9 (US)
Y00446-01
310
WIRING DIAGRAM 30
Components:
B32 Fuel level sensor
B35 Oil pressure sensor
K20 Turn signal relay
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
311
30 WIRING DIAGRAM
30.17 Page 8 of 9 (US)
Y00447-01
312
WIRING DIAGRAM 30
Components:
F3 Fuse
K30 Power relay
X295 Diagnostics connector
X296 USB charging plug
313
30 WIRING DIAGRAM
30.18 Page 9 of 9 (US)
Y00448-01
314
WIRING DIAGRAM 30
Components:
A30 ABS control unit
B21 Coolant temperature sensor
B38 Clutch switch
B70 Front wheel speed sensor
B71 Rear wheel speed sensor
B80 Throttle grip
F21 ABS fuse
F22 ABS fuse
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
lbu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
315
31 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade
and unsuitable antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec-
tion and lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that
has the relevant properties.
Antifreeze protection to at least −25 °C (−13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs
to be diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.
MOTOREX®
– COOLANT M3.0
Engine oil (SAE 15W/50)

– JASO T903 MA2 ( p. 334)
– SAE ( p. 334) (SAE 15W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
Semi-synthetic engine oil
MOTOREX®
– Formula 4T
316
SUBSTANCES 31
Fork oil (SAE 4) (48601166S1)

– SAE ( p. 334) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Gasohol 95 E20 (RON 95)

– Gasohol 95 E20 (RON 95)
Guideline
– Only use super unleaded fuel that matches or is equivalent to the specifications.
– Super unleaded fuel with an ethanol content of 19 to 20% is permissible.
Info
Do not use fuel made of methanol (e. g. M15, M85, M100).
Do not use fuel with less than 19% ethanol (e. g. E10).
Do not use fuel with more than 20% ethanol (e. g. E30, E85, E100).
Super unleaded (ROZ 95/RON 95/PON 91)

– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15,
E25, E85, E100).
Super unleaded, type C (ROZ 95/RON 95/PON 91)

– ANP (Agência Nacional do Petróleo) #57 (ROZ 95/RON 95/PON 91)
Guideline
– Only use super unleaded fuel that matches or is equivalent to the following specifications.
– Super unleaded fuel with an ethanol content of 19 to 27 % is permissible.
Info
Do not use fuel made of methanol (e. g. M15, M85, M100).
Do not use fuel with less than 19 % ethanol (e. g. E10).
Do not use fuel with more than 27 % ethanol (e. g. E30, E85, E100). Krzysztof Szczypka, kristofsx@gmail.com,
317
32 AUXILIARY SUBSTANCES
Chain cleaner
MOTOREX®
– Chain Clean
Fuel additive
MOTOREX®
– Fuel Stabilizer
High viscosity grease

SKF®
– LGHB 2
Long-life grease
MOTOREX®
– Bike Grease 2000
Lubricant (T14034)
WP Performance Systems
– WP Racing Grease IPR 2
Lubricant (T159)
Bel‑Ray®
– MC‑11®
Motorcycle cleaner
MOTOREX®
– Moto Clean
Perfect finish and high gloss polish for paints

MOTOREX®
– Moto Shine
Preserving materials for paints, metal and rubber

MOTOREX®
– Moto Protect
318
AUXILIARY SUBSTANCES 32
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
MOTOREX®
– Quick Cleaner
Street chain spray

Guideline
MOTOREX®
– Chainlube Road Strong
Universal oil spray

MOTOREX®
– Joker 440 Synthetic
319
33 SPECIAL TOOLS
Bleeder cover
Art. no.: 00029013009
H00508-01
Bleeder cover
Art. no.: 00029013014
H00513-01
Bleeding device
Art. no.: 00029013100
H00518-01
EU battery charger XCharge‑professional

Art. no.: 00029095050
Feature
EU safety plug
Nominal voltage 230 V
Mains fuse 16 A
Power cable length 5 m (16 ft)
approx.
Charger cable length 5 m (16 ft)
H01065-01
approx.
320
SPECIAL TOOLS 33
US battery charger XCharge‑professional

Art. no.: 00029095051
Feature
US plug
Mains fuse 32 A
approx.
H01065-01
approx.
UK battery charger XCharge‑professional

Art. no.: 00029095052
Feature
UK safety plug
Mains fuse 16 A
approx.
H01065-01
approx.
CH battery charger XCharge‑professional

Art. no.: 00029095053
Feature
CH plug
Mains fuse 16 A
approx.
H01065-01
approx.
Groove nut wrench

Art. no.: 45229021000
Feature
Drive 1/2 in
Outside diameter 19 mm (0.75 in)
Length 45 mm (1.77 in)
H00530-01
321
33 SPECIAL TOOLS
Syringe
Art. no.: 50329050000
500689-01
Lock ring plier

Art. no.: 51012011000
H00572-01
Holding wrench
Art. no.: 51129003000
H00575-01
Valve spring mounter

Art. no.: 59029019000
H00610-01
322
SPECIAL TOOLS 33
Feeler gauge
Art. no.: 59029041100
Feature
5 piece 0.10 … 0.25 mm (0.0039 …
0.0098 in)
H00616-01
Plastigauge clearance gauge

Art. no.: 60029012000
Feature
0.025 … 0.175 mm (0.00098 … 0.00689 in)
H00627-01
Piston ring compressor

Art. no.: 60029015000
Feature
Height 80 mm (3.15 in)
Diameter 57 … 125 mm (2.24 … 4.92 in)
H00628-01
Chain rivet tool

Art. no.: 60029020000
H00631-01
323
33 SPECIAL TOOLS
Spring band clamps plier

Art. no.: 60029057100
H00651-01
Testing hose
Art. no.: 61029093000
H00659-01
Pressure testing tool

Art. no.: 61029094000
H00660-01
Retaining adapter
Art. no.: 61029955244
H00978-01
324
SPECIAL TOOLS 33
Engine work stand

Art. no.: 61229001000
H00662-01
Locking screw
Art. no.: 61229015000
H00670-01
Work stand
Art. no.: 62529055200
H02865-01
Multi-tooth wrench socket

Art. no.: 63529075000
Feature
Drive 1/2 in
H02641-01
325
33 SPECIAL TOOLS
Rear wheel work stand

Art. no.: 69329955000
H01139-01
Mounting pin
Art. no.: 69329965030
Feature
H01867-01
Front wheel work stand, large

Art. no.: 69329965100
500388-01
Floor jack attachment

Art. no.: 75029055000
H00722-01
326
SPECIAL TOOLS 33
Limit plug gauge

Art. no.: 77029026000
Feature
Diameter 5.05 mm (0.1988 in)
H00741-01
Insert for valve spring lever

Art. no.: 77029041200
H00746-01
Spark plug wrench with link

Art. no.: 77229172000
Feature
Drive 3/8 in
Hexagonal part 14 mm (0.55 in)
H00761-01
Insertion for piston ring lock

Art. no.: 77329030100
H00768-01
327
33 SPECIAL TOOLS
Holder and fitting for work stand

Art. no.: 90129002000
H00814-01
Protection cap
Art. no.: 90129005000
H00816-01
Pressing tool
Art. no.: 90129020000
H00821-01
Groove nut wrench

Art. no.: 90129022000
Feature
Drive 1/2 in
H00823-01
328
SPECIAL TOOLS 33
Puller
Art. no.: 90129048100
H00828-01
Groove nut wrench

Art. no.: 90129050100
Feature
Drive 1/2 in
H00830-01
Hook wrench
Art. no.: 90129051000
H00831-01
Pressing tool
Art. no.: 90129056000
H00832-01
329
33 SPECIAL TOOLS
Oil pressure adapter

Art. no.: 90129094000
H01909-01
Puller
Art. no.: 90229009000
H00835-01
Pressing tool
Art. no.: 93829043000
H02703-01
XC_1 NG DE
Art. no.: 00029196000DE
H01112-01
330
SPECIAL TOOLS 33
XC_1 NG EN
Art. no.: 00029196000EN
H01113-01
XC_1 NG ES
Art. no.: 00029196000ES
H01117-01
XC_1 NG FR
Art. no.: 00029196000FR
H01116-01
XC_1 NG IT
Art. no.: 00029196000IT
H01115-01
331
33 SPECIAL TOOLS
XC_1 NG JP
Art. no.: 00029196000JP
H01118-01
XC_1 NG US
Art. no.: 00029196000US
H01114-01
Hook wrench
Art. no.: T106S
Feature
Diameter 68 … 75 mm (2.68 … 2.95 in)
H00841-01
Spring compressor
Art. no.: T14050S
H00925-01
332
SPECIAL TOOLS 33
Ring wrench
Art. no.: T14091
Feature
Hexagonal part 45 mm (1.77 in)
H02442-01
Protecting sleeve
Art. no.: T512
Feature
H00865-01
Mounting tool
Art. no.: T528S
Feature
H00868-01
Clamping stand
Art. no.: T612S
Feature
H00870-01
333
34 STANDARDS
JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2
standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor-
cycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high
performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils
according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
334
GLOSSARY OF TECHNICAL TERMS 35
ABS Anti-lock braking system Safety system that prevents locking of the wheels
when driving straight ahead without the influence of
lateral forces
- KTM MY RIDE System for wireless communication with appropriate
cellphones and headsets for telephony and audio
OBD On-board diagnosis Vehicle system, which monitors the specified parame-
ters of the vehicle electronics
335
36 LIST OF ABBREVIATIONS
Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly
336
LIST OF SYMBOLS 37
37.1 Red symbols

Red symbols indicate an error condition that requires immediate intervention.
The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately,
taking care not to endanger yourself or other road users in the process, and switch off the
engine.
37.2 Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are
also represented by yellow or orange symbols.
Malfunction indicator lamp lights up yellow – The OBD has detected a malfunction in the
vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.
The ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS
warning lamp flashes if the ABS mode Super Moto is enabled.
TC indicator lamp lights up yellow – MTC is not enabled or is currently intervening. The TC
indicator lamp also lights up if a malfunction is detected. Contact an authorized KTM work-
shop. The TC indicator lamp flashes if MTC makes an active intervention.
The general warning lamp lights up yellow – A note/warning note on operating safety has been
detected. This is shown in addition.
37.3 Green and blue symbols

Green and blue symbols reflect information.
The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn
signal is switched on.
The idle indicator lamp lights up green – The transmission is in neutral.
The high beam indicator lamp lights up blue – The high beam is switched on.
337
INDEX
of rear brake, adding . . . . . . . . . . . . . . . . . 125

INDEX
1 of the front brake, changing . . . . . . . . . . . . 118

12-V battery of the rear brake, changing . . . . . . . . . . . . 126
charging . . . . . . . . . . . . . . . . . . . . . . . . . 107 Brake fluid level
installing . . . . . . . . . . . . . . . . . . . . . . . . . 105 front brake, checking . . . . . . . . . . . . . . . . 116
negative cable, connecting . . . . . . . . . . . . . 106 rear brake, checking . . . . . . . . . . . . . . . . . 124
negative cable, disconnecting . . . . . . . . . . . 106 Brake linings
removing . . . . . . . . . . . . . . . . . . . . . . . . . 105 front brake, checking . .. . . . . . . . . . . . . . 113
A of front brake, changing . . . . . . . . . . . . . . 113
of rear brake, changing .. . . . . . . . . . . . . . 120
ABS fuses
rear brake, checking . . .. . . . . . . . . . . . . . 120
changing . . . . . . . . . . . . . . . . . . . . . . . . . 111
C
ACC1
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Camshafts
ACC2 installing . . . . . . . . . . . . . . . . . . . . . . . . . 251
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 removing . . . . . . . . . . . . . . . . . . . . . . . . . 250
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Capacity
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Air filter
engine oil . . . . . . . . . . . . . . . . . . . . 156, 266
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 65
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Alternator
Chain
stator winding, checking . . . . . . . . . . . . . . 258
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Antifreeze cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 99
checking . . . . . . . . . . . . . . . . . . . . . . . . . 239 opening . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Assembling the engine riveting . . . . . . . . . . . . . . . . . . . . . . . . . . 101
balancer shaft, installing . . . . . .. . . . . . . . 200 Chain tension
chain securing guide, installing .. . . . . . . . 224 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 97
clutch cover, installing . . . . . . .. . . . . . . . 221 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 96
crankshaft, installing . . . . . . . . .. . . . . . . . 200
Charging voltage
locking lever, installing . . . . . . .. . . . . . . . 204
checking . . . . . . . . . . . . . . . . . . . . . . . . . 108
oil screen, installing . . . . . . . . .. . . . . . . . 224
shift drum, installing . . . . . . . . .. . . . . . . . 201 Checking the valve clearance, changing the spark
plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
shift forks, installing . . . . . . . . .. . . . . . . . 201
shift rails, installing . . . . . . . . .. . . . . . . . 202 Clutch
shift shaft, installing . . . . . . . . .. . . . . . . . 205 checking . . . . . . . . . . . . . . . . . . . . . . . . . 226
spark plug, installing . . . . . . . . .. . . . . . . . 222 Clutch lever play
starter motor, installing . . . . . . .. . . . . . . . 215 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 35
suction pump, installing . . . . . .. . . . . . . . 210 Combination instrument . . . . . . . . . . . . . . 129-146
timing chain tensioner, installing . . . . . . . . 219 ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
transmission shafts, installing . .. . . . . . . . 201 activation and test . . . . . . . . . . . . . . . . . . 129
valve clearance, adjusting . . . . .. . . . . . . . 220 Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
water pump cover, installing . . .. . . . . . . . 214 Bluetooth (optional) . . . . . . . . . . . . . . . . . . 143
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . 9 coolant temperature indicator . . . . . . . . . . . 133
B day-night mode . . . . . . . . . . . . . . . . . . . . 129
display . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Brake disc
Distance . . . . . . . . . . . . . . . . . . . . . . . . . 144
of front brake, changing . . . . . . . . . . . . . . . 85
Extra Functions . . . . . . . . . . . . . . . . . . . . . 146
of the rear brake, changing . . . . . . . . . . . . . 91
Favourites . . . . . . . . . . . . . . . . . . . . . . . . 142
Brake discs Favourites display . . . . . . . . . . . . . . . . . . . 134
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 83 fuel level display . . . . . . . . . . . . . . . . . . . 134
Brake fluid Fuel Cons . . . . . . . . . . . . . . . . . . . . . . . . . 145
of front brake, adding . . . . . . . . . . . . . . . . 116 General Info . . . . . . . . . . . . . . . . . . . . . . . 140
338
INDEX
Headset . . . . . . . . . . . . . . . . . . . . . . . . . . 138 E
indicator lamps . . . . . . . . . . . . . . . . . . . . 130
Engine
KTM MY RIDE . . . . . . . . . . . . . . . . . . . . . . 135
assembling . . . . . . . . . . . . . . . . . . . . . . . 200
Language . . . . . . . . . . . . . . . . . . . . . . . . . 145
disassembling . . . . . . . . . . . . . . . . . . . . . 157
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
installing . . . . . . . . . . . . . . . . . . . . . . . . . 152
Motorcycle . . . . . . . . . . . . . . . . . . . . . . . . 136
removing . . . . . . . . . . . . . . . . . . . . . . . . . 148
ODO display . . . . . . . . . . . . . . . . . . . . . . . 133
working on individual parts . . . . . . . . . . . . 176
overview . . . . . . . . . . . . . . . . . . . . . . . . . 129
Pairing . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Engine - Work on individual parts
Phone . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 balancer shaft bearing, changing . . . . . . . . 183
Quick Selector 1 . . . . . . . . . . . . . . . . . . . . 142 cylinder head, checking . . . . . . . . . . . . . . . 184
Quick Selector 1 display . . . . . . . . . . . . . . . 135 oil pump, checking . . . . . . . . . . . . . . . . . . 188
Quick Selector 2 . . . . . . . . . . . . . . . . . . . . 142 piston ring end gap, checking . . . . . . . . . . . 186
Quick Selector 2 display . . . . . . . . . . . . . . . 135 piston/cylinder mounting clearance, checking 188
Service . . . . . . . . . . . . . . . . . . . . . . . . . . 145 shift shaft, preassembling . . . . . . . . . . . . . 191
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 136 stator, changing . . . . . . . . . . . . . . . . . . . . 198
shift warning light . . . . . . . . . . . . . . . . . . . 132 transmission, checking . . . . . . . . . . . . . . . 193
speed . . . . . . . . . . . . . . . . . . . . . . . . 132-133 Engine – working on the individual parts
telephony . . . . . . . . . . . . . . . . . . . . . . . . 140 camshafts, checking the pivot points . . . . . . 185
Temperature . . . . . . . . . . . . . . . . . . . . . . . 145 checking the electric starter drive . . . . . . . . 199
time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 clutch, checking . . . . . . . . . . . . . . . . . . . . 189
Trip 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 conrod bearing . . . . . . . . . . . . . . . . . . . . . 180
Trip 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 countershaft, assembling . . . . . . . . . . . . . . 195
Trips/Data . . . . . . . . . . . . . . . . . . . . . . . . 136 countershaft, disassembling . . . . . . . . . . . . 193
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 141 cylinder head . . . . . . . . . . . . . . . . . . . . . . 183
warnings . . . . . . . . . . . . . . . . . . . . . . . . . 130 cylinder, checking/measuring . . . . . . . . . . . 186
Coolant freewheel, checking . . . . . . . . . . . . . . . . . 200
changing . . . . . . . . . . . . . . . . . . . . . . . . . 241 main shaft, assembling . . . . . . . . . . . . . . . 195
draining . . . . . . . . . . . . . . . . . . . . . . . . . 237 main shaft, disassembling . . . . . . . . . . . . . 192
oil pressure control valve, checking . . . . . . . 189
Coolant level
piston, checking . . . . . . . . . . . . . . . . . . . . 187
checking . . . . . . . . . . . . . . . . . . . . . . 239-240
piston, measuring . . . . . . . . . . . . . . . . . . . 187
Cooling system radial clearance of lower conrod bearing,
filling/bleeding . . . . . . . . . . . . . . . . . . . . . 237 checking . . . . . . . . . . . . . . . . . . . . . . . . . 179
D radial shaft seal ring of water pump, changing 179
Diagnostics connector . . . . . . . . . . . . . . . . . . . 268 section of the engine case, left . . . . . . . . . . 176
section of the engine case, right . . . . . . . . . 178
Disassembling the engine
shift mechanism, checking . . . . . . . . . . . . 190
alternator cover, removing . . . . .. . . . . . . . 165
timing assembly, checking . . . . . . . . . . . . . 197
balancer shaft, removing . . . . . .. . . . . . . . 176
chain securing guide, removing .. . . . . . . . 158 Engine assembly
crankshaft, removing . . . . . . . . .. . . . . . . . 176 alternator cover, installing . . . . . . . . . . . . . 214
engine oil, draining . . . . . . . . . .. . . . . . . . 157 camshafts, installing . . . . . . . . . . . . . . . . . 218
locking lever, removing . . . . . . .. . . . . . . . 173 clutch basket, installing . . . . . . . . . . . . . . 208
shift drum locating, removing . . .. . . . . . . . 172 cylinder head, installing . . . . . . . . . . . . . . 217
shift rails, removing . . . . . . . . .. . . . . . . . 175 drive gear wheel of the balancer shaft,
spark plug, removing . . . . . . . . .. . . . . . . . 159 installing . . . . . . . . . . . . . . . . . . . . . . . . . 212
starter motor, removing . . . . . . .. . . . . . . . 164 engine, removing from the engine work stand 225
suction pump, removing . . . . . .. . . . . . . . 168 gear position sensor, installing . . . . . . . . . . 211
timing chain tensioner, removing . . . . . . . . 161 left engine case, installing . . . . . . . . . . . . . 202
transmission shafts, removing . .. . . . . . . . 176 oil filter, installing . . . . . . . . . . . . . . . . . . 204
water pump wheel, removing . . .. . . . . . . . 165 oil pump, installing . . . . . . . . . . . . . . . . . . 205
piston, installing . . . . . . . . . . . . . . . . . . . 215
Drivetrain kit
primary gear wheel, installing . . . . . . . . . . . 207
changing . . . . . . . . . . . . . . . . . . . . . . . . . 102
339
INDEX
rotor, installing . . . . . . . . . . . . . .. . . . . . . 213 Foot brake lever

shift drum locating unit, installing . . . . . . . 205 free travel, adjusting . . . . . . . . . . . . . . . . . 123
shift shaft sensor, installing . . . . .. . . . . . . 222 free travel, checking . . . . . . . . . . . . . . . . . 123
spacer, installing . . . . . . . . . . . .. . . . . . . 210 Footrest bracket
starter drive, installing . . . . . . . .. . . . . . . 213 changing . . . . . . . . . . . . . . . . . . . . . . . . . . 41
timing chain, installing . . . . . . . .. . . . . . . 215
Fork legs
valve clearance, checking . . . . . .. . . . . . . 219
assembling . . . . . . . . . . . . . . . . . . . . . . . . 23
valve cover, installing . . . . . . . . .. . . . . . . 223
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine disassembly disassembling . . . . . . . . . . . . . . . . . . . . . . 20
camshaft, removing . . . . . . . . . . . . . . . . . 162 dust boots, cleaning . . . . . . . . . . . . . . . . . . 17
clutch basket, removing . . . . . . . . . . . . . . . 169 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 18
clutch cover, removing . . . . . . . . . . . . . . . 159 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 17
cylinder head, removing . . . . . . . . . . . . . . . 162
Frame
drive gear wheel of the balancer shaft,
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 45
removing . . . . . . . . . . . . . . . . . . . . . . . . . 167
engine, positioning at ignition top dead center 160 Front fender
force pump, removing . . . . . . . . . . . . . . . . 171 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 75
gear position sensor, removing . . . . . . . . . . 167 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 75
left engine case, removing . . . . . . . . . . . . . 173 Front rider’s seat
oil filter, removing . . . . . . . . . . . . . . . . . . 173 mounting . . . . . . . . . . . . . . . . . . . . . . . . . 68
piston, removing . . . . . . . . . . . . . . . . . . . . 163 Front rider's seat
preparations . . . . . . . . . . . . . . . . . . . . . . 157 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 68
primary gear wheel, removing . . . . . . . . . . . 170
Front wheel
rotor, removing . . . . . . . . . . . . . . . . . . . . . 166
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 84
shift drum, removing . . . . . . . . . . . . . . . . . 175
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 84
shift forks, removing . . . . . . . . . . . . . . . . . 175
shift shaft sensor, removing . . . . . . . . . . . . 159 Fuel filter
shift shaft, removing . . . . . . . . . . . . . . . . . 172 changing . . . . . . . . . . . . . . . . . . . . . . . . . . 78
starter drive, removing . . . . . . . . . . . . . . . . 166 Fuel pressure
timing chain, removing . . . . . . . . . . . . . . . 164 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 76
valve cover, removing . . . . . . . . . . . . . . . . 158 Fuel pump
Engine guard changing . . . . . . . . . . . . . . . . . . . . . . . . . . 79
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Fuel tank
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 74 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Engine guard retaining bracket removing . . . . . . . . . . . . . . . . . . . . . . . . . . 71
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Fuel tank cover
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 80 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 11 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Engine oil Fuel tank filler cap
adding . . . . . . . . . . . . . . . . . . . . . . . . . . 257 closing . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
changing . . . . . . . . . . . . . . . . . . . . . . . . . 255 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine oil level Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
checking . . . . . . . . . . . . . . . . . . . . . . . . . 253 Fuse
Engine sprocket of individual power consumers, changing . . . 109
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 97
G
Exhaust system
Gear position sensor
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 62
programming . . . . . . . . . . . . . . . . . . . . . . 234
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 61
H
F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Headlight
range, adjusting . . . . . . . . . . . . . . . . . . . . 147
340
INDEX
Headlight setting P
checking . . . . . . . . . . . . . . . . . . . . . . . . . 147
Passenger seat
Heim joint mounting . . . . . . . . . . . . . . . . . . . . . . . . . 69
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 47 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 68
I Play in the clutch lever
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . . 9 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 130 Preparing for use
Initialization run after storage . . . . . . . . . . . . . . . . . . . . . . 276
performing . . . . . . . . . . . . . . . . . . . . . . . . 262 R
K Rear hub damping rubber pieces
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 checking . . . . . . . . . . . . . . . . . . . . . . . . . 100
L Rear sprocket
Link fork checking . . . . . . . . . . . . . . . . . . . . . . . . . . 97
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 54 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 89
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 52 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Link fork bearing S
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Service interval display
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 57
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 146
Lower triple clamp
Service schedule . . . . . . . . . . . . . . . . . . . 277-279
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 29
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Shift lever
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 233
M
Shift shaft sensor
Main silencer changing . . . . . . . . . . . . . . . . . . . . . . . . . 234
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 64 programming . . . . . . . . . . . . . . . . . . . . . . 234
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Shock absorber
Manufacturer warranty . . . . . . . . . . . . . . . . . . . . . 9 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motorcycle removing . . . . . . . . . . . . . . . . . . . . . . . . . . 47
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 273 spring preload, adjusting . . . . . . . . . . . . . . . 46
lifting with front lifting gear . . . . . . . . . . . . . 12 spring, installing . . . . . . . . . . . . . . . . . . . . 50
rear lifting gear, raising with . . . . . . . . . . . . . 12 spring, removing . . . . . . . . . . . . . . . . . . . . . 50
removing the rear from the lifting gear . . . . . . 12 static sag, checking . . . . . . . . . . . . . . . . . . 46
taking off front lifting gear . . . . . . . . . . . . . . 13 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
work stand, raising with . . . . . . . . . . . . . . . . 13
Spark plug
work stand, removing from . . . . . . . . . . . . . . 14
changing . . . . . . . . . . . . . . . . . . . . . . . . . 260
O Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 to make checks . . . . . . . . . . . . . . . . . . . . . 16
Oil filter Steering head bearing
changing . . . . . . . . . . . . . . . . . . . . . . . . . 255 changing . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil pressure Steering head bearing play
checking . . . . . . . . . . . . . . . . . . . . . . . . . 253 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil screens checking . . . . . . . . . . . . . . . . . . . . . . . . . . 31
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 255 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Open-circuit current T
checking . . . . . . . . . . . . . . . . . . . . . . . . . 109
Technical data
capacity – coolant . . . . . . . . . . . . . . . . . . . 266
capacity – engine oil . . . . . . . . . . . . . . . . . 266
341
INDEX
capacity – fuel . . . . . . . . . . . . . . . . . . . . . 266

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 267
chassis tightening torques . . . . . . . . . . . . . 269
electrical system . . . . . . . . . . . . . . . . . . . 267
engine . . . . . . . . . . . . . . . . . . . . . . . . . . 263
engine – tolerance, wear limits . . . . . . . . . . 264
engine tightening torques . . . . . . . . . . . . . 264
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
shock absorber . . . . . . . . . . . . . . . . . . . . . 269
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Throttle grip
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Time
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 143
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
V
Valve clearance
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 250
checking . . . . . . . . . . . . . . . . . . . . . . . . . 243
Vehicle identification number . . . . . . . . . . . . . . . 10
W
Wheel bearing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 88
of the front wheel, changing . . . . . . . . . . . . . 86
of the rear wheel, changing . . . . . . . . . . . . . 92
Winter operation
checks and maintenance steps . . . . . . . . . . 274
Wiring diagram ................... 280-315
Page 1 of 9 ................... 280, 298
Page 2 of 9 ................... 282, 300
Page 3 of 9 ................... 284, 302
Page 4 of 9 ................... 286, 304
Page 5 of 9 ................... 288, 306
Page 6 of 9 ................... 290, 308
Page 7 of 9 ................... 292, 310
Page 8 of 9 ................... 294, 312
Page 9 of 9 ................... 296, 314
Work rules ............................ 8
342

2020 KTM 390 Adventure Repair Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2020 KTM 390 Adventure Repair Manual

Uploaded by

Copyright:

Available Formats

Krzysztof Szczypka, kristofsx@gmail.

This document is valid for the following models:

390 Adventure AR (F5342T5, F5342T6)

1 MEANS OF REPRESENTATION ...................... 7

29.2 Required work ............................... 277

1.1 Symbols used

Indicates an unexpected reaction (e.g. of a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

Name® Indicates a protected name.

Brand™ Indicates a brand available on the open market.

2.1 Repair Manual

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Work rules

3.1 Manufacturer warranty, implied warranty

3.2 Fuel, auxiliary substances

3.3 Spare parts, accessories

Krzysztof Szczypka, kristofsx@gmail.com,

4.1 Vehicle identification number

4.2 Type label

4.3 Key number

4.4 Engine number

Krzysztof Szczypka, kristofsx@gmail.com,

5.1 Raising the motorcycle with rear lifting gear

– Mount the supports of the lifting gear.

– Secure the motorcycle against falling over.

5.3 Lifting the motorcycle with the front lifting gear

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

402345-01 – Lift the motorcycle at the front.

5.4 Taking the motorcycle off the front lifting gear

– Mount protection cap 1.

5.5 Raising the motorcycle with work stand

5.6 Removing the motorcycle from the work stand

– Secure the motorcycle against falling over.

– Mount and tighten screws 1.

– Position the side cover.

– Unlock the steering.

The green idle indicator lamp N lights up.

5.8 Starting the motorcycle to make checks

– Turn the emergency OFF switch to the position .

6.1 Cleaning the dust boots of the fork legs

6.2 Removing the fork legs

– Loosen screw 3 by several rotations.

6.3 Installing the fork legs

– Check the wheel bearing for damage and wear.

G04686-10 – Insert the spacers.

– Clean the thread of the wheel spindle and screw 4.

– Position the brake caliper with the spacers.

– Mount screws 5, but do not tighten yet.

– Remove the locking piece of the hand brake lever.

– Position the wheel speed sensor in the hole.

– Remove the load from the rear of the vehicle.

6.4 Disassembling the fork legs

– Unclamp the fork leg.

– Unclamp the fork leg with the axle clamp.

– Remove the cartridge.

– Remove dust boot 6.