Professional Documents
Culture Documents
2012 Duke 125-200 Repair Manual
2012 Duke 125-200 Repair Manual
125 Duke EU
125 Duke DE
200 Duke EU
200 Duke 2013 COL
Art. no. 3206127en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, 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 portrayed partly contain special equipment that does not belong to the regular scope of supply.
2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
11 FUEL TANK, SEAT, TRIM ...........................................
11.1 Opening the filler cap......................................
11.2 Closing the filler cap .......................................
11.3 Removing the seat ..........................................
11.4 Mounting the seat ...........................................
11.5 Removing the passenger seat ...........................
11.6 Mounting the passenger seat............................
11.7 Removing the fuel tank cover ...........................
11.8 Installing the fuel tank cover ............................
11.9 Removing the fuel tank....................................
11.10 Installing the fuel tank ....................................
11.11 Removing the front spoiler ...............................
11.12 Fitting front spoiler .........................................
11.13 Dismounting the front fender ...........................
11.14 Installing the front fender ................................
11.15 Checking the fuel pressure...............................
11.16 Changing the fuel filter....................................
11.17 Replacing the fuel pump .................................
12 WHEELS ...................................................................
12.1 Checking the tire air pressure...........................
12.2 Checking the tire condition ..............................
12.3 Checking the brake discs .................................
12.4 Front wheel ....................................................
12.4.1
Removing the front wheel ............................
12.4.2
Installing the front wheel .............................
12.4.3
Removing the brake disc of the front brake....
12.4.4
Installing the brake disc of the front brake ....
12.5 Rear wheel .....................................................
12.5.1
Removing the rear wheel .............................
12.5.2
Installing the rear wheel ..............................
12.5.3
Removing the brake disc of the rear brake .....
12.5.4
Installing the brake disc of the rear brake......
12.5.5
Checking the chain tension..........................
12.5.6
Adjusting the chain tension .........................
12.5.7
Checking the chain, rear sprocket, and
engine sprocket ..........................................
12.5.8
Cleaning the chain ......................................
12.5.9
Checking the rear hub rubber dampers..........
13 WIRING HARNESS, BATTERY.....................................
13.1 Removing the battery ......................................
13.2 Installing the battery .......................................
13.3 Disconnecting the negative cable of the
battery ...........................................................
13.4 Reconnecting the negative cable of the
battery ...........................................................
13.5 Recharging the battery ....................................
13.6 Checking the charging voltage ..........................
13.7 Changing the fuses of individual power
consumers......................................................
14 BRAKE SYSTEM ........................................................
14.1 Checking the front brake linings .......................
14.2 Changing the front brake linings .......................
14.3 Checking the brake fluid level of the front
brake .............................................................
14.4 Adding front brake fluid...................................
14.5 Changing the front brake fluid ..........................
14.6 Checking the rear brake linings ........................
14.7 Changing the rear brake linings ........................
14.8 Checking the free travel of foot brake lever ........
14.9 Adjusting the free travel of the foot brake
lever ..............................................................
14.10 Checking the rear brake fluid level....................
38
38
38
38
39
39
39
39
42
44
46
47
47
48
48
48
50
51
53
53
53
54
54
54
54
55
55
56
56
56
57
57
58
58
59
60
61
62
62
62
63
63
63
64
65
66
66
66
68
68
69
70
71
72
73
73
TABLE OF CONTENTS
14.11 Adding rear brake fluid .................................... 74
14.12 Changing the rear brake fluid ........................... 74
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 76
15.1 Setting kilometers or miles............................... 76
15.2 Adjusting the shift speed RPM 1 ...................... 76
15.3 Adjusting the shift speed RPM 2 ...................... 76
15.4 Setting the time.............................................. 77
15.5 Resetting the service interval display ................ 77
15.6 Checking the headlight setting ......................... 77
15.7 Adjusting the headlight range........................... 78
15.8 Changing the parking light bulb........................ 79
15.9 Changing the headlight bulb ............................ 80
16 ENGINE .................................................................... 82
16.1 Removing the engine....................................... 82
16.2 Installing the engine........................................ 85
16.3 Disassembling the engine ................................ 90
16.3.1
Preparations (125 Duke) ............................. 90
16.3.2
Draining the engine oil (125 Duke)............... 90
16.3.3
Removing the chain securing guide (125
Duke) ........................................................ 91
16.3.4
Removing the valve cover (125 Duke) ........... 91
16.3.5
Removing the spark plug (125 Duke)............ 91
16.3.6
Removing the clutch cover (125 Duke) ......... 91
16.3.7
Setting the engine to ignition top dead
center (125 Duke) ...................................... 92
16.3.8
Removing the starter motor (125 Duke) ........ 92
16.3.9
Removing the timing chain tensioner (125
Duke) ........................................................ 93
16.3.10 Removing the camshaft (125 Duke).............. 93
16.3.11 Removing the cylinder head (125 Duke) ....... 94
16.3.12 Removing the piston (125 Duke) .................. 94
16.3.13 Removing the water pump wheel (125
Duke) ........................................................ 95
16.3.14 Removing the alternator cover (125 Duke)..... 96
16.3.15 Removing the rotor (125 Duke) .................... 96
16.3.16 Removing the starter drive (125 Duke).......... 97
16.3.17 Removing the balancer shaft drive wheel
(125 Duke) ................................................ 97
16.3.18 Removing the gear position sensor (125
Duke) ........................................................ 98
16.3.19 Removing the spacer (125 Duke) ................. 99
16.3.20 Removing the clutch basket (125 Duke) ....... 99
16.3.21 Removing the primary gear (125 Duke) ....... 100
16.3.22 Removing the oil pump (125 Duke) ............ 100
16.3.23 Removing the shift shaft (125 Duke) .......... 101
16.3.24 Removing the shift drum locating (125
Duke) ...................................................... 101
16.3.25 Removing the locking lever (125 Duke)....... 101
16.3.26 Removing the oil filter (125 Duke) ............. 101
16.3.27 Removing the left engine case (125
Duke) ...................................................... 102
16.3.28 Removing the shift rails (125 Duke) ........... 103
16.3.29 Removing the shift drum (125 Duke).......... 103
16.3.30 Removing the shift forks (125 Duke) .......... 103
16.3.31 Removing the transmission shafts (125
Duke) ...................................................... 103
16.3.32 Removing the balancer shaft (125 Duke) .... 104
16.3.33 Removing the crankshaft (125 Duke).......... 104
16.3.34 Preparations (200 Duke) ........................... 104
16.3.35 Draining the engine 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
3
16.3.38
16.3.39
16.3.40
105
105
106
106
107
107
108
108
109
110
110
111
111
112
113
113
114
114
115
115
115
115
116
117
117
117
117
118
118
118
118
119
119
120
121
122
123
123
124
125
125
126
126
127
127
TABLE OF CONTENTS
16.4.16
16.4.17
16.4.18
16.4.19
16.4.20
16.4.21
16.4.22
16.4.23
16.4.24
16.4.25
16.4.26
16.4.27
16.4.28
16.4.29
16.4.30
16.4.31
16.4.32
16.4.33
16.4.34
16.4.35
16.4.36
16.4.37
16.4.38
16.4.39
16.4.40
16.4.41
16.4.42
16.4.43
16.4.44
16.4.45
16.4.46
16.4.47
16.4.48
16.4.49
16.4.50
16.4.51
16.4.52
16.4.53
16.4.54
16.4.55
16.4.56
16.4.57
16.4.58
127
128
129
130
131
131
132
132
133
134
136
136
137
138
138
139
139
140
141
142
143
143
144
145
145
146
146
147
147
147
148
149
150
151
151
152
152
153
154
156
156
157
158
158
158
158
159
159
159
160
160
161
161
161
162
162
163
163
164
164
165
166
167
167
167
168
169
170
171
172
172
172
173
173
174
174
174
175
175
175
176
176
176
177
177
178
178
178
179
179
180
180
181
TABLE OF CONTENTS
16.5.50
17
18
19
20
21
22
5
22.2
181
182
183
184
184
184
185
186
187
188
189
189
189
190
190
191
191
191
192
193
193
194
194
194
195
196
198
198
198
198
200
201
202
202
203
203
203
203
204
204
205
205
206
206
206
206
207
207
208
208
208
208
211
211
212
213
213
213
214
214
216
216
218
220
222
224
226
228
230
232
234
236
238
240
242
244
246
248
250
252
261
262
MEANS OF REPRESENTATION
1.1
Symbols used
1.2
Formats used
Name
Brand
Identifies a trademark.
SAFETY ADVICE
2.1
Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
2.2
Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3
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 lead to environmental damage if the appropriate measures are not taken.
2.4
Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
IMPORTANT NOTES
3.1
Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2
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
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 PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4
Figures
SERIAL NUMBERS
4.1
B00699-10
4.2
Key number
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.
B00755-10
4.3
Engine number
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
B00700-10
MOTORCYCLE
5.1
10
Note
Danger of damageThe parked vehicle may roll away or fall over.
p. 253)
p. 253)
Stand the motorcycle upright, align the lifting gear with the swingarm and the
adapters, and lift the motorcycle.
C00195-01
5.2
Note
Danger of damageThe parked vehicle may roll away or fall over.
Remove the rear wheel stand and lean the vehicle on the side stand 1.
B00714-10
5.3
Note
Danger of damageThe parked vehicle may roll away or fall over.
C00196-10
p. 10)
MOTORCYCLE
11
Move the handlebar to the straight-ahead position. Attach the lifting gear to the
steering stem.
Adapter (61029955620) (
p. 254)
p. 253)
Info
Always raise the rear of the motorcycle first.
C00197-01
5.4
Note
Danger of damageThe parked vehicle may roll away or fall over.
Mount cap 1.
B00781-01
C00196-10
5.5
Note
Danger of damageThe parked vehicle may roll away or fall over.
307317-10
Remove screw 1.
MOTORCYCLE
12
p. 254)
307318-10
Remove screw 3.
307319-10
p. 254)
307320-10
Position the motorcycle upright, align the special tool and raise the motorcycle.
307321-10
5.6
Note
Danger of damageThe parked vehicle may roll away or fall over.
307321-11
MOTORCYCLE
13
M8
30 Nm
(22.1 lbf ft)
307322-10
5.7
Starting
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidentsIf the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
Note
Engine failureUnfiltered intake air has a negative effect on the service life of the engine.
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Note
Engine failureHigh engine speeds in cold engines have a negative effect on the service life of the engine.
Sit on the vehicle, take the weight off of the side stand, and move up all the way.
.
.
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 run at the
same time.
Info
Do not press the electric starter button until the function test of the combination instrument is finished.
When starting, DO NOT open the throttle. If you open the throttle during the
starting procedure, fuel is not injected by the engine management system
and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds
before trying again.
This motorcycle is equipped with a safety start system. You can only start
the engine if the transmission is in neutral or if the clutch is pulled when a
gear is engaged. If the side stand is folded out and you shift into gear and
release the clutch, the engine stops.
MOTORCYCLE
5.8
14
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
Info
Do not open the throttle.
B00782-10
.
.
6.1
15
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidentsReduced braking efficiency due to oil or grease on the
brake discs.
304854-10
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray (
6.2
p. 251)
p. 11)
p. 48)
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 been removed.
304857-10
Unscrew screw 2 about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw 2.
Warning
Danger of accidentsReduced braking effect caused by damaged brake
discs.
304858-10
304859-10
Always lay the wheel down in such a way that the brake discs are not
damaged.
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Remove screws 4.
Remove the cable binder and hang the wheel speed sensor to one side.
16
Loosen screws 5. Remove the fork legs from the bottom.
304860-10
6.3
Following modifications, ride slowly at first to get the feel of the new ride behavior.
Main work
Push the fork legs into the triple clamps.
Align the fork legs in the required position using the fork rings.
Tighten screw 1.
304863-10
Guideline
Screw, top triple clamp
M8
M8
15 Nm
(11.1 lbf ft)
304860-11
M4
4 Nm (3 lbf ft)
304859-11
Clean and grease the shaft seal rings 4 and mating surfaces A of the spacers.
Long-life grease (
304861-10
p. 250)
17
Lift the front wheel into the fork, position it, and insert the wheel spindle.
M8
30 Nm
(22.1 lbf ft)
304858-11
Position the brake calipers and check that the brake linings are seated correctly.
Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point. Fix the hand brake lever in the activated position.
304857-11
M8x1
30 Nm
(22.1 lbf ft)
Loctite 243
Pull the front brake and compress the fork powerfully a few times.
p. 12)
Tighten screws 7.
Guideline
Screw, fork stub
M8
304862-10
Finishing work
Install front fender. (
6.4
p. 48)
Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) (
201505-10
p. 260)
15 Nm
(11.1 lbf ft)
18
Loosen the screw cap 1.
Info
The screw cap cannot be removed yet.
201506-10
Release the fork leg and clamp it with the fork stub.
201507-10
Info
Use soft jaws.
201508-10
201509-10
Info
Place a container underneath to catch any oil that may run out.
201510-10
201511-10
19
Clamp the outer tube in the area of the lower triple clamp.
Clamping stand (T612S) (
p. 260)
201512-10
Info
The lock ring has a beveled end where a screwdriver can be applied.
201513-10
201514-10
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.
201515-10
6.5
Check the inner tube and the axle clamp for damage.
If damage is found:
201516-10
20
Measure the outside diameter of the inner tube in several places.
External diameter of inner tube
200684-10
200685-10
If damage is found:
200632-10
201517-10
6.6
p. 19)
Main work
Clamp in the inner tube with the axle clamp.
Guideline
Use soft jaws.
202092-10
p. 250)
Info
Always change the dust boot, lock ring, seal ring, and support ring.
Install the dust boot with the sealing lip and spring expander facing downward.
21
p. 250)
Info
Mount with the sealing lip facing down and the open side facing up.
Sand the edges of sliding bushing 5 with 600-grit sandpaper, then clean and
grease.
Fork oil (SAE 4) (48601166S1) (
p. 249)
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.
Hold the seal ring with the shorter shoulder of the special tool.
202093-10
p. 260)
Push the seal ring and support ring all the way into the outer tube.
202094-10
Info
The lock ring must engage audibly.
202095-10
202096-10
22
Mount screw cap 6 onto the piston rod.
Info
Nut 7 must be turned all the way down.
M12x1
30 Nm
(22.1 lbf ft)
202097-10
450 ml
(15.21 fl. oz.)
Info
If it should be impossible to add the full quantity of oil, close the screw cap
of the outer tube, unclamp the fork and bounce a number of times. Then
add the remaining quantity.
201523-10
Unclamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) (
p. 260)
M47x1.5
201522-10
6.7
p. 11)
p. 48)
p. 15)
Main work
Remove expanding rivets 1.
304864-10
304865-10
Remove screws 2.
30 Nm
(22.1 lbf ft)
23
Disconnect connector 7.
Remove screws 8.
304866-10
304867-10
304868-10
304869-10
304870-10
304871-10
24
Remove the upper triple clamp with the handlebar and set aside.
Info
Protect the vehicle and its attachments from damage by covering them.
304872-10
p. 258)
304873-10
304874-10
6.8
p. 250)
304874-11
Alternative 1
A new steering head bearing is used.
M30x1
Step 1
50 Nm
(36.9 lbf ft)
2nd stage
(loosen, counterclockwise)
2 turns
Step 3
5 Nm (3.7 lbf ft)
304873-11
p. 258)
Alternative 2
The steering head bearing is used again.
M30x1
25
Castle nut wrench; " drive (90129050000) (
p. 258)
304872-10
Guideline
Screw, top steering head
M16x1.5
52 Nm
(38.4 lbf ft)
304875-10
M6
304876-10
Plug in connector 7.
304868-10
304867-11
304866-11
M6
26
M6
304865-11
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Tighten screw 4.
p. 16)
304864-11
Guideline
Screw, top steering head
M16x1.5
52 Nm
(38.4 lbf ft)
M8
304877-10
Finishing work
Check that the wiring harness, throttle cables, and brake line have the necessary
freedom of movement and are correctly routed.
6.9
p. 26)
p. 12)
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged with time.
Preparatory work
Raise the motorcycle with the work stand. (
p. 11)
Main work
Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
400738-11
p. 27)
Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
27
Finishing work
Remove the motorcycle from the work stand. (
6.10
p. 27)
p. 12)
p. 11)
Main work
Loosen screws 1.
Loosen screw 2.
Tighten nut 3 with the special tool until there is no play in the steering head bearing.
304855-10
p. 259)
304856-10
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)
M8
Tighten screw 1.
Guideline
Screw, top triple clamp
304855-10
Finishing work
Check the steering head bearing play. (
p. 26)
p. 12)
HANDLEBAR, CONTROLS
7.1
28
Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable.
Throttle cable play
p. 28)
Danger
400192-10
Danger of poisoningExhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
7.2
B00728-10
7.3
Slide on sleeve 1.
Move the handlebar to the straight-ahead position. Lightly pull the clutch lever and
ascertain the clutch lever play A.
p. 29)
Note
B00729-10
Clutch damageIf there is no play on the clutch lever, the clutch will begin to slip.
When operating the motorcycle, always check the clutch lever play.
Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
HANDLEBAR, CONTROLS
7.4
29
B00730-10
Slide on sleeve 1.
8.1
30
Warning
Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior.
Following modifications, ride slowly at first to get the feel of the new ride behavior.
Info
The spring preload defines the initial situation of the spring process on the shock absorber.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger,
thus ensuring an ideal compromise between maneuverability and stability.
3 clicks
Full payload
6 clicks
Info
B01419-10
8.2
p. 259)
p. 11)
Main work
Remove screw 1.
Info
Protect the link fork and attachments from damage.
Ensure that the chain and brake line are not damaged.
304841-10
Remove fitting 2.
Lift the link fork and take out the shock absorber 3 toward the rear.
304842-10
8.3
304842-11
M10x1.25
45 Nm
(33.2 lbf ft)
31
M10x1.25
50 Nm
(36.9 lbf ft)
M10x1.25
45 Nm
(33.2 lbf ft)
Tighten fitting 2.
Guideline
Fitting, bottom shock absorber
304841-11
Finishing work
Remove the motorcycle from the work stand. (
8.4
p. 12)
Clamp the shock absorber in the vise using soft jaws for protection.
p. 259)
201698-10
p. 260)
Info
Use the ring of the special tool with the smallest possible inside diameter. It
must be pressed directly onto the spring.
201697-10
8.5
Release the spring. Remove the shock absorber from the special tool.
p. 260)
Info
Use the ring of the special tool with the smallest possible inside diameter. It
must be pressed directly onto the spring.
201697-10
Release the spring. Remove the shock absorber from the special tool.
Clamp the shock absorber in the vise using soft jaws for protection.
32
Alternative 1
Tension the spring to the prescribed position by turning the adjusting ring.
Guideline
Spring preload
Standard
3 clicks
Full payload
6 clicks
p. 259)
Alternative 2
Warning
Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior.
Extreme modifications to the adjustment of the suspension components can cause a serious deterioration in the handling characteristics and overload some components.
After making adjustments, ride slowly at first to get the feel of the
new ride behavior.
Tension the spring to the position measured during dismantling by turning the
adjusting ring.
EXHAUST
9.1
33
Warning
Danger of burnsThe exhaust system gets very hot when the vehicle is driven.
Allow the exhaust system to cool down. Do not touch hot components.
Remove the cable binder, expose the connector 2 of the lambda probe, and
detach.
304843-10
304844-10
304845-10
304846-10
304847-10
EXHAUST
34
304848-10
9.2
304848-10
Guideline
Nut, exhaust flange (125 Duke)
M8
22 Nm
(16.2 lbf ft)
M8
22 Nm
(16.2 lbf ft)
M8
22 Nm
(16.2 lbf ft)
M8
22 Nm
(16.2 lbf ft)
304847-11
Tighten nuts 1.
Guideline
304846-11
M18x1.5
304845-10
304844-11
Plug in connector 4.
40 60 Nm
(29.5
44.3 lbf ft)
Lubricant (T152)
( p. 251)
EXHAUST
35
M6
304843-11
9.3
p. 33)
p. 47)
Main work
Remove screw 1 with washers.
304849-10
Remove screw 3.
304850-10
Info
Do not misplace the sleeves.
304851-10
304852-10
EXHAUST
9.4
36
Main work
Position the main silencer.
304852-10
M8
Info
Make sure the sleeves are seated correctly.
304851-11
M6
304850-10
M6
304849-11
Finishing work
Fit the front spoiler. (
p. 47)
p. 34)
10
AIR FILTER
10.1
37
Note
Engine failureUnfiltered intake air has a negative effect on the service life of the engine.
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Preparatory work
Remove the passenger seat. (
p. 39)
p. 38)
Main work
Remove screws 1.
Pull the air filter box lid forward and move to the side.
304818-10
304819-10
10.2
304819-11
Info
Make sure the air filter box lid is seated correctly.
M6
304818-11
Finishing work
Mount the seat. (
p. 39)
p. 39)
11
11.1
38
Danger
Fire hazardFuel is highly flammable.
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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.
Lift the cover 1 of the filler cap and insert the ignition key in the lock.
Note
Danger of damageIgnition key breakage.
B00710-10
11.2
To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
B00711-01
11.3
After closing the filler cap, ensure that it is locked properly. Change
clothing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.
p. 39)
Main work
Remove screws 1.
B00725-10
Raise the rear of the seat, pull it towards the rear, and remove it upwards.
11
11.4
39
Main work
Attach seat recesses A at screws 1 and lower at the rear.
M6
B00727-10
Finishing work
Mount the passenger seat. (
11.5
p. 39)
Raise the rear of the seat, push it towards the rear, and remove it upwards.
Attach hooks 1 on the passenger seat to brackets 2 on the subframe, and lower it
at the rear while pushing forward.
B00712-01
11.6
Warning
Danger of accidentsThe passenger seat can come loose from the anchoring
if it is not mounted correctly.
B00724-10
11.7
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
11
40
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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)
p. 38)
Screw
M5x50
Length A
40 mm (1.57 in)
304820-10
Remove screw 2.
Info
Always remove the screws individually and replace them with a special
screw to avoid distorting the fuel tank.
Remove screw 2.
Remove screw 2.
304821-10
304822-10
304823-10
11
41
Remove screw 2.
Remove screws 5.
Remove screws 6.
Remove screws 8.
p. 38)
304824-10
304825-10
304826-10
304827-10
304828-10
304829-10
11
42
304830-10
304831-10
304832-10
11.8
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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.
Main work
Remove the plug.
304832-10
11
43
304831-11
304830-10
Guideline
Remaining screws, chassis
M5
304829-11
304833-10
Info
Always replace the screws individually, or the fuel tank will become distorted 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
304834-10
M5
4 Nm (3 lbf ft)
11
44
304835-10
Guideline
Screw, fuel tank
M6
M5
M6
304836-10
304827-11
Finishing work
Mount the seat. (
11.9
p. 39)
p. 39)
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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)
p. 38)
p. 39)
11
45
Main work
Remove screw 1.
Info
Protect the frame and attachments from damage.
304878-10
Remove screws 2.
Detach connector 4.
Pull off the fuel line and remove the fuel tank.
304879-10
304880-10
304881-10
304885-10
304886-10
11
11.10
46
Danger
Fire hazardFuel is highly flammable.
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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.
Main work
Connect the fuel line.
Remove tool 2.
Plug in connector 3.
304886-11
304885-11
304881-11
304880-11
11
47
M6
M4
4 Nm (3 lbf ft)
304879-11
304878-11
Finishing work
Install the fuel tank cover. (
11.11
p. 42)
Remove screws 1.
Remove screws 2.
Position the front spoiler. Mount screws 1 but do not tighten yet.
p. 39)
p. 39)
B00770-10
B00771-10
11.12
B00770-10
11
48
M6
M6
Tighten screw 1.
Guideline
Remaining screws, chassis
B00771-10
11.13
304853-10
11.14
M6
304853-10
11.15
Danger
Fire hazardFuel is highly flammable.
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Condition
The fuel tank is full.
Ensure that the battery voltage does not drop below 12.5 V.
The ignition is off.
The diagnostics tool is connected.
11
49
Push back hose clamp 1 and pull off the fuel line.
304895-10
3
0
2
0
p. 254)
p. 254)
400926-10
10 l (2.6 US gal)
p. 38)
400927-01
400928-01
304895-10
p. 50)
p. 51)
Stop the "Function test of fuel pump control" actuator test by pressing the "Quit" button.
11
11.16
50
Danger
Fire hazardFuel is highly flammable.
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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)
Drain the fuel from the fuel tank into a suitable container.
p. 38)
p. 39)
p. 44)
Main work
Take fuel filter 1 out of the holder.
304887-10
304888-10
304890-10
11
51
304887-10
Finishing work
Install the fuel tank. (
11.17
p. 46)
p. 42)
p. 39)
p. 39)
Danger
Fire hazardFuel is highly flammable.
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoningFuel is poisonous and a health hazard.
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazardImproper 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)
Drain the fuel from the fuel tank into a suitable container.
p. 38)
p. 39)
p. 44)
Main work
Remove screws 1.
Position gasket 2.
304889-10
304891-10
11
52
M5
304889-10
Finishing work
Install the fuel tank. (
p. 46)
p. 42)
p. 39)
p. 39)
12
WHEELS
12.1
53
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
Rear
12.2
Rear
Front
Warning
Danger of crashingPoor vehicle handling due to different tire tread patterns on front and rear wheels.
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidentsUncontrollable 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, especially on wet surfaces.
Check the front and rear tires for cuts, run-in objects and other damage.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth
400602-10
2 mm ( 0.08 in)
Info
The tire's date of the manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits refer
to the week of manufacture and last two digits refer to the year of manufacture.
KTM recommends that the tires are changed regardless of the actual wear,
at the latest after 5 years.
12
WHEELS
54
12.3
Check the thickness of the front and rear brake discs at several places on the disk
to see if it conforms to measurement A.
Info
Wear reduces the thickness of the brake disc in area 1 of the brake disc.
Brake discs - wear limit
400480-10
12.4.1
Front wheel
Rear
Check the front and rear brake discs for damage, cracking, and deformation.
12.4
Front
Preparatory work
Raise the motorcycle with the rear wheel stand. (
p. 10)
p. 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 accidentsReduced braking effect caused by damaged brake
discs.
B00743-10
Always lay the wheel down in such a way that the brake discs are not
damaged.
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
12.4.2
Warning
Danger of accidentsReduced 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.
12
WHEELS
55
Main work
Check the wheel bearing for damage and wear.
Clean and grease the shaft seal rings 1 and mating surfaces A of the spacers.
Long-life grease (
p. 250)
B00744-10
M8
30 Nm
(22.1 lbf ft)
Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
Tighten screws 3.
p. 11)
Guideline
Screw, fork stub
M8
15 Nm
(11.1 lbf ft)
Finishing work
Take the motorcycle off of the rear wheel stand. (
12.4.3
p. 10)
p. 10)
p. 10)
p. 54)
Main work
Remove screws 1.
304806-10
12.4.4
M8
Finishing work
Install the front wheel. (
p. 54)
29 Nm
(21.4 lbf ft)
304806-10
p. 10)
Loctite 243
12
WHEELS
12.5
Rear wheel
12.5.1
56
Preparatory work
Raise the motorcycle with the rear wheel stand. (
p. 10)
Main work
Remove nut 1 and the washer. Remove chain adjuster 2.
Push the rear wheel forward as far as possible and take the chain off the rear
sprocket.
Warning
Danger of accidentsReduced braking effect caused by damaged brake
discs.
Always lay the wheel down in such a way that the brake discs are not
damaged.
Pull the rear wheel back and take it out of the swingarm.
Info
Do not operate the foot brake when the rear wheel is removed.
B00745-10
12.5.2
Warning
Danger of accidentsReduced braking efficiency due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsNo 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. (
Clean and grease the shaft seal rings 1 and mating surfaces A of the spacers.
Long-life grease (
B00748-10
p. 61)
p. 250)
Clean the fixing locations on the brake caliper support and swingarm.
Install the rubber damper and rear sprocket carrier on the rear wheel.
Push the rear wheel as far forward as possible and place the chain on the rear
sprocket.
12
WHEELS
57
Info
Mount the left and right chain adjusters 4 in the same position.
Push the rear wheel forward so that the chain adjusters are on the screws, and
tighten nut 2.
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 B.
Nut, rear wheel spindle
M14x1.5
60 Nm
(44.3 lbf ft)
B00745-11
Finishing work
Take the motorcycle off of the rear wheel stand. (
12.5.3
p. 10)
p. 10)
p. 56)
Main work
Remove screws 1.
304805-10
12.5.4
M8
29 Nm
(21.4 lbf ft)
304805-10
Finishing work
Install the rear wheel. (
p. 56)
p. 10)
Loctite 243
12
WHEELS
12.5.5
58
Warning
Danger of accidentsDanger caused by incorrect chain tension.
If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.
In the area of chain sliding guard, press the chain upward toward 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
p. 58)
B00731-10
12.5.6
Warning
Danger of accidentsDanger caused by incorrect chain tension.
If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.
Preparatory work
Check the chain tension. (
p. 58)
12
WHEELS
59
Main work
Loosen nut 1.
Loosen nuts 2.
Adjust the chain tension by turning adjusting screws 3 on the left and right.
Guideline
Chain tension
Turn adjusting screws 3 on the left and right so that the markings on the left
and right chain adjuster 4 are in the same position in relation to reference
marks C. The rear wheel is then correctly aligned.
Info
The upper chain section must be taut.
Chain wear is not always even, so you should check the setting at different
chain positions.
Tighten nuts 2.
Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3.
Tighten nut 1.
Guideline
B00732-10
12.5.7
M14x1.5
60 Nm
(44.3 lbf ft)
Info
The engine sprocket, rear sprocket, and chain should always be
replaced together.
100132-10
15 kg (33 lb.)
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
A
0
1 2 3
B
0
Info
18 19 20
401288-10
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
12
WHEELS
60
Remove screws 2 and 3 and release screw 1. Push the chain guard aside.
C00198-10
C00199-10
EJOT PT
4 Nm (3 lbf ft)
EJOT PT
4 Nm (3 lbf ft)
M5
Tighten screw 2.
Guideline
Screw, chain guard
Tighten screw 3.
Guideline
Remaining screws, chassis
C00198-10
12.5.8
Warning
Danger of accidentsOil or grease on the tires reduces their grip.
Warning
Danger of accidentsReduced 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.
12
WHEELS
61
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
p. 250)
p. 250)
400725-01
12.5.9
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during
operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
Preparatory work
Raise the motorcycle with the rear wheel stand. (
p. 10)
p. 56)
Main work
Check bearing 1.
Check the rubber dampers 2 of the rear hub for damage and wear.
B00746-10
Lay the read wheel on a workbench with the rear sprocket facing upwards and
insert the wheel spindle in the hub.
To check the play A, hold the rear wheel tight and try to rotate the rear sprocket.
Info
Measure the play on the outside of the rear sprocket.
Play in rubber dampers, rear wheel
B00747-10
Finishing work
Install the rear wheel. (
5 mm ( 0.2 in)
p. 56)
p. 10)
13
13.1
62
Warning
Risk of injuryBattery acid and battery gases cause serious chemical burns.
Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Preparatory work
Remove the passenger seat. (
p. 39)
p. 38)
Main work
Pull back the negative terminal cover 1.
B00750-10
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle is therefore no longer roadworthy.
B00751-10
13.2
Info
The battery terminals must be at the top.
B00751-11
B00750-11
Finishing work
Mount the seat. (
p. 39)
p. 77)
p. 39)
13
13.3
63
Preparatory work
Remove the passenger seat. (
p. 39)
p. 38)
Main work
Pull back the negative terminal cover 1.
B00750-10
13.4
B00750-10
Finishing work
Mount the seat. (
13.5
p. 39)
p. 39)
p. 77)
Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazardThe 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 when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
13
64
Preparatory work
Switch off all power consumers and switch off the engine.
Disconnect the negative cable of the battery to avoid damage to the motorcycle's
electronics.
p. 39)
p. 38)
Main work
Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the battery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on
battery housing 2.
3 months
B01395-10
Finishing work
Mount the seat. (
13.6
p. 39)
p. 39)
p. 77)
p. 39)
p. 38)
Main work
Start the motorcycle to make checks. (
p. 14)
304934-10
13.5 15.0 V
Check the cable from the voltage regulator to the wiring harness.
p. 202)
13
13.7
65
Info
The fuse box with the main fuse and the fuses of the individual power consumers is located under the passenger seat.
Preparatory work
Switch off all power consumers and switch off the engine.
p. 39)
Main work
Open fuse box cover 1.
B00753-10
B00754-10
Info
A defective fuse is indicated by a burned-out fuse wire A.
Warning
Fire hazardThe electrical system can be overloaded if the wrong fuses are
used.
Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.
p. 207)
Fuse (75011088015) (
p. 207)
Fuse (75011088030) (
p. 207)
Tip
Replace the spare fuse in the fuse box so that it is available if needed.
Finishing work
Mount the passenger seat. (
p. 39)
14
BRAKE SYSTEM
14.1
66
Warning
Danger of accidentsReduced braking efficiency caused by worn brake linings.
Note
Danger of accidentsReduced braking efficiency caused by damaged brake discs.
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
1 mm ( 0.04 in)
p. 66)
p. 66)
B00739-10
14.2
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidentsReduced 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 accidentsReduced braking efficiency due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsReduced braking efficiency due to use of non-approved brake linings.
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be 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.
14
BRAKE SYSTEM
67
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws 1.
Remove bolts 5.
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
304811-10
304812-10
304813-10
304814-10
Info
Protect the components against damage.
304815-10
Info
Always change the brake linings in pairs.
304814-10
14
BRAKE SYSTEM
68
Position springs 6.
Mount bolts 5.
Info
Make sure the springs are seated correctly.
Activate the hand brake lever until there is a firm pressure point.
304813-10
Guideline
Level A
Brake fluid DOT 4 / DOT 5.1 (
5 mm (0.2 in)
p. 248)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
304936-10
14.3
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 accidentsReduced braking efficiency due to old brake fluid.
Change the brake fluid of the front and rear brake according to the service schedule.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
p. 68)
C00200-10
14.4
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
Skin irritationBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidentsReduced braking efficiency due to old brake fluid.
Change the brake fluid of the front and rear brake according to the service schedule.
14
BRAKE SYSTEM
69
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be 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.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws 1.
C00201-10
5 mm (0.2 in)
p. 248)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
14.5
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be 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.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws 1.
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) (
Brake fluid DOT 4 / DOT 5.1 (
201524-10
p. 252)
p. 248)
Mount the corresponding bleeder cover 3 from the special tool set.
Bleeder cover (00029013000) (
201525-10
p. 252)
p. 252)
14
BRAKE SYSTEM
70
Info
Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is set on pressure gauge A. Correct the filling pressure on the pressure regulator B if necessary.
Guideline
Filling pressure
201494-10
Pull off dust cap 5 of the bleeder screw of the brake caliper. Connect the hose of
the bleeder bottle.
Bleeding device (00029013100) (
p. 252)
Info
Drain until fresh brake fluid emerges from the hose of the bleeder bottle
without bubbles.
201526-10
Open the bleeder screw again until no more brake fluid emerges.
Info
This prevents overfilling of the brake fluid reservoir.
Tighten the bleeder screw. Remove the hose of the bleeder bottle. Attach the dust
cap.
5 mm (0.2 in)
p. 248)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
201527-10
14.6
Note
Danger of accidentsReduced braking efficiency caused by damaged brake discs.
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
p. 71)
B00742-10
1 mm ( 0.04 in)
p. 71)
14
BRAKE SYSTEM
14.7
71
Warning
Skin irritationBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidentsReduced 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 accidentsReduced braking efficiency due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsReduced braking efficiency due to use of non-approved brake linings.
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be 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.
Push the brake caliper toward the brake disc with your hand to push back the brake
piston; ensure that brake fluid does not runs out of the brake fluid reservoir, removing it if it does.
Remove bolts 4.
304807-10
304808-10
304809-10
14
BRAKE SYSTEM
72
Mount bolts 4.
Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
304810-10
304808-11
p. 248)
Info
Clean up overflowed or spilt brake fluid immediately with water.
304807-11
14.8
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.
Disconnect spring 1.
Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel A.
Guideline
Free travel at foot brake lever
B00735-10
Reconnect spring 1.
p. 73)
14
BRAKE SYSTEM
14.9
73
Warning
Danger of accidentsBrake 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.
Disconnect spring 1.
Release nut 2 and use screw 3 to adjust the specified free travel A.
Guideline
Free travel at foot brake lever
Info
The range of adjustment is limited.
Attach spring 1.
B00737-10
14.10
Warning
Danger of accidentsFailure 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 accidentsReduced braking efficiency due to old brake fluid.
Change the brake fluid of the front and rear brake according to the service schedule.
C00202-10
p. 74)
14
BRAKE SYSTEM
14.11
74
Warning
Danger of accidentsFailure 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
Skin irritationBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidentsReduced braking efficiency due to old brake fluid.
Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be 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.
p. 248)
Info
C00203-10
14.12
Warning
Skin irritationBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be 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.
14
BRAKE SYSTEM
75
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) (
Brake fluid DOT 4 / DOT 5.1 (
p. 252)
p. 248)
201529-10
Mount the corresponding bleeder cover 2 from the special tool set.
Bleeder cover (00029013000) (
p. 252)
p. 252)
201530-10
Info
Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is set on pressure gauge A. Correct the filling pressure on the pressure regulator B if necessary.
Guideline
Filling pressure
201494-11
Pull off dust cap 4 of the bleeder screw. Connect the hose of the bleeder bottle.
Bleeding device (00029013100) (
p. 252)
Info
Drain until fresh brake fluid emerges from the hose of the bleeder bottle
without bubbles.
201531-10
Open the bleeder screw again until no more brake fluid emerges.
Info
This prevents overfilling of the brake fluid reservoir.
Tighten the bleeder screw. Remove the hose of the bleeder bottle. Attach the dust
cap.
p. 248)
Info
Clean up overflowed or spilt brake fluid immediately with water.
201532-10
15
15.1
76
Info
Make the country-specific setting.
Condition
The ignition is on.
The motorcycle is stationary.
Press the MODE button briefly and repeatedly until ODO appears on the display.
401303-01
15.2
Press the MODE button briefly and repeatedly until TRIP 2 appears on the display.
Info
The engine speed can be set at intervals of 50.
RPM 1 is the engine speed above which the shift warning light starts to
flash.
401307-01
Info
The MODE button increases the value.
The SET button decreases the value.
15.3
Press the MODE button briefly and repeatedly until TRIP 2 appears on the display.
Info
The engine speed can be set at intervals of 50.
RPM 2 is the engine speed above which the shift warning light lights up constantly.
The speed RPM 2 must always be higher than the speed RPM 1.
401308-01
Info
The MODE button increases the value.
The SET button decreases the value.
15
77
15.4
Press the MODE button briefly and repeatedly until ODO appears on the display.
15.5
Info
The service interval display can only be reset. It is not possible to individually adjust the distance or time to the next required service.
401358-01
15.6
A
0
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.
0
B
Distance B
5 cm (2 in)
Position the vehicle vertically at a distance A in front of the wall and switch on the
low beam.
Guideline
400726-10
Distance A
5 m (16 ft)
The rider, with luggage and passenger if applicable, now mounts the motorcycle.
If the boundary between light and dark does not meet specifications:
p. 78)
15
15.7
78
Main work
Remove expanding rivets 1.
601915-10
Remove screws 2.
601914-10
Guideline
For a motorcycle 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.
B00764-10
M6
601914-10
601915-10
Finishing work
Check the headlight setting. (
p. 77)
15
15.8
79
Note
Damage to reflectorReduced 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.
Main work
Remove expanding rivets 1.
601915-10
Remove screws 2.
Remove screws 3.
304865-10
B00762-10
B00763-10
p. 207)
15
Position cover 4.
80
B00762-10
Guideline
Screw, headlight mask
M6
304865-10
601915-10
15.9
Note
Damage to reflectorReduced 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.
Main work
Remove expanding rivets 1.
601915-10
601914-10
Remove screws 2.
15
81
B00760-10
p. 207)
Info
Insert the headlight bulb so that the catches latch into the recesses.
B00761-10
B00760-10
Guideline
Screw, headlight mask
M6
601914-10
601915-10
16
ENGINE
16.1
82
Preparatory work
Raise the motorcycle with the rear wheel stand. (
p. 47)
p. 39)
p. 38)
p. 194)
Main work
Push back the rubber cap.
Detach connector 3.
304896-10
304897-10
304898-10
304899-10
304900-10
p. 10)
p. 33)
p. 63)
16
ENGINE
83
Remove screws 6.
Remove screw 7.
Pull the engine sprocket off of the countershaft and remove it.
304901-10
304902-10
304903-10
304904-10
304905-10
304906-10
16
ENGINE
84
Push the throttle valve body upward out of the intake flange.
304907-10
304908-10
304909-10
304910-10
304911-10
304912-10
16
ENGINE
85
Position the floor jack under the engine and fix it using the special tool.
304913-10
p. 255)
304914-10
304915-10
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.
304916-10
16.2
p. 255)
16
ENGINE
86
Main work
Position the engine in the frame.
Info
Watch out for clutch lever 1.
You should have an assistant for this step.
Protect the frame and attachments from damage.
304916-11
M10
55 Nm
(40.6 lbf ft)
M10
55 Nm
(40.6 lbf ft)
304915-11
p. 255)
304914-10
304913-11
304912-11
M6
16
ENGINE
87
304911-11
Guideline
Fitting, engine mounting bracket
M10
55 Nm
(40.6 lbf ft)
M8
30 Nm
(22.1 lbf ft)
M10
55 Nm
(40.6 lbf ft)
304917-10
304910-11
304909-11
304908-11
304907-11
16
ENGINE
88
M5
304906-11
Guideline
Screw, shift activation
M6
11 Nm
(8.1 lbf ft)
Loctite 243
304905-11
Position the engine sprocket in the chain and slide it onto the countershaft.
304904-10
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
304903-11
M14x1.5
60 Nm
(44.3 lbf ft)
M6
15 Nm
(11.1 lbf ft)
M6
15 Nm
(11.1 lbf ft)
M6
15 Nm
(11.1 lbf ft)
304902-11
304901-11
16
ENGINE
89
304900-11
304899-11
304898-11
304897-11
Guideline
Remaining nuts, chassis
M6
15 Nm
(11.1 lbf ft)
Remove the oil filler plug cq with the O-ring from the clutch cover and fill up with
engine oil.
304896-11
Engine oil
First filling
B00773-12
After oil
change
approx.
External temperature: 0 50 C
(32 122 F)
Engine oil
(SAE 15W/50)
( p. 248)
External temperature: 10 40 C
(14 104 F)
Engine oil
(SAE 10W/40)
( p. 248)
External temperature: 0 50 C
(32 122 F)
Engine oil
(SAE 15W/50)
( p. 248)
16
ENGINE
90
After oil
change
approx.
Finishing work
Install the exhaust manifold. (
16.3
16.3.1
External temperature: 10 40 C
(14 104 F)
p. 34)
Read out the fault memory using the KTM diagnostics tool.
p. 77)
p. 39)
p. 39)
p. 194)
p. 198)
p. 196)
p. 256)
p. 255)
p. 254)
Info
Have an assistant help you or use a crane.
304417-10
16.3.2
304420-10
304421-10
p. 10)
p. 47)
p. 63)
Engine oil
(SAE 10W/40)
( p. 248)
16
ENGINE
16.3.3
91
Remove screws 1.
304422-10
16.3.4
Take off the valve cover with the valve cover seal.
304729-10
16.3.5
p. 255)
304730-10
16.3.6
Remove screws 1.
304731-10
Info
Pull the clutch lever forward slightly.
304732-10
16
ENGINE
92
Remove dowels 2.
304733-10
16.3.7
Turn the crankshaft counterclockwise until markings A align with the edge of the
cylinder head.
304734-10
304429-10
16.3.8
304434-10
Remove screws 1.
p. 257)
16
ENGINE
16.3.9
93
Remove screw 2.
305040-10
305039-10
Release screws 1 from the outside to the inside and remove them.
Remove dowels.
304735-10
304736-10
304737-10
16
ENGINE
94
Remove screws 1.
Release screws 2 in a crisscross pattern and remove them with the washers.
Remove dowels 4.
304444-10
304739-10
304740-10
304741-10
304743-10
Info
If no other work is required on the cylinder and the piston, you can leave the
piston in the cylinder.
16
ENGINE
95
Remove dowels 3.
304744-10
Info
If the timing chain is to be reused, mark the direction of travel.
304745-10
Remove screw 5.
304746-10
Remove screws 1.
Lock the clutch basket and primary gear using special tool 3.
304747-10
304748-10
304749-10
p. 259)
16
ENGINE
96
Remove screws 1.
Remove dowels 2.
Lock the clutch basket and primary gear using special tool 1.
304754-10
304755-10
p. 259)
304756-10
p. 259)
304757-10
p. 257)
Info
Left-handed thread!
Hold it tight using the special tool and pull off the rotor by turning the screw in.
Extractor (90129009000) (
304758-10
p. 256)
p. 257)
16
ENGINE
97
Remove screw 1.
Remove screws 2.
304759-10
304760-10
304761-10
304762-10
304756-10
Lock the clutch basket and primary gear using special tool 1.
16
ENGINE
98
p. 257)
304763-10
304764-10
304765-10
Remove screws 1.
304771-10
304772-10
16
ENGINE
99
304773-10
Lock the clutch basket and primary gear using special tool 1.
Gear segment (90129081100) (
p. 259)
Remove screws 2.
p. 259)
304774-10
p. 256)
p. 257)
Info
Left-handed thread!
304775-10
p. 256)
Info
The washer usually sticks to the inner clutch hub.
Lock the clutch basket and primary gear using special tool 1.
Gear segment (90129081100) (
p. 259)
304776-10
304777-10
p. 257)
16
ENGINE
100
304778-10
304781-10
304782-10
304783-10
304784-10
16
ENGINE
101
Remove screws 3.
Remove dowels.
304785-10
Push sliding plate 1 away from the shift drum locating 2. Remove shift shaft 3
with the washer.
304786-10
Remove screw 1.
Press locking lever 2 away from shift drum locating 3 and take off the shift drum
locating.
304787-10
Remove screw 1.
Take off locking lever 2 together with the washers and spring.
304789-10
304491-10
Remove screws 1.
16
ENGINE
102
p. 252)
304492-10
304790-10
Remove screws 1.
Swing the left section of the engine case up and remove the fitting of the engine fixing arm.
p. 257)
304791-10
p. 258)
Info
Use the drill hole marked with 901.
Pull off the section of the engine case by screwing in the screw.
Info
304792-10
16
ENGINE
103
Remove dowels 4.
305903-10
Remove shift rail 1 together with upper spring and the lower spring.
305904-10
304795-10
304796-10
304798-10
16
ENGINE
104
Remove screw 1.
304799-10
p. 257)
304800-10
p. 256)
p. 255)
p. 254)
Info
Have an assistant help you or use a crane.
305800-10
305801-10
305802-10
16
ENGINE
105
Remove screws 1.
305803-10
Take off the valve cover with the valve cover seal.
305804-10
p. 255)
305806-10
Remove screws 1.
305807-10
Info
Pull the clutch lever forward slightly.
305808-10
16
ENGINE
106
Remove dowels 2.
305809-10
16.3.40 Setting the engine to ignition top dead center (200 Duke)
Turn the crankshaft counterclockwise until markings A align with the edge of the
cylinder head.
305810-10
305811-10
305812-10
Remove screws 1.
p. 257)
16
ENGINE
107
Remove screw 2.
305813-10
305814-10
Release screws 1 from the outside to the inside and remove them.
Remove dowels.
305820-10
305821-10
305822-10
16
ENGINE
108
Remove screws 1.
Release screws 2 in a crisscross pattern and remove them with the washers.
Remove dowels 4.
305825-10
305826-10
305827-10
305828-10
305830-10
Info
If no other work is required on the cylinder and the piston, you can leave the
piston in the cylinder.
16
ENGINE
109
Remove dowels 3.
305831-10
Info
If the timing chain is to be reused, mark the direction of travel.
305832-10
Remove screw 5.
305833-10
Remove screws 1.
Lock the clutch basket and primary gear using special tool 3.
305837-10
305838-10
305839-10
p. 259)
16
ENGINE
110
Remove screws 1.
Remove dowels 2.
Lock the clutch basket and primary gear using special tool 1.
305840-10
305841-10
p. 259)
305842-10
p. 259)
305843-10
p. 257)
Info
Left-handed thread!
Hold it tight using the special tool and pull off the rotor by turning the screw in.
Extractor (90129009000) (
305844-10
p. 256)
p. 257)
16
ENGINE
111
Remove screw 1.
Remove screws 2.
305845-10
305846-10
305847-10
305848-10
305849-10
Lock the clutch basket and primary gear using special tool 1.
16
ENGINE
112
p. 257)
305850-10
305851-10
305852-10
Remove screws 1.
305855-10
305856-10
16
ENGINE
113
305857-10
Lock the clutch basket and primary gear using special tool 1.
Gear segment (90129081100) (
p. 259)
Remove screws 2.
p. 259)
305858-10
p. 256)
p. 257)
Info
Left-handed thread!
305859-10
p. 256)
Info
The washer usually sticks to the inner clutch hub.
Lock the clutch basket and primary gear using special tool 1.
Gear segment (90129081100) (
p. 259)
305860-10
305861-10
p. 257)
16
ENGINE
114
305862-10
305865-10
305866-10
305867-10
305868-10
16
ENGINE
115
Remove screws 3.
Remove dowels.
305869-10
Push sliding plate 1 away from the shift drum locating 2. Remove shift shaft 3
with the washer.
305872-10
Remove screw 1.
Press locking lever 2 away from shift drum locating 3 and take off the shift drum
locating.
305873-10
Remove screw 1.
Take off locking lever 2 together with the washers and spring.
305874-10
305876-10
Remove screws 1.
16
ENGINE
116
p. 252)
305877-10
305878-10
Remove screws 1.
Swing the left section of the engine case up and remove the fitting of the engine fixing arm.
p. 257)
305879-10
p. 258)
Info
Use the drill hole marked with 901.
Pull off the section of the engine case by screwing in the screw.
Info
305880-10
16
ENGINE
117
Remove dowels 4.
305881-10
Remove shift rail 1 together with upper spring and the lower spring.
305882-10
305883-10
305884-10
305886-10
16
ENGINE
118
Remove screw 1.
305887-10
p. 257)
305888-10
16.4
16.4.1
Remove shaft seal ring 2 of the shift shaft and 3 of the countershaft.
Remove any sealing mass remnants and clean the engine case section thoroughly.
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.
304769-10
Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing 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 are pressed in.
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
16
ENGINE
119
Press in shaft seal ring 2 of the shift shaft with the open side facing inward so that
it is flush.
Press in shaft seal ring 3 of the countershaft with the open side facing inward so
that it is flush.
16.4.2
M5
6 Nm
(4.4 lbf ft)
Loctite 243
Blow out the oil channel with compressed air and check that it is clear.
Remove any sealing mass remnants and clean the engine case section thoroughly.
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 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 are pressed in.
304768-10
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
16.4.3
304770-10
12 Nm
(8.9 lbf ft)
Loctite 243
Blow compressed air through the oil channel and check that it is clear.
Changing the shaft seal ring of the water pump (125 Duke)
M6
16
ENGINE
120
Press the new shaft seal ring 3 in all the way with the open side facing inward.
304543-10
p. 258)
304544-10
Press shaft seal ring 2 all the way in with the open side facing outward.
Mounting sleeve (90129043000) (
p. 258)
304543-10
304770-10
16.4.4
p. 257)
304522-10
p. 256)
304523-10
16
ENGINE
121
p. 257)
304524-10
p. 256)
304525-10
16.4.5
Checking the radial play of the lower conrod bearing (125 Duke)
Position 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 the packaging.
Guideline
Connecting rod - radial play of lower conrod bearing
304560-10
New condition
Wear limit
Info
The width of the Plastigauge clearance gauge is equivalent to the bearing
play.
16
ENGINE
16.4.6
122
Remove the conrod bearing cover and crankshaft. Remove the bearing shells.
304561-10
Guideline
Crankshaft diameter, crank pin
Crankshaft classification A
Crankshaft classification B
Info
The crankshaft classification is indicated by marking 2.
p. 121)
304562-10
Guideline
Nut, conrod bearing
304563-10
M7
24 Nm
(17.7 lbf ft)
16
ENGINE
16.4.7
123
p. 259)
304566-10
p. 255)
304567-10
p. 259)
304568-10
16.4.8
Info
Protect the outer cam of the camshaft against damage with adhesive tape.
Remove screw 2.
304564-10
304545-10
p. 256)
16
ENGINE
124
304547-10
20 Nm
(14.8 lbf ft)
Loctite 243
304546-10
16.4.9
M8
p. 256)
Take the shims 2 out of the valve spring retainers and lay them to one side according to their normal built-in position.
304551-10
p. 252)
p. 259)
304552-10
Remove valve spring, valve stem seal 5, and valve spring seat 6.
Info
Place the valve into a box according to the installation position and label the
box.
304537-10
Mount valve spring seat 6 and the new valve stem seal 5.
p. 125)
16
ENGINE
125
p. 252)
p. 259)
Info
When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.
304552-10
Place shims into the valve spring retainers according to the installation position.
Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
304520-10
p. 257)
Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) (
p. 253)
304521-10
302808-10
Blow compressed air through all oil holes and check that they are clear.
Measure the cylinder diameter at several places in the X and Y axes using a
micrometer to check for oval wear.
Guideline
Cylinder - bore diameter
304540-10
16
ENGINE
126
Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) (
p. 253)
0.10 mm ( 0.0039 in)
304539-10
Place the piston ring in the cylinder and align it with the piston.
Guideline
Under the upper edge of the cylinder
20 mm (0.79 in)
304519-10
Compression ring
p. 125)
p. 253)
Mount the piston ring with the marking facing toward the piston head.
Check that the piston rings can move easily in the piston ring grooves.
Tip
Use an old piston ring to clean the piston ring groove.
304550-10
Info
Mount the piston ring with the marking facing upward.
Insert the piston pin into the connecting rod and check the bearing for play.
16
ENGINE
127
Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance B.
Guideline
Distance B
9 mm (0.35 in)
Piston - diameter
304538-10
The piston/cylinder mounting clearance is the result of the cylinder bore diameter
minus the piston diameter.
p. 125)
p. 126)
Guideline
Piston/cylinder - mounting clearance
304550-10
New condition
Wear limit
With special tool 1, check the play between the internal rotor and 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
Oil pump
304531-10
Change the oil pump and, if necessary, the oil pump housing.
Change the oil pump and, if necessary, the oil pump housing.
304532-10
Remove washer 1.
Remove spring 2.
304533-10
16
ENGINE
128
Check the control piston bore in the oil pump housing 4 for damage and wear.
Mount washer 1.
304515-10
Check the contact surfaces of the clutch facing discs in the clutch basket 5 for wear.
Contact surface, clutch facing discs in clutch basket
37 mm ( 1.46 in)
16
ENGINE
If there is discoloration or scoring:
129
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.
304556-10
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 all further clutch facing discs and clutch
discs alternately.
304557-10
304558-10
304559-10
Position the release bearing holder and mount screws 4 but do not tighten yet.
16
ENGINE
130
304513-10
Check the shift forks 1 (see A) for damage and wear (visual check).
If there is run-out:
Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
16
ENGINE
131
Check the play F between the sliding plate and the shift quadrant.
p. 131)
304514-10
304512-10
Mount sliding plate 1 with the guide pin facing down and attach the guide pin to
the shift quadrant.
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.
305899-10
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
16
ENGINE
132
305900-10
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Remove washer 8.
16
ENGINE
133
305902-10
Check the pivot points of main shaft 2 and countershaft 3 for damage and wear.
Check sliding gears 5 for smooth operation in the profile of main shaft 2.
Check the tooth profiles of sliding gears 5 for damage and wear.
Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
Check the shift dogs of idler gears 4 and sliding gears 5 for damage and wear.
Check the pivot points of idler gears 4 for damage and wear.
Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
16
ENGINE
134
Preparatory work
Oil all parts carefully before assembling.
p. 132)
305899-11
Main work
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Mount 3rd/4th-gear sliding gear 6 with the small gear wheel facing up.
p. 132)
16
ENGINE
135
305901-10
Main work
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Mount the 5th-gear sliding gear 6 with the shift groove facing upward.
Mount 6th-gear sliding gear bo with the shift groove facing downward.
16
ENGINE
136
304529-10
Let the timing chain hang down freely. Check that the timing chain links move easily.
304553-10
Remove screw 1.
16
ENGINE
137
Remove screws 2.
304554-10
Guideline
Screw, stator
M5
8 Nm
(5.9 lbf ft)
Loctite 243
8 Nm
(5.9 lbf ft)
Loctite 243
304555-10
Guideline
Screw, retaining bracket,
stator cable
M5
304553-10
304530-10
Check the teeth and seating of the starter idler gear 1 for damage and wear.
Check the teeth and seating of the torque limiter 2 for damage and wear.
Change the torque limiter.
Check the toothing and bearing of freewheel gear 3 for damage and wear.
16
ENGINE
If there is damage or wear:
138
Clamp the minus (negative) cable of a 12 Volt power supply to the starter motor housing. Briefly connect the positive cable of the
power supply to the starter motor connection.
If the starter motor does not turn when you close the power circuit:
Insert freewheel gear 1 into the freewheel hub by turning the freewheel gear clockwise; do not wedge!
If the freewheel gear does not turn clockwise or if it does not lock counterclockwise:
304255-10
16.4.30 Work on the left section of the engine case (200 Duke)
Remove shaft seal ring 2 of the shift shaft and 3 of the countershaft.
Remove any sealing mass remnants and clean the engine case section thoroughly.
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.
304769-10
Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing 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 are pressed in.
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
Press in shaft seal ring 2 of the shift shaft with the open side facing inward so that
it is flush.
16
ENGINE
139
Press in shaft seal ring 3 of the countershaft with the open side facing inward so
that it is flush.
M5
6 Nm
(4.4 lbf ft)
Loctite 243
Blow out the oil channel with compressed air and check that it is clear.
16.4.31 Work on the right section of the engine case (200 Duke)
Remove any sealing mass remnants and clean the engine case section thoroughly.
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 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 are pressed in.
304768-10
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
304770-10
12 Nm
(8.9 lbf ft)
Loctite 243
Blow compressed air through the oil channel and check that it is clear.
16.4.32 Changing the shaft seal ring of the water pump (200 Duke)
M6
16
ENGINE
140
Press the new shaft seal ring 3 in all the way with the open side facing inward.
304543-10
p. 258)
304544-10
Press shaft seal ring 2 all the way in with the open side facing outward.
Mounting sleeve (90129043000) (
p. 258)
304543-10
304770-10
p. 257)
305890-10
p. 256)
305891-10
16
ENGINE
141
p. 257)
305892-10
p. 256)
305893-10
16.4.34 Checking the radial play of the lower conrod bearing (200 Duke)
Position 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 the packaging.
Guideline
Connecting rod - radial play of lower conrod bearing
305895-10
New condition
Wear limit
Info
The width of the Plastigauge clearance gauge is equivalent to the bearing
play.
16
ENGINE
142
Remove screws 1.
Remove the conrod bearing cover and crankshaft. Remove the bearing shells.
305894-10
Guideline
Crankshaft diameter, crank pin
Crankshaft classification A
Crankshaft classification B
Info
The crankshaft classification is indicated by marking 2.
p. 141)
305897-10
Guideline
Screw, conrod bearing
305896-10
M7
24 Nm
(17.7 lbf ft)
16
ENGINE
143
p. 259)
304566-10
p. 255)
304567-10
p. 259)
304568-10
Info
Protect the outer cam of the camshaft against damage with adhesive tape.
Remove screw 2.
304564-10
304545-10
p. 256)
16
ENGINE
144
304547-10
M8
Loctite 243
304546-10
20 Nm
(14.8 lbf ft)
p. 256)
Take the shims 2 out of the valve spring retainers and lay them to one side according to their normal built-in position.
304551-10
p. 252)
p. 259)
304552-10
Remove valve spring, valve stem seal 5, and valve spring seat 6.
Info
Place the valve into a box according to the installation position and label the
box.
304537-10
Mount valve spring seat 6 and the new valve stem seal 5.
p. 145)
16
ENGINE
145
p. 252)
p. 259)
Info
When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.
304552-10
Place shims into the valve spring retainers according to the installation position.
Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
304520-10
p. 257)
Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) (
p. 253)
304521-10
302808-10
Blow compressed air through all oil holes and check that they are clear.
Measure the cylinder diameter at several places in the X and Y axes using a
micrometer to check for oval wear.
Guideline
Cylinder - bore diameter
304540-10
16
ENGINE
146
Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) (
p. 253)
0.10 mm ( 0.0039 in)
304539-10
Place the piston ring in the cylinder and align it with the piston.
Guideline
Under the upper edge of the cylinder
20 mm (0.79 in)
304519-10
Compression ring
p. 145)
p. 253)
Mount the piston ring with the marking facing toward the piston head.
Check that the piston rings can move easily in the piston ring grooves.
Tip
Use an old piston ring to clean the piston ring groove.
305905-10
Info
Mount the piston ring with the marking facing upward.
Insert the piston pin into the connecting rod and check the bearing for play.
16
ENGINE
147
Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance B.
Guideline
Distance B
9 mm (0.35 in)
Piston - diameter
304538-10
The piston/cylinder mounting clearance is the result of the cylinder bore diameter
minus the piston diameter.
p. 145)
p. 146)
Guideline
Piston/cylinder - mounting clearance
305905-10
New condition
Wear limit
With special tool 1, check the play between the internal rotor and 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
Oil pump
304531-10
Change the oil pump and, if necessary, the oil pump housing.
Change the oil pump and, if necessary, the oil pump housing.
304532-10
Remove washer 1.
Remove spring 2.
304533-10
16
ENGINE
148
Check the control piston bore in the oil pump housing 4 for damage and wear.
Mount washer 1.
305870-10
Check the contact surfaces of the clutch facing discs in the clutch basket 5 for wear.
Contact surface, clutch facing discs in clutch basket
37 mm ( 1.46 in)
16
ENGINE
If there is discoloration or scoring:
149
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.
304556-10
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 all further clutch facing discs and clutch
discs alternately.
305871-10
304558-10
305889-10
Position the release bearing holder and mount screws 4 but do not tighten yet.
16
ENGINE
150
304513-10
Check the shift forks 1 (see A) for damage and wear (visual check).
If there is run-out:
Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
16
ENGINE
151
Check the play F between the sliding plate and the shift quadrant.
p. 151)
304514-10
304512-10
Mount sliding plate 1 with the guide pin facing down and attach the guide pin to
the shift quadrant.
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.
305899-10
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
16
ENGINE
152
305900-10
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Remove washer 8.
16
ENGINE
153
305902-10
Check the pivot points of main shaft 2 and countershaft 3 for damage and wear.
Check sliding gears 5 for smooth operation in the profile of main shaft 2.
Check the tooth profiles of sliding gears 5 for damage and wear.
Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
Check the shift dogs of idler gears 4 and sliding gears 5 for damage and wear.
Check the pivot points of idler gears 4 for damage and wear.
Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
16
ENGINE
154
Preparatory work
Oil all parts carefully before assembling.
p. 152)
305899-11
Main work
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Mount 3rd/4th-gear sliding gear 6 with the small gear wheel facing up.
p. 152)
16
ENGINE
155
305901-10
Main work
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
Mount the 5th-gear sliding gear 6 with the shift groove facing upward.
Mount 6th-gear sliding gear bo with the shift groove facing downward.
16
ENGINE
156
304529-10
Let the timing chain hang down freely. Check that the timing chain links move easily.
304553-10
Remove screw 1.
16
ENGINE
157
Remove screws 2.
304554-10
Guideline
Screw, stator
M5
8 Nm
(5.9 lbf ft)
Loctite 243
8 Nm
(5.9 lbf ft)
Loctite 243
304555-10
Guideline
Screw, retaining bracket,
stator cable
M5
304553-10
304530-10
Check the teeth and seating of the starter idler gear 1 for damage and wear.
Check the teeth and seating of the torque limiter 2 for damage and wear.
Change the torque limiter.
Check the toothing and bearing of freewheel gear 3 for damage and wear.
16
ENGINE
If there is damage or wear:
158
Clamp the minus (negative) cable of a 12 Volt power supply to the starter motor housing. Briefly connect the positive cable of the
power supply to the starter motor connection.
If the starter motor does not turn when you close the power circuit:
Insert freewheel gear 1 into the freewheel hub by turning the freewheel gear clockwise; do not wedge!
If the freewheel gear does not turn clockwise or if it does not lock counterclockwise:
304255-10
16.5
16.5.1
304801-10
Guideline
150 C (302 F)
304802-10
16.5.2
304503-10
p. 256)
16
ENGINE
159
Info
If necessary, heat the engine case.
304799-11
M6
Loctite 243
16.5.3
12 Nm
(8.9 lbf ft)
p. 256)
304798-10
16.5.4
Shift fork 1 has a smaller inside diameter; mount it in the shift groove of the main
shaft.
304797-10
16.5.5
304795-11
16
ENGINE
16.5.6
160
Mount shift rail 1 together with upper spring and the lower spring.
305904-10
16.5.7
Mount dowels 1.
305903-11
304790-11
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.
M6x60
Loctite 243
M6x40
16
ENGINE
161
16.5.8
Tilt the engine sideways and fill the oil filter housing approx. full with engine oil.
Fill oil filter 1 with engine oil and insert it in the oil filter housing.
304492-11
Guideline
Screw, oil filter cover
M5
304491-11
16.5.9
M6
12 Nm
(8.9 lbf ft)
Loctite 243
304789-11
Press locking lever 2 away from the shift drum locating and position the shift drum
locating 3.
Guideline
Screw, shift drum locating
304489-10
M6
12 Nm
(8.9 lbf ft)
Loctite 243
16
ENGINE
162
Slide shift shaft 1 with the washer into the bearing seat.
Push sliding plate 2 away from the shift drum locating 3. Insert the shift shaft all
the way.
304786-11
304816-10
304817-10
Check that the oil holes are clear and fill with a small amount of oil.
M6
12 Nm
(8.9 lbf ft)
304785-11
304784-11
Loctite 243
16
ENGINE
163
304783-11
304782-11
304781-11
Slide the clutch basket 2 onto the gearbox main shaft. Turn the oil pump gear
until the gear teeth of the clutch basket mesh.
304778-11
304777-11
16
ENGINE
164
Lock the clutch basket and primary gear using special tool 3.
Gear segment (90129081100) (
p. 259)
M14
55 Nm
(40.6 lbf ft)
p. 257)
304776-11
Info
Make sure that the upper clutch facing disc is offset by one notch.
Lock the clutch basket and primary gear using special tool 3.
Gear segment (90129081100) (
p. 259)
Tighten screws 5.
Guideline
304779-10
M6
M14LH
60 Nm
(44.3 lbf ft)
p. 257)
Mount bearing 7.
304780-10
p. 250)
Mount spacer 1.
304773-10
304772-11
Loctite 243
16
ENGINE
165
M5
6 Nm
(4.4 lbf ft)
Loctite 243
Info
304771-11
M5
6 Nm
(4.4 lbf ft)
Loctite 243
Mount wedge 3.
Lock the clutch basket and primary gear using the special tool.
304766-10
p. 259)
304756-11
M8
20 Nm
(14.8 lbf ft)
Loctite 243
304764-11
Mount washer 5.
The outer side of the washer is in contact with the drive wheel and the inside
faces away from the drive wheel.
304767-10
16
ENGINE
166
M28
60 Nm
(44.3 lbf ft)
p. 257)
p. 259)
304763-11
304762-11
304761-10
Guideline
Screw, ignition pulse generator
M5
6 Nm
(4.4 lbf ft)
Loctite 243
M6
12 Nm
(8.9 lbf ft)
Loctite 243
304760-11
304759-11
16
ENGINE
167
Lock the clutch basket and primary gear using special tool 1.
Gear segment (90129081100) (
p. 259)
304756-10
Info
Turn the freewheel gear counterclockwise to simplify assembly.
304757-10
M10
46 Nm
(33.9 lbf ft)
Loctite 243
p. 259)
304755-11
Guideline
Screw, alternator cover
M6
304754-11
Lock the clutch basket and primary gear using special tool 2.
Gear segment (90129081100) (
p. 259)
304749-11
M6
10 Nm
(7.4 lbf ft)
Loctite 243
16
ENGINE
168
304748-11
Guideline
Screw, water pump cover
M6
304747-11
Info
The piston rings should not become caught; otherwise, they may be damaged.
304510-10
304511-10
Guideline
Screw, timing chain tensioning rail
M6
12 Nm
(8.9 lbf ft)
Loctite 243
304746-11
304745-11
16
ENGINE
169
Thread the timing chain through the chain shaft. Mount piston pin 5.
Insert the special tool and firmly press it toward the piston.
304744-11
304743-11
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.
Keep the timing chain tensioned. Push the cylinder down carefully and let the dowels engage.
304753-11
304742-10
16
ENGINE
170
Mount dowels 2.
304740-11
Guideline
Cylinder head screw
M10
Step 1
20 Nm
(14.8 lbf ft)
Step 2
40 Nm
(29.5 lbf ft)
Thread is oiled,
head flat is
greased
304739-11
M6
304444-11
Place the timing chain over the camshaft gear of the intake camshaft.
304443-10
Markings A of the camshafts align with the edge of the cylinder head.
304442-10
16
ENGINE
171
Clean all oil nozzles thoroughly and blow out with compressed air.
M6
304735-11
304804-10
Holding it with the correct orientation, mount the timing chain tensioner 1 with
the gasket.
M6
304751-10
304750-10
Guideline
Screw, unlocking of timing chain tensioner
304752-10
M6
16
ENGINE
172
p. 257)
Check the valve clearance at all valves between the camshaft and cam lever.
p. 92)
304431-10
Guideline
Valve clearance, exhaust, cold
304432-10
p. 253)
p. 172)
M18x1.5
15 Nm
(11.1 lbf ft)
304734-10
p. 93)
Correct the shims 2 as indicated by the results of the valve clearance check.
p. 93)
p. 170)
p. 171)
304738-10
Finishing work
Check the valve clearance. (
p. 172)
p. 250)
304434-10
M6
16
ENGINE
173
304733-11
Info
Pivot the clutch lever.
304732-10
M6
304731-11
304730-10
M12
p. 255)
15 Nm
(11.1 lbf ft)
16
ENGINE
174
Degrease the sealing areas and thinly coat with sealant in areas A and B.
Loctite 5910
304803-10
Guideline
Screw, valve cover
M6
304729-10
M6
304422-10
304421-11
11 Nm
(8.1 lbf ft)
Loctite 243
16
ENGINE
175
M24x1.5
304420-11
16.5.34 Removing the engine from the engine assembly stand (125 Duke)
p. 256)
p. 255)
Info
Have an assistant help you or use a crane.
304417-10
304801-10
Guideline
150 C (302 F)
305898-10
304503-10
p. 256)
15 Nm
(11.1 lbf ft)
16
ENGINE
176
Info
If necessary, heat the engine case.
305887-11
M6
12 Nm
(8.9 lbf ft)
Loctite 243
p. 256)
305886-10
Shift fork 1 has a smaller inside diameter; mount it in the shift groove of the main
shaft.
305885-10
305883-11
16
ENGINE
177
Mount shift rail 1 together with upper spring and the lower spring.
305882-10
Mount dowels 1.
305881-11
305878-11
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.
M6x60
Loctite 243
M6x40
16
ENGINE
178
Tilt the engine sideways and fill the oil filter housing approx. full with engine oil.
Fill oil filter 1 with engine oil and insert it in the oil filter housing.
305877-11
Guideline
Screw, oil filter cover
M5
305876-11
M6
12 Nm
(8.9 lbf ft)
Loctite 243
305874-11
Press locking lever 2 away from the shift drum locating and position the shift drum
locating 3.
Guideline
Screw, shift drum locating
305875-10
M6
12 Nm
(8.9 lbf ft)
Loctite 243
16
ENGINE
179
Slide shift shaft 1 with the washer into the bearing seat.
Push sliding plate 2 away from the shift drum locating 3. Insert the shift shaft all
the way.
305872-11
304816-10
304817-10
Check that the oil holes are clear and fill with a small amount of oil.
M6
12 Nm
(8.9 lbf ft)
305869-11
305868-11
Loctite 243
16
ENGINE
180
305867-11
305866-11
305865-11
Slide the clutch basket 2 onto the gearbox main shaft. Turn the oil pump gear
until the gear teeth of the clutch basket mesh.
305862-11
305861-11
16
ENGINE
181
Lock the clutch basket and primary gear using special tool 3.
Gear segment (90129081100) (
p. 259)
M14
55 Nm
(40.6 lbf ft)
p. 257)
305860-11
Info
Make sure that the upper clutch facing disc is offset by one notch.
Lock the clutch basket and primary gear using special tool 3.
Gear segment (90129081100) (
p. 259)
Tighten screws 5.
Guideline
305863-10
M6
M14LH
60 Nm
(44.3 lbf ft)
p. 257)
Mount bearing 7.
305864-10
p. 250)
Mount spacer 1.
305857-10
305856-11
Loctite 243
16
ENGINE
182
M5
6 Nm
(4.4 lbf ft)
Loctite 243
Info
305855-11
M5
6 Nm
(4.4 lbf ft)
Loctite 243
Mount wedge 3.
Lock the clutch basket and primary gear using the special tool.
305853-10
p. 259)
305849-11
M8
20 Nm
(14.8 lbf ft)
Loctite 243
305851-11
Mount washer 5.
The outer side of the washer is in contact with the drive wheel and the inside
faces away from the drive wheel.
305854-10
16
ENGINE
183
M28
60 Nm
(44.3 lbf ft)
p. 257)
p. 259)
305850-11
305848-11
305847-10
Guideline
Screw, ignition pulse generator
M5
6 Nm
(4.4 lbf ft)
Loctite 243
M6
12 Nm
(8.9 lbf ft)
Loctite 243
305846-11
305845-11
16
ENGINE
184
Lock the clutch basket and primary gear using special tool 1.
Gear segment (90129081100) (
p. 259)
305842-10
Info
Turn the freewheel gear counterclockwise to simplify assembly.
305843-10
M10
46 Nm
(33.9 lbf ft)
Loctite 243
p. 259)
305841-11
Guideline
Screw, alternator cover
M6
305840-11
Lock the clutch basket and primary gear using special tool 2.
Gear segment (90129081100) (
p. 259)
305839-11
M6
10 Nm
(7.4 lbf ft)
Loctite 243
16
ENGINE
185
305838-11
Guideline
Screw, water pump cover
M6
305837-11
Info
The piston rings should not become caught; otherwise, they may be damaged.
304510-10
304511-10
Guideline
Screw, timing chain tensioning rail
M6
12 Nm
(8.9 lbf ft)
Loctite 243
305833-11
305832-11
16
ENGINE
186
Thread the timing chain through the chain shaft. Mount piston pin 5.
Insert the special tool and firmly press it toward the piston.
305831-11
305830-11
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.
Keep the timing chain tensioned. Push the cylinder down carefully and let the dowels engage.
305835-10
305829-10
16
ENGINE
187
Mount dowels 2.
305827-11
Guideline
Cylinder head screw
M10
Step 1
20 Nm
(14.8 lbf ft)
Step 2
40 Nm
(29.5 lbf ft)
Thread is oiled,
head flat is
greased
305826-11
M6
305825-11
Place the timing chain over the camshaft gear of the intake camshaft.
305823-10
Markings A of the camshafts align with the edge of the cylinder head.
305824-10
16
ENGINE
188
Clean all oil nozzles thoroughly and blow out with compressed air.
M6
305820-11
304804-10
Holding it with the correct orientation, mount the timing chain tensioner 1 with
the gasket.
M6
305818-10
305817-10
Guideline
Screw, unlocking of timing chain tensioner
305813-11
M6
16
ENGINE
189
p. 257)
Check the valve clearance at all valves between the camshaft and cam lever.
p. 106)
305816-10
Guideline
Valve clearance, exhaust, cold
305815-10
p. 253)
p. 189)
M18x1.5
15 Nm
(11.1 lbf ft)
305836-10
p. 107)
Correct the shims 2 as indicated by the results of the valve clearance check.
p. 107)
p. 187)
p. 188)
305819-10
Finishing work
Check the valve clearance. (
p. 189)
p. 250)
305812-10
M6
16
ENGINE
190
305809-11
Info
Pivot the clutch lever.
305808-10
M6
305807-11
305806-10
M12
p. 255)
15 Nm
(11.1 lbf ft)
16
ENGINE
191
Degrease the sealing areas and thinly coat with sealant in areas A and B.
Loctite 5910
305805-10
Guideline
Screw, valve cover
M6
305804-10
M6
305803-10
305802-11
11 Nm
(8.1 lbf ft)
Loctite 243
16
ENGINE
192
M24x1.5
305801-11
16.5.68 Removing the engine from the engine assembly stand (200 Duke)
p. 256)
p. 255)
Info
Have an assistant help you or use a crane.
305800-10
15 Nm
(11.1 lbf ft)
17
SHIFT MECHANISM
17.1
193
Info
The adjustment range of the shift lever is limited.
Loosen nuts 1.
Info
Make the same adjustments on both sides.
At least five screw threads must be screwed into the seating.
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.
B00780-10
Check the shift lever to ensure it is functioning properly and can move freely.
18
18.1
194
Warning
Danger of scaldingDuring motorcycle operation, the coolant gets very hot and is under pressure.
Do not remove the radiator cap, radiator 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 poisoningCoolant 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 immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
Preparatory work
Remove the front spoiler. (
p. 47)
Main work
Stand the motorcycle upright.
Remove screw 1.
B00768-10
18.2
M6
M6
Coolant must not come into contact with the skin, eyes, or clothing. 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 coolant is swallowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Pour in coolant until it emerges without bubbles at the vent hole, and then mount
and tighten the bleeder screw immediately.
B00767-11
Alternative 1
Coolant (
p. 248)
Alternative 2
B00769-10
p. 248)
18
195
Fill the radiator completely with coolant. Mount the radiator cap.
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
When the engine is cool, check the coolant level in the radiator and, if necessary,
add coolant.
Remove the cap of the compensating tank 3 and add coolant until the coolant
level is up to the MAX mark.
p. 47)
B00766-11
18.3
Do not remove the radiator cap, radiator 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 poisoningCoolant 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 immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
B00766-10
p. 248)
Alternative 2
Coolant (mixed ready to use) (
p. 248)
18
196
B00767-10
Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant (
p. 248)
Alternative 2
Coolant (mixed ready to use) (
18.4
p. 248)
p. 194)
Do not remove the radiator cap, radiator 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 poisoningCoolant 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 immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
B00766-10
p. 248)
Alternative 2
Coolant (mixed ready to use) (
p. 248)
Screw off radiator cap 2 and check the coolant level in the radiator.
The radiator must be completely filled.
Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant (
p. 248)
Alternative 2
B00767-10
p. 248)
18
197
p. 194)
19
LUBRICATION SYSTEM
19.1
Oil circuit
198
304938-60
Oil pump
Oil filter
19.2
Info
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.
B00772-01
19.3
p. 201)
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
19
LUBRICATION SYSTEM
199
Main work
Place a suitable container under the engine.
Remove screws 1. Take off the oil filter cover with the O-ring.
304892-10
p. 252)
304893-10
Position the special tool with the O-ring. Mount and tighten the screws.
Guideline
304894-10
M5
M5
p. 255)
Connect the pressure tester to the special tool without the T-plate.
Pressure testing tool (61029094000) (
p. 254)
p. 198)
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Coolant temperature: 70 C
( 158 F)
Engine speed: 5,000 rpm
Coolant temperature: 70 C
( 158 F)
Engine speed: 1,500 rpm
Check oil pumps for wear. Check all oil channels for free flow.
Warning
Danger of burnsSome vehicle components get very hot when the machine
is driven.
19
LUBRICATION SYSTEM
200
Oil the O-ring of the oil filter cover. Mount the oil filter cover.
M5
M5
Finishing work
Check the engine oil level. (
19.4
p. 198)
Changing the engine oil and oil filter, cleaning the oil screen
Warning
Danger of scaldingEngine oil and gear oil get very hot when the motorcycle is ridden.
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the engine oil only when the engine is warm.
Preparatory work
Remove the front spoiler. (
p. 47)
Main work
Place a suitable container under the engine.
Position oil screen 2 and mount and tighten oil drain plug 1 with the O-ring.
Guideline
B00774-10
M24x1.5
15 Nm
(11.1 lbf ft)
M24x1.5
15 Nm
(11.1 lbf ft)
Remove screws 3. Remove the oil filter cover 4 with the O-ring.
p. 252)
Oil the O-ring of the oil filter cover. Mount oil filter cover 6.
B00775-10
Guideline
Screw, oil filter cover (125 Duke)
M5
M5
Info
B00776-10
Too little engine oil or poor-quality engine oil results in premature wear to
the engine.
19
LUBRICATION SYSTEM
201
Remove the oil filler plug 7 with the O-ring from the clutch cover and fill up with
engine oil.
Engine oil
First filling
B00773-11
After oil
change
approx.
External temperature: 0 50 C
(32 122 F)
Engine oil
(SAE 15W/50)
( p. 248)
External temperature: 10 40 C
(14 104 F)
Engine oil
(SAE 10W/40)
( p. 248)
External temperature: 0 50 C
(32 122 F)
Engine oil
(SAE 15W/50)
( p. 248)
External temperature: 10 40 C
(14 104 F)
Engine oil
(SAE 10W/40)
( p. 248)
Install and tighten the oil filler plug with the O-ring.
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Finishing work
Fit the front spoiler. (
19.5
p. 47)
p. 198)
p. 248)
p. 248)
Info
For optimal performance of the engine oil, do not mix different types of
engine oil.
If appropriate, change the engine oil.
B00773-10
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Finishing work
Check the engine oil level. (
p. 198)
20
IGNITION SYSTEM
20.1
202
L00082-10
L00082-10
304934-10
21
TECHNICAL DATA
21.1
Engine
21.1.1
125 Duke
203
Design
Displacement
Stroke
Bore
58 mm (2.28 in)
Compression ratio
12.8:1
Control
19 mm (0.75 in)
Crankshaft bearing
Conrod bearing
Sleeve bearing
Pistons
Piston rings
Engine lubrication
Primary transmission
22:72
Clutch
Transmission
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
Ignition
Alternator
12 V, 238 W
Spark plug
BOSCH VR 5 NE
Cooling
Idle speed
Starting aid
Electric starter
21.1.2
200 Duke
Design
Displacement
Stroke
49 mm (1.93 in)
Bore
72 mm (2.83 in)
Compression ratio
11,5:1
Control
24 mm (0.94 in)
Crankshaft bearing
Conrod bearing
Sleeve bearing
Pistons
21
TECHNICAL DATA
204
Piston rings
Engine lubrication
Primary transmission
22:72
Clutch
Transmission
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
Ignition
Alternator
12 V, 238 W
Spark plug
BOSCH VR 5 NE
Cooling
Idle speed
Starting aid
Electric starter
21.2
21.2.1
125 Duke
Exhaust
Piston - diameter
Wear limit
Wear limit
Crankshaft classification B
37 mm ( 1.46 in)
Oil pump
Play between external rotor and oil pump housing
Axial play
21
TECHNICAL DATA
21.2.2
200 Duke
205
Exhaust
Piston - diameter
Wear limit
Wear limit
Crankshaft classification B
37 mm ( 1.46 in)
Oil pump
Play between external rotor and oil pump housing
Axial play
21.3
Oil nozzle
M5
Loctite 243
M5
Loctite 243
M5
Loctite 243
M5
Loctite 243
M5
M5
Loctite 243
M5
Loctite 243
Screw, stator
M5
Loctite 243
M6
M6
Loctite 243
M6
M6
M6
Loctite 243
M6
M6
Loctite 243
M6
M6
M6x40
M6x60
Loctite 243
M6
Loctite 243
M6
Loctite 243
21
TECHNICAL DATA
206
M6
Loctite 243
M6
Loctite 243
M6
Loctite 243
M6
M6
M6
Loctite 243
M6
M6
M6
M7
M7
M8
M8
Loctite 243
M8
Loctite 243
M8
Loctite 243
M8
M10
Step 1
20 Nm (14.8 lbf ft)
Step 2
40 Nm (29.5 lbf ft)
M10
Rotor screw
M10
Loctite 243
M10
Spark plug
M12
M14LH
Loctite 243
M14
M14
Loctite 243
M18x1.5
M24x1.5
M28
21.4
Capacities
21.4.1
Engine oil
Engine oil
First filling
21.4.2
External temperature: 0
50 C (32 122 F)
External temperature: 10
40 C (14 104 F)
External temperature: 0
50 C (32 122 F)
External temperature: 10
40 C (14 104 F)
Coolant
Coolant
1 l (1 qt.)
Coolant (
p. 248)
21.4.3
p. 248)
Fuel
p. 249)
21
TECHNICAL DATA
207
21.5
Chassis
Frame
Fork
WP Suspension
Shock absorber
WP Suspension
Brake system
Front
Rear
Suspension travel
Front
Rear
Rear
Rear
Rear
Rear
Rear
14:45
14:42
Chain
65
Wheelbase
21.6
Electrical system
FTZ-7
Battery voltage: 12 V
Nominal capacity: 6 Ah
Maintenance-free
FTZ-9
Battery voltage: 12 V
Nominal capacity: 8 Ah
Maintenance-free
Fuse
75011088010
10 A
Fuse
75011088015
15 A
Fuse
75011088030
30 A
Headlight
H4/socket P43t
12 V
60/55 W
Parking light
W5W/socket W2.1x9.5d
12 V
5W
LED
Turn signal
LED
Brake/tail light
LED
21
TECHNICAL DATA
21.7
208
LED
Tires
Front tires
Rear tires
21.8
Fork
90101000044
Fork
WP Suspension
Fork length
Fork oil
21.9
p. 249)
Shock absorber
90604010000
Shock absorber
WP Suspension
Spring preload
Standard
3 clicks
Full payload
6 clicks
Static sag
15 mm (0.59 in)
Riding sag
Fitted length
21.10
Exhaust clamp
EJOT PT
4 Nm (3 lbf ft)
Screw, headlight
EJOT
4 Nm (3 lbf ft)
M4
4 Nm (3 lbf ft)
M4
4 Nm (3 lbf ft)
PT
M4
M5
M5
M5
Loctite 243
M5
M5
M5
4 Nm (3 lbf ft)
M5
M5
M5
Loctite 243
M5
Loctite 243
Screw, spoiler
M5
M5
Loctite 243
Screw, windshield
M5
M6
Nut, radiator
M6
M6
M6
21
TECHNICAL DATA
209
M6
M6
M6
M6
Loctite 243
M6
Loctite 243
M6
M6
Loctite 243
M6
M6
M6
M6
M6
M6
M6
M6
Loctite 243
M6
M6
M6
M6
M6
Screw, seat
M6
M6
Loctite 243
M6
M6
M8
M8
M8
M8
M8
Loctite 243
M8
M8
Loctite 243
M8
M8
Screw, handrail
M8
Screw, horn
M8
M8
M8
Loctite 243
M8
Loctite 243
M8
Loctite 243
M8
M8x1
Loctite 243
M10
M10
Nut, mirror
M10
M10
M10
M10x1.25
M10x1.25
M10x1.25
M10x1.25
M10x1.25
21
TECHNICAL DATA
210
25 Nm (18.4 lbf ft)
Loctite 243
M10x1.25
M14x1.5
M14x1.5
M16x1.5
Lambda sensor
M18x1.5
40 60 Nm (29.5
44.3 lbf ft)
Lubricant (T152)
( p. 251)
M30x1
M10x1.25
22
CLEANING/PROTECTIVE TREATMENT
22.1
211
Note
Material damageDamage and destruction of components by high-pressure cleaning equipment.
When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors,
cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component.
Excessive pressure can cause malfunctions or destroy these parts.
Warning
Environmental hazardHazardous substances cause environmental damage.
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a
paintbrush.
Motorcycle cleaner (
p. 251)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner 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.
401061-01
After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
Warning
Danger of accidentsReduced braking efficiency due to a wet or dirty brake
system.
Clean or dry a dirty or wet brake system by riding and braking gently.
After cleaning, ride the vehicle a short distance until the engine warms up.
Info
The heat produced causes water at inaccessible locations in the engine and
on the brake system to evaporate.
Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate.
After the motorcycle has cooled off, lubricate all moving parts and bearings.
Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
p. 60)
p. 250)
p. 250)
Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
surfaces ( p. 251)
p. 251)
22
CLEANING/PROTECTIVE TREATMENT
22.2
212
Info
If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corrosion.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of
salt.
p. 211)
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.
401060-01
Treat the engine, swingarm, and all other bright and zinc-plated parts (except for
the brake discs) with a wax-based corrosion inhibitor.
Info
Corrosion inhibitor is not permitted to come in contact with the brake discs
as this would greatly reduce the braking force.
p. 60)
23
STORAGE
23.1
Storage
213
Info
If you want to garage the motorcycle for a longer period, take the following steps.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive (
401058-01
p. 250)
Refuel.
Change the engine oil and oil filter, clean the oil screen. (
p. 211)
p. 200)
p. 195)
p. 53)
p. 62)
p. 63)
Guideline
Storage temperature 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 temperature.
Info
KTM recommends jacking up the motorcycle.
Cover the motorcycle with a tarp or similar cover that is permeable to air.
p. 10)
p. 10)
Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot
warm up properly, the water vapor produced during combustion condenses
and causes valves and exhaust system to rust.
23.2
401059-01
Refuel.
p. 11)
p. 10)
p. 63)
p. 62)
p. 77)
24
SERVICE SCHEDULE
24.1
Service schedule
214
Read out the fault memory using the KTM diagnostics tool.
Change the engine oil and oil filter, clean the oil screen. (
Check the front brake linings. (
Check the rear brake linings. (
p. 200)
p. 66)
p. 70)
p. 54)
p. 73)
p. 53)
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.
Clean the dust boots of the fork legs. (
Check the steering head bearing play. (
p. 15)
p. 68)
p. 26)
p. 59)
p. 58)
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and bellows for cracking, leaks, and correct routing.
p. 195)
Check the cables for damage and routing without sharp bends.
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
p. 69)
p. 74)
p. 77)
Final check: Check the vehicle for roadworthiness and take a test ride.
Read out the fault memory using the KTM diagnostics tool after a test ride.
Make the service entry in KTM DEALER.NET and in the service record.
One-time interval
Periodic interval
215
216
25
WIRING DIAGRAM
25.1
-K19
ye-rd
AK/2
-X1
AH/2
rd
-X7
GI/12
ye-rd
ye-rd
wh-gn
-A50
/2.A7
EF/14
-X55
gn-rd
gn-rd
46
46
bu-gr
bu-gr
13
13
wh-or
14
14
HA/4
-X6
GI/12
-X7
-X7
GI/12
-X6
HA/4
bl-ye
GK/56
-X31
-F4
wh-or
9
9
rd-gr
GK/56
-X31
-K11
-A11
/2.A2
-X3
HA/4
wh-br
GZ/20
-K17
gn-rd
GJ/20
-X54
AP/6
gn-rd
-X5
-X5
BH/6 BH/6
AP/6
AP/6
HA/4
-X3
gn-rd
15A
-P10
/3.A3
-S23
/6.C5
AP/6
11
BH/6 BH/6
-X5
-X5
10
wh-gn
HA/4
-X2
GN/6
-X28
-X2
HA/4
2
GN/6
-X28
-K18
-A60
/5.A7
-F1
GI/12
-X7
wh-or
4
4
1
wh-gn
ye-bu
1
1
ye-bu
10
-G10
bl
1
2
1
11
5
-M10
-X305
bl-ye
rd-gr
rd-gr
2
wh-or
wh-or
wh-or
ye-rd
3
4
3
wh-or
rd
1
1
30A
7
7
wh-bl
bl
rd
rd
wh-or
wh-bl
c /2.E1
b /5.E1
a /2.B1
wh-br
d /2.F1
1/ 8
bl-ye
308041-01
25
WIRING DIAGRAM
Components:
A11
A50
A60
F1
Fuse
F4
Fuse
G10
Battery
K11
K17
K18
K19
Starter relay
M10
Starter motor
P10
Combination instrument
S23
217
218
25
WIRING DIAGRAM
25.2
-F3
-A11
/1.A5
/3.A6
-X7
GI/12
GI/12
-X7
-K30
wh-br
HA/4
-X8
wh-br
bu-or
HA/4
-X9
-M13
/4.D6
-X10
AN/4
CU/4
M
CU/4
AN/4
-X10
-F5
-X7
GI/12
GI/12
-X7
-K50
or
ye-gr
HA/4
-X11
-M14
-X12
GP/2
GY/2
GY/2
GP/2
-X12
-S11
-A50
/1.A7
/3.A4
-X13
GP/2
GY/2
GY/2
GP/2
-X13
-F6
12
12
GK/56
-X31
gn-pk
-X11
HA/4
1
EF/14
-X55
bu-br
49
2
wh-rd
49
2
GK/56
-X31
wh-bu
-X9
HA/4
-K40
gn-pk
wh-br
19
2
wh-rd
19
2
GK/56
-X31
bu-gn
-X8
HA/4
wh-br
wh-bl
/1.E8 c
bl-ye
/1.B8 a
/1.F8 d
wh-bu
wh-br
2
2
2
bu-gn
wh-rd
bu-br
GI/12
-X7
-X7
GI/12
bu-br
15A
12
12
br
wh-bl
ye-gr
2
2
1
bl-ye
wh-bl
5
5
15A
11
11
or
bu-or
2
2
1
1
bl-ye
wh-bl
3
3
10A
9
9
wh-rd
wh-bl
br
wh-bl
c /4.E1
e /6.E1
a /3.B1
wh-br
d /3.F1
2/ 8
bl-ye
308042-01
25
WIRING DIAGRAM
Components:
A11
A50
F3
Fuse
F5
Fuse
F6
Fuse
K30
Power relay
K40
K50
M13
Fuel pump
M14
Radiator fan
S11
Ignition/steering lock
219
220
25
WIRING DIAGRAM
25.3
-F2
-X7
GI/12
GI/12
-X7
-T20
-X304
-P10
/1.A4
/4.A7
-X14
AU/2
1
2
3
1
2
3
BI/2
3
G
-G20
GZ/20
-A50
/2.A7
/7.A2
-A11
/2.A2
/4.A1
GK/56
-X31
GK/56
-X31
-X295
AP/6
-R30
bl-ye
-X27
AT/2
bu
EF/14
-X55
-X24
GP/2
ye
EF/14
-X55
-X52
BS/2
BV/2
BV/2
BS/2
-X52
EF/14
-X55
-B36
bu
ye
GJ/20
-X54
36
48
wh
bu
ye
bl-ye
1
2
3
6
wh-bl
bl-ye
wh
ye-bu
bu-gn
36
48
35
47
ye-bu
bu-gn
35
47
pu
wh
wh
7
7
bl
wh
wh
pu
1
2
/2.B8 a
/2.F8 d
HB/3
HC/3
1
2
1
2
bl-ye
wh-bl
wh-bl
1
2
1
2
wh-bl
2
2
15A
8
8
wh
bl-ye
d /5.F1
3/8
308043-01
25
WIRING DIAGRAM
Components:
A11
A50
B36
F2
Fuse
G20
Alternator
P10
Combination instrument
R30
T20
Voltage regulator
X295
Diagnostics connector
221
25
WIRING DIAGRAM
25.4
222
-A11
/3.A6
/5.A1
/2.E8 c
-M51
wh-br
wh-bl
wh-br
wh-bl
wh-br
GL/4
-X20
GV/4
ye-bu
bl-gn
wh-br
bu-br
53
14
53
14
ye-bu
43
43
2
t
-X20
GL/4
GV/4
-B10
bl-gn
ye-gn
31
10
31
10
bl-rd
bl-rd
bl-ye
42
42
bl-gn
ye-gn
-X16
GW/3
3
1
-B26
gn-gr
bu-rd
gn-gr
7
23
7
23
CU/4
bu-rd
br-gn
GK/56
-X31
AN/4
-X18
-X19
AN/4
2
3
bu-rd
br-gn
-B30
CU/4
3
1
CU/4
AN/4
-X19
bl-ye
3
1
GK/56
-X31
3
1
bl-ye
4
2
wh-br
GK/56
-X31
-B51
bu-br
GK/56
-X31
-X15
GQ/2
1
2
1
4
32
32
-X18
AN/4
GK/56
-X31
1
4
CU/4
bl-ye
-B45
3
4
2
wh-rd
gn
gn-rd
gn-rd
22
24
22
24
-B32
/2.D4
bu-rd
wh-rd
gn
GK/56
-X31
-X17
GX/4
GX/4
-X17
bl-ye
3
4
2
11
11
GK/56
-X31
-X10
AN/4
CU/4
CU/4
AN/4
-X10
6
bl-ye
-P10
/3.A3
/5.A5
GJ/20
-X54
GZ/20
gn-rd
4/8
A
308044-01
25
WIRING DIAGRAM
Components:
A11
B10
B26
Rollover sensor
B30
B32
B45
B51
M51
P10
Combination instrument
223
25
WIRING DIAGRAM
25.5
224
F
wh-or
/1.E8 b
bl-ye
-A11
/4.A1
/8.A6
/3.F8 d
-R51
bl
wh-or
bl
55
55
GK/56
-X31
-X29
AT/2
wh-or
-M65
M
1
2
3
4
37
38
26
25
ye-gn
gn-rd
wh-gr
bl-bu
wh-rd
wh-rd
39
39
bl-ye
bl-ye
27
27
bu-pk
bu-pk
wh-ye
ye-gn
wh-ye
40
44
40
44
lbu
28
28
GK/56
-X31
-X21
GM/4
1
37
38
26
25
ye-gn
gn-rd
wh-gr
bl-bu
-B37
/5.D5
1
4
2
1
2
3
4
GK/56
-X31
-X22
CU/4
AN/4
-B21
30
30
GK/56
-X31
-X23
GR/2
GR/2
-X23
wh-ye
GK/56
-X31
-P10
/4.A7
/6.A3
5
-B34
/5.D3
2nd
5th
3rd
1
2
3
4
5
6
wh-bu
bl
gn
rd
wh
ye
6
5
4
3
2
1
14
14
GZ/20
GJ/20
-X54
wh-bu
6
5
4
3
2
1
-X49
BH/6
AP/6
wh-bu
bl
gn
rd
wh
ye
13
9
BH/6
4th
lbu
13
9
GZ/20
1
2
3
4
5
6
6th
-X22
CU/4
AN/4
1st
wh-ye
lbu
AP/6
-X48
GJ/20
-X54
-A60
/1.A3
/6.A1
7
-B70
wh-bu
wh-bu
wh-bu
GN/6
-X4
-X30
CU/4
-B38
AT/2
AN/4
AT/2
1
4
AN/4
2
3
AL/2
-X26
2
3
CU/4
-X30
wh-or
bl-ye
lbu
ye-gn
ye-gn
3
6
3
6
GN/6
-X28
-X26
AL/2
bl-ye
bl-ye
d /6.F1
5/8
308045-01
25
WIRING DIAGRAM
Components:
A11
A60
B21
B34
B37
B38
Clutch switch
B70
M65
P10
Combination instrument
R51
225
226
25
WIRING DIAGRAM
25.6
-A60
/5.A7
/7.A1
-X43
FF/1
GY/2
-S24
/7.C2
GP/2
-X53
-P15
FF/1
-X42
GT/6
GT/6
GZ/20
GY/2
GJ/20
-X54
-P10
/5.A5
/7.A4
GP/2
-X53
GT/6
HI
GS/6
-X33
P.light
LO
AN/4 GT/6
GS/6
-X33
-X38 -P35
DG/4
BP/4
-X41
-X39
DI/2
br
DI/2
-X39
-E13
-X40
BW/3
BW/3
-X40
-X41
BP/4
DG/4
-X38
-S23
/1.C4
-X37
AK/2
AP/6
AH/2
-X5
BH/6
AP/6
AK/2
-X37
AH/2
BH/6
-X5
-B76
-B77
-X34
AH/2
-E60
-X35
GO/2
-P36
-X36
AG/3
BE/3
BE/3
GU/2
AK/2
GU/2
AK/2
AG/3
-X36
bl-ye
GO/2
-X35
AH/2
-X34
bl-ye
bu
1
2
br
bl-ye
1
2
bl-ye
/2.E8 e
bl-ye
/5.F8 d
br
bu
br
br
FG/1
FG/1
bu
2
br
wh-br
6
bl-ye
4
4
bl-ye
6
1
bl-ye
ye-rd
bl-rd
2
3
2
3
1
1
bl-ye
pu
4
5
2
2
1
1
bl-ye
1
1
4
5
2
bl-rd
ye-rd
br
bl-rd
bl-rd
wh-br
pu
1
ye-rd
bl-rd
br
2
1
3
bl
3
6
3
bl-ye
2
1
3
bl-rd
ye-rd
br
bl
1
1
2
1
br
br
br
d /7.F1
6/8
308046-01
25
WIRING DIAGRAM
Components:
A60
B76
B77
E13
E60
P10
Combination instrument
P15
Horn
P35
Parking light
P36
Brake/tail light
S23
S24
Light switch, horn button, headlight flasher switch, turn signal switch
227
228
25
WIRING DIAGRAM
25.7
-A60
/6.A1
/8.A1
/6.F8 d
bl-ye
-X32
CU/4
AN/4
EF/14
-X55
EF/14
-X55
-P45
-P10
/6.A3
/8.A4
-X46
GO/2
GU/2
GU/2
-P41
GZ/20
GJ/20
-X54
-P46
-A50
/3.A4
/8.A3
LR
AN/4
GO/2
-X46
-X47
GO/2
GU/2
GU/2
GO/2
-X47
-X44
GO/2
GZ/20
-X45
GO/2
GU/2
GU/2
GU/2
GU/2
GO/2
-X44
GJ/20
-X54
-P42
GO/2
-X45
GZ/20
GJ/20
-X54
GZ/20
GJ/20
-X54
-B35
16
-X50
GU/2
GO/2
-X51
br-pk
16
br-pk
18
bu-pk
GN/6
-X4
-S24
/6.C2
CU/4
-X32
bl-ye
18
bl-ye
bu-pk
1
2
1
2
bl-ye
bl-ye
gr
2
1
2
1
bl-ye
gr
1
bl-ye
gr
gn
9
9
gr
10
10
gn
gn
2
1
bl-ye
gn
2
1
2
1
bl-ye
gn
gr
4
3
2
4
3
2
or
2
2
or
bl-ye
d /8.F1
7/ 8
308047-01
25
WIRING DIAGRAM
Components:
A50
A60
B35
P10
Combination instrument
P41
P42
P45
P46
S24
Light switch, horn button, headlight flasher switch, turn signal switch
229
25
WIRING DIAGRAM
25.8
230
-A60
/7.A1
/7.F8 d
bl-ye
bl-ye
bl-ye
-A50
/7.A2
3
GN/6
-X4
bl
GN/6
-X4
wh-gn
GN/6
-X28
bl-ye
GN/6
-X4
bl-ye
bl-ye
wh-gr
11
11
EF/14
-X55
bl-ye
bl-ye
bl-ye
bl
bl-pu
19
19
wh-ye
12
12
br-rd
15
15
bu-or
GZ/20
2
10
17
GJ/20
-X54
2
10
17
-P10
/7.A4
4
bl-ye
bl-ye
wh-gr
bl-ye
bl-ye
GZ/20
GJ/20
-X54
-X301
bl-ye
-X302
-A11
/5.A1
bl-ye
-X303
bl
21
21
bl-ye
1
br-rd
wh-ye
bl-pu
20
20
wh-gn
45
45
50
51
52
50
51
52
GK/56
-X31
bl-ye
bl-ye
bl-ye
GK/56
-X31
-X300
bl-ye
bl-ye
bl-ye
1
3
7
bl-ye
bu-or
8/ 8
A
308048-01
25
WIRING DIAGRAM
Components:
A11
A50
A60
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
231
232
25
WIRING DIAGRAM
25.9
-K19
ye-rd
AK/2
-X1
AH/2
rd
-X7
GI/12
ye-rd
ye-rd
4
5
wh-gn
-A50
/2.A7
EF/14
-X55
gn-rd
gn-rd
46
46
bu-gr
bu-gr
13
13
wh-or
14
14
HA/4
-X6
GI/12
-X7
-X7
GI/12
-X6
HA/4
bl-ye
GK/56
-X31
-F4
wh-or
9
9
rd-gr
GK/56
-X31
-K11
-A11
/2.A2
-X3
HA/4
wh-br
GZ/20
-K17
gn-rd
GJ/20
-X54
AP/6
gn-rd
-X5
-X5
BH/6 BH/6
AP/6
AP/6
HA/4
-X3
gn-rd
15A
-P10
/3.A3
-S23
/6.C5
AP/6
11
BH/6 BH/6
-X5
-X5
10
wh-gn
HA/4
-X2
GN/6
-X28
-X2
HA/4
2
GN/6
-X28
-K18
-A60
/5.A7
-F1
GI/12
-X7
wh-or
4
4
1
wh-gn
ye-bu
1
1
ye-bu
10
-G10
bl
1
2
1
11
5
-M10
-X305
bl-ye
rd-gr
rd-gr
2
wh-or
wh-or
wh-or
ye-rd
3
4
3
wh-or
rd
1
1
30A
7
7
wh-bl
bl
rd
rd
wh-or
wh-bl
c /2.E1
b /5.E1
a /2.B1
wh-br
d /2.F1
1/ 8
bl-ye
308051-01
25
WIRING DIAGRAM
Components:
A11
A50
A60
F1
Fuse
F4
Fuse
G10
Battery
K11
K17
K18
K19
Starter relay
M10
Starter motor
P10
Combination instrument
S23
233
234
25
WIRING DIAGRAM
25.10
-F3
-K30
wh-br
HA/4
-X8
bu-or
HA/4
-X9
-M13
/4.D6
-X10
AN/4
CU/4
M
CU/4
AN/4
-X10
-F5
-X7
GI/12
GI/12
-X7
-K50
or
ye-gr
HA/4
-X11
-M14
-X12
GP/2
GY/2
GY/2
GP/2
-X12
-S11
-A50
/1.A7
/3.A4
-X13
GP/2
GY/2
GY/2
GP/2
-X13
-F6
12
12
GK/56
-X31
gn-pk
-X11
HA/4
1
EF/14
-X55
bu-br
49
2
wh-rd
49
2
GK/56
-X31
wh-bu
-X9
HA/4
-K40
gn-pk
wh-br
19
2
19
2
GK/56
-X31
wh-rd
-X8
HA/4
bu-gn
-A11
/1.A5
/3.A6
-X7
GI/12
GI/12
-X7
wh-br
wh-bl
/1.E8 c
bl-ye
/1.B8 a
/1.F8 d
wh-bu
wh-br
2
2
2
bu-gn
wh-rd
bu-br
GI/12
-X7
-X7
GI/12
bu-br
15A
12
12
br
wh-bl
ye-gr
2
2
1
bl-ye
wh-bl
5
5
15A
11
11
or
bu-or
2
2
1
1
bl-ye
wh-bl
3
3
10A
9
9
wh-rd
wh-br
wh-bl
br
wh-bl
c /4.E1
e /6.E1
a /3.B1
wh-br
d /3.F1
2/ 8
bl-ye
308052-01
25
WIRING DIAGRAM
Components:
A11
A50
F3
Fuse
F5
Fuse
F6
Fuse
K30
Power relay
K40
K50
M13
Fuel pump
M14
Radiator fan
S11
Ignition/steering lock
235
236
25
WIRING DIAGRAM
25.11
-F2
-X7
GI/12
GI/12
-X7
-T20
-X304
1
2
3
3
G
-G20
GZ/20
-A50
/2.A7
/7.A2
EF/14
-X55
-A11
/2.A2
/4.A1
GK/56
-X31
GK/56
-X31
-X295
AP/6
-R30
bl-ye
-X27
AT/2
bu
EF/14
-X55
ye
EF/14
-X55
-X52
BS/2
BV/2
BV/2
BS/2
-X52
-X24
GP/2
bu
ye
GJ/20
-X54
-B36
-P10
/1.A4
/4.A7
-X14
AU/2
1
2
3
BI/2
36
48
wh
bu
ye
bl-ye
1
2
3
6
wh-bl
bl-ye
wh
ye-bu
bu-gn
36
48
35
47
ye-bu
bu-gn
35
47
pu
wh
wh
7
7
bl
wh
wh
pu
1
2
/2.B8 a
/2.F8 d
HB/3
HC/3
1
2
1
2
bl-ye
wh-bl
wh-bl
1
2
1
2
wh-bl
2
2
15A
8
8
wh
bl-ye
d /5.F1
3/ 8
308053-01
25
WIRING DIAGRAM
Components:
A11
A50
B36
F2
Fuse
G20
Alternator
P10
Combination instrument
R30
T20
Voltage regulator
X295
Diagnostics connector
237
25
WIRING DIAGRAM
25.12
238
-A11
/3.A6
/5.A1
/2.E8 c
-M51
wh-br
wh-bl
wh-br
wh-bl
wh-br
GL/4
-X20
GV/4
ye-bu
bl-gn
wh-br
bu-br
53
14
53
14
ye-bu
43
43
2
t
-X20
GL/4
GV/4
-B10
bl-gn
ye-gn
bl-gn
ye-gn
31
10
31
10
bl-rd
bl-rd
bl-ye
42
42
3
1
-X16
GW/3
-B26
gn-gr
bu-rd
gn-gr
7
23
7
23
CU/4
bu-rd
br-gn
GK/56
-X31
AN/4
-X18
-X19
AN/4
2
3
bu-rd
br-gn
-B30
CU/4
CU/4
AN/4
-X19
bl-ye
3
1
3
1
GK/56
-X31
3
1
bl-ye
4
2
wh-br
GK/56
-X31
-B51
bu-br
GK/56
-X31
-X15
GQ/2
1
2
1
4
32
32
-X18
AN/4
GK/56
-X31
1
4
CU/4
bl-ye
-B45
2
1
3
wh-rd
gn
gn-rd
gn-rd
22
24
22
24
-B32
/2.D4
bu-rd
wh-rd
gn
GK/56
-X31
-X17
GX/4
GX/4
-X17
bl-ye
2
1
3
11
11
GK/56
-X31
-X10
AN/4
CU/4
CU/4
AN/4
-X10
6
bl-ye
-P10
/3.A3
/5.A5
GJ/20
-X54
GZ/20
gn-rd
4/ 8
A
308054-01
25
WIRING DIAGRAM
Components:
A11
B10
B26
Rollover sensor
B30
B32
B45
B51
M51
P10
Combination instrument
239
25
WIRING DIAGRAM
25.13
240
F
wh-or
/1.E8 b
bl-ye
-A11
/4.A1
/8.A6
/3.F8 d
-R51
bl
wh-or
bl
55
55
GK/56
-X31
-X29
AT/2
wh-or
-M65
M
1
2
3
4
37
38
26
25
ye-gn
gn-rd
wh-gr
bl-bu
wh-rd
wh-rd
39
39
bl-ye
bl-ye
27
27
bu-pk
bu-pk
wh-ye
ye-gn
wh-ye
40
44
40
44
lbu
28
28
GK/56
-X31
-X21
GM/4
37
38
26
25
ye-gn
gn-rd
wh-gr
bl-bu
-B37
/5.D5
1
4
2
1
2
3
4
GK/56
-X31
-X22
CU/4
AN/4
-B21
30
30
GK/56
-X31
-X23
GR/2
GR/2
-X23
wh-ye
GK/56
-X31
-P10
/4.A7
/6.A3
5
-B34
/5.D3
2nd
5th
3rd
1
2
3
4
5
6
wh-bu
bl
gn
rd
wh
ye
6
5
4
3
2
1
14
14
GZ/20
GJ/20
-X54
wh-bu
6
5
4
3
2
1
-X49
BH/6
AP/6
wh-bu
bl
gn
rd
wh
ye
13
9
BH/6
4th
lbu
13
9
GZ/20
1
2
3
4
5
6
6th
-X22
CU/4
AN/4
1st
wh-ye
lbu
AP/6
-X48
GJ/20
-X54
-A60
/1.A3
/6.A1
7
-B70
wh-bu
wh-bu
wh-bu
GN/6
-X4
-X30
CU/4
-B38
AT/2
AN/4
AT/2
1
4
AN/4
2
3
AL/2
-X26
2
3
CU/4
-X30
wh-or
bl-ye
lbu
ye-gn
ye-gn
3
6
3
6
bl-ye
GN/6
-X28
-X26
AL/2
bl-ye
d /6.F1
5/ 8
308055-01
25
WIRING DIAGRAM
Components:
A11
A60
B21
B34
B37
B38
Clutch switch
B70
M65
P10
Combination instrument
R51
241
242
25
WIRING DIAGRAM
25.14
-A60
/5.A7
/7.A1
-X43
FM/1
GY/2
-S24
/7.C2
GT/6
GT/6
GZ/20
GY/2
GJ/20
-X54
-P10
/5.A5
/7.A4
GP/2
-X53
GT/6
HI
GS/6
-X33
P.light
LO
AN/4 GT/6
GS/6
-X33
-X38 -P35
DG/4
BP/4
-X41
-X39
DI/2
br
DI/2
-X39
-E13
-X40
BW/3
BW/3
-X40
-X41
BP/4
DG/4
-X38
-S23
/1.C4
-X5
-X37
BH/6 AK/2
AP/6
AH/2
AP/6
AH/2
BH/6 AK/2
-X5
-X37
-B76
-B77
-X34
AH/2
-E60
-X35
GO/2
-P36
-X36
AG/3
BE/3
BE/3
GU/2
AK/2
GU/2
bl-ye
AG/3
-X36
AK/2
bl-ye
bu
GO/2
-X35
AH/2
-X34
bl-ye
GP/2
-X53
-P15
FM/1
-X42
1
2
bl-ye
br
/2.E8 e
bl-ye
br
/5.F8 d
bu
2
2
1
2
br
br
bu
1
br
FG/1
FG/1
wh-br
6
bl-ye
3
3
bl-ye
6
1
bl-ye
ye-rd
bl-rd
2
3
2
3
1
1
bl-ye
pu
4
5
2
2
1
1
bl-ye
1
1
4
5
2
bl-rd
ye-rd
br
bl-rd
bl-rd
wh-br
pu
1
ye-rd
bl-rd
br
1
2
4
bl
3
6
3
bl-ye
1
2
4
bl-rd
ye-rd
br
bl
1
1
2
1
br
br
br
d /7.F1
6/ 8
308056-01
25
WIRING DIAGRAM
Components:
A60
B76
B77
E13
E60
P10
Combination instrument
P15
Horn
P35
Parking light
P36
Brake/tail light
S23
S24
Light switch, horn button, high beam flasher button, turn signal switch
243
244
25
WIRING DIAGRAM
25.15
-A60
/6.A1
/8.A1
/6.F8 d
bl-ye
-X32
CU/4
AN/4
EF/14
-X55
EF/14
-X55
-P45
-P10
/6.A3
/8.A4
-X46
GO/2
GU/2
GU/2
-P41
GZ/20
GJ/20
-X54
-P46
-A50
/3.A4
/8.A3
LR
AN/4
GO/2
-X46
-X47
GO/2
GU/2
GU/2
GO/2
-X47
-X44
GO/2
GZ/20
-X45
GO/2
GU/2
GU/2
GU/2
GU/2
GO/2
-X44
GJ/20
-X54
-P42
GO/2
-X45
GZ/20
GJ/20
-X54
GZ/20
GJ/20
-X54
-B35
16
-X50
GU/2
GO/2
-X51
gr-or
16
gr-or
18
bu-pk
GN/6
-X4
-S24
/6.C2
CU/4
-X32
bl-ye
18
bl-ye
bu-pk
1
2
1
2
bl-ye
bl-ye
gr
2
1
2
1
bl-ye
gr
1
bl-ye
gr
gn
9
9
gr
10
10
gn
gn
2
1
bl-ye
gn
2
1
2
1
bl-ye
gn
gr
4
3
2
4
3
2
or
2
2
or
bl-ye
d /8.F1
7/ 8
308057-01
25
WIRING DIAGRAM
Components:
A50
A60
B35
P10
Combination instrument
P41
P42
P45
P46
S24
Light switch, horn button, high beam flasher button, turn signal switch
245
25
WIRING DIAGRAM
25.16
246
-A60
/7.A1
/7.F8 d
bl-ye
bl-ye
bl-ye
GN/6
-X4
bl
GN/6
-X4
wh-gn
GN/6
-X28
bl-ye
GN/6
-X4
bl-ye
-A50
/7.A2
3
bl-ye
wh-gr
11
11
EF/14
-X55
bl-ye
bl-ye
bl-ye
bl
bl-pu
19
19
wh-ye
12
12
br-rd
15
15
bu-or
GZ/20
2
10
17
GJ/20
-X54
2
10
17
-P10
/7.A4
4
bl-ye
bl-ye
wh-gr
bl-ye
bl-ye
GZ/20
GJ/20
-X54
-X301
bl-ye
-X302
-A11
/5.A1
bl-ye
-X303
21
21
bu-or
br-rd
bl
bl-ye
bl-pu
20
20
wh-gn
45
45
50
51
52
50
51
52
GK/56
-X31
bl-ye
bl-ye
bl-ye
GK/56
-X31
-X300
bl-ye
bl-ye
bl-ye
wh-ye
7
bl-ye
8/ 8
A
308058-01
25
WIRING DIAGRAM
Components:
A11
A50
A60
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
247
26
SUBSTANCES
248
Coolant
Guideline
Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends Motorex products.
Mixture ratio
Antifreeze protection: 25 45 C (13
49 F)
50 % corrosion inhibitor/antifreeze
50 % distilled water
Antifreeze
Supplier
Motorex
COOLANT G48
SAE (
p. 261)
Guideline
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex products.
Partially synthetic engine oil
Supplier
Motorex
Formula 4T
SAE (
p. 261)
Guideline
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex products.
Partially synthetic engine oil
Supplier
Motorex
Formula 4T
26
SUBSTANCES
249
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
27
AUXILIARY SUBSTANCES
Chain cleaner
Guideline
KTM recommends Motorex products.
Supplier
Motorex
Chain Clean
Fuel additive
Guideline
KTM recommends Motorex products.
Supplier
Motorex
Fuel Stabilizer
Long-life grease
Guideline
KTM recommends Motorex products.
Supplier
Motorex
Bike Grease 2000
Lubricant (T511)
Guideline
KTM recommends Lubcon products.
Supplier
Lubcon
Turmsilon GTI 300 P
250
27
AUXILIARY SUBSTANCES
Lubricant (T152)
Guideline
KTM recommends BelRay products.
Supplier
BelRay
Molylube AntiSeize
Motorcycle cleaner
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
251
28
SPECIAL TOOLS
252
Bleeder cover
Art. no.: 00029013000
201490-10
Bleeding device
Art. no.: 00029013100
201491-10
Bleed syringe
Art. no.: 50329050000
400058-01
400059-01
400101-01
28
SPECIAL TOOLS
253
Feeler gauge
Art. no.: 59029041100
35
30
25
20
15
12
5
10
400110-01
400122-01
Adapter
Art. no.: 61029055130
C00194-01
500077-01
B00756-01
28
SPECIAL TOOLS
254
Testing hose
Art. no.: 61029093000
201314-01
400149-01
Adapter
Art. no.: 61029955620
B00757-01
200306-01
Work stand
Art. no.: 62529055000
400151-01
28
SPECIAL TOOLS
255
400184-01
400169-01
Separator plate
Art. no.: 77229032000
302922-10
304549-10
304419-10
28
SPECIAL TOOLS
256
304418-10
Mounting sleeve
Art. no.: 90129005000
201612-01
Extractor
Art. no.: 90129009000
304569-10
Holding spanner
Art. no.: 90129012000
304548-10
304528-10
28
SPECIAL TOOLS
257
Protecting sleeve
Art. no.: 90129019000
304526-10
304527-10
304430-10
304469-10
305035-10
28
SPECIAL TOOLS
258
305036-10
Mounting sleeve
Art. no.: 90129043000
304541-10
304570-10
305037-10
305037-10
28
SPECIAL TOOLS
259
304951-10
304565-10
305038-10
Gear segment
Art. no.: 90129081100
304453-10
Hook wrench
Art. no.: T106S
301085-01
28
SPECIAL TOOLS
260
Spring compressor
Art. no.: T14050S
201648-10
Mounting tool
Art. no.: T528S
200634-10
Clamping stand
Art. no.: T612S
200638-10
29
STANDARDS
261
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground 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 according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
262
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air filter
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator
stator winding, checking . . . . . . . . . . . . . . . . . . . . . 202
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Assembling the engine
alternator cover, installing . . . . . . . .
balancer shaft drive wheel, installing .
balancer shaft, installing . . . . . . . . .
camshafts, installing . . . . . . . . . . . .
chain securing guide, installing . . . .
clutch basket, installing . . . . . . . . .
clutch cover, installing . . . . . . . . . .
crankshaft, installing . . . . . . . . . . . .
cylinder head, installing . . . . . . . . .
gear position sensor, installing . . . . .
left engine case, installing . . . . . . . .
locking lever, installing . . . . . . . . . .
oil filter, installing . . . . . . . . . . . . .
oil pump, installing . . . . . . . . . . . . .
oil screen, installing . . . . . . . . . . . .
piston, installing . . . . . . . . . . . . . .
primary gear, installing . . . . . . . . . .
removing the engine from the engine
stand . . . . . . . . . . . . . . . . . . . . . .
rotor, installing . . . . . . . . . . . . . . . .
shift drum locating, installing . . . . . .
shift drum, installing . . . . . . . . . . . .
shift forks, installing . . . . . . . . . . . .
shift rails, installing . . . . . . . . . . . .
shift shaft, installing . . . . . . . . . . . .
spacer, installing . . . . . . . . . . . . . .
spark plug, installing . . . . . . . . . . . .
starter drive, installing . . . . . . . . . .
starter motor, installing . . . . . . . . . .
timing chain tensioner, installing . . .
transmission shafts, installing . . . . .
valve clearance, adjusting . . . . . . . .
valve clearance, checking . . . . . . . .
valve cover, installing . . . . . . . . . . .
water pump cover, installing . . . . . .
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
assembly
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
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.......
.......
.......
.......
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167,
165,
158,
170,
174,
163,
173,
158,
169,
164,
160,
161,
161,
162,
174,
168,
163,
184
182
175
187
191
180
190
175
186
181
177
178
178
179
191
185
180
.
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.
175, 192
167, 184
161, 178
159, 176
159, 176
160, 177
162, 179
164, 181
173, 190
166, 183
172, 189
171, 188
159, 176
172, 189
172, 189
174, 191
167, 184
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B
Battery
connecting minus cable . .
disconnecting minus cable
installing . . . . . . . . . . . .
recharging . . . . . . . . . . .
removing . . . . . . . . . . . .
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63
63
62
63
62
Brake disc
front brake, changing
front brake, removing
rear brake, installing
rear brake, removing
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55
55
57
57
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..
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.
Brake fluid
front brake, adding .
front brake, changing
rear brake, adding .
rear brake, changing
..
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..
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68
69
74
74
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66
66
71
70
C
Capacity
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
engine oil . . . . . . . . . . . . . . . . . . . . . . . . 89, 201, 206
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Charging voltage
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutch cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clutch lever play
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Coolant
draining
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195-196
Cooling system
filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
D
Disassembling the engine
alternator cover, removing . . . . . . . . . . .
balancer shaft drive wheel, removing . . . .
balancer shaft, removing . . . . . . . . . . . .
camshaft, removing . . . . . . . . . . . . . . .
chain securing guide, removing . . . . . . .
clutch basket, removing . . . . . . . . . . . . .
clutch cover, removing . . . . . . . . . . . . .
crankshaft, removing . . . . . . . . . . . . . . .
cylinder head, removing . . . . . . . . . . . . .
engine oil, draining . . . . . . . . . . . . . . . .
engine, setting to ignition top dead center
gear position sensor, removing . . . . . . . .
left engine case, removing . . . . . . . . . . .
locking lever, removing . . . . . . . . . . . . .
oil filter, removing . . . . . . . . . . . . . . . .
oil pump, removing . . . . . . . . . . . . . . . .
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. 96, 110
. 97, 111
104, 118
. 93, 107
. 91, 105
. 99, 113
. 91, 105
104, 118
. 94, 108
. 90, 104
. 92, 106
. 98, 112
102, 116
101, 115
101, 115
100, 114
INDEX
263
piston, removing . . . . . . . . . . .
preparations . . . . . . . . . . . . .
primary gear, removing . . . . . .
rotor, removing . . . . . . . . . . . .
shift drum locating, removing . .
shift drum, removing . . . . . . . .
shift forks, removing . . . . . . . .
shift rails, removing . . . . . . . .
shift shaft, removing . . . . . . . .
spacer, removing . . . . . . . . . .
spark plug, removing . . . . . . . .
starter drive, removing . . . . . . .
starter motor, removing . . . . . .
timing chain tensioner, removing
transmission shafts, removing .
valve cover, removing . . . . . . .
water pump wheel, removing . .
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..
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. 94, 108
. 90, 104
100, 114
. 96, 110
101, 115
103, 117
103, 117
103, 117
101, 115
. 99, 113
. 91, 105
. 97, 111
. 92, 106
. 93, 107
103, 117
. 91, 105
. 95, 109
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E
Engine
assembling . . . . . . . .
disassembling . . . . . .
installing . . . . . . . . . .
removing . . . . . . . . . .
work on individual parts
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123,
123,
128,
129,
122,
134,
132,
124,
125,
125,
137,
138,
118,
120,
133,
131,
127,
127,
126,
126,
127,
126,
121,
119,
119,
130,
131,
136,
136,
132,
158
. 90
. 85
. 82
118
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20
19
17
15
16
15
143
143
148
149
142
154
152
144
145
145
157
158
138
140
153
151
147
147
146
146
147
146
141
139
139
150
151
156
156
152
Front fender
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Headlight bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Front spoiler
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fuel pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel pump
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuel tank
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel tank cover
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fuse
individual power consumers, changing . . . . . . . . . . . . . 65
H
Headlight adjustment
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
K
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INDEX
264
Kilometers or miles
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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211
. 10
. 10
. 11
. 12
. 11
. 10
O
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
P
Parking light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Passenger seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Play in throttle cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Preparing for use
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
R
Rear hub rubber dampers
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
S
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Service interval display
reinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Shift lever
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Shock absorber
fitting . . . . . . . . . . . . .
removing . . . . . . . . . . .
spring preload, adjusting
spring, installing . . . . .
spring, removing . . . . . .
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30
30
30
31
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 . . . . . . . . .
capacity - engine oil . . . . . . .
capacity - fuel . . . . . . . . . . .
chassis . . . . . . . . . . . . . . . .
chassis tightening torques . . .
electrical system . . . . . . . . .
engine . . . . . . . . . . . . . . . .
engine - tolerance, wear limits
engine tightening torques . . .
fork . . . . . . . . . . . . . . . . . .
shock absorber . . . . . . . . . . .
tires . . . . . . . . . . . . . . . . . .
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206
206
206
207
208
207
203
204
205
208
208
208
Time
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . 212
Wiring diagram
page 1 of 8
page 2 of 8
page 3 of 8
page 4 of 8
page 5 of 8
page 6 of 8
page 7 of 8
page 8 of 8
Work rules
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216-247
216, 232
218, 234
220, 236
222, 238
224, 240
226, 242
228, 244
230, 246
................................... 7
*3206127en*
3206127en
07/2013
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM