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ENGINE

124

304547-10

–

Remove the spacer

–

Take off bearing

–

Oil the new bearing and slide it onto the camshaft.

Lubricated with engine oil

–

Mount the spacer.

304546-10

–

Mount camshaft gear

Holding lug

engages in the recess of the camshaft.

–

Mount and tighten screw

Guideline

Screw, camshaft drive
sprocket

20 Nm
(14.8 lbf ft)

Loctite

243™

–

Remove the special tool.

Holding spanner (90129012000) (

p. 256)

–

Repeat these steps on the second camshaft.

16.4.9

Work on the cylinder head (125 Duke)

304551-10

–

Fold cam lever

up.

–

Take the shims

out of the valve spring retainers and lay them to one side accord-

ing to their normal built-in position.

304552-10

–

Pretension the valve spring using the special tool.

Valve spring compressor (59029019000) (

p. 252)

Insert for valve spring lever (90129060000) (

p. 259)

304537-10

–

Remove valve keys

and relax the valve spring.

–

Remove valve spring retainer

–

Remove valve spring, valve stem seal

, and valve spring seat

Info

Place the valve into a box according to the installation position and label the
box.

–

Check the cylinder head. (

p. 125)

–

Mount valve spring seat

and the new valve stem seal

–

Mount the valve spring.

–

Mount valve spring retainer

Содержание 125 Duke DE

Страница 1: ...REPAIR MANUAL 2012 125 Duke EU 125 Duke DE 200 Duke EU 200 Duke 2013 COL Art no 3206127en ...

Страница 2: ......

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

Страница 4: ...SEAT TRIM 38 11 1 Opening the filler cap 38 11 2 Closing the filler cap 38 11 3 Removing the seat 38 11 4 Mounting the seat 39 11 5 Removing the passenger seat 39 11 6 Mounting the passenger seat 39 11 7 Removing the fuel tank cover 39 11 8 Installing the fuel tank cover 42 11 9 Removing the fuel tank 44 11 10 Installing the fuel tank 46 11 11 Removing the front spoiler 47 11 12 Fitting front spoi...

Страница 5: ... oil 200 Duke 104 16 3 36 Removing the chain securing guide 200 Duke 105 16 3 37 Removing the valve cover 200 Duke 105 16 3 38 Removing the spark plug 200 Duke 105 16 3 39 Removing the clutch cover 200 Duke 105 16 3 40 Setting the engine to ignition top dead center 200 Duke 106 16 3 41 Removing the starter motor 200 Duke 106 16 3 42 Removing the timing chain tensioner 200 Duke 107 16 3 43 Removing...

Страница 6: ...ne 158 16 5 1 Installing the crankshaft 125 Duke 158 16 5 2 Installing the balancer shaft 125 Duke 158 16 5 3 Installing the transmission shafts 125 Duke 159 16 5 4 Installing the shift forks 125 Duke 159 16 5 5 Installing the shift drum 125 Duke 159 16 5 6 Installing the shift rails 125 Duke 160 16 5 7 Installing the left engine case 125 Duke 160 16 5 8 Installing the oil filter 125 Duke 161 16 5...

Страница 7: ... 4 Changing the engine oil and oil filter cleaning the oil screen 200 19 5 Adding engine oil 201 20 IGNITION SYSTEM 202 20 1 Alternator checking the stator winding 202 21 TECHNICAL DATA 203 21 1 Engine 203 21 1 1 125 Duke 203 21 1 2 200 Duke 203 21 2 Engine tolerance wear limits 204 21 2 1 125 Duke 204 21 2 2 200 Duke 205 21 3 Engine tightening torques 205 21 4 Capacities 206 21 4 1 Engine oil 206...

Страница 8: ...page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Identifies a proprietary name Name Identifies a prot...

Страница 9: ... are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will...

Страница 10: ...anger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 Spare parts accessories Only use spare parts and accessories approved and or recommended by KTM KTM accepts no liability for other products and any resulting damage or loss The current KTM Power...

Страница 11: ...abel 2 is on the right of the frame behind the steering head 4 2 Key number B00755 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 4 3 Engine number B00700 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket ...

Страница 12: ...d lift the motorcycle 5 2 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface B00714 10 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand 1 Remove the support of the wheel stand 5 3 Raising the motorcycle with the front wh...

Страница 13: ...5 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface B00781 01 Secure the motorcycle against falling over Remove the front wheel stand C00196 10 Mount cap 1 5 5 Raising the motorcycle with the work stand Note Danger of damage The parked vehicle may roll away or fall over Always...

Страница 14: ...ide of the vehicle Work stand 62529055000 p 254 307321 10 Position the motorcycle upright align the special tool and raise the motorcycle 5 6 Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 307321 11 Secure the motorcycle against falling over Remove special tool 1 ...

Страница 15: ...engine Always warm up the engine at low engine speeds B00782 10 Sit on the vehicle take the weight off of the side stand and move up all the way Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the position After you switch on the ignition you can hear the fuel pump working for about two seconds The function test of the combination instrument is r...

Страница 16: ...icient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Info Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again B00782 10 Turn the emergency OFF switch to the position Shift gear to neutral Switch on the ignition by turning the ignition key to the position Press the electric starter button In...

Страница 17: ...ory work Raise the motorcycle with the work stand p 11 Tie the rear of the vehicle down Dismount the front fender p 48 304857 10 Main work Remove screws 1 Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever when the brake caliper has b...

Страница 18: ...e clamps Align the fork legs in the required position using the fork rings 304860 11 Tighten screw 1 Guideline Screw top triple clamp M8 11 Nm 8 1 lbf ft Fully tighten screws 2 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 304859 11 Position the wheel speed sensor Mount and tighten screws 3 Guideline Remaining screws chassis M4 4 Nm 3 lbf ft 304861 10 Check the wheel bearing for damage ...

Страница 19: ...e lever in the acti vated position The brake calipers straighten Fully tighten screw 6 Guideline Screw front brake caliper M8x1 30 Nm 22 1 lbf ft Loctite 243 Remove the fixation of the hand brake lever Unload the rear of the vehicle Remove the motorcycle from the work stand p 12 304862 10 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws 7 Gu...

Страница 20: ...8 10 Release the fork leg and clamp it with the fork stub Info Use soft jaws 201509 10 Push the outer tube downward Hold screw cap 1 Loosen nut 2 Remove the screw cap 201510 10 Detach the outer tube from the inner tube Info Place a container underneath to catch any oil that may run out 201511 10 Unclamp the inner tube Drain the oil ...

Страница 21: ...201514 10 Remove seal ring 5 Remove support ring 6 201515 10 Unclamp the outer tube Heat up the outer tube in the area of sliding bushing 7 Guideline 50 C 122 F Strike the lower edge of the outer fork tube on a wooden board Sliding bushing 7 must fall out of its seat 6 5 Checking the fork legs Condition The fork legs have been disassembled 201516 10 Check the inner tube and the axle clamp for dama...

Страница 22: ... leg 200632 10 Check the outer tube for damage If damage is found Change the fork leg 201517 10 Check the surface of the sliding bushings If the dark layer A is worn off Change the fork leg 6 6 Assembling the fork legs Info These operations are the same on both fork legs Preparatory work Check the fork legs p 19 202092 10 Main work Clamp in the inner tube with the axle clamp Guideline Use soft jaw...

Страница 23: ...e outer tube in the lower sliding bushing area A Guideline 50 C 122 F Slide the outer tube onto the inner tube Hold the sliding bushing with the longer shoulder of the special tool Mounting tool T528S p 260 Push the sliding bushing all the way into the outer tube 202094 10 Position the support ring Hold the seal ring with the shorter shoulder of the special tool Mounting tool T528S p 260 Push the ...

Страница 24: ...nclamp the fork and bounce a number of times Then add the remaining quantity 201522 10 Push the outer tube upward Mount screw cap 6 Unclamp the fork leg in the area of the lower triple clamp Clamping stand T612S p 260 Tighten the screw cap Guideline Screw cap on outer tube M47x1 5 30 Nm 22 1 lbf ft 6 7 Removing the lower triple clamp Preparatory work Raise the motorcycle with the work stand p 11 T...

Страница 25: ...0 Detach connectors 3 and 4 304867 10 Detach connectors 5 and 6 304868 10 Disconnect connector 7 304869 10 Remove the combination instrument 304870 10 Remove screws 8 Remove the headlight mask 304871 10 Remove screw 9 with the washer ...

Страница 26: ...an the bearing and sealing elements check for damage and grease High viscosity grease p 250 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing 1 Mount washer 2 with the cut out facing downward 304873 11 Alternative 1 A new steering head bearing is used Mount and tighten nut 3 Guideline Nut steering head M30x1 Step 1 50 Nm 36 9 lbf ft 2nd stage loosen counter...

Страница 27: ... M16x1 5 52 Nm 38 4 lbf ft Holding lugs A reach into the drilled holes 304876 10 Position the headlight mask Mount and tighten screw 5 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft Mount and tighten screw 6 with the spacer washer Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 304868 10 Position the combination instrument Plug in connector 7 304867 11 Plug in connectors 8 and 9 304866 11 P...

Страница 28: ...e from the work stand p 12 6 9 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged with time Preparatory work Raise the motorcycle ...

Страница 29: ... 304855 10 Main work Loosen screws 1 Loosen screw 2 304856 10 Tighten nut 3 with the special tool until there is no play in the steering head bear ing Key for steering head bearing 90129051000 p 259 304855 10 Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screw 2 Guideline Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Tighten screw 1 Guideline Screw top t...

Страница 30: ...hange If the idle speed changes Check the throttle cable routing 7 2 Adjusting the play in the throttle cable B00728 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the throttle cable by turning adjusting screw 3 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut 2 Slide on sleeve 1 7 3 Checking the clutch lever play B0072...

Страница 31: ...e play B00730 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the clutch level A by turning adjusting screw 3 Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut 2 Slide on sleeve 1 ...

Страница 32: ...y and stability B01419 10 Turn adjusting ring 1 to adjust the spring preload Guideline Spring preload Standard 3 clicks Full payload 6 clicks Hook wrench T106S p 259 Info The spring preload can be set to 10 different positions 8 2 Removing the shock absorber Preparatory work Raise the motorcycle with the work stand p 11 304841 10 Main work Remove screw 1 Info Protect the link fork and attachments ...

Страница 33: ...ecial tool Spring compressor T14050S p 260 Info Use the ring of the special tool with the smallest possible inside diameter It must be pressed directly onto the spring Compress the spring Remove spring retainer 1 Release the spring Remove the shock absorber from the special tool Remove the spring 8 5 Installing the spring 201697 10 Mount the spring The tight coil of the spring is at the bottom Cla...

Страница 34: ...s to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the suspension compo nents can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Tension the spring...

Страница 35: ... is driven Allow the exhaust system to cool down Do not touch hot components 304843 10 Remove the nuts 1 Swing the radiator forward slightly 304844 10 Remove the cable binder expose the connector 2 of the lambda probe and detach 304845 10 Remove lambda sensor 3 304846 10 Loosen exhaust clamp 4 304847 10 Remove the nuts 5 ...

Страница 36: ...t Nut exhaust flange 200 Duke M8 22 Nm 16 2 lbf ft 304846 11 Position and tighten exhaust clamp 2 Guideline Exhaust clamp 10 Nm 7 4 lbf ft Tighten nuts 1 Guideline Nut exhaust flange 125 Duke M8 22 Nm 16 2 lbf ft Nut exhaust flange 200 Duke M8 22 Nm 16 2 lbf ft 304845 10 Mount and tighten lambda sensor 3 Guideline Lambda sensor M18x1 5 40 60 Nm 29 5 44 3 lbf ft Lubricant T152 p 251 304844 11 Plug ...

Страница 37: ...ft 9 3 Removing the main silencer Preparatory work Remove the exhaust manifold p 33 Remove the front spoiler p 47 304849 10 Main work Remove screw 1 with washers 304850 10 Remove screw 2 with washers 304851 10 Remove screw 3 Info Do not misplace the sleeves 304852 10 Remove the main silencer toward the bottom ...

Страница 38: ...encer M8 23 Nm 17 lbf ft Info Make sure the sleeves are seated correctly 304850 10 Mount and tighten screw 2 with the washers Guideline Screw main silencer M6 11 Nm 8 1 lbf ft 304849 11 Mount and tighten screw 3 with the washers Guideline Screw main silencer M6 11 Nm 8 1 lbf ft Finishing work Fit the front spoiler p 47 Install the exhaust manifold p 34 ...

Страница 39: ...ssenger seat p 39 Remove the seat p 38 304818 10 Main work Remove screws 1 Pull the air filter box lid forward and move to the side 304819 10 Remove air filter 2 Clean the air filter box 10 2 Installing the air filter 304819 11 Main work Position air filter 1 304818 11 Mount air filter box lid Info Make sure the air filter box lid is seated correctly Mount and tighten screws 2 Guideline Screw air ...

Страница 40: ...ster and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system B00710 10 Lift the cover 1 of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Dama...

Страница 41: ...e subframe and lower it at the rear while pushing forward Press down the passenger seat until it clicks into place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up Finally check that the passenger seat is correctly mounted 11 7 Removing the fuel tank cove...

Страница 42: ...g Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Preparatory work Remove the passenger seat p 39 Remove the seat p 38 304820 10 Create the tool special screw Four ordinary screws are needed Cut off screw 1 to length A Guideline Screw M5x50 Length A 40 mm 1 57 in Cut a slot into the top end...

Страница 43: ...unt and tighten another special screw 1 Open the filler cap p 38 304825 10 Remove filler cap 3 304826 10 Remove screws 4 with the washers 304827 10 Remove screws 5 Remove screws 6 304828 10 Remove cap 7 from the compensating tank 304829 10 Remove screws 8 ...

Страница 44: ...arm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is sw...

Страница 45: ...Remaining screws chassis M5 5 Nm 3 7 lbf ft 304833 10 Mount filler cap 3 304834 10 Remove special screws 4 individually and replace them with screws 5 Info Always replace the screws individually or the fuel tank will become dis torted and it will no longer be possible to mount the screws When all screws have been replaced tighten the screws crosswise Guideline Screw fuel tank cover M5 4 Nm 3 lbf f...

Страница 46: ...mediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated a...

Страница 47: ...t to one side Info Protect the frame and attachments from damage 304879 10 Remove screws 2 304880 10 Take off the holder 3 304881 10 Detach connector 4 304885 10 Detach the fuel line with a suitable tool 5 304886 10 Push back hose clamp 6 Pull off the fuel line and remove the fuel tank ...

Страница 48: ...he skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environm...

Страница 49: ...crews 6 Guideline Screw EFI control unit M4 4 Nm 3 lbf ft Finishing work Install the fuel tank cover p 42 Mount the seat p 39 Mount the passenger seat p 39 11 11 Removing the front spoiler B00770 10 Remove screws 1 B00771 10 Remove screws 2 Take off the front spoiler 11 12 Fitting front spoiler B00770 10 Position the front spoiler Mount screws 1 but do not tighten yet ...

Страница 50: ...el is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with wat...

Страница 51: ...t 400927 01 Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active 2 5 2 9 bar 36 42 psi If the specification is not reached Open the filler cap p 38 Check the tank air vent system 400928 01 Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 2 5 2 9 bar 36 42 psi If the specification is not reached Check that the fuel ...

Страница 52: ...ean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Preparato...

Страница 53: ...ot come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away fro...

Страница 54: ...he fuel pump with the gasket Install the screws 1 and tighten them diagonally Guideline Screw fuel pump M5 5 Nm 3 7 lbf ft Finishing work Install the fuel tank p 46 Install the fuel tank cover p 42 Mount the seat p 39 Mount the passenger seat p 39 ...

Страница 55: ...he vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especi...

Страница 56: ...n Change the brake discs 12 4 Front wheel 12 4 1 Removing the front wheel Preparatory work Raise the motorcycle with the rear wheel stand p 10 Raise the motorcycle with the front wheel stand p 10 B00743 10 Main work Loosen screw 1 and screws 2 Unscrew screw 1 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw 1 Warning Danger of accidents ...

Страница 57: ...heel stand p 11 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Tighten screws 3 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 10 12 4 3 Removing the brake disc of the front brake Preparatory work Raise the motorcycle with the rear wheel stand p 10 Raise the motorcycle with the front wh...

Страница 58: ...iscs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers p 61 B00748 10 Check the wheel bearing for damage and wear If the wheel beari...

Страница 59: ...le M14x1 5 60 Nm 44 3 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 10 12 5 3 Removing the brake disc of the rear brake Preparatory work Raise the motorcycle with the rear wheel stand p 10 Remove the rear wheel p 56 304805 10 Main work Remove screws 1 Remove the brake disc 12 5 4 Installing the brake disc of the rear brake 304805 10 Main work Clean the contact surface of ...

Страница 60: ...rd the swingarm and determine chain tension A Info The upper chain section B must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 5 7 mm 0 2 0 28 in If the chain tension does not meet specifications Adjust the chain tension p 58 12 5 6 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tens...

Страница 61: ...ing the chain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rear sprocket and chain should always be replaced together 1 2 3 18 19 20 0 0 0 B B 0 0 A A 401288 10 Shift gear to neutral Pull the lower chain section with specified weight A Guideline Weight...

Страница 62: ...tion the chain guard and tighten screw 1 Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw 2 Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft 12 5 8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of...

Страница 63: ...n time the rear sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with the rear wheel stand p 10 Remove the rear wheel p 56 B00746 10 Main work Check bearing 1 If the bearing is damaged or worn Change the bearing Check the rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in...

Страница 64: ...rminal cover 1 Disconnect the negative cable 2 of the battery B00751 10 Pull back the positive terminal cover 3 Disconnect the positive cable 4 of the battery Detach rubber band 5 Pull the battery up and out of the battery holder Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehicle is ther...

Страница 65: ...e eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environment Do not discard batteries 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 Info Even ...

Страница 66: ...deline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Finishing work Mount the seat p 39 Mount the passenger seat p 39 Set the clock p 77 13 6 Checking the charging voltage Condition The battery must be fully functional and completely charged Preparatory work Remove the passenger seat p 39 Remove the se...

Страница 67: ...ignition coil alarm system OPTIONAL Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Info A defective fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare ...

Страница 68: ...t a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger o...

Страница 69: ... locking clip 4 304813 10 Remove bolts 5 Take off springs 6 304814 10 Remove brake linings 7 Clean the brake caliper 304815 10 Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir Info Protect the components against damage 304814 10 Position brake linings 7 Info Always change the brake linings in pairs ...

Страница 70: ...d brake fluid Change the brake fluid of the front and rear brake according to the service schedule C00200 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in viewer 1 If the brake fluid is below the MIN marking Add front brake fluid p 68 14 4 Adding front brake fluid Warning Danger of accidents Failure of the brake system If the brake ...

Страница 71: ... and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulatio...

Страница 72: ...device Remove the bleeder cover 201527 10 Correct the brake fluid level to level A Guideline Level A 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 248 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water Check the hand brake lever for a firm pressure point 14 6 Checking the rear brake linings Warning Danger of accidents Re...

Страница 73: ...d and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no lon...

Страница 74: ...king the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications B00735 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the ...

Страница 75: ...0 2 in Info The range of adjustment is limited Hold screw 3 and tighten nut 2 Attach spring 1 14 10 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Warning Danger of accidents Reduced b...

Страница 76: ...e disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container C00203 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 248 Refit screw cap with membrane Info Clean up overflowed or spilt brake fluid immedi...

Страница 77: ...g pressure 2 2 5 bar 29 36 psi 201531 10 Pull off dust cap 4 of the bleeder screw Connect the hose of the bleeder bottle Bleeding device 00029013100 p 252 Open bleeder screw 5 by approximately one half turn Info Drain until fresh brake fluid emerges from the hose of the bleeder bottle without bubbles Tighten the bleeder screw Close shut off valve 3 Open the bleeder screw again until no more brake ...

Страница 78: ...the engine speed above which the shift warning light starts to flash Set the speed with the MODE and SET buttons Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds The display RPM 1 goes out and the set speed is stored 15 3 Adjusting the shift speed RPM 2 Condition The ignition is on The motorcycle is stationary 401308 ...

Страница 79: ... service interval display can only be reset It is not possible to individu ally adjust the distance or time to the next required service 15 6 Checking the headlight setting 0 0 A A 0 0 B B 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the first mar...

Страница 80: ...otorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range 601914 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 601915 10 Moun...

Страница 81: ...mounting Preparatory work Switch off all power consumers and switch off the engine 601915 10 Main work Remove expanding rivets 1 304865 10 Remove screws 2 Lift the headlight mask slightly and swing forward B00762 10 Remove screws 3 Take off cover 4 B00763 10 Pull the socket with bulb 5 out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 2...

Страница 82: ... that the lighting is functioning properly 15 9 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine 601915 10 Main work Remove expanding rivets 1 601914 10 Remove s...

Страница 83: ...ousing Headlight H4 socket P43t p 207 Info Insert the headlight bulb so that the catches latch into the recesses Attach retaining clamp 5 B00760 10 Connect plug in connection 4 Mount protection cap 3 601914 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 601915 10 Mount expanding rivets 1 on both sides Check that the lighting is functioni...

Страница 84: ...Disconnect the negative cable of the battery p 63 Drain the coolant p 194 Remove the exhaust manifold p 33 304896 10 Main work Push back the rubber cap Remove nut 1 with washers Hang the cable to one side 304897 10 Bend up the lock washer 2 Detach the clutch cable 304898 10 Detach connector 3 304899 10 Push back hose clamp 4 Pull off the vent hose 304900 10 Pull off spark plug connector 5 ...

Страница 85: ...e lock washer 304903 10 Remove nut 9 with washer Remove chain adjuster bk Push the rear wheel into the foremost position 304904 10 Pull the engine sprocket off of the countershaft and remove it 304905 10 Remove screw bl Pull off the shift linkage and hang it to one side 304906 10 Push back the rubber cap Remove nut bm with washer ...

Страница 86: ...tach connector bp 304909 10 Loosen hose clip bq Push the throttle valve body upward out of the intake flange 304910 10 Remove screws br Remove fitting bs Remove both engine fixing arms 304911 10 Push back hose clamp bt Pull off the radiator hose 304912 10 Push back hose clamp ck Pull off the radiator hose ...

Страница 87: ...0 Remove fitting cm Remove fitting cn Hang ground wire co to one side 304916 10 Lower the engine Info Watch out for clutch lever cp You should have an assistant for this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments from damage 16 2 Installing the engine Preparatory work Raise the engine onto the special tool and fix it Floor jack att...

Страница 88: ...hten yet Guideline Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft Mount fitting 4 but do not tighten yet Guideline Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft 304914 10 Remove the floor jack with the special tool Floor jack attachment 75029055000 p 255 304913 11 Mount the radiator pipe with the O ring Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf f...

Страница 89: ...tighten screws 8 Guideline Screw engine bearer on frame M8 30 Nm 22 1 lbf ft Mount and tighten fitting 9 Guideline Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft 304909 11 Position the throttle valve body in the intake flange Tighten hose clamp bk 304908 11 Plug in connector bl Position the cable and fix it with cable binders 304907 11 Plug in connectors bm and bn Position the cable and fix...

Страница 90: ...ith the washer Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M14x1 5 60 Nm 44 3 lbf ft 304902 11 Mount the lock washer and turn it slightly The lock washer engages in the gear teeth of the countershaft Mount and tighten screws bs Guideline Remaining...

Страница 91: ... nuts chassis M6 15 Nm 11 1 lbf ft Position the rubber cap Position the cable and fix it with cable binders B00773 12 Remove the oil filler plug cq with the O ring from the clutch cover and fill up with engine oil Engine oil First filling 1 5 l 1 6 qt External temper ature 0 50 C 32 122 F Engine oil SAE 15W 50 p 248 External tempera ture 10 40 C 14 104 F Engine oil SAE 10W 40 p 248 After oil chang...

Страница 92: ...ke a short test ride Read out the fault memory using the KTM diagnostics tool Check the engine for leakage Check the engine oil level p 198 Check the coolant level p 196 16 3 Disassembling the engine 16 3 1 Preparations 125 Duke 304417 10 Mount special tools 1 and 2 on the engine assembly stand Engine fixing arm 90129002060 p 256 Engine fixing arm 90129002050 p 255 Engine assembly stand 6122900100...

Страница 93: ...4729 10 Remove screws 1 with the gasket Take off the valve cover with the valve cover seal 16 3 5 Removing the spark plug 125 Duke 304730 10 Remove the spark plug using special tool 1 Spark plug wrench 77229172000 p 255 16 3 6 Removing the clutch cover 125 Duke 304731 10 Remove screws 1 304732 10 Take off the clutch cover Info Pull the clutch lever forward slightly ...

Страница 94: ...ead center 125 Duke 304734 10 Remove screw plug 1 304429 10 Turn the crankshaft counterclockwise until markings A align with the edge of the cylinder head Castle nut wrench drive 90129021000 p 257 Markings B and C align 16 3 8 Removing the starter motor 125 Duke 304434 10 Remove screws 1 Take off the starter motor ...

Страница 95: ...screw clockwise The timing chain tensioner is locked Remove screw 2 Remove the timing chain tensioner with the gasket 16 3 10 Removing the camshaft 125 Duke 304735 10 Release screws 1 from the outside to the inside and remove them Remove the camshaft bearing bridge Remove dowels 304736 10 Remove intake camshaft 2 304737 10 Remove exhaust camshaft 3 ...

Страница 96: ...ve dowels 4 304741 10 Remove timing chain guide rail 5 16 3 12 Removing the piston 125 Duke 304743 10 Push the cylinder upward Info Push the cylinder upward only far enough to allow removal of the piston pin Remove piston pin retainer 1 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 pi...

Страница 97: ...6 10 Remove screw 5 Take off the timing chain tensioning rail from above 16 3 13 Removing the water pump wheel 125 Duke 304747 10 Remove screws 1 Remove the water pump cover with the gasket 304748 10 Remove locating pins 2 304749 10 Lock the clutch basket and primary gear using special tool 3 Gear segment 90129081100 p 259 Remove nut 4 with washer Take off the water pump wheel 5 ...

Страница 98: ...tool 1 Gear segment 90129081100 p 259 304757 10 Remove screw 2 with the washer Remove the special tool Gear segment 90129081100 p 259 304758 10 Mount special tool 3 Pressure screw for crankshaft 90129020000 p 257 Mount special tool 4 on the rotor Info Left handed thread Hold it tight using the special tool and pull off the rotor by turning the screw in Extractor 90129009000 p 256 Remove the specia...

Страница 99: ...bracket 304760 10 Remove screws 2 Hang the ignition pulse generator to one side 304761 10 Remove freewheel gear 3 304762 10 Take off torque limiter 4 Remove starter idler gear 5 16 3 17 Removing the balancer shaft drive wheel 125 Duke 304756 10 Lock the clutch basket and primary gear using special tool 1 ...

Страница 100: ...4765 10 Remove balancer shaft gear 4 with a wedge Take off drive wheel 5 of the balancer shaft Remove the spring washer 16 3 18 Removing the gear position sensor 125 Duke 304771 10 Remove screws 1 Take off the retaining bracket Remove screws 2 and take off the gear position sensor 304772 10 Remove contact pin 3 and the contact spring ...

Страница 101: ...0 Mount special tool 3 Holding spanner 90129012000 p 256 Hold the inner clutch hub with the special tool Remove nut 4 with washer Castle nut wrench drive 90129021000 p 257 Info Left handed thread Remove the special tool Holding spanner 90129012000 p 256 Remove the inner clutch hub with the clutch discs Remove the washer Info The washer usually sticks to the inner clutch hub 304776 10 Lock the clut...

Страница 102: ...emoving the primary gear 125 Duke 304781 10 Remove timing chain sprocket 1 304782 10 Take off primary gear 2 304783 10 Remove spring washer 3 Take off spacer ring 4 16 3 22 Removing the oil pump 125 Duke 304784 10 Remove lock ring 1 Take off oil pump gear 2 ...

Страница 103: ... Removing the shift drum locating 125 Duke 304787 10 Remove screw 1 Press locking lever 2 away from shift drum locating 3 and take off the shift drum locating Release the locking lever 16 3 25 Removing the locking lever 125 Duke 304789 10 Remove screw 1 Take off locking lever 2 together with the washers and spring 16 3 26 Removing the oil filter 125 Duke 304491 10 Remove screws 1 Remove the oil fi...

Страница 104: ...engine fixing arm 304791 10 Mount special tool 2 Pressure screw for crankshaft 90129020000 p 257 304792 10 Mount special tool 3 with suitable screws Case separating tool 90129048000 p 258 Info Use the drill hole marked with 901 Pull off the section of the engine case by screwing in the screw Info Do not wedge the engine case section The washer of the main shaft usually sticks to the bearing Take o...

Страница 105: ... upper spring and the lower spring Remove shift rail 2 16 3 29 Removing the shift drum 125 Duke 304795 10 Swing shift forks 1 to one side Remove shift drum 2 16 3 30 Removing the shift forks 125 Duke 304796 10 Remove shift forks 1 16 3 31 Removing the transmission shafts 125 Duke 304798 10 Pull both transmission shafts 1 out of the bearing seats together ...

Страница 106: ...press Press out the crankshaft 16 3 34 Preparations 200 Duke 305800 10 Mount special tools 1 and 2 on the engine assembly stand Engine fixing arm 90129002060 p 256 Engine fixing arm 90129002050 p 255 Engine assembly stand 61229001000 p 254 Mount the engine on special tool Info Have an assistant help you or use a crane 16 3 35 Draining the engine oil 200 Duke 305801 10 Remove oil drain plug 1 with ...

Страница 107: ...05804 10 Remove screws 1 with the gasket Take off the valve cover with the valve cover seal 16 3 38 Removing the spark plug 200 Duke 305806 10 Remove the spark plug using special tool 1 Spark plug wrench 77229172000 p 255 16 3 39 Removing the clutch cover 200 Duke 305807 10 Remove screws 1 305808 10 Take off the clutch cover Info Pull the clutch lever forward slightly ...

Страница 108: ...ead center 200 Duke 305810 10 Remove screw plug 1 305811 10 Turn the crankshaft counterclockwise until markings A align with the edge of the cylinder head Castle nut wrench drive 90129021000 p 257 Markings B and C align 16 3 41 Removing the starter motor 200 Duke 305812 10 Remove screws 1 Take off the starter motor ...

Страница 109: ... screw clockwise The timing chain tensioner is locked Remove screw 2 Remove the timing chain tensioner with the gasket 16 3 43 Removing the camshaft 200 Duke 305820 10 Release screws 1 from the outside to the inside and remove them Remove the camshaft bearing bridge Remove dowels 305821 10 Remove intake camshaft 2 305822 10 Remove exhaust camshaft 3 ...

Страница 110: ...ove dowels 4 305828 10 Remove timing chain guide rail 5 16 3 45 Removing the piston 200 Duke 305830 10 Push the cylinder upward Info Push the cylinder upward only far enough to allow removal of the piston pin Remove piston pin retainer 1 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 p...

Страница 111: ...33 10 Remove screw 5 Take off the timing chain tensioning rail from above 16 3 46 Removing the water pump wheel 200 Duke 305837 10 Remove screws 1 Remove the water pump cover with the gasket 305838 10 Remove locating pins 2 305839 10 Lock the clutch basket and primary gear using special tool 3 Gear segment 90129081100 p 259 Remove nut 4 with washer Take off the water pump wheel 5 ...

Страница 112: ...tool 1 Gear segment 90129081100 p 259 305843 10 Remove screw 2 with the washer Remove the special tool Gear segment 90129081100 p 259 305844 10 Mount special tool 3 Pressure screw for crankshaft 90129020000 p 257 Mount special tool 4 on the rotor Info Left handed thread Hold it tight using the special tool and pull off the rotor by turning the screw in Extractor 90129009000 p 256 Remove the specia...

Страница 113: ...bracket 305846 10 Remove screws 2 Hang the ignition pulse generator to one side 305847 10 Remove freewheel gear 3 305848 10 Take off torque limiter 4 Remove starter idler gear 5 16 3 50 Removing the balancer shaft drive wheel 200 Duke 305849 10 Lock the clutch basket and primary gear using special tool 1 ...

Страница 114: ...5852 10 Remove balancer shaft gear 4 with a wedge Take off drive wheel 5 of the balancer shaft Remove the spring washer 16 3 51 Removing the gear position sensor 200 Duke 305855 10 Remove screws 1 Take off the retaining bracket Remove screws 2 and take off the gear position sensor 305856 10 Remove contact pin 3 and the contact spring ...

Страница 115: ...0 Mount special tool 3 Holding spanner 90129012000 p 256 Hold the inner clutch hub with the special tool Remove nut 4 with washer Castle nut wrench drive 90129021000 p 257 Info Left handed thread Remove the special tool Holding spanner 90129012000 p 256 Remove the inner clutch hub with the clutch discs Remove the washer Info The washer usually sticks to the inner clutch hub 305860 10 Lock the clut...

Страница 116: ...emoving the primary gear 200 Duke 305865 10 Remove timing chain sprocket 1 305866 10 Take off primary gear 2 305867 10 Remove spring washer 3 Take off spacer ring 4 16 3 55 Removing the oil pump 200 Duke 305868 10 Remove lock ring 1 Take off oil pump gear 2 ...

Страница 117: ... Removing the shift drum locating 200 Duke 305873 10 Remove screw 1 Press locking lever 2 away from shift drum locating 3 and take off the shift drum locating Release the locking lever 16 3 58 Removing the locking lever 200 Duke 305874 10 Remove screw 1 Take off locking lever 2 together with the washers and spring 16 3 59 Removing the oil filter 200 Duke 305876 10 Remove screws 1 Remove the oil fi...

Страница 118: ...engine fixing arm 305879 10 Mount special tool 2 Pressure screw for crankshaft 90129020000 p 257 305880 10 Mount special tool 3 with suitable screws Case separating tool 90129048000 p 258 Info Use the drill hole marked with 901 Pull off the section of the engine case by screwing in the screw Info Do not wedge the engine case section The washer of the main shaft usually sticks to the bearing Take o...

Страница 119: ... upper spring and the lower spring Remove shift rail 2 16 3 62 Removing the shift drum 200 Duke 305883 10 Swing shift forks 1 to one side Remove shift drum 2 16 3 63 Removing the shift forks 200 Duke 305884 10 Remove shift forks 1 16 3 64 Removing the transmission shafts 200 Duke 305886 10 Pull both transmission shafts 1 out of the bearing seats together ...

Страница 120: ...F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitable tool Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing all the way to the stop or so that ...

Страница 121: ...in the engine case section must be removed using a suitable tool Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing all the way to the stop or so that it is flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer rin...

Страница 122: ...all the way in with the open side facing outward Mounting sleeve 90129043000 p 258 304770 10 Mount lock ring 1 16 4 4 Removing the main bearing 125 Duke 304522 10 Mount special tool 1 Protecting sleeve 90129019000 p 257 304523 10 Mount special tool 2 Puller for main bearing 90129018000 p 256 Holding arms A engage in the outer bearing race Tension the holding arms by turning nut 3 Pull off the main...

Страница 123: ...ition the bearing shells Insert the Plastigauge clearance gauge 1 offset by 90 to the bearing face Plastigauge measuring strips 60029012000 p 253 Position the conrod bearing cover Mount and tighten the nuts Guideline Nut conrod bearing M7 24 Nm 17 7 lbf ft Info Do not twist the connecting rod Remove the conrod bearing cover again Compare the Plastigauge clearance gauge with the specifications on t...

Страница 124: ...eline Crankshaft diameter crank pin Crankshaft classification A 25 990 25 998 mm 1 02323 1 02354 in Crankshaft classification B 25 999 26 006 mm 1 02358 1 02386 in Info The crankshaft classification is indicated by marking 2 Check the radial play of the lower conrod bearing p 121 304563 10 Oil the bearing shells Position the conrod bearing cover according to marking 3 Mount and tighten nuts 1 Guid...

Страница 125: ... 255 Press out the bearing 304568 10 Press on the balancer shaft bearing with a suitable tool Remove the special tools Disassembly tool balancer shaft bearing 90129056000 p 259 16 4 8 Changing the camshaft bearing 125 Duke 304564 10 Clamp the camshaft in a vise using soft jaws Info Protect the outer cam of the camshaft against damage with adhesive tape Mount special tool 1 Holding spanner 90129012...

Страница 126: ...ke 304551 10 Fold cam lever 1 up Take the shims 2 out of the valve spring retainers and lay them to one side accord ing to their normal built in position 304552 10 Pretension the valve spring using the special tool Valve spring compressor 59029019000 p 252 Insert for valve spring lever 90129060000 p 259 304537 10 Remove valve keys 3 and relax the valve spring Remove valve spring retainer 4 Remove ...

Страница 127: ... cylinder head 304521 10 Check the sealing area of the cylinder for distortion using a straight edge and the special tool Feeler gauge 59029041100 p 253 Cylinder cylinder head distortion of sealing area 0 10 mm 0 0039 in If the measured value does not equal the specified value Change the cylinder head 302808 10 Check sealing seat A of the valves Valve sealing seat width Intake 0 90 1 10 mm 0 0354 ...

Страница 128: ...ylinder p 125 If the cylinder wear is within the tolerance range Change the piston ring Mount the piston ring with the marking facing toward the piston head 16 4 13 Checking measuring the piston 125 Duke 304550 10 Check the piston bearing surface for damage If the piston bearing surface is damaged Change the piston and if necessary the cylinder Check that the piston rings can move easily in the pi...

Страница 129: ...d external rotor and between the external rotor and the oil pump housing Feeler gauge 59029041100 p 253 Oil pump Play between external rotor and internal rotor 0 10 0 20 mm 0 0039 0 0079 in Oil pump Play between external rotor and oil pump housing 0 09 0 20 mm 0 0035 0 0079 in If the play exceeds the specification Change the oil pump and if necessary the oil pump housing 304532 10 Check axial play...

Страница 130: ...s 2 Clutch spring length 37 mm 1 46 in If the clutch spring length is less than the specified value Change all clutch springs Check inner clutch hub 3 for damage and wear If there is damage or wear Change the inner clutch hub Check clutch pressure cap 4 for damage and wear If there is damage or wear Change the clutch pressure cap Check the contact surfaces of the clutch facing discs in the clutch ...

Страница 131: ...g the clutch 125 Duke 304556 10 Lubricate the clutch facing discs thoroughly Push support ring 1 and pretension ring 2 onto the inner clutch hub Info The pretension ring must be installed so that it is flush with the inner edge on the support ring 304557 10 Position the clutch facing disc with the notch for the pretension ring on the inner clutch hub face down Beginning with a clutch disc position...

Страница 132: ... stiffness and wear If the bearings do not move freely or are worn Change the bearing Check shift rail 4 on a flat surface for run out If there is run out Change the shift rail Check the shift rail for scoring signs of corrosion and stiffness in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate 5 in contact areas C for wear If ...

Страница 133: ... facing down and attach the guide pin to the shift quadrant Mount preload spring 2 Push on spring guide 3 push return spring 4 over the spring guide with the offset end facing upward and lift the offset end over abutment bolt 5 Mount washer 6 16 4 21 Disassembling the main shaft 125 Duke 305899 10 Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Remove sto...

Страница 134: ... 3 Remove the 6th gear sliding gear 4 Remove lock ring 5 Remove stop disk 6 Remove the 3rd gear idler gear 7 Remove washer 8 Remove the 4th gear idler gear 9 Remove stop disk bk and lock ring bl Remove 5th gear sliding gear bm Remove lock ring bn Remove collar bushing bo Remove the 2nd gear idler gear bp Remove stop disk bq and lock ring br 16 4 23 Checking the transmission 125 Duke Condition The ...

Страница 135: ... 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 tooth profiles of sliding gears 5 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 5 for smooth operation in the profile of main shaft 2 If the sliding gear does n...

Страница 136: ...unt collar bushing 3 Mount stop disk 4 and lock ring 5 Mount 3rd 4th gear sliding gear 6 with the small gear wheel facing up Mount lock ring 7 Mount stop disk 8 Mount 5th gear idler gear 9 Mount 2nd gear fixed gear bk and stop disk bl Finally check all gear wheels for smooth operation 16 4 25 Assembling the countershaft 125 Duke Info Use new lock rings in every repair job Preparatory work Oil all ...

Страница 137: ... the 5th gear sliding gear 6 with the shift groove facing upward Install lock ring 7 and stop disk 8 Mount 4th gear idler gear 9 Mount washer bk Mount 3rd gear idler gear bl Mount stop disk bm and lock ring bn Mount 6th gear sliding gear bo with the shift groove facing downward Mount collar bushing bp Mount 1st gear idler gear bq Mount stop disk br Replace O ring bs of the countershaft Finally che...

Страница 138: ...re is damage or wear Change the timing chain guide rail Check timing chain tensioning rail 3 for damage and wear If there is damage or wear Change the timing chain tensioning rail Check timing chain sprocket 4 for damage and wear If there is damage or wear Change the timing chain sprocket Check camshaft gears 5 for damage and wear If there is damage or wear Change the camshaft gears Check camshaft...

Страница 139: ...screw 1 Guideline Screw retaining bracket stator cable M5 8 Nm 5 9 lbf ft Loctite 243 16 4 28 Checking the electric starter drive 125 Duke 304530 10 Check the teeth and seating of the starter idler gear 1 for damage and wear If there is damage or wear Change the starter idler gear Check the teeth and seating of the torque limiter 2 for damage and wear If there is damage or wear Change the torque l...

Страница 140: ...and 3 of the countershaft Remove oil nozzle 4 Remove any sealing mass remnants and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 150 C 302 F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitable too...

Страница 141: ... suitable tool Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing all the way to the stop or so that it is flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer ring otherwise the bearings will be damaged when they...

Страница 142: ...all the way in with the open side facing outward Mounting sleeve 90129043000 p 258 304770 10 Mount lock ring 1 16 4 33 Removing the main bearing 200 Duke 305890 10 Mount special tool 1 Protecting sleeve 90129019000 p 257 305891 10 Mount special tool 2 Puller for main bearing 90129018000 p 256 Holding arms A engage in the outer bearing race Tension the holding arms by turning nut 3 Pull off the mai...

Страница 143: ...tion the bearing shells Insert the Plastigauge clearance gauge 1 offset by 90 to the bearing face Plastigauge measuring strips 60029012000 p 253 Position the conrod bearing cover Mount and tighten the nuts Guideline Screw conrod bearing M7 24 Nm 17 7 lbf ft Info Do not twist the connecting rod Remove the conrod bearing cover again Compare the Plastigauge clearance gauge with the specifications on ...

Страница 144: ...ine Crankshaft diameter crank pin Crankshaft classification A 29 995 30 003 mm 1 1809 1 18122 in Crankshaft classification B 30 004 30 011 mm 1 18126 1 18153 in Info The crankshaft classification is indicated by marking 2 Check the radial play of the lower conrod bearing p 141 305896 10 Oil the bearing shells Position the conrod bearing cover according to marking 3 Mount and tighten screws 1 Guide...

Страница 145: ... 255 Press out the bearing 304568 10 Press on the balancer shaft bearing with a suitable tool Remove the special tools Disassembly tool balancer shaft bearing 90129056000 p 259 16 4 37 Changing the camshaft bearing 200 Duke 304564 10 Clamp the camshaft in a vise using soft jaws Info Protect the outer cam of the camshaft against damage with adhesive tape Mount special tool 1 Holding spanner 9012901...

Страница 146: ...ke 304551 10 Fold cam lever 1 up Take the shims 2 out of the valve spring retainers and lay them to one side accord ing to their normal built in position 304552 10 Pretension the valve spring using the special tool Valve spring compressor 59029019000 p 252 Insert for valve spring lever 90129060000 p 259 304537 10 Remove valve keys 3 and relax the valve spring Remove valve spring retainer 4 Remove ...

Страница 147: ... cylinder head 304521 10 Check the sealing area of the cylinder for distortion using a straight edge and the special tool Feeler gauge 59029041100 p 253 Cylinder cylinder head distortion of sealing area 0 10 mm 0 0039 in If the measured value does not equal the specified value Change the cylinder head 302808 10 Check sealing seat A of the valves Valve sealing seat width Intake 0 90 1 10 mm 0 0354 ...

Страница 148: ...ylinder p 145 If the cylinder wear is within the tolerance range Change the piston ring Mount the piston ring with the marking facing toward the piston head 16 4 42 Checking measuring the piston 200 Duke 305905 10 Check the piston bearing surface for damage If the piston bearing surface is damaged Change the piston and if necessary the cylinder Check that the piston rings can move easily in the pi...

Страница 149: ...nd external rotor and between the external rotor and the oil pump housing Feeler gauge 59029041100 p 253 Oil pump Play between external rotor and internal rotor 0 10 0 20 mm 0 0039 0 0079 in Oil pump Play between external rotor and oil pump housing 0 09 0 20 mm 0 0035 0 0079 in If the play exceeds the specification Change the oil pump and if necessary the oil pump housing 304532 10 Check axial pla...

Страница 150: ...s 2 Clutch spring length 37 mm 1 46 in If the clutch spring length is less than the specified value Change all clutch springs Check inner clutch hub 3 for damage and wear If there is damage or wear Change the inner clutch hub Check clutch pressure cap 4 for damage and wear If there is damage or wear Change the clutch pressure cap Check the contact surfaces of the clutch facing discs in the clutch ...

Страница 151: ...g the clutch 200 Duke 304556 10 Lubricate the clutch facing discs thoroughly Push support ring 1 and pretension ring 2 onto the inner clutch hub Info The pretension ring must be installed so that it is flush with the inner edge on the support ring 305871 10 Position the clutch facing disc with the notch for the pretension ring on the inner clutch hub face down Beginning with a clutch disc position...

Страница 152: ... stiffness and wear If the bearings do not move freely or are worn Change the bearing Check shift rail 4 on a flat surface for run out If there is run out Change the shift rail Check the shift rail for scoring signs of corrosion and stiffness in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate 5 in contact areas C for wear If ...

Страница 153: ... facing down and attach the guide pin to the shift quadrant Mount preload spring 2 Push on spring guide 3 push return spring 4 over the spring guide with the offset end facing upward and lift the offset end over abutment bolt 5 Mount washer 6 16 4 50 Disassembling the main shaft 200 Duke 305899 10 Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Remove sto...

Страница 154: ... 3 Remove the 6th gear sliding gear 4 Remove lock ring 5 Remove stop disk 6 Remove the 3rd gear idler gear 7 Remove washer 8 Remove the 4th gear idler gear 9 Remove stop disk bk and lock ring bl Remove 5th gear sliding gear bm Remove lock ring bn Remove collar bushing bo Remove the 2nd gear idler gear bp Remove stop disk bq and lock ring br 16 4 52 Checking the transmission 200 Duke Condition The ...

Страница 155: ... 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 tooth profiles of sliding gears 5 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 5 for smooth operation in the profile of main shaft 2 If the sliding gear does n...

Страница 156: ...unt collar bushing 3 Mount stop disk 4 and lock ring 5 Mount 3rd 4th gear sliding gear 6 with the small gear wheel facing up Mount lock ring 7 Mount stop disk 8 Mount 5th gear idler gear 9 Mount 2nd gear fixed gear bk and stop disk bl Finally check all gear wheels for smooth operation 16 4 54 Assembling the countershaft 200 Duke Info Use new lock rings in every repair job Preparatory work Oil all ...

Страница 157: ... the 5th gear sliding gear 6 with the shift groove facing upward Install lock ring 7 and stop disk 8 Mount 4th gear idler gear 9 Mount washer bk Mount 3rd gear idler gear bl Mount stop disk bm and lock ring bn Mount 6th gear sliding gear bo with the shift groove facing downward Mount collar bushing bp Mount 1st gear idler gear bq Mount stop disk br Replace O ring bs of the countershaft Finally che...

Страница 158: ...re is damage or wear Change the timing chain guide rail Check timing chain tensioning rail 3 for damage and wear If there is damage or wear Change the timing chain tensioning rail Check timing chain sprocket 4 for damage and wear If there is damage or wear Change the timing chain sprocket Check camshaft gears 5 for damage and wear If there is damage or wear Change the camshaft gears Check camshaft...

Страница 159: ...screw 1 Guideline Screw retaining bracket stator cable M5 8 Nm 5 9 lbf ft Loctite 243 16 4 57 Checking the electric starter drive 200 Duke 304530 10 Check the teeth and seating of the starter idler gear 1 for damage and wear If there is damage or wear Change the starter idler gear Check the teeth and seating of the torque limiter 2 for damage and wear If there is damage or wear Change the torque l...

Страница 160: ...10 Insert freewheel gear 1 into the freewheel hub by turning the freewheel gear clock wise do not wedge Check the locking action of the freewheel gear If the freewheel gear does not turn clockwise or if it does not lock counterclock wise Replace the freewheel 16 5 Assembling the engine 16 5 1 Installing the crankshaft 125 Duke 304801 10 Warm the engine case section in an oven Guideline 150 C 302 F...

Страница 161: ...04798 10 Oil the bearing Slide both transmission shafts 1 into the bearing seats together 16 5 4 Installing the shift forks 125 Duke 304797 10 Oil all parts carefully before assembling Shift fork 1 has a smaller inside diameter mount it in the shift groove of the main shaft Mount shift fork 2 in the lower shift groove of the countershaft Mount shift fork 3 in the upper shift groove of the counters...

Страница 162: ...nt the engine case gasket 304790 11 Warm the left engine case section in an oven Guideline 150 C 302 F Mount the engine case section If necessary tap lightly with a rubber mallet while turning the transmission shafts Info Do not tighten the engine case sections using the screws Mount screws 2 but do not tighten them yet Guideline Screw engine case M6x60 12 Nm 8 9 lbf ft Loctite 243 Mount screws 3 ...

Страница 163: ...lter cover M5 8 Nm 5 9 lbf ft 16 5 9 Installing the locking lever 125 Duke 304789 11 Mount locking lever 1 with the sleeve washers and spring Mount and tighten screw 2 with the washer Guideline Screw locking lever M6 12 Nm 8 9 lbf ft Loctite 243 16 5 10 Installing the shift drum locating 125 Duke 304489 10 Mount spacer ring 1 on the shift drum locating unit Press locking lever 2 away from the shif...

Страница 164: ...the oil pump 125 Duke 304816 10 Position the external rotor in the oil pump housing The marking A is visible after mounting 304817 10 Mount the internal rotor with the oil pump shaft The marking B is visible after mounting 304785 11 Check that the oil holes are clear and fill with a small amount of oil Mount the dowels Position oil pump 1 Mount and tighten screws 2 Guideline Screw oil pump M6 12 N...

Страница 165: ... spring washer 2 304782 11 Mount primary gear 3 304781 11 Mount timing chain sprocket 4 16 5 14 Installing the clutch basket 125 Duke 304778 11 Mount collar sleeve 1 304777 11 Slide the clutch basket 2 onto the gearbox main shaft Turn the oil pump gear until the gear teeth of the clutch basket mesh ...

Страница 166: ...ear using special tool 3 Gear segment 90129081100 p 259 Tighten screws 5 Guideline Screw clutch spring M6 10 Nm 7 4 lbf ft Mount and tighten nut 6 with the washer Guideline Nut inner clutch hub M14LH 60 Nm 44 3 lbf ft Loctite 243 Castle nut wrench drive 90129021000 p 257 304780 10 Mount bearing 7 16 5 15 Installing the spacer 125 Duke 304773 10 Grease the shaft seal ring of the countershaft before...

Страница 167: ...e 243 16 5 17 Installing the balancer shaft drive wheel 125 Duke 304766 10 Mount the spring washer Mount drive wheel 1 of the balancer shaft Position balancer shaft gear 2 Markings A and B align Mount wedge 3 304756 11 Lock the clutch basket and primary gear using the special tool Gear segment 90129081100 p 259 304764 11 Mount and tighten screw 4 Guideline Screw balancer shaft gear M8 20 Nm 14 8 l...

Страница 168: ...lling the starter drive 125 Duke 304762 11 Mount starter idler gear 1 Mount torque limiter 2 304761 10 Position freewheel gear 3 304760 11 Position the crankshaft position sensor Mount and tighten screws 4 Guideline Screw ignition pulse gen erator M5 6 Nm 4 4 lbf ft Loctite 243 304759 11 Position the retaining bracket Mount and tighten screw 5 Guideline Screw freewheel gear retaining bracket M6 12...

Страница 169: ...90129081100 p 259 16 5 20 Installing the alternator cover 125 Duke 304755 11 Mount the dowels 1 Seal the cable guide Loctite 5910 Mount the alternator cover gasket 2 304754 11 Position the alternator cover Install the screws 3 and tighten them diagonally Guideline Screw alternator cover M6 12 Nm 8 9 lbf ft 16 5 21 Installing the water pump cover 125 Duke 304749 11 Mount water pump impeller 1 Lock ...

Страница 170: ... of the piston rings by 120 Push the piston carefully into the cylinder from below Info The piston rings should not become caught otherwise they may be dam aged 304511 10 Ensure that piston marking A faces the outfeed side 304746 11 Thread in the timing chain tensioning rail from above Mount and tighten screw 1 Guideline Screw timing chain ten sioning rail M6 12 Nm 8 9 lbf ft Loctite 243 304745 11...

Страница 171: ...on Insertion for piston ring lock 90129030000 p 258 Turn the special tool clockwise thereby pressing the piston pin retainer into the groove Make sure that the piston pin retainer is seated correctly on both sides Remove the cloth Keep the timing chain tensioned Push the cylinder down carefully and let the dow els engage 16 5 23 Installing the cylinder head 125 Duke 304742 10 Position timing chain...

Страница 172: ...5 lbf ft Thread is oiled head flat is greased 304444 11 Mount and tighten screws 5 Guideline Cylinder head screw M6 12 Nm 8 9 lbf ft 16 5 24 Installing the camshafts 125 Duke 304443 10 Turn the crankshaft clockwise until markings 1 and 2 align 304442 10 Pull up the timing chain and insert exhaust camshaft 3 Place the timing chain over the camshaft gear of the intake camshaft Markings A of the cams...

Страница 173: ...5 Duke 304804 10 Turn the timing chain tensioner screw clockwise The timing chain tensioner is locked 304751 10 Holding it with the correct orientation mount the timing chain tensioner 1 with the gasket Mount and tighten screws 2 Guideline Screw timing chain tensioner M6 12 Nm 8 9 lbf ft 304750 10 Unlock the timing chain tensioner screw counterclockwise Check the timing chain tension 304752 10 Mou...

Страница 174: ...Adjust the valve clearance p 172 304734 10 Mount and tighten screw plug 1 Guideline Screw plug alternator cover M18x1 5 15 Nm 11 1 lbf ft 16 5 27 Adjusting the valve clearance 125 Duke Main work Remove the timing chain tensioner p 93 Remove the camshaft p 93 304738 10 Swing up cam lever 1 Correct the shims 2 as indicated by the results of the valve clearance check Install the camshafts p 170 Insta...

Страница 175: ...sition the clutch cover Info Pivot the clutch lever 304731 11 Mount and tighten screws 3 Guideline Screw clutch cover M6 12 Nm 8 9 lbf ft 16 5 30 Installing the spark plug 125 Duke 304730 10 Mount and tighten the spark plug using special tool 1 Guideline Spark plug M12 15 Nm 11 1 lbf ft Spark plug wrench 77229172000 p 255 ...

Страница 176: ...tion the valve cover with the gasket Mount and tighten screws 1 with the gaskets Guideline Screw valve cover M6 12 Nm 8 9 lbf ft 16 5 32 Installing the chain securing guide 125 Duke 304422 10 Position the chain securing guide Mount and tighten screws 1 Guideline Screw chain securing guide M6 11 Nm 8 1 lbf ft Loctite 243 16 5 33 Installing the oil screen 125 Duke 304421 11 Mount oil screen 1 with t...

Страница 177: ...m the engine assembly stand Info Have an assistant help you or use a crane 16 5 35 Installing the crankshaft 200 Duke 304801 10 Warm the engine case section in an oven Guideline 150 C 302 F Mount main bearing 1 305898 10 Heat the main bearing Guideline 150 C 302 F Slide crankshaft 2 into the bearing seat Heat the left main bearing Guideline 150 C 302 F Mount the main bearing on the crankshaft Cool...

Страница 178: ...05886 10 Oil the bearing Slide both transmission shafts 1 into the bearing seats together 16 5 38 Installing the shift forks 200 Duke 305885 10 Oil all parts carefully before assembling Shift fork 1 has a smaller inside diameter mount it in the shift groove of the main shaft Mount shift fork 2 in the lower shift groove of the countershaft Mount shift fork 3 in the upper shift groove of the counter...

Страница 179: ...unt the engine case gasket 305878 11 Warm the left engine case section in an oven Guideline 150 C 302 F Mount the engine case section If necessary tap lightly with a rubber mallet while turning the transmission shafts Info Do not tighten the engine case sections using the screws Mount screws 2 but do not tighten them yet Guideline Screw engine case M6x60 12 Nm 8 9 lbf ft Loctite 243 Mount screws 3...

Страница 180: ...lter cover M5 8 Nm 5 9 lbf ft 16 5 43 Installing the locking lever 200 Duke 305874 11 Mount locking lever 1 with the sleeve washers and spring Mount and tighten screw 2 with the washer Guideline Screw locking lever M6 12 Nm 8 9 lbf ft Loctite 243 16 5 44 Installing the shift drum locating 200 Duke 305875 10 Mount spacer ring 1 on the shift drum locating unit Press locking lever 2 away from the shi...

Страница 181: ...the oil pump 200 Duke 304816 10 Position the external rotor in the oil pump housing The marking A is visible after mounting 304817 10 Mount the internal rotor with the oil pump shaft The marking B is visible after mounting 305869 11 Check that the oil holes are clear and fill with a small amount of oil Mount the dowels Position oil pump 1 Mount and tighten screws 2 Guideline Screw oil pump M6 12 N...

Страница 182: ... spring washer 2 305866 11 Mount primary gear 3 305865 11 Mount timing chain sprocket 4 16 5 48 Installing the clutch basket 200 Duke 305862 11 Mount collar sleeve 1 305861 11 Slide the clutch basket 2 onto the gearbox main shaft Turn the oil pump gear until the gear teeth of the clutch basket mesh ...

Страница 183: ...ear using special tool 3 Gear segment 90129081100 p 259 Tighten screws 5 Guideline Screw clutch spring M6 10 Nm 7 4 lbf ft Mount and tighten nut 6 with the washer Guideline Nut inner clutch hub M14LH 60 Nm 44 3 lbf ft Loctite 243 Castle nut wrench drive 90129021000 p 257 305864 10 Mount bearing 7 16 5 49 Installing the spacer 200 Duke 305857 10 Grease the shaft seal ring of the countershaft before...

Страница 184: ...e 243 16 5 51 Installing the balancer shaft drive wheel 200 Duke 305853 10 Mount the spring washer Mount drive wheel 1 of the balancer shaft Position balancer shaft gear 2 Markings A and B align Mount wedge 3 305849 11 Lock the clutch basket and primary gear using the special tool Gear segment 90129081100 p 259 305851 11 Mount and tighten screw 4 Guideline Screw balancer shaft gear M8 20 Nm 14 8 l...

Страница 185: ...lling the starter drive 200 Duke 305848 11 Mount starter idler gear 1 Mount torque limiter 2 305847 10 Position freewheel gear 3 305846 11 Position the crankshaft position sensor Mount and tighten screws 4 Guideline Screw ignition pulse gen erator M5 6 Nm 4 4 lbf ft Loctite 243 305845 11 Position the retaining bracket Mount and tighten screw 5 Guideline Screw freewheel gear retaining bracket M6 12...

Страница 186: ...90129081100 p 259 16 5 54 Installing the alternator cover 200 Duke 305841 11 Mount the dowels 1 Seal the cable guide Loctite 5910 Mount the alternator cover gasket 2 305840 11 Position the alternator cover Install the screws 3 and tighten them diagonally Guideline Screw alternator cover M6 12 Nm 8 9 lbf ft 16 5 55 Installing the water pump cover 200 Duke 305839 11 Mount water pump impeller 1 Lock ...

Страница 187: ... of the piston rings by 120 Push the piston carefully into the cylinder from below Info The piston rings should not become caught otherwise they may be dam aged 304511 10 Ensure that piston marking A faces the outfeed side 305833 11 Thread in the timing chain tensioning rail from above Mount and tighten screw 1 Guideline Screw timing chain ten sioning rail M6 12 Nm 8 9 lbf ft Loctite 243 305832 11...

Страница 188: ...on Insertion for piston ring lock 90129030000 p 258 Turn the special tool clockwise thereby pressing the piston pin retainer into the groove Make sure that the piston pin retainer is seated correctly on both sides Remove the cloth Keep the timing chain tensioned Push the cylinder down carefully and let the dow els engage 16 5 57 Installing the cylinder head 200 Duke 305829 10 Position timing chain...

Страница 189: ...5 lbf ft Thread is oiled head flat is greased 305825 11 Mount and tighten screws 5 Guideline Cylinder head screw M6 12 Nm 8 9 lbf ft 16 5 58 Installing the camshafts 200 Duke 305823 10 Turn the crankshaft clockwise until markings 1 and 2 align 305824 10 Pull up the timing chain and insert exhaust camshaft 3 Place the timing chain over the camshaft gear of the intake camshaft Markings A of the cams...

Страница 190: ...0 Duke 304804 10 Turn the timing chain tensioner screw clockwise The timing chain tensioner is locked 305818 10 Holding it with the correct orientation mount the timing chain tensioner 1 with the gasket Mount and tighten screws 2 Guideline Screw timing chain tensioner M6 12 Nm 8 9 lbf ft 305817 10 Unlock the timing chain tensioner screw counterclockwise Check the timing chain tension 305813 11 Mou...

Страница 191: ...Adjust the valve clearance p 189 305836 10 Mount and tighten screw plug 1 Guideline Screw plug alternator cover M18x1 5 15 Nm 11 1 lbf ft 16 5 61 Adjusting the valve clearance 200 Duke Main work Remove the timing chain tensioner p 107 Remove the camshaft p 107 305819 10 Swing up cam lever 1 Correct the shims 2 as indicated by the results of the valve clearance check Install the camshafts p 187 Ins...

Страница 192: ...sition the clutch cover Info Pivot the clutch lever 305807 11 Mount and tighten screws 3 Guideline Screw clutch cover M6 12 Nm 8 9 lbf ft 16 5 64 Installing the spark plug 200 Duke 305806 10 Mount and tighten the spark plug using special tool 1 Guideline Spark plug M12 15 Nm 11 1 lbf ft Spark plug wrench 77229172000 p 255 ...

Страница 193: ...tion the valve cover with the gasket Mount and tighten screws 1 with the gaskets Guideline Screw valve cover M6 12 Nm 8 9 lbf ft 16 5 66 Installing the chain securing guide 200 Duke 305803 10 Position the chain securing guide Mount and tighten screws 1 Guideline Screw chain securing guide M6 11 Nm 8 1 lbf ft Loctite 243 16 5 67 Installing the oil screen 200 Duke 305802 11 Mount oil screen 1 with t...

Страница 194: ...15 Nm 11 1 lbf ft 16 5 68 Removing the engine from the engine assembly stand 200 Duke 305800 10 Remove the fitting from special tools 1 and 2 Engine fixing arm 90129002060 p 256 Engine fixing arm 90129002050 p 255 Remove the engine from the engine assembly stand Info Have an assistant help you or use a crane ...

Страница 195: ...same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle B Guideline Adjusting angle B shift rod deflector shift lever 90 Tighten nuts 1 Info After the nuts have been tightened the bearings of the shift rod must be centrally and identically aligned to each other in order to ensure freedom of movement in the bearing shells Check the shift lev...

Страница 196: ...ain work Stand the motorcycle upright Place a suitable container under the engine Remove screw 1 Remove the radiator cap Completely drain the coolant Mount screw 1 with a new seal ring and tighten it Guideline Plug water pump drain hole 125 Duke M6 8 Nm 5 9 lbf ft Plug water pump drain hole 200 Duke M6 8 Nm 5 9 lbf ft 18 2 Filling bleeding the cooling system Warning Danger of poisoning Coolant is ...

Страница 197: ...ator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Imm...

Страница 198: ...immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that ...

Страница 199: ...18 WATER PUMP COOLING SYSTEM 197 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 194 Mount the radiator cap ...

Страница 200: ... After switching off the engine wait one minute before checking the level The engine oil must be between the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 201 19 3 Checking the engine oil pressure Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothin...

Страница 201: ...st gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine Check the engine oil pressure Engine oil pressure Coolant temperature 70 C 158 F Engine speed 1 500 rpm 0 7 bar 10 psi Coolant...

Страница 202: ... Stand the motorcycle on its side stand on a horizontal surface B00774 10 Main work Place a suitable container under the engine Remove the oil drain plug 1 with the O ring Remove oil screen 2 with the O ring Completely drain the engine oil Clean the oil drain plug and oil screen thoroughly Position oil screen 2 and mount and tighten oil drain plug 1 with the O ring Guideline Oil drain plug 125 Duk...

Страница 203: ...aust extraction system Start the engine and check that it is oil tight Finishing work Fit the front spoiler p 47 Check the engine oil level p 198 19 5 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine B00773 10 Main work Remove the oil filler plug 1 with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 15W 50 ...

Страница 204: ...tor Stator winding measurement II check the resistance Measure the resistance between the specified points Stator connector HB pin 1 Stator connector HB pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 Ω If the displayed value does not equal the setpoint value Change the stator L00082 10 304934 10 Stator winding check the short circuit to ground terminal 31 Measure the resistance betwe...

Страница 205: ...w shifted Transmission ratio 1st gear 12 34 2nd gear 15 31 3rd gear 18 28 4th gear 21 26 5th gear 22 23 6th gear 24 22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Alternator 12 V 238 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulat...

Страница 206: ...ing area 0 10 mm 0 0039 in Cylinder bore diameter 58 006 58 013 mm 2 2837 2 28397 in Piston diameter 57 963 57 975 mm 2 282 2 28248 in Piston cylinder mounting clearance New condition 0 031 0 050 mm 0 00122 0 00197 in Wear limit 0 08 mm 0 0031 in Piston ring end gap Compression ring 0 40 mm 0 0157 in Oil scraper ring 0 80 mm 0 0315 in Connecting rod radial play of lower conrod bearing New conditio...

Страница 207: ...0 mm 0 0035 0 0079 in Play between external rotor and internal rotor 0 10 0 20 mm 0 0039 0 0079 in Axial play 0 10 0 25 mm 0 0039 0 0098 in Shift shaft play in sliding plate shift quadrant 0 15 0 45 mm 0 0059 0 0177 in 21 3 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite 243 Screw engine vent plate M5 7 Nm 5 2 lbf ft Loctite 243 Screw gear sensor M5 6 Nm 4 4 lbf ft Loctite 243 Scre...

Страница 208: ...1 20 Nm 14 8 lbf ft Step 2 40 Nm 29 5 lbf ft Thread is oiled head flat is greased Oil pressure sensor M10 14 Nm 10 3 lbf ft Rotor screw M10 46 Nm 33 9 lbf ft Loctite 243 Water temperature sensor M10 14 Nm 10 3 lbf ft Spark plug M12 15 Nm 11 1 lbf ft Nut inner clutch hub M14LH 60 Nm 44 3 lbf ft Loctite 243 Nut primary gear M14 55 Nm 40 6 lbf ft Nut timing chain sprocket M14 55 Nm 40 6 lbf ft Loctit...

Страница 209: ...si Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary ratio 125 Duke 14 45 Secondary ratio 200 Duke 14 42 Chain 5 8 x 1 4 520 O ring Steering head angle 65 Wheelbase 1 367 15 mm 53 82 0 59 in Seat height unloaded 810 mm 31 89 in Ground clearance unloaded 170 mm 6 69 in Weight without fuel approx 125 kg 276 lb 21 6 Electrical system ...

Страница 210: ... EJOT PT 4 Nm 3 lbf ft Remaining screws chassis M4 4 Nm 3 lbf ft Screw EFI control unit M4 4 Nm 3 lbf ft Screw trim subframe bottom M4 2 Nm 1 5 lbf ft Remaining nuts chassis M5 3 Nm 2 2 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw brake fluid reservoir of rear brake M5 6 Nm 4 4 lbf ft Loctite 243 Screw fuel pump M5 5 Nm 3 7 lbf ft Screw fuel tank closure flange M5 3 Nm 2 2 lbf ft Screw...

Страница 211: ...gulator holder M6 15 Nm 11 1 lbf ft Remaining nuts chassis M8 30 Nm 22 1 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw engine bearer on frame M8 30 Nm 22 1 lbf ft Screw foot brake lever M8 15 Nm 11 1 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake disc M8 29 Nm 21 4 lbf ft Loctite 243 Screw front wheel spindle M8...

Страница 212: ... shock absorber M10x1 25 50 Nm 36 9 lbf ft Nut rear wheel spindle M14x1 5 60 Nm 44 3 lbf ft Nut swingarm pivot M14x1 5 140 Nm 103 3 lbf ft Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Lambda sensor M18x1 5 40 60 Nm 29 5 44 3 lbf ft Lubricant T152 p 251 Nut steering head M30x1 5 Nm 3 7 lbf ft ...

Страница 213: ...leaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake syst...

Страница 214: ...1 Clean the 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 they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the...

Страница 215: ... of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subject to large fluctuations in tem perature Info KTM recommends jacking up the motorcycle Raise the motorcycle with the rear wheel stand p 10 Raise the motorcycle with the front wheel stand p 10 Cover the motorcycle with a tarp or similar cover that is permeable to air Info Do not use non porous ma...

Страница 216: ...ain and check for smooth operation Clean the dust boots of the fork legs p 15 Check the brake fluid level of the front brake p 68 Check the steering head bearing play p 26 Change the spark plugs Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and bellows for cracking leaks and correct routing Check the antifreeze and coolant level p 195 Check the cables for damage a...

Страница 217: ...215 ...

Страница 218: ...6 X5 4 K11 2 1 4 3 1 HA 4 X6 4 1 4 4 46 GK 56 X31 46 2 2 15A F4 10 4 GI 12 X7 10 GI 12 X7 4 HA 4 X3 3 HA 4 X6 3 c d 30A F1 7 1 GI 12 X7 1 GI 12 X7 7 a 13 13 9 GK 56 X31 9 BH 6 X5 2 GJ 20 X54 11 BH 6 X5 5 b 14 EF 14 X55 14 BH 6 X5 3 GZ 20 11 6 C5 S23 4 2 3 5 AP 6 AP 6 AP 6 AP 6 X305 4 1 ye bu gn rd gn rd bu gr rd gr wh or wh gn rd gr bl bl rd rd wh gn wh gn ye rd gn rd gn rd gn rd rd rd bu gr rd gr...

Страница 219: ... system optional A60 Vehicle control unit F1 Fuse F4 Fuse G10 Battery K11 Start auxiliary relay 1 K17 Start auxiliary relay 2 K18 Start auxiliary relay 3 K19 Starter relay M10 Starter motor P10 Combination instrument S23 Emergency OFF switch electric starter button ...

Страница 220: ...56 X31 19 1 2 4 D6 M13 CU 4 CU 4 2 1 HA 4 X9 3 AN 4 X10 2 d AN 4 X10 1 K50 2 1 4 3 M14 GY 2 GY 2 2 1 49 GK 56 X3149 1 2 15A F5 11 5 GI 12 X7 5 GI 12 X7 11 HA 4 X11 3 HA 4 X11 4 GP 2 X12 2 GP 2 X12 1 S11 GY 2 GY 2 2 1 15A F6 6 2 1 GI 12 X7 6 GI 12 X7 12 GP 2 X13 2 12 EF 14 X55 12 a a GP 2 X13 1 c e d bu gn wh bu gn pk bu br bu gn wh bu bu or gn pk ye gr ye gr bu br bu br wh bl wh bl wh bl bu or wh ...

Страница 221: ... DIAGRAM 219 Components A11 EFI control unit A50 Alarm system optional F3 Fuse F5 Fuse F6 Fuse K30 Power relay K40 Fuel pump relay K50 Radiator fan relay M13 Fuel pump M14 Radiator fan S11 Ignition steering lock ...

Страница 222: ... 12 X7 2 GI 12 X7 8 a 1 AU 2 X14 2 GZ 20 1 GJ 20 X54 1 8 EF 14 X55 8 X304 T20 BI 2 HC 3 1 2 3 2 1 G20 2 3 HB 3 1 d BV 2 BV 2 1 2 B36 EF 14 X55 4 BS 2 X52 1 BS 2 X52 2 EF 14 X55 7 7 4 35 1 GP 2 X24 2 35 2 3 AP 6 X295 6 36 36 R30 2 1 AT 2 X27 2 47 GK 56 X31 47 48 GK 56 X31 48 1 1 d wh wh pu bl ye bu bu gn ye bu wh bl wh bl wh bl pu ye bu bu bu gn ye bu ye bl ye wh wh wh wh bl ye bl ye wh bl ye wh bl...

Страница 223: ...Components A11 EFI control unit A50 Alarm system optional B36 Alarm system switch optional F2 Fuse G20 Alternator P10 Combination instrument R30 CAN bus terminating resistor 1 T20 Voltage regulator X295 Diagnostics connector ...

Страница 224: ...17 2 31 31 3 14 14 GL 4 X20 3 32 GK 56 X31 32 1 42 2 D4 B32 CU 4 CU 4 4 3 AN 4 X10 3 AN 4 X10 4 GK 56 X31 11 11 B26 CU 4 CU 4 1 2 4 3 GK 56 X31 42 AN 4 X19 2 AN 4 X18 3 GX 4 X17 1 43 GK 56 X31 43 GZ 20 4 GJ 20 X54 4 GL 4 X20 1 B10 3 1 2 53 53 B51 t L 4 2 3 1 GV 4 GV 4 4 2 M51 1 2 GQ 2 X15 2 wh br bl ye bl ye bl ye wh br bl ye bl ye wh br wh bl bl rd bu rd ye gn wh rd br gn gn gn gr ye bu gn rd bl ...

Страница 225: ...l unit B10 Throttle position sensor circuit A B26 Rollover sensor B30 Side stand switch B32 Fuel tank sensor B45 Temperature and manifold absolute pressure sensor B51 Lambda sensor cylinder 1 M51 Injection valve cylinder 1 P10 Combination instrument ...

Страница 226: ... GK 56 X31 30 GR 2 X23 2 30 GR 2 X23 1 GJ 20 X54 14 GN 6 X4 1 6 B70 1 4 2 3 AN 4 AN 4 CU 4 X30 1 d d AL 2 X26 1 2 b CU 4 X30 3 AP 6 X48 1 2 3 4 5 6 BH 6 X49 6 5 4 3 2 1 GZ 20 9 13 GZ 20 14 BH 6 1 2 3 4 5 6 5 D5 B37 1 2 4 AN 4 5 D3 B34 N 1st 6th 4th 2nd 5th 3rd 5 6 AP 6 4 1 2 3 3 AN 4 1 6 3 6 GK 56 X31 55 1 55 R51 2 1 AT 2 X29 2 wh or bl ye bl ye bl bu wh gr bl ye lbu lbu ye gn gn rd wh rd ye gn wh...

Страница 227: ...A60 Vehicle control unit B21 Engine coolant temperature sensor cylinder 1 B34 Gear position sensor B37 Ignition pulse alternator B38 Clutch switch B70 Front wheel speed sensor M65 Idle speed actuator P10 Combination instrument R51 Ignition coil cylinder 1 ...

Страница 228: ...X39 1 BW 3 X40 1 2 BW 3 X40 3 1 2 BP 4 X41 3 BP 4 X41 4 P15 2 1 FF 1 X42 1 GS 6 X33 3 d GS 6 X33 6 FF 1 X43 1 CU 4 X32 1 d AH 2 X34 2 AG 3 X36 2 GO 2 X35 1 1 BH 6 X5 1 BH 6 X5 6 GJ 20 X54 3 GZ 20 3 GS 6 X33 1 GS 6 X33 2 5 4 B76 2 1 AK 2 X37 1 AK 2 X37 2 1 C4 S23 1 6 1 2 1 2 AP 6 AP 6 AH 2 AH 2 FG 1 FG 1 7 C2 S24 4 5 1 2 GT 6 1 AN 4 GT 6 6 GT 6 3 GT 6 GY 2 1 GY 2 2 pu bl rd br br ye rd bl rd bl bu ...

Страница 229: ...t switch B77 Brake light switch rear E13 Low beam high beam E60 License plate lamp P10 Combination instrument P15 Horn P35 Parking light P36 Brake tail light S23 Emergency OFF switch electric starter button S24 Light switch horn button headlight flasher switch turn signal switch ...

Страница 230: ...1 GU 2 P46 2 GU 2 1 GU 2 P42 2 GU 2 1 GU 2 CU 4 X32 3 GO 2 X44 2 GO 2 X45 2 d d GO 2 X45 1 GO 2 X44 1 GJ 20 X54 7 4 GO 2 X46 2 GO 2 X47 2 GJ 20 X54 6 GO 2 X46 1 GO 2 X47 1 GZ 20 7 GZ 20 6 GZ 20 18 GJ 20 X54 18 GU 2 X50 2 1 1 GO 2 X51 2 GZ 20 16 GJ 20 X54 16 9 EF 14 X55 9 10 EF 14 X55 10 6 C2 S24 4 3 2 AN 4 AN 4 B35 2 or gr bu pk br pk gn gn gr gr gr gr gn gn gn bu pk bl ye br pk or bl ye bl ye bl ...

Страница 231: ...l A60 Vehicle control unit B35 Oil pressure sensor P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S24 Light switch horn button headlight flasher switch turn signal switch ...

Страница 232: ...EF 14 X55 11 2 11 GK 56 X31 45 GN 6 X4 4 4 45 1 GJ 20 X54 5 3 15 8 12 20 19 19 12 15 GZ 20 5 1 3 8 20 d GN 6 X4 5 GN 6 X28 5 5 5 X300 51 GK 56 X31 52 50 50 51 52 10 17 10 17 6 6 X301 X302 X303 bl bl bl wh gr wh gn bu or br rd wh ye bl pu bu or br rd wh ye bl pu bl ye bl ye bl ye bl ye bl ye bl ye wh gr wh gn bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye ...

Страница 233: ...nents A11 EFI control unit A50 Alarm system optional A60 Vehicle control unit P10 Combination instrument Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Страница 234: ...X6 4 1 4 4 46 GK 56 X31 46 2 2 15A F4 10 4 GI 12 X7 10 GI 12 X7 4 HA 4 X3 3 HA 4 X6 3 c d 30A F1 7 1 GI 12 X7 1 GI 12 X7 7 a 13 9 GK 56 X31 9 GJ 20 X54 11 b EF 14 X55 14 GZ 20 11 6 C5 S23 4 2 3 5 AP 6 AP 6 AP 6 AP 6 X305 4 1 2 AK 2 X1 1 13 14 BH 6 X5 4 BH 6 X5 2 BH 6 X5 5 BH 6 X5 3 ye bu gn rd gn rd bu gr rd gr wh or wh gn rd gr bl bl rd rd wh gn wh gn ye rd gn rd gn rd gn rd rd rd bu gr rd gr ye ...

Страница 235: ... system optional A60 Vehicle control unit F1 Fuse F4 Fuse G10 Battery K11 Start auxiliary relay 1 K17 Start auxiliary relay 2 K18 Start auxiliary relay 3 K19 Starter relay M10 Starter motor P10 Combination instrument S23 Emergency OFF switch electric starter button ...

Страница 236: ...X31 19 1 2 4 D6 M13 CU 4 CU 4 2 1 HA 4 X9 3 d K50 2 1 4 3 M14 GY 2 GY 2 2 1 49 GK 56 X3149 1 2 15A F5 11 5 GI 12 X7 5 GI 12 X7 11 HA 4 X11 3 HA 4 X11 4 GP 2 X12 2 GP 2 X12 1 S11 GY 2 GY 2 2 1 15A F6 12 6 GI 12 X7 6 GI 12 X7 12 GP 2 X13 2 EF 14 X55 12 a a GP 2 X13 1 c e d 12 AN 4 X10 2 AN 4 X10 1 bu gn wh bu gn pk bu br bu gn wh bu bu or gn pk ye gr ye gr bu br bu br wh bl wh bl wh bl bu or wh br w...

Страница 237: ... DIAGRAM 235 Components A11 EFI control unit A50 Alarm system optional F3 Fuse F5 Fuse F6 Fuse K30 Power relay K40 Fuel pump relay K50 Radiator fan relay M13 Fuel pump M14 Radiator fan S11 Ignition steering lock ...

Страница 238: ... X7 2 GI 12 X7 8 a GZ 20 1 GJ 20 X54 1 EF 14 X55 8 X304 T20 BI 2 HC 3 1 2 3 2 1 G20 2 3 HB 3 1 d BV 2 BV 2 1 2 B36 EF 14 X55 4 BS 2 X52 1 BS 2 X52 2 EF 14 X55 7 35 1 GP 2 X24 2 35 2 3 AP 6 X295 6 36 36 R30 2 1 AT 2 X27 2 47 GK 56 X31 47 48 GK 56 X31 48 1 1 d 8 7 4 1 AU 2 X14 2 wh wh pu bl ye bu bu gn ye bu wh bl wh bl wh bl pu ye bu bu bu gn ye bu ye bl ye wh wh wh wh bl ye bl ye wh bl ye wh bl bl...

Страница 239: ...Components A11 EFI control unit A50 Alarm system optional B36 Alarm system switch optional F2 Fuse G20 Alternator P10 Combination instrument R30 CAN bus terminating resistor 1 T20 Voltage regulator X295 Diagnostics connector ...

Страница 240: ...2 2 D4 B32 CU 4 CU 4 4 3 GK 56 X31 11 11 B26 CU 4 CU 4 1 2 4 3 GK 56 X31 42 1 43 GK 56 X31 43 GZ 20 4 GJ 20 X54 4 GL 4 X20 1 B10 3 1 2 53 53 B51 t L 4 2 3 1 GV 4 GV 4 2 4 M51 1 2 GQ 2 X15 2 AN 4 X10 3 AN 4 X10 4 AN 4 X18 4 1 AN 4 X18 3 3 AN 4 X19 1 AN 4 X19 2 2 GX 4 X17 4 p t B45 4 2 1 3 wh br bl ye bl ye bl ye wh br bl ye bl ye wh br wh bl bl rd bu rd ye gn wh rd br gn gn gn gr ye bu gn rd bl ye ...

Страница 241: ...l unit B10 Throttle position sensor circuit A B26 Rollover sensor B30 Side stand switch B32 Fuel tank sensor B45 Temperature and manifold absolute pressure sensor B51 Lambda sensor cylinder 1 M51 Injection valve cylinder 1 P10 Combination instrument ...

Страница 242: ... 56 X31 30 GR 2 X23 2 30 GR 2 X23 1 GJ 20 X54 14 GN 6 X4 1 6 B70 1 4 2 3 AN 4 AN 4 CU 4 X30 1 d d AL 2 X26 1 2 b CU 4 X30 3 AP 6 X48 1 2 3 4 5 6 GZ 20 9 13 GZ 20 14 BH 6 1 2 3 4 5 6 5 D5 B37 1 2 4 AN 4 5 D3 B34 N 1st 6th 4th 2nd 5th 3rd 5 6 AP 6 4 1 2 3 3 AN 4 1 6 3 6 GK 56 X31 55 1 55 R51 2 1 AT 2 X29 2 BH 6 X49 6 5 4 3 2 1 wh or bl ye bl ye bl bu wh gr bl ye lbu lbu ye gn gn rd wh rd ye gn wh ye...

Страница 243: ...nit A60 Vehicle control unit B21 Coolant temperature sensor cylinder 1 B34 Gear position sensor B37 Ignition pulse generator B38 Clutch switch B70 Wheel speed sensor front M65 Idle speed actuator P10 Combination instrument R51 Ignition coil cylinder 1 ...

Страница 244: ...FM 1 X42 1 GS 6 X33 3 d GS 6 X33 6 FM 1 X43 1 CU 4 X32 1 d AH 2 X34 2 GO 2 X35 1 GJ 20 X54 3 GZ 20 3 GS 6 X33 1 GS 6 X33 2 5 4 B76 2 1 1 C4 S23 1 6 1 2 1 2 AP 6 AP 6 AH 2 AH 2 FG 1 FG 1 7 C2 S24 4 5 1 2 GT 6 1 AN 4 GT 6 6 GT 6 3 GT 6 GY 2 1 GY 2 2 AG 3 X36 3 AG 3 X36 2 1 AK 2 X37 1 AK 2 X37 2 BH 6 X5 1 BH 6 X5 6 BW 3 X40 1 2 BW 3 X40 3 1 DG 4 X38 4 1 BP 4 X41 4 pu bl rd br br ye rd bl rd bl bu bu ...

Страница 245: ...ch front B77 Brake light switch rear E13 Low beam high beam E60 License plate lamp P10 Combination instrument P15 Horn P35 Parking light P36 Brake tail light S23 Emergency OFF switch electric starter button S24 Light switch horn button high beam flasher button turn signal switch ...

Страница 246: ...U 2 P46 2 GU 2 1 GU 2 P42 2 GU 2 1 GU 2 CU 4 X32 3 GO 2 X44 2 GO 2 X45 2 d d GO 2 X45 1 GO 2 X44 1 GJ 20 X54 7 4 GO 2 X46 2 GO 2 X47 2 GJ 20 X54 6 GO 2 X46 1 GO 2 X47 1 GZ 20 7 GZ 20 6 GZ 20 18 GJ 20 X54 18 GU 2 X50 2 1 1 GO 2 X51 2 GZ 20 16 GJ 20 X54 16 EF 14 X55 9 EF 14 X55 10 6 C2 S24 4 3 2 AN 4 AN 4 B35 2 9 10 or gr bu pk gr or gn gn gr gr gr gr gn gn gn bu pk bl ye gr or or bl ye bl ye bl ye ...

Страница 247: ...l A60 Vehicle control unit B35 Oil pressure sensor P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S24 Light switch horn button high beam flasher button turn signal switch ...

Страница 248: ...14 X55 11 2 GK 56 X31 45 GN 6 X4 4 4 45 1 GJ 20 X54 5 3 15 8 12 20 19 19 12 15 GZ 20 5 1 3 8 20 d GN 6 X4 5 GN 6 X28 5 5 5 X300 51 GK 56 X31 52 50 50 51 52 10 17 10 17 6 X301 X302 X303 11 6 bl bl bl wh gr wh gn bu or br rd wh ye bl pu bu or br rd wh ye bl pu bl ye bl ye bl ye bl ye bl ye bl ye wh gr wh gn bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ...

Страница 249: ...nents A11 EFI control unit A50 Alarm system optional A60 Vehicle control unit P10 Combination instrument Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Страница 250: ... F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 15W 50 According to JASO T903 MA p 261 SAE p 261 SAE 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Parti...

Страница 251: ... possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel 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 containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Страница 252: ...Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Gr...

Страница 253: ...ner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Страница 254: ...r cover 201490 10 Art no 00029013000 Bleeding device 201491 10 Art no 00029013100 Bleed syringe 400058 01 Art no 50329050000 Circlip pliers reverse 400059 01 Art no 51012011000 Valve spring compressor 400101 01 Art no 59029019000 ...

Страница 255: ... 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Plastigauge measuring strips 400122 01 Art no 60029012000 Adapter C00194 01 Art no 61029055130 Rear wheel stand 500077 01 Art no 61029055400 Front wheel stand B00756 01 Art no 61029055500 ...

Страница 256: ... Testing hose 201314 01 Art no 61029093000 Pressure testing tool 400149 01 Art no 61029094000 Adapter B00757 01 Art no 61029955620 Engine assembly stand 200306 01 Art no 61229001000 Work stand 400151 01 Art no 62529055000 ...

Страница 257: ...ck attachment 400184 01 Art no 75029055000 Oil pressure adapter 400169 01 Art no 75029094000 Separator plate 302922 10 Art no 77229032000 Spark plug wrench 304549 10 Art no 77229172000 Engine fixing arm 304419 10 Art no 90129002050 ...

Страница 258: ...ine fixing arm 304418 10 Art no 90129002060 Mounting sleeve 201612 01 Art no 90129005000 Extractor 304569 10 Art no 90129009000 Holding spanner 304548 10 Art no 90129012000 Puller for main bearing 304528 10 Art no 90129018000 ...

Страница 259: ... 304526 10 Art no 90129019000 Pressure screw for crankshaft 304527 10 Art no 90129020000 Castle nut wrench drive 304430 10 Art no 90129021000 Castle nut wrench drive 304469 10 Art no 90129022000 Limit plug gauge 305035 10 Art no 90129026000 ...

Страница 260: ...n ring lock 305036 10 Art no 90129030000 Mounting sleeve 304541 10 Art no 90129043000 Case separating tool 304570 10 Art no 90129048000 Castle nut wrench drive 305037 10 Art no 90129050000 Castle nut wrench drive 305037 10 Art no 90129050100 ...

Страница 261: ...d bearing 304951 10 Art no 90129051000 Disassembly tool balancer shaft bearing 304565 10 Art no 90129056000 Insert for valve spring lever 305038 10 Art no 90129060000 Gear segment 304453 10 Art no 90129081100 Hook wrench 301085 01 Art no T106S ...

Страница 262: ...28 SPECIAL TOOLS 260 Spring compressor 201648 10 Art no T14050S Mounting tool 200634 10 Art no T528S Clamping stand 200638 10 Art no T612S ...

Страница 263: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Страница 264: ...stalling 174 191 water pump cover installing 167 184 Auxiliary substances 8 B Battery connecting minus cable 63 disconnecting minus cable 63 installing 62 recharging 63 removing 62 Brake disc front brake changing 55 front brake removing 55 rear brake installing 57 rear brake removing 57 Brake discs checking 54 Brake fluid front brake adding 68 front brake changing 69 rear brake adding 74 rear brak...

Страница 265: ...ft disassembling 131 151 oil pressure regulator valve checking 127 147 oil pump checking 127 147 piston ring end gap checking 126 146 piston checking 126 146 piston cylinder mounting clearance checking 127 147 pistons measuring 126 146 radial play of lower conrod bearing checking 121 141 right engine case section 119 139 shaft seal ring of water pump changing 119 139 shift mechanism checking 130 1...

Страница 266: ...rval display reinstalling 77 Service schedule 214 Shift lever adjusting 193 Shift speed RPM 1 adjusting 76 Shift speed RPM 2 adjusting 76 Shock absorber fitting 30 removing 30 spring preload adjusting 30 spring installing 31 spring removing 31 Spare parts 8 Starting 13 to make checks 14 Steering head bearing play adjusting 27 checking 26 Storage 213 T Technical data capacity coolant 206 capacity e...

Страница 267: ... 3206127en 3206127en 07 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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