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KTM 2013 690 SMC R EU, Repair Manual

The KTM 2013 690 SMC R EU is an exceptional off-road motorcycle, built to deliver an exhilarating riding experience. To ensure its longevity, you can rely on the comprehensive Repair Manual available for free download at manualshive.com. This manual offers precise instructions, empowering you to maintain and optimize your KTM to perfection.

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13

WIRING HARNESS, BATTERY

79

13.1

Removing the battery

Warning

Risk of injury

 

Battery acid and battery gases cause serious chemical burns.

–

Keep batteries out of the reach of children.

–

Wear suitable protective clothing and goggles.

–

Avoid contact with battery acid and battery gases.

–

Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

–

In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.

Preparatory work

–

Switch off all power consumers and switch off the engine.

–

Remove the seat. (

p. 59)

601907-10

Main work

–

Disconnect the negative (minus) cable of the battery.

–

Pull plug

1

off upward.

–

Remove screws

2

.

–

Pull the retaining bracket

3

of the battery forward and remove it.

–

Take off the positive pole cover

4

.

–

Disconnect the positive (plus) cable of the battery.

–

Push the wiring harness to the side and pull the battery out of the battery holder.

Info

Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle is therefore no longer roadworthy.

13.2

Installing the battery

601907-11

Main work

–

Slide the battery into the battery holder.

Info

The battery terminals must be at the rear.

–

Attach the positive cable and mount positive terminal cover

1

.

–

Position retaining bracket

2

.

–

Mount and tighten screws

3

.

Guideline

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

–

Plug in connector

4

.

–

Attach the minus cable .

Finishing work

–

Mount the seat. (

p. 60)

–

Set the clock. (

p. 95)

13.3

Disconnecting the battery

Preparatory work

–

Switch off all power consumers and switch off the engine.

–

Remove the seat. (

p. 59)

Summary of Contents for 2013 690 SMC R EU

Page 1: ...REPAIR MANUAL 2013 690 SMC R EU 690 SMC R AUS UK Art no 3206153en ...

Page 2: ......

Page 3: ... modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The ...

Page 4: ...low speed compression damping of the shock absorber 32 8 3 Adjusting the rebound damping of the shock absorber 33 8 4 Measuring the unloaded rear wheel sag 33 8 5 Checking the static sag of the shock absorber 33 8 6 Checking the riding sag of the shock absorber 34 8 7 Adjusting the spring preload of the shock absorber 34 8 8 Adjusting the riding sag 35 8 9 Removing the shock absorber 35 8 10 Insta...

Page 5: ...ing thermostat 109 16 3 10 Setting engine to ignition top dead center 109 16 3 11 Removing water pump wheel 110 16 3 12 Removing clutch cover 110 16 3 13 Removing spacer and spring 110 16 3 14 Removing spark plug 111 16 3 15 Removing timing chain tensioner 111 16 3 16 Removing camshafts 111 16 3 17 Removing cylinder head 111 16 3 18 Removing piston 112 16 3 19 Removing rotor 112 16 3 20 Removing t...

Page 6: ...g the starter motor 159 16 5 34 Installing valve cover 160 16 5 35 Removing the engine from the engine assembly stand 160 17 CLUTCH 161 17 1 Checking rectifying the fluid level of the hydraulic clutch 161 17 2 Changing the hydraulic clutch fluid 161 18 WATER PUMP COOLING SYSTEM 162 18 1 Draining the coolant 162 18 2 Filling bleeding the cooling system 162 18 3 Checking the antifreeze and coolant l...

Page 7: ...page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Identifies a proprietary name Name Identifies a prot...

Page 8: ... 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 Warning Identifies a danger that will...

Page 9: ...anger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 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 current KTM Power...

Page 10: ...f the frame 4 3 Engine number 601860 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 4 4 Key number 100179 10 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 4 5 Fork part number 601861 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 11: ...4 SERIAL NUMBERS 9 4 6 Shock absorber part number 601862 10 The shock absorber part number 1 is on the left of the shock absorber ...

Page 12: ... vehicle may roll away or fall over Always place the vehicle on a firm and even surface 601873 11 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand 5 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work R...

Page 13: ...ycle upright on a level surface Raise the motorcycle in the area of the footrest bracket Secure the motorcycle against falling over 5 6 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 601873 11 Remove the motorcycle from the lift stand and rest it on its side stand Remove the lift st...

Page 14: ...Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic compon...

Page 15: ...ng again This motorcycle is equipped with a safety starting system 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 Take the weight off the side stand and swing it back up with your foot as far as it will go 5 10 Starting the m...

Page 16: ... the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 601877 10 Turn adjusting screws 1 clockwise all the way Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 20 clicks ...

Page 17: ...d oil the dust boots and inside fork tube of both fork legs Universal oil spray p 209 Push the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 15 Remove the motorcycle from the lift stand p 11 6 5 Removing the fork protector S00054 12 Remove screws 1 and take off clamp Remove screws 2 on left fork leg Remove the fork protector Remove the scr...

Page 18: ...sen screws 3 and 4 Unscrew screw 3 about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw 3 Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 201376 10...

Page 19: ...iple clamp The upper fork projection must be the same on both sides Tighten screws 1 on both sides Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 201378 11 Position the fork protection Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 201377 11 Position the wheel speed sensor Mount and tighten screws 3 Guideline S...

Page 20: ...Mount screws 6 spacers 7 but do not tighten Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Fix the hand brake lever in the activated position The brake caliper straightens Fully tighten screw 6 Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Remove the fixation of the hand brake lever Unload the rear of...

Page 21: ...oth fork legs Condition The fork legs have been removed 200660 01 Establish and note the current state of the rebound damping 1 and compression damping 2 Completely open the adjusters of the rebound and compression damping 200643 10 Clamp the fork leg in the area of the lower triple clamp Clamping stand T1403S p 221 200644 12 Loosen screw cover 3 Info The screw cover cannot be removed yet ...

Page 22: ...en end wrench T14032 p 221 Info The preload spacers 4 should be above the special tool 200647 12 Clamp the special tool in the vise Loosen screw cover 3 200648 12 Remove screw cover 3 with preload spacers 4 Remove adjusting tube 5 200649 01 Pull the spring downward Remove the special tool Remove the spring 200650 01 Drain the fork oil Info Pull out and push in the piston rod a few times to empty t...

Page 23: ... and remove it with the sealing ring Info Place a container underneath to catch any oil that may run out 200653 01 Remove the cartridge 200654 12 Remove valve 8 of the rebound damping with the spring from the cartridge 200655 12 Remove dust boot 9 200656 12 Remove lock ring bk Info The lock ring has a beveled end where a screwdriver can be applied ...

Page 24: ...apart by hand 200659 12 Take off the lower sliding bushing bl Take off support ring bn Take off seal ring bo Take off lock ring bk Take off dust boot 9 6 11 Checking the fork legs Condition The fork legs have been disassembled 200686 10 Check the inner tube and the axle clamp for damage If damage is found Replace the inner tube 200684 10 Measure the external diameter of the inner tube in several p...

Page 25: ...ith preload spacer s 462 mm 18 19 in If the measured value is greater than the specified value Reduce the strength of the pretensioning bushes If the measured value is less than the specified value Increase the strength of the preload spacers 6 12 Assembling the fork legs Info These operations are the same on both fork legs Preparatory work Check the fork legs p 22 200669 10 Main work Clamp the in...

Page 26: ...ithout using a tool carefully pull the stack apart by hand 200672 10 Heat up the outer tube in area A of the lower sliding bushings Guideline 50 C 122 F Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer side of the special tool Assembly tool T1402S p 221 Push the sliding bushing all the way into the outer tube 200673 10 Position the support ring Hold the seal ...

Page 27: ...ainst the resistance of the spring Screw on fluid barrier B as far as it will go Info The fluid barrier must be tightened as much as possible Do not use tools 200675 10 Install the special tool on the cartridge Gripping tool T14026S1 p 221 Info The special tool must be used to prevent the adjusting tube from being lifted and thus to prevent oil from reaching the piston rod 200683 10 Push the cartr...

Page 28: ...d wrench T14032 p 221 Remove the special tool Gripping tool T14026S1 p 221 200680 10 Clamp the special tool in the vise Grease the thread of the piston rod Lubricant T159 p 209 Grease the upper edge of the piston rod Lubricant T158 p 208 Screw the screw cover with the preload spacers on to the piston rod Info The screw cover must be screwed to the stop before the piston rod starts to turn If the t...

Page 29: ...ri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the suspension compo nents can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Turn the adjusting screws to the position they were i...

Page 30: ...the motorcycle from the work stand p 12 6 14 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with the work stand p 11 Push down the rear of vehicle tighten it down in this position and secure the motorcycle against falling over The front wheel is no longer in contact with the ground and the fork legs are no longer under tension S00060 10 Main work Loosen screws 1 Rem...

Page 31: ...Take off the handlebar and set it aside Info Cover the motorcycle and attachments to protect them from damage Do not kink the cables and lines Remove the two screws 2 Take off the handlebar holder Move the handlebar holder to the desired position Mount and tighten the two screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the handlebar holders evenly on the ...

Page 32: ...throttle cable p 30 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering...

Page 33: ...7 HANDLEBAR CONTROLS 31 Tighten counter nut 1 ...

Page 34: ...payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 8 2 Adjusting the low speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info The low speed setting takes effect during the slow to norm...

Page 35: ...ar wheel sag Preparatory work Raise the motorcycle with a lift stand p 11 0 0 A A 400988 10 Main work Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Note down the value as dimension A Finishing work Remove the motorcycle from the lift stand p 11 8 5 Checking the static sag of the shock absorber 0 0 A A 0 0 B B 400989 10 Mea...

Page 36: ... parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the work stand p 11 Remove the seat p 59 Take off the side cover p 60 Remove the shock absorber p 35 After removing the sho...

Page 37: ...7 lb in Hard 85 N mm 485 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber p 36 Mount the side cover p 60 Mount the seat p 60 Remove the motorcycle from the work stand p 12 Check the static sag of the shock absorber p 33 Adjust the rebound damping of the shock absorber p 33 8 9 Removing the shock absorber Preparatory work Raise the motorcycl...

Page 38: ...s 5 S00066 10 Loosen screw 6 Remove screw 7 Remove screw 6 S00067 10 Fold the rear upward Take out shock absorber 8 toward the top 8 10 Installing the shock absorber S00067 11 Main work Fold the rear upward and maneuver in shock absorber 1 from above Fold the rear down and position the shock absorber ...

Page 39: ...00065 11 Mount and tighten screws 4 Guideline Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 S00064 11 Lift the rear fairing Mount and tighten screws 5 Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft S00063 11 Mount and tighten screws 6 Guideline Screw side cover M6 5 Nm 3 7 lbf ft S00062 11 Position grab handle 7 Mount and tighten screws 8 Guideline Screw handrail ...

Page 40: ...40 Check the damper p 41 Remove the heim joint p 42 Install the heim joint p 43 Assemble the piston rod p 44 Assemble the damper p 45 Install the spring p 50 8 12 Removing the spring Condition The shock absorber has been removed 201271 10 Clamp the shock absorber in the vise using soft jaws for protection Measure and note spring length in preloaded state Loosen retaining ring 1 and the adjusting r...

Page 41: ...pen the adjusters of the rebound and compression damping Remove rubber cap 1 of the reservoir Open screw 2 slowly The pressurized nitrogen escapes 201274 10 Clamp the damper in the vise using soft jaws Remove locking cap 3 201276 10 Press in seal ring retainer 4 Remove lock ring 5 Info Do not scratch the inner surface 201277 10 Remove screw 6 Drain the oil 201278 10 Remove the piston rod Drain the...

Page 42: ...9 300540 10 Main work Clamp the piston rod with the heim joint in a vise Remove nut 1 300541 10 Remove supporting plate 2 and rebound shim stack 3 together with piston 4 Info Thread the rebound shim set on a screwdriver and set the parts down together 200572 11 Remove compression shim stack 6 with supporting plate 5 Info Thread the compression shim stack on a screwdriver and set the parts down tog...

Page 43: ...is greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge 300554 10 Measure the diameter of the piston rod Piston rod Diameter 17 95 mm 0 7067 in If the specification is not reached Change the piston rod Measure the run out of the piston rod Piston rod Run out 0 03 mm 0 0012 in If the measur...

Page 44: ... Condition The shock absorber has been removed 200577 10 Clamp the shock absorber in the vise using soft jaws for protection Remove collar bushing 1 of the heim joint Pin T120 p 220 Turn over the shock absorber and remove collar bushing 2 of the heim joint Pin T120 p 220 200578 10 Remove seal rings 3 on both sides 200579 10 Remove lock rings 4 on both sides ...

Page 45: ...ng the heim joint 200581 10 Place special tool 1 underneath and press in the heim joint as far as the center using special tool 2 Pressing tool T1206 p 220 Pressing tool T129 p 220 200579 11 Mount lock rings 3 on both sides 200578 11 Mount seal rings 4 on both sides and grease them Lubricant T158 p 208 200582 10 Press in both collar sleeves 5 of the heim joint ...

Page 46: ...ing and push seal ring retainer 4 on to the piston rod Lubricant T625 p 209 Remove the special tool 200572 11 Mount supporting plate 5 with the rounded side facing downward Mount the compression shim stack 6 with the smaller shims facing downward 201270 10 Sand both sides of the piston on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View A Piston from ab...

Page 47: ...9 11 Main work Push the spring and sleeve onto the compression adjuster Mount the piston Mount and tighten compression adjuster 1 Guideline Compression adjuster M26x1 30 Nm 22 1 lbf ft 201277 11 Mount and tighten screw 2 Guideline Filling port screw M10x1 14 Nm 10 3 lbf ft 201288 10 Clamp the damper in the vise using soft jaws Fill the damper cartridge about half full Shock absorber oil SAE 2 5 50...

Page 48: ... screw 7 clockwise with a screwdriver up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Turn adjusting screw 8 all the way clockwise using a socket wrench Turn back counterclockwise the number of turns c...

Page 49: ...Info Before working with the vacuum pump be sure to read the operating instructions carefully Completely open the adjusters of the rebound and compression damping 201286 10 Remove the screw of the filling port Install adapter 1 on the damper Info Tighten only hand tight without the use of tools Connect the adapter 1 to connector 2 of the vacuum pump Vacuum pump T1240S p 220 Clamp the damper with s...

Page 50: ...Damper control lever 4 to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge rises to the specified value 3 bar 200269 10 When the pressure gauge reaches the specified value turn the Damper 4 control lever to Vacuum Guideline 3 bar The pressure gauge falls to the specified value 0 bar 200270 10 When the pressure gauge reaches the specified value turn the Oil reservoir 5 con ...

Page 51: ...he special tool by the specified value distance A minus specified value Guideline 10 mm Depth micrometer T107S p 219 Slide the floating piston into the reservoir to the shortened position using the spe cial tool Info The floating piston must be positioned at exactly this point when the rod is fully extended otherwise damage will occur during compression of the shock absorber Remove the special too...

Page 52: ... handle A Close spigot B and take the damper out of the special tool Tighten the filling port screw Guideline Screw reservoir filling port M5 3 Nm 2 2 lbf ft Mount the rubber cap of the reservoir 8 22 Installing the spring 201272 11 Clamp the damper in the vise using soft jaws Install retaining ring 1 and turn it down as far as possible The collar points to the adjusting ring Mount adjusting ring ...

Page 53: ...uspension compo nents can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Tension the spring to the amount measured during dismantling by turning adjusting ring 2 Hook wrench T106S p 219 Tighten lock nut 1 and the adju...

Page 54: ... binders 1 Push the cable to the right Unplug connector 2 of the lambda sensor Feed out the cable of the lambda sensor S00061 10 Remove screws 3 Remove the heat shield S00069 10 Remove nuts 4 of the manifold Info Do not misplace the spacer S00070 11 Loosen screw 5 Take off the manifold 9 2 Installing the manifold S00069 11 Main work Position the manifold with the seals Position the spacer Mount an...

Page 55: ...and tighten screws 5 Guideline Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Loctite 243 Finishing work Mount the side cover p 60 Mount the seat p 60 9 3 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Preparatory work Raise the motorcycle with the work stand p 11 Remove ...

Page 56: ...S00073 11 Remove screws 6 Remove the main silencer 9 4 Installing the main silencer S00073 10 Main work Position the main silencer Mount and tighten screws 1 Guideline Screw main silencer holder M8 25 Nm 18 4 lbf ft S00071 10 Position the screw clamp Tighten screw 2 Guideline Screw main silencer clamp M8 12 Nm 8 9 lbf ft Copper paste ...

Page 57: ... shield M5 8 Nm 5 9 lbf ft Loctite 243 S00072 11 Mount and tighten screws 4 Guideline Rear fairing screw M6 5 Nm 3 7 lbf ft S00062 13 Position grab handle 5 Mount and tighten screws 6 Guideline Screw handrail M8 20 Nm 14 8 lbf ft Finishing work Mount the seat p 60 Remove the motorcycle from the work stand p 12 ...

Page 58: ...r 3 10 2 Installing the air filter 601881 10 Main work Clean the air filter box Mount air filter 1 Info The air filter must lie flush against the air filter box along the entire sealing surface A If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Hook air filter box top 2 into the front of the air filter box and swing down 601882 11 Mount and tighten scr...

Page 59: ...ox at the rear Loosen the spring loaded band type clamp with the special tool and detach bleed hose 6 Pliers for spring band clamp 60029057100 p 213 Detach connector 7 of the intake air temperature sensor Take off the air filter box 10 4 Installing the air filter box S00078 11 Main work Attach connector 1 of the intake air temperature sensor Mount bleed hose 2 Mount the spring loaded band type cla...

Page 60: ...s chassis M6 10 Nm 7 4 lbf ft S00075 11 Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S00074 11 Position the voltage regulator Mount and tighten screws 6 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Route and mount vent hose 7 without kinking Finishing work Mount the side cover p 60 Mount the seat p 60 ...

Page 61: ...mediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage syst...

Page 62: ...side Finishing work Mount the seat p 60 11 7 Checking the fuel pressure Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow...

Page 63: ... fuel pump is active 3 3 3 7 bar 48 54 psi If the specification is not reached Open the filler cap p 59 Check the fuel tank breather 400928 01 Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 3 3 3 7 bar 48 54 psi If the specification is not reached Check that the fuel line is clear Change the fuel filter p 61 Change the fuel pump p 65 Stop the Function t...

Page 64: ... fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 59 Disconnect the battery p 79 Drain the fuel from the fuel tank i...

Page 65: ...9 10 Remove hose clamps 8 Remove fuel filter Mount the new fuel filter Arrow A points away from the fuel pump Mount hose clamps 8 Hose clamp pliers 60029057000 p 212 202050 10 Press locking mechanism 9 on both sides Pull off the fuel pump housing 202051 10 Change fuel screen bk Mount the fuel pump housing S00328 10 Connect both fuel hose connections 6 Attach connector 7 ...

Page 66: ...3 lbf ft S00065 12 Position the rear end Mount and tighten screw 3 on both sides Guideline Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 S00064 10 Lift the rear fairing Mount and tighten screws 2 Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft S00063 10 Mount and tighten screws 1 Guideline Screw side cover M6 5 Nm 3 7 lbf ft Finishing work Disconnect the battery p ...

Page 67: ...es rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel ...

Page 68: ...ew fuel pump attaching both fuel hose connections 6 Attach connector 7 S00113 10 Position the fuel pump Mount and tighten screws 5 Guideline Screw fuel pump M5 4 Nm 3 lbf ft S00327 10 Position the splash protector Mount and tighten screws 4 Guideline Remaining screws chassis M5 4 Nm 3 lbf ft S00065 12 Position the rear end Mount and tighten screw 3 on both sides Guideline Screw fuel tank bottom M8...

Page 69: ...ount and tighten screws 2 Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft S00063 10 Mount and tighten screws 1 Guideline Screw side cover M6 5 Nm 3 7 lbf ft Finishing work Disconnect the battery p 80 Mount the seat p 60 Set the clock p 95 ...

Page 70: ...e vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be...

Page 71: ... 0 mm 0 157 in Rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Replace the brake disc Check the front and rear brake discs for damage cracks and deformation If damage cracks or deformation are visible on the brake disc Replace the brake disc 12 4 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the...

Page 72: ...he rim if it is excessively deformed Correct the spoke tension 12 6 Front wheel 12 6 1 Removing front wheel Preparatory work Raise the motorcycle with the rear wheel stand p 10 Raise the motorcycle with the front wheel stand p 10 601901 10 Main work Remove screws 1 and spacers 2 Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper ...

Page 73: ...ert the wheel spindle Mount and tighten screw 2 Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Position the brake caliper and check that the brake linings are seated correctly Position spacers 3 Mount screws 4 but do not tighten Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Fix the hand brake lever in...

Page 74: ...ll the front wheel p 71 Take the motorcycle off of the rear wheel stand p 10 12 7 Rear wheel 12 7 1 Removing rear wheel Preparatory work Raise the motorcycle with the rear wheel stand p 10 601913 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Remove nut 1 Remove chain adjuster 2 Holding the rear wheel withdraw the wheel spindle 3 601903 01...

Page 75: ... Long life grease p 208 Install the rubber damper and rear sprocket carrier in the rear wheel Position the rear wheel The brake linings are correctly positioned 601883 11 Push the rear wheel forward as far as possible and lay the chain on the rear sprocket Mount the wheel spindle chain adjusters and nuts Guideline In order that the rear wheel is correctly aligned the markings on the left and right...

Page 76: ...r ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary...

Page 77: ...he left and right adjusting screws 3 so that the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks C The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain positions Tighten nuts 2 Make sure that the chain adjusters 4 are installed correctly o...

Page 78: ...is not always even so you should repeat this measurement at different chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the specified measurement Replace the chain Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets 401170 01 Check the chain slid...

Page 79: ...e chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 10 12 7 9 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or greas...

Page 80: ...0 Remove the rear wheel p 72 601906 10 Main work Check bearing 1 If the bearing is damaged or worn Replace the bearings Check rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 601905 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub...

Page 81: ...ing bracket 3 of the battery forward and remove it Take off the positive pole cover 4 Disconnect the positive plus cable of the battery Push the wiring harness to the side and pull the battery out of the battery holder Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehicle is therefore no lo...

Page 82: ... with the household waste Dispose of faulty batteries in an environmentally compatible manner Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Even whe...

Page 83: ...shing work Install the battery p 79 Mount the seat p 60 Set the clock p 95 13 6 Checking the charging voltage Condition The battery must be fully functional and completely charged Preparatory work Remove the seat p 59 S00082 10 Main work Remove screws 1 Push the retaining bracket forward and take off the terminal cover Start the motorcycle to make checks p 13 S00084 10 Measure the voltage between ...

Page 84: ...t p 59 C00185 10 Main work Remove protection covers 1 C00186 10 Remove a defective main fuse 2 with needle nose pliers Install a new main fuse Fuse 58011109130 p 177 Info A reserve fuse 3 is located in the starter relay Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 60 Set the clock p 95 13 8 Changing fuses of individual power consumer...

Page 85: ...e fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Replace with a spare fuse of the right rating Fuse 75011088010 p 177 Fuse 75011088015 p 177 Tip Put a new spare fuse in the fuse box for future use if needed Check the function of power cons...

Page 86: ...ith extremely direct responsive ness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness Set the Map Select switch to poor fuel quality Set the adjusting wheel to position 0 Poor fuel quality homologated performance is reduced in accordance with the fuel quality use for no more than 1 tank of fuel ...

Page 87: ...nd consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning...

Page 88: ...6 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 14 3 Adjusting the basic position of the hand brake lever 601894 10 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing wheel 1 Info Pull the hand brake lever forward and turn the adjusting wheel Do not make any adjustments wh...

Page 89: ...nts Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color...

Page 90: ...ove screws 1 Remove cover 2 with membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 p 211 Brake fluid DOT 4 DOT 5 1 p 206 201969 10 Mount bleeder cover 3 Bleeder cover 00029013010 p 210 Connect the bleeding device Bleeding device 00029013100 p 210 201494 10 Open shut off valve 4 Info Follow the operating inst...

Page 91: ...troyed Check the brake linings regularly 601900 10 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 89 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings p 89 14 8 Changing the rear brake linings Warning Danger of accident Brake syst...

Page 92: ...rake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 601899 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 Press the brake caliper by hand onto the brake disc in order to retract the brake piston Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing...

Page 93: ...t brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications 601897 10 Loosen fitting 3 on foot brake cylinder 4 To adjust the basic position of the foot brake lever individually loosen nut 1 and turn screw 2 accordingly Info The range of adjustment is limited The screw must be screwed i...

Page 94: ...ly Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicon...

Page 95: ...d membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 p 211 Brake fluid DOT 4 DOT 5 1 p 206 201971 10 Mount bleeder cover 2 Bleeder cover 00029013004 p 210 Connect the bleeding device Bleeding device 00029013100 p 210 201494 11 Open shut off valve 3 Info Follow the operating instructions of the bleeding device...

Page 96: ...ove the hose of the bleeder bottle Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover 201973 10 Add brake fluid to the MAX mark C Brake fluid DOT 4 DOT 5 1 p 206 Mount the screw cap with the washer and membrane Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 97: ... The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simultaneously The time is set 15 1 3 Setting resetting display TRIP 1 Info The TRIP 1 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling s...

Page 98: ...n The motorcycle is stationary Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 97 302064 10 Main work Unplug connector ED from the combination instrument Unlock pin 18 A and remove it from connector ED Plug connector ED into the combination instrument Switch on the ignition by turning the ignition key to position ON Press the...

Page 99: ...ark does not meet specifications Adjust the headlight range p 97 15 3 Adjusting the headlight range Preparatory work Check the headlight setting p 97 C00193 10 Main work Turn adjusting screw 1 to adjust the headlight range Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider instructions on how to apply the mark Checking the headlight settin...

Page 100: ...groove 4 on counterpiece 5 601909 11 Position brake line guide 6 Mount and tighten screws 7 Guideline Screw headlight mask M5 5 Nm 3 7 lbf ft Finishing work Check the headlight setting p 97 15 6 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease bef...

Page 101: ...tness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 97 600610 10 Main work Pull off connector 1 Take off protection cap 2 of the headlight bulb 600611 10 Detach spring bar 3 Remove he...

Page 102: ...al glass 1 forward and take it off Press the turn signal bulb carefully into the socket turn it counterclockwise by about 30 and take it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 177 Position the turn signal glass Ins...

Page 103: ... the radiator hoses Pliers for spring band clamp 60029057100 p 213 S00087 10 Remove screws 2 S00088 10 Remove screws 3 Take off the engine sprocket cover Remove screw 4 Take off the shift lever S00089 10 Have an assistant operate the rear brake Bend up the lock washer Remove nut 5 with the lock washer Remove screws 6 S00090 10 Remove nut 7 Remove the chain adjuster Pull out the wheel spindle only ...

Page 104: ... of the starter motor S00092 10 Release hose clip bk Pull off the throttle valve body from the rear S00094 10 Disconnect connector bl of the gear position sensor the crankshaft position sensor and the alternator Remove the cable binders and expose the cable S00093 10 Pull off spark plug connector bm Unplug the connector of the engine coolant temperature sensor bn Unplug the connector of the oil pr...

Page 105: ... bt and screw ck of the lower engine bracket S00098 10 Remove screw cl of the swingarm pivot Remove the swingarm pivot S00095 10 Lower the engine Info You should have an assistant for this step Make sure that the motorcycle is sufficiently secured against falling over Protect the frame and attachments from damage 16 2 Installing the engine Preparatory work Raise the engine onto the special tool an...

Page 106: ...ith the special tool Floor jack attachment 75029055000 p 217 S00097 11 Position the engine bearer Mount and tighten screws 4 Guideline Screw engine bearer on frame M10 45 Nm 33 2 lbf ft Mount and tighten screw 5 with nut 6 Guideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Tighten the swingarm pivot Guideline Screw swingarm pivot M12 80 Nm 59 lbf ft Tighten the lower engine bracket ...

Page 107: ...rew cable on starter motor M5 3 Nm 2 2 lbf ft Position the ground wire on the starter motor Mount and tighten screw bp Guideline Screw starter motor M6 10 Nm 7 4 lbf ft Loctite 243 S00089 11 Insert the clutch push rod Position the clutch slave cylinder Mount and tighten screws bq Guideline Screw clutch slave cylin der M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylin der M6x35 10 Nm 7 4 ...

Page 108: ...ft Loctite 243 S00087 11 Mount and tighten screws cn Guideline Screw upper radiator bracket M6 10 Nm 7 4 lbf ft S00086 11 Position the radiator hoses Install the spring band clamps co Install the manifold p 52 Disconnect the battery p 80 S00100 10 Remove the oil filler plug cp with the O ring from the clutch cover and fill up with engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 000620100...

Page 109: ...assembly stand 61229001000 p 214 Support for engine assembly stand 75012001060 p 214 Holder for engine assembly stand 75012001070 p 214 Mount the engine on special tool 1 Info Have an assistant help you or use a crane 16 3 2 Draining the engine oil 300002 10 Remove the oil drain plug 1 with the magnet and seal ring Remove plug 2 with oil screen and the O rings 300161 10 Remove plug 3 with oil scre...

Page 110: ...ng the alternator cover 300004 10 Remove screws 1 Take off the alternator cover Remove dowels 16 3 6 Removing spacer 302124 10 Remove the spacer 1 of the countershaft 16 3 7 Removing gear position sensor 302126 10 Remove screws Remove the gear position sensor 1 300007 10 Remove O ring 2 Remove contact pin 3 and the contact springs 4 ...

Page 111: ...iers reverse 51012011000 p 211 16 3 9 Removing thermostat 300010 10 Remove screws Take off the thermostat case 1 with the radiator hose Pull out the thermostat 2 16 3 10 Setting engine to ignition top dead center 300023 10 Turn the crankshaft counterclockwise until markings 1 of the camshafts are flush with the marks of the camshaft support plate 300024 10 Remove screw 2 Info Look through the hole...

Page 112: ... pump wheel 3 Take off the water pump cover seal Info Do not lose the centering pins 300014 10 Remove the shaped washer 4 16 3 12 Removing clutch cover 300015 10 Remove screws 1 Take off the clutch cover Take off the dowels Remove the clutch cover seal 16 3 13 Removing spacer and spring 300154 10 Remove the spacer 1 and spring 2 of the shift shaft ...

Page 113: ...ew 1 Take off the seal ring Pull out timing chain tensioner 2 16 3 16 Removing camshafts 300019 10 Remove screw 1 Take off the camshaft support plate 2 300020 10 Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft 16 3 17 Removing cylinder head 300029 10 Remove screws 1 Alternately loosen screws 2 and remove them Take off the cylinder head ...

Page 114: ...n the cylinder and the piston you can leave the piston in the cylinder Take off the cylinder base gasket Info Ensure that the two grooved pins remain in place 16 3 19 Removing rotor 300044 10 Remove special tool 1 Engine blocking screw 77329010000 p 219 300040 10 Use the special tool to hold the rotor tight Holding spanner 75029091000 p 218 Loosen the nut 1 of the rotor and remove it with the tab ...

Page 115: ...ain tensioning rail 4 out of the timing chain securing guide Remove the timing chain tensioning rail upward out of the timing chain shaft Remove the timing chain securing guide 3 16 3 21 Removing timing chain and timing chain sprocket 300148 10 Slip out timing chain 1 Info Mark the direction of travel Take off lock ring 300149 10 Pull of the timing chain sprocket with the special tool 2 Extractor ...

Page 116: ... clutch springs Remove the pressure cap 3 300053 10 Remove the pressure piece 4 Bend up the lock washer 5 300054 10 Hold the clutch cage using the special tool and remove the nut 6 of the inner clutch hub Gear segment 75029081000 p 218 Info Make sure that the crankshaft is not blocked Remove the nut 7 of the primary gear Info Left handed thread 302125 10 Take off the stepped washer and remove the ...

Page 117: ...ring of the starter idler gear 1 and the torque limiter 2 Take off the starter idler gear 1 with the washers Remove the torque limiter 2 with the washers and needle bearing 300065 10 Take off the free wheel gear 3 Remove the woodruff key 4 and both needle bearings 5 16 3 26 Removing shift shaft 300066 10 Push sliding plate 1 away from the shift drum locating 2 Remove shift shaft 3 with the washer ...

Page 118: ...m both oil pumps Take off the oil pump toothed wheels 3 300071 10 Remove the pins 4 and washers 5 Remove screws Take off the oil pump cover 6 300072 10 Remove both oil pump shafts 7 with internal rotors 8 Take the external rotors out of the engine case 16 3 30 Removing left engine case 300075 10 Remove screws 1 Swing the left section of the engine case up and remove the nut or screw of the engine ...

Page 119: ...ncer shaft and the main shaft have a stop disk these usually stick to the bearing Take off the left section of the engine case Remove the special tool 302132 10 Remove dowels Remove O ring 3 16 3 31 Removing crankshaft and balancer shaft 302133 10 Remove the crankshaft 1 and the balancer shaft 2 16 3 32 Removing transmission shafts 300079 10 Remove the shift rail 1 300080 10 Swing shift forks 2 to...

Page 120: ...se section thoroughly Pull the dowels out of the housing Warm the engine case section in an oven Guideline 150 C 302 F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitable tool 300095 10 Remove oil jet 2 Remove the cover plate 6 for the oil r...

Page 121: ... in After the engine case section 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 locks Mount and tighten the screws Guideline Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 Mount and tighten the oi...

Page 122: ...must be removed using a suitable tool Press out the shaft seal ring of the crankshaft from the outside to the inside Press in the shaft seal ring of the crankshaft from the inside to the outside with the open side facing out Info The shaft seal ring must be flush on the outside Warm the engine case section again Guideline 150 C 302 F Insert the new cold bearings into the bearing seats of the hot e...

Page 123: ...10 Lubricate piston valve 9 and mount it with pressure spring 8 Mount and tighten screw plug 7 with the new seal ring Guideline Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Position the membrane support plate 5 with membrane 6 Mount and tighten the screws Guideline Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Info The membrane support plate is curved and must point away fr...

Page 124: ...the crankshaft bearing inner ring p 122 302147 10 Main work Screw in 2 M6 screws 1 in the threads Tighten the two screws evenly to pull the drive wheel 2 off the crankshaft 16 4 6 Changing the connecting rod conrod bearing and crank pin Preparatory work Remove the crankshaft bearing inner ring p 122 Remove the drive wheel of the balancer shaft p 122 302151 10 Main work Position the crankshaft with...

Page 125: ...ecting rod and the bearing Position the second crankweb 302152 10 Position the special tool 7 with the heel at the bottom Pressing device for crankshaft complete 75029047000 p 216 Press the upper crankweb in as far as possible Info The press mandrel must be applied above the crank pin Take the crankshaft out of the special tool and check the connecting rod for free dom of movement 302149 10 Measur...

Page 126: ...75029047050 p 216 Under part pressing out tool 75029047051 p 216 Warm the drive wheel Guideline 100 C 212 F 300159 10 Place the drive wheel on the crankshaft The dowel of the crankshaft must fit in the drill hole 4 The side of the drive wheel with the punch mark 3 must be visible after assembly and the side with the bevel 2 must be in contact with the crankweb Finishing work Install the crankshaft...

Page 127: ...move compensation shims equally on both sides Info If the axial clearance is too small remove compensation shims If the axial clearance is too large add compensation shims Install the crankshaft bearing inner ring p 124 300164 10 Mount the dial gauge support on the engine case and measure and note the axial clearance of the balancer shaft Guideline Balancer shaft axial clearance 0 05 0 20 mm 0 002...

Page 128: ...the cylinder head for distortion using a straight edge and the special tool Feeler gauge 59029041100 p 212 Cylinder cylinder head sealing area distortion 0 10 mm 0 0039 in If the measured value does not equal the specified value Change the cylinder 16 4 13 Checking measuring the piston 0 0 A A 0 0 A A 0 0 A A 400484 10 Use the special tool to measure clearance A of the piston rings in the piston r...

Page 129: ...g from the piston Place the piston ring in the cylinder and align it with the piston Guideline Under the upper edge of the cylinder 10 mm 0 39 in Measure the end gap with a feeler gauge A Guideline Piston ring end gap Compression rings 0 80 mm 0 0315 in Oil scraper ring 1 00 mm 0 0394 in If the end gap is more than the specified value Check measure the cylinder p 126 If the cylinder wear is within...

Page 130: ...ecessary the engine case 16 4 17 Replacing autodecompressor 300107 10 Take the lock ring 1 off the autodecompression shaft and dispose of it 300108 10 Pull the autodecompression shaft 2 from the camshaft 300109 10 Disconnect the autodecompression spring Loosen the screw 3 and remove it together with the autodecompression spring and the autodecompression weight 4 300110 10 When assembling first con...

Page 131: ...r is now pressed in once more while it is installed and then pulled out no more than halfway preventing it from coming out fully the latching system locks and the timing chain tensioner can no longer be compacted this function is necessary to ensure sufficient tension of the timing chain even at low oil pressure 16 4 19 Checking timing assembly 0 0 1 1 0 0 1 1 0 0 2 2 0 0 3 3 0 0 4 4 0 0 5 5 30011...

Page 132: ...e rocker arm p 130 300226 10 Main work Clamp the cylinder head Clamping plate 75029050000 p 217 Remove the large camshaft bearing using the special tool 1 Push out drift 75029051000 p 217 300228 10 Remove the small camshaft bearing using special tool 2 Insert for bearing puller 15112018100 p 210 Bearing puller 15112017000 p 210 300229 10 Press in the small camshaft bearing as far as possible using...

Page 133: ...r 59029019000 p 212 Valve spring mounting device 78029060000 p 219 Remove valve keys and release tension on the valve springs Remove spring retainers and spring Pull the valve down and out of the valve guide remove the valve stem seal and valve spring retainer 300117 10 Mark the valves according to their normal built in position Info Place the valves into a box according to the installation positi...

Page 134: ...wear visual check If the valve spring retainer is fractured or worn Change the valve spring retainer Measure the thickness of the valve spring retainer Valve spring cap thickness 2 4 2 5 mm 0 094 0 098 in If the measured value does not equal the specified value Change the valve spring retainer 16 4 26 Checking cylinder head 300119 10 Check the valve guides using the special tool 1 Limit plug gauge...

Page 135: ... 4 4 300118 01 Position the valve spring cap 1 Install new valve stem seals 2 Mount valves 3 according to their normal built in position Install the valve springs 4 and the spring retainers 300116 11 Pretension the valve springs using the special tool Valve spring compressor 59029019000 p 212 Valve spring mounting device 78029060000 p 219 300115 11 Mount valve keys Info When mounting the valve key...

Page 136: ... 29 Disassembling the antihopping clutch 300120 10 Clamp the clutch 1 in a vise Info Use soft jaws Carefully loosen and gradually remove the special tool 2 300121 10 Take the clutch out of the vise and lay it on a clean workbench with the outer clutch hub 5 facing down Take the inner clutch hub 3 and release springs 4 out of the outer clutch hub 5 300122 10 Take off the clutch facing discs 6 from ...

Page 137: ... clutch spring length is less than the specified value Change all clutch springs Check the contact surface of pressure cap 5 for damage and wear If there is damage or wear Change the pressure cap Check the contact surfaces of the clutch facing discs in the outer clutch hub 6 for wear Clutch basket contact surface of clutch facing discs 0 5 mm 0 02 in If the contact surface is very worn Change the ...

Page 138: ...oughly oil the clutch facing discs Push the support ring 1 and the pretension ring 2 on to the outer clutch hub Info The pretension ring must be installed so that it is flush with the inner edge A on the support ring 300124 10 Position the trimmed clutch facing disc with the recess for the pretension ring on the outer clutch hub Beginning with the coated intermediate clutch disc position all furth...

Page 139: ...ess in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate 6 in contact areas C for wear If the sliding plate is worn Change the sliding plate Check return surface D on the sliding plate for wear If deep notches are present Change the sliding plate Check guide pin E for looseness and wear If the guide pin is loose and or worn Cha...

Page 140: ...the sixth gear idler gear 3 Remove the split needle bearing 4 and stop disk 5 Remove lock ring 6 Remove the third fourth gear sliding gear 7 Remove lock ring 8 Remove stop disk 9 and fifth gear idler gear bk Remove bearing bush bl 16 4 35 Dismantling countershaft 2 2 3 3 1 1 4 4 5 5 6 6 7 7 8 8 9 9 bk bk bl bl bs bs br br bp bp bo bo bn bn bm bm bq bq 300128 01 Fix the countershaft in the vise wit...

Page 141: ... 8 3 3 305511 01 Check needle bearing 1 for damage and wear If there is damage or wear Change the needle bearing Check the pivot points of main shaft 2 and countershaft 3 for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear If there is damage or wear Change the main shaft and or coun...

Page 142: ... work Oil all parts carefully before assembling Check the transmission p 139 Main work 9 9 7 7 5 5 4 4 3 3 2 2 1 1 bl bl bk bk 6 6 8 8 301980 02 Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Lubricate and mount bearing bush 1 Long life grease p 208 Push on the fifth gear idler gear 2 with the shift dogs facing upward Mount stop disk 3 and lock ring 4 Pu...

Page 143: ... gear 2 on the countershaft with the protruding collar facing downward Mount stop disk 3 and lock ring 4 Mount the sixth gear sliding gear 5 with the shift groove facing upward Mount lock ring 6 and stop disk 7 Mount needle bearing 8 and the fourth gear idler gear 9 with the collar facing upward Mount needle bearing bk and the third gear idler gear bl with the collar facing downward Mount stop dis...

Page 144: ...wear Replace the freewheel Check the toothing of the starter motor 5 for damage and wear If there is damage or wear Replace the starter motor Clamp the minus negative cable of a 12 Volt power supply to the starter motor housing Briefly connect the plus positive cable of the power supply to the starter motor connection If the starter motor does not turn when you close the power circuit Replace the ...

Page 145: ...liers Take the freewheel 3 out of the primary gear 16 4 42 Installing freewheel 300129 10 Lubricate all parts thoroughly Push the freewheel 1 into the primary gear Info Note the direction of rotation 300128 11 Install the expansion ring 2 300130 10 Make sure that all lugs of the expansion ring locate in the slits A of the freewheel Info If necessary use a screwdriver to ease them in ...

Page 146: ...gine assembly stand 61229001000 p 214 Make sure that both stop disks 1 are installed Mount the inner bearing race 2 on the countershaft 300088 10 Lubricate all bearings Assemble the two transmission shafts and slide them into the bearing seats together 300089 10 Mount the upper shift fork 3 the middle shift fork 4 and the lower shift fork 5 Info For the assembly of the middle shift fork 4 the slid...

Page 147: ...the special tool 1 on the alternator side of the crankshaft Mounting sleeve 75029080000 p 217 Mount the special tool 2 on the balancer shaft Mounting sleeve 58529005000 p 211 302135 10 Push the crankshaft into the bearing seat and take off the special tool Grease the shaft seal rings of the balancer shaft Push the balancer shaft 3 into the bearing seat and take off the special tool Align marks A a...

Page 148: ...them diagonally Guideline Screw engine case M6 10 Nm 7 4 lbf ft Info Install the screw in the oil filter housing with a new copper washer 16 5 4 Installing oil pumps 300073 10 Install pins and internal rotors on both oil pump shafts Mount external rotors in the engine case The marking is not visible after mounting Mount the oil pump shafts 1 with internal rotors 2 Oil the parts 300071 11 Position ...

Page 149: ...g are not symmetric 300067 11 Release the locking lever Mount and tighten screw 2 Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 16 5 7 Installing shift shaft 300066 11 Slide shift shaft 1 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 Shif...

Page 150: ...t 300057 10 Mount supporting plate 1 and needle bearing 2 300058 10 Install the clutch basket 3 Info Turn the clutch basket and oil pump gear wheels backwards and forwards slightly to help them mesh more easily Mount the half washers with the sharp edge facing outward Info Grease the half washers to ease assembly Position stepped washer with the recesses toward the half washers 302123 10 Insert th...

Page 151: ...hten the nut 7 Guideline Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 300061 10 Insert the pressure piece 8 300052 11 Place the pressure cap on Install and tighten the screws 9 with the spring retainers and clutch springs Guideline Screw clutch spring M5 6 Nm 4 4 lbf ft Info Ensure that all clutch springs have a blue color coding Remove the special tool 16 5 11 Installing crankshaft po...

Page 152: ...ert the support bush ing into the timing chain securing guide 300045 11 Thread in the timing chain guide rail 3 from above Insert the support bushing into the timing chain securing guide Mount and tighten screws 4 Guideline Screw timing chain guide rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain ten sioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Info Ensure that there is no thread locking ma...

Page 153: ... tighten screws 3 Guideline Screw ignition pulse gen erator M6 10 Nm 7 4 lbf ft Loctite 243 16 5 16 Setting engine to top dead center 300025 10 Set the crankshaft to top dead center and lock it with the special tool 1 Engine blocking screw 77329010000 p 219 16 5 17 Installing piston 302600 10 Shift the joint of the piston rings by 120 Push the oiled piston into the special tool Piston assembly rin...

Page 154: ...oth Thread the timing chain through the chain shaft Mount the piston pin Info For clarity the following steps are illustrated using a disassembled piston 400366 10 Position the piston pin retainer 300038 10 Insert the special tool and firmly press it toward the piston Turn the special tool counterclockwise thereby pressing the piston pin retainer into the groove Insertion for piston ring lock 7502...

Page 155: ...ten diag onally begin ning with the rear screw on the timing chain shaft Step 1 15 Nm 11 1 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 45 Nm 33 2 lbf ft Step 4 60 Nm 44 3 lbf ft Lubricated with engine oil Info Always use new cylinder head screws Mount and tighten screws 2 Guideline Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 16 5 19 Installing camshafts 300163 10 Lay the timing chain over the c...

Page 156: ...toward the timing chain Release device for timing chain tensioner 77329051000 p 219 The timing chain tensioner unlocks Mount and tighten screw 3 Guideline Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft 16 5 21 Checking valve clearance 300044 10 Remove special tool 1 Crank the engine several times Set the engine to ignition top dead center p 109 300155 10 Check the valve clearanc...

Page 157: ...rocker arm shafts Take off the rocker arm 300158 10 Remove shims 4 and set them down according to the installation position Correct the shims as indicated by the results of the valve clearance check Insert suitable shims Position the rocker arms and push in the rocker arm shafts Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards The small drill hole and the f...

Page 158: ... 1 and spring 2 of the shift shaft 16 5 25 Installing clutch cover 300015 11 Mount the dowels Put on the clutch cover seal Position the clutch cover Mount and tighten screws 1 Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 16 5 26 Mounting water pump cover 300014 11 Push on the shaped washer 1 300013 12 Attach the water pump wheel 2 Mount and tighten screw 3 Guideline Screw water pump wheel M6 1...

Page 159: ...talling the oil filter 300009 11 Insert the oil filter 1 Lubricate the O ring of the oil filter cover Install the oil filter cover 2 Mount and tighten the screws Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft 306801 11 Insert the oil filter 3 Lubricate the O ring of the oil filter cover Install the oil filter cover 4 Mount and tighten the screws Guideline Screw oil filter cover M5 6 Nm 4 4 lb...

Page 160: ...tershaft with a twisting motion The recess with the O ring faces inward The shaft seal ring rests against the spacer along its entire circumference 16 5 31 Installing oil screens 300152 10 Push the oil screen with O rings on to a pin wrench Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case 30...

Page 161: ...alternator cover M6 10 Nm 7 4 lbf ft Mount and tighten screw 3 Guideline Screw alternator cover chain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 300024 11 Remove special tool 4 Engine blocking screw 77329010000 p 219 Mount and tighten screw 5 Guideline Screw plug crankshaft clamp M8 20 Nm 14 8 lbf ft 16 5 33 Installing the starter motor 302576 10 Grease O ring Mount the starter motor Long ...

Page 162: ...with the seal Mount and tighten screws 1 Guideline Screw valve cover M6 10 Nm 7 4 lbf ft 16 5 35 Removing the engine from the engine assembly stand 300144 11 Remove the screw 1 or the nut 2 Remove the engine from the engine assembly stand Info Have an assistant help you or use a crane ...

Page 163: ...ironmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 202086 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Fill bleeding syringe 4 with the appropriate hydraulic fluid Bleed syringe 50329050000 p 211 Hydraulic fluid 15 p 207 On the clutch ...

Page 164: ...en C00191 10 Stand the motorcycle upright Place a suitable container under the engine Remove screw 1 Take off the radiator cap Completely drain the coolant Mount screw 1 with a new seal ring and tighten it Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft 18 2 Filling bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not com...

Page 165: ...tely with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is cont...

Page 166: ...nse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition Engine is cold C00188 11 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compe...

Page 167: ...nsmission 8 Clutch 9 Oil jet for piston cooling 10 Oil filter 11 Oil nozzle for conrod bearing lubrication Oil circuit of suction pump 12 Oil screen 13 Suction pump 7 Transmission 19 2 Checking the engine oil level Info The engine oil level must be checked when the engine is warm Condition The engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface ...

Page 168: ...ble regulations S00101 10 Main work Remove screw 1 S00102 10 Position the banjo bolt with the connector and sealing rings Mount and tighten the banjo bolt Guideline Banjo bolt M10x1 8 Nm 5 9 lbf ft Oil pressure adapter 77329006000 p 218 Connect the pressure tester to the special tool without the T plate Pressure testing tool 61029094000 p 214 Check the engine oil level p 165 Danger Danger of poiso...

Page 169: ...01022 10 Drain the engine oil p 167 Remove the oil filter p 168 Clean the oil screens p 169 Install the oil filter p 168 Fill up with engine oil p 170 19 5 Draining the engine oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environm...

Page 170: ...ke fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 100202 10 Main work Remove screws 1 Remove the oil filter cover 2 with the O ring Pull oil filter 3 out of the oil filter housing Circlip pliers reverse 51012011000 p 211 C00181 10 Remove screws 4 Take off the oil filter cover 5 with the O ring Pull oil filter 6 o...

Page 171: ...ipulated in applicable regulations Preparatory work Place a suitable container under the engine 100205 10 Main work Remove screw plug 1 with oil screen 2 and the O rings 100206 10 Remove screw plug 3 with oil screen 4 and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 100207 10 Position oil screen 2 with the O rings Mount and tighten screw plug 1 ...

Page 172: ...s oil tight Finishing work Check the engine oil level p 165 19 10 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine C00179 10 Main work Remove the oil filler plug 1 with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 206 Engine oil SAE 10W 50 p 206 Info For optimal performance of the eng...

Page 173: ...s Stator connector EN pin 1 Stator connector EN pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 Ω If the displayed value is not equal to the setpoint value Replace the stator 600894 10 S00084 10 Stator winding check for a short circuit to ground terminal 31 Measure the resistance between the specified points Stator connector EN pin 1 Measuring point Ground Resistance Ω If the displaye...

Page 174: ...rk Remove the seat p 59 Take off the side cover p 60 600739 13 Main work Ignition coil cylinder 1 check the secondary winding resistance Measure the resistance between the specified points Ignition coil pin 2 Ignition coil pin 3 Ignition coil Resistance of secondary winding at 20 C 68 F 10 4 15 6 kΩ If the displayed value does not correspond to the nominal value Change the ignition coil ...

Page 175: ...st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 21 23 5th gear 23 22 6th gear 23 20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Alternator 12 V 224 W Spark plug NGK LKAR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed Cool...

Page 176: ...0 15 0 25 mm 0 0059 0 0098 in Crankshaft run out at bearing pin 0 10 mm 0 0039 in Balancer shaft axial clearance 0 05 0 20 mm 0 002 0 0079 in Clutch facing disc thickness 2 5 mm 0 098 in Intermediate disk thickness 1 35 mm 0 0531 in Clutch spring length 31 5 33 5 mm 1 24 1 319 in Clutch basket contact surface of clutch facing discs 0 5 mm 0 02 in Oil pressure regulator valve minimum spring length ...

Page 177: ...m 7 4 lbf ft Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw rocker arm shaft M6 12 Nm 8 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lb...

Page 178: ...g timing chain tensioner M20x1 5 25 Nm 18 4 lbf ft Plug oil thermostat M24x1 5 15 Nm 11 1 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft 21 4 Capacities 21 4 1 Engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 206 Alternative engine oil Engine oil SAE 10W 50 p 206 21 4 2 Coolant Coolant 1 20 l 1 27 qt Coolant p 206 Coolant mixed ready to use p 206 21 4 3 Fuel Total ...

Page 179: ...rmissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb 21 6 Electrical system Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal RY10W sock...

Page 180: ...48601166S1 p 207 21 9 Shock absorber Shock absorber part number 15 18 7L 12 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks S...

Page 181: ...t Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Screw air filter box top M6 2 Nm 1 5 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw chain guard M6 2 Nm 1 5 lbf ft Loctite 243 Screw chain guide M6 8 Nm 5 9 lbf ft Screw chain sliding g...

Page 182: ...Screw steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Screw engine bearer on frame M10 45 Nm 33 2 lbf ft Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite ...

Page 183: ...aner to the dry vehicle always rinse with water first If the vehicle was operated in road salt clean it with cold water Warm water enhances the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a ...

Page 184: ... 181 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Treat the engine the swingarm and all other bare or galvanized parts exc...

Page 185: ...vice add fuel additive Fuel additive p 208 Ride the motorcycle until the low fuel warning lamp lights up and the display changes to TRIP F so that you can fill up with fresh fuel when you take the motorcycle back into service Check the tire air pressure p 68 Remove the battery p 79 Recharge the battery p 80 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Store the v...

Page 186: ...tension p 74 Grease all moving parts e g side stand hand lever chain and check for smooth operation Clean the dust boots of the fork legs p 15 Check the front brake fluid level p 86 Bleed the fork legs p 14 Check the steering head bearing play p 27 Change the spark plug Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect rout...

Page 187: ...185 ...

Page 188: ... 3 0 2 T 0 1 G BI 2 EM 3 1 2 3 2 1 G20 2 3 EN 3 1 K11 2 1 4 3 1 AF 4 X13 2 1 a AF 4 X13 3 EB 4 X19 3 4 c 1 0 3 X 2 0 3 X 1 2 DS 44 X18 43 AU 2 X12 2 EB 4 X19 4 b 10A F9 1 2 FJ 2 X9 1 CR 1 X292 1 CR 1 X291 1 FJ 2 X9 2 M10 43 wh rd wh rd wh rd bl bl bl bl bl rd bl rd wh rd gn rd bu rd bu br bl gn gn gn br wh rd bl rd wh rd ye rd ye rd br 602001 01 ...

Page 189: ...se G10 Battery G20 Alternator K10 Starter relay with main fuse K11 Start auxiliary relay M10 Starter motor T20 Voltage regulator X291 Connector for accessory ground terminal 31 ACC 1 not assigned X292 Connector for accessory plus terminal 30 ACC 1 not assigned ...

Page 190: ...c 1 c 6 DS 44 X18 8 2 d EB 4 X15 3 e EB 4 X14 4 BY 4 X41 3 BY 4 X41 4 BR 4 X37 4 2 2 BR 4 X37 3 DT 36 X21 1 DS 44 X18 1 b 1 FJ 2 X1 2 S11 CV 4 CV 4 4 3 2 1 ED 32 X63 1 15 ED 32 X63 18 S23 BK 4 BK 4 4 3 1 2 1 15 18 1 8 1 27 10 10 27 AP 6 X295 4 wh rd wh bl wh rd wh rd wh rd rd rd rd ye rd wh bl wh rd wh rd ye rd ye rd ye rd br gn ye rd ye rd br br ye rd ye rd br br bl rd br wh rd bl rd gn br br gr ...

Page 191: ... Components A11 EFI control unit A12 EPT control unit F1 Fuse K12 Light relay K30 Power relay P10 Combination instrument S11 Ignition steering lock S23 Emergency OFF switch electric starter button X295 Diagnostics connector ...

Page 192: ...FJ 2 X6 1 c FF 1 X24 1 FF 1 X25 1 f g c d DI 2 X61 1 DI 2 X61 2 E13 1 2 3 2 1 BP 4 X29 2 3 BP 4 X29 4 1 DG 4 X28 2 3 DG 4 X28 4 BW 3 X23 3 3 AC 6 X34 6 BW 3 X23 2 4 AC 6 X34 5 15A F7 1 2 FJ 2 X7 1 d FJ 2 X7 2 FJ 2 X6 2 ED 32 X63 8 1 3 4 6 2 1 5 C1 S29 BC 6 BC 6 5 8 gr gr gn ye bu ye bu ye br gn bu bu gn gn bu gn bu br br br bu bu ye gn ye br gn ye bu gn br ye br br bu 602003 01 ...

Page 193: ...25 WIRING DIAGRAM 191 Components E13 Low beam high beam F6 Fuse F7 Fuse P10 Combination instrument P15 Horn P35 Parking light S29 High beam low beam switch horn button turn signal switch ...

Page 194: ... F8 3 F8 5 F1 5 F1 P 3 F8 f c f c B76 AK 2 AK 2 2 1 AH 2 X26 1 AH 2 X27 1 B77 AK 2 AK 2 2 1 AJ 3 X32 3 E60 1 2 1 AH 2 X27 2 AH 2 X26 2 DI 2 X58 2 DI 2 X58 1 P36 BG 3 BG 3 BS 2 BS 2 1 2 3 1 2 BV 2 X22 1 BV 2 X22 2 AJ 3 X32 2 g wh gn wh gn wh gn ye bu ye bu br ye wh wh br br ye bu br ye ye bu br 602004 01 ...

Page 195: ...25 WIRING DIAGRAM 193 Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light ...

Page 196: ...CW 2 1 CW 2 f c c CX 2 X47 2 CX 2 X46 2 3 CV 4 X59 4 3 BY 4 X60 4 CX 2 X47 1 CX 2 X46 1 CV 4 X59 2 BY 4 X60 2 AH 2 X20 1 BT 3 X17 1 2 BT 3 3 AH 2 X20 2 CX 2 X30 1 P42 1 CW 2 2 CW 2 CX 2 X30 2 P41 1 CW 2 2 CW 2 CX 2 X31 1 CX 2 X31 2 10 ED 32 X63 9 3 C3 S29 BG 3 BG 3 2 3 1 10 9 bl pu bl pu br pu bl pu pu bl bl br br ye bu bl or bl or br br bl br pu br ye bu br 602005 01 ...

Page 197: ...mponents K20 Turn signal relay P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 High beam low beam switch horn button turn signal switch ...

Page 198: ...5 4 3 2 1 8 7 6 5 4 3 2 1 6 10 M t 5 F8 3 B8 7 F1 M14 BI 2 BI 2 1 2 B33 2 1 10A F5 1 2 FJ 2 X5 1 10A F8 1 2 FJ 2 X8 1 AU 2 X10 2 c d AV 2 X33 1 AV 2 X33 2 c CR 1 X294 1 CR 1 X293 1 AU 2 X10 1 FJ 2 X8 2 FJ 2 X5 2 gn bl bl gn wh bl wh bl bl rd bl rd br br gn br br 602006 01 ...

Page 199: ...M 197 Components B33 Radiator fan temperature switch F5 Fuse F8 Fuse M14 Radiator fan X293 Connector for accessory ground terminal 31 ACC 2 not assigned X294 Connector for accessory plus terminal 15 ACC 2 not assigned ...

Page 200: ...0 8 3 c M60 FK 8 7 8 6 5 4 3 2 1 30 1 29 2 24 3 31 4 14 5 16 6 15 7 DT 36 X21 13 DR 8 X39 8 DT 36 X21 36 35 10A F3 1 2 FJ 2 X3 1 FJ 2 X2 2 FJ 2 X4 2 FJ 2 X3 2 ED 32 X63 24 24 19 35 36 11 12 17 20 8 13 14 15 16 24 29 30 31 16 6 5 28 21 39 3 br pu bu gr ye rd ye rd bl bu wh bu gn or bl bu or br bl bu rd gn bl bu br wh gn wh rd wh or bu rd gn bl bu br wh gn wh rd wh or bu br br ye rd bu or br pu br p...

Page 201: ...25 WIRING DIAGRAM 199 Components A11 EFI control unit A12 EPT control unit F2 Fuse F3 Fuse F4 Fuse M13 Fuel pump M60 Motor drive P10 Combination instrument ...

Page 202: ...L 1 X44 1 3 DS 44 X18 17 DF 2 X40 2 DS 44 X18 18 DS 44 X18 41 DS 44 X18 22 FM 1 X48 1 DS 44 X18 12 FS 4 X45 2 42 4 25 i FS 4 X45 1 M20 1 2 DW 2 X42 1 DQ 2 X43 1 ED 32 X63 2 B70 CZ 3 CZ 3 1 2 3 CY 3 X62 3 23 1 ED 32 X63 3 CY 3 X62 2 DS 44 40 4 2 23 3 4 17 18 41 22 12 42 25 40 or bl or rd gr bl gr wh pu gn rd lbu bl bl or rd gr bl gr wh pu gn rd lbu or or or or or bl or bl or bu br bl or bu br bl or...

Page 203: ...nts A11 EFI control unit B51 Lambda sensor cylinder 1 B70 Front wheel speed sensor M20 Fuel evaporation valve USA version only M21 Secondary air valve M51 Injector cylinder 1 P10 Combination instrument R51 Ignition coil cylinder 1 ...

Page 204: ... 3 DS 44 X18 26 32 1 31 2 DS 44 X18 10 AM 3 X50 3 DS 44 X18 15 AP 6 X51 5 DS 44 X18 34 i i AR 3 X49 2 4 DS 44 X18 4 j 1 AP 6 X51 6 DS 44 X18 13 FT 3 X36 2 DS 44 X18 11 FT 3 X35 2 3 3 CM 2 X16 2 CM 2 X16 1 ED 32 X63 11 FT 3 X35 1 FT 3 X36 1 11 26 32 31 10 15 34 4 11 13 B35 2 1 14 GB 2 X435 2 ED 32 X63 14 pk ye br gr bl gn bl gn ye gn rd bu ye or wh pk pk ye br gr bl gn ye gn ye or wh pk bl bl bu bu...

Page 205: ...EFI control unit B10 Throttle position sensor circuit A B12 Intake air temperature sensor B26 Rollover sensor B30 Side stand switch B31 Accelerator position sensor B34 Gear position sensor B35 Oil pressure sensor P10 Combination instrument ...

Page 206: ... 44 X18 24 AL 2 X52 2 DP 3 X53 3 DS 44 X18 14 DS 44 X18 35 c AL 2 X54 1 DS 44 X18 20 44 DV 2 X55 2 DS 44 X1833 DV 2 X55 1 DS 44 X18 2 AL 2 X54 2 36 1 EC 3 X57 3 38 i DP 3 X53 2 EC 3 X57 2 1 j AT 2 X56 2 AT 2 X56 1 ED 32 X63 5 12 ED 32 X63 7 B32 AL 2 AL 2 1 2 5 12 7 23 24 14 35 44 20 33 2 36 38 wh ye ye bu gn gr pu br br bl br ye bl ye wh wh ye ye bu gn gr pu bl br ye bl ye bu or br rd br br bl bl ...

Page 207: ...e sensor cylinder 1 B32 Fuel level indicator B37 Crankshaft position sensor B38 Clutch switch B41 Manifold absolute pressure sensor cylinder 1 P10 Combination instrument S55 Map Select Switch 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 ...

Page 208: ...rosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 223 SAE p 223 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motore...

Page 209: ... recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 223 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel...

Page 210: ...x products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Lubricant T511 Guideline KTM recommends Lubcon products Supplier Lubcon Turm...

Page 211: ...deline KTM recommends Molykote products Supplier Molykote 33 Medium Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motor...

Page 212: ...30 10 Art no 00029013004 Bleeder cover 201606 10 Art no 00029013010 Bleeding device 201491 10 Art no 00029013100 Bearing puller 400037 01 Art no 15112017000 Insert for bearing puller 400125 01 Art no 15112018100 Feature 18 23 mm 0 71 0 91 in ...

Page 213: ...syringe 400058 01 Art no 50329050000 Circlip pliers reverse 400059 01 Art no 51012011000 Extractor 400073 01 Art no 58429009000 Tool for inner bearing race 400082 01 Art no 58429037043 Mounting sleeve 400095 01 Art no 58529005000 ...

Page 214: ...ompressor 400101 01 Art no 59029019000 Limit plug gauge 400104 01 Art no 59029026006 Extractor 400105 01 Art no 59029033000 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Hose clamp pliers 400142 01 Art no 60029057000 ...

Page 215: ...ers for spring band clamp 400085 01 Art no 60029057100 Adapter 500079 01 Art no 61029055110 Front wheel stand 500078 01 Art no 61029055300 Rear wheel stand 500077 01 Art no 61029055400 Testing hose 201314 01 Art no 61029093000 ...

Page 216: ...400149 01 Art no 61029094000 Engine assembly stand 200306 01 Art no 61229001000 Work stand 400151 01 Art no 62529055000 Support for engine assembly stand 400153 01 Art no 75012001060 Holder for engine assembly stand 400154 01 Art no 75012001070 ...

Page 217: ...sembly ring 400156 01 Art no 75029015102 Extractor 400157 01 Art no 75029021000 Assembly screws 400158 01 Art no 75029033000 Insertion for piston ring lock 400160 01 Art no 75029035000 Work stand adapter 400161 01 Art no 75029036000 ...

Page 218: ...Art no 75029044010 Push in drift 500162 01 Art no 75029044020 Pressing device for crankshaft complete 400185 01 Art no 75029047000 Upper part pressing out tool 400186 01 Art no 75029047050 Under part pressing out tool 400187 01 Art no 75029047051 ...

Page 219: ...Extractor 400162 01 Art no 75029048000 Clamping plate 400163 01 Art no 75029050000 Push out drift 400164 01 Art no 75029051000 Floor jack attachment 400184 01 Art no 75029055000 Mounting sleeve 400165 01 Art no 75029080000 ...

Page 220: ...r segment 400068 01 Art no 75029081000 Protection cover 400167 01 Art no 75029090000 Holding spanner 400168 01 Art no 75029091000 Spark plug wrench 400170 01 Art no 75029172000 Oil pressure adapter 400176 01 Art no 77329006000 ...

Page 221: ...screw 400177 01 Art no 77329010000 Release device for timing chain tensioner 400181 01 Art no 77329051000 Valve spring mounting device 500165 01 Art no 78029060000 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S ...

Page 222: ...28 SPECIAL TOOLS 220 Pin 201235 10 Art no T120 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Vacuum pump 200273 10 Art no T1240S Pressing tool 200584 01 Art no T129 ...

Page 223: ...AL TOOLS 221 Protecting sleeve 200635 10 Art no T1401 Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art no T1402S Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S ...

Page 224: ...28 SPECIAL TOOLS 222 Mounting sleeve 300569 10 Art no T1515 Nitrogen filling tool 300574 10 Art no T170S1 ...

Page 225: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 226: ...shafts installing 144 valve clearance adjusting 155 valve clearance checking 154 valve cover installing 160 water pump cover mounting 156 Auxiliary substances 7 B Battery connecting 80 disconnecting 79 fitting 79 recharging 80 removing 79 Brake disc front brake installing 72 front brake removing 72 rear brake installing 74 rear brake removing 73 Brake discs checking 69 Brake fluid front brake addi...

Page 227: ...ling 124 crankshaft bearing inner ring removing 122 crankshaft run out at bearing pin checking 124 cylinder Nikasil coating 125 cylinder head checking 132 cylinder checking measuring 126 freewheel checking 142 freewheel installing 143 freewheel removing 143 left engine case section 120 main shaft assembling 140 main shaft disassembling 138 oil pumps for wear checking 128 piston ring end gap checki...

Page 228: ...uit 165 Oil filter changing 167 installing 168 removing 168 Oil screens cleaning 167 169 Operating substances 7 P Parking light bulb changing 98 Play in throttle cable adjusting 30 checking 30 Preparing for use after storage 183 R Rear hub rubber dampers checking 78 Rear sprocket checking 75 Rear wheel fitting 73 removing 72 Riding sag adjusting 35 Rim run out checking 70 S Seat mounting 60 removi...

Page 229: ...e 173 engine tightening torques 175 engine tolerance wear limits 173 fork 178 shock absorber 178 tires 177 Throttle cable routing checking 29 Tire air pressure checking 68 Tire condition checking 68 Type label 8 W Warranty 7 Winter operation checks and maintenance steps 182 Wiring diagram 186 205 page 01 of 10 186 page 02 of 10 188 page 03 of 10 190 page 04 of 10 192 page 05 of 10 194 page 06 of 1...

Page 230: ... 3206153en 3206153en 10 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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