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KTM 690 Enduro R 2013, Repair Manual

The KTM 690 Enduro R 2013 Repair Manual is a comprehensive guide for maintaining and fixing your motorcycle. This manual is available for free download from manualshive.com, providing users with step-by-step instructions and troubleshooting tips. Ensure smooth rides by accessing this valuable resource and keeping your bike in optimal condition.

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INDEX

228

INDEX

A

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air filter

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Air filter box

fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Alternator

stator winding, checking . . . . . . . . . . . . . . . . . . . . . 175

Antifreeze

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Assembling the engine

alternator cover, installing . . . . . . . . . . . . . . . . . . . . 163
camshafts, installing . . . . . . . . . . . . . . . . . . . . . . . . 157
clutch cage, installing . . . . . . . . . . . . . . . . . . . . . . . 152
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 160
crankshaft and balancer shaft, installing . . . . . . . . . . 149
crankshaft position sensor distance, adjusting . . . . . . 155
crankshaft position sensor, installing . . . . . . . . . . . . . 153
cylinder head, installing . . . . . . . . . . . . . . . . . . . . . 157
engine, setting to top dead center . . . . . . . . . . . . . . . 155
gear position sensor, installing . . . . . . . . . . . . . . . . . 161
left engine case, installing . . . . . . . . . . . . . . . . . . . . 150
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 151
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 161
oil pumps, installing . . . . . . . . . . . . . . . . . . . . . . . . 150
oil screens, installing . . . . . . . . . . . . . . . . . . . . . . . 162
piston, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 155
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 152
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
shift drum locating, installing . . . . . . . . . . . . . . . . . . 151
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 151
spacer and spring, installing . . . . . . . . . . . . . . . . . . 160
spacer, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 162
spark plug, installing . . . . . . . . . . . . . . . . . . . . . . . . 160
starter drive, installing . . . . . . . . . . . . . . . . . . . . . . 151
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 163
taking engine off universal mounting rack . . . . . . . . . 164
thermostat, installing . . . . . . . . . . . . . . . . . . . . . . . 161
timing chain and timing chain sprocket, installing . . . . 154
timing chain rails, installing . . . . . . . . . . . . . . . . . . . 154
timing chain tensioner, installing . . . . . . . . . . . . . . . 158
transmission shafts, installing . . . . . . . . . . . . . . . . . 148
valve clearance, adjusting . . . . . . . . . . . . . . . . . . . . 159
valve clearance, checking . . . . . . . . . . . . . . . . . . . . 158
valve cover, installing . . . . . . . . . . . . . . . . . . . . . . . 164
water pump cover, mounting . . . . . . . . . . . . . . . . . . 160

Auxiliary substances

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

B

Battery

connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Brake disc

front brake, installing . . . . . . . . . . . . . . . . . . . . . . . . 75

front brake, removing . . . . . . . . . . . . . . . . . . . . . . . . 74
rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . . . 77
rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . . . 76

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 91
front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 91
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 96
rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 96

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 90
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 95

Brake linings

front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 88
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 88
rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 93
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 93

C

Capacity

coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
engine oil . . . . . . . . . . . . . . . . . . . . . . . 110, 174, 180
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Cartridge

fork legs, assembling . . . . . . . . . . . . . . . . . . . . . . . . 25
fork legs, disassembling . . . . . . . . . . . . . . . . . . . . . . 21

Chain

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Chain guide

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Charging voltage

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Chassis number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Clutch

checking/correcting fluid level . . . . . . . . . . . . . . . . . 165
fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Combination instrument

clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
setting kilometers or miles . . . . . . . . . . . . . . . . . . . . . 98

TRIP 1

display, setting/resetting . . . . . . . . . . . . . . . . . 98

TRIP 2

display, setting/resetting . . . . . . . . . . . . . . . . . 98

wheel circumference, setting . . . . . . . . . . . . . . . . . . . 99

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167-168

Cooling system

filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Cylinder - Nikasil

®

coating

. . . . . . . . . . . . . . . . . . . . . . . 129

Summary of Contents for 690 Enduro R 2013

Page 1: ...REPAIR MANUAL 2013 690 Enduro R EU 690 Enduro R AUS UK 690 Enduro R USA Art no 3206150en ...

Page 2: ......

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

Page 4: ...e low speed compression damping of the shock absorber 37 9 3 Adjusting the rebound damping of the shock absorber 38 9 4 Measuring the unloaded rear wheel sag 38 9 5 Checking the static sag of the shock absorber 38 9 6 Checking the riding sag of the shock absorber 39 9 7 Adjusting the spring preload of the shock absorber 39 9 8 Adjusting the riding sag 40 9 9 Removing the shock absorber 40 9 10 Ins...

Page 5: ...r position sensor 111 17 3 8 Removing oil filter 112 17 3 9 Removing thermostat 112 17 3 10 Setting engine to ignition top dead center 112 17 3 11 Removing water pump wheel 113 17 3 12 Removing clutch cover 113 17 3 13 Removing spacer and spring 114 17 3 14 Removing spark plug 114 17 3 15 Removing timing chain tensioner 114 17 3 16 Removing camshafts 114 17 3 17 Removing cylinder head 115 17 3 18 ...

Page 6: ...g alternator cover 163 17 5 33 Installing the starter motor 163 17 5 34 Installing valve cover 164 17 5 35 Removing the engine from the engine assembly stand 164 18 CLUTCH 165 18 1 Checking rectifying the fluid level of the hydraulic clutch 165 18 2 Changing the hydraulic clutch fluid 165 19 WATER PUMP COOLING SYSTEM 166 19 1 Draining the coolant 166 19 2 Filling bleeding the cooling system 166 19...

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

Page 8: ... are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will...

Page 9: ...anger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 Spare parts accessories Only use spare parts and accessories approved and or recommended by KTM KTM accepts no liability for other products and any resulting damage or loss The current KTM Power...

Page 10: ...f the frame 4 3 Engine number 100211 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 4 4 Key number 100179 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 4 5 Fork part number 601780 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 11: ...4 SERIAL NUMBERS 9 4 6 Shock absorber part number 101048 10 The shock absorber part number 1 is on the left of the shock absorber ...

Page 12: ... Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface B01290 01 Remove the motorcycle from the lift stand and rest it on its side stand Remove the lift stand 5 3 Raising the motorcycle with the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 300579 1...

Page 13: ...exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at ...

Page 14: ...ide stand is folded out and you shift into gear and release the clutch lever the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go 5 6 Starting the motorcycle to make checks Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficien...

Page 15: ... the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 601776 10 Turn adjusting screws 1 clockwise all the way Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 20 clicks ...

Page 16: ...e dust boots and inner fork tube of both fork legs Universal oil spray p 213 Press the dust boots back into their normal position Remove excess oil Finishing work Position the fork protector p 14 Remove the motorcycle from the lift stand p 10 6 5 Loosening the fork protection B01282 10 Remove screws 1 and take off clamp Remove screws 2 on left fork leg Push the fork protection downwards Remove scr...

Page 17: ... screw 3 about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw 3 Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 202024 10 Remove screws 4 Take the ...

Page 18: ...st face forwards The second groove A of the fork leg must be flush with the upper edge of the upper triple clamp The upper fork overhang must be the same on both sides Tighten screws 2 on both sides Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 202025 11 Position the wheel speed sensor Mount and tighten screws 3 Guideline Screw wheel speed sens...

Page 19: ...k that the brake linings are seated correctly Mount and tighten screws 7 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Release the rear of the vehicle Remove the motorcycle from the lift stand p 10 202023 12 Pull the front brake and compress the fork forcefully a few times This aligns the fork legs Tighten screws 8 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 6 9 Servicing...

Page 20: ...bound and compression damping 200643 10 Clamp the fork leg in the area of the lower triple clamp Clamping stand T1403S p 225 200644 12 Loosen screw cover 3 Info The screw cover cannot be removed yet 201471 10 Release the fork leg and clamp it with the axle clamp Info Use soft jaws 200646 12 Push the outer tube downward Pull the spring down Mount the special tool on the hexagonal part Open end wren...

Page 21: ...special tool Remove the spring 200650 01 Drain the fork oil Info Pull out and push in the piston rod a few times to empty the cartridge 201472 10 Clamp the fork leg with the axle clamp Guideline Use soft jaws Loosen and remove screw 6 Info Place a container underneath to catch any oil that may run out 201473 10 Loosen and remove compression damping A Info This operation is not needed for further d...

Page 22: ...sliding bushings Guideline 50 C 122 F Pull the outer tube forcefully off of the inner tube Info The lower sliding bushing 9 must be pulled out of its bearing seat when doing this 200658 01 Remove upper sliding bushing bk Info Without using a tool carefully pull the stack apart by hand 200659 11 Take off the lower sliding bushing 9 Take off support ring bl Take off seal ring bm Take off lock ring 8...

Page 23: ...e fluid barrier 1 from the piston rod 201479 10 Take washer 2 and spring seat 3 off of the cartridge 201480 10 Degrease the cartridge and clamp it with the special tool Clamping stand T14015S p 224 Remove lock ring 4 Pull tap compression 5 out of the cartridge using a screw 201481 10 Take piston rod 6 out of the cartridge 200749 12 Heat the cartridge in area A Guideline 50 C 122 F Unscrew and remo...

Page 24: ...8 completely 200699 11 Remove the piston Completely remove shim stack 9 200700 10 Remove spring bk Loosen and remove tap rebound bl 200701 10 Remove spring bm Remove valve bn of the rebound damping with the spring Unclamp the piston rod 6 12 Disassembling the tap compression Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs p 18 ...

Page 25: ...the tap compression Remove O ring 5 6 13 Checking the fork legs Condition Fork dismantled 200728 10 Check the inner tube and the axle clamp for damage If damage is found Replace the inner tube 200684 10 Measure the external diameter of the inner tube in several places External diameter of inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Replace ...

Page 26: ...bronze colored layer A under sliding layer B is visible Replace the sliding bushings 200666 10 Check the spring length Guideline Spring length with preload spacer s 472 mm 18 58 in If the measured value is greater than the specified value Reduce the strength of the pretensioning bushes If the measured value is less than the specified value Increase the strength of the preload spacers 6 14 Assembli...

Page 27: ...t the spring force Lock the nut using a punch Extract the tap compression 6 15 Assembling the cartridge Info The steps are identical for both fork legs 200715 10 Clamp in the piston rod Clamping stand T14016S p 224 Mount valve 1 of the rebound damping with the spring and O ring Lubricate the O ring Lubricant T158 p 212 Mount spring 2 200718 10 Grease the O ring of tap rebound 3 Lubricant T158 p 21...

Page 28: ... nut with the collar facing downward Lock the nut using a punch 200749 11 Degrease the cartridge and clamp it with the special tool Clamping stand T14015S p 224 Mount and tighten screw sleeve 9 Guideline Screw sleeve M29x1 46 Nm 33 9 lbf ft Loctite 241 201481 11 Before mounting on the piston wrap the piston ring around the shaft of a screw driver Slide piston rod bk into the cartridge 201487 10 Mo...

Page 29: ...se soft jaws Mount special tool Protecting sleeve T1401 p 224 Grease and push on dust boot 1 Lubricant T511 p 212 Info Always change the dust boot lock ring seal ring and support ring Mount the sealing lip with the spring expander facing downward Push on lock ring 2 Grease and slide on seal ring 3 Lubricant T511 p 212 Info Mount with the sealing lip facing downward with the open side facing upward...

Page 30: ...horter side of the special tool Assembly tool T1402S p 225 Push the seal ring and support ring all the way into the outer tube 200656 11 Mount lock ring 2 Info The lock ring must engage audibly 200655 11 Mount dust boot 1 200725 10 Mount adjusting tube 7 of the rebound damping in the cartridge The adjusting tube protrudes 5 mm from the cartridge and can be pressed in against the resistance of the ...

Page 31: ...rtridge turns as well press the piston rod slightly to the side 200677 10 Clamp the fork vertically Fill it with fork oil Fork oil per fork leg 620 ml 20 96 fl oz Fork oil SAE 4 48601166S1 p 211 Info Pull out the piston rod and push back in a number of times to bleed the car tridge 201476 10 Remove pin D of the special tool Gripping tool T14026S1 p 225 Pull out the piston rod Mount the spring Moun...

Page 32: ...lbf ft 200646 11 Release the special tool Pull the spring downward and remove the special tool 200681 10 Push the outer tube upward Clamp the outer tube in the area of the lower triple clamp Clamping stand T1403S p 225 Grease the O ring of the screw cover Lubricant T158 p 212 Screw on and tighten the screw cover Guideline Screw cover on outer tube M51x1 5 50 Nm 36 9 lbf ft 201470 11 Alternative 1 ...

Page 33: ...with the lift stand p 10 100298 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 Adjust the play of the steering head bearing p 31 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily o...

Page 34: ...6 FORK TRIPLE CLAMP 32 Guideline Screw steering stem M8 20 Nm 14 8 lbf ft Finishing work Check the steering head bearing play p 31 Remove the motorcycle from the lift stand p 10 ...

Page 35: ...ve the handlebar and lay it to one side Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove the two screws 2 Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar ...

Page 36: ...ttle cable p 34 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering ran...

Page 37: ...7 HANDLEBAR CONTROLS 35 Tighten lock nut 1 ...

Page 38: ...ft and right Pull the engine guard forward out of the holders and set it down 8 2 Installing the engine guard 202021 11 Slide the engine guard into holders 1 at the rear Position the engine guard Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 39: ...ll payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 9 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 n...

Page 40: ... rear wheel sag Preparatory work Raise the motorcycle with the lift stand p 10 0 0 A A 400988 10 Main work Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Note down the value as dimension A Finishing work Remove the motorcycle from the lift stand p 10 9 5 Checking the static sag of the shock absorber 0 0 A A 0 0 B B 400989 1...

Page 41: ...ed 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 10 Remove the seat p 62 Take off the side cover p 63 Remove the shock absorber p 40 After removing the s...

Page 42: ...7 lb in Hard 85 N mm 485 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber p 41 Mount the side cover p 63 Mount the seat p 63 Remove the motorcycle from the work stand p 11 Check the static sag of the shock absorber p 38 Adjust the rebound damping of the shock absorber p 38 9 9 Removing the shock absorber Preparatory work Raise the motorcycl...

Page 43: ...the shock absorber 202045 10 Main work Insert shock absorber 1 from above 202044 11 Mount screw 2 but do not tighten yet Mount and tighten screw 3 Guideline Screw bottom shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Tighten screw 2 Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 202043 11 Mount and tighten screw 4 Guideline Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctit...

Page 44: ...le from the work stand p 11 9 11 Servicing 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 Condition The shock absorber has been removed 201289 01 Remove the spring p 43 Dismantle the damper p 43 Disassemble the piston rod p 44 Check the damper p 45 Remove t...

Page 45: ... sion 201272 10 Remove spring retainer 2 Take off spring 3 with the retaining ring and adjusting ring 4 9 13 Dismantling the damper Preparatory work Remove the spring p 43 201273 10 Main work Establish and note the current state of the rebound damping and compression damping Completely open the adjusters of the rebound and compression damping Remove rubber cap 1 of the reservoir Open screw 2 slowl...

Page 46: ...ston rod Drain the remaining oil 201279 10 Remove compression adjuster 7 Remove the spring sleeve and piston 9 14 Disassembling the piston rod Preparatory work Remove the spring p 43 Dismantle the damper p 43 300540 10 Main work Clamp the piston rod with the heim joint in a vise Remove nut 1 ...

Page 47: ...d set the parts down together 300542 10 Remove seal ring retainer 7 300543 10 Remove locking cap 8 and rubber buffer 9 9 15 Checking the damper Condition The damper has been disassembled 201280 10 Measure the inside diameter at both ends and in the center of the damper car tridge Damper cartridge Minimum diameter 46 10 mm 1 815 in If the measured value is greater than the specified value Change th...

Page 48: ...heck the piston rod for damage and wear If there is damage or wear Change the piston rod 300460 01 Check the heim joint for damage and wear If there is damage or wear Change the heim joint 9 16 Removing the heim joint Condition The shock absorber has been removed 200577 10 Clamp the shock absorber in the vise using soft jaws for protection Remove collar bushing 1 of the heim joint Pin T120 p 223 T...

Page 49: ...7S p 223 9 17 Installing the heim joint 200581 10 Place special tool 1 underneath and press in the heim joint as far as the center using special tool 2 Pressing tool T1206 p 223 Pressing tool T129 p 224 200579 11 Mount lock rings 3 on both sides 200578 11 Mount seal rings 4 on both sides and grease them Lubricant T158 p 212 200582 10 Press in both collar sleeves 5 of the heim joint ...

Page 50: ...ing and push seal ring retainer 4 on to the piston rod Lubricant T625 p 213 Remove the special tool 200572 11 Mount supporting plate 5 with the rounded side facing downward Mount the compression shim stack 6 with the smaller shims facing downward 201270 10 Sand both sides of the piston on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View A Piston from ab...

Page 51: ...9 11 Main work Push the spring and sleeve onto the compression adjuster Mount the piston Mount and tighten compression adjuster 1 Guideline Compression adjuster M26x1 30 Nm 22 1 lbf ft 201277 11 Mount and tighten screw 2 Guideline Filling port screw M10x1 14 Nm 10 3 lbf ft 201288 10 Clamp the damper in the vise using soft jaws Fill the damper cartridge about half full Shock absorber oil SAE 2 5 50...

Page 52: ...ing screw 7 clockwise with a screwdriver up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Turn adjusting screw 8 all the way clockwise using a socket wrench Turn back counterclockwise the number of turns corr...

Page 53: ...Info Before working with the vacuum pump be sure to read the operating instructions carefully Completely open the adjusters of the rebound and compression damping 201286 10 Remove the screw of the filling port Install adapter 1 on the damper Info Tighten only hand tight without the use of tools Connect the adapter 1 to connector 2 of the vacuum pump Vacuum pump T1240S p 224 Clamp the damper with s...

Page 54: ...Damper control lever 4 to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge rises to the specified value 3 bar 200269 10 When the pressure gauge reaches the specified value turn the Damper 4 control lever to Vacuum Guideline 3 bar The pressure gauge falls to the specified value 0 bar 200270 10 When the pressure gauge reaches the specified value turn the Oil reservoir 5 con ...

Page 55: ...he special tool by the specified value distance A minus specified value Guideline 10 mm Depth micrometer T107S p 223 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 56: ... handle A Close spigot B and take the damper out of the special tool Tighten the filling port screw Guideline Screw reservoir filling port M5 3 Nm 2 2 lbf ft Mount the rubber cap of the reservoir 9 22 Installing the spring 201272 11 Clamp the damper in the vise using soft jaws Install retaining ring 1 and turn it down as far as possible The collar points to the adjusting ring Mount adjusting ring ...

Page 57: ...uspension compo nents can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Tension the spring to the amount measured during dismantling by turning adjusting ring 2 Hook wrench T106S p 223 Tighten lock nut 1 and the adju...

Page 58: ...e binders 1 Push the cable to the right Unplug connector 2 of the lambda sensor Feed out the cable of the lambda sensor 202032 10 Remove screws 3 Remove the heat guard 202033 10 Remove nuts 4 of the manifold Info Do not misplace the spacer 202034 10 Loosen screw 5 Take off the manifold 10 2 Installing the manifold 202033 11 Main work Position the manifold with the seals Position the spacer Mount a...

Page 59: ... 11 Position the heat guard Mount and tighten screws 5 Guideline Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Loctite 243 Finishing work Mount the side cover p 63 Mount the seat p 63 10 3 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 202032 12 Remove screws 1 Take off ...

Page 60: ...ews 1 Guideline Screw main silencer holder M8 25 Nm 18 4 lbf ft 202036 11 Mount and tighten screws 2 Guideline Rear fairing screw M6 5 Nm 3 7 lbf ft 202034 13 Position the exhaust clamp Tighten screw 3 Guideline Screw main silencer clamp M8 12 Nm 8 9 lbf ft Copper paste 202032 13 Position the exhaust heat guard Mount and tighten screws 4 Guideline Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Locti...

Page 61: ...r 3 11 2 Installing the air filter 601785 10 Main work Clean the air filter box Mount air filter 1 Info The air filter must lie flush against the air filter box along the entire sealing surface A If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Hook air filter box top 2 into the front of the air filter box and swing down 601783 11 Mount and tighten scr...

Page 62: ...ox at the rear Loosen the spring loaded band type clamp with the special tool and detach bleed hose 6 Pliers for spring band clamp 60029057100 p 217 Detach connector 7 of the intake air temperature sensor Take off the air filter box 11 4 Installing the air filter box 202042 11 Main work Attach connector 1 of the intake air temperature sensor Mount bleed hose 2 Mount the spring loaded band type cla...

Page 63: ...s chassis M6 10 Nm 7 4 lbf ft 202039 11 Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 202038 11 Position the voltage regulator Mount and tighten screws 6 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Route and mount vent hose 7 without kinking Finishing work Mount the side cover p 63 Mount the seat p 63 ...

Page 64: ...mediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage syst...

Page 65: ...that the seat is correctly mounted 12 5 Taking off the side cover Preparatory work Remove the seat p 62 202029 10 Main work Remove screws 1 Pull off the side cover in area A and take off from above Repeat the operation on the opposite side 12 6 Mounting the side cover 202030 10 Main work Attach the side cover in area A and engage it in area B 202029 11 Mount and tighten screws 1 Guideline Screw si...

Page 66: ...ly Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The ignition is on The diagnostics tool is connected 302037 10 Press on the metal plate and disconnect the fuel hose connection 1 Info Remaining fuel may run out of the fuel hos...

Page 67: ...verfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physi...

Page 68: ... screws 5 Pull out the fuel pump 202048 10 Disconnect both fuel hose connections 6 Unplug connector 7 Remove the fuel pump 202049 10 Remove hose clamps 8 Remove fuel filter Mount the new fuel filter Arrow A points away from the fuel pump Mount hose clamps 8 Hose clamp pliers 60029057000 p 216 202050 10 Press locking mechanism 9 on both sides Pull off the fuel pump housing ...

Page 69: ...e Screw fuel pump M5 4 Nm 3 lbf ft 202046 10 Position the splash protector Mount and tighten screws 4 Guideline Remaining screws chassis M5 4 Nm 3 lbf ft 202043 10 Position the rear end Mount and tighten screw 3 on both sides Guideline Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 202037 12 Lift the rear fairing Mount and tighten screws 2 Guideline Screw main silencer holder on fuel tank...

Page 70: ... must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep a...

Page 71: ... pump 202048 10 Disconnect both fuel hose connections 6 Unplug connector 7 Remove the fuel pump Connect the new fuel pump attaching both fuel hose connections 6 Attach connector 7 202047 10 Position the fuel pump Mount and tighten screws 5 Guideline Screw fuel pump M5 4 Nm 3 lbf ft 202046 10 Position the splash protector Mount and tighten screws 4 Guideline Remaining screws chassis M5 4 Nm 3 lbf f...

Page 72: ...om M8 25 Nm 18 4 lbf ft Loctite 243 202037 12 Lift the rear fairing Mount and tighten screws 2 Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft 202036 12 Mount and tighten screws 1 Guideline Screw side cover M6 5 Nm 3 7 lbf ft Finishing work Disconnect the battery p 83 Mount the seat p 63 Set the clock p 98 ...

Page 73: ...nd rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended 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 ...

Page 74: ...ce 1 of the brake disc Brake discs wear limit Front 4 5 mm 0 177 in Rear 3 5 mm 0 138 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 13 4 Checking the spoke tension Warning Danger of accidents Instable ha...

Page 75: ... run out of the rim Axial run out outside of the rim joint 1 8 mm 0 071 in Radial run out outside of the rim joint 1 8 mm 0 071 in If the measured value is greater than the specified value Center the rim Info Center the rim by tightening the spoke nipple on the opposite side of the rim run out Change the rim if it is excessively deformed Correct the spoke tension 13 6 Front wheel 13 6 1 Removing t...

Page 76: ... or worn Replace the wheel bearing Clean and grease the shaft seal rings 1 and bearing surface A of the distance bushings Long life grease p 212 Insert the spacers 601808 11 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Activate the hand brake lever multiple ti...

Page 77: ...n to the brake disc in order to press back the brake piston Remove nut 1 Remove chain adjuster 2 Holding the rear wheel withdraw the wheel spindle 3 100268 01 Push the rear wheel forwards as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not da...

Page 78: ...ctly positioned 100270 10 Push the rear wheel forward as far as possible and lay the chain on the rear sprocket Install the wheel spindle the chain adjusters and the nut Guideline In order that the rear wheel is correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks A Info Mount the left and right chain adjusters 4 in the s...

Page 79: ...correct and adjust it if necessary 100249 10 Lean the motorcycle on the side stand Shift gear to neutral Push the chain upward at a distance B from the chain sliding guard and determine the chain tension A Info The upper chain section C 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 1...

Page 80: ...pindle M25x1 5 90 Nm 66 4 lbf ft 13 7 7 Adjusting chain guide 100299 10 Remove screws 1 and 2 Take off the chain guide Condition Number of teeth 44 teeth Insert nut 3 in hole A Position the chain guide Mount and tighten screws 1 and 2 Guideline Screw chain guide M6 8 Nm 5 9 lbf ft Condition Number of teeth 45 teeth Insert nut 3 in hole B Position the chain guide Mount and tighten screws 1 and 2 Gu...

Page 81: ...uld also be changed New chains wear out faster on old worn sprockets 401118 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...

Page 82: ...ease 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...

Page 83: ...he rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play A hold the rear wheel tight and try to rotate the rear sprocket 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 A is larger than the specified value Change all rubber dampers in the rear hub Finishing...

Page 84: ...ing bracket 3 of the battery forward and remove it Take off the positive pole cover 4 Disconnect the positive plus cable of the battery Push the wiring harness to the side and pull the battery out of the battery holder Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehicle is therefore no lo...

Page 85: ... with the household waste Dispose of faulty batteries in an environmentally compatible manner Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Even whe...

Page 86: ...shing work Install the battery p 82 Mount the seat p 63 Set the clock p 98 14 6 Checking the charging voltage Condition The battery must be fully functional and completely charged Preparatory work Remove the seat p 62 302035 10 Main work Remove screws 1 Push the retaining bracket forward and take off the terminal cover Start the motorcycle to make checks p 12 601014 10 Measure the voltage between ...

Page 87: ...t p 62 601791 10 Main work Remove protection covers 1 601792 10 Remove a defective main fuse 2 with needle nose pliers Install a new main fuse Fuse 58011109130 p 181 Info A reserve fuse 3 is located in the starter relay Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 63 Set the clock p 98 14 8 Changing fuses of individual power consumer...

Page 88: ...e fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Replace with a spare fuse of the right rating Fuse 75011088010 p 181 Fuse 75011088015 p 181 Tip Put a new spare fuse in the fuse box for future use if needed Check the function of power cons...

Page 89: ...ith extremely direct responsive ness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness Set the Map Select switch to poor fuel quality Set the adjusting wheel to position 0 Poor fuel quality homologated performance is reduced in accordance with the fuel quality use for no more than 1 tank of fuel ...

Page 90: ...an 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 Danger of accidents...

Page 91: ...ove pin 5 toward the right by striking it and remove the brake linings Clean brake caliper and brake caliper support 400418 10 Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly 101057 01 Insert the brake linings insert the pin and mount the cotter pin Operate the hand brake lever repeatedly until the brake linings are in contact wit...

Page 92: ...wise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make adjustments while riding 15 5 Checking the front brake fluid level Warning Danger of accidents Fai...

Page 93: ...d for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 88 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position 601806 10 Remove screws 1 Remove cover 2 with membrane 3 Add brake fluid to level A Guideline Measuremen...

Page 94: ...pressure 2 2 5 bar 29 36 psi 202054 10 Pull off protection cap 5 of the brake caliper bleeder screw Connect the hose of the bleeder bottle Bleeding device 00029013100 p 214 Open bleeder screw 6 by approx one half turn Info Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve 4 Open the bleeder screw again until brake flui...

Page 95: ... 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 Danger of accidents R...

Page 96: ...contact with the brake disc and there is a pressure point Adjust the brake fluid level to the MAX mark Brake fluid DOT 4 DOT 5 1 p 210 Mount the screw cap with the membrane Info Clean up overflowed or spilt brake fluid immediately with water 15 10 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressur...

Page 97: ...linder 4 so that the foot brake lever has the necessary free travel Hold screws 3 in place and tighten the nuts Guideline Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Check the free travel of the foot brake lever p 94 Tighten nut 1 15 12 Checking rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicat...

Page 98: ...e in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 93 101059 10 Main work Stand the vehicle upright Remove screw cap 1 with the washer and membrane 2 Add brake fluid to the MAX mark Brake fluid DOT ...

Page 99: ...tor B Guideline Inflation pressure 2 2 5 bar 29 36 psi 202056 10 Pull off protection cap 4 of the bleeder screw Connect the hose of the bleeder bottle Bleeding device 00029013100 p 214 Open bleeder screw 5 by approx one half turn Info Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve 3 Open the bleeder screw again unti...

Page 100: ...on pressed simultaneously 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 16 1 3 Setting resetting display TRIP 1 Info The TRIP 1 trip counter runs constantly and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or ...

Page 101: ... The motorcycle is stationary Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 100 302064 10 Main work Unplug connector ED from the combination instrument Unlock pin 18 A and remove it from connector ED Plug connector ED into the combination instrument Switch on the ignition by turning the ignition key to position ON Press the...

Page 102: ...ark does not meet specifications Adjust the headlight range p 100 16 3 Adjusting the headlight range Preparatory work Check the headlight setting p 100 601796 10 Main work Turn adjusting screw 1 to adjust the headlight range Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider instructions on how to apply the mark Checking the headlight sett...

Page 103: ...brake line guide 4 Mount and tighten screws 5 Guideline Screw headlight mask M5 5 Nm 3 7 lbf ft Finishing work Check the headlight setting p 100 16 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 mounting Preparatory work Switch off all ...

Page 104: ...before mounting Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 100 600610 10 Main work Pull off connector 1 Take off protection cap 2 of the headlight bulb 600611 10 Detach spring bar 3 Remove headlight bulb 4 Insert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 181 Fix the headlight bulb in the ...

Page 105: ...nge plug Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly 601889 10 690 Enduro R USA Remove the screw on the rear of the turn signal housing Tilt headlamp diffuser 1 forward carefully 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 sock...

Page 106: ...ool Detach the radiator hoses Pliers for spring band clamp 60029057100 p 217 202067 10 Remove screws 2 202068 10 Remove screws 3 Take off the engine sprocket cover Remove screw 4 Take off the shift lever 202069 10 Bend open lock washer 5 Have an assistant operate the rear brake Remove the nut of the engine sprocket with the lock washer 300215 10 Remove nut 6 Remove the chain adjuster Pull out the ...

Page 107: ...h rod 202072 10 Pull back the protection cap Remove nut 9 Remove screw bk 202073 10 Loosen hose clip bl Pull off the throttle valve body from the rear 202074 10 Disconnect connector bm of the gear position sensor the crankshaft position sensor and the alternator 202075 10 Pull off the spark plug connector Unplug the connector of the engine coolant temperature sensor bn 202076 10 Loosen the spring ...

Page 108: ...or jack attachment 75029055000 p 221 202080 10 Remove nut bt of the lower engine bracket Remove screw Remove screw ck of the swingarm pivot Remove the swingarm pivot 202081 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 17 2 Installing the engine Preparatory...

Page 109: ...rew engine bearer on frame M10 45 Nm 33 2 lbf ft Mount and tighten screw 4 with nut Guideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Tighten the swingarm pivot Guideline Screw swingarm pivot M12 80 Nm 59 lbf ft Tighten the lower engine bracket Guideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 202078 11 Position the line with the oil pressure sensor Mount and tighte...

Page 110: ...the throttle valve body Position and tighten hose clip bk 202072 11 Position the electrical connection bl 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 bm Guideline Screw starter motor M6 10 Nm 7 4 lbf ft Loctite 243 202070 11 Insert the clutch pus...

Page 111: ...ne sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Secure the nut with lock washer bq 202068 11 Position the rear sprocket cover Mount and tighten screw br Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Mount and tighten screw bs Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the shift lever Mount and tighten screw bt Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite ...

Page 112: ...engine for leakage Check the engine oil level p 169 Check the coolant level p 168 17 3 Engine disassembly 17 3 1 Clamping the engine into the engine assembly stand 300144 10 Mount special tool 1 on engine work stand 2 Engine assembly stand 61229001000 p 217 Support for engine assembly stand 75012001060 p 218 Holder for engine assembly stand 75012001070 p 218 Mount the engine on special tool 1 Info...

Page 113: ...move screws 1 Take off the valve cover with the valve cover seal 17 3 5 Removing the alternator cover 300004 10 Remove screws 1 Take off the alternator cover Remove dowels 17 3 6 Removing spacer 302124 10 Remove the spacer 1 of the countershaft 17 3 7 Removing gear position sensor 302126 10 Remove screws Remove the gear position sensor 1 ...

Page 114: ...06801 10 Remove screws Remove the oil filter cover 3 with the O ring Pull oil filter 4 out of the oil filter housing Circlip pliers reverse 51012011000 p 215 17 3 9 Removing thermostat 300010 10 Remove screws Take off the thermostat case 1 with the radiator hose Pull out the thermostat 2 17 3 10 Setting engine to ignition top dead center 300023 10 Turn the crankshaft counterclockwise until marking...

Page 115: ...p 222 17 3 11 Removing water pump wheel 300012 10 Remove screws 1 Take off the water pump cover 300013 10 Remove screw 2 Take off the water pump wheel 3 Take off the water pump cover seal Info Do not lose the centering pins 300014 10 Remove the shaped washer 4 17 3 12 Removing clutch cover 300015 10 Remove screws 1 Take off the clutch cover Take off the dowels Remove the clutch cover seal ...

Page 116: ...e special tool 1 Spark plug wrench 75029172000 p 222 17 3 15 Removing timing chain tensioner 300017 10 Remove screw 1 Take off the seal ring Pull out timing chain tensioner 2 17 3 16 Removing camshafts 300019 10 Remove screw 1 Take off the camshaft support plate 2 300020 10 Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft ...

Page 117: ...ton pin retainer 3 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 Take off the cylinder base gasket Info Ensure that the two grooved pins remain in place 17 3 19 Removing rotor 300044 10 Remove special tool 1 Engine blocking screw 7732901...

Page 118: ...rails into the timing chain securing guide Remove the timing chain guide rails upward out of the timing chain shaft 300046 10 Hold the timing chain securing guide tight and pull the timing chain tensioning rail 4 out of the timing chain securing guide Remove the timing chain tensioning rail upward out of the timing chain shaft Remove the timing chain securing guide 3 17 3 21 Removing timing chain ...

Page 119: ...9033000 p 218 Info Apply the special tool with the hand only do not use another tool 300052 10 Loosen the screws 2 diagonally and remove them with their spring retainers and clutch springs Remove the pressure cap 3 300053 10 Remove the pressure piece 4 Bend up the lock washer 5 300054 10 Hold the clutch cage using the special tool and remove the nut 6 of the inner clutch hub Gear segment 750290810...

Page 120: ...ial tool 1 on to the primary gear 2 Extractor 75029021000 p 218 Hold it using the special tool and pull off the primary gear by turning the screw in Remove the special tools 17 3 25 Removing starter drive 300064 10 Remove the lock ring of the starter idler gear 1 and the torque limiter 2 Take off the starter idler gear 1 with the washers Remove the torque limiter 2 with the washers and needle bear...

Page 121: ... away from shift drum locating 3 and take off the shift drum locating Release the locking lever 17 3 28 Removing locking lever 300069 10 Remove screw 1 Take off locking lever 2 with the sleeve and spring 17 3 29 Removing oil pumps 300070 10 Remove the lock washers 1 and normal washers 2 from both oil pumps Take off the oil pump toothed wheels 3 300071 10 Remove the pins 4 and washers 5 Remove scre...

Page 122: ...stall the special tool 2 with suitable screws Extractor 75029048000 p 220 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 special tool 302132 10 Remove dowels Remove O ring 3 17 3 31 ...

Page 123: ... Remove shift drum 3 300081 10 Remove shift forks 2 Info Ensure that the pins remain in place 300082 10 Remove the lock ring 4 and the stop disk 300083 10 Pull both transmission shafts 5 out of the bearing seats together Info The stop disk of the countershaft usually sticks to the bearing Take the O ring off the countershaft 6 ...

Page 124: ...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 again Guideline 150 C 302 F 300096 10 Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing from the inside to the outside all the way to the stop or so it is flush ...

Page 125: ...screw plug 7 and take pressure spring 8 with piston valve 9 out of the drill hole Remove any sealing mass remnants and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 150 C 302 F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section ...

Page 126: ...sed air through all oil channels and check that they are clear 200155 10 Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve minimum spring length 25 36 mm 0 9984 in If the measured value does not equal the specified value Change the spring Check the piston valve for damage and wear If there is damage or wear Replace the piston valve 300093 10 Lubricate pisto...

Page 127: ... 302146 10 Heat the special tool 3 Guideline 150 C 302 F Tool for inner bearing race 58429037043 p 215 Push the heated special tool 3 on to the inner bearing race press them hard together and pull them together off the crankshaft Take off the compensation shim Repeat the operation on the opposite side 17 4 5 Removing balancer shaft drive wheel Preparatory work Remove the crankshaft bearing inner r...

Page 128: ...g 300138 10 Press the crank pin out of the crankweb 300140 10 Press in the new crank pin 3 as far as possible Info The crank pin must be pressed in so that oil channel A is aligned with oil channel B 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 300141 10 Install the bearing 4 and...

Page 129: ... value Finishing work Check the crankshaft run out at the bearing pin p 127 Install the drive wheel of the balancer shaft p 127 Install the crankshaft bearing inner ring p 128 Measure the axial clearance of the crankshaft and the balancer shaft p 128 17 4 7 Checking crankshaft run out at bearing pin 300132 10 Position the crankshaft on a roller block Rotate the crankshaft slowly Check the cranksha...

Page 130: ...pensation 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 128 17 4 10 Me...

Page 131: ...arge add compensation shims 17 4 11 Cylinder Nikasil coating 302591 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 tivity r...

Page 132: ...cified value Change the piston and piston rings Check measure the cylinder p 129 302137 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 r...

Page 133: ...g with the marking facing toward the piston head 17 4 15 Checking piston cylinder mounting clearance Check measure the cylinder p 129 Check measure the piston p 130 The smallest piston cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam eter The largest piston cylinder mounting clearance is the result of the largest cylinder bore diameter ...

Page 134: ...weight The arm of the autodecompression spring 5 is long enough to pass right through the autodecompression weight Position the autodecompression weight Mount and tighten screw 3 Reconnect the autodecompression spring Guideline Screw autodecompression M6 3 4 Nm 2 2 3 lbf ft Loctite 243 Mount the autodecompression shaft in the camshaft Install a new lock ring Check the functioning If the autodecomp...

Page 135: ...iming chain even at low oil pressure 17 4 19 Checking timing assembly 0 0 1 1 0 0 1 1 0 0 2 2 0 0 3 3 0 0 4 4 0 0 5 5 300113 01 Clean all parts well Check the timing chain gear timing chain sprocket 1 for damage and wear If there is damage or wear Replace the timing chain gear timing chain sprocket Check timing chain tensioning rail 2 for damage and wear If there is damage or wear Change the timin...

Page 136: ...ge camshaft bearing using the special tool 1 Push out drift 75029051000 p 220 300228 10 Remove the small camshaft bearing using special tool 2 Insert for bearing puller 15112018100 p 214 Bearing puller 15112017000 p 214 300229 10 Press in the small camshaft bearing as far as possible using the special tool 3 Push in drift 75029044020 p 219 300230 10 Press in the large camshaft bearing as far as po...

Page 137: ...alve stem seal and valve spring retainer 300117 10 Mark the valves according to their normal built in position Info Place the valves into a box according to the installation position and label the box 17 4 23 Checking valves 200193 10 Check the run out at the valve plate Valve run out On the valve plate 0 05 mm 0 002 in If the measured value does not equal the specified value Change the valve 0 0 ...

Page 138: ...ner 17 4 26 Checking cylinder head 300119 10 Check the valve guides using the special tool 1 Limit plug gauge 59029026006 p 216 If the special tool is easy to insert into the valve guide Change the valve guide and valve Check the sealing area of the spark plug thread and the valve seats for damage and tearing If there is wear or tearing Change the cylinder head 400375 10 Check the sealing area of ...

Page 139: ...9019000 p 216 Valve spring mounting device 78029060000 p 222 300115 11 Mount valve keys Info When mounting the valve keys check that they are seated correctly prefer ably fix the valve keys to the valve with a little grease Place shims 5 into the valve spring retainers according to the installation position 17 4 28 Installing rocker arm 300114 11 Position the rocker arm 1 and push in the rocker ar...

Page 140: ...ly remove the special tool 2 300121 10 Take the clutch out of the vise and lay it on a clean workbench with the outer clutch hub 5 facing down Take the inner clutch hub 3 and release springs 4 out of the outer clutch hub 5 300122 10 Take off the clutch facing discs 6 from the inner clutch hub Remove pretension ring 7 and support ring 8 Clean all parts well Check the clutch p 138 17 4 30 Checking t...

Page 141: ... clutch spring length is less than the specified value Change all clutch springs Check the contact surface of pressure cap 5 for damage and wear If there is damage or wear Change the pressure cap Check the contact surfaces of the clutch facing discs in the outer clutch hub 6 for wear Clutch basket contact surface of clutch facing discs 0 5 mm 0 02 in If the contact surface is very worn Change the ...

Page 142: ...oughly oil the clutch facing discs Push the support ring 1 and the pretension ring 2 on to the outer clutch hub Info The pretension ring must be installed so that it is flush with the inner edge A on the support ring 300124 10 Position the trimmed clutch facing disc with the recess for the pretension ring on the outer clutch hub Beginning with the coated intermediate clutch disc position all furth...

Page 143: ...ess in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate 6 in contact areas C for wear If the sliding plate is worn Change the sliding plate Check return surface D on the sliding plate for wear If deep notches are present Change the sliding plate Check guide pin E for looseness and wear If the guide pin is loose and or worn Cha...

Page 144: ...the sixth gear idler gear 3 Remove the split needle bearing 4 and stop disk 5 Remove lock ring 6 Remove the third fourth gear sliding gear 7 Remove lock ring 8 Remove stop disk 9 and fifth gear idler gear bk Remove bearing bush bl 17 4 35 Dismantling countershaft 2 2 3 3 1 1 4 4 5 5 6 6 7 7 8 8 9 9 bk bk bl bl bs bs br br bp bp bo bo bn bn bm bm bq bq 300128 01 Fix the countershaft in the vise wit...

Page 145: ... 8 3 3 305511 01 Check needle bearing 1 for damage and wear If there is damage or wear Change the needle bearing Check the pivot points of main shaft 2 and countershaft 3 for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear If there is damage or wear Change the main shaft and or coun...

Page 146: ... work Oil all parts carefully before assembling Check the transmission p 143 Main work 9 9 7 7 5 5 4 4 3 3 2 2 1 1 bl bl bk bk 6 6 8 8 301980 02 Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Lubricate and mount bearing bush 1 Long life grease p 212 Push on the fifth gear idler gear 2 with the shift dogs facing upward Mount stop disk 3 and lock ring 4 Pu...

Page 147: ... gear 2 on the countershaft with the protruding collar facing downward Mount stop disk 3 and lock ring 4 Mount the sixth gear sliding gear 5 with the shift groove facing upward Mount lock ring 6 and stop disk 7 Mount needle bearing 8 and the fourth gear idler gear 9 with the collar facing upward Mount needle bearing bk and the third gear idler gear bl with the collar facing downward Mount stop dis...

Page 148: ...wear Replace the freewheel gear and or the bearing Check freewheel 4 when removed for damage and wear If there is damage or wear Replace the freewheel Check the toothing of the starter motor 5 for damage and wear If there is damage or wear Replace the starter motor Clamp the minus negative cable of a 12 Volt power supply to the starter motor housing Briefly connect the plus positive cable of the p...

Page 149: ...heel gear 1 If the primary gear does not turn clockwise or if it does not lock counterclock wise Remove the freewheel p 146 Turn the freewheel 180 Install the freewheel p 147 17 4 42 Installing freewheel 300129 10 Lubricate all parts thoroughly Push the freewheel 1 into the primary gear Info Note the direction of rotation 300128 11 Install the expansion ring 2 300130 10 Make sure that all lugs of ...

Page 150: ...gine assembly stand 61229001000 p 217 Make sure that both stop disks 1 are installed Mount the inner bearing race 2 on the countershaft 300088 10 Lubricate all bearings Assemble the two transmission shafts and slide them into the bearing seats together 300089 10 Mount the upper shift fork 3 the middle shift fork 4 and the lower shift fork 5 Info For the assembly of the middle shift fork 4 the slid...

Page 151: ...the special tool 1 on the alternator side of the crankshaft Mounting sleeve 75029080000 p 221 Mount the special tool 2 on the balancer shaft Mounting sleeve 58529005000 p 215 302135 10 Push the crankshaft into the bearing seat and take off the special tool Grease the shaft seal rings of the balancer shaft Push the balancer shaft 3 into the bearing seat and take off the special tool Align marks A a...

Page 152: ...them diagonally Guideline Screw engine case M6 10 Nm 7 4 lbf ft Info Install the screw in the oil filter housing with a new copper washer 17 5 4 Installing oil pumps 300073 10 Install pins and internal rotors on both oil pump shafts Mount external rotors in the engine case The marking is not visible after mounting Mount the oil pump shafts 1 with internal rotors 2 Oil the parts 300071 11 Position ...

Page 153: ...g are not symmetric 300067 11 Release the locking lever Mount and tighten screw 2 Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 17 5 7 Installing shift shaft 300066 11 Slide shift shaft 1 with the washer into the bearing seat Push sliding plate 2 away from the shift drum locating 3 Insert the shift shaft all the way Let the sliding plate engage in the shift drum locating Shif...

Page 154: ...g 300057 10 Install supporting plate 1 and needle bearing 2 300058 10 Install the clutch cage 3 Info Turn the clutch basket and oil pump gear wheels backwards and forwards slightly to help them mesh more easily Mount the half washers with the sharp edge facing outward Info Grease the half washers to ease assembly Position stepped washer with the recesses toward the half washers 302123 10 Insert th...

Page 155: ...ighten the nut 7 Guideline Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 300061 10 Insert the pressure piece 8 300052 11 Place the pressure cap on Install and tighten the screws 9 with the spring retainers and clutch springs Guideline Screw clutch spring M5 6 Nm 4 4 lbf ft Info Ensure that all clutch springs have a blue color coding Remove the special tool 17 5 11 Installing crankshaft ...

Page 156: ...ert the support bush ing into the timing chain securing guide 300045 11 Thread in the timing chain guide rail 3 from above Insert the support bushing into the timing chain securing guide Mount and tighten screws 4 Guideline Screw timing chain guide rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain ten sioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Info Ensure that there is no thread locking ma...

Page 157: ... tighten screws 3 Guideline Screw ignition pulse gen erator M6 10 Nm 7 4 lbf ft Loctite 243 17 5 16 Setting engine to top dead center 300025 10 Set the crankshaft to top dead center and lock it with the special tool 1 Engine blocking screw 77329010000 p 222 17 5 17 Installing piston 302600 10 Shift the joint of the piston rings by 120 Push the oiled piston into the special tool Piston assembly rin...

Page 158: ...oth Thread the timing chain through the chain shaft Mount the piston pin Info For clarity the following steps are illustrated using a disassembled piston 400366 10 Position the piston pin retainer 300038 10 Insert the special tool and firmly press it toward the piston Turn the special tool counterclockwise thereby pressing the piston pin retainer into the groove Insertion for piston ring lock 7502...

Page 159: ...ten diag onally begin ning with the rear screw on the timing chain shaft Step 1 15 Nm 11 1 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 45 Nm 33 2 lbf ft Step 4 60 Nm 44 3 lbf ft Lubricated with engine oil Info Always use new cylinder head screws Mount and tighten screws 2 Guideline Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 17 5 19 Installing camshafts 300163 10 Lay the timing chain over the c...

Page 160: ...toward the timing chain Release device for timing chain tensioner 77329051000 p 222 The timing chain tensioner unlocks Mount and tighten screw 3 Guideline Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft 17 5 21 Checking valve clearance 300044 10 Remove special tool 1 Crank the engine several times Set the engine to ignition top dead center p 112 300155 10 Check the valve clearanc...

Page 161: ...rocker arm shafts Take off the rocker arm 300158 10 Remove shims 4 and set them down according to the installation position Correct the shims as indicated by the results of the valve clearance check Insert suitable shims Position the rocker arms and push in the rocker arm shafts Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards The small drill hole and the f...

Page 162: ... 1 and spring 2 of the shift shaft 17 5 25 Installing clutch cover 300015 11 Mount the dowels Put on the clutch cover seal Position the clutch cover Mount and tighten screws 1 Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 17 5 26 Mounting water pump cover 300014 11 Push on the shaped washer 1 300013 12 Attach the water pump wheel 2 Mount and tighten screw 3 Guideline Screw water pump wheel M6 1...

Page 163: ...talling the oil filter 300009 11 Insert the oil filter 1 Lubricate the O ring of the oil filter cover Install the oil filter cover 2 Mount and tighten the screws Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft 306801 11 Insert the oil filter 3 Lubricate the O ring of the oil filter cover Install the oil filter cover 4 Mount and tighten the screws Guideline Screw oil filter cover M5 6 Nm 4 4 lb...

Page 164: ...tershaft with a twisting motion The recess with the O ring faces inward The shaft seal ring rests against the spacer along its entire circumference 17 5 31 Installing oil screens 300152 10 Push the oil screen with O rings on to a pin wrench Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case 30...

Page 165: ...alternator cover M6 10 Nm 7 4 lbf ft Mount and tighten screw 3 Guideline Screw alternator cover chain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 300024 11 Remove special tool 4 Engine blocking screw 77329010000 p 222 Mount and tighten screw 5 Guideline Screw plug crankshaft clamp M8 20 Nm 14 8 lbf ft 17 5 33 Installing the starter motor 302576 10 Grease O ring Mount the starter motor Long ...

Page 166: ...with the seal Mount and tighten screws 1 Guideline Screw valve cover M6 10 Nm 7 4 lbf ft 17 5 35 Removing the engine from the engine assembly stand 300144 11 Remove the screw 1 or the nut 2 Remove the engine from the engine assembly stand Info Have an assistant help you or use a crane ...

Page 167: ...ironmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 202086 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Fill bleeding syringe 4 with the appropriate hydraulic fluid Bleed syringe 50329050000 p 215 Hydraulic fluid 15 p 211 On the clutch ...

Page 168: ...0616 10 Main work Stand the motorcycle upright Place a suitable container under the engine Remove screw 1 Take off the radiator cap Completely drain the coolant Mount screw 1 with a new seal ring and tighten it Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft Finishing work Install the engine guard p 36 19 2 Filling bleeding the cooling system Warning Danger of poisoning Coolant is ...

Page 169: ...tely with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is cont...

Page 170: ...nse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition Engine is cold B01293 10 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compe...

Page 171: ...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 172: ...ble regulations 202059 10 Main work Remove screw 1 202060 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 222 Connect the pressure tester to the special tool without the T plate Pressure testing tool 61029094000 p 217 Check the engine oil level p 169 Danger Danger of poiso...

Page 173: ...l p 171 Remove the oil filter p 172 Clean the oil screens p 173 Install the oil filter p 172 Fill up with engine oil p 174 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 Environmental hazard Hazardous subst...

Page 174: ...ke fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 100202 10 Main work Remove screws 1 Remove the oil filter cover 2 with the O ring Pull oil filter 3 out of the oil filter housing Circlip pliers reverse 51012011000 p 215 C00181 10 Remove screws 4 Take off the oil filter cover 5 with the O ring Pull oil filter 6 o...

Page 175: ...ipulated in applicable regulations Preparatory work Place a suitable container under the engine 100205 10 Main work Remove screw plug 1 with oil screen 2 and the O rings 100206 10 Remove screw plug 3 with oil screen 4 and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 100207 10 Position oil screen 2 with the O rings Mount and tighten screw plug 1 ...

Page 176: ...ishing work Install the engine guard p 36 Check the engine oil level p 169 20 10 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Main work Remove the oil filler plug 1 with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 210 Engine oil SAE 10W 50 p 210 Info For optimal perform...

Page 177: ...s Stator connector EN pin 1 Stator connector EN pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 Ω If the displayed value is not equal to the setpoint value Replace the stator 600894 10 601014 10 Stator winding check for a short circuit to ground terminal 31 Measure the resistance between the specified points Stator connector EN pin 1 Measuring point Ground Resistance Ω If the displaye...

Page 178: ...ory work Remove the seat p 62 Remove the fuel tank 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 is not equal to the setpoint value Replace the ignition coil ...

Page 179: ...st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 21 23 5th gear 23 22 6th gear 23 20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Alternator 12 V 224 W Spark plug NGK LKAR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed Cool...

Page 180: ...0 15 0 25 mm 0 0059 0 0098 in Crankshaft run out at bearing pin 0 10 mm 0 0039 in Balancer shaft axial clearance 0 05 0 20 mm 0 002 0 0079 in Clutch facing disc thickness 2 5 mm 0 098 in Intermediate disk thickness 1 35 mm 0 0531 in Clutch spring length 31 5 33 5 mm 1 24 1 319 in Clutch basket contact surface of clutch facing discs 0 5 mm 0 02 in Oil pressure regulator valve minimum spring length ...

Page 181: ...m 7 4 lbf ft Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw rocker arm shaft M6 12 Nm 8 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lb...

Page 182: ...bf ft Plug timing chain tensioner M20x1 5 25 Nm 18 4 lbf ft Plug oil thermostat M24x1 5 15 Nm 11 1 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft 22 4 Capacities 22 4 1 Engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 210 Alternative engine oil Engine oil SAE 10W 50 p 210 22 4 2 Coolant Coolant 1 20 l 1 27 qt Coolant p 210 Coolant mixed ready to use p 210 22 4 3 Fu...

Page 183: ... voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal 690 Enduro R EU AUS UK R10W socket BA15s 12 V 10 W Turn signal 690 Enduro R USA RY10W socket BAU15s 12 V 10 W Brake tail light 690 Enduro R EU ...

Page 184: ... SAE 4 48601166S1 p 211 22 9 Shock absorber Shock absorber part number 15 18 7L 10 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks ...

Page 185: ... Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Screw air filter box top M6 2 Nm 1 5 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw chain guard M6 2 Nm 1 5 lbf ft Loctite 243 Screw chain guide M6 8 Nm 5 9 lbf ft Screw chain sliding gu...

Page 186: ...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 screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Screw engine bearer on frame M10 45 Nm 33 2...

Page 187: ...aner to the dry vehicle always rinse with water first If the vehicle was operated in road salt clean it with cold water Warm water enhances the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a ...

Page 188: ... 185 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Treat the engine the swingarm and all other bare or galvanized parts exc...

Page 189: ...he antifreeze and coolant level p 167 Check the tire air pressure p 71 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 Info KTM recommends jacking up the motorcycle Raise the motorcycle with the lift stand p 10 Cover the mot...

Page 190: ...ension 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 14 Check the front brake fluid level p 90 Bleed the fork legs p 13 Check the steering head bearing play p 31 Change the spark plug Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect routi...

Page 191: ...189 ...

Page 192: ... 3 0 2 T 0 1 G BI 2 EM 3 1 2 3 2 1 G20 2 3 EN 3 1 K11 2 1 4 3 1 AF 4 X13 2 1 a AF 4 X13 3 EB 4 X19 3 4 c 1 0 3 X 2 0 3 X 1 2 DS 44 X18 43 AU 2 X12 2 EB 4 X19 4 b 10A F9 1 2 FJ 2 X9 1 CR 1 X292 1 CR 1 X291 1 FJ 2 X9 2 M10 43 wh rd wh rd wh rd bl bl bl bl bl rd bl rd wh rd gn rd bu rd bu br bl gn gn gn br wh rd bl rd wh rd ye rd ye rd br 602001 01 ...

Page 193: ...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 194: ...c 1 c 6 DS 44 X18 8 2 d EB 4 X15 3 e EB 4 X14 4 BY 4 X41 3 BY 4 X41 4 BR 4 X37 4 2 2 BR 4 X37 3 DT 36 X21 1 DS 44 X18 1 b 1 FJ 2 X1 2 S11 CV 4 CV 4 4 3 2 1 ED 32 X63 1 15 ED 32 X63 18 S23 BK 4 BK 4 4 3 1 2 1 15 18 1 8 1 27 10 10 27 AP 6 X295 4 wh rd wh bl wh rd wh rd wh rd rd rd rd ye rd wh bl wh rd wh rd ye rd ye rd ye rd br gn ye rd ye rd br br ye rd ye rd br br bl rd br wh rd bl rd gn br br gr ...

Page 195: ... Components A11 EFI control unit A12 EPT control unit F1 Fuse K12 Light relay K30 Power relay P10 Combination instrument S11 Ignition steering lock S23 Emergency OFF switch electric starter button X295 Diagnostics connector ...

Page 196: ...FJ 2 X6 1 c FF 1 X24 1 FF 1 X25 1 f g c d DI 2 X61 1 DI 2 X61 2 E13 1 2 3 2 1 BP 4 X29 2 3 BP 4 X29 4 1 DG 4 X28 2 3 DG 4 X28 4 BW 3 X23 3 3 AC 6 X34 6 BW 3 X23 2 4 AC 6 X34 5 15A F7 1 2 FJ 2 X7 1 d FJ 2 X7 2 FJ 2 X6 2 ED 32 X63 8 1 3 4 6 2 1 5 C1 S29 BC 6 BC 6 5 8 gr gr gn ye bu ye bu ye br gn bu bu gn gn bu gn bu br br br bu bu ye gn ye br gn ye bu gn br ye br br bu 602003 01 ...

Page 197: ...26 WIRING DIAGRAM 195 Components E13 Low beam high beam F6 Fuse F7 Fuse P10 Combination instrument P15 Horn P35 Parking light S29 High beam low beam switch horn button turn signal switch ...

Page 198: ... F8 3 F8 5 F1 5 F1 P 3 F8 f c f c B76 AK 2 AK 2 2 1 AH 2 X26 1 AH 2 X27 1 B77 AK 2 AK 2 2 1 AJ 3 X32 3 E60 1 2 1 AH 2 X27 2 AH 2 X26 2 DI 2 X58 2 DI 2 X58 1 P36 BG 3 BG 3 BS 2 BS 2 1 2 3 1 2 BV 2 X22 1 BV 2 X22 2 AJ 3 X32 2 g wh gn wh gn wh gn ye bu ye bu br ye wh wh br br ye bu br ye ye bu br 602004 01 ...

Page 199: ...26 WIRING DIAGRAM 197 Components B76 Front brake light switch B77 Brake light switch rear E60 License plate lamp P36 Brake tail light ...

Page 200: ...CW 2 1 CW 2 f c c CX 2 X47 2 CX 2 X46 2 3 CV 4 X59 4 3 BY 4 X60 4 CX 2 X47 1 CX 2 X46 1 CV 4 X59 2 BY 4 X60 2 AH 2 X20 1 BT 3 X17 1 2 BT 3 3 AH 2 X20 2 CX 2 X30 1 P42 1 CW 2 2 CW 2 CX 2 X30 2 P41 1 CW 2 2 CW 2 CX 2 X31 1 CX 2 X31 2 10 ED 32 X63 9 3 C3 S29 BG 3 BG 3 2 3 1 10 9 bl pu bl pu br pu bl pu pu bl bl br br ye bu bl or bl or br br bl br pu br ye bu br 602005 01 ...

Page 201: ...mponents K20 Turn signal relay P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 High beam low beam switch horn button turn signal switch ...

Page 202: ...5 4 3 2 1 8 7 6 5 4 3 2 1 6 10 M t 5 F8 3 B8 7 F1 M14 BI 2 BI 2 1 2 B33 2 1 10A F5 1 2 FJ 2 X5 1 10A F8 1 2 FJ 2 X8 1 AU 2 X10 2 c d AV 2 X33 1 AV 2 X33 2 c CR 1 X294 1 CR 1 X293 1 AU 2 X10 1 FJ 2 X8 2 FJ 2 X5 2 gn bl bl gn wh bl wh bl bl rd bl rd br br gn br br 602006 01 ...

Page 203: ...201 Components B33 Temperature switch for radiator fan F5 Fuse F8 Fuse M14 Radiator fan X293 Connector for accessory ground terminal 31 ACC 2 not assigned X294 Connector for accessory plus terminal 15 ACC 2 not assigned ...

Page 204: ...0 8 3 c M60 FK 8 7 8 6 5 4 3 2 1 30 1 29 2 24 3 31 4 14 5 16 6 15 7 DT 36 X21 13 DR 8 X39 8 DT 36 X21 36 35 10A F3 1 2 FJ 2 X3 1 FJ 2 X2 2 FJ 2 X4 2 FJ 2 X3 2 ED 32 X63 24 24 19 35 36 11 12 17 20 8 13 14 15 16 24 29 30 31 16 6 5 28 21 39 3 br pu bu gr ye rd ye rd bl bu wh bu gn or bl bu or br bl bu rd gn bl bu br wh gn wh rd wh or bu rd gn bl bu br wh gn wh rd wh or bu br br ye rd bu or br pu br p...

Page 205: ...26 WIRING DIAGRAM 203 Components A11 EFI control unit A12 EPT control unit F2 Fuse F3 Fuse F4 Fuse M13 Fuel pump M60 Throttle stepper motor P10 Combination instrument ...

Page 206: ...L 1 X44 1 3 DS 44 X18 17 DF 2 X40 2 DS 44 X18 18 DS 44 X18 41 DS 44 X18 22 FM 1 X48 1 DS 44 X18 12 FS 4 X45 2 42 4 25 i FS 4 X45 1 M20 1 2 DW 2 X42 1 DQ 2 X43 1 ED 32 X63 2 B70 CZ 3 CZ 3 1 2 3 CY 3 X62 3 23 1 ED 32 X63 3 CY 3 X62 2 DS 44 40 4 2 23 3 4 17 18 41 22 12 42 25 40 or bl or rd gr bl gr wh pu gn rd lbu bl bl or rd gr bl gr wh pu gn rd lbu or or or or or bl or bl or bu br bl or bu br bl or...

Page 207: ...nts A11 EFI control unit B51 Lambda sensor cylinder 1 B70 Front wheel speed sensor M20 Fuel evaporation valve USA version only M21 Secondary air valve M51 Injector cylinder 1 P10 Combination instrument R51 Ignition coil cylinder 1 ...

Page 208: ... 3 DS 44 X18 26 32 1 31 2 DS 44 X18 10 AM 3 X50 3 DS 44 X18 15 AP 6 X51 5 DS 44 X18 34 i i AR 3 X49 2 4 DS 44 X18 4 j 1 AP 6 X51 6 DS 44 X18 13 FT 3 X36 2 DS 44 X18 11 FT 3 X35 2 3 3 CM 2 X16 2 CM 2 X16 1 ED 32 X63 11 FT 3 X35 1 FT 3 X36 1 11 26 32 31 10 15 34 4 11 13 B35 2 1 14 GB 2 X435 2 ED 32 X63 14 pk ye br gr bl gn bl gn ye gn rd bu ye or wh pk pk ye br gr bl gn ye gn ye or wh pk bl bl bu bu...

Page 209: ...EFI control unit B10 Throttle position sensor circuit A B12 Intake air temperature sensor B26 Rollover sensor B30 Side stand switch B31 Accelerator position sensor B34 Gear position sensor B35 Oil pressure sensor P10 Combination instrument ...

Page 210: ... 44 X18 24 AL 2 X52 2 DP 3 X53 3 DS 44 X18 14 DS 44 X18 35 c AL 2 X54 1 DS 44 X18 20 44 DV 2 X55 2 DS 44 X1833 DV 2 X55 1 DS 44 X18 2 AL 2 X54 2 36 1 EC 3 X57 3 38 i DP 3 X53 2 EC 3 X57 2 1 j AT 2 X56 2 AT 2 X56 1 ED 32 X63 5 12 ED 32 X63 7 B32 AL 2 AL 2 1 2 5 12 7 23 24 14 35 44 20 33 2 36 38 wh ye ye bu gn gr pu br br bl br ye bl ye wh wh ye ye bu gn gr pu bl br ye bl ye bu or br rd br br bl bl ...

Page 211: ...ure sensor cylinder 1 B32 Fuel tank sensor B37 Crankshaft position sensor B38 Clutch switch B41 Manifold absolute pressure sensor cylinder 1 P10 Combination instrument S55 Map Select Switch Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 212: ...rosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 227 SAE p 227 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motore...

Page 213: ... recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 227 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel...

Page 214: ...products Supplier Motorex Fuel Stabilizer High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Lubricant T158 Guideline KTM recommends Lubcon products Supplier Lubcon Turmogrease PP 300 Lubricant T511 Guideline KTM recommends Lubcon products Supplier Lubcon Tu...

Page 215: ...r Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 216: ...30 10 Art no 00029013004 Bleeder cover 201831 10 Art no 00029013009 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 217: ...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 218: ...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 219: ...r spring band clamp 400085 01 Art no 60029057100 Testing hose 201314 01 Art no 61029093000 Pressure testing tool 400149 01 Art no 61029094000 Engine assembly stand 200306 01 Art no 61229001000 Work stand 400151 01 Art no 62529055000 ...

Page 220: ... assembly stand 400153 01 Art no 75012001060 Holder for engine assembly stand 400154 01 Art no 75012001070 Piston assembly ring 400156 01 Art no 75029015102 Extractor 400157 01 Art no 75029021000 Assembly screws 400158 01 Art no 75029033000 ...

Page 221: ... ring lock 400160 01 Art no 75029035000 Work stand adapter 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 ...

Page 222: ... pressing out tool 400186 01 Art no 75029047050 Under 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 ...

Page 223: ...or jack attachment 400184 01 Art no 75029055000 Mounting 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 ...

Page 224: ... Art no 75029172000 Oil pressure adapter 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 ...

Page 225: ...29 SPECIAL TOOLS 223 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 226: ...CIAL TOOLS 224 Vacuum pump 200273 10 Art no T1240S Pressing tool 200584 01 Art no T129 Protecting sleeve 200635 10 Art no T1401 Clamping stand 200733 10 Art no T14015S Clamping stand 200688 10 Art no T14016S ...

Page 227: ...IAL TOOLS 225 Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art no T1402S Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S Mounting sleeve 300569 10 Art no T1515 ...

Page 228: ...29 SPECIAL TOOLS 226 Nitrogen filling tool 300574 10 Art no T170S1 ...

Page 229: ...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 230: ...iming chain tensioner installing 158 transmission shafts installing 148 valve clearance adjusting 159 valve clearance checking 158 valve cover installing 164 water pump cover mounting 160 Auxiliary substances 7 B Battery connecting 83 disconnecting 82 fitting 82 recharging 83 removing 82 Brake disc front brake installing 75 front brake removing 74 rear brake installing 77 rear brake removing 76 Br...

Page 231: ...d conrod bearing and crank pin changing 125 countershaft assembling 145 countershaft dismantling 142 crankshaft bearing inner ring installing 128 crankshaft bearing inner ring removing 125 crankshaft run out at bearing pin checking 127 cylinder Nikasil coating 129 cylinder head checking 136 cylinder checking measuring 129 freewheel checking 147 freewheel installing 147 freewheel removing 146 left ...

Page 232: ...stand 11 O Oil circuit 169 Oil filter changing 171 installing 172 removing 172 Oil screens cleaning 171 173 Operating substances 7 P Parking light bulb changing 101 Play in throttle cable adjusting 34 checking 34 Preparing for use after storage 187 R Rear hub rubber dampers checking 80 Rear sprocket checking 78 Rear wheel installing 75 removing 75 Riding sag adjusting 40 Rim run out checking 73 S ...

Page 233: ...ing torques 183 electrical system 181 engine 177 engine tolerance wear limits 177 engine tightening torques 179 fork 182 shock absorber 182 tires 181 Throttle cable routing checking 33 Tire air pressure checking 71 Tire condition checking 71 Turn signal bulb changing 102 Type label 8 W Warranty 7 Winter operation checks and maintenance steps 186 Wiring diagram 190 209 page 01 of 10 190 page 02 of ...

Page 234: ... 3206150en 3206150en 10 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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