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KTM 690 Enduro R AUS/UK 2012, Repair Manual

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KTM 690 Enduro R AUS/UK 2012 Repair Manual Download Page 39

9

SHOCK ABSORBER, SWINGARM

37

9.1

Adjusting the high-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 high-speed setting takes effect during the fast compression of the shock absorber.

601777-11

–

Turn adjusting screw

1

clockwise all the way using a socket wrench.

Info

Do not loosen fitting

2

!

–

Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline

Compression damping, high-speed

Comfort

2 turns

Standard

1.5 turns

Sport

1 turn

Full 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 normal compression of the shock absorber.

601777-10

–

Turn adjusting screw

1

clockwise with a screwdriver up to the last perceptible

click.

Info

Do not loosen fitting

2

!

–

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

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

Summary of Contents for 690 Enduro R AUS/UK 2012

Page 1: ...REPAIR MANUAL 2012 690 Enduro R EU 690 Enduro R AUS UK 690 Enduro R USA Art no 3206125en...

Page 2: ......

Page 3: ...r 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 sto...

Page 4: ...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...

Page 5: ...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...

Page 6: ...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...

Page 7: ...age 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...

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...

Page 9: ...nger 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...

Page 10: ...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...

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 stan...

Page 13: ...xhaust 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 t...

Page 14: ...de 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 th...

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...

Page 16: ...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 protection p 14 Remov...

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 A...

Page 18: ...t 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 Gu...

Page 19: ...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...

Page 20: ...ound 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 20...

Page 21: ...pecial 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 so...

Page 22: ...liding 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...

Page 23: ...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 Rem...

Page 24: ...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 wit...

Page 25: ...he 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 1...

Page 26: ...ronze 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 valu...

Page 27: ...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...

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 Guideli...

Page 29: ...e 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...

Page 30: ...orter 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...

Page 31: ...tridge 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 P...

Page 32: ...bf 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 s...

Page 33: ...ith 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...

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: ...e 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 suppor...

Page 36: ...tle 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...

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

Page 38: ...t 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...

Page 39: ...l 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 Disa...

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 examp...

Page 41: ...d 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...

Page 42: ...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 motorcy...

Page 43: ...he 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 l...

Page 44: ...e 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 Adh...

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...

Page 46: ...ton 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 damp...

Page 47: ...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 Meas...

Page 48: ...eck 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 Removin...

Page 49: ...S 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 22...

Page 50: ...ng 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 s...

Page 51: ...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...

Page 52: ...ng 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 s...

Page 53: ...nfo 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 fill...

Page 54: ...amper 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...

Page 55: ...e 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...

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...

Page 57: ...spension 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 sl...

Page 58: ...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 ma...

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...

Page 60: ...ws 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...

Page 61: ...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 th...

Page 62: ...x 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 sen...

Page 63: ...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 R...

Page 64: ...ediately 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...

Page 65: ...hat 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 Rep...

Page 66: ...y 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...

Page 67: ...erfilled 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 fue...

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 Ar...

Page 69: ...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 tight...

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 conta...

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 th...

Page 72: ...m 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...

Page 73: ...d 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 a...

Page 74: ...e 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 bra...

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 r...

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 an...

Page 77: ...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 pos...

Page 78: ...tly 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 rea...

Page 79: ...orrect 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 tensi...

Page 80: ...indle 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...

Page 81: ...ld 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 guar...

Page 82: ...ase 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...

Page 83: ...e 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 I...

Page 84: ...ng 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 t...

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 Wa...

Page 86: ...hing 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 Remo...

Page 87: ...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...

Page 88: ...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 repa...

Page 89: ...th extremely direct responsive ness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness Set the Map...

Page 90: ...n 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 accid...

Page 91: ...ve 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 b...

Page 92: ...ise 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 o...

Page 93: ...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...

Page 94: ...ressure 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 appr...

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 acciden...

Page 96: ...ontact 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...

Page 97: ...inder 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...

Page 98: ...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 contai...

Page 99: ...or 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 scr...

Page 100: ...n 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 Th...

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 t...

Page 102: ...rk 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 adj...

Page 103: ...rake 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 refl...

Page 104: ...efore 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...

Page 105: ...ge 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 t...

Page 106: ...ol 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 lev...

Page 107: ...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 posi...

Page 108: ...r 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...

Page 109: ...ew 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...

Page 110: ...he 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...

Page 111: ...e 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...

Page 112: ...ngine 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 eng...

Page 113: ...ove 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...

Page 114: ...6801 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...

Page 115: ...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 l...

Page 116: ...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...

Page 117: ...on 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...

Page 118: ...ails 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 tensio...

Page 119: ...033000 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 p...

Page 120: ...al 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 dr...

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 spri...

Page 122: ...tall 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 bala...

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 bea...

Page 124: ...n 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 b...

Page 125: ...crew 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 G...

Page 126: ...ed 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...

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...

Page 128: ...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 I...

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 clearan...

Page 130: ...ensation 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 Aft...

Page 131: ...rge 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 materia...

Page 132: ...ified 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...

Page 133: ...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 mountin...

Page 134: ...eight 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 autodeco...

Page 135: ...ming 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...

Page 136: ...e 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...

Page 137: ...lve 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...

Page 138: ...er 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 val...

Page 139: ...019000 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 valv...

Page 140: ...y 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 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...

Page 142: ...ughly 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 t...

Page 143: ...ss 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 sli...

Page 144: ...he 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 g...

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 i...

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 facin...

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 st...

Page 148: ...ear 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 dama...

Page 149: ...eel 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 freewhe...

Page 150: ...ine 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 sh...

Page 151: ...he 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 cranksh...

Page 152: ...hem 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...

Page 153: ...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...

Page 154: ...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 mo...

Page 155: ...ghten 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 s...

Page 156: ...rt 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 tigh...

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 th...

Page 158: ...th 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 3000...

Page 159: ...en 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 I...

Page 160: ...oward 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 M10...

Page 161: ...ocker 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 In...

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 co...

Page 163: ...alling 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 N...

Page 164: ...ershaft 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...

Page 165: ...lternator 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...

Page 166: ...ith 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...

Page 167: ...ronmental 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...

Page 168: ...616 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 t...

Page 169: ...ely 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 wit...

Page 170: ...se 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...

Page 171: ...smission 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 eng...

Page 172: ...le 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...

Page 173: ...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 oi...

Page 174: ...e 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...

Page 175: ...as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 100205 10 Main work Remove plug 1 with oil screen 2 and the O rings 100206 10 Remove plug 3 with oi...

Page 176: ...shing 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 1...

Page 177: ...ts Stator connector EN pin 1 Stator connector EN pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 If the displayed value is not equal to the setpoint value Replace the stator 600894 10 601...

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...

Page 179: ...t 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 dig...

Page 180: ...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 d...

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...

Page 182: ...f 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...

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...

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...

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...

Page 186: ...older 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 24...

Page 187: ...ner 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 wi...

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 d...

Page 189: ...e 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...

Page 190: ...nsion 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...

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 X...

Page 193: ...e 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...

Page 194: ...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...

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...

Page 196: ...J 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...

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...

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: ...W 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...

Page 201: ...ponents 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...

Page 202: ...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...

Page 203: ...01 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...

Page 204: ...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...

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: ...1 X44 1 3 DS 44 X18 17 DF 2 X40 2 DS 44 X18 18 DS 44 X18 41 DS 44 X1822 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...

Page 207: ...ts 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...

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 X1...

Page 209: ...FI 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 pres...

Page 210: ...4 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 X18 33 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...

Page 211: ...re 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 color...

Page 212: ...osion 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 S...

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 se...

Page 214: ...roducts 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...

Page 215: ...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 plas...

Page 216: ...0 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 1...

Page 217: ...yringe 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...

Page 218: ...mpressor 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...

Page 219: ...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 sta...

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 Assem...

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 cranksh...

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 dri...

Page 223: ...r 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 4001...

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 spr...

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: ...IAL 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 T...

Page 227: ...AL 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...

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

Page 229: ...vice 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 wi...

Page 230: ...ming 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 sub...

Page 231: ...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 r...

Page 232: ...tand 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...

Page 233: ...ng torques 183 clectrical 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 pressur...

Page 234: ...3206125en 3206125en 10 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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