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KTM 2014 690 SMC R EU, Repair Manual

The KTM 2014 690 SMC R EU Repair Manual is a comprehensive guide to maintaining and servicing your motorcycle. With detailed instructions and step-by-step procedures, this manual ensures easy repairs and maintenance. Download the free manual from manualshive.com to keep your KTM in top-notch condition.

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Summary of Contents for 2014 690 SMC R EU

Page 1: ...REPAIR MANUAL 2014 690 SMC R EU 690 SMC R AU GB Art no 3206193en ...

Page 2: ......

Page 3: ...lete 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 models portra...

Page 4: ...ear wheel sag 34 8 5 Checking the static sag of the shock absorber 34 8 6 Checking the riding sag of the shock absorber 35 8 7 Adjusting the spring preload of the shock absorber 35 8 8 Adjusting the riding sag 36 8 9 Removing the shock absorber 36 8 10 Installing the shock absorber 37 8 11 Servicing the shock absorber 39 8 12 Removing the spring 39 8 13 Dismantling the damper 40 8 14 Disassembling...

Page 5: ... 16 3 13 Removing the camshafts 114 16 3 14 Removing the cylinder head 115 16 3 15 Removing the piston 115 16 3 16 Removing the water pump impeller 116 16 3 17 Removing the rotor 116 16 3 18 Removing the timing chain rails 117 16 3 19 Removing the timing chain and timing chain sprocket 117 16 3 20 Removing the ignition pulse generator 118 16 3 21 Removing the clutch cover 118 16 3 22 Removing the ...

Page 6: ...y stand 173 17 CLUTCH 174 17 1 Checking rectifying the fluid level of the hydraulic clutch 174 17 2 Changing the hydraulic clutch fluid 174 18 SHIFT MECHANISM 175 18 1 Changing the gear position sensor 175 18 2 Programming the gear position sensor 177 19 WATER PUMP COOLING SYSTEM 178 19 1 Draining the coolant 178 19 2 Filling bleeding the cooling system 178 19 3 Checking the antifreeze and coolant...

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: ...a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 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 Po...

Page 10: ...of the frame 4 3 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Key number 100179 10 The key number 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 401947 10 The fork part number is stamped on the inner side of the fork stub ...

Page 11: ...4 SERIAL NUMBERS 9 4 6 Shock absorber part number 402025 10 The shock absorber part number 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 401943 10 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 401943 10 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: ...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 401426 11 Switching off ABS KTM recommends riding with ABS at all times However situations may arise in which ABS is no...

Page 16: ... Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 6 2 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 101982 10 Turn the red adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the right fork leg The rebound damping is locate...

Page 17: ...me dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind the dust boots can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inside fork tube of both fork legs Universal o...

Page 18: ...e screws and spacers Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the handbrake lever when the brake caliper is removed G00827 10 Loosen screw and screws Unscrew screw about 6 turns and press your hand on the screw to push the wheel spindle out of t...

Page 19: ...5 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft G00832 11 Position the fork protection Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft G00828 11 Position the brake line wiring harness and clamp Mount and tighten screws G00830 11 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of o...

Page 20: ...cle from the work stand p 12 G00827 11 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 6 9 Disassembling the fork legs Info These operations are the same on both fork legs Condition The fork legs have been removed 202305 10 Note down the current state of the rebound and compression damping Note...

Page 21: ...nfo Preload spacers should be above the special tool 202311 10 Clamp the special tool in the vise Release Preload Adjuster 202312 10 Remove Preload Adjuster with preload spacers Remove adjusting tube 202313 10 Pull the spring downwards Remove the special tool Remove the spring 202314 10 Clamp the fork leg with the axle clamp Guideline Use soft jaws Remove screw of the cartridge Info Place a contai...

Page 22: ...area of the lower sliding bushing Guideline 50 C 122 F Pull the outer tube from the inner tube with a jerk Info The lower sliding bushing must be pulled from its bearing seat 202104 12 Remove the upper sliding bushing Info Without using a tool carefully pull the stack apart by hand Take off the lower sliding bushing Take off support ring Take off seal ring Take off lock ring Take off dust boot Unc...

Page 23: ...005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the inner tube 200685 10 Measure the run out of the inner tube Run out of inner tube 0 20 mm 0 0079 in If the measured value is greater than the specified value Change the inner tube 202112 10 Check the outer tube for damage If there is damage Change the outer tube 200665 10 Check the surface of the sliding bus...

Page 24: ... axle clamp Install the special tool Protecting sleeve T1401 p 239 Grease and push on dust boot Lubricant T511 p 226 Info Always replace the dust boot lock ring seal ring and support ring Install the dust boot with the sealing lip and spring expander facing down ward Push on lock ring Grease and push on seal ring Lubricant T511 p 226 Info Sealing lip downward open side upward Push on support ring ...

Page 25: ...port ring Hold the seal ring with the shorter side of the special tool Mounting tool T14040S p 240 Push the seal ring and support ring all the way into the outer tube 200656 13 Mount lock ring Info The lock ring must engage audibly 200655 13 Install dust boot 202316 10 Assemble related individual components accordingly Info Compression damping side cartridge with additional oil holes white adjuste...

Page 26: ...tube protrudes more than 7 mm 0 275 in from the cartridge and cannot be pressed in against the resistance of the spring Lubricate the thread of the piston rod Lubricant T159 p 226 Lubricate the upper edge of the piston rod Lubricant T158 p 226 Screw the Preload Adjuster with the preload spacers onto the piston rod Info The Preload Adjuster must reach the stop before the piston rod begins turn ing ...

Page 27: ...ping side red adjuster axle clamp marked R 202323 10 Alternative 1 Turn the adjusting screw of rebound damping and the adjusting screw of compression damping clockwise as far as possible Turn back counterclockwise by the number of clicks corresponding to the fork leg type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Compression damping Comfo...

Page 28: ...hten 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 600636 10 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present ...

Page 29: ...ing a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw steering stem M8 20 Nm 14 8 lbf ft Finishing work Check the steering head bearing play p 26 Release the rear of the vehicle Remove the motorcycle from the work stand p 12 ...

Page 30: ...otorcycle and attachments to protect them from damage Do not kink the cables and lines Remove the two screws Take off the handlebar holder Move the handlebar holder to the desired position Mount and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the handlebar holders evenly on the left and right Position the handlebar Info Ensure that the c...

Page 31: ...10 Remove the cable binder G00780 10 Remove screw Push the trim aside G00782 10 Disconnect plug in connector Expose the cable of the accelerator position sensor G00783 10 Remove screws Take the combination instrument up out of the holder and hang to the side G00784 10 Loosen screw ...

Page 32: ...nsor from the handlebar G00788 10 Position throttle grip and accelerator position sensor on the handlebar Catch engages in driver G00789 10 Mount and tighten screws Guideline Screw throttle grip M5 3 5 Nm 2 58 lbf ft Catch engages in recess G00785 10 Position the handlebar guard Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 33: ...cure the cable with the cable binders G00783 10 Position the combination instrument in the holder Mount and tighten screws Guideline Remaining screws chassis M4 4 Nm 3 lbf ft G00780 10 Mount and tighten screw Guideline Remaining screws chassis M4 4 Nm 3 lbf ft G00779 10 Position the side cover Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 34: ...e the cable with the cable binder Finishing work Install the headlight mask with the headlight p 102 Check the headlight setting p 101 Reset the control unit engine electronics KHRS Program the gear position sensor p 177 Mount the seat p 62 ...

Page 35: ...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 36: ...d rear 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 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 M...

Page 37: ... 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 61 Take off the side cover p 62 Remove the shock absorber p 36 After removing the sho...

Page 38: ... 457 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 37 Mount the side cover p 62 Mount the seat p 62 Remove the motorcycle from the work stand p 12 Check the static sag of the shock absorber p 34 Adjust the rebound damping of the shock absorber p 34 8 9 Removing the shock absorber Preparatory work Raise the motorc...

Page 39: ...screws G00825 11 Loosen screw Remove screw Remove screw G00824 10 Fold the rear upward Take out shock absorber toward the top 8 10 Installing the shock absorber G00824 11 Main work Fold the rear upward and maneuver in shock absorber from above Fold the rear down and position the shock absorber ...

Page 40: ... G00818 12 Mount and tighten screws Guideline Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 G00742 15 Lift the rear fairing Mount and tighten screws Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft G00816 14 Mount and tighten screws Guideline Screw side cover M6 5 Nm 3 7 lbf ft G00821 11 Position grab handle Mount and tighten screws Guideline Screw handrail M8 20 Nm...

Page 41: ...d p 41 Check the damper p 42 Remove the heim joint p 43 Install the heim joint p 44 Assemble the piston rod p 45 Assemble the damper p 46 Install the spring p 51 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 and the adjusting...

Page 42: ...tely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw slowly The pressurized nitrogen escapes 201274 10 Clamp the damper in the vise using soft jaws Remove locking cap 201276 10 Press in seal ring retainer Remove lock ring Info Do not scratch the inner surface 201277 10 Remove screw Drain the oil 201278 10 Remove the piston rod Drain the remai...

Page 43: ...r p 40 300540 10 Main work Clamp the piston rod with the heim joint in a vise Remove nut 300541 10 Remove supporting plate and rebound shim stack together with piston Info Thread the rebound shim set on a screwdriver and set the parts down together 200572 11 Remove compression shim stack with supporting plate Info Thread the compression shim stack on a screwdriver and set the parts down together ...

Page 44: ...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 measured ...

Page 45: ...oint Condition The shock absorber has been removed 200577 10 Clamp the shock absorber in the vise using soft jaws for protection Remove collar bushing of the heim joint Pin T120 p 238 Turn over the shock absorber and remove collar bushing of the heim joint Pin T120 p 238 200578 10 Remove seal rings on both sides 200579 10 Remove lock rings on both sides ...

Page 46: ...lling the heim joint 200581 10 Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool T1206 p 238 Pressing tool T129 p 239 200579 11 Mount lock rings on both sides 200578 11 Mount seal rings on both sides and grease them Lubricant T158 p 226 200582 10 Press in both collar sleeves of the heim joint ...

Page 47: ...al ring and push seal ring retainer on to the piston rod Lubricant T625 p 226 Remove the special tool 200572 11 Mount supporting plate with the rounded side facing downward Mount the compression shim stack 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 Piston from above ...

Page 48: ...9 11 Main work Push the spring and sleeve onto the compression adjuster Mount the piston Mount and tighten compression adjuster Guideline Compression adjuster M26x1 30 Nm 22 1 lbf ft 201277 11 Mount and tighten screw 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 fluid SAE 2 5 5018...

Page 49: ...screw 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 all the way clockwise using a socket wrench Turn back counterclockwise the number of turns corres...

Page 50: ...amper 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 on the damper Info Tighten only hand tight without the use of tools Connect the adapter to connector of the vacuum pump Vacuum pump T1240S p 239 Clamp the damper with s...

Page 51: ...e Damper control lever 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 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 con trol...

Page 52: ... the special tool by the specified value distance minus specified value Guideline 10 mm Depth micrometer T107S p 238 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 53: ... tap handle Close spigot 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 and turn it down as far as possible The collar points to the adjusting ring Mount adjusting ring an...

Page 54: ... 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 Tension the spring to the amount measured during dismantling by turning adjusting ring Hook wrench T106S p 238 Tighten lock nut and the adjust...

Page 55: ...rk Remove the seat p 61 Take off the side cover p 62 G00811 10 Main work Remove cable binders Push the cable to the right Disconnect plug in connector of the lambda sensor Feed out the cable of the lambda sensor G00812 10 Remove screws Remove the exhaust heat shield G00813 10 Remove nuts of the manifold Info Do not misplace the spacer G00814 10 Loosen screw G00815 10 Remove screw Take off the mani...

Page 56: ...in silencer clamp M8 12 Nm 8 9 lbf ft Copper paste G00815 12 Position the screw clamp Mount and tighten screw Guideline Screw exhaust clamp M8 12 Nm 8 9 lbf ft Copper paste G00811 11 Connect plug in connector of the lambda sensor Route the wiring harness with out tension and secure it with cable binders G00812 11 Position the exhaust heat guard Mount and tighten screws Guideline Screw exhaust heat...

Page 57: ...em to cool down Do not touch hot components Preparatory work Raise the motorcycle with the work stand p 11 Remove the seat p 61 G00812 12 Main work Remove screws Remove the exhaust heat guard G00814 11 Loosen screw G00821 12 Remove screws Remove grab handle G00816 10 Remove screws Lift the rear fairing G00817 10 Remove screws Remove the main silencer ...

Page 58: ...ilencer clamp M8 12 Nm 8 9 lbf ft Copper paste G00812 13 Position the exhaust heat guard Mount and tighten screws Guideline Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Loctite 243 G00816 11 Mount and tighten screws Guideline Rear fairing screw M6 5 Nm 3 7 lbf ft G00821 13 Position grab handle Mount and tighten screws Guideline Screw handrail M8 20 Nm 14 8 lbf ft Finishing work Mount the seat p 62...

Page 59: ...er 10 2 Installing the air filter 601881 10 Main work Clean the air filter box Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing surface If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Hook air filter box top into the front of the air filter box and swing down 601882 11 Mount and tighten screws Gui...

Page 60: ...n work Remove screws Take off the voltage regulator and hang it to the side in a de energized state G00793 10 Remove screws G00794 10 Remove screws G00795 10 Loosen hose clip G00796 10 Detach vent hose G00797 10 Remove battery cover ...

Page 61: ... sensor Raise the air filter box at the rear Take off the air filter box 10 4 Installing the air filter box G00799 11 Main work Position the air filter box Plug in connector of the intake air temperature sensor and secure with the cable binder G00798 11 Position control unit G00797 11 Mount battery cover G00796 11 Route vent hose without bends and mount ...

Page 62: ...ng screws chassis M6 10 Nm 7 4 lbf ft G00793 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft G00792 11 Position the voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Mount the side cover p 62 Mount the seat p 62 ...

Page 63: ...Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage sy...

Page 64: ...he opposite side Finishing work Mount the seat p 62 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 overf...

Page 65: ...ty 10 l 2 6 US gal Perform the Actuator Test Function test of fuel pump control Guideline Maximum duration of actuator test 3 min 400927 01 Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active 3 3 3 7 bar 48 54 psi If the specification is not reached Open the filler cap p 61 Check the fuel tank breather 400928 01 Check the fuel pressure with the filler cap ...

Page 66: ...ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground wat...

Page 67: ...hose connections Unplug connector Remove the fuel pump 202049 10 Remove hose clamps Remove fuel filter Mount the new fuel filter Arrow points away from the fuel pump Mount hose clamps Hose clamp pliers 60029057000 p 230 202050 10 Press locking mechanism on both sides Pull off the fuel pump housing 202051 10 Change fuel screen Mount the fuel pump housing ...

Page 68: ...ne Remaining screws chassis M5 4 Nm 3 lbf ft G00818 10 Position the rear end Mount and tighten screw on both sides Guideline Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 G00817 12 Lift the rear fairing Mount and tighten screws Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft G00816 12 Mount and tighten screws Guideline Screw side cover M6 5 Nm 3 7 lbf ft Finishing ...

Page 69: ... the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allo...

Page 70: ...the new fuel pump attaching both fuel hose connections Connect plug in connector S00113 10 Position the fuel pump Mount and tighten screws Guideline Screw fuel pump M5 4 Nm 3 lbf ft G00819 10 Position the splash protector Mount and tighten screws Guideline Remaining screws chassis M5 4 Nm 3 lbf ft G00818 10 Position the rear end Mount and tighten screw on both sides Guideline Screw fuel tank botto...

Page 71: ...deline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft G00816 12 Mount and tighten screws Guideline Screw side cover M6 5 Nm 3 7 lbf ft Finishing work Install the air filter box p 59 Mount the side cover p 62 Disconnect the battery p 83 Mount the seat p 62 Set the clock p 99 ...

Page 72: ...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 73: ... 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 s...

Page 74: ...im run out Change the 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 101995 10 Main work Remove screw and pull wheel speed sensor out of the hole Remove screws and spacers Press back the brake linings with a light latera...

Page 75: ...nd grease the thread of the wheel spindle and screw Long life grease p 226 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Insert wheel speed sensor into the hole Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake caliper and check that th...

Page 76: ...with the ABS sensor wheel 12 6 4 Installing the brake disc of the front brake 402044 10 Main work Clean the contact surface of the brake disc Position the brake disc with the ABS sensor wheel The lettering on the ABS sensor wheel is located on the outside Mount and tighten screws Guideline Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Finishing work Install the front wheel p 73 Take the ...

Page 77: ...r grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers p 80 102002 10 Check the wheel bearing for damage and ...

Page 78: ...to the hole Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Check the chain tension Finishing work Take the motorcycle off of the rear wheel stand p 10 12 7 3 Removing the brake disc of the rear brake Preparatory work Raise the motorcycle with the rear wheel stand p 10 Remove the rear wheel p 74 402046 10 Main work Remove screws Take off the brake disc with the ABS s...

Page 79: ... deter mine the chain tension Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain positions Chain tension 5 mm 0 2 in Distance to chain sliding guard 30 mm 1 18 in If the chain tension does not meet specifications Adjust the chain tension p 77 12 7 6 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect cha...

Page 80: ...dle M25x1 5 90 Nm 66 4 lbf ft 12 7 7 Adjusting chain guide S00080 10 Remove screws and Take off the chain guide Condition Number of teeth 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Screw chain guide M6 8 Nm 5 9 lbf ft Condition Number of teeth 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Screw chain gui...

Page 81: ...lso be changed New chains wear out faster on old worn sprockets 401170 01 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M6 8 Nm 5 9 lb...

Page 82: ...se and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove o...

Page 83: ...rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play hold the rear wheel tight and try to rotate the rear sprocket with your hand Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If play is larger than the specified value Change all rubber dampers in the rear hub Finishing work I...

Page 84: ...onnect negative cable of the battery Take off the positive terminal cover and disconnect the positive cable from the battery Remove screws Pull retaining bracket of the battery forward and remove it Lift the battery up and out 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 therefo...

Page 85: ... 62 Set the clock p 99 13 5 Recharging 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...

Page 86: ...d to be checked Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 61 Remove the battery p 82 100151 10 Main work Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the battery and to test the alternator With this device you c...

Page 87: ... work Remove the battery cover Disconnect the negative minus cable of the battery Measure the current between battery ground and the negative cable Info The value of the open circuit current only applies to vehicles in the original state without additional power consumers Maximum open circuit current 1 0 mA If the measured value is greater than the specified value Disconnect the voltage regulator ...

Page 88: ... Insert a new replacement fuse into the starter relay to have it available when needed Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 62 Set the clock p 99 13 9 Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all powe...

Page 89: ...ses Info A defective fuse is indicated by a burned out fuse wire 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 194 Fuse 75011088015 p 194 Tip Put a new spare fuse in the fuse box for future use if needed Check the funct...

Page 90: ...th 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 P...

Page 91: ... 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 D...

Page 92: ... 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 B01955 10 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing wheel Info Pull the hand brake lever forward and turn the adjusting wheel Do not make any adjustments while riding 14 4 ...

Page 93: ...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 94: ...tal position Cover the painted parts Remove screws Remove cover 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 229 Brake fluid DOT 4 DOT 5 1 p 224 G00804 10 Mount bleeder cover Bleeder cover 00029013010 p 228 Connect the bleeding device Bleeding device 00029013100 p 228 201494 10 Open shut off valv...

Page 95: ...uced and the brake discs are destroyed Check the brake linings regularly 101994 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 93 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings p 93 14 8 Changing the rear brake linings Warning D...

Page 96: ...ween brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 101993 10 Stand the vehicle upright Remove screw cap with membrane 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 pushi...

Page 97: ...he foot 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 101991 10 Loosen fitting on foot brake cylinder To adjust the basic position of the foot brake lever individually loosen nut and turn screw accordingly Info The range of adjustment is limited The screw must be screwed int...

Page 98: ...ely 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 silico...

Page 99: ...Take off screw cap with the washer and 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 229 Brake fluid DOT 4 DOT 5 1 p 224 G00809 10 Mount bleeder cover Bleeder cover 00029013004 p 228 Connect the bleeding device Bleeding device 00029013100 p 228 201494 11 Open shut off valve Info Follow the operating in...

Page 100: ...ir Tighten the bleeder screw Remove the hose of the bleeder bottle Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover G00808 11 Add brake fluid to the MAX mark Brake fluid DOT 4 DOT 5 1 p 224 Mount the screw cap with the washer and membrane Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 101: ... 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 102: ...ion The motorcycle is stationary Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 101 302064 10 Main work Unplug connector ED from the combination instrument Unlock pin 18 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 th...

Page 103: ...ark does not meet specifications Adjust the headlight range p 101 15 3 Adjusting the headlight range Preparatory work Check the headlight setting p 101 102024 10 Main work Turn adjusting screw 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 104: ...groove on counterpiece 102025 11 Position brake line guides Mount and tighten screws Guideline Screw headlight mask M5 5 Nm 3 7 lbf ft Finishing work Check the headlight setting p 101 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 before mo...

Page 105: ...htness 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 101 600610 10 Main work Pull off connector Take off protection cap of the headlight bulb 600611 10 Detach spring bar Remove headli...

Page 106: ...nal glass 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 194 Position the turn signal glass Inse...

Page 107: ...h the radiator hoses Pliers for spring band clamp 60029057100 p 231 G00834 10 Remove screws G00835 10 Remove screws Take off the engine sprocket cover Remove screw Take off the shift lever G00836 10 Bend up lock washer Have an assistant operate the rear brake Remove the nut of the engine sprocket with the lock washer G00837 10 Remove nut Remove the chain adjuster Pull out the wheel spindle only fa...

Page 108: ...f the clutch push rod G00839 10 Pull back the protection cap Remove nut Remove screw G00840 10 Loosen hose clip Pull off the throttle valve body from the rear G00841 10 Disconnect plug in connector of the gear position sensor crankshaft position sensor and alternator G00842 10 Detach the spark plug connectors Unplug the connector of the engine coolant temperature sensor G00843 10 Loosen the spring...

Page 109: ...it using the special tool Floor jack attachment 75029055000 p 235 G00847 10 Remove nut and screw of the lower engine bracket G00848 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 t...

Page 110: ...5 G00845 11 Position the engine bearer Mount and tighten screws Guideline Screw engine bearer on frame M10 45 Nm 33 2 lbf ft Mount and tighten fitting Guideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Tighten the screw of swingarm pivot Guideline Screw swingarm pivot M12 80 Nm 59 lbf ft Tighten fitting of the lower engine bracket Guideline Engine carrying screw M10 45 Nm 33 2 lbf f...

Page 111: ...tion the throttle valve body Position and tighten hose clip G00839 11 Position the electrical connection on the starter motor Mount and tighten screw Mount the protection cap Guideline Screw cable on starter motor M5 3 Nm 2 2 lbf ft Position the ground wire on the starter motor Mount and tighten screw Guideline Screw starter motor M6x20 10 Nm 7 4 lbf ft Loctite 243 G00838 11 Insert the clutch push...

Page 112: ...et M20x1 5 80 Nm 59 lbf ft Loctite 243 Secure the nut with lock washer G00835 11 Position the engine sprocket cover Mount and tighten screw Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the shift lever Mount and tighten screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 G00834 11 Mount...

Page 113: ... fault memory using the KTM diagnostics tool Check the engine for leakage Check the engine oil level p 181 Check the coolant level p 180 16 3 Disassembling the engine 16 3 1 Clamping the engine into the engine assembly stand 305506 10 Mount special tool on engine assembly stand Engine assembly stand 61229001000 p 232 Support for engine assembly stand 75012001060 p 232 Holder for engine assembly st...

Page 114: ...6 3 4 Removing the valve cover 305517 10 Remove screws Take off the valve cover with the valve cover seal 16 3 5 Removing the alternator cover 305518 10 Remove screws Take off the alternator cover 305520 10 Take off alternator cover gasket and remove dowels 16 3 6 Removing the spacer 305521 10 Remove spacer ...

Page 115: ...r Circlip pliers reverse 51012011000 p 229 305549 10 Remove screws Take off the oil filter cover with the O ring Remove oil filter Circlip pliers reverse 51012011000 p 229 16 3 9 Removing the thermostat 305528 10 Remove screws Take off the thermostat case Remove thermostat 16 3 10 Setting engine to ignition top dead center 305531 10 Turn the crankshaft counterclockwise until markings of the camsha...

Page 116: ... the spark plugs 305516 10 Remove spark plugs and Spark plug wrench 75029172000 p 236 16 3 12 Removing the timing chain tensioner 305539 10 Remove screw with the seal ring Remove timing chain tensioner 16 3 13 Removing the camshafts 305542 10 Remove screw Take off the camshaft support plate 305543 10 Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the ...

Page 117: ...Push the cylinder upward only far enough to allow removal of the piston pin Ensure that the two grooved pins remain in place 305551 10 Remove piston pin retainer Remove the piston pin Take off the cylinder with the piston Push the piston upward out of the cylinder Info If no other work is required on the cylinder and the piston you can leave the piston in the cylinder 305552 10 Take off the cylind...

Page 118: ...f the water pump cover seal Info Ensure the locating pins remain in place 305558 10 Remove formed washer 16 3 17 Removing the rotor 305560 10 Remove special tool Engine blocking screw 77329010000 p 237 305561 10 Hold the rotor with special tool Holding spanner 75029091000 p 236 Info Make sure that the crankshaft is not blocked Remove nut and the locking edge washer ...

Page 119: ...iming chain securing guide through the timing chain guide rails Remove the timing chain guide rails upward out of the timing chain shaft 305566 10 Hold the timing chain securing guide tight and pull the timing chain tensioning rail 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 16 3 19 Remov...

Page 120: ...on pulse generator 305572 10 Remove screws Pull cable sleeve out of the engine case Remove the ignition pulse generator 16 3 21 Removing the clutch cover 305573 10 Remove screws Take off the clutch cover 305574 10 Remove the clutch cover gasket Take off dowels 16 3 22 Removing the spacer and spring 305575 10 Remove spacer and spring ...

Page 121: ...onally and remove them with their spring retainers and clutch springs Remove pressure cap 305578 10 Remove pressure piece Bend open lock washer 305579 10 Hold the clutch basket with special tool Gear segment 75029081000 p 236 Info Make sure that the crankshaft is not blocked Remove nut Remove the lock washer Remove nut Info Left handed thread Remove the special tool Gear segment 75029081000 p 236 ...

Page 122: ...24 Removing the primary gear 305585 10 Position special tool Protection cover 75029090000 p 236 Mount special tool Extractor 75029021000 p 233 Hold it using the special tool and pull off the primary gear by turning the screw in Remove the special tools 16 3 25 Removing the starter drive 305614 10 Remove lock ring Take off the starter idler gear with the washers ...

Page 123: ...Remove woodruff key and both needle bearings 16 3 26 Removing shift shaft 305618 10 Push sliding plate away from the shift drum locating Remove shift shaft with the washer 16 3 27 Removing shift drum locating 305619 10 Remove screw Press locking lever away from shift drum locating and take off the shift drum locating Release the locking lever ...

Page 124: ...and spring 16 3 29 Removing the oil pumps 305624 10 Remove lock washers and normal washers from both oil pumps Take off the oil pump gear wheels 305625 10 Remove pins and washers 305626 10 Remove screws Take off the oil pump cover 305627 10 Remove oil pump shaft with the internal rotors Remove external rotor ...

Page 125: ...up and remove the nut or screw of the engine fixing arm 305633 10 Install special tool with suitable screws Extractor 75029048000 p 235 Info Use the 750 drill hole Pull off the section of the engine case Info Do not tension the section of the engine case The balancer 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...

Page 126: ...emove balancer shaft and crankshaft 16 3 32 Removing the transmission shafts 305638 10 Remove shift rail 305639 10 Swing shift forks to one side Remove shift drum 305640 10 Remove shift forks Info Ensure that the pins remain in place 305641 10 Remove lock ring and the stop disk ...

Page 127: ...shaft seal ring of the crankshaft from the inside to the outside Remove the shaft seal rings of the water pump Press in the shaft seal ring of the crankshaft from the outside to the inside with the open side facing in Info The shaft seal ring must be flush on the outside Press in the shaft seal rings of the water pump with the open side facing out so that it is flush Warm the engine case section a...

Page 128: ...er plate for oil return line M5 6 Nm 4 4 lbf ft Reinstall the dowels 16 4 2 Work on the left section of the engine case 305646 10 Remove all dowels Remove oil jet Remove the shaft seal ring of countershaft and shift shaft Info The shaft seal ring of the crankshaft cannot be removed before the crankshaft bearing Screw off the membrane support plate and remove it together with membrane Remove screw ...

Page 129: ...ase when warm In this case the engine case must be renewed Mount and tighten screw with the washer Guideline Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 Press in the shaft seal ring of countershaft and shift shaft with the open side facing inwards so that it is flush Mount and tighten the oil jet Guideline Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Mount the dowels Blow ...

Page 130: ...ing 302145 10 Fix the crankshaft with special tools and in the vise Upper part pressing out tool 75029047050 p 234 Under part pressing out tool 75029047051 p 235 302146 10 Heat the special tool Guideline 150 C 302 F Tool for inner bearing race 58429037043 p 229 Push the heated special tool on to the inner bearing race press them hard together and pull them together off the crankshaft Take off the ...

Page 131: ...earing 300138 10 Press the crank pin out of the crankweb 305653 10 Press in the new crank pin as far as possible Info The crank pin must be pressed in so that oil channel is aligned with oil channel If the oil channels are not correctly aligned the conrod bearing will not be supplied with oil Blow compressed air through the oil channel to check that it is clear 305654 10 Mount bearing and connecti...

Page 132: ...e Finishing work Check the crankshaft run out at the bearing pin p 130 Install the drive wheel of the balancer shaft p 130 Install the crankshaft bearing inner ring p 131 Measure the axial clearance of the crankshaft and the balancer shaft p 131 16 4 7 Checking crankshaft run out at bearing pin 300132 10 Position the crankshaft on a roller block Rotate the crankshaft slowly Check the crankshaft ru...

Page 133: ...tion shim Heat the special tool Install the inner bearing race Guideline 120 C 248 F Repeat the operation on the opposite side Make sure that the new inner bearing race is installed flush Info After changing the crankshaft bearing and the conrod bearing measure the axial play of the crankshaft Finishing work Measure the axial clearance of the crankshaft and the balancer shaft p 131 16 4 10 Measuri...

Page 134: ...too large add compensation shims 16 4 11 Cylinder Nikasil coating 305656 10 Nikasil is a surface protection layer for a coating method developed by the Mahle company The name is derived from the two materials used in this method a layer of nickel in which silicon carbide a particularly hard substance is embedded The most important advantages of the Nikasil coating are the excellent heat conduc tiv...

Page 135: ...the piston and piston rings Check measure the cylinder p 132 305645 10 Check the piston bearing surface for damage If the piston bearing surface is damaged Change the piston and if necessary the cylinder Check that the piston rings can move easily in the piston ring grooves If the piston ring is stiff Clean the piston ring groove Tip Use an old piston ring to clean the piston ring groove Check the...

Page 136: ...rking facing toward the piston head 16 4 15 Determining the piston cylinder mounting clearance 305645 10 Check measure the cylinder p 132 Check measure the piston p 133 The smallest piston cylinder mounting clearance is the result of the smallest cylin der bore diameter minus the largest piston diameter The largest piston cylinder mounting clearance is the result of the largest cylinder bore diame...

Page 137: ...ere is damage or wear Change the oil pumps Check oil pump shafts for damage and wear If there is damage or wear Change the oil pump shaft Check both oil pump covers for damage and wear If there is damage or wear Change the oil pump cover 16 4 17 Replacing autodecompressor 300107 10 Take the lock ring off the autodecompression shaft and dispose of it 300108 10 Pull the autodecompression shaft from ...

Page 138: ...ain tensioner for installation 200171 10 Fully compress the timing chain tensioner Info This requires considerable force since the oil has to be pressed out Release the timing chain tensioner Without pressure the timing chain tensioner expands fully 200172 10 Place two compensating disks or similar aids next to the piston of the timing chain tensioner This should ensure that when pushed down the p...

Page 139: ...mage and wear If there is damage or wear Change the timing chain guide rail Check timing chain securing guide for damage and wear If there is damage or wear Change the timing chain securing guide Check timing chain for damage and wear If there is damage or wear Change the timing chain Check that the timing chain links move easily Let the timing chain hang down freely If the chain links no longer s...

Page 140: ... screw into the rocker arm shafts Pull out the rocker arm shafts Take off rocker arm 16 4 21 Changing the camshaft bearing Preparatory work Remove the rocker arm p 138 305668 10 Main work Mount the cylinder head on the special tool Clamping plate 75029050000 p 235 305669 10 Remove the large camshaft bearing using special tool Push out drift 75029051000 p 235 Info Brace the back of the special tool...

Page 141: ...Finishing work Install the rocker arm p 142 16 4 22 Removing the valves 300116 10 Pretension the valve springs using the special tool Valve spring compressor 59029019000 p 230 Valve spring mounting device 78029060000 p 237 Remove the valve keys and release the tension on the valve springs Remove the spring retainer and spring Pull the valve down and out of the valve guide and remove the valve stem...

Page 142: ...nimum length without valve spring cap 42 3 mm 1 665 in If the measured value does not equal the specified value Change the valve spring 16 4 25 Checking valve spring retainer 305594 10 Check the valve spring retainer for fractures and 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 ...

Page 143: ...ured value does not equal the specified value Machine the valve seat Blow compressed air through all oil channels and check that they are clear 16 4 27 Installing the valves 305596 10 Position the valve spring seat Mount the new valve stem seals Mount valves according to their normal built in position Mount valve springs and the spring retainers 300116 11 Pretension the valve springs using the spe...

Page 144: ...ill hole and the flat surface must face upward Remove screw 305665 11 Mount and tighten screws Guideline Screw rocker arm shaft M6x30 12 Nm 8 9 lbf ft 305664 11 Place shims into the valve spring retainers according to their normal built in position 16 4 29 Disassembling the antihopping clutch 300120 10 Clamp the clutch in a vise Info Use soft jaws Carefully loosen and gradually remove the special ...

Page 145: ...e clutch facing discs from the inner clutch hub Remove pretension ring and support ring Clean all parts well Check the clutch p 143 16 4 30 Checking the clutch Preparatory work Disassemble the antihopping clutch p 142 305657 10 Main work Check pressure piece for damage and wear If there is damage or wear Change the pressure piece Check axial bearing for damage and wear If there is damage or wear C...

Page 146: ...not even or are pitted Change all intermediate clutch discs Check clutch facing discs for discoloration and scoring If there is discoloration or scoring Change all clutch facing discs Check the thickness of clutch facing discs Clutch facing disc thickness 2 5 mm 0 098 in If the clutch facing disc does not meet specifications Change all clutch facing discs Check stepped washer for damage and wear I...

Page 147: ...hub Push the two clutch hubs firmly together and have an assistant screw in the special tool Assembly screws 75029033000 p 233 Info Apply the special tool with the hand only do not use another tool Apply the special tool only firmly enough so that the clutch facing discs can still be turned against each other since they still have to be aligned for mounting in the clutch basket 16 4 32 Checking th...

Page 148: ...is worn Change the sliding plate Check return surface on the sliding plate for wear If deep notches are present Change the sliding plate Check guide pin for looseness and wear If the guide pin is loose and or worn Change the sliding plate Preassemble the shift shaft p 146 305598 10 Check play between the sliding plate and the shift quadrant Shift shaft play in sliding plate shift quadrant 0 40 0 8...

Page 149: ...emove stop disk and second gear fixed gear Remove the sixth gear idler gear Remove the split needle bearing and stop disk Remove lock ring Info Open the lock ring with a screwdriver and twist it off the transmission shaft with pliers Remove the third fourth gear sliding gear Remove lock ring Remove stop disk and fifth gear idler gear Remove bearing bush ...

Page 150: ...ing gear and lock ring Info Open the lock ring with a screwdriver and twist it off the transmission shaft with pliers Remove stop disk and third gear idler gear Remove needle bearing and the fourth gear idler gear Remove needle bearing and stop disk Remove lock ring and sixth gear sliding gear Remove lock ring and stop disk Remove the second gear idler gear and bearing bush 16 4 36 Checking the tr...

Page 151: ...eel pair Check the shift dogs of idler gears sliding gears and fixed gear for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears sliding gears and fixed gear for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears for damage and wear If there is damage or wear Change the gear wheel p...

Page 152: ...all parts carefully before assembling Check the transmission p 148 306234 10 Main work Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Lubricate and mount bearing bush Long life grease p 226 Push on the fifth gear idler gear with the shift dogs facing upward Mount stop disk Position special tool on the transmission shaft Mounting tool for lock ring 750290...

Page 153: ... mount stop disk Finally check all gear wheels for smooth operation 16 4 38 Assembling the countershaft Info Use new lock rings in every repair job Preparatory work Lubricate all parts carefully before assembling Check the transmission p 148 306235 10 Main work Fix the countershaft in the vise with the geared end facing downward Guideline Use soft jaws Mount bearing bush and the second gear idler ...

Page 154: ... p 233 Position lock ring on special tool and push down with sleeve The lock ring engages in the groove of the transmission shaft Mount the fifth gear sliding gear with the shift groove facing downward and stop disk Mount needle bearing first gear idler gear with the recess facing downward and stop disk Finally check all gear wheels for smooth operation 16 4 39 Checking the starter drive 305600 10...

Page 155: ...ge O ring of the starter motor 16 4 40 Checking freewheel 300131 10 Insert the freewheel gear in the primary gear turning the primary gear clockwise do not twist Check the locking action of the freewheel gear If the primary gear does not turn clockwise or if it does not lock counterclock wise Remove the freewheel p 153 Turn the freewheel 180 Install the freewheel p 153 16 4 41 Removing freewheel 3...

Page 156: ...seated correctly 16 5 Assembling the engine 16 5 1 Installing the transmission shafts 305652 10 Clamp the right section of the engine case Holder for engine assembly stand 75012001070 p 232 Support for engine assembly stand 75012001060 p 232 Engine assembly stand 61229001000 p 232 Make sure that both stop disks are installed Mount the inner bearing race on the countershaft 305642 11 Oil all bearin...

Page 157: ...ft drum into the bearing seat Hang the shift forks into the shift drum 305638 11 Mount shift rail Check the transmission for smooth operation 305641 11 Mount the washer and lock ring 16 5 2 Installing crankshaft and balancer shaft 302136 10 Mount the special tool on the alternator side of the crankshaft Mounting sleeve 75029080000 p 236 Mount the special tool on the balancer shaft Mounting sleeve ...

Page 158: ...ction of the engine case If necessary tap lightly with a rubber mallet and turn the transmission shafts Info Do not tighten the engine case sections using the screws Mount screw but do not tighten it yet Guideline Screw engine case M6x80 10 Nm 7 4 lbf ft Mount screw but do not tighten it yet Guideline Screw engine case M6x70 10 Nm 7 4 lbf ft Mount screws but do not tighten yet Guideline Screw engi...

Page 159: ...m 4 4 lbf ft Loctite 243 305631 10 Mount the pin and internal rotor on the oil pump shaft Position the external rotor in the engine case The marking is not visible after mounting Mount the oil pump shaft with internal rotor Oil the parts 305626 11 Position the oil pump cover Mount and tighten screws Guideline Screw oil pump cover top M5 6 Nm 4 4 lbf ft Loctite 243 Mount and tighten screws Guidelin...

Page 160: ...t drum locating are not symmetric 305621 10 Release the locking lever Mount and tighten screw Guideline Screw shift drum locating M6x30 10 Nm 7 4 lbf ft Loctite 243 16 5 7 Installing shift shaft 305618 11 Slide shift shaft with the washer into the bearing seat Push sliding plate away from the shift drum locating Insert the shift shaft all the way Let the sliding plate engage in the shift drum loca...

Page 161: ...305614 11 Mount the starter idler gear with the washer Mount lock ring 16 5 9 Installing the primary gear 305586 10 Ensure that the woodruff key is seated properly Mount primary gear Info Turn freewheel gear backwards and forwards to ease meshing 16 5 10 Installing the clutch basket 305583 11 Mount supporting plate and needle bearing ...

Page 162: ... uppermost clutch facing disc is offset by one tooth Info If necessary turn the main shaft a little to ease access 305584 10 Mount the new lock washer with nut Lock the clutch basket and primary gear using special tool and tighten the nut Guideline Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Gear segment 75029081000 p 236 Info Make sure that the crankshaft is not blocked Secure the...

Page 163: ... 5 11 Installing the spacer and spring 305575 10 Position spacer and spring 16 5 12 Installing the clutch cover 305574 11 Mount dowels and position the clutch cover gasket 305587 10 Position the clutch cover Mount screws but do not tighten yet Guideline Screw clutch cover M6x30 10 Nm 7 4 lbf ft Mount screw but do not tighten it yet Guideline Screw clutch cover M6x35 10 Nm 7 4 lbf ft Mount screws a...

Page 164: ... chain sprocket and push it immediately on to the crankshaft Guideline 100 C 212 F Mount lock ring 305569 11 Thread the timing chain in and lay it over the timing chain sprocket Info If the timing chain is not new pay attention to the direction of travel 16 5 15 Installing the timing chain rails 305567 10 Position the timing chain securing guide The ignition pulse generator cable is routed in the ...

Page 165: ...otor 305563 10 Ensure that woodruff key is seated properly Degrease the cone of the crankshaft and rotor Mount the rotor Info Make sure that the crankshaft is not blocked 305561 10 Hold the rotor with special tool Holding spanner 75029091000 p 236 Mount and tighten nut with the locking edge washer Guideline Rotor nut M18x1 5 100 Nm 73 8 lbf ft 16 5 17 Adjusting crankshaft position sensor distance ...

Page 166: ...305559 10 Mount water pump impeller Mount and tighten screw Guideline Screw water pump impeller M6x15 10 Nm 7 4 lbf ft Loctite 243 Lay on the water pump cover seal 305556 11 Position the water pump cover Mount and tighten screws Guideline Screw water pump cover M6x30 10 Nm 7 4 lbf ft 16 5 20 Installing piston 302600 10 Shift the joint of the piston rings by 120 Push the oiled piston into the speci...

Page 167: ...ton marking faces the outfeed side 305553 10 Apply a thin layer of sealing compound in area Loctite 5910 Place the cylinder base gasket on Info Make sure the grooved pins are seated correctly 305554 10 Cover the engine case opening with a cloth Thread the timing chain through the chain shaft Mount the piston pin Info For clarity the following steps are illustrated using a disassembled piston 40036...

Page 168: ...oved pins engage 16 5 21 Installing the cylinder head 305545 11 Put on the cylinder head gasket Info Make sure the grooved pins are seated correctly Mount the cylinder head Mount and tighten screws with the washers Guideline Cylinder head screw M10 Tightening sequence Tighten 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...

Page 169: ... head are aligned 305547 10 Position the camshaft support plate Mount and tighten screw Guideline Screw camshaft support plate M6x12 10 Nm 7 4 lbf ft Loctite 243 Marking of the camshaft is aligned with the marking of the camshaft sup port plate 16 5 23 Installing timing chain tensioner 305540 10 Insert the timing chain tensioner Mount and tighten plug with the new seal ring Guideline Plug timing c...

Page 170: ...3 10 Remove special tool Crank the engine several times Set the engine to ignition top dead center p 113 305534 10 Check the valve clearance on all valves between the valve and the rocker arm using the special tool Guideline Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Feeler gauge 59029041100 p 230 If valve clearance does not meet specifications Adjust the valve clearance p 169 306140 10 Remove ...

Page 171: ...ing to the installation position Correct the shims as indicated by the results of the valve clearance check Insert suitable shims 305537 10 Position the rocker arms and mount the rocker arm shafts The tapped hole of the rocker arm shaft faces outward Drill hole and the flat surface face upward 305535 11 Mount and tighten screws Guideline Screw rocker arm shaft M6x30 12 Nm 8 9 lbf ft Mount and tigh...

Page 172: ...on thermostat with the gasket Drill hole must face upward 305530 10 Position the thermostat case Mount and tighten screws Guideline Screw thermostat case M6x20 10 Nm 7 4 lbf ft Loctite 243 16 5 28 Installing the oil filter 305527 10 Insert oil filter Oil the O ring of the oil filter cover and mount it with the oil filter cover Mount and tighten screws Guideline Screw oil filter cover M5x16 6 Nm 4 ...

Page 173: ...rea and O ring before mounting Long life grease p 226 Position the O ring in the recess of the spacer 305521 10 Grease the shaft seal ring Long life grease p 226 Slide the spacer with the O ring onto the countershaft 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 the alternator cover 3055...

Page 174: ...te engine case wall and push the oil screen as far as possible into the engine case 305508 10 Mount the oil drain plug with the magnet and a new seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 305511 10 Position the oil screen with O rings Mount and tighten screw...

Page 175: ...alve cover with the gasket Mount and tighten screws Guideline Screw valve cover M6 10 Nm 7 4 lbf ft 16 5 35 Removing the engine from the engine assembly stand 305506 11 Remove the engine from the engine assembly stand Info Have an assistant help you or use a motorized hoist ...

Page 176: ...environmental 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 Remove cover with membrane Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 p 229 Hydraulic fluid 15 p 225 On the clutch slave...

Page 177: ...ise the motorcycle with a lift stand p 11 G00772 10 Main work Remove screw Take off the engine sprocket cover G00773 10 Remove cable binder G00774 10 Disconnect plug in connector G00775 10 Remove cable binder Expose the cable G00776 10 Remove screws Take off the gear position sensor ...

Page 178: ...cure the wiring harness with cable binder G00774 10 Connect plug in connector Route the cable without tension G00773 10 Secure the connector with cable binder G00772 11 Position the engine sprocket cover Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Finishing work Program the gear posit...

Page 179: ...ics tool is connected and running Preparatory work Reset the control unit engine electronics KHRS Main work Execute Engine electronics Functions Program the gear position sensor Switch to the main menu Switch the ignition off and on again The green idling speed indicator lamp N lights up ...

Page 180: ...ildren 102016 10 Stand the motorcycle upright Place a suitable container under the engine Remove screw Take off the radiator cap Completely drain the coolant Mount screw with a new seal ring and tighten it Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft 19 2 Filling bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not com...

Page 181: ...ately 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 con...

Page 182: ...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 contaminated with coolant Keep coolant out of reach of children Condition Engine is cold 102014 10 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the com...

Page 183: ...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 20 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 184: ...able regulations S00101 10 Main work Remove screw 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 237 Connect the pressure tester to the special tool without the T plate Pressure testing tool 61029094000 p 232 Check the engine oil level p 181 Danger Danger of poison...

Page 185: ... 601022 10 Drain the engine oil p 183 Remove the oil filter p 184 Clean the oil screens p 185 Install the oil filter p 184 Fill up with engine oil p 186 20 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 Enviro...

Page 186: ...ners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 102020 10 Main work Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 p 229 102021 10 Remove screws Take off the oil filter cover with the O ring Pull oil filter out o...

Page 187: ...of as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 100205 10 Main work Remove screw plug with oil screen and the O rings 100206 10 Remove screw plug with oil screen and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 100207 10 Position oil screen with the O rings Mount and tighten screw plug with...

Page 188: ...s oil tight Finishing work Check the engine oil level p 181 20 10 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 0 0 1 1 401955 10 Main work Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 224 Engine oil SAE 10W 50 p 224 Info For optimal performance of t...

Page 189: ...tator 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 G00802 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 displayed v...

Page 190: ...emove the seat p 61 Take off the side cover p 62 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 191: ... 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 without activating the throttle grip Guideline Coolant temperature 25 C 77 F Let the engine idle for at least 10 minutes 600 seconds Info Do not activate the throttle grip during the initialization p...

Page 192: ...atio 1st 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 Inside spark plug NGK LKAR8BI 9 Outside spark plug NGK LMAR7A 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permane...

Page 193: ...ankshaft axial clearance 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 val...

Page 194: ... 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 lbf ft Screw crankshaft position sensor M6x16 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition coil M6 10 Nm 7 4 lbf ft Screw locking lever M6x20 10 N...

Page 195: ...ith magnet M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Screw plug oil channel M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 6...

Page 196: ... loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary drive ratio 16 42 Chain 5 8 x 1 4 X ring Steering head angle 63 Wheelbase 1 480 15 mm 58 27 0 59 in Seat height unloaded 890 mm 35 04 in Ground clearance unloaded 270 mm 10 63 in Weight without fuel approx 144 kg 317 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb Maximum permissible ov...

Page 197: ...te Medium standard 5 3 N mm 30 3 lb in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Fork length 895 mm 35 24 in Fork oil per fork leg 625 ml 21 13 fl oz Fork oil SAE 4 48601166S1 p 225 23 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 ...

Page 198: ... 3 Nm 2 2 lbf ft Screw fuel pump M5 4 Nm 3 lbf ft Screw fuel tank closure flange M5 2 5 Nm 1 84 lbf ft Screw headlight mask M5 5 Nm 3 7 lbf ft Screw pressure regulator M5 4 Nm 3 lbf ft Screw throttle grip M5 3 5 Nm 2 58 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws on fuel tank M6 5 Nm 3 7 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw connection foot brake cylinder...

Page 199: ... Nm 18 4 lbf ft Screw rear footrest bracket M8x16 25 Nm 18 4 lbf ft Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 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 scr...

Page 200: ...al motorcycle cleaner and a soft sponge Never apply motorcycle cleaner 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 bra...

Page 201: ...with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 198 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 tho...

Page 202: ...6 Refuel Clean the motorcycle p 198 Change the engine oil and filter clean the oil screens p 183 Check the antifreeze and coolant level p 179 Check the tire air pressure p 70 Remove the battery p 82 Recharge the battery p 83 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Store the vehicle in a dry location that is not subject to large fluctuations in tem perature I...

Page 203: ... p 77 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 brake fluid level of the front brake p 90 Bleed the fork legs p 15 Check the steering head bearing play p 26 Change the spark plug Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrec...

Page 204: ... b c 30 AF 4 X12 2 1 AF 4 X12 3 4 EB 4 X19 4 EB 4 X19 3 1 2 K10 30A 3 1 2 4 A B Oese 1 X75 1 Oese 1 X74 1 FJ 2 X119 1 FJ 2 X119 2 CR 1 X292 1 CR 1 X291 1 1 AU 2 X11 2 G20 2 3 EN 3 1 T20 BI 2 EM 3 1 2 3 2 1 GF 48 X1 30 1 0 3 X 2 0 3 X start relais wh rd bl rd bl rd wh rd gn rd bu rd bu br bl gn br wh rd ye rd ye rd wh rd wh rd wh rd bl rd bl rd rd bl bl bl wh rd wh rd rd rd gn gn gn G00401 01 ...

Page 205: ...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 206: ...BK 4 4 3 1 2 10A F3 1 2 M13 2 1 29 3 46 1 17 AP 6 X295 1 DV 2 X38 1 DV 2 X38 2 EB 4 X14 4 2 1 EB 4 X14 3 EB 4 X15 4 2 1 EB 4 X15 3 FJ 2 X121 1 FJ 2 X121 2 FJ 2 X120 1 FJ 2 X120 2 ED 32 X2 1 BY 4 X50 4 BY 4 X50 3 GF 48 X1 29 3 GF 48 X1 46 1 AZ 4 X17 4 2 AZ 4 X17 3 wh or wh bl wh rd wh rd wh rd rd rd rd wh bl ye rd ye rd br gn bl ye br wh rd wh rd wh rd br br gn br br br br bl rd bl rd wh or bl ye b...

Page 207: ...Components A11 EFI control unit F1 Fuse F3 Fuse K12 Light relay K30 Power relay M13 Fuel pump P10 Combination instrument S11 Ignition steering lock S23 Emergency OFF switch electric starter button X295 Diagnostics connector ...

Page 208: ...F6 1 2 e 10A F5 1 2 8 1 DG 4 X62 4 DI 2 X66 1 DI 2 X66 2 DG 4 X62 2 BP 4 X61 2 3 3 3 BW 3 X64 1 BW 3 X64 2 FJ 2 X122 1 FJ 2 X122 2 FJ 2 X126 1 FJ 2 X126 2 ED 32 X2 8 CR 1 X24 1 CR 1 X25 1 3 4 6 2 1 5 C3 S24 BC 6 5 3 4 AC 6 X22 6 2 AC 6 X22 5 bu gr gr bu bu br ye bu ye gn br br br br ye bu ye bu ye bu br br br br br br gn gn gn ye gn ye gn br br bu bu br br bu gn bu gn br gn ye gn ye bu 228 226 230...

Page 209: ...27 WIRING DIAGRAM 207 Components E13 Low beam high beam F5 Fuse F6 Fuse P10 Combination instrument P15 Horn P35 Parking light S24 Light switch horn button headlight flasher switch turn signal switch ...

Page 210: ...K 2 AK 2 2 1 B77 AK 2 AK 2 2 1 P36 BG 3 BG 3 2 1 3 g AH 2 X26 1 AH 2 X26 2 AH 2 X27 1 AH 2 X27 2 AJ 3 X132 3 2 AJ 3 X132 1 1 2 AJ 3 X32 3 1 2 BG 3 X34 3 E60 CX 2 CX 2 1 2 CW 2 X63 1 CW 2 X63 2 ye bu ye bu br ye bu ye bu ye bu br br br br br br br br br br br br br ye bu wh gn wh gn wh gn ye wh gn wh gn wh wh wh br wh gn wh br br wh wh gn ye br br G00404 01 ...

Page 211: ...27 WIRING DIAGRAM 209 Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light ...

Page 212: ... CW 2 P41 1 CW 2 2 CW 2 P42 1 CW 2 2 CW 2 h 3 A3 P10 8 A6 d d 9 10 CX 2 X30 1 CX 2 X30 2 CX 2 X31 1 CX 2 X31 2 CX 2 X65 1 CX 2 X65 2 P46 1 CW 2 2 CW 2 CX 2 X58 2 CX 2 X58 1 2 3 FR 4 X70 4 CV 4 X71 4 3 2 ED 32 X2 9 10 3 C3 S24 2 3 1 BT 3 X23 1 BT 3 X23 3 2 IE 2 X29 2 IE 2 X29 1 bl pu bl bl pu ye bu ye or ye or br br br br ye bu bl pu pu bl br pu br G00405 01 ...

Page 213: ...ts 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 S24 Light switch horn button headlight flasher switch turn signal switch ...

Page 214: ...6 5 4 3 2 1 6 11 690 SMC R 2014 M t 5 F8 3 B8 10 F1 11 B1 M14 BI 2 BI 2 1 2 B33 1 2 10A F4 1 2 10A F8 1 2 d e d e FJ 2 X128 1 FJ 2 X128 2 FJ 2 X129 1 FJ 2 X129 2 CR 1 X294 1 CR 1 X293 1 AV 2 X33 1 AV 2 X33 2 ID 2 X110 1 ID 2 X110 2 gn bl bl gn wh bl wh bl bl rd bl rd br br gn G00406 01 ...

Page 215: ...M 213 Components B33 Radiator fan temperature switch F4 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 216: ...X16 1 AS 2 X16 2 3 2 1 4 5 BH 6 X35 6 DQ 2 X43 1 DQ 2 X43 2 FJ 2 X127 1 FJ 2 X127 2 2 1 3 GH 6 X36 5 4 6 DF 2 X40 1 DF 2 X40 2 IA 2 X103 1 IA 2 X103 2 GF 48 X1 4 2 17 38 GF 48 X1 19 21 5 22 6 37 GF 48 X1 18 GF 48 X1 15 GF 48 X1 16 GF 48 X1 13 GF 48 X1 45 bl ye or or bl ye or or or bu gn gn or bl pk bu pk wh or bu gn gn or bl pk bu pk wh or bu pk bl pk gn pk pu gn bl pu bu pu gn pk pu gn bl pu bu p...

Page 217: ...AGRAM 215 Components A11 EFI control unit B80 Accelerator position sensor F2 Fuse M20 Fuel evaporation valve M51 Injector cylinder 1 M60 Motor drive R51 1 Ignition coil 1 cylinder 1 R51 2 Ignition coil 2 cylinder 1 ...

Page 218: ... 3 2 23 20 19 B35 2 1 14 AL 2 X54 1 AL 2 X54 2 CM 2 X37 1 CM 2 X37 2 DV 2 X55 1 DV 2 X55 2 2 ED 32 X2 5 ED 32 X2 23 20 19 ED 32 X2 14 ED 32 X2 2 1 EC 3 X57 2 EC 3 X57 3 GB 2 X68 2 GF 48 X1 24 44 GF 48 X1 26 GF 48 X1 23 GF 48 X111 GF 48 X1 7 1 2 IJ 3 X69 3 CU 4 X45 1 CU 4 X45 2 3 4 gn rd gn rd or or or ye ye rd rd br pu br pu rd rd br pu bl br bl br br pu bl ye bl ye rd pu rd pu br pu br pu bu br g...

Page 219: ...A11 EFI control unit B12 Intake air temperature sensor B21 Engine coolant temperature sensor cylinder 1 B35 Oil pressure sensor B38 Clutch switch B51 Lambda sensor cylinder 1 P10 Combination instrument S37 Switch S55 Map Select Switch ...

Page 220: ...A2 p B13 2 3 1 p B41 3 2 1 8 A6 P10 10 A6 9 42 10 20 39 41 8 6 AP 6 X51 5 4 AP 6 X51 6 1 DP 3 X53 2 DP 3 X53 3 1 DX 3 X111 2 DX 3 X111 3 ED 32 X2 6 1 IB 3 X49 2 IB 3 X49 3 GF 48 X1 9 GF 48 X1 42 GF 48 X1 10 GF 48 X1 20 GF 48 X1 39 GF 48 X1 8 GF 48 X1 41 IM 4 X21 4 1 IM 4 X21 2 pk br gn ye gn bu pk br gn ye gn bl bl bu bu bu bu bl bl bl gn gr pu gn gr pu bl bl bu bu br gn bu bl G00409 01 ...

Page 221: ... 219 Components A11 EFI control unit B13 Ambient air pressure sensor B26 Rollover sensor B30 Side stand switch B31 Accelerator position sensor B41 Manifold absolute pressure sensor cylinder 1 P10 Combination instrument ...

Page 222: ...1 F1 B37 1 2 AT 2 9 A1 A11 11 A1 d 9 A6 P10 11 A3 d 36 35 47 48 14 28 32 43 4 12 18 7 11 B32 IK 2 IK 2 1 2 1 AL 2 X52 2 4 12 ED 32 X2 7 ED 32 X2 18 11 36 GF 48 X1 35 GF 48 X1 48 47 14 28 32 GF 48 X1 43 II 2 X56 1 II 2 X56 2 wh ye ye bu br br wh gn wh gn wh wh br rd br wh ye ye bu br rd br br br br br br br bl gn bl gn G00410 01 ...

Page 223: ...27 WIRING DIAGRAM 221 Components A11 EFI control unit B32 Fuel level indicator B37 Crankshaft position sensor P10 Combination instrument ...

Page 224: ...X295 6 FJ 2 X125 1 FJ 2 X125 2 24 ED 32 X2 3 22 15 1 DM 2 X42 2 DM 2 X39 2 1 EA 2 X124 1 EA 2 X124 2 EA 2 X123 1 EA 2 X123 2 GE 18 X3 4 3 GE 18 X3 12 GE 18 X3 13 14 GE 18 X3 9 GE 18 X3 18 1 GE 18 X3 10 2 11 8 15 17 GF 48 X1 1 33 34 X300 X303 bl gr gr wh wh bl wh wh bl bl gr gr gn gn gn rd gn rd or or rd rd rd rd bl bu wh bu bl bu wh bu bl bu wh bu gn gn bl or bl or bl ye bl ye br pu br pu br pu br...

Page 225: ...nit B70 Front wheel speed sensor B71 Wheel speed sensor rear F9 Fuse F21 ABS fuse F22 ABS fuse P10 Combination instrument X295 Diagnostics connector 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 226: ...n inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Recommended supplier Motorex COOLANT M5 0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 241 SAE p 241 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 Sy...

Page 227: ...rties Recommended supplier Motorex Hydraulic Fluid 75 Shock absorber fluid SAE 2 5 50180751S1 Standard classification SAE p 241 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 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unlead...

Page 228: ...ease Recommended supplier Motorex Bike Grease 2000 Lubricant T511 Recommended supplier Lubcon Turmsilon GTI 300 P Lubricant T159 Recommended supplier Bel Ray MC 11 Lubricant T158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant T625 Recommended supplier Molykote 33 Medium Motorcycle cleaner Recommended supplier Motorex Moto Clean Perfect Finish and high gloss polish for paints Recommended ...

Page 229: ...aints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 230: ...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 231: ...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 232: ...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 233: ...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 234: ...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 235: ...for lock ring 305660 10 Art no 75029005000 Piston assembly 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 ...

Page 236: ...400161 01 Art no 75029036000 Push in drift 500163 01 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 ...

Page 237: ...part pressing out tool 400187 01 Art no 75029047051 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 ...

Page 238: ...ounting sleeve 400165 01 Art no 75029080000 Gear 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 ...

Page 239: ... 400176 01 Art no 77329006000 Engine blocking 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 Pin wrench 200734 10 Art no T103 ...

Page 240: ...30 SPECIAL TOOLS 238 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Pin 201235 10 Art no T120 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S ...

Page 241: ...CIAL TOOLS 239 Vacuum pump 200273 10 Art no T1240S Pressing tool 200584 01 Art no T129 Protecting sleeve 200635 10 Art no T1401 Gripping tool 200639 10 Art no T14026S1 Open end wrench 200640 10 Art no T14032 ...

Page 242: ...30 SPECIAL TOOLS 240 Clamping stand 200637 10 Art no T1403S Mounting tool 200634 10 Art no T14040S Mounting sleeve 300569 10 Art no T1515 Nitrogen filling tool 300574 10 Art no T170S1 ...

Page 243: ...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 244: ...transmission shafts installing 154 valve clearance adjusting 169 valve clearance checking 168 valve cover installing 173 water pump cover mounting 164 Auxiliary substances 7 B Battery connecting 83 disconnecting 83 fitting 82 recharging 83 removing 82 Brake disc front brake installing 74 front brake removing 74 rear brake installing 76 rear brake removing 76 Brake discs checking 71 Brake fluid fro...

Page 245: ...g 148 crankshaft bearing inner ring installing 131 crankshaft bearing inner ring removing 128 crankshaft run out at bearing pin checking 130 cylinder Nikasil coating 132 cylinder head checking 140 cylinder checking measuring 132 freewheel checking 153 freewheel installing 153 freewheel removing 153 left engine case section 126 main shaft assembling 150 main shaft disassembling 147 oil pumps checki...

Page 246: ...and 11 taking off of the rear wheel stand 10 O Oil circuit 181 Oil filter changing 183 installing 184 removing 184 Oil screens cleaning 183 185 Operating substances 7 P Parking light bulb changing 102 Preparing for use after storage 200 R Rear hub rubber dampers checking 80 Rear sprocket checking 78 Rear wheel installing 75 removing 74 Riding sag adjusting 36 Rim run out checking 72 S Seat mountin...

Page 247: ... engine tightening torques 192 engine tolerance wear limits 190 fork 195 shock absorber 195 tires 195 Throttle grip changing 28 Tire air pressure checking 70 Tire condition checking 70 Type label 8 W Warranty 7 Winter operation checks and maintenance steps 199 Wiring diagram 202 223 page 01 of 11 202 page 02 of 11 204 page 03 of 11 206 page 04 of 11 208 page 05 of 11 210 page 06 of 11 212 page 07 ...

Page 248: ... 3206193en 3206193en 03 2014 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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Yamaha YZ65J Owner'S Manual preview
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