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KTM Freeride 250 R AUS 2014, Repair Manual, Page: 207 / 222

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KTM Freeride 250 R AUS 2014 Repair Manual Download Page 207

31

AUXILIARY SUBSTANCES

205

Off-road chain spray

Recommended supplier
Motorex

®

–

Chainlube Offroad

Oil for foam air filter

Recommended supplier
Motorex

®

–

Twin Air Liquid Bio Power

Preserving materials for paints, metal and rubber

Recommended supplier
Motorex

®

–

Moto Protect

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces

Recommended supplier
Motorex

®

–

Quick Cleaner

Universal oil spray

Recommended supplier
Motorex

®

–

Joker 440 Synthetic

Summary of Contents for Freeride 250 R AUS 2014

Page 1: ...REPAIR MANUAL 2014 Freeride 250 R EU Freeride 250 R AUS Art no 3206188en...

Page 2: ......

Page 3: ...the right to 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 condit...

Page 4: ...e guard 35 8 2 Installing the engine guard 35 9 SHOCK ABSORBER SWINGARM 36 9 1 Adjusting the high speed compression damping of the shock absorber 36 9 2 Adjusting the low speed compression damping of...

Page 5: ...ging the headlight bulb 98 17 10 Changing the speedometer battery 99 18 30 ENGINE 101 18 1 Removing the engine 101 18 2 Installing the engine 104 18 3 Engine disassembly 108 18 3 1 Clamping the engine...

Page 6: ...4 Refilling coolant 158 22 LUBRICATION SYSTEM 160 22 1 Changing the gear oil 160 22 2 Draining the gear oil 160 22 3 Filling in gear oil 161 22 4 Checking the gear oil level 161 22 5 Adding gear oil 1...

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: ...1 is fixed to the frame at the front right 4 3 Key number 500125 10 The key number 1 for the steering lock is stamped onto the key connector 4 4 Engine number B01653 10 The engine number 1 is stamped...

Page 11: ...4 SERIAL NUMBERS 9 4 6 Shock absorber part number B01654 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side...

Page 12: ...d up and secured with the rubber band 5 3 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make s...

Page 13: ...e throttle to start 5 4 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 a...

Page 14: ...damp ing Mount protection caps 1 6 2 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior B01728 10 Turn adjusting screws 1 clockwise a...

Page 15: ...e on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oi...

Page 16: ...take off the clamp Remove cable binder 2 Remove screws 3 and the spacers and take off the brake caliper Allow the brake caliper and brake line to hang tension free to the side B01054 10 Release screws...

Page 17: ...rming a fork service Condition The fork legs have been removed 201467 01 Disassemble the fork legs p 15 Disassemble the cartridge p 18 Disassemble the compression holder p 20 Check the fork legs p 20...

Page 18: ...p the fork leg and clamp it with the axle clamp Info Use soft jaws 201427 10 Push the outer tube down Pull the spring downward Place the special tool on the hexagonal part Open end wrench T14032 p 212...

Page 19: ...pump out the cartridge until it is empty 201432 10 Clamp the fork leg with the axle clamp Guideline Use soft jaws Unscrew and remove compression holder 6 Info Place a fluid collector beneath it as us...

Page 20: ...ut using a tool pull the stack apart by hand slightly 201438 10 Take off the lower sliding bushing 9 Take off support ring bl Take off seal ring bm Take off lock ring 8 Take off dust boot 7 Take out t...

Page 21: ...96 10 Remove screw sleeve 2 with washer and spring seat from the cartridge 201461 10 Degrease the piston rod Clamp the piston rod with the special tool Clamping stand T14016S p 211 201462 10 Remove nu...

Page 22: ...e fork legs p 15 200702 10 Main work Clamp the compression holder in a bench vise using soft jaws Remove nut 1 Remove the spring Remove washer 2 200703 10 Remove piston 3 Remove shim stack 4 200704 10...

Page 23: ...tube for damage If there is damage Change the outer tube 201466 10 Check the surface of the sliding bushing If the bronze colored layer A under sliding layer B is visible Replace the sliding bushing...

Page 24: ...ces up Grease the piston O ring Fork oil SAE 4 48601166S1 p 202 200706 10 Mount washer 5 Mount spring 6 with the tighter coil facing downward Mount and tighten nut 7 Guideline Nut compression holder M...

Page 25: ...rgest inside diameter faces downward 201465 10 Mount shim stack 7 Info Align the triangular plate exactly with the piston opening Mount and tighten nut 8 Guideline Tap rebound nut M6x0 5 5 Nm 3 7 lbf...

Page 26: ...amp Guideline Use soft jaws Mount the special tool Protecting sleeve T512 p 213 Lubricate and mount dust boot 1 Lubricant T511 p 204 Info Always change the dust boot lock ring seal ring and support ri...

Page 27: ...port ring Hold seal ring with the shorter section of the special tool Mounting tool T528S p 213 Push the seal ring and support ring all the way into the outer tube 201435 11 Mount lock ring 2 Info The...

Page 28: ...d push in the piston rod several times to bleed air from the car tridge 201445 10 Remove pin C of the special tool Support tool T14026 p 212 Pull out the piston rod Mount spring Reinstall the pin Guid...

Page 29: ...M46x1 50 Nm 36 9 lbf ft 201449 10 Alternative 1 Turn the adjusting screw of rebound damping 9 and the adjusting screw of compression damping bk clockwise all the way Turn back counterclockwise by the...

Page 30: ...ont wheel p 71 Remove the fork legs p 14 Remove the front fender p 67 B01755 01 Main work Remove the cable holder in front of the radiator B01738 10 Remove screw 1 Remove screw 2 take off the upper tr...

Page 31: ...d Slide on protective ring 2 and O ring 3 B01739 10 Position the upper triple clamp with the handlebar Mount screw 4 but do not tighten yet Position the clutch line and wiring harness B01740 10 Positi...

Page 32: ...nishing work Install the front fender p 67 Install the front wheel p 71 Refit the headlight mask with the headlight p 68 Check that the wiring harness throttle cables and brake and clutch lines can mo...

Page 33: ...djust the play of the steering head bearing p 31 Check the steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 10 6 21 Adjusting the play of the st...

Page 34: ...emove screws 2 Take off the handlebar supports Move the handlebar supports into the desired position Mount and tighten screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info...

Page 35: ...ar to the straight ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable A Throttle cable play 2 3 mm 0 08 0 12 in If the throttle cable play does not...

Page 36: ...n Push back sleeve 1 Ensure that the throttle cable sleeve is pushed fully into adjusting screw 2 Loosen nut 3 Turn adjusting screw 2 so that there is play A in the throttle cable at the throttle grip...

Page 37: ...Installing the engine guard B01706 10 Position the engine guard on the frame at the front and mount screws 1 but do not tighten yet Position the engine guard on the frame at the rear and mount and ti...

Page 38: ...mping high speed Comfort 2 5 turns Standard 2 turns Sport 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Finishing work Install the shock absorber p 40 Lock th...

Page 39: ...ptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Info Turn clockwise t...

Page 40: ...ing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now measures the distance between the rear a...

Page 41: ...62 Remove the motorcycle from the lift stand p 10 9 8 Adjusting the riding sag Preparatory work Raise the motorcycle with the lift stand p 10 Fold the seat up p 62 Remove the shock absorber p 40 Afte...

Page 42: ...absorber M12 80 Nm 59 lbf ft Loctite 243 Mount and tighten screw 3 Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 243 Info The heim joint for the shock absorber at the swing arm is...

Page 43: ...ng length in a preloaded state Loosen screw 1 Turn adjusting ring 2 until the spring is relaxed as much as possible Hook wrench T106S p 210 201736 10 Clamp the shock absorber into the special tool Spr...

Page 44: ...oil 201739 10 Remove protection cap 6 Push in seal ring retainer 7 Remove lock ring 8 Info Do not scratch the inner surface 201738 10 Remove the piston rod Drain the remaining oil Remove adjusting rin...

Page 45: ...ide the compression shim stack onto a screwdriver and put them aside together 201745 10 Remove sleeve 5 Remove nut 6 201746 10 Remove supporting plate 7 Remove rebound shim stack 8 Info Guide the rebo...

Page 46: ...41 Disassemble the piston rod p 42 201733 10 Main work Remove rebound rubber 1 Remove washer 2 200786 10 Remove seal ring 3 Remove washer 4 from seal ring 3 200787 10 Remove washer 5 Remove O ring 6...

Page 47: ...ecial tool through the new pilot bushing Calibration pin T1205 p 211 The pilot bushing is calibrated Finishing work Assemble the seal ring retainer p 48 9 17 Checking the damper Condition The damper h...

Page 48: ...rface is visible Replace the piston rings 9 18 Removing the heim joint Info The steps are identical on the upper and lower heim joints Condition The shock absorber has been removed 201773 10 Clamp the...

Page 49: ...dentical on the upper and lower heim joints 201777 10 Position the new heim joint 1 and the special tool Pressing tool T1206 p 211 Press the heim joint all the way in 201775 11 Press the heim joint ag...

Page 50: ...the O ring groove Lubricant T158 p 204 Mount O ring 2 Mount washer 3 200794 10 Position washer 4 on seal ring 5 Grease the seal ring and mount with the washer facing downward Lubricant T511 p 204 2017...

Page 51: ...ack 5 with the smaller shims facing downward 201752 11 Sand both sides of piston 6 on a surface plate using 1200 grit sandpaper Clean the piston Mount the piston Guideline View A Top view of piston Vi...

Page 52: ...201759 10 Main work Slide the spring and piston onto the compression adjuster A Grease the O ring Lubricant T158 p 204 Grease the threads Lubricant T159 p 204 Mount and tighten compression adjuster A...

Page 53: ...of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Turn adjusting screw 8 clockwise with a screwdriver up to the last per...

Page 54: ...201766 10 Remove the screw from the filling port Mount adapter 1 on the damper Info Hand tighten only without using a tool Connect adapter 1 to connector 2 of the vacuum pump Vacuum pump T1240S p 211...

Page 55: ...value turn control lever Damper 4 to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar 200270 10 When the pressure gauge reaches the required value turn control lever Oil res...

Page 56: ...s fully extended otherwise damage will occur during compression of the shock absorber Remove the special tool 201769 10 Remove adapter 1 from connector 2 of the vacuum pump Info Hold the damper so tha...

Page 57: ...k absorber into the special tool Spring compressor T14050S p 212 Info Use a suitable ring with the smallest possible inside diameter of the special tool Press directly on the spring Mount washer 1 and...

Page 58: ...ORBER SWINGARM 56 Tighten the spring by turning adjusting ring 3 to the value measured when it was removed Hook wrench T106S p 210 Tighten screw 4 Guideline Screw shock absorber adjusting ring M6 5 Nm...

Page 59: ...lencer with rubber sleeve 2 Mount and tighten screws 1 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 10 3 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns T...

Page 60: ...ng 3 from the connecting cap Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling 3 on the connecting cap Slide main silencer sleeve 4 over the connecting cap with the new...

Page 61: ...nter the engine and cause damage Finishing work Lock the seat p 62 11 3 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never...

Page 62: ...e Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack t...

Page 63: ...e filler cap counterclockwise and lift it free 12 2 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engi...

Page 64: ...ap p 62 Lock the seat p 62 12 3 Closing the filler cap B01662 11 Main work Replace the filler cap and turn clockwise until the release button 1 locks in place Info Run the fuel tank breather hose 2 wi...

Page 65: ...the seat 12 7 Mounting the seat 305982 11 Main work Grease the O ring of the sliding bushings before mounting Long life grease p 204 Position the seat Mount sliding bushings 1 with the O ring 305981 1...

Page 66: ...poiler Repeat the operation on the opposite side 12 9 Mounting the spoiler 305980 10 Main work Position the spoiler and hook it in at area A 305978 11 Mount and tighten screw 1 Mount and tighten screw...

Page 67: ...handle 1 of the fuel tap to the OFF position Figure B01660 10 p 66 Pull off the fuel hose Info Remaining fuel may flow out of the fuel hose B01717 10 Remove the tube from the fuel tank breather Remov...

Page 68: ...nt and tighten screw 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the fuel tank breather Finishing work Lock the seat p 62 12 12 Fuel tap B01660 10 The fuel tap is on the left side o...

Page 69: ...on the front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Make sure the holding lugs engage in the headlight mask 13 3 Removing the headlight mask with...

Page 70: ...work Connect connector 2 of the headlight and 1 turn signals B01041 11 Position the headlight mask and fix it with the rubber band 3 Info Make sure that the holding lugs engage in the fender Position...

Page 71: ...nd rear wheels must have a similar profile Worn tires have a negative effect on riding behavior especially on wet surfaces If used regularly on public roads tires wear much faster and the minimum trea...

Page 72: ...the brake disc 14 4 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Info A loose spoke causes wheel imb...

Page 73: ...s not dam aged B01046 10 Remove spacers 3 14 5 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs f...

Page 74: ...ke Preparatory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 71 305971 10 Main work Remove screws 1 Remove the brake disc 14 5 4 Installing the brake disc of the front br...

Page 75: ...lay the wheel down in such a way that the brake disc is not dam aged B01048 10 Remove spacers 4 14 6 2 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or gr...

Page 76: ...ngs are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 10 14 6 3 Removing the brake disc of the rear brake Preparatory work Rai...

Page 77: ...rning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the tran...

Page 78: ...sure the distance B of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B at the longest...

Page 79: ...guide If the light part of the chain guide is worn Change the chain guide B01713 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining...

Page 80: ...er 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 regula...

Page 81: ...n cap 1 B01685 10 Remove the faulty main fuse 2 Info A defective fuse is indicated by a burned out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109110...

Page 82: ...tioning properly Close the fuse box cover Finishing work Lock the seat p 62 15 3 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries...

Page 83: ...ttery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Ke...

Page 84: ...t overcharge the battery Info Never remove lid 1 Charge the battery with a maximum of 10 of the capacity specified on the battery housing 2 Switch off the charger after charging Disconnect the battery...

Page 85: ...oltage regulator from the wiring harness and perform the measurement again Finishing work Install the shock absorber p 40 Lock the seat p 62 Remove the motorcycle from the lift stand p 10 15 8 Checkin...

Page 86: ...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...

Page 87: ...sition retaining spring 7 Mount bolt 6 Mount cotter pin 5 Info To make it easier to mount the bolt push the retaining spring down Make sure the retaining spring is seated correctly B01697 10 Position...

Page 88: ...ssure point moves away from the handlebar When the adjusting screw is turned counterclockwise the free travel increases The pressure point moves towards the handlebar The range of adjustment is limite...

Page 89: ...lor 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 B0...

Page 90: ...ideline Filling pressure 2 2 5 bar 29 36 psi 202685 10 Pull off protection cap 5 of the brake caliper bleeder screw Connect the hose of the bleeder bottle Bleeding device 00029013100 p 206 Open bleede...

Page 91: ...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 g...

Page 92: ...brake linings Info Always change the full set of brake linings B01690 10 Position retaining spring 5 Mount bolt 4 Mount cotter pin 3 Info To make it easier to mount the bolt push the retaining spring...

Page 93: ...lever according to specifications B01695 10 Disconnect spring 1 Loosen nut 4 and with push rod 5 turn it back until you have maximum free travel To adjust the basic position of the foot brake lever i...

Page 94: ...a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Envir...

Page 95: ...brane and ring Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 p 206 Brake fluid DOT 4 DOT 5 1 p 202 202687 10 Mount...

Page 96: ...pro tection cap Disconnect the bleeding device Remove the bleeder cover 202689 10 Stand the vehicle upright Add brake fluid to level C Brake fluid DOT 4 DOT 5 1 p 202 Mount the cover with the membran...

Page 97: ...12h display of the clock 401912 01 Wait for 5 seconds The speedometer changes to the next menu item The symbol flashes Resetting the time Press the left button The value decreases Advancing the time P...

Page 98: ...Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock to flash Press one of the buttons to select the 24h or 12h display of the clock 4...

Page 99: ...Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 17 6 Checking the headlight setting 0 0 A A 0...

Page 100: ...crew on the rear of the turn signal housing Carefully remove diffuser 1 Lightly squeeze orange cap 2 in the area of the holding lugs and take it off Press the turn signal bulb carefully into the socke...

Page 101: ...th the headlight p 68 Check the headlight setting p 97 17 10 Changing the speedometer battery Preparatory work Remove the headlight mask with the headlight p 67 B01643 10 Main work Remove screws 1 Pul...

Page 102: ...17 LIGHTING SYSTEM INSTRUMENTS 100 Set the speedometer p 95...

Page 103: ...fuel tank p 65 202700 10 Main work Remove springs 1 Spring hooks 50305017000 p 206 Remove screw 2 Take off the exhaust manifold 202701 10 Detach connector 3 Remove screws 4 and take off the radiator s...

Page 104: ...02706 10 Pull off the spark plug connector bm 202707 10 Detach connector bn Remove screws bo Take off the ground wire Remove the ignition coil 202708 10 Detach connector bp Remove cable binders bq 202...

Page 105: ...e clutch slave cylinder and hang it to the side Info Do not activate the clutch lever if the clutch slave cylinder has been removed 202715 10 Remove nut co Remove the chain adjuster Pull out the wheel...

Page 106: ...tly secured against falling over Protect the frame and attachments from damage 18 2 Installing the engine 202718 11 Main work Position the engine in the frame Mount screws 1 but do not tighten yet Gui...

Page 107: ...sprocket Mount lock ring 6 Put the chain on the engine sprocket 202715 11 Position the rear wheel Mount the chain adjuster and nut Push the rear wheel forward so that the chain adjusters are in contac...

Page 108: ...cover M4 3 Nm 2 2 lbf ft 202710 11 Attach spring bp 202709 11 Position the electrical connection on the starter motor Mount and tighten nut bq Guideline Nut cable on starter motor M6 4 Nm 3 lbf ft Pos...

Page 109: ...s Position and tighten hose clips co Mount hose cp 202702 11 Plug in connector cq Plug in connector cr Position the wiring harness Mount cable binder cs 202701 11 Position the radiator shield and horn...

Page 110: ...he coolant p 158 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 ti...

Page 111: ...agnet and seal ring Completely drain the gear oil 18 3 3 Removing the clutch push rod 202723 10 Remove clutch push rod 1 18 3 4 Removing the shift lever 202724 10 Remove screw 1 with washers Take off...

Page 112: ...0 Remove screws 1 Take off cover 2 202728 10 Remove screws 3 Remove starter motor 202729 10 Remove screws 4 and 5 Remove the cover 202730 10 Remove gasket and dowels 6 202731 10 Remove starter idler g...

Page 113: ...11 202733 10 Remove gasket and dowels 9 202734 10 Take off Bendix bk 18 3 7 Removing the cylinder head 202737 10 Alternately loosen screws 1 and remove them Remove the cylinder head 202738 10 Remove O...

Page 114: ...move nuts 1 Carefully slide the cylinder up and take it off 202740 10 Take off gasket 2 18 3 9 Removing the piston 202741 10 Uncover the crankcase Remove the piston ring lock 1 Remove piston pin Take...

Page 115: ...emove dowels 2 Remove the form ring 18 3 11 Removing the clutch cover 202745 10 Remove screws 1 Take off the clutch cover 202746 10 Remove dowels 2 and clutch cover gasket 3 18 3 12 Removing the clutc...

Page 116: ...with the special tool Loosen nut 1 Clutch holder 51129003000 p 207 Remove the nut with the lock washer 202751 10 Take off inner clutch hub 2 and washer 3 Info The washer usually sticks to the inner cl...

Page 117: ...he shift drum locating unit 202756 10 Remove screw 1 Push away locking lever 2 from shift drum locating unit 3 and remove the shift drum locating unit Relieve tension from the locking lever 18 3 16 Re...

Page 118: ...10 Remove reed valve housing 2 Take off the gasket 18 3 19 Removing the left engine case section 202762 10 Remove screws 1 Tilt the left section of the engine case upward and remove the fitting of the...

Page 119: ...shift rollers Remove shift drum 2 18 3 22 Removing the shift forks 202766 10 Remove shift forks 1 Info Do not misplace the shift rollers 18 3 23 Removing the transmission shafts 202767 10 Pull both t...

Page 120: ...the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing the beari...

Page 121: ...the bearings in via the outer ring otherwise the bearings will be damaged when they are pressed in After the engine case section has cooled check that the bearings are firmly seated Info If the bearin...

Page 122: ...for inner bearing race 58429037040 p 208 Ensure that the new crankshaft bearing inner race is flush 18 4 5 Changing the connecting rod conrod bearing and crank pin 303485 10 Main work Position cranksh...

Page 123: ...d bearing 0 60 0 70 mm 0 0236 0 0276 in If the specification is not reached Correct it so the dimension is equal to the specified value Finishing work Check the crankshaft run out at the bearing pin p...

Page 124: ...piston 202785 10 Check the piston bearing surface for damage If the piston bearing surface is damaged Replace the piston and if necessary the cylinder Check that the piston rings move easily in the pi...

Page 125: ...uring the mounting clearance 202785 10 Check measure the cylinder p 121 Check measure the piston p 122 The smallest piston cylinder mounting clearance equals the smallest cylinder bore diameter minus...

Page 126: ...mage 202788 10 Remove screw 1 Take off water pump impeller 2 202789 10 Remove water pump shaft 3 202790 10 Remove shaft seal ring 4 202791 10 Press out bearing 5 toward the inside Press the new bearin...

Page 127: ...clutch push rod Place the clutch push rod 2 on a flat surface and check for run out If there is run out Change the clutch push rod Check the length of clutch springs 3 Clutch spring length 38 0 mm 1...

Page 128: ...ess 1 9 mm 0 075 in If the clutch facing discs do not meet specifications Change all clutch facing discs Check washer bk for damage and wear If there is damage or wear Change the washer Check the inne...

Page 129: ...and wear If there is damage or wear Change the shift rollers Check the springs of shift rails 4 for damage and wear If the spring is damaged or worn Change the spring of the shift rail Check the shift...

Page 130: ...ifications Change the sliding plate 18 4 17 Disassembling the main shaft 303334 10 Secure the main shaft with the toothed end facing downward in the vise Guideline Use soft jaws Remove stop disk 1 and...

Page 131: ...p disk 4 Remove sixth gear sliding gear 5 Remove lock ring 6 Remove stop disk 7 Remove third gear idler gear 8 and needle bearing 9 Remove fourth gear idler gear bk Remove needle bearing bl Remove sto...

Page 132: ...amage or wear Change the gear wheel pair Check the tooth faces of idler gears 4 sliding gears 5 and fixed gear 6 for damage and wear If there is damage or wear Change the gear wheel pair Check the too...

Page 133: ...ar 2 Mount stop disk 3 and lock ring 4 Mount third fourth gear sliding gear 5 with the small gear wheel facing downward Mount lock ring 6 and stop disk 7 Mount needle bearing 8 Mount fifth gear idler...

Page 134: ...d lock ring 4 Mount fifth gear sliding gear 5 with the shift groove facing up Mount lock ring 6 and stop disk 7 Mount needle bearing 8 and fourth gear idler gear 9 Mount needle bearing bk Mount third...

Page 135: ...damage or wear Change the starter motor Change O ring 4 of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the...

Page 136: ...Lubricant T625 p 204 18 5 Engine assembly 18 5 1 Installing the crankshaft 202769 11 Mount O ring 1 202768 11 Position the right section of the engine case in the engine work stand Engine assembly st...

Page 137: ...orks 2 in the shift drum Info Do not misplace the shift rollers 18 5 5 Installing the shift rails 202764 11 Install shift rail 1 together with upper spring and the lower spring Install shift rail 2 to...

Page 138: ...e Screw engine case M6x60 10 Nm 7 4 lbf ft Fix the engine in the engine work stand Remove the excess lengths of the engine case gasket in the area of the cylinder support and the reed valve housing 18...

Page 139: ...e shift drum locating unit are not symmetrical 202756 11 Relieve tension from the locking lever Mount and tighten screw 2 Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 18 5 11 In...

Page 140: ...1 Position the new lock washer and mount nut 8 Tighten the nut holding the inner clutch hub with a special tool Guideline Nut inner clutch hub M18x1 5 120 Nm 88 5 lbf ft Loctite 648 Clutch holder 5112...

Page 141: ...7 4 lbf ft 18 5 14 Installing the clutch cover 302981 10 Apply a thin layer of sealing compound in area A on both sides Loctite 5910 202746 11 Mount dowels 1 Mount clutch cover gasket 2 202745 11 Posi...

Page 142: ...side 202774 10 Cover the engine case opening with a cloth Slide piston pin 1 into the connecting rod by hand Position the piston pin retainer in the 6 o clock or 12 o clock position Ensure that the pi...

Page 143: ...ce must be checked very carefully If the X distance is too large the compression decreases and the engine loses power If the X distance is too small the engine knocks and overheats 202777 10 Apply spe...

Page 144: ...ned Finishing work Install the cylinder p 140 18 5 20 Installing the cylinder head 202738 11 Mount O rings 1 and 2 Info Ensure that the dowels are seated correctly 202737 11 Put the cylinder head in p...

Page 145: ...2 11 Position the alternator cover Mount and tighten screw 3 Guideline Screw alternator cover M6 8 Nm 5 9 lbf ft 202731 11 Grease and mount starter idler gear 4 Lubricant T625 p 204 202730 11 Mount do...

Page 146: ...se spacer 1 in area A and O Ring 2 Long life grease p 204 Position the O ring in the cut out of the spacer 202725 10 Grease the shaft seal ring Long life grease p 204 Push spacer 1 with the O ring ont...

Page 147: ...22 10 Mount and tighten the gear oil drain plug 1 with the magnet and the new seal ring Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 18 5 26 Removing the engine from the work st...

Page 148: ...ure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Adjust the idle speed with adjusting screw 1 Guideline Choke...

Page 149: ...rn handle 1 of the fuel tap to the OFF position Figure B01660 10 p 66 Fuel no longer flows from the fuel tank to the carburetor B01672 10 Main work Place a cloth under the carburetor to capture the dr...

Page 150: ...slide 202692 10 Loosen hose clip 4 Pull the carburetor out of the intake flange toward the rear Drain the remaining fuel 19 5 Installing the carburetor 202692 11 Main work Position the carburetor on t...

Page 151: ...n The carburetor has been removed 306820 10 Disassemble the carburetor p 149 Check the jet needle p 151 Check the throttle slide p 151 Check the float needle valve p 152 Check the choke slide p 151 As...

Page 152: ...10 Remove needle jet holder 5 with needle jet Info The needle jet is usually lodged in the carburetor housing 306311 10 Remove idling jet 6 306312 10 Note down the setting of the idle air adjusting s...

Page 153: ...ng mechanism is not functional Change the choke slide 19 9 Checking the jet needle Condition The jet needle has been removed 306315 10 Check whether the jet needle is bent or if the coating is worn of...

Page 154: ...g the carburetor 306313 11 Mount and tighten choke slide 1 Guideline Choke slide M10 5 Nm 3 7 lbf ft 306312 11 Mount idle air adjusting screw 2 with the spring and O ring Alternative 1 Set the idle ai...

Page 155: ...Check adjust the float level p 153 306307 11 Position the hoses on the carburetor Position the float chamber Mount and tighten screws 8 Guideline Other carburetor screws M4 2 Nm 1 5 lbf ft 306306 10 M...

Page 156: ...the carburetor until the float is resting against the float needle valve but the float needle valve is not squeezed If when in this position the edge of the float is not parallel max 1 deviation in a...

Page 157: ...ch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Add fluid to level A Guideline Level A fluid level below container rim 4 mm 0 16 in...

Page 158: ...B01708 10 Inject the liquid into the system until it escapes from opening A of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remov...

Page 159: ...tor Coolant level A above radiator fins 10 mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 202 Alternative 2 Coolant mixed ready to use p...

Page 160: ...ve screw 1 Take off radiator cap 2 Completely drain the coolant Mount screw 1 with a new seal ring and tighten it Guideline Drain plug water pump cover M10x1 15 Nm 11 1 lbf ft 21 4 Refilling coolant W...

Page 161: ...UMP COOLING SYSTEM 159 Return the vehicle to the horizontal position B01679 10 Completely fill the radiator with coolant Mount radiator cap 2 Let the engine warm up Finishing work Check the coolant le...

Page 162: ...se environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the gear oil while the engine is warm Preparatory work...

Page 163: ...oil tight Finishing work Check the gear oil level p 161 22 4 Checking the gear oil level Info The gear oil level must be checked when the engine is cold Preparatory work Stand the motorcycle upright...

Page 164: ...eline Screw gear oil level check M6 10 Nm 7 4 lbf ft Mount and tighten screw cap 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When...

Page 165: ...open the throttle Check the ignition sparks If no ignition sparks are visible Check the emergency OFF switch Check the wiring harness to the emergency OFF switch Check the kill switch Check the groun...

Page 166: ...en using the peak voltage adapter adjust the measuring range of the multimeter to DCV Start the motorcycle to make checks p 11 Ignition coil cylinder 1 check the primary winding voltage Measure the vo...

Page 167: ...tion pulse generator connector AN pin 1 Alternator charging coil ignition pulse generator connector AN pin 2 Alternator Resistance of ignition charging coil at 20 C 68 F 11 98 16 21 If the specificati...

Page 168: ...esistance between the specified points Alternator charging coil ignition pulse generator connector AN pin 3 Alternator charging coil ignition pulse generator connector AN pin 4 Crankshaft position sen...

Page 169: ...Condition The alternator cover has been removed 202735 10 Remove screw 1 Remove cable support sleeve 2 from the alternator cover 202736 10 Remove screw 3 Remove the stator and crankshaft position sen...

Page 170: ...and rotor 4 Take off Bendix 5 and clean Grease gear teeth A and the points marked with a B Lubricant T625 p 204 Mount Bendix 5 Position the gasket Check that dowels 6 are seated correctly Mount alter...

Page 171: ...en removed 309402 10 Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly with connector 1 of the starter mot...

Page 172: ...nt BTDC 1 9 mm 0 075 in Spark plug NGK BR 7 ES Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Electric starter 25 2 Engine tolerance wear limits Piston diameter Size I 66 355 66 365 mm 2 6124...

Page 173: ...e reed valve housing M6 10 Nm 7 4 lbf ft Screw kick starter spring M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4...

Page 174: ...Front 1 5 bar 22 psi Rear 1 5 bar 22 psi Secondary ratio 14 46 12 46 Chain 5 8 x 1 4 X ring Rear sprockets available 46 48 Steering head angle 67 Wheelbase 1 428 10 mm 56 22 0 39 in Ground clearance...

Page 175: ...der 75 85 kg 165 187 lb 445 mm 17 52 in Weight of rider 85 95 kg 187 209 lb 445 mm 17 52 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6...

Page 176: ...m 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 243 Nut rim lock M8 10 Nm 7 4 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw...

Page 177: ...lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft 25 11 Carburetor Carburetor type KEIHIN PWK...

Page 178: ...d for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 401798 01 M FT ASL...

Page 179: ...mal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 204 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry ve...

Page 180: ...he brakes 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 the...

Page 181: ...the last time before taking the motorcycle out of service add fuel additive Fuel additive p 204 Refuel p 61 Clean the motorcycle p 177 Change the gear oil p 160 Check the antifreeze and coolant level...

Page 182: ...Grease all moving parts e g side stand hand lever chain and check for smooth operation Check the fluid level of the hydraulic clutch p 155 Check the brake fluid level of the front brake p 86 Check the...

Page 183: ...head bearing p 28 Change the glass fiber yarn filling of the main silencer p 57 Check adjust the carburetor components Perform a fork service p 15 Service the shock absorber p 40 Checking cleaning and...

Page 184: ...E 4 CE 4 2 4 1 3 BU 18 X1 7 6 1 b CA 4 X30 3 CA 4 X30 4 2 1 CU 4 X8 2 EE 1 X9 1 5 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 20A 4 1 2 3 0 1 G 0 1 M AF 4 X38 2 4 BR 4 X37 3 2 X302 S21 BK 4 BK 4 2 1 4 3 1 A...

Page 185: ...29 WIRING DIAGRAM 183 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button T20 Voltage regulator...

Page 186: ...4 X25 3 4 AC 6 X26 2 AC 6 X26 1 3 CR 1 X32 1 4 AC 6 X26 5 b 6 CR 1 X36 1 a S22 BC 6 BC 6 3 1 4 6 2 1 5 BF 1 BC 6 BA 1 X22 1 FF 1 X27 1 FF 1 X6 1 FP 1 X5 1 DI 2 X3 1 DI 2 X3 2 CX 2 X15 2 c b a d 10A F...

Page 187: ...29 WIRING DIAGRAM 185 Components A15 CDI controller E13 Low beam high beam F1 Fuse P15 Horn P23 High beam indicator lamp P35 Parking light S22 Light switch horn button kill switch...

Page 188: ...X34 1 E60 2 1 DI 2 X35 1 DI 2 X35 2 P36 CV 4 CV 4 4 1 2 3 2 BY 4 X31 1 BY 4 X31 3 d CV 4 X19 1 2 CV 4 X19 3 4 2 BY 4 X20 3 BY 4 X20 4 c e 2 CY 3 X2 3 1 e 1 2 CZ 3 3 1 CX 2 2 B70 CW 2 1 2 10A F2 2 1 F...

Page 189: ...7 Components B33 Radiator fan temperature switch B70 Wheel speed sensor front B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp F2 Fuse M14 Radiator fan P13 Speedometer P...

Page 190: ...8 3 B8 R L K20 2 1 P21 1 2 P42 1 CW 2 2 CW 2 P45 1 CW 2 2 CW 2 P46 1 CW 2 2 CW 2 P41 1 CW 2 2 CW 2 AJ 3 X10 1 AH 2 X11 2 2 1 CX 2 X13 1 CX 2 X16 1 AJ 3 X10 3 CX 2 X17 1 CX 2 X18 1 AH 2 X11 1 CX 2 X13...

Page 191: ...DIAGRAM 189 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signa...

Page 192: ...EU 2014 E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 5 2 A1 A15 R51 1 BU 18 X1 1 FF 1 X4 1 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1 1 1 S50 EI 1 EH 1 X...

Page 193: ...A15 CDI controller B37 Crankshaft position sensor R51 Ignition coil cylinder 1 S50 Map switch for ride mode Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu...

Page 194: ...CE 4 2 4 1 3 BU 18 X1 7 6 1 b CA 4 X30 3 CA 4 X30 4 2 1 CU 4 X8 2 EE 1 X9 1 5 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 20A 4 1 2 3 0 1 G 0 1 M AF 4 X38 2 4 BR 4 X37 3 2 X302 1 AF 4 X38 3 BU 18 X1 2 2 1 B...

Page 195: ...29 WIRING DIAGRAM 193 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button T20 Voltage regulator...

Page 196: ...AC 6 X26 2 AC 6 X26 1 3 CR 1 X32 1 4 AC 6 X26 5 b 6 CR 1 X36 1 a FF 1 X27 1 FF 1 X6 1 FP 1 X5 1 DI 2 X3 1 DI 2 X3 2 CX 2 X15 2 c b a d 10A F1 2 1 FJ 2 X29 1 FJ 2 X29 2 e BU 18 X1 5 5 1 1 BA 1 BF 1 1...

Page 197: ...RAM 195 Components A15 CDI controller E13 Low beam high beam F1 Fuse P15 Horn P23 High beam indicator lamp P35 Parking light S22 Light switch horn button kill switch S23 Emergency OFF switch electric...

Page 198: ...X34 1 E60 2 1 DI 2 X35 1 DI 2 X35 2 P36 CV 4 CV 4 4 1 2 3 2 BY 4 X31 1 BY 4 X31 3 d CV 4 X19 1 2 CV 4 X19 3 4 2 BY 4 X20 3 BY 4 X20 4 c e 2 CY 3 X2 3 1 e 1 2 CZ 3 3 1 CX 2 2 B70 CW 2 1 2 10A F2 2 1 FJ...

Page 199: ...7 Components B33 Radiator fan temperature switch B70 Wheel speed sensor front B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp F2 Fuse M14 Radiator fan P13 Speedometer P...

Page 200: ...B8 3 B8 R L K20 2 1 P21 1 2 P42 1 CW 2 2 CW 2 P45 1 CW 2 2 CW 2 P46 1 CW 2 2 CW 2 P41 1 CW 2 2 CW 2 AJ 3 X10 1 AH 2 X11 2 2 1 CX 2 X13 1 CX 2 X16 1 AJ 3 X10 3 CX 2 X17 1 CX 2 X18 1 AH 2 X11 1 CX 2 X13...

Page 201: ...DIAGRAM 199 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signa...

Page 202: ...R AUS 2014 E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 5 2 A1 A15 R51 1 BU 18 X1 1 FF 1 X4 1 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1 1 1 S50 EI 1 EH 1...

Page 203: ...A15 CDI controller B37 Crankshaft position sensor R51 Ignition coil cylinder 1 S50 Map switch for ride mode Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu...

Page 204: ...res Using inferior antifreeze can result in corrosion and foaming Use only coolant based on ethylene glycol Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 dis...

Page 205: ...ON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel cont...

Page 206: ...d supplier Motorex Fuel Stabilizer High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Lubricant T158 Recommended supplier Lubcon Turmo...

Page 207: ...ded supplier Motorex Twin Air Liquid Bio Power Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and...

Page 208: ...06 Bleeder cover 201608 10 Art no 00029013012 Bleeder cover 201965 10 Art no 00029013018 Bleeding device 201491 10 Art no 00029013100 Spring hooks 400363 01 Art no 50305017000 Bleed syringe 400058 01...

Page 209: ...lder 400289 01 Art no 51129003000 Adjustment gauge 303079 10 Art no 54829001100 Separator plate 303483 10 Art no 54829009000 Lift stand 500071 01 Art no 54829055000 Insert for crankshaft pressing tool...

Page 210: ...spanner rotor 302997 10 Art no 55129001000 Gear segment 302982 10 Art no 56012004000 Engine fixing arm 302945 10 Art no 56029002030 Extractor 400073 01 Art no 58012009000 Tool for inner bearing race...

Page 211: ...2000 Torque wrench with various accessories in set 200910 10 Art no 58429094000 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Engine assembly stand 200306 01 Art no 61229001000 Pre...

Page 212: ...SPECIAL TOOLS 210 Gear quadrant 500164 01 Art no 80029004000 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Pin 201235 10 Art no T120 Mounting sleeve 200788 10 Art no T120...

Page 213: ...ECIAL TOOLS 211 Calibration pin 200790 10 Art no T1205 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Vacuum pump 200273 10 Art no T1240S Clamping stand 200688 10 Art no T1...

Page 214: ...32 SPECIAL TOOLS 212 Support tool 200639 10 Art no T14026 Open end wrench 200640 10 Art no T14032 Spring compressor 201648 10 Art no T14050S Press drift 200789 10 Art no T1504...

Page 215: ...TOOLS 213 Assembly tool 200791 10 Art no T150S Mounting sleeve 300578 10 Art no T1554 Nitrogen filling tool 300574 10 Art no T170S1 Protecting sleeve 200635 10 Art no T512 Mounting tool 200634 10 Art...

Page 216: ...32 SPECIAL TOOLS 214 Pin 200687 10 Art no T605 Clamping stand 200638 10 Art no T612S...

Page 217: ...rom the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performan...

Page 218: ...147 installing 148 removing 147 Carburetor work on individual parts choke slide checking 151 float level checking adjusting 153 float needle valve checking 152 jet needle checking 151 throttle slide...

Page 219: ...stalling 135 shift forks installing 135 shift lever installing 144 shift rails installing 135 shift shaft installing 137 spacer installing 144 starter motor installing 142 transmission shafts installi...

Page 220: ...10 O Open circuit current checking 83 Operating substances 7 P Play in the throttle cable adjusting 34 checking 33 Preparing for use after storage 179 R Rear sprocket checking 76 Rear wheel installin...

Page 221: ...ities 171 carburetor 175 carburetor tuning 176 chassis 172 chassis tightening torques 174 electrical system 172 engine 170 engine tolerance wear limits 170 engine tightening torques 171 fork 173 shock...

Page 222: ...3206188en 3206188en 10 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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