990 Supermoto T EU 990 Supermoto T FR 990 Supermoto T AUS/UK 990 Supermoto T USA

REPAIR MANUAL 2011
990 Supermoto T EU
990 Supermoto T FR
990 Supermoto T AUS/UK
990 Supermoto T USA
Art. no. 3206109en
INTRODUCTION 1
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
Only use ORIGINAL KTM SPARE PARTS.
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 will not be 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 specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not form part of the regular scope of delivery.
© 2011 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: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
05/EXHAUST .................................................................... 48
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................ 5

IMPORTANT NOTES ............................................................ 6 Removing the exhaust manifold ...................................... 48
SERIAL NUMBERS.............................................................. 7 Installing exhaust manifold............................................. 50
Chassis number/type label................................................ 7 Removing the main silencer with the distributor pipe ........ 52
Key number .................................................................... 7 Installing the main silencer with the distributor pipe......... 54
Engine number................................................................ 8 06/AIR FILTER.................................................................. 57
Fork part number............................................................. 8 Removing the air filter ................................................... 57
Shock absorber part number............................................. 8 Installing the air filter .................................................... 58
MOTORCYCLE..................................................................... 9 Removing the air filter box ............................................. 59
Raising the motorcycle with the rear wheel stand................ 9 Installing the air filter box .............................................. 60
Taking the motorcycle off of the rear wheel stand ............... 9 07/FUEL TANK, SEAT, TRIM.............................................. 62
Raising the motorcycle with the front wheel stand .............. 9 Opening the filler cap .................................................... 62
Taking the motorcycle off of the front wheel stand .............. 9 Closing the filler cap...................................................... 62
Lifting the motorcycle with the lift stand.......................... 10 Removing the seat ......................................................... 62
Removing the motorcycle from the work stand.................. 10 Mounting the seat ......................................................... 63
Starting ........................................................................ 11 Reinstalling the fuel tank ............................................... 63
Starting the motorcycle to make checks........................... 12 Positioning the fuel tank ................................................ 63
01/FORK, TRIPLE CLAMP.................................................. 13 Removing the fuel tank .................................................. 64
Adjusting the compression damping of the fork ................ 13 Installing the fuel tank ................................................... 65
Adjusting the rebound damping of the fork....................... 13 Changing the fuel filter .................................................. 66
Bleeding the fork legs .................................................... 14 Checking the fuel pressure ............................................. 67
Cleaning the dust boots of the fork legs ........................... 14 08/MASK, FENDER, DECAL ............................................... 69
Removing fork legs ........................................................ 14 Removing the front fender .............................................. 69
Installing the fork legs ................................................... 15 Removing the front fender .............................................. 69
Servicing the fork .......................................................... 17 Removing the mask spoiler ............................................. 69
Disassembling the fork legs ............................................ 17 Installing the mask spoiler.............................................. 70
Checking the fork legs.................................................... 20 09/FRONT WHEEL ............................................................ 71
Assembling the fork legs ................................................ 21 Removing the front wheel ............................................... 71
Checking the steering head bearing play .......................... 26 Installing the front wheel................................................ 71
Removing the lower triple clamp ..................................... 26 Checking the tire air pressure ......................................... 72
Installing the lower triple clamp...................................... 27 Checking the tire condition............................................. 72
Lubricating the steering head bearing.............................. 28 Checking the front brake discs........................................ 73
Adjusting the steering head bearing play.......................... 28 Removing the front brake discs ....................................... 74
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 29 Installing the front brake discs........................................ 74
Adjusting the basic position of the clutch lever................. 29 10/REAR WHEEL .............................................................. 76
Checking the play in the throttle cable............................. 29 Removing the rear wheel ................................................ 76
Adjusting the play in the throttle cable ............................ 29 Installing the rear wheel ................................................. 76
04/SHOCK ABSORBER, SWINGARM................................... 30 Checking the chain tension ............................................ 77
Adjusting the high-speed compression damping of the Adjusting the chain tension ............................................ 78
shock absorber .............................................................. 30 Checking the chain, rear sprocket, engine sprocket and
Adjusting the low-speed compression damping of the chain guide................................................................... 78
shock absorber .............................................................. 30 Cleaning the chain......................................................... 79
Adjusting the rebound damping of the shock absorber....... 31 Checking the rear brake disc........................................... 80
Adjusting the spring preload of the shock absorber ........... 31 Removing the brake disc of the rear brake........................ 80
Removing the shock absorber ......................................... 32 Installing the brake disc of the rear brake ........................ 81
Installing the shock absorber .......................................... 32 Checking rear hub shock absorbers ................................. 81
Servicing the shock absorber .......................................... 33 Changing the rear hub shock absorbers............................ 81
Removing the spring ...................................................... 33 11/WIRING HARNESS, BATTERY ....................................... 83
Disassembling the damper ............................................. 34 Removing the battery ..................................................... 83
Disassembling the piston rod .......................................... 35 Installing the battery...................................................... 83
Disassembling the seal ring retainer ................................ 36 Disconnecting the battery............................................... 84
Changing the pilot bushing............................................. 37 Connecting the battery ................................................... 84
Checking the damper ..................................................... 37 Recharging the battery ................................................... 84
Removing the heim joint ................................................ 38 Changing the main fuse ................................................. 85
Installing the heim joint ................................................. 39 Changing the fuses of individual power consumers............ 86
Assembling the seal ring retainer .................................... 39 Ignition curve plug-in connector...................................... 86
Assembling the piston rod .............................................. 40 Adjusting the ignition curve to the fuel quality.................. 87
Assembling the damper.................................................. 41 13/BRAKE SYSTEM........................................................... 88
Bleeding and filling the damper ...................................... 43 Checking the front brake linings...................................... 88
Filling the damper with nitrogen ..................................... 45 Changing the front brake linings ..................................... 88
Installing the spring....................................................... 46 Adjusting the basic position of the hand brake lever.......... 90
Checking the front brake fluid level ................................. 90
TABLE OF CONTENTS 3
Adding front brake fluid ................................................. 90 Removing the shift drum locating.................................. 141
Changing the front brake fluid ........................................ 91 Removing the locking lever........................................... 141
Checking the rear brake linings ....................................... 92 Removing the gear position sensor ................................ 141
Changing the rear brake linings....................................... 93 Removing the alternator cover....................................... 141
Checking the free travel of the foot brake lever ................. 94 Removing the rotor ...................................................... 142
Adjusting the basic position of the foot brake lever ........... 94 Removing the timing chain of cylinder 2........................ 143
Checking the rear brake fluid level .................................. 95 Removing the oil filter.................................................. 143
Adding rear brake fluid .................................................. 95 Removing the left engine case ...................................... 144
Changing the rear brake fluid.......................................... 96 Removing the crankshaft .............................................. 144
14/LIGHT SYSTEM, INSTRUMENTS ................................... 98 Removing the transmission shafts ................................. 145
Setting kilometers or miles ............................................. 98 Removing the oil pumps............................................... 146
Setting the clock ........................................................... 98 30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 147
Combination instrument - setting/resetting TRIP 1............ 98 Work on the left section of the engine case .................... 147
Combination instrument - setting/resetting TRIP 2............ 98 Work on the right section of the engine case .................. 148
Combination instrument - setting the wheel Removing the left main bearing .................................... 149
circumference ............................................................... 99 Removing the right main bearing................................... 150
Removing the headlight trim........................................... 99 Selecting main bearing shells ....................................... 150
Installing the headlight trim ......................................... 100 Installing the left main bearing ..................................... 151
Removing the headlight ............................................... 101 Installing the right main bearing ................................... 151
Installing the headlight ................................................ 101 Changing the conrod bearing ........................................ 152
Checking the headlight setting...................................... 102 Checking the radial clearance of lower conrod bearing..... 153
Adjusting headlight range............................................. 102 Changing the support bearing of the crankshaft .............. 154
Changing the headlight bulb......................................... 102 Changing the water pump bearing ................................. 155
Changing the parking light bulb .................................... 103 Removing the cylinder head from the cylinder ................ 156
Changing the turn signal bulb ....................................... 104 Checking the oil pressure regulator valve........................ 157
Changing the brake light bulb ....................................... 104 Checking the oil pumps................................................ 157
Changing the tail light bulbs......................................... 107 Cylinder - Nikasil® coating ............................................ 158
Changing the license plate lamp ................................... 109 Work on the cylinder head ............................................ 158
Activating/deactivating the ignition key .......................... 109 Checking the cylinder head .......................................... 159
Activating the immobilizer control unit .......................... 111 Checking/measuring the cylinder................................... 159
30/ENGINE..................................................................... 113 Checking/measuring the piston ..................................... 160
Removing the engine ................................................... 113 Checking the piston/cylinder mounting clearance............ 161
Installing the engine .................................................... 118 Checking the piston ring end gap .................................. 161
30/DISASSEMBLING THE ENGINE................................... 125 Installing the piston..................................................... 161
Clamping the engine into the engine assembly stand ...... 125 Mounting the cylinder head on the cylinder.................... 162
Preparing the engine for disassembly............................. 125 Checking the timing assembly ...................................... 164
Removing the starter motor .......................................... 126 Preassembling the spread transmission.......................... 165
Removing the ignition coils .......................................... 127 Checking the clutch..................................................... 166
Removing the valve cover of cylinder 2 .......................... 127 Checking the shift mechanism ...................................... 167
Removing the valve cover of cylinder 1 .......................... 127 Preassembling the shift shaft........................................ 168
Removing the spark plugs ............................................ 128 Disassembling the main shaft ....................................... 169
Setting the engine to ignition top dead center of Dismantling the countershaft........................................ 169
cylinder 1 ................................................................... 128 Checking the transmission............................................ 170
Removing the camshafts of cylinder 1 ........................... 128 Assembling the main shaft ........................................... 171
Removing the timing chain tensioner of cylinder 1.......... 129 Assembling the countershaft......................................... 172
Removing the timing gears of cylinder 1 ........................ 129 Work on the alternator cover ......................................... 172
Removing the cylinder head of cylinder 1 with cylinder ... 130 Checking the electric starter drive ................................. 174
Setting the engine to ignition top dead center of Checking the freewheel ................................................ 175
cylinder 2 ................................................................... 131
Removing the freewheel ............................................... 175
Removing the camshafts of cylinder 2 ........................... 132
Installing the freewheel ................................................ 175
Removing the timing chain tensioner of cylinder 2.......... 132
30/ASSEMBLING THE ENGINE ........................................ 177
Removing the timing gears of cylinder 2 ........................ 133
Installing the oil pumps ............................................... 177
Removing the cylinder head of cylinder 2 with cylinder ... 133
Installing the transmission shafts .................................. 178
Removing the water pump impeller ............................... 134
Installing the crankshaft............................................... 179
Removing the clutch cover ........................................... 135
Installing the left engine case ....................................... 179
Removing the clutch discs............................................ 135
Installing the oil filter .................................................. 181
Removing the clutch cage ............................................ 136
Installing the timing chain of cylinder 2......................... 182
Removing the spread transmission ................................ 138
Installing the rotor ....................................................... 182
Removing the primary gear ........................................... 139
Installing the alternator cover ....................................... 183
Removing the timing chain of cylinder 1........................ 139
Installing the gear position sensor ................................. 184
Removing the oil pump gear wheel ................................ 140
Installing the locking lever............................................ 184
Removing the shift shaft .............................................. 140
TABLE OF CONTENTS 4
Installing the shift drum locating .................................. 184 Requesting the EFI control unit activation code.............. 221
Installing the shift shaft ............................................... 185 Coding the EFI control unit........................................... 221
Removing the oil pump gear wheel ................................ 185 IMMOBILIZER BLINK CODE............................................. 223
Installing the timing chain of cylinder 1......................... 185 TECHNICAL DATA - ENGINE ............................................ 232
Installing the primary gear............................................ 186 Capacity- engine oil ..................................................... 232
Installing the spread transmission ................................. 187 Capacity - coolant........................................................ 233
Installing the clutch cage ............................................. 187 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
Installing the clutch discs ............................................ 189 ENGINE ......................................................................... 234
Installing the clutch cover ............................................ 190 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 237
Installing the water pump impeller ................................ 192 TECHNICAL DATA - CHASSIS .......................................... 239
Installing cylinder 1 with the cylinder head .................... 192 Lighting equipment ..................................................... 239
Installing the timing gears of cylinder 1 ......................... 194 Capacity - fuel............................................................. 240
Installing the timing chain tensioner of cylinder 1 .......... 194 TECHNICAL DATA - FORK................................................ 241
Installing the camshafts of cylinder 1 ............................ 195 TECHNICAL DATA - SHOCK ABSORBER ........................... 242
Setting the engine to ignition top dead center of TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 243
cylinder 2 ................................................................... 195 CLEANING/CONSERVATION............................................. 245
Installing cylinder 2 with the cylinder head .................... 196 Cleaning motorcycle .................................................... 245
Installing the timing gears of cylinder 2 ......................... 197 Checks and maintenance measures for winter
Installing the timing chain tensioner of cylinder 2 .......... 198 operation .................................................................... 246
Installing the camshafts of cylinder 2 ............................ 198 STORAGE ....................................................................... 247
Checking the valve clearance of cylinder 1 ..................... 199 Storage....................................................................... 247
Adjusting the valve clearance of cylinders 1 ................... 199 Preparing for use after storage ...................................... 247
Setting the engine to ignition top dead center of SERVICE SCHEDULE....................................................... 248
cylinder 2 ................................................................... 199 Service schedule ......................................................... 248
Checking the valve clearance of cylinders 2 ................... 199 WIRING DIAGRAM .......................................................... 250
Adjusting the valve clearance of cylinders 2 ................... 200 Page 1 of 11............................................................... 250
Installing the spark plugs ............................................. 200 Page 2 of 11............................................................... 252
Installing the valve cover of cylinder 1 ........................... 200 Page 3 of 11............................................................... 254
Installing the valve cover of cylinder 2 ........................... 201 Page 4 of 11............................................................... 256
Installing the ignition coils ........................................... 202 Page 5 of 11............................................................... 258
Installing the starter motor ........................................... 202 Page 6 of 11............................................................... 260
Preparing the engine for installation .............................. 202 Page 7 of 11............................................................... 262
Removing the engine from the engine assembly stand..... 204 Page 8 of 11............................................................... 264
32/CLUTCH .................................................................... 205 Page 9 of 11............................................................... 266
Checking/rectifying the fluid level of the hydraulic Page 10 of 11............................................................. 268
clutch ........................................................................ 205 Page 11 of 11............................................................. 270
Changing the hydraulic clutch fluid ............................... 205 SUBSTANCES................................................................. 272
35/WATER PUMP, COOLING SYSTEM .............................. 206 AUXILIARY SUBSTANCES................................................ 274
Draining the coolant .................................................... 206 SPECIAL TOOLS.............................................................. 276
Filling/bleeding the cooling system................................ 206 STANDARDS................................................................... 290
Checking the antifreeze and coolant level ...................... 207 INDEX ............................................................................ 291
Checking the coolant level in the compensating tank ...... 208
38/LUBRICATION SYSTEM .............................................. 210
Oil circuit ................................................................... 210
Checking the engine oil level ........................................ 211
Changing the engine oil and filter, cleaning the oil
screens....................................................................... 211
Draining the engine oil and filter, cleaning the oil
screens....................................................................... 211
Draining the engine oil ................................................. 214
Filling up with engine oil.............................................. 214
Adding engine oil ........................................................ 215
Checking the engine oil pressure................................... 215
Checking the oil jet for the clutch lubrication ................. 216
41/THROTTLE VALVE BODY............................................. 219
Throttle position sensor circuit A - check in zero
position ...................................................................... 219
Throttle position sensor circuit A - adjusting the
position ...................................................................... 219
Removing the throttle valve body................................... 220
Installing the throttle valve body ................................... 220
Flashing the EFI control unit ........................................ 221
MEANS OF REPRESENTATION 5
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name® Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 6
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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage
resulting from manipulation and/or other changes to the vehicle.
Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the repair manual.
Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring mounter (59029019000)
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.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Repair manual
– Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and service your vehicle.
– This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.
SERIAL NUMBERS 7
Chassis number/type label

3.1
The chassis number  is stamped on the frame behind the steering head on the right.
B00664-10
(990 Supermoto T EU, 990 Supermoto T FR, 990 Supermoto T AUS/UK)

Type label  is fitted on the frame tube on the right.
B00660-10
(990 Supermoto T USA)

The type label for the USA  is fitted on the frame tube on the right.
601116-10

The type label for Canada  is fitted on the frame tube on the left.
601115-10
Key number
3.2
The Code number  key number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
Use the orange programming key to activate and deactivate the black ignition
key. Keep the orange programming key in a safe place: it must only be used for
learning and programming functions.
700563-01
SERIAL NUMBERS 8
Engine number
3.3
The engine number  is stamped on the left side of the engine under the engine
sprocket.
B00120-10
Fork part number

3.4
The fork part number  is stamped on the inner side of the fork stub.
B00606-10
Shock absorber part number

3.5
The shock absorber part number  is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
B00607-10
MOTORCYCLE 9
Raising the motorcycle with the rear wheel stand

4.1
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Mount the lifting bushings on the swingarm.

– Insert the adapter in the rear wheel stand.
Adapter (61029055120) ( p. 284)
Rear wheel stand (61029055400) ( p. 285)
– Stand the motorcycle upright, align the wheel stand with the swingarm and the
adapters, and lift the motorcycle.
B00622-01
Taking the motorcycle off of the rear wheel stand

4.2
Note
– Secure the motorcycle against falling over.

– Remove the rear wheel stand and lean the vehicle on the side stand.
– Remove the lifting bushings from the swingarm.
Raising the motorcycle with the front wheel stand

4.3
Note
– Raise the motorcycle with the rear wheel stand. ( p. 9)

– Move the handlebar to the straight-ahead position. Align the front wheel stand with
the fork legs using the adapters.
Front wheel stand (61029055300) ( p. 284)
Info
Always raise the rear of the motorcycle first.
– Raise the front of the motorcycle.
B00623-01
Taking the motorcycle off of the front wheel stand

4.4
Note

– Remove the front wheel stand.
MOTORCYCLE 10
Lifting the motorcycle with the lift stand

4.5
Note
– Remove nut .
– Take off the footrest rubber and holder.
304332-10
– Mount special tool .

Work stand adapter (75029036000) ( p. 286)
– Repeat the operation on the opposite side.
– Mount special tool .
Work stand (62529055000) ( p. 286)
– Place the motorcycle in a vertical position, align the special tool and lift the motor-
cycle.
304333-10
Removing the motorcycle from the work stand

4.6
Note

– Remove the special tool  and .
Work stand (62529055000) ( p. 286)
Work stand adapter (75029036000) ( p. 286)
304333-11
– Position the footrest rubber with the holder.

– Mount nut .
Guideline
Remaining chassis nuts M6 15 Nm
(11.1 lbf ft)
304332-11
MOTORCYCLE 11
Starting
4.7
Danger
Danger of poisoning Exhaust gases are poisonous 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 accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
– Press the emergency OFF switch into the position .

– Switch on the ignition by turning the ignition key to the ON position.
After you switch on the ignition, you can hear the fuel pump working for about
two seconds. The function test of the combination instrument is run at the
same time.
The ABS warning lamp lights up and goes back out after starting off.
– Shift the transmission to neutral.
The green idling speed indicator lamp N  lights up.
B00650-10 – Press the electric starter button .
Info
Do not press the electric starter button until the function test of the combi-
nation 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.
– Take the weight off the side stand and swing it upwards with your foot as far as it
will go.
Switching off ABS
KTM recommends riding with ABS at all times. However, situations may arise in
which ABS is not advantageous.
Condition
Vehicle stationary, engine running.
– Press button  for 3 - 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
400886-11
MOTORCYCLE 12
Starting the motorcycle to make checks

4.8
Danger
Danger of poisoning Exhaust gases are poisonous 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.

The green idling speed indicator lamp N  lights up.
– Switch on the ignition.
– Press the electric starter button .
Info
Do not open the throttle.
B00650-10
01/FORK, TRIPLE CLAMP 13
Adjusting the compression damping of the fork

5.1
Info
The hydraulic compression damping determines the fork suspension behavior.
An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or
when the load shifts very fast. It gives the rider good feedback about the road conditions.
– Turn adjusting screws  clockwise all the way.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
B00617-10 Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Full payload 15 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Adjusting the rebound damping of the fork

5.2
Info
The hydraulic rebound damping determines the fork rebound behavior.
An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to
the zero position.
– Turn adjusting screws  clockwise all the way.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
B00618-10 Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
ing.
Bleeding the fork legs

5.3
– Lean the motorcycle on the side stand.

– Remove bleeder screws  briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten the bleeder screws.
Info
Carry out this operation on both fork legs.
B00621-10
Cleaning the dust boots of the fork legs

5.4
– Push dust boot  of both fork legs downwards.
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 accidents Reduced braking efficiency due to oil or grease on the
304297-10 brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
– Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 275)
– Press the dust boots back into their normal position.
– Remove excess oil.
Removing fork legs

5.5
– Lift the motorcycle with the lift stand. ( p. 10)

– Clamp down the rear of the vehicle.
– Remove the front fender. ( p. 69)
– Remove the mask spoiler. ( p. 69)
– Remove the screws  from both brake calipers.
– Press back the brake linings with a light lateral tilting of the brake calipers on the
brake disc. Pull the brake caliper carefully back from the brake discs and hang it to
the side.
Info
Do not pull the hand brake lever when the brake calipers are removed.
304334-10
– Take the speed sensor cable out of the clamp .

– Remove screw .
304335-10
– Pull the wheel speed sensor with sleeve  out of the hole.
304336-10
– Loosen screws  and .

– Unscrew screw  about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking efficiency due to damaged brake
discs.
– Always lay down the wheel in such a way that the brake discs are not
damaged.
304337-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Unscrew screw . Remove the fork legs downward.
304341-10
Installing the fork legs

5.6
Warning
Danger of accidents Modifications 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.
– Push the fork legs into the triple clamps.

– Align the fork leg in the desired position by means of the fork rings.
304342-10
– Tighten screws .
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
– Fully tighten screws .
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
304341-11
– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Replace the wheel bearing.
– Clean and grease the shaft seal rings  and mating surfaces  of the spacers.
Long-life grease ( p. 274)
304339-10
– Insert the wide spacer on the left-hand side  (when looking in the direction of
travel).
– Insert the narrow spacer on the right-hand side (when viewed in the direction of
travel).
304338-10
– Clean screw  and the wheel spindle.

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
The arrow on the spoke points in the direction of motion.
– Mount and tighten screw .
Guideline
Bolt, front axle M25x1.5 45 Nm
(33.2 lbf ft)
– Slide sleeve onto the wheel speed sensor and push them into the hole together.
304340-10
Mount and tighten screw .
Guideline
Screw, wheel speed sensor M6 6 Nm Loctite® 243™
(4.4 lbf ft)
– Fasten the speed sensor cable in the bracket .
– Position the brake calipers and check that the brake linings are seated correctly.
– Mount screws  on both brake calipers but do not tighten them yet.
– 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 acti-
vated position.
The brake calipers straighten.
– Tighten screws  on both brake calipers.
Guideline
304334-11 Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
– Release the fixation of the hand brake lever.
– Release the rear of the vehicle.
– Remove the motorcycle from the work stand. ( p. 10)
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
– Install the mask spoiler. ( p. 70)
– Remove the front fender. ( p. 69)
304343-10
Servicing the fork

5.7
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.
– Disassemble the fork legs. ( p. 17)
– Check the fork legs. ( p. 20)
– Assemble the fork legs. ( p. 21)
201240-01
Disassembling the fork legs

5.8
Info
Condition
The fork legs have been removed.
– Determine and note down the current setting of rebound damping  and compres-
sion damping .
– Completely open the adjusting elements of the rebound and compression damping.
– Determine and note down the current setting of spring preload .
– Completely open the adjusting elements of the spring preload.
201316-10
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 288)
200643-10
– Release Preload Adjuster .

Pin wrench (T103) ( p. 286)
Info
The Preload Adjuster cannot be removed yet.
201317-10
– Unclamp the fork leg and clamp it with the axle clamp.
Info
Use soft jaws.
201318-10
– Slide the outer tube down.

– Pull the spring downwards. Mount the special tool on the hexagonal piece.
Open-end wrench (T14032) ( p. 288)
Info
The preload spacers  should be above the special tool.
201319-10
– Clamp the special tool in the vise. Release Preload Adjuster .
200647-12
– Remove Preload Adjuster  with preload spacers .

– Remove adjusting tube .
201320-10
– Pull the spring downwards. Remove the special tool.

– Remove the spring.
200649-01
– Drain the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.
200650-01
– Clamp the fork leg with the axle clamp.

– Remove screws  of the axle clamp.
201321-10
– Loosen screw  of the cartridge and remove it with the sealing ring.
Info
Place a container underneath to catch any oil that may run out.
201322-10
– Remove the cartridge.
200653-01
– Remove valve  of the rebound damping with the spring from the cartridge.
200654-12
– Remove dust boot .
200655-12
– Remove lock ring .
Info
The lock ring has a beveled end where a screwdriver can be applied.
200656-12
– Heat up the outer tube in area  of the lower sliding bushing.

Guideline
50 °C (122 °F)
– Pull the fork outer tube with a jerk from the inner tube.
Info
The lower sliding bushing  must be pulled from its bearing seat.
201323-10
– Remove the upper sliding bushing .
Info
Without using a tool, carefully pull the stack apart by hand.
200658-12
– Take off the lower sliding bushing .

– Take off support ring .
– Take off seal ring .
– Take off lock ring .
– Take off dust boot .
200659-12
Checking the fork legs

5.9
Condition
The fork legs must be disassembled.
– Check the inner tube and axle clamp for damage.
» If there is damage:
– Change the inner tube.
201330-10
– Measure the outside diameter at several locations on the inner tube.

Outside diameter of inner tube 47.975… 48.005 mm (1.88878…
1.88996 in)
» If the measured value is less than the specified value:
200684-10
– Measure the run-out of the inner tube.

Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in)
» If the measured value is greater than the specified value:
200685-10
– Check the outer tube for damage.

» If there is damage:
– Change the outer tube.
200632-10
– Check the surface of the sliding bushings.

» If the bronze-colored layer  under the sliding layer  is visible:
– Replace the sliding bushings.
200665-10
– Check the spring length.

Guideline
Spring length with preload spacer(s) 384 mm (15.12 in)
– Reduce the thickness of the preload spacer.
» If the measured value is less than the specified value:
– Increase the thickness of the preload spacer.
200666-10
Assembling the fork legs

5.10
Info
– Check the fork legs. ( p. 20)

– Clamp the inner tube with the axle clamp.

– Install the special tool.
Protecting sleeve (T1401) ( p. 288)
– Grease and push on dust boot .
Lubricant (T511) ( p. 274)
Info
200669-10 Always replace the dust boot, seal ring, lock ring, and support ring.
Install the dust boot with the sealing lip and spring expander facing down-
ward.
– Push on lock ring .

– Grease and push on seal ring .
Info
Sealing ring downward, open side upward.
– Push on support ring .

– Remove the special tool.
– Sand the edges of the sliding bushes with 600-grain sandpaper, then clean and
grease them.
Fork oil (SAE 5) ( p. 273)
200670-10
– Push on the lower sliding bushing .

– Mount the upper sliding bushing .
Info
Without using a tool, carefully pull the stack apart by hand.
200671-10
– Push on the outer tube.

– Heat up the outer tube in area  of the lower sliding bushings.
Guideline
50 °C (122 °F)
– Hold the lower sliding bushing with the longer side of the special tool.
Assembly tool (T1402S) ( p. 288)
– Press on the outer tube as far as it will go.
201324-10
– Position the support ring.

– Hold the seal ring with the shorter side of the special tool.
– Press on the outer tube as far as it will go.
201325-10
– Mount lock ring .
Info
The lock ring must engage audibly.
200656-11
– Install dust boot .
200655-11
– Grease the O-ring of valve  of the rebound damping.

– Mount valve  of the rebound damping with the spring on adjusting tube .
– Mount valve  of the rebound damping from below in cartridge .
The adjusting tube protrudes 5 mm (0.197 in) from the cartridge and can be
pressed in against the resistance of the spring.
The adjusting tube protrudes more than 7 mm (0.275 in) from the cartridge
and cannot be pressed in against the resistance of the spring.
Screw on fluid barrier  as far as it will go.
200674-10
–
Info
The fluid barrier must be tightened as much as possible. Do not use tools.
– Install the special tool on the cartridge.

Support tool (T14026) ( p. 288)
Info
The special tool must be used to prevent the adjusting tube from being
raised, which would cause oil to enter into the piston rod.
200675-10
– Pull the rebound valve  out of the cartridge until it hits the stop.
201327-10
– Push the cartridge with the spring seat and preload spacer into the inner tube.
– Mount screw  of the cartridge with the seal ring and tighten it.
Guideline
Screw, cartridge M12x1 25 Nm
(18.4 lbf ft)
201326-10
– Grease and mount screws  of the axle clamp but do not tighten.
201321-11
– Clamp the fork vertically.

– Add fork oil.
Fork oil per fork 737 ml Fork oil (SAE 5) ( p. 273)
leg (24.92 fl. oz.)
Info
Pull out the piston rod and push back in a number of times to bleed the car-
tridge.
200677-10
– Remove pin  of the special tool.

– Pull out the piston rod. Mount the spring. Mount the spring again.
Guideline
Spring rate
Soft 6.5 N/mm (37.1 lb/in)
Medium (standard) 7.0 N/mm (40 lb/in)
200678-12 Hard 7.5 N/mm (42.8 lb/in)
– Pull the spring downwards. Mount the special tool on the hexagonal piece.
Open-end wrench (T14032) ( p. 288)
200679-10
– Clamp the special tool in the vise.

– Lubricate the thread of the piston rod.
– Lubricate the upper edge of the piston rod.
– Screw the Preload Adjuster with the preload spacers onto the piston rod.
201328-10
Info
The Preload Adjuster must reach the stop before the piston rod begins turn-
ing as well. If the piston rod thread is stiff, the rod must be held to prevent
it from turning. If the Preload Adjuster is not screwed in all the way, the
rebound adjustment will not function properly.
– Tighten Preload Adjuster.

Guideline
Screw cover on piston rod M12x1 25 Nm
(18.4 lbf ft)
– Release the special tool. Pull the spring downward and take off the special tool.
200646-11
– Push the outer tube upward.

– Clamp the fork in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 288)
– Lubricate the O-ring of the Preload Adjuster.
– Screw on the Preload Adjuster and tighten.
Guideline
201329-10
Screw cover on outer tube M51x1.5 50 Nm
(36.9 lbf ft)
Alternative 1
– Turn the adjusting screw of rebound damping  and the adjusting screw of
compression damping  clockwise as far as possible.
– Turn back counterclockwise by the number of clicks corresponding to the fork
leg type.
Guideline
Rebound damping
Comfort 25 clicks
201316-11 Standard 20 clicks
Sport 15 clicks
Compression damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
– Turn spring preload  clockwise all the way.
– Turn back counterclockwise by the number of turns corresponding to the fork
leg type.
Guideline
Spring preload - Preload Adjuster
Comfort 5 turns
Standard 5 turns
Sport 3 turns
Full payload 3 turns
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.
– Return the adjusting screws to the position determined when the unit was dis-
assembled.
Checking the steering head bearing play

5.11
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
– Adjust the steering head bearing play without delay.
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and subsequently the bearing
seats in the frame are damaged.

– Move the handlebar to the straight-ahead position. Move the fork legs back and
forth in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is no detectable play:
– Adjust the steering head bearing play. ( p. 28)
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire steering range.
400738-11
There should be no detectable detent positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 28)
– Check the steering head bearing and adjust if necessary.
Removing the lower triple clamp

5.12
– Remove the fork legs. ( p. 14)

– Remove screws .
– Hang the brake lines carefully to the side.
Info
Do not damage the brake lines.
304346-10
– Remove screw . Release screw , remove the upper triple clamp with the han-
dlebar and set aside.
Info
Protect the motorcycle and attachments against damage by covering them.
Do not kink cables and lines.
304347-10
– Remove protective ring .
304348-10
– Remove O-ring .
– Take out the lower triple clamp with the steering stem.
– Take out the upper steering head bearing.
304349-10
Installing the lower triple clamp

5.13
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 274)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
– Check that the upper steering head seal  is positioned correctly.
– Slide on O-ring .
304349-11
– Mount protective ring .
304348-11
– Position the upper triple clamp with the handlebar.
Info
Ensure that the throttle cable, the other cables, and the lines are correctly
routed.
– Mount and tighten screw .

Guideline
Screw, steering head M20x1.5 12 Nm (8.9 lbf ft)
304347-11
– Position the brake lines.

– Mount and tighten screws .
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
– Install the fork legs. ( p. 15)
304346-11
– Tighten screw .
Guideline
Screw, steering stem M8 20 Nm
(14.8 lbf ft)
– Check that the wiring harness, cables, and brake and clutch lines are free to move
and correctly routed.
– Check the steering head bearing play. ( p. 26)
304345-10
Lubricating the steering head bearing

5.14
– Remove the lower triple clamp. ( p. 26)

– Install the lower triple clamp. ( p. 27)
303848-10
Adjusting the steering head bearing play

5.15

– Loosen screws  and .
– Loosen and retighten screw .
Guideline
Screw, steering head M20x1.5 12 Nm (8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Guideline
304344-10 Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
– Tighten screw .
Guideline
Screw, steering stem M8 20 Nm
(14.8 lbf ft)
– Check the steering head bearing play. ( p. 26)
02/HANDLEBAR, CONTROLS AND INSTRUMENTS 29
Adjusting the basic position of the clutch lever

6.1
Info
Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
– Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
– When adjusting the clutch lever, make sure that there is a minimum clearance to
other parts of the vehicle.
Guideline
Minimum clearance 5 mm (0.2 in)
B00608-12
Checking the play in the throttle cable

6.2
– Check the throttle grip for smooth operation.

– Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable. ( p. 29)
Danger
400192-10 Danger of poisoning Exhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
– Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. ( p. 29)
Adjusting the play in the throttle cable

6.3
– Move the handlebar to the straight-ahead position.

– Use the KTM diagnostics tool to set the throttle stepper motor to the basic position.
– Push back sleeve .
– Loosen lock nut .
– Set the play in the throttle cable by turning adjusting screw .
Guideline
B00666-10 – Tighten lock nut .

– Slide on sleeves .
– Check the throttle grip for ease of movement.
04/SHOCK ABSORBER, SWINGARM 30
Adjusting the high-speed compression damping of the shock absorber

7.1
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw  clockwise all the way using a socket wrench.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed
B00619-11
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Info
ing.
Adjusting the low-speed compression damping of the shock absorber

7.2
Caution
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible

click.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
B00619-10 Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
ing.
Adjusting the rebound damping of the shock absorber

7.3
Caution
– Turn adjusting screw  clockwise up to the last perceptible click.

absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
B00620-10
Info
ing.
Adjusting the spring preload of the shock absorber

7.4
Warning
Danger of accidents Modifications 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.
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
– Take the weight off the rear wheel and swingarm.
Info
The spring preload can be adjusted correctly only if the rear wheel and the
swingarm are fully relieved of weight.
– Loosen retaining ring .

– Turn adjusting ring  until the spring is no longer under tension.
Hook wrench (T157S) ( p. 289)
– Measure the overall spring length without a load.
– Tension the spring by turning adjusting ring  to the prescribed value.
Guideline
Spring preload
B00619-12 Comfort 10 mm (0.39 in)
Standard 10 mm (0.39 in)
Sport 10 mm (0.39 in)
Full payload 12 mm (0.47 in)
– Tighten retaining ring .
Removing the shock absorber

7.5

– Remove the main silencer with the distributor pipe. ( p. 52)
– Remove cover .
– Remove cover .
304350-10
– Hold the rear wheel with the swingarm and remove screw .
– Lower the rear wheel with the swingarm.
Info
Ensure that the chain and brake line are not damaged.
304351-10
– Remove screw .
– Remove the shock absorber toward the rear.
304352-10
Installing the shock absorber

7.6
– Position the shock absorber.

– Mount screw  but do not tighten them yet.
304352-11
– Lift the rear wheel with the swingarm and position the shock absorber.
– Mount and tighten screw .
Guideline
Screw, bottom shock M14x1.5 80 Nm Thread greased
absorber (59 lbf ft)
– Mount and tighten screw .
Guideline
Screw, top shock absorber M14x1.5 80 Nm Thread greased
304351-11
(59 lbf ft)
– Mount covers  and .

– Install the main silencer with the distributor pipe. ( p. 54)
304350-11
Servicing the shock absorber

7.7
Caution
Condition
The shock absorber has been removed.
– Remove the spring. ( p. 33)
– Disassemble the damper. ( p. 34)
– Disassemble the piston rod. ( p. 35)
– Disassemble the seal ring retainer. ( p. 36)
– Check the damper. ( p. 37)
– Remove the heim joint. ( p. 38)
– Install the heim joint. ( p. 39)
– Assemble the seal ring retainer. ( p. 39)
– Assemble the piston rod. ( p. 40)
– Assemble the damper. ( p. 41)
– Bleed and fill the damper. ( p. 43)
– Fill the damper with nitrogen. ( p. 45)
– Install the spring. ( p. 46)
201469-01
Removing the spring

7.8
Condition
– Clamp the shock absorber into the vice with soft jaws.
– Measure and note the spring length while the spring is under tension.
– Release retaining ring .
– Turn adjusting ring  until the spring is fully relaxed.
201044-10
– Remove spring retainer  and washer .

– Remove the spring.
201011-10
– Remove retaining ring  and adjusting ring  with the washer.
201045-10
Disassembling the damper

7.9
– Remove the spring. ( p. 33)

– Note down the current state of the rebound  and compression damping .
– Completely open the adjusting elements of the rebound and compression damping.
201014-11
– Remove rubber cap  of the reservoir.

– Slowly open screw .
The nitrogen pressure dissipates.
201015-10
– Remove locking cap .
201016-10
– Push in seal ring retainer .

– Remove lock ring .
Info
Do not scratch the inside surface.
– Unclamp the damper.
201017-10
– Remove screw . Let the oil drain. Mount the screw again.
201018-10
– Remove the piston rod. Drain the remaining oil.
201019-10
– Remove compression adjuster . Remove the spring and piston.
201020-10
Disassembling the piston rod

7.10
– Disassemble the damper. ( p. 34)

– Clamp the piston rod in a vise.
– Remove screw  with washer .
201021-10
– Remove nut .
– Remove supporting plate .
201022-10
– Remove rebound shim stack .
Info
Slip the rebound shim stack onto a screwdriver and set the shims down
together.
– Remove piston .
201023-10
– Remove the compression shim stack .
Info
Slip the compression shim stack onto a screwdriver and set the shims down
together.
– Remove rebound washer .
201024-10
– Remove seal ring retainer .

– Remove locking cap  and rubber buffer .
201025-10
Disassembling the seal ring retainer

7.11
– Disassemble the piston rod. ( p. 35)

– Remove O-ring .
– Remove dust boot .
200981-10
– Remove rebound rubber .

– Remove centering disk .
200982-10
– Remove washer .
– Remove seal ring .
– Remove washer .
200983-10
Changing the pilot bushing

7.12
– Disassemble the seal ring retainer. ( p. 36)

– Press pilot bushing  out of seal ring retainer  using the special tool.
Press drift (T1504) ( p. 289)
200986-10
– Slide the new pilot bushing  onto the special tool.

– Position the pilot bushing in the seal ring retainer with the special tool.
– Support seal ring retainer  with sleeve  of the special tool. Press the pilot bush-
ing all the way in.
200797-10
– Lubricate the special tool.

Fork oil (SAE 5) ( p. 273)
Calibration pin (T1205) ( p. 287)
– Support seal ring retainer  with sleeve  of the special tool.
– Press the special tool through the new pilot bushing.
200798-10
Calibration pin (T1205) ( p. 287)
The pilot bushing is calibrated.
Checking the damper

7.13
Condition
The damper has been disassembled.
– Measure the inside diameter at both ends and in the middle of the damper car-
tridge.
Damper cartridge
Minimum diameter 46.10 mm (1.815 in)
– Change the damper cartridge.
– Check the damper cartridge for damage and wear.
201026-10 » If there is damage or wear:
– Change the damper cartridge.
– Check the heim joint for damage and wear.
» If there is damage or wear:
– Change the heim joint.
– Measure the diameter of the piston rod.
Piston rod
Diameter ≥ 17.95 mm (≥ 0.7067 in)
» If the specified value is not reached:
– Change the piston rod.
– Measure the run-out of the piston rod.
Piston rod
201027-10
Run-out ≤ 0.03 mm (≤ 0.0012 in)

– Check the piston rod for damage and wear.
Removing the heim joint

7.14
Info
The operations are the same for the upper and lower heim joints.
Condition
– Clamp the shock absorber into the vice with soft jaws.
– Remove both collar bushings  of the heim joint with a drift.
Pin (T120) ( p. 287)
200906-10
– Remove seal rings  on both sides.
200907-10
– Press heim joint  aside.

Pressing tool (T1207S) ( p. 287)
The heim joint is resting against one lock ring.
– Remove the other lock ring .
200908-10
– Place special tool  underneath and push out the heim joint with special tool .
200909-10
Installing the heim joint

7.15
Info
The operations are the same for the upper and lower heim joints.
– Place special tool  underneath and press in the heim joint as far as the lock ring
using special tool .
Pressing tool (T1206) ( p. 287)
200911-10
– Mount the second lock ring .

– Mount and grease seal rings  on both sides.
200912-10
– Push in both collar bushings of the heim joint.
201028-10
Assembling the seal ring retainer

7.16
– Position washer .
– Grease and mount seal ring .
– Mount washer .
200984-10
– Mount centering disk .

– Mount rebound rubber .
200985-10
– Grease the nut of the O-ring.

– Mount the O-ring .
– Grease the sealing lip of the dust boot.
– Install dust boot .
200981-11
Assembling the piston rod

7.17

– Clamp the piston rod with the fork in a vise.
– Mount rubber buffer plug  and locking cap .
– Position special tool on the piston rod.
Mounting sleeve (T1515) ( p. 289)
– Grease the dust boot and push seal ring retainer  on to the piston rod.
201029-10
– Mount rebound washer  with cut-out  facing down.

– Mount compression shim stack  with the smaller shims at the bottom.
201030-10
– Sand both sides of piston  on a surface plate using grain 1200 sandpaper.
– Clean the piston.
– Mount the piston.
Guideline
View  Piston from above
View  Piston from below
201031-10
– Mount rebound shim stack  with the smaller shims at the top.
– Mount supporting plate .
201032-10
– Mount and tighten nut .

Guideline
Nut, piston rod M12x1 40 Nm
(29.5 lbf ft)
– Mount washer .
201033-10
– Mount and tighten screw .

Guideline
Screw, piston rod M6x0.5 6 Nm Loctite® 2701
(4.4 lbf ft)
201034-10
Assembling the damper

7.18
– Assemble the piston rod. ( p. 40)

– Slide the spring and piston onto the compression adjuster .
– Lubricate the O-rings.
– Lubricate the thread.
– Mount and tighten the compression adjuster.
Guideline
201035-10
Compression adjuster M31x1 50 Nm
(36.9 lbf ft)
– Mount screw  but do not tighten yet.
201018-11
– Lubricate O-ring of the seal ring retainer.

– Fill the damper cartridge about half full.
Shock absorber oil (SAE 2.5) (50180342S1) ( p. 273)
– Carefully mount the piston rod.
201019-10
– Mount seal ring retainer  and slide it under the ring groove.
– Mount lock ring .
Info
Do not scratch the inside surface.
– Pull out the piston rod until the seal ring retainer rests against the lock ring.
201017-11
– Mount locking cap  of the damper cartridge.

– Bleed and fill the damper. ( p. 43)
– Fill the damper with nitrogen. ( p. 45)
201036-10
– Mount rubber cap  of the reservoir.
201037-10
Alternative 1
– Turn adjusting screw  clockwise up to the last perceptible click.
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
201014-10 Sport 10 clicks
– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible
click.
absorber type.
Guideline
Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
– Turn adjusting screw  clockwise all the way using a socket wrench.
– Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Alternative 2
Warning
new ride behavior.
– Turn adjusting screws ,  and  to the position determined during disas-

sembly.
Bleeding and filling the damper

7.19
Info
Before working with the vacuum pump, carefully read the operating manual included with the vacuum pump.
Completely open the adjusting elements of the rebound and compression damping.
– Remove the filling port screw.

– Mount adapter  on the damper.
Info
Hand-tighten only without using a tool.
– Connect adapter  to connector  of the vacuum pump.

Vacuum pump (T1240S) ( p. 287)
201038-10 – Clamp the damper with soft jaws or hold it as shown in the photo.
Info
Clamp the damper only lightly.
The filling port must be located at the highest position.
The piston rod moves in and out during filling; do not immobilize it by hold-
ing it with your hand.
– Position the control lever as shown in the photo.

Control lever External tank  is set to Closed, Damper  is set to Vacuum and
Oil reservoir  is set to Vacuum.
– Activate On/Off switch .
The suction process begins.
Pressure gauge  drops to the required value.
< 0 bar
200271-10
Vacuum gauge  drops to the required value.
4 mbar
– Determine distance  between the floating piston and reservoir hole with the spe-
cial tool.
Depth micrometer (T107S) ( p. 286)
The floating piston is positioned all the way at the bottom.
201039-10
– When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir  to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.
0 bar
200267-10
– When the pressure gauge reaches the required value, turn control lever Damper 
to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
3 bar
200268-10
to Vacuum.
Guideline
3 bar
The pressure gauge drops to the required value.
0 bar
200269-10
– When the pressure gauge reaches the required value, turn control lever Oil reser-
voir  to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.
8 mbar
200270-10
– When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir  to Equalize Pressure.
Guideline
8 mbar
0 bar
200267-10
to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
3 bar
200268-10
to Vacuum.
Guideline
3 bar
0 bar
– When the pressure gauge reaches the required value, activate the On/Off switch.
200269-10 Guideline
0 bar
The vacuum pump is switched off.
– Slide O-ring  to the end of the special tool by the specified value (distance 
minus specified value).
Guideline
10 mm
Depth micrometer (T107S) ( p. 286)

– Push the floating piston into the reservoir to the distance described above using the
special tool.
201040-10
Info
When the piston rod is fully extended, the floating piston must be at pre-
cisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.

– Remove adapter  from connector  of the vacuum pump.
Info
Hold the damper so that the filling port is at the highest location.
– Remove the adapter.

– Mount and tighten screw .
Guideline
Screw, filling port M10x1 14 Nm
201041-10 (10.3 lbf ft)
Filling the damper with nitrogen

7.20
– Screw in screw  by approx. 2 turns but do not tighten.
Info
The piston rod is fully extended.
201042-10
– Fix the special tool in the vise.

Nitrogen filling tool (T170S1) ( p. 289)
– Connect the special tool to the pressure regulator of the filling cylinder.
Filling gas - nitrogen
– Adjust the pressure regulator.
Guideline
Gas pressure 10 bar (145 psi)
201043-10
– Position the damper in the special tool.
The hexagonal part of the tap handle  engages in the hexagon socket of the
filling port screw.
– Open filler tap .

– Fill the damper for at least 15 seconds.
Guideline
Info
Watch the pressure regulator dial.
Ensure that the damper is filled to the specified pressure.
– Close the filling port screw using tap handle .

– Close tap  and take the damper out of the special tool.
– Tighten the filling port screw.
Guideline
Screw, filling port, reservoir M5 3.5 Nm
(2.58 lbf ft)
Installing the spring

7.21
– Screw on retaining ring  and adjusting ring  with the washer.
201045-10
– Measure the overall spring length without a load.

– Position the spring.
Guideline
Spring rate
Soft 140 N/mm (799 lb/in)
Medium (standard) 150 N/mm (857 lb/in)
– Mount washer  and spring retainer .
201013-11 Alternative 1
– Tension the spring by turning the adjusting ring to the prescribed value.
Guideline
Spring preload
Comfort 10 mm (0.39 in)

Alternative 2
Warning
new ride behavior.
– Adjust the spring to the value determined when it was removed by turning the
adjusting ring.
– Hold adjusting ring  and tighten retaining ring .

201044-10
05/EXHAUST 48
Removing the exhaust manifold

8.1
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down. Do not touch hot components.

– Remove the fuel tank. ( p. 64)
– Remove the cover.
304361-10
– Disconnect plug .
– Expose the lambda sensor cable.
304362-10
– Disconnect plug .
304363-10
– Remove screws .
304364-10
– Disconnect plug .
304365-10
05/EXHAUST 49
– Remove screws .
– Remove nut .
– Expose the cables of the lambda sensor and the side stand.
– Remove the side stand bracket.
304366-10
– Release the exhaust clamp.
304367-10
– Release exhaust clamp .
304368-10
– Remove nuts .
– Remove distance sleeve .
304369-10
– Remove nuts .

– Remove the distance sleeve.
304370-10
– Remove fitting .

– Take off the exhaust manifold.
304371-10
05/EXHAUST 50
Installing exhaust manifold

8.2
– Position the exhaust manifold.

– Mount fitting  but do not tighten yet.
Guideline
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
304371-11
– Mount the distance sleeve.

– Mount nuts  but do not tighten them yet.
Guideline
Nut, manifold on cylinder head M8 Tightening
sequence:
Tighten the nuts
uniformly. Do not
bend the metal.
304370-11
– Mount the distance sleeve.

– Mount and tighten nuts .
Guideline
sequence:
Tighten the nuts
uniformly. Do not
bend the metal.
304369-11 – Tighten nuts .

Guideline
sequence:
Tighten the nuts
uniformly. Do not
bend the metal.
– Position and tighten exhaust clamp .
Guideline
(18.4 lbf ft)
304368-11
– Position and tighten exhaust clamp .

Guideline
Screw, exhaust clamp on distributor M8 35 Nm
pipe (25.8 lbf ft)
– Tighten fitting .
Guideline
(18.4 lbf ft)
304367-11
05/EXHAUST 51
– Position the lambda sensor cable.

– Position the side stand bracket.
– Mount and tighten screws .
Guideline
Screw, side stand bracket M10 45 Nm Loctite® 243™
(33.2 lbf ft)
– Mount and tighten the nut .
Guideline
304366-10
Screw connection, engine mounting M10 45 Nm
bracket (33.2 lbf ft)
– Position the side stand cable.
– Plug in connector .
304365-11
– Position the cover.

– Mount and tighten screws .
Guideline
304364-11
– Plug in connector .

– Attach the cables of the lambda sensor and the side stand with cable binders.
304363-11
– Position the lambda sensor cable.

– Plug in connector .
– Attach the lambda sensor cable with cable binders.
304362-11

– Mount and tighten screws .
Guideline
– Install the fuel tank. ( p. 65)
304361-11
05/EXHAUST 52
Removing the main silencer with the distributor pipe

8.3
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down. Do not touch hot components.
– Remove the seat. ( p. 62)

– Release nuts .
– Fold both turn signals down.
304353-10
– Remove screws .
– Remove the grab handles.
304354-10
– Remove screws  on the left and right heat protectors.

– Remove the heat protectors.
304355-10
05/EXHAUST 53
– Remove screws  on the left and right rear side part.

– Remove screws .
– Remove the rear side parts.
304356-10
304357-10
– Remove screws .
– Remove screws .
– Slip out the side part carrier with the exhaust clamp toward the rear.
304358-10
– Loosen screw .
304359-10
05/EXHAUST 54
– Remove screws .

– Take off the main silencer with the distributor pipe.
304360-10
Installing the main silencer with the distributor pipe

8.4
– Position the main silencer with the distributor pipe.

– Mount screws  but do not tighten them yet.
Guideline
(18.4 lbf ft)
304360-11
– Position the side part carrier with the exhaust clamp.

– Mount screws  and  but do not tighten yet.
Guideline
Screw, exhaust clamp on main silencer M8 20 Nm
(14.8 lbf ft)
304358-11
05/EXHAUST 55
– Mount and tighten screws .

Guideline
(18.4 lbf ft)
304357-11
– Fully tighten screws .

Guideline
Screw, exhaust clamp on main silencer M8 20 Nm
(14.8 lbf ft)
– Fully tighten screws .
Guideline
Guideline
(18.4 lbf ft)
305043-10
– Position and tighten exhaust clamp .

Guideline
Screw, exhaust clamp on distributor M8 35 Nm
pipe (25.8 lbf ft)
304359-11
– Position the rear side parts.

Guideline
Remaining frame bolts EJOT PT K50x12 1.2 Nm
T20 (0.89 lbf ft)
– Mount and tighten screws  on the left and right rear side part.
Guideline
Screw, rear side part EJOT Altracs Initial screw con-
50x16 nection
3.3 Nm
(2.43 lbf ft)
Subsequent screw
connection
2 Nm (1.5 lbf ft)
304356-11
05/EXHAUST 56
– Position the heat protectors.

– Mount and tighten screws  on the left and right heat protectors.
Guideline
Screw, bag carrier M8 15 Nm Loctite® 243™
(11.1 lbf ft)
304355-11
– Position the grab handles.

Guideline
Screw, handrail M8 20 Nm
(14.8 lbf ft)
304354-11
– Position the turn signal.

– Mount and tighten nuts .
– Mount the seat. ( p. 63)
304353-11
06/AIR FILTER 57
Removing the air filter

9.1
Note
Engine failure Unfiltered 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.

– Push back spring band clamps .
Pliers for spring band clamp (60029057100) ( p. 283)
– Pull off engine vent hoses and remove the spring band clamps.
304372-10
– Remove the cable binder and detach connector .
304373-10
– Remove screws .
Info
The screws stay in the air filter box lid.
– Take off air filter box lid.
Info
Pay attention to the engine vent hoses.
304374-10
– Turn intake trumpet  counterclockwise and remove it.
304375-10
– Remove air filter .

– Clean the air filter box.
304376-10
06/AIR FILTER 58
Installing the air filter

9.2
– Position air filter .
304376-11
– Mount intake trumpet .
304375-11
– Position the air filter box lid.

– Fully tighten screws .
304374-10
– Plug in connector  and secure with a cable binder.
304373-11
– Mount the engine vent hoses with hose clips .

304372-11
06/AIR FILTER 59
Removing the air filter box

9.3
– Remove the air filter. ( p. 57)

– Loosen screws .
Info
The screws stay in the intake flange.
– Remove the intake flange.
304377-10
– Pull manifold absolute pressure sensor  from the holder and hang to one side.
– Remove the side panel.
304378-10
– Pull connector  off of the holder and disconnect it.

– Pull manifold absolute pressure sensor  from the holder and hang to one side.
– Remove the side panel.
304379-10
– Push spring band clamp  back.

– Pull off the fuel hose and remove the spring band clamp.
304380-10
– Pull secondary air valve  off of the holder.
304381-10
– Unscrew screw .
– Lift the air filter box slightly.
304382-10
06/AIR FILTER 60
– Detach hose .

– Pull fuel hose  downward out of the air filter box.
– Pull the air filter box upward with the throttle valve body.
– Remove the air filter box.
304383-10
– Raise the throttle valve body at the front and fix it on the handlebar.
Info
Protect the vehicle and attachments against damage by covering them.
– Cover the intake duct with a cloth.
304384-10
Installing the air filter box

9.4
– Take the cloth out of the intake duct and remove the fixation of the throttle valve
body.
304384-10
– Position rubber sleeves .

– Position the air filter box.
– Push on hose .
304385-10
– Mount the throttle valve body.

– Position and tighten clamps .
304382-11
– Mount secondary air valve  on the holder.
304381-11
06/AIR FILTER 61
– Mount the fuel hose with spring band clamp .

304380-11
– Position the side panel.

– Plug in connector  and mount on the holder.
– Mount manifold absolute pressure sensor  on the holder.
304379-11
– Position the side panel.

– Mount manifold absolute pressure sensor  on the holder.
304378-11
– Position the intake flange.

– Fully tighten screws .
– Install the air filter. ( p. 58)
304377-11
07/FUEL TANK, SEAT, TRIM 62
Opening the filler cap

10.1
Danger
Fire hazard Fuel 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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Lift the cover of the filler cap  and insert the ignition key.
Note
Danger of damage Ignition key breakage.
– To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
– Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
B00615-10
The filler cap has a tank air vent system.
Closing the filler cap

10.2
– Put the filler cap back on and turn the ignition key 90° clockwise.
– Remove the ignition key and fold down the cover.
B00616-01
Removing the seat

10.3
– Insert the ignition key in the seat lock  and turn it clockwise.
– Raise the rear of the seat, push it towards the rear, and remove it upwards.
– Remove the ignition key from the seat lock.
600922-10
Mounting the seat

10.4
– Position front recesses  of the seat on the oval head screws of the fuel tank,
lower the rear and simultaneously push it forward. Both lugs  must hook into the
frame and locking bolt  must be inserted into the lock housing.
The seat engages with an audible click.
– Finally, check that the seat is correctly mounted.
B00624-10
Reinstalling the fuel tank

10.5

– Remove screws  and the spoiler on both sides.
304308-10
– Remove screw  on both sides.
Info
The fuel hoses do not need to be disconnected.
– Carefully push the fuel tank back.
B00670-11
Positioning the fuel tank

10.6
– Carefully push the fuel tank forward.

The fuel tank fixations must engage in the recesses.
– Install and tighten screw  with the bearing sleeve and rubber bushing on both
sides.
Guideline
(18.4 lbf ft)
– Check the routing of the fuel lines.
B00670-10
– Position the spoilers on both sides. Mount and tighten screws .

Guideline
Screw, spoiler M6 3.3 Nm
(2.43 lbf ft)
304308-11
Removing the fuel tank

10.7
Danger
Warning

– Close fuel cocks .
– Push back the hose clips and detach the fuel hoses.
– Press down the metal plate and disconnect the fuel hose connection .
Info
Remaining fuel may run out of the fuel hose.
– Remove the cable clip.

304312-10
– Pull off vent hose .
304311-10
– Remove screws  and spoilers on both sides.
304309-10
– Remove screw  on both sides.

– Take off the fuel tank.
304310-10
Installing the fuel tank

10.8
Danger
Warning
– Position the fuel tank.

– Install and tighten screw  with the bearing sleeve and rubber bushing on both
sides.
Guideline
(18.4 lbf ft)
304310-11
– Position the spoiler on both sides. Mount and tighten screws .

Guideline
Screw, spoiler M6 3.3 Nm
(2.43 lbf ft)
304309-11
– Mount vent hose .
304311-11
– Plug in connector .
– Mount the fuel hoses with hose clips.
– Connect fuel hose connector  with the new O-ring.
– Open fuel cocks .
304312-11
Changing the fuel filter

10.9
Danger
Warning
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Drain the fuel from the fuel tank into a suitable container.
– Pull out the fuel pump.
304331-10
– Release locking mechanism .

– Remove fuel pump housing.
303969-10
– Press lock .
– Remove the fuel filter housing.
303970-10
– Change fuel filter .
303971-10
– Mount fuel filter housing .

The locking mechanism engages.
303972-10
– Mount the fuel pump housing.

The locking mechanism  engages.
303969-10
– Position the fuel pump.

– Mount and tighten screws .
Guideline
Screw, fuel pump M6 6 Nm (4.4 lbf ft)
304331-10
Checking the fuel pressure

10.10
Danger
Warning
Condition
The fuel tank is completely full.
The ignition is off.
The diagnostic tool is connected.
– Press down the metal plate and disconnect the fuel hose connection .
Info
Remaining fuel may run out of the fuel hose.
304313-10
– Mount special tool .

3
0 Pressure testing tool (61029094000) ( p. 285)
– Mount special tool  with nozzle code 1,05.
Testing hose (61029093000) ( p. 285)
– Insert the hose end in a fuel canister.
2
0 Guideline
Minimum size of fuel canister 10 l (2.6 US gal)
400926-10
– Switch on the ignition.
– Select model.
– Select "ECU Diagnosis".
– Highlight control unit "Injection management EFI LC8".
– Press "Continue".
– Select "Actuator Test".
– "Please enter the password:"
– Select "Fuel pump relay function test".
– Read the information screen on the KTM diagnostics tool and use "Continue" to start
the actuator test.
Guideline
Maximum duration of actuator test 3 min
– Check the fuel pressure with the filler cap closed.
Fuel pressure
When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)
» If the specified value is not achieved:
– Open the filler cap. ( p. 62)
– Check the tank air vent system.
400927-01
– Check the fuel pressure with the filler cap open.

Fuel pressure
When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)
» If the specified value is not achieved:
– Check that the fuel lines are free of blockages.
– Change the fuel filter. ( p. 66)
– Change the fuel pump.
400928-01 – Stop the "Function test of fuel pump control" actuator test by pressing the "Quit" but-
ton.
– Remove the special tools.
– Connect the fuel hose connection.
08/MASK, FENDER, DECAL 69
Removing the front fender

11.1
– Remove screws . Remove the front fender.
304307-10
Removing the front fender

11.2
– Position the front fender. Mount and tighten screws .

Guideline
304307-10
Removing the mask spoiler

11.3
B00625-10
– Remove the mask spoiler.
B00671-10
– Remove the inside trim of the mask spoiler.
700633-01
08/MASK, FENDER, DECAL 70
Installing the mask spoiler

11.4
– Position the inside trim of the mask spoiler.

700633-10
– Position the mask spoiler.

– Mount and tighten screws .
B00625-11
– Mount and tighten screws .

B00671-11
09/FRONT WHEEL 71
Removing the front wheel

12.1

– Raise the motorcycle with the front wheel stand. ( p. 9)
– Take the speed sensor cable out of the clamp.
– Remove screw  and pull wheel speed sensor  out of the hole with the sleeve.
– Remove screws  from both brake calipers.
– Press back the brake linings with a light lateral tilting of the brake calipers on the
brake disc. Pull the brake calipers carefully back from the brake discs and hang
them to one side.
Info
Do not pull the hand brake lever when the brake calipers are removed.
B00632-10
– Loosen screws  and .

– Unscrew screw  about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
discs.
– Always lay down the wheel in such a way that the brake discs are not
damaged.
B00633-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Installing the front wheel

12.2
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

» If the wheel bearing is broken or worn:
– Clean, grease, and mount the left and right spacers and the shaft seal rings.
– Clean screw  and wheel spindle .
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
The arrow on the spoke indicates the direction of travel.
Guideline
Bolt, front axle M25x1.5 45 Nm
(33.2 lbf ft)
B00634-10
– Slide the sleeve onto the wheel speed sensor  and push them into the hole
together. Mount and tighten screw .
Guideline
(4.4 lbf ft)
– Fasten the speed sensor cable in the bracket.
B00632-11
09/FRONT WHEEL 72
– Position the brake calipers and check that the brake linings are seated correctly.
– Mount screws  on both brake calipers but do not tighten yet.
– Operate the hand brake lever repeatedly until the brake lining presses up against
the brake disc and there is a pressure point. Fix the hand brake lever in its engaged
position.
The brake calipers straighten.
– Tighten screws  on both brake calipers.
Guideline
Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
– Remove the fixation of the hand brake lever.
– Take the motorcycle off of the front wheel stand. ( p. 9)
– Take the motorcycle off of the rear wheel stand. ( p. 9)
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
B00686-10
Checking the tire air pressure

12.3
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.
– Remove the dust cap.

– Check the tire air pressure when the tires are cold.
Tire air pressure, solo
Front 2.4 bar (35 psi)
Rear 2.4 bar (35 psi)
Tire air pressure with passenger/full payload

400695-01
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.
Info
The rubber seal in the dust cap prevents air from leaking out of the tire if
the valve is faulty.
Checking the tire condition

12.4
Warning
Danger of accidents Uncontrollable vehicle handling in the event of a flat tire.
– In the interest of safety, replace damaged or worn tires immediately.
Warning
Danger of crashing Poor 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.
09/FRONT WHEEL 73
Warning
Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be
roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not
achieved until the tires have been run in.
Info
The type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle.
Worn tires have a negative effect on vehicle handling, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tires exhibit cuts, run-in objects or other damage:
– Change the tires.
– Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum permissible depth:
– Check the age of the tires.
Info
The tire's date of 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 manufac-
ture.
KTM recommends that the tires be changed after 5 years at the latest,
regardless of the actual state of wear.
» If a tire is more than five years old:

Checking the front brake discs

12.5
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay.
– Check the thickness of the brake disc in several places to see if it conforms to mea-
surement .
Info
Wear reduces the thickness of the brake discs in area  of the brake discs.
Brake discs - wear limit

Front 4.5 mm (0.177 in)
100135-10
» If the brake disc thickness is less than the specified value:
– Change the brake discs.
– Check the brake discs for damage, cracking and deformation.
» If the brake discs exhibit damage, cracking or deformation:
09/FRONT WHEEL 74
Removing the front brake discs

12.6
– Remove the front wheel. ( p. 71)

Right side
– Take off the brake disc.
304321-10
Left side
– Take off ABS sensor wheel .
304322-10
304323-10
Installing the front brake discs

12.7
Right side
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward.
Guideline
Screw, front brake disc M8 30 Nm Loctite® 243™
(22.1 lbf ft)
304321-10
Left side
304323-10
09/FRONT WHEEL 75
– Position ABS sensor wheel .

Guideline
Screw, front brake disc M8 30 Nm Loctite® 243™
(22.1 lbf ft)
– Install the front wheel. ( p. 71)
304322-11
10/REAR WHEEL 76
Removing the rear wheel

13.1

– Remove screw  and pull wheel speed sensor  out of the hole.
– Remove nut . Remove chain adjuster .
– Pull out wheel spindle  to the point where the chain adjuster is no longer in con-
tact with the adjusting screw.
B00626-11
– Push the rear wheel forward as far as possible and take the chain off the rear
sprocket.
– Withdraw the wheel spindle.
– Pull the rear wheel backward until the brake caliper support hangs free between the
brake disc and the wheel rim.
Warning
discs.
B00135-01 – Always lay down the wheel in such a way that the brake discs are not
damaged.
– Take the rear wheel carefully out of the swingarm without damaging the rim and/or
brake disc.
Info
Do not operate the foot brake when the rear wheel is removed.
Installing the rear wheel

13.2
Warning
Warning
Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.
– Check the rear hub shock absorbers. ( p. 81)

» If the wheel bearing is broken or worn:
– Remove bushing . Clean and grease the mating surfaces of the bushing and the
shaft seal ring.
B00635-10
10/REAR WHEEL 77
– Install the bushing.

– Clean and grease the thread of the wheel spindle and nut.
– Clean the fixing locations on the brake caliper support and swingarm.
– Engage the counter bearing of the brake caliper support  and swingarm. Carefully
lift the rear wheel into the swingarm and engage the brake disc. Lay the chain on
the rear sprocket and mount the wheel spindle.
– Mount chain adjuster  and nut .
Info
Mount the left and right chain adjusters in the same position.
– Push the rear wheel forward so that the chain adjusters are in contact with the
adjusting screws, and tighten the nut.
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 reference marks .
Nut, rear wheel spindle M25x1.5 90 Nm Thread greased

(66.4 lbf ft)
– Insert wheel speed sensor  into the hole. Mount and tighten screw .
Guideline
B00626-12 (4.4 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.
– Check the chain tension. ( p. 77)
Checking the chain tension

13.3
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
– Lean the motorcycle on the side stand.

– In the area after the chain sliding guard, press the chain upward toward the link
fork and measure chain tension .
Info
The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
700570-01 Chain tension 7 mm (0.28 in)

» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 78)
10/REAR WHEEL 78
Adjusting the chain tension

13.4
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  on the left and right.
Guideline
Chain tension 7 mm (0.28 in)
Turn adjusting screws  on the left and right so that the markings on the left
and right chain adjuster  are in the same position in relation to reference
marks . 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 .
– Make sure that chain adjusters  are resting against adjusting screws .
– Tighten nut .
Guideline
B00626-10 Nut, rear wheel spindle M25x1.5 90 Nm Thread greased
(66.4 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary transmissions with the same chain length.
Chain adjusters  can be turned through 180°.
Checking the chain, rear sprocket, engine sprocket and chain guide
13.5
– Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket or engine sprocket is worn:
– Replace the rear sprocket or engine sprocket.
Info
The rear sprocket, engine sprocket and chain should always be
changed together.
100132-10
10/REAR WHEEL 79

– Pull the lower chain section with specified weight .
Guideline
Weight, chain wear measurement 15 kg (33 lb.)
– Measure the distance  of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance  at the longest 272 mm (10.71 in)

chain section
» If distance  is greater than the specified measurement:
– Replace the chain.
Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
700572-01
For safety reasons, the chain has no chain joint.
– Check the chain sliding guard for wear.

» If there is no gap between the chain and the upper edge of the screw:
– Change the chain sliding guard.
– Check the chain sliding guard for tightness.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
Guideline
Screw, chain sliding M5 5 Nm –
B00653-01
guard (3.7 lbf ft)
Screw, chain sliding M6 6 Nm Loctite® 243™
guard (4.4 lbf ft)
– Check the chain sliding piece for wear.
» If the drill hole becomes visible on the chain sliding piece in area :
– Change the chain sliding piece.
– Check the chain sliding piece for tightness.
» If the chain sliding piece is loose:
– Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece EJOT PT 2 Nm
B00654-10
K60x20 (1.5 lbf ft)
Cleaning the chain

13.6
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
10/REAR WHEEL 80
– Clean the chain regularly.

– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
Chain cleaner ( p. 274)
– After drying, apply chain spray.
Chain lube for road use ( p. 274)
400725-01
Checking the rear brake disc

13.7
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay.
– Check the thickness of the brake disc in several places to see if it conforms to mea-
surement .
Info
Wear reduces the thickness of the brake disc in area  of the brake disc.
Brake disc - wear limit

Rear 4.5 mm (0.177 in)
400480-10
» If the brake disc thickness is less than the specified value:
– Change the brake disc.
– Check the brake disc for damage, cracking and deformation.
» If damage, cracks or deformation are visible on the brake disc:
Removing the brake disc of the rear brake

13.8
– Remove the rear wheel. ( p. 76)

– Take off ABS sensor wheel .
304319-10
304320-10
10/REAR WHEEL 81
Installing the brake disc of the rear brake

13.9

304320-10
– Position ABS sensor wheel .

Guideline
Screw, rear brake disc M8 30 Nm Loctite® 243™
(22.1 lbf ft)
– Install the rear wheel. ( p. 76)
304319-11
Checking rear hub shock absorbers

13.10
Info
The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out
during operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged.

– Remove the rear sprocket carrier.
– Check the rear hub for damage and wear.
» If the rear hub shock absorbers are damaged or worn:
– Change the rear hub shock absorber. ( p. 81)
– Position the rear sprocket carrier.
Info
A set of bolts and shock absorbers should have as little free travel as possi-
B00636-01
ble to increase the service life of the shock absorbers.
Changing the rear hub shock absorbers

13.11
Info
The steps are the same for all 5 rear hub shock absorbers. Always change the rear hub shock absorbers in pairs.

– Remove rear sprocket carrier .
201579-10
10/REAR WHEEL 82
– Mount inside part  of the special tool in rear hub shock absorber .
Pressure damper tool (61029010000) ( p. 284)
201580-10
– Swing out arms  of the special tool by turning clockwise all the way.
Info
The figure to the right shows the rear hub shock absorber and special tool
disassembled.
201581-10
– Position sleeve  of the special tool. Mount screw .

Pressure damper tool (61029010000) ( p. 284)
201582-10
– Hold screw . Pull the rear hub shock absorber out of the rim by tightening the
nut.
– Remove the special tool from the rear hub shock absorber.
201583-10
– Position the new rear hub shock absorber  and press in all the way using the back
of sleeve .
– Mount the rear sprocket carrier.
201584-10
11/WIRING HARNESS, BATTERY 83
Removing the battery

14.1
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– 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.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
– Switch off all power consumers and the engine.

– Disconnect negative (minus) cable  of the battery.
B00637-10
– Remove positive terminal cover .

– Disconnect the positive (plus) cable  of the battery.
– Detach rubber band .
– Pull the battery up and out of the battery rack.
B00638-10
Installing the battery

14.2
– Position the battery in the battery rack.
Info
The terminals of the battery must face in the direction of travel.
– Attach rubber band .

– Reconnect the positive (plus)  cable of the battery.
– Position positive terminal cover .
B00638-11
– Reconnect the negative (minus) cable  of the battery.

– Set the clock. ( p. 98)
B00637-11
Disconnecting the battery

14.3
– Switch off all power consumers and switch off the engine.
– Disconnect the negative (minus) cable  of the battery.
B00637-10
Connecting the battery

14.4
– Reconnect minus cable .

B00637-10
Recharging the battery

14.5
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– 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 hazard The battery contains elements that are harmful to the environment.
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Info
Even when there is no load on the battery, it discharges 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, i.e., the acid level does not have to be checked.

– Disconnect the negative (minus) cable of the battery to avoid damage to the motor-
cycle's electronics.
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the 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 .
Charge the battery at no more than 10% of the capacity specified on battery
housing .
– Switch off the charger after charging. Disconnect the battery.

Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the 3 months
motorcycle is not in use
700588-01
Changing the main fuse

14.6
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle. The main fuse is under the seat.
– Switch off all power consumers and the engine.

– Remove protection covers .
– Remove the faulty main fuse .
Info
A defective fuse can be identified by the burned-out fuse wire .
A reserve fuse  is located in the starter relay.
– Install a new main fuse.

Fuse (58011109130) ( p. 239)
Tip
Place the spare fuse in the starter relay so that it is available if needed.
– Attach the protection covers .

B00640-10
Changing the fuses of individual power consumers

14.7
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
– Open fuse box cover .
– Check the fuses.
Info
A faulty fuse can be identified by the burned-out fuse wire .
– Remove the faulty fuse.

Guideline
Fuse 1 - 10 A - ignition, fuel pump, hazard warning flasher
B00648-10
Fuse 2 - 15 A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 3 - 10 A - horn, brake light, turn signal
Fuse 4 - 10 A - radiator fan
Fuse 5 - 10 A - ignition (EFI control unit), immobilizer
Fuse 6 - 10 A - combination instrument, auxiliary equipment (permanent posi-
tive), alarm system (optional), socket
Fuse 7 - 10 A - supplementary equipment (accessories connected to the ignition
switch)
Fuse 8 - 10 A - ABS
Fuse 9 - not used
Fuse 10 - not used
Fuse SPARE - 10 A/15 A - spare fuses
– Use spare fuses with the correct rating only.
Fuse (75011088010) ( p. 239)
Fuse (75011088015) ( p. 239)
Tip
Insert a spare fuse so that it is available if needed.
– Close the fuse box cover.

Ignition curve plug-in connector

14.8
The plug-in connection is located under the seat in front of the tail light.
By disconnecting the plug-in connector, the ignition curve for fuel with an octane rat-
ing below 95 (ROZ 95/RON 95/PON 91) is activated. While the engine will have a
slightly lower power output, this setting prevents engine damage by hindering spark
knocking due to poor fuel quality.
Possible states
• Plug-in connector disconnected – Fuel with an octane rating of 80 to 94 (RON)
can be used for one tank full.
• Plug-in connector connected – Fuel with an octane rating of 95 or higher can be
B00667-01
used.
Adjusting the ignition curve to the fuel quality

14.9
– Switch off the ignition by turning the ignition key to the OFF position.
To activate the ignition curve for low octane fuel:
Note
Engine failure Low-quality fuel damages the engine.
– Operate the vehicle with fuel with an octane rating below 95 (ROZ 95/RON 95/PON 91) for no more than one tank full.
– The ignition curve must be adjusted to low octane fuel.
– Disconnect the plug-in connector.

Plug-in connector disconnected – Fuel with an octane rating of 80 to 94 (RON) can be used for one tank full. ( p. 86)
Activate the ignition curve for fuel with an octane rating of 95 or higher (ROZ 95/RON 95/PON 91):
– Connect the plug-in connector.
Plug-in connector connected – Fuel with an octane rating of 95 or higher can be used. ( p. 86)
13/BRAKE SYSTEM 88
Checking the front brake linings

15.1
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately.
Note
Danger of accidents Reduced 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 rendered unserviceable. Check the brake linings regularly.
– Check all brake linings on both brake calipers to ensure they have minimum thick-
ness .
Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings. ( p. 88)
– Check all brake linings on both brake calipers for damage and cracking.
» If damage or wear is encountered:
B00630-01
– Change the front brake linings. ( p. 88)
Changing the front brake linings

15.2
Warning
Skin irritation Brake 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 accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Warning
Danger of accidents Reduced 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 construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
13/BRAKE SYSTEM 89
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove cover  with membrane .
Info
For clarity, the following steps are illustrated using a disassembled brake
caliper.
304298-10
– Remove bolt .
304299-10
– Take off springs .
304300-10
– Remove brake linings .

– Clean the brake caliper.
– Press the brake piston back into the basic position and ensure that brake fluid does
not flow out of the brake fluid reservoir, sucking it away if necessary.
– Install new brake linings.
304301-10
– Position springs .
304300-10
– Mount bolt .
– Activate the hand brake lever several times until the brake linings are in contact
with the brake disc.
– Add brake fluid to the MAX level.
Brake fluid DOT 4 / DOT 5.1 ( p. 272)
– Position the cover with the membrane. Mount and tighten the screws.
304299-10 Info
Clean up overflowed or spilt brake fluid immediately with water.
13/BRAKE SYSTEM 90
Adjusting the basic position of the hand brake lever

15.3
– Pull the hand brake lever forward.

– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing wheel .
Info
B00627-10
Checking the front brake fluid level

15.4
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding.
Warning
– Check the brake fluid level in the brake fluid reservoir .
» If the brake fluid is below the MIN marking:
– Add front brake fluid. ( p. 90)
B00628-10
Adding front brake fluid

15.5
Warning
Warning
Warning
Warning
Info
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces.
13/BRAKE SYSTEM 91
– Remove screws.
– Remove cover  with membrane .
– Add brake fluid to the MAX level.
Info
B00629-10
Changing the front brake fluid

15.6
Warning
Warning
Info
– Cover the painted parts.
– Remove cover  with membrane.
– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 277)
201492-10
– Mount the corresponding bleeder cover  from the special tool set.
Bleeder cover (00029013000) ( p. 276)
– Connect the bleeding device.
Bleeding device (00029013100) ( p. 276)
201493-10
– Open shut-off valve .
Info
Follow the operating instructions of the bleeding device.
– Ensure that the filling pressure is set on pressure gauge . Correct the filling pres-
sure on pressure regulator  if necessary.
Guideline
Filling pressure 2… 2.5 bar (29… 36 psi)
201494-10
13/BRAKE SYSTEM 92
– Pull off dust cap  of the bleeder screw of the left brake caliper. Connect the hose
of the bleeder bottle.
– Open bleeder screw  by approximately one half turn.
Info
Drain until fresh brake fluid emerges from the hose of the bleeder bottle
without bubbles.
201495-10
– Tighten the bleeder screw. Remove the hose of the bleeder bottle. Attach the dust
cap.
– Pull off dust cap  of the bleeder screw of the right brake caliper. Connect the
hose of the bleeder bottle.
– Open bleeder screw  by approximately one half turn.
Info
without bubbles.
201496-10
– Tighten the bleeder screw.
– Close shut-off valve .
– Open the bleeder screw again until no more brake fluid emerges.
Info
This prevents overfilling of the brake fluid reservoir.
cap.
– Disconnect the bleeding device. Remove the bleeder cover.
– Correct the brake fluid level to marking MAX .
Info
– Check the hand brake lever for a firm pressure point.

201497-10
Checking the rear brake linings

15.7
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately.
Note
Danger of accidents Reduced 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 rendered unserviceable. Check the brake linings regularly.
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings. ( p. 93)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
B00631-01
13/BRAKE SYSTEM 93
– Change the rear brake linings. ( p. 93)
Changing the rear brake linings

15.8
Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally.
Warning
Warning
Warning
Warning
Danger of accidents Reduced 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 construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
– Stand the vehicle upright.

– Press the brake caliper onto the brake disc by hand in order to push back the brake
piston. Ensure that brake fluid does not overflow from the brake fluid reservoir,
using suction to remove it if it does.
304304-10
– Remove locking split pins .

– Remove pin  and the brake linings.
– Press the brake piston back into the basic position and ensure that brake fluid does
not flow out of the brake fluid reservoir, sucking it away if necessary.
– Clean the brake caliper and brake caliper support.
304302-10
13/BRAKE SYSTEM 94
– Check that leaf spring  in the brake caliper and sliding plate  in the brake
caliper support are seated correctly.
303926-10
– Insert the brake linings, insert the bolt, and mount the cotter pin.
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.
304303-10
– Add brake fluid to level .

– Mount the cover and membrane.
– Mount and tighten the screws.
Info
304305-10
Checking the free travel of the foot brake lever

15.9
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
– Move the foot brake lever back and forth between the end stop and the contact to
the piston rod and check free travel .
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
Info
The piston rod should not move.
» If the free travel does not meet specifications:

600921-10
– Adjust the free travel to the specified value.
Adjusting the basic position of the foot brake lever

15.10
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
13/BRAKE SYSTEM 95
– Release nut  and turn push rod  until the foot brake lever is in the desired posi-
tion.
At least two thread turns are visible at the lower nut.
Info
The range of adjustment is limited.
– Check the free travel of the foot brake lever. ( p. 94)

– Tighten nut .
B00665-10
Checking the rear brake fluid level

15.11
Warning
Warning
– Stand the vehicle upright.

– Check the brake fluid level of the brake fluid reservoir.
» If the fluid level reaches the MIN mark :
– Add rear brake fluid. ( p. 95)
304306-10
Adding rear brake fluid

15.12
Warning
Warning
Warning
Warning
Info
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces.
13/BRAKE SYSTEM 96
304304-10
– Add brake fluid to level .

Info
304305-10
Changing the rear brake fluid

15.13
Warning
Warning
Info
– Cover the painted parts.

– Remove cover  with membrane.
– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 277)
201498-10
– Mount the corresponding bleeder cover  from the special tool set.
Bleeder cover (00029013000) ( p. 276)
– Connect the bleeding device.
201499-10
13/BRAKE SYSTEM 97
– Open shut-off valve .
Info
Follow the operating instructions of the bleeding device.
– Ensure that the filling pressure is set on pressure gauge . Correct the filling pres-
sure on pressure regulator  if necessary.
Guideline
Filling pressure 2… 2.5 bar (29… 36 psi)
201494-10
– Pull off the dust cap of the bleeder screw. Connect the hose of the bleeder bottle.
– Open bleeder screw  by approximately one half turn.
Info
without bubbles.
– Tighten the bleeder screw.

201500-10
– Close shut-off valve .
– Open the bleeder screw again until no more brake fluid emerges.
Info
This prevents overfilling of the brake fluid reservoir.
cap.
– Disconnect the bleeding device. Remove the bleeder cover.
– Correct the brake fluid to level .
Info
– Check the foot brake lever for a firm pressure point.

304305-11
14/LIGHT SYSTEM, INSTRUMENTS 98
Setting kilometers or miles

16.1
Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is stationary.
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button pressed until the display mode changes from km/h to mph or
from mph to km/h.
400893-10
Setting the clock

16.2
Condition
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button and the SET button pressed simultaneously.
The time display begins to flash.
– Press the MODE button to set the hour.
– Press the SET button to set the minute.
The time is set.
400893-12
Combination instrument - setting/resetting TRIP 1

16.3
Info
The TRIP 1 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value
999.9 is reached, the trip counter starts at 0.0 again.

– Press the MODE button repeatedly until the TRIP 1 mode is active.
– Keep the SET button pressed.
The TRIP 1 display is set to 0.0.
400840-01
Combination instrument - setting/resetting TRIP 2

16.4
Info
The TRIP 2 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value
999.9 is reached, the trip counter starts at 0.0 again.

– Keep the SET button pressed.
The TRIP 2 display is set to 0.0.
400841-01
Combination instrument - setting the wheel circumference

16.5
Danger
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub-
lic roads in the homologated version.
– If the vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle
owner and rider of this.
– If you undertake any modifications, please insist on receiving a signed workshop order from your customer in which you
inform the customer in writing that these modifications are performed at the customer's own risk and that the vehicle will
no longer be approved for use on public roads once modified.
Condition
– Remove the headlight trim. ( p. 99)
– Unplug connector ED from the combination instrument.
– Unlock pin 18  and remove it from connector ED.
Cable connector unlocking set (00029014000) ( p. 276)
– Plug connector ED into the combination instrument.
– Press and hold the MODE button for 10 seconds.
302064-10 The wheel circumference is displayed in millimeters.
Increasing the wheel circumference
– Press the MODE button .
Reducing the wheel circumference
– Press the SET button .
The settings are saved and the Setup menu is closed.
– Unplug connector ED from the combination instrument.
304327-10 – Connect pin 18 to connector ED.
– Plug connector ED into the combination instrument.
– Install the headlight trim. ( p. 100)
Removing the headlight trim

16.6

304324-10
304325-10
– Take off the headlight trim.
304326-10
Installing the headlight trim

16.7
– Position the headlight trim.

Guideline
T20 (0.89 lbf ft)
304326-11

Guideline
304325-10

Guideline
T20 (0.89 lbf ft)
304324-11
Removing the headlight

16.8
– Remove the headlight trim. ( p. 99)
304328-10
– Swing the headlight forward.
Info
Pay attention to the headlight range adjustment .
– Pull cable guide  of the parking light carefully out of the housing.
– Take off the headlight.
304329-10
Installing the headlight

16.9
– Plug in connector .
– Mount cable guide .
304329-11
– Position the headlight.

Headlight range adjustment  engages in hole .
304330-10

Guideline
– Check that the lighting is functioning properly.
– Install the headlight trim. ( p. 100)
– Check the headlight setting. ( p. 102)
304328-11
Checking the headlight setting

16.10
– Park the vehicle on a horizontal surface in front of a light-colored wall and make a
mark at the level of the center of the headlight.
A
0 – Make another mark at a distance of  under the first mark.
Guideline
Distance  5 cm (2 in)
B
0 – Park the vehicle at a distance of  vertically in front of the wall and switch on the
low beam headlight.
Guideline
Distance 
400726-10
5 m (16 ft)
– The rider, with luggage and passenger if applicable, now mounts the motorcycle.
– Check the headlight setting.
The light-dark boundary must lie exactly on the lower mark when the motorcycle
is ready to operate with the rider mounted along with any luggage and a passen-
ger if applicable.
» If the boundary between light and dark does not meet specifications:
– Adjust the headlight range. ( p. 102)
Adjusting headlight range

16.11
– Check the headlight setting. ( p. 102)

– Turn adjusting wheel  to adjust the headlight range.
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
Turning up increases the range, while turning down decreases the range.
B00139-10
Changing the headlight bulb

16.12
Note
Damage to reflector Reduced luminance.
– 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.
B00668-01
– Disconnect connector .
– Remove rubber cap .
B00673-10
– Detach retaining clamps .

– Remove headlight bulb .
– Position the new headlight bulb in the headlight housing.
Low beam/high beam (H4/socket P43t) ( p. 239)
Info
Insert the headlight bulb so that the bayonet lugs latch into the slots.
B00674-10 – Position the retaining clamps.

– Mount rubber cap .
– Plug in connector .
B00673-10
– Mount the cover.

B00668-01
Changing the parking light bulb

16.13
Note
before mounting.
B00668-01
– Pull cable guide  and the socket of the parking light carefully out of the housing.
– Remove the bulb.
– Position a new light bulb in the socket.
Parking light (W5W/socket W2.1x9.5d) ( p. 239)
– Carefully position the socket with the bulb in the housing.
– Mount the cable guide.
B00675-10
– Mount the cover.

B00668-01
Changing the turn signal bulb

16.14
Note
before mounting.
– Remove the screw on the rear of the turn signal housing.

– Carefully remove diffuser .
– Press bulb  carefully into the socket, turn it counterclockwise by about 30°, and
pull it out of the socket.
– Press the new bulb carefully into the socket and turn it clockwise until it stops.
Turn signal (RY10W/socket BAU15s) ( p. 239)
– Check the turn signal to make sure it is functioning properly.
101147-10
– Position the diffuser.
– Insert the screw and first turn it counterclockwise until it engages in the thread.
Tighten the screw slightly.
Changing the brake light bulb

16.15
Note
before mounting.

B00641-10
– Remove screws  on the left and right heat protectors.

B00642-10
– Remove screws  on the left and right rear side parts.

B00643-10
– Remove the rear top part.
B00644-10
– Turn bulb socket  counterclockwise all the way and take it out of the tail light.
– Push the bulb carefully into the socket, turn it counterclockwise, and pull it out of
the socket.
– Press the new bulb carefully into the socket and turn it clockwise until it stops.
Brake light (PR21W/socket BAW15s) ( p. 240)
Brake light (P21W/socket BA15s) ( p. 240)
– Insert the bulb socket into the tail light and turn clockwise until it stops.
– Check that the brake light system is functioning properly.
B00645-10
– Position the rear top part.

Guideline
Remaining frame bolts EJOT PT K50x18 2 Nm (1.5 lbf ft)
T20
B00644-10

– Mount and tighten screws  on the left and right rear side parts.
Guideline
50x16 nection
3.3 Nm
(2.43 lbf ft)
Subsequent screw
connection
2 Nm (1.5 lbf ft)
Guideline
T20 (0.89 lbf ft)
B00643-10

– Mount and tighten screws  on the left and right heat protectors.
Guideline
(11.1 lbf ft)
B00642-10

Guideline
(14.8 lbf ft)
B00641-10
Changing the tail light bulbs

16.16
Note
before mounting.

B00641-10
– Remove screws  on the left and right heat protectors.

B00642-10
– Remove screws  on the left and right rear side parts.

B00643-10
– Remove the rear top part.
B00644-10
– Pull bulb sockets  carefully out of the bracket.

– Position a new light bulb in the socket.
Tail light (WR5W/socket W2.1x9.5d) ( p. 239)
Tail light (W5W/socket W2.1x9.5d) ( p. 240)
– Carefully position the sockets with the bulbs into the bracket in the tail light.
B00646-10
– Check that the tail light bulbs are functioning properly.
– Position the rear top part.
Guideline
Remaining frame bolts EJOT PT K50x18 2 Nm (1.5 lbf ft)
T20
B00644-10

– Mount and tighten screws  on the left and right rear side parts.
Guideline
50x16 nection
3.3 Nm
(2.43 lbf ft)
Subsequent screw
connection
2 Nm (1.5 lbf ft)
Guideline
T20 (0.89 lbf ft)
B00643-10

– Mount and tighten screws  on the left and right heat protectors.
Guideline
(11.1 lbf ft)
B00642-10

Guideline
(14.8 lbf ft)
B00641-10
Changing the license plate lamp

16.17
– Remove the license plate lamp cover.
700602-01
– Pull holder  carefully out of the bracket.

– Position a new light bulb in the holder.
License plate lamp (W5W/socket W2.1x9.5d) ( p. 240)
– Carefully position the holder with the bulb into the bracket.
700603-01

– Check that the license plate lamp is functioning properly.
700602-01
Activating/deactivating the ignition key

16.18
Info
The orange programming key must only be used for activating and deactivating!
If a black ignition key is lost or replaced, the black ignition keys must be individually activated/deactivated using the orange
programming key. This will also prevent the vehicle from being operated without authorization with the lost black ignition key.
You can activate or deactivate up to four black ignition keys. Only the black ignition keys programmed during an activation pro-
cedure are valid. All black ignition keys not programmed during the activation procedure are invalid, but can be reprogrammed
in a further activation procedure.
Loss of a black ignition key (second black ignition key available):

The following procedure deactivates all activated black ignition keys that are not
included in the procedure.
401184-10
– Insert the orange programming key in the ignition lock.

– Switch on the ignition by turning the orange programming key to the ON posi-
tion .
FI warning lamp (MIL) lights up, switches off, and then starts to flash.
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the orange programming key to the OFF posi-
tion .
– Pull out the orange programming key.
B00652-10 – Insert the black ignition key in the ignition lock.
The immobilizer indicator lamp lights up, switches off briefly, and
switches on again.
– Remove the black ignition key.
tion .
Immobilizer indicator lamp lights up, switches off briefly and flashes;
the number of flashes equals the number of functional black ignition keys
including the orange programming key. In this case, twice.
tion .
The lost black ignition key is deactivated.
The existing black ignition key is reactivated.
Loss of both black ignition keys (no black ignition key available):
This procedure is important to prevent misuse of the lost black ignition key.
401184-11

tion .
tion .
B00652-10 tion .
Immobilizer indicator lamp lights up, switches off briefly and flashes;
the number of flashes equals the number of functional black ignition keys
including the orange programming key. In this case once, since all black
ignition keys are deactivated.
tion .
All black ignition keys are deactivated.
– Order a new black ignition key according to the key number on the KEYCODE-
CARD and activate it.
Activating the ignition key:

tion .
tion .
– Insert the black ignition key in the ignition lock.
The immobilizer indicator lamp lights up, switches off briefly, and lights
up again.
– Remove the black ignition key.
– To activate further ignition keys, repeat the last 4 steps with the respective
ignition key.
– Insert the orange programming key into the ignition lock.
tion .
The immobilizer indicator lamp lights up, switches off briefly and
flashes; the number of flashes equals the number of functional black
ignition keys including the orange programming key.
tion .
All black ignition keys are activated included in this job sequence are acti-
vated.
Activating the immobilizer control unit

16.19
Info
To program the new ICU, the two black ignition keys are needed.
– Install a new immobilizer control unit.

– Insert the supplied orange programming key into the ignition lock.
– Switch on the ignition by turning the orange programming key to the ON position .
tion .
B00652-10
– Insert the first black ignition key into the ignition lock.
The immobilizer indicator lamp lights up, switches off briefly, and switches
on again.
– Pull out the first black ignition key.
– Insert the second black ignition key into the ignition lock.
The immobilizer indicator lamp lights up, switches off briefly, and switches
on again.
– Connect the diagnostic tool.

– Start diagnostic software.
– Select model.
– Select "Coding".
400687-60
– Select "Teach in the immobilizer control unit".
– Read the information page in the KTM diagnostics tool; then, using "Continue",
teach in the ICU.
– Carry out the start procedure. ( p. 11)
Guideline
The start procedure was successful.
– Clear the fault memory using the KTM diagnostics tool.
30/ENGINE 113
Removing the engine

17.1

– Disconnect the battery. ( p. 84)
– Remove the exhaust manifold. ( p. 48)
– Drain the coolant. ( p. 206)
– Drain the engine oil. ( p. 214)
– Remove the air filter. ( p. 57)
– Remove the air filter box. ( p. 59)
– Detach the electrical connections  of the horn.
304387-10
– Detach connector .
– Expose the cable.
– Push spring band clamp  back.
– Pull off the radiator hose.
304388-10
– Detach connector .
304389-10
– Push spring band clamp  back.

– Pull off the radiator hose.
304390-10
30/ENGINE 114
– Remove screw  and take off the radiator.
304391-10
– Remove screws .
– Take off the retaining bracket.
– Pull out the oil lines and remove the O-rings.
304392-10
– Push spring band clamp  back.

– Pull off the oil hose.
304393-10
– Remove screws .

– Remove nut .
304394-10
– Remove screws .

– Remove screw . Remove the oil tank.
304395-10
30/ENGINE 115
– Unplug connector  of the gear position sensor.

– Unplug connector  of the ignition pulse generator.
304396-10
– Unplug connector  of the alternator.

304397-10
– Unplug connector  of the secondary air valve.
304398-10
– Unplug connector  of the manifold absolute pressure sensor.
304399-10
– Unplug connector  of the ignition coils.
304400-10
– Unplug connector  of the oil pressure sensor.
304401-10
30/ENGINE 116
– Push back the rubber cap.

– Remove nut  from the electrical connection on the starter motor and take off the
cable.
304402-10
– Remove screw .

– Take off both ground wires.
304403-10
– Unplug connector  of the coolant temperature sensor.
304404-10
– Remove screw .

– Remove the ground wire.
304405-10
– Remove screws .

– Take off the engine sprocket cover.
304406-10
– Remove screws .

– Take off the clutch slave cylinder and hang it to the side.
Info
Do not actuate the clutch lever while the slave cylinder of the clutch is
removed.
Do not bend the clutch line.
304407-10
30/ENGINE 117
– Remove adapter  of the clutch slave cylinder.
304408-10
– Remove screw .

– Take off the chain securing guide.
304409-10
– Take off adapter  of the clutch slave cylinder.

– Remove locking pin .
304410-10
– Detach connector .

– Remove screws  and take off the voltage regulator.
304411-10
– Remove nut .

– Remove chain adjuster .
304416-10
– Push the rear wheel into the foremost position.

– Remove the chain from the rear sprocket.
Info
Protect the link fork and attachments from damage.
303960-10
30/ENGINE 118
– Remove the chain from the engine sprocket.
304413-10
– Position special tool  with the floor jack.

Floor jack attachment (60029055100) ( p. 282)
– Mount pin  and raise the engine slightly.
304412-10
– Remove nut .

– Remove the swingarm pivot.
– Remove fitting .
304414-10
– Pull the engine forward slightly and lower carefully.
304415-10
Installing the engine

17.2
– Raise the engine onto the special tool and fix it.
304415-10
– Position the engine in the frame.

– Mount the swingarm pivot.
– Mount nut  but do not tighten yet.
Guideline
Nut, swingarm pivot M19x1.5 130 Nm Thread greased
(95.9 lbf ft)
– Mount screw  but do not tighten them yet.
304414-11
30/ENGINE 119
Guideline
– Remove the floor jack with the special tool.
304412-11
– Lay the chain over the engine sprocket and the rear sprocket.
– Pull back the rear wheel.
– Position chain adjuster  and push the wheel spindle in all the way.
The chain adjuster is resting against the tensioning screw.
– Mount and tighten nut .
Guideline
Nut, rear wheel spindle M25x1.5 90 Nm Thread greased
(66.4 lbf ft)
304416-11
– Position the voltage regulator.
Guideline
– Plug in connector .
304411-11
– Mount locking pin .

– Mount adapter  of the clutch slave cylinder.
The locking pin engages in the cut-out.
304410-11
– Position the chain securing guide.

– Mount and tighten screw .
Guideline
(18.4 lbf ft)
304409-11
30/ENGINE 120
– Mount adapter  of the clutch slave cylinder.
304408-11
– Position the clutch slave cylinder with the O-ring.

– Mount and tighten screws .
Guideline
Remaining engine screws M6 10 Nm (7.4 lbf ft)
304407-11
– Position the engine sprocket cover.

– Mount and tighten screws .
Guideline
304406-11
– Position the ground wire with the washer.

– Mount and tighten screw .
Guideline
304405-11
– Plug in connector  of the coolant temperature sensor.
304404-11
– Position the ground wire.

– Mount and tighten screws .
Guideline
Screw, starter motor M6 10 Nm (7.4 lbf ft)
304403-11
30/ENGINE 121
– Position the electrical connection on the starter motor.

– Mount and tighten nut .
Guideline
Remaining chassis nuts M6 15 Nm
(11.1 lbf ft)
– Position the rubber cap.
304402-11
– Plug in connector  of the oil pressure sensor.
304401-11
– Plug in connector  of the ignition coil.
304400-11
– Plug in connector  of the manifold absolute pressure sensor.
304399-11
– Plug in connector  of the secondary air valve.
304398-11
– Plug in connector  of the alternator.
304397-11
30/ENGINE 122
– Plug in connector  of the gear position sensor.

– Plug in connector  of the ignition pulse generator.
304396-11
– Position the oil tank.

– Mount screw .
– Mount screws  but do not tighten them yet.
Guideline
Remaining frame bolts M10 45 Nm
(33.2 lbf ft)
Info
304395-11 To make it easier to mount the screws, raise or lower the engine slightly.
– Mount screws  but do not tighten them yet.

Guideline
(33.2 lbf ft)
Info
To make it easier to mount the screws, raise or lower the engine slightly.
– Mount and tighten nut .

304394-11
Guideline
– Tighten the swingarm pivot nut.
Guideline
Nut, swingarm pivot M19x1.5 130 Nm Thread greased
(95.9 lbf ft)
– Tighten screws  and .
Guideline
(33.2 lbf ft)
– Mount the oil hose with spring band clamp .
304393-11
– Fill the intake line with engine oil.

– Mount the oil lines with the O-rings.
– Position the retaining bracket. Mount and tighten screws .
Guideline
304392-11
30/ENGINE 123
– Position the radiator.

– Mount and tighten screws .
Guideline
– Mount and tighten screw .
Guideline
304391-11
– Mount the radiator hose with spring band clamp .

304390-11
– Plug in connector .

– Route the cable so it is not under tension.
304389-11
– Plug in connector .

– Route the cable so it is not under tension.
– Mount the radiator hose with spring band clamp .
304388-11
– Plug in the electrical connections  of the horn.
304387-11
30/ENGINE 124
– The oil must be added in two steps.

Engine oil 3.80 l External tem- Engine oil
(1.004 US gal) perature: ≥ 0 °C (SAE 10W/50)
(≥ 32 °F) ( p. 272)
External tem- Engine oil
perature: < 0 °C (SAE 5W/40)
(< 32 °F) ( p. 272)
– Remove screw plug  and add engine oil to the top marking .
305045-10 – Mount the screw plug.
– Install the air filter box. ( p. 60)
– Install the air filter. ( p. 58)
– Install the exhaust manifold. ( p. 50)
– Fill/bleed the cooling system. ( p. 206)
– Reconnect the battery. ( p. 84)
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may
– Start the engine and run it until it reaches operating temperature.

Six bars of the temperature display light up.
– Check the lubrication system for leaks.
– Switch off the engine.
– Park the motorcycle on a horizontal surface in a vertical position (not on the side
stand).
– Remove the screw plug.
– Add engine oil to the top marking.
– Mount the screw plug.
– Take a short test ride.
– Read out the trouble code memory using the KTM diagnostics tool.
– Check the engine for leakage.
– Check the engine oil level. ( p. 211)
– Check the coolant level in the compensating tank. ( p. 208)
30/DISASSEMBLING THE ENGINE 125
Clamping the engine into the engine assembly stand

18.1
– Mount special tool  on engine assembly stand .

Engine assembly stand (61229001000) ( p. 285)
Engine fixing arm (60029002000) ( p. 278)
– Mount the engine on special tool .
Info
Have an assistant help you or use a crane.
303976-10
Preparing the engine for disassembly

18.2
– Remove hose clamp .

– Remove the vent hose.
303977-10
303978-10
– Remove the SAS hose.
303979-10
– Remove membrane .
303980-10
– Remove hose clamps .
303981-10
– Remove the radiator hose.
303982-10
– Remove screw .
– Remove the ground wire.
303983-10
Removing the starter motor

18.3
– Take off the starter motor.
303985-10
Removing the ignition coils

18.4
– Remove ignition coils .
303986-10
Removing the valve cover of cylinder 2

18.5
– Take off the valve cover with the valve cover seal.
303990-10
– Remove spark plug shaft insert  with gasket.
303991-10
Removing the valve cover of cylinder 1

18.6
– Take off the valve cover with the valve cover seal.
303987-10
– Remove spark plug shaft insert  with gasket.
303988-10
Removing the spark plugs

18.7
– Remove the spark plugs using the special tool.

Spark plug wrench (75029172000) ( p. 286)
303989-10
Setting the engine to ignition top dead center of cylinder 1

18.8
– Remove screw  of the generator cover.
303994-10
– Turn the crankshaft counterclockwise until markings  of the rear camshafts are
flush with the edge of the cylinder head.
303995-10
– Remove screw  with the washer.

– Look through the hole to check that the position notch of the crankshaft is visible.
– Screw in special tool .
Crankshaft locking bolt (113080802) ( p. 276)
303996-10
Removing the camshafts of cylinder 1

18.9
– Loosen and remove screws  from the outside to the inside.
Info
The cams must not actuate the valves.
– Remove the camshaft bearing bridge.
303997-10
– Remove camshafts .
303998-10
Removing the timing chain tensioner of cylinder 1

18.10
– Remove screw  with the washer.
304001-10
– Position the screw of the timing chain tensioner with the washer.
The spring of the timing chain tensioner is not pressed.
– Measure distance  between the washer and cylinder head.
Distance  6… 10.5 mm (0.24… 0.413 in)
» If the measured value is higher than the specified value:
– Change the timing chain tensioning rail and, if necessary, the timing chain.
304002-10
– Remove timing chain tensioner .
304003-10
Removing the timing gears of cylinder 1

18.11
– Remove screw .
304005-10
– Pry out bearing bolt  with a suitable tool.

– Remove the bearing bolt with the bearing.
304006-10
– Using a wire hook, lift timing chain  off of timing gears  toward the inside.
304007-10
– Remove the timing gears.
304008-10
Removing the cylinder head of cylinder 1 with cylinder

18.12
– Remove nuts  with the washers.
304009-10
– Release nuts  and  in a crisscross pattern and remove.

Special socket 13 mm; ½" drive (60029083000) ( p. 284)
304010-10
– Push the cylinder up.
Info
Push the cylinder up until the piston pin can be removed.
– Cover the engine case opening with a cloth.

– Remove piston pin retainer .
304011-10
– Remove piston pin .

– Remove the cylinder head with cylinder and piston.
304012-10
– Remove cylinder base gasket .
304013-10

18.13
– Loosen special tool  by several turns.

304044-10
– Hold the connecting rod in a centered position and keep the timing chain taut.
304045-10
– Continue turning the crankshaft counterclockwise until markings  of the front

camshafts are flush with the edge of the cylinder head.
– Screw special tool  back in.
304046-10
Removing the camshafts of cylinder 2

18.14
– Loosen and remove screws  from the outside to the inside.
Info
The cams must not actuate the valves.
– Remove the camshaft bearing bridge.
304047-10
– Remove camshafts .
304048-10
Removing the timing chain tensioner of cylinder 2

18.15
304049-10
– Position the screw of the timing chain tensioner with the washer.
The spring of the timing chain tensioner is not pressed.
– Measure distance  between the washer and cylinder head.
Distance  6… 10.5 mm (0.24… 0.413 in)
» If the measured value is higher than the specified value:
– Change the timing chain tensioning rail and, if necessary, the timing chain.
304050-10
– Remove timing chain tensioner .
304051-10
Removing the timing gears of cylinder 2

18.16
304052-10
– Pry out bearing bolt  with a suitable tool.

– Remove the bearing bolt with the bearing.
304053-10
– Using a wire hook, lift timing chain  off of timing gears  toward the inside.
304054-10
– Remove the timing gears.
304055-10
Removing the cylinder head of cylinder 2 with cylinder

18.17
– Remove nuts  with the washers.
304056-10
– Release nuts  and  in a criss-cross pattern and remove.

304057-10
– Push the cylinder up.
Info
Push the cylinder up until the piston pin can be removed.

– Remove piston pin retainer .
304058-10
– Remove piston pin .

– Remove the cylinder head with cylinder and piston.
304059-10
– Remove cylinder base gasket .
304060-10
Removing the water pump impeller

18.18
– Take off the water pump cover.
304137-10
– Remove dowels .
– Use the special tool to hold the water pump impeller tight.
Holding spanner, water pump impeller (60029082000) ( p. 284)
– Remove screw . Remove the water pump impeller with the washer below it.
304138-10
Removing the clutch cover

18.19
– Remove screws  and take off the oil screen cover.
304139-10
– Remove oil screen .
304140-10
– Remove screw  of the outer clutch cover.

– Take off the clutch cover.
304141-10
– Take off dowel .

– Remove clutch cover gasket .
304142-10
Removing the clutch discs

18.20
– Release screws  in a crisscross pattern and remove together with the washers and
clutch springs.
– Remove pressure cap .
304146-10
– Remove push rod .
304147-10
– Remove clutch discs .

The support ring and pretension ring remain in the inner clutch hub.
304148-10
Removing the clutch cage

18.21
– Position special tool .

Clutch holder (60029003000) ( p. 278)
– Remove nut .
304152-10
Alternative 1
Only remove the outer clutch hub.
– Remove washer .
304153-10
– Turn the crankshaft counterclockwise until the flat area  of the trigger wheel
faces the toothing of the outer clutch hub.
304154-10
– Remove needle bearing  with a suitable tool.

– Press outer clutch hub  away from the primary gear and remove it.
304155-10
– Remove washer .
304167-10
Alternative 2
Disassemble the engine.
– Remove screws .
– Take off the crankshaft position sensor.
304156-10
– Remove nut  with the washer.
Info
Left-handed thread!
304157-10
– Remove washer .
304158-10
– Remove outer clutch hub  with trigger wheel .
304159-10
– Remove needle bearing  and washer .
304160-10
Removing the spread transmission

18.22
– Remove nut  with the washer.
Info
Make sure that the crankshaft is blocked.
304161-10
– Take off spring washer .
304163-10
– Turn the clamping wheel counterclockwise using the special tool and secure with a
suitable tool .
Holding spanner, clamping wheel (60029051000) ( p. 282)
304162-10
Alternative 1
The spread transmission can be removed by hand.
– Take off the spread transmission.
304164-10
Alternative 2
The spread transmission must be removed with a puller.
– Carefully remove clamping wheel  with the clamping spring.
304165-10

Extractor (59029021044) ( p. 277)
Arms for puller (60029058000) ( p. 283)
– Pull off the drive wheel by screwing in the screw.
304166-10
Removing the primary gear

18.23
– Mount special tool .

Pressure piece (60029031000) ( p. 280)
– Turn balancer shaft  upward.
Puller, 2-arm (60029033000) ( p. 280)
– Pull off the primary wheel by screwing in the screw.
304169-10
Removing the timing chain of cylinder 1

18.24
– Remove balance weight .
304171-10
– Unthread timing chain .
Info
If the timing chain is to be used again, mark on it the direction of travel and
the cylinder to which it belongs.
304172-10
– Remove spring washer .

– Pull off timing chain sprocket .
Info
If the timing chain sprocket is to be used again, mark on it the cylinder to
which it belongs.
304173-10
– Take off spring washer and bearing ring .
304175-10
– Remove screw .
– Remove timing chain tensioning rail  upward.
304174-10
Removing the oil pump gear wheel

18.25
– Remove lock washer  and washer .
304176-10
– Remove oil pump gear wheel .
304177-10
– Remove pin  and washer .
304178-10
Removing the shift shaft

18.26
– Push sliding plate  away from the shift drum locating .

– Remove shift shaft  with the washer.
304179-10
Removing the shift drum locating

18.27
– Press locking lever  away from shift drum locating  and take off the shift drum
locating.
– Release the locking lever.
304180-10
Removing the locking lever

18.28
– Take off locking lever  with the sleeve and spring.
304182-10
Removing the gear position sensor

18.29
– Take the cable out of holder .

– Remove screws  and take off the gear position sensor with the O-ring.
304184-10
– Remove contact pin  and the contact springs.
304185-10
Removing the alternator cover

18.30
304187-10
– Remove dowels . Take off alternator cover gasket .
304188-10
Removing the rotor

18.31
– Remove torque limiter .
304189-10
– Remove screw  with the washer.
Info
304190-10

Insert for crankshaft (60029009110) ( p. 279)
– Mount special tool .
Puller for rotor (60029009000) ( p. 279)
– Pull off the rotor by screwing in the screw.
304191-10
– Remove screws . Take off the holder.
304192-10
– Remove starter idler gear .
304193-10
– Remove free wheel gear .
304194-10
Removing the timing chain of cylinder 2

18.32
– Remove balancer shaft .

– Remove timing chain .
Info
If the timing chain is to be used again, mark on it the direction of travel and
304195-10
– Remove timing chain tensioning rail  upward.
304196-10
Removing the oil filter

18.33
– Remove screws . Take off the oil filter cover with the O-ring.
304197-10
– Pull oil filter  out of the oil filter housing.

Circlip pliers reverse (51012011000) ( p. 277)
304198-10
Removing the left engine case

18.34
304199-10
– Swing the left section of the engine case upward and remove the fitting of the engine fixing arm.
– Release the left section of the engine case by striking it lightly with a plastic hammer and remove it.
– Remove dowels .
– Remove gasket .
304203-10
Removing the crankshaft

18.35
– Remove crankshaft .
304204-10
Removing the transmission shafts

18.36
– Remove oil spray tube .
Info
The oil spray tube is secured in the housing with an anti-rotation lock .
If necessary, turn the main shaft slightly.
304205-10
– Remove shift rails  with the springs.
304206-10
– Swing shift forks  to one side.
Info
Do not misplace shift rollers .
– Remove shift drum .
304207-10
– Remove shift forks .
Info
Do not misplace the shift rollers.
304208-10
– Erect the engine.

– Remove lock ring  and the washer.
304209-10
– Pull both transmission shafts out of the bearing seats together.
304210-10
Removing the oil pumps

18.37
– Remove the pressure pump housing.
304212-10
– Remove intake pump housing .
304213-10
– Remove external rotor  and internal rotor .
304214-10
– Remove needle roller .
304215-10
– Remove oil pump shafts  together with the pin, internal rotor  and external
rotor .
304216-10
30/ENGINE - WORK ON INDIVIDUAL PARTS 147
Work on the left section of the engine case

19.1

– Remove oil jet .
304271-10
– Remove oil jet .

– Remove oil spray tube .
– Remove oil jet .
– Remove bearing retainer .
– Remove shaft seal rings .
– Clean the engine case section thoroughly.
– Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
– Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
– Warm the engine case section again.

Guideline
304272-10
150 °C (302 °F)
– 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.
– Press in the bearing of the shift shaft from the inside to the outside so it is flush.
Pressing tool (60029043030) ( p. 281)
– 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 the shaft seal ring of the push rod with the open side facing in so that it is
flush.
Pressing tool (60029043010) ( p. 281)
– Press in the shaft seal ring of the countershaft with the open side facing in so that
it is flush.
Pressing tool (60029043020) ( p. 281)
– Press in the shaft seal ring of the shift shaft with the open side facing in so that it
is flush.
Pressing tool (60029043030) ( p. 281)
– Mount and tighten oil jet .

Guideline
Oil jet M5 4 Nm Loctite® 243™
(3 lbf ft)
– Mount oil spray tube .
– Mount and tighten screw.
Guideline
Screw, oil spray tube M4 6 Nm Loctite® 243™
(4.4 lbf ft)
– Mount and tighten oil jet .
Guideline
Oil jet M6x0.75 4 Nm Loctite® 243™
(3 lbf ft)
– Mount and tighten bearing retainer .
Guideline
Screw, bearing retainer M5 6 Nm Loctite® 243™
(4.4 lbf ft)
304272-11
– Mount and tighten the oil jet .

Guideline
(3 lbf ft)
– Mount and tighten screw  with the washer.
Guideline
Plug, clutch lubrication M10 15 Nm
(11.1 lbf ft)
304271-10
– Blow compressed air through all oil holes and check that they are clear.
Work on the right section of the engine case

19.2
– Remove oil jet .

– Remove oil spray tube .
– Remove bearing retainers .
– Remove jet .
– Remove dowels.
– Clean the engine case section thoroughly.
– Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
– Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
– Warm the engine case section again.

Guideline
304273-10
150 °C (302 °F)
– 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.
– Mount and tighten bearing retainers .

Guideline
(4.4 lbf ft)
– Mount and tighten jet .
Guideline
(3 lbf ft)
– Mount oil spray tube .
– Mount and tighten screw.
Guideline
Screw, oil spray tube M4 6 Nm Loctite® 243™
(4.4 lbf ft)
– Mount and tighten oil jet .
Guideline
Oil jet M5 4 Nm Loctite® 243™
(3 lbf ft)
– Mount the dowels.
Removing the left main bearing

19.3
– Remove the screws and take off bearing shell retaining bracket .
304276-10
– Mark joint  of the main bearing shells as shown.
304279-10
– Mount special tool  with the smaller diameter onto the bearing shells and press
from inside to outside.
Press drift/press sleeve (61229044000) ( p. 285)
304282-10
Removing the right main bearing

19.4
– Remove the screws and take off bearing shell retaining bracket .
304280-10
– Mark joint  of the main bearing shells as shown.
304277-10
– Mount special tool  with the smaller diameter onto the bearing shells and press
from inside to outside.
Pressing tool (60029044050) ( p. 282)
304281-10
Selecting main bearing shells

19.5
New crankshaft
– Select the new bearing shells according to color coding .
304274-10
Used crank shaft

– Measure both pivot points and select the new bearing shells accordingly.
Guideline
Crankshaft - main bearing diameter
Yellow 49.965… 49.975 mm (1.96712…
1.96752 in)
Blue 49.976… 49.985 mm (1.96756…
1.96791 in)
304275-10 Red 49.986… 49.995 mm (1.96795…
1.9683 in)
Installing the left main bearing

19.6
– Select the main bearing shells. ( p. 150)

– Center the new main bearing shells  on the special tool.
– Push special tool  over the main bearing shells.
Pressing tool (60029044050) ( p. 282)
304283-10
– Align the joint of the new bearing shells with the mark made during disassembly.
– Using the shouldered side of special tool , press the bearing shells through spe-
cial tool  all the way in from the outside to the inside.
Pressing tool (60029044050) ( p. 282)
304284-10
– Position bearing shell holding plate . Mount and tighten the screws.
Guideline
(4.4 lbf ft)
304276-11
Installing the right main bearing

19.7
– Select the main bearing shells. ( p. 150)

– Center the new main bearing shells  on the special tool.
– Push special tool  over the main bearing shells.
Pressing tool (60029044050) ( p. 282)
304283-10
– Align the joint of the new bearing shells with the mark made during disassembly.
– Using the shouldered side of special tool , press the bearing shells through spe-
cial tool  all the way in from the outside to the inside.
Pressing tool (60029044050) ( p. 282)
304285-10
– Position bearing shell holding plate . Mount and tighten the screws.
Guideline
(4.4 lbf ft)
304280-11
Changing the conrod bearing

19.8
Info
Perform this step on both connecting rods.
– Clamp each connecting rod individually into soft jaws.

Multi-tooth wrench socket 10 mm; ½" drive (60029075000) ( p. 283)
– Remove the conrod bearing cover and connecting rod. Remove the bearing shells.
Info
Mark the conrod bearing cover and connecting rod to ensure that each con-
rod bearing cover is mounted on the same connecting rod.
304258-10
– Measure the crank pin diameter and select the new bearing shells accordingly.
Guideline
Crankshaft - crank pin diameter
Yellow 41.978… 41.989 mm (1.65267…
1.65311 in)
Blue 41.990… 42.000 mm (1.65315…
1.65354 in)
Red 42.001… 42.011 mm (1.65358…
304260-10 1.65397 in)
– Check the radial clearance of lower conrod bearing. ( p. 153)
– Oil the bearing shells.

– Position the conrod bearing cover according to the markings made during disassem-
bly. Mount the new screws and tighten using the special tool.
Guideline
Screw, conrod bearing M10x1 Step 1
25 Nm
(18.4 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
60°
Multi-tooth wrench socket 10 mm; ½" drive (60029075000) ( p. 283)

Graduated disc (60029010000) ( p. 279)
Info
The bearing shells are laterally offset in the connecting rod to make space
for radius  of the crank shaft. If the bearing shells are mounted incor-
rectly, they press against the radius, blocking the connecting rods.
304261-10
Checking the radial clearance of lower conrod bearing

19.9
Info
Perform this step on both connecting rods.
– Position the bearing shells. Insert Plastigauge clearance gauge  offset by 90° to
the bearing joint.
Plastigauge measuring strips (60029012000) ( p. 279)
– Position the conrod bearing cover. Mount and tighten the screws.
Guideline
Screw, conrod bearing M10x1 Step 1
25 Nm
(18.4 lbf ft)
Step 2
30 Nm
(22.1 lbf ft)
Step 3
60°
Info
Do not twist connecting rod.
– Remove the conrod bearing cover again. Compare Plastigauge clearance gauge with
the specifications on the package.
304262-10
Guideline
Connecting rod - radial clearance of lower conrod bearing
New condition 0.030… 0.060 mm (0.00118…
0.00236 in)
Wear limit 0.080 mm (0.00315 in)
Info
The width of the Plastigauge clearance gauge equals the bearing play.
– Clean the parts.

Changing the support bearing of the crankshaft

19.10
– Mark the position of bearing joint .
304266-10
– Pull out support bearing shells  with the special tool.

Bearing puller (15112017000) ( p. 276)
Insert for bearing puller (60029018000) ( p. 280)
304267-10
– Measure the diameter of the support bearing at 3 points.

Crankshaft - support bearing diameter 27.985… 28.000 mm (1.10177…
1.10236 in)
» If the specified value is not reached:
– Change the crankshaft.
304268-10
– Center the new support bearing shells  with the special tool.
Step bearing tool (60029046028) ( p. 282)
304269-10
– Support the clutch cover directly under the support bearing.

– Align the support bearing shell with the markings and press in using the special
tool so it is flush.
Step bearing tool (60029046028) ( p. 282)
304270-10
Changing the water pump bearing

19.11
– Remove shaft seal ring .
304286-10
– Remove lock ring .
304287-10
– Press water pump shaft  to the inside and remove.
Info
Lock ring  does not need to be removed.
304288-10
– Heat the clutch cover.

Guideline
150 °C (302 °F)
– Strike the clutch cover against a flat wooden plate; this causes the bearing to drop
out of the bearing seat.
– Remove lock ring .
– Strike the clutch cover against a flat wooden plate; this causes the bearing to drop
out of the bearing seat.
– Insert a new cold bearing into the bearing seat of the hot clutch cover; if necessary,
use the special tool to press it all the way into place.
Press drift (60029043060) ( p. 281)
Info
When pressing the bearing in, ensure that the clutch cover is level to pre-
vent damage.
Only press the bearing in via the outer ring.
– Mount lock ring .

304573-10 – Insert a new cold bearing into the bearing seat of the hot clutch cover; if necessary,
use the special tool to press it all the way into place.
Press drift (60029043060) ( p. 281)
Info
When pressing the bearing in, ensure that the clutch cover is level to pre-
vent damage.
Only press the bearing in via the outer ring.
– Mount water pump shaft  from the inside.
304288-11
– Mount lock ring .
304287-10
– Mount special tool .

Mounting sleeve (58529005000) ( p. 277)
– Press in shaft seal ring  so it is flush.
304291-10
Removing the cylinder head from the cylinder

19.12
Info
The following operations apply to both cylinder heads.
– Remove bucket tappet  and set down in the installation position.
304243-10
– Take the shims  out of the valve spring retainers and lay them to one side accord-
ing to their normal built-in position.
304244-10
– Take off the cylinder head.
304245-10
– Remove cylinder head gasket .
304246-10
– Remove screw  with the washer.

– Remove the timing chain guide rail.
304247-10
Checking the oil pressure regulator valve

19.13
– Remove lock ring  and washer .

– Remove spring .
– Measure the length of spring .
Oil pressure regulator valve - minimum 42.00 mm (1.6535 in)
spring length
» If the measured length is less than the specified value:
– Change the spring.
304263-10
– Check control piston  for damage and wear.
– Change the control piston.
– Check the control piston hole in pressure pump housing  for damage and wear.
– Change the pressure pump housing.
– Oil control piston  and spring  well and mount them.
– Mount washer  and lock ring .
Checking the oil pumps

19.14
Info
The following steps apply to both oil pumps.
– Using special tool , check the clearance between the internal rotor and external
rotor, or between the external rotor and engine case or oil pump housing.
Feeler gauge (59029041100) ( p. 278)
Oil pumps
Clearance between external rotor 0.10… 0.20 mm (0.0039…
and internal rotor 0.0079 in)
Oil pumps
304265-10
Clearance, external rotor/engine 0.20… 0.40 mm (0.0079…
case or oil pump housing 0.0157 in)
» If the clearance exceeds the specifications:
– Change the oil pump and if necessary the engine case or oil pump housing.
– Checking axial play  of the oil pump.
Oil pumps
Axial clearance: New condition 0.04… 0.09 mm (0.0016…
0.0035 in)
Oil pumps
Axial clearance: Wear limit 0.25 mm (0.0098 in)
» If the clearance exceeds the specifications:
304264-10
– Change the oil pump and if necessary the engine case or oil pump housing.
Cylinder - Nikasil® coating

19.15
Nikasil® is a surface protection layer for a coating method developed by the Mahle
company. The name is derived from the two materials used in this method - a layer of
nickel, in which silicon carbide (a particularly hard substance) is embedded.
The most important advantages of the Nikasil® coating are the excellent heat conduc-
tivity resulting in better performance, less wear, and low cylinder weight.
304231-10
Work on the cylinder head

19.16
Info
Perform the following steps on all valves.
– Pretension the valve springs using the special tool.

Valve spring compressor (59029019000) ( p. 277)
Insert for valve spring lever (60029041000) ( p. 281)
304251-10
– Remove valve keys  and relax the valve springs.

– Remove valve spring retainer .
– Remove inside and outside valve spring, valve stem seal  and valve spring
seat .
Info
Place the valve into a box according to the installation position and label the
box.
304250-10 – Check the cylinder head. ( p. 159)

– Mount valve spring seat  and the new valve stem seal .
– Mount the inside and outside valve springs.
The tight winding of the valve spring is at the bottom.
– Mount valve spring retainer .
– Pretension the valve springs using the special tool.
Valve spring compressor (59029019000) ( p. 277)
Insert for valve spring lever (60029041000) ( p. 281)
– Mount valve keys. Relax the valve springs.
Info
When mounting the valve keys, check that they are seated correctly; prefer-
ably, fix the valve keys to the valve with a little grease.
304251-10
Checking the cylinder head

19.17
– Check valve guides  with the special tool.

Limit plug gauge (59029026006) ( p. 278)
» If the special tool is easy to insert into the valve guide:
– Changing the cylinder head and valve.
– Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
» If there is wear or tearing:
304233-10
– Change the cylinder head.
– Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) ( p. 278)
Cylinder/cylinder head - distortion of ≤ 0.10 mm (≤ 0.0039 in)

sealing area
» If the measured value does not equal the specified value:
– Change the cylinder head.
304234-10
– Check sealing seat  of the valves.

Valve - sealing seat width
Intake: Wear limit 1.20… 1.80 mm (0.0472…
0.0709 in)

Exhaust: Wear limit 1.50… 2.00 mm (0.0591…
0.0787 in)
302808-10 » If the measured value does not equal the specified value:
– Machine the valve seat.
Checking/measuring the cylinder

19.18
– Check the cylinder bearing surface for damage.

» If the cylinder bearing surface is damaged:
– Change the cylinder and piston.
– Measure the cylinder diameter at several places on the contact surface in the 
and  axes using a micrometer to check for oval wear.
304227-10
Guideline
Cylinder - bore diameter
Size I 101.000… 101.012 mm (3.97637…
3.97684 in)
Size II 101.013… 101.025 mm (3.97688…
3.97735 in)
– The cylinder size  is labeled on the side of the cylinder.
304229-10
– Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) ( p. 278)
Cylinder/cylinder head - distortion of ≤ 0.10 mm (≤ 0.0039 in)

sealing area
– Change the cylinder.
304228-10
Checking/measuring the piston

19.19
– Check the piston bearing surface for damage.

» If the piston bearing surface is damaged:
– Change the piston and, if necessary, the cylinder.
– Check that the piston rings can move easily in the piston ring grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.
Tip
304231-10 Use an old piston ring to clean the piston ring groove.
– Check the piston rings for damage.

» If a piston ring is damaged:
– Change the piston ring.
Info
Mount the piston ring with the marking facing upward.
– Check the piston pin for discoloration or signs of wear.

» If the piston pin has strong discoloration/signs of wear:
– Change the piston pin.
– Insert the piston pin into the connecting rod and check the bearing for play.
» If the piston pin bearing has too much play:
– Change the connecting rod and the piston pin.
– Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance .
Guideline
Distance  9 mm (0.35 in)
Piston - diameter
Size I 100.943… 100.957 mm (3.97413…
3.97468 in)
Size II 100.953… 100.967 mm (3.97452…
304230-10 3.97507 in)
Info
Piston size  is marked on the piston head.
Checking the piston/cylinder mounting clearance

19.20
– Check/measure the cylinder. ( p. 159)

– Check/measure the piston. ( p. 160)
– The smallest piston/cylinder mounting clearance is the result of the smallest cylin-
der bore diameter minus the largest piston diameter. The largest piston/cylinder
mounting clearance is the result of the largest cylinder bore diameter minus the
smallest piston diameter.
Guideline
Piston/cylinder - mounting clearance
304231-10 New condition 0.043… 0.072 mm (0.00169…
0.00283 in)
Checking the piston ring end gap

19.21
Info
The following operations apply to all piston rings.
– Remove the piston ring from the piston.

– 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)
– Measure end gap  with a feeler gauge.
Guideline
Piston ring end gap
304232-10 Ring 1 ≤ 0.40 mm (≤ 0.0157 in)
Ring 2 ≤ 0.40 mm (≤ 0.0157 in)
Ring 3 ≤ 0.40 mm (≤ 0.0157 in)
» If the end gap is more than the specified value:
– Check/measure the cylinder. ( p. 159)
» If the cylinder wear is within the tolerance range:
– Change the piston ring.
– Mount the piston ring with the marking facing toward the piston head.
Installing the piston

19.22
Info
The following operations apply to both pistons.
– Shift the joint of the piston rings by 120°.

– Place the oiled piston on the cylinder. Jointly clamp piston rings with special
tool .
Piston ring mounting tool (60029015000) ( p. 280)
The special tool presses the piston rings together properly and rests flush on
the cylinder.
304252-10
– Drive the piston into the cylinder by striking it carefully with the hammer handle.
The piston rings should not become caught; otherwise, they may be damaged.
304253-10
– Ensure that piston marking  faces the outfeed side.
304254-10
Mounting the cylinder head on the cylinder

19.23
Info
– Position the timing chain guide rail.

Guideline
Screw, timing chain guide M8 15 Nm Loctite® 243™
rail (11.1 lbf ft)
304247-11
– Put on cylinder head gasket .
304246-11
– Position the cylinder head.

Guideline
Screw, cylinder head M8 Step 1 Loctite® 243™
18 Nm
(13.3 lbf ft)
Step 2
23 Nm
(17 lbf ft)
Info
The cylinder head and cylinder are labeled with markings  to indicate that
they belong together.
304248-10
– Place shims  into the valve spring retainers.
Info
Note the installation position.
304244-11
– Position the bucket tappet .
Info
Note the installation position.
304243-11
Checking the timing assembly

19.24
304236-10
– Check the teeth of balancer shaft  for damage and wear.

– Change the balancer shaft.
– Check timing chains  for damage and wear.
– Change the timing chains.
– Check timing chains guide rails  for damage and wear.
– Change the timing chain guide rails.
– Check timing chain tensioning rails  for damage and wear.
– Changing the timing chain tensioning rails.
– Check timing gears  for damage and wear.
– Change the timing gears.
– Check camshaft gears  for damage and wear.
– Change the camshafts.
– Check the camshafts for damage and wear.
– Change the camshafts.
– Check spring washer  for damage and wear.
– Change the spring washer.
– Check clamping wheel  for damage and wear.
– Change the clamping wheel.
– Check clamping spring  for damage and wear.
– Changing the clamping spring.
– Check drive wheel  for damage and wear.
– Change the drive wheel.
Preassembling the spread transmission

19.25
– Mount the clamping spring on the drive wheel.

Holding lugs  engage in the drilled hole .
304237-10
– Position clamping wheel .

Holding lugs  engage in the drilled hole .
304238-10
– Press clamping wheel  onto the drive wheel.

The holding lugs engage in the drilled holes.
304239-10
– Clamp special tool  in the vise.

Holder for clamping wheel (60029050000) ( p. 282)
– Mount the washer and nut  of the balancer shaft.
304240-10
– Turn the clamping wheel with special tool  until the holes align with the fixation.
Holding spanner, clamping wheel (60029051000) ( p. 282)
304241-10
– Secure the spread transmission with suitable tool .

– Remove the nut and washer.
Holder for clamping wheel (60029050000) ( p. 282)
304242-10
Checking the clutch

19.26
304225-10
– Check thrust bearing  for damage and wear.

– Change the thrust bearing.
– Place push rod  on a level surface and check it for run-out.
» If there is run-out:
– Change the push rod.
– Check the length of clutch springs .
Clutch spring - length ≥ 29.00 mm (≥ 1.1417 in)
» If the clutch spring length is less than the specified value:
– Change all clutch springs.
– Check the intermediate clutch discs  for damage and wear.
» If the intermediate clutch discs are not level and have pittings:
– Change all intermediate clutch discs.
– Check the thickness of intermediate clutch discs.
Intermediate disk - thickness
New condition 1.95… 2.05 mm (0.0768… 0.0807 in)
» If the intermediate clutch discs do not meet specifications:
– Change all intermediate clutch discs.
– Check clutch facing discs  for discoloration and scoring.
» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs.
Clutch facing disc - thickness ≥ 2.6 mm (≥ 0.102 in)
» If the clutch facing discs do not meet specifications:
– Change all clutch facing discs.

– Check inner clutch hub  for damage and wear.
– Change the inner clutch hub.
– Check needle bearing  for damage and wear.
– Change the needle bearing.
– Check the springs  of the outer clutch hub for damage and wear.
» If there is damage, wear or play in the direction of rotation:
– Change the outer clutch hub.
– Check the components of clutch pressure booster  for damage and wear.
– Change all components of the clutch pressure booster.
– Check pretension ring  and support ring  for damage and wear.
– Change the pretension ring and support ring.
Checking the shift mechanism

19.27
304226-10
– Check the shift forks  (see ) for damage and wear (visual check).
– Change the shift fork an gear wheel pair.
– Check shift grooves  of shift drum  for wear.
» If the shift groove is worn:
– Change the shift drum.
– Check the seat of the shift drum in the bearings .
» If the shift drum is not seated correctly:
– Replace the shift drum and/or the bearing.
– Check bearing  for stiffness and wear.
» If the bearings do not move freely or are worn:
– Replace the bearings.
– Check the shift rollers for damage and wear.
– Change the shift rollers.
– Check springs of the shift rails  for damage and wear.
» If the spring is broken or worn:
– Change the spring of the shift rail.

– Check shift rail  on a flat surface for run-out.
» If there is run-out:
– Change the shift rail.
– Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
– Change the shift rail.
– Check sliding plate  in contact areas  for wear.
» If the sliding plate is worn:
– Change the sliding plate.
– Check return surface  on the sliding plate for wear.
» If deep notches are present:
– Check guide pin  for looseness and wear.
» If the guide pin is loose and/or worn:
– Preassemble the shift shaft. ( p. 168)

– Check the clearance  between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift 0.40… 0.80 mm (0.0157…
quadrant 0.0315 in)
303008-10
Preassembling the shift shaft

19.28
– Fix the short end of the shift shaft in a vise.

Guideline
Use soft jaws.
– Mount sliding plate  with the guide pin facing down and attach the guide pin to
the shift quadrant.
– Mount preload spring .
– Push on spring guide , push return spring  over the spring guide with the offset
end facing upward and lift the offset end over abutment bolt .
304186-10
– Mount stop disk .
Disassembling the main shaft

19.29
304219-10
– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
– Remove stop disk  and second-gear fixed gear .
– Remove the fifth-gear idler gear  and needle bearing .
– Remove stop disk .
– Remove the third/fourth-gear sliding gear .
– Remove lock ring .
– Remove stop disk .
– Remove the sixth-gear idler gear .
– Remove needle bearing .
Dismantling the countershaft

19.30
304221-10
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Remove stop disk  and the first-gear idler gear .

– Remove needle bearing  and stop disk .
– Remove the sixth-gear sliding gear .
– Remove lock ring .
– Remove stop disk .
– Remove the third-gear idler gear  and needle bearing .
– Remove the fourth-gear idler gear .
– Remove needle bearing .
– Remove stop disk  and lock ring .
– Remove the fifth-gear sliding gear .
– Remove lock ring .
– Remove stop disk .
– Remove the second-gear idler gear  and needle bearing .
Checking the transmission

19.31
– Disassemble the main shaft. ( p. 169)

– Dismantle the countershaft. ( p. 169)
304223-10
– Check needle bearing  for damage and wear.

– Change the needle bearing.
– Check the pivot points of main shaft  and countershaft  for damage and wear.
– Change the main shaft and/or countershaft.
– Check the tooth profiles of main shaft and countershaft for damage and wear.
– Change the main shaft and/or countershaft.
– Check the pivot points of idler gears  for damage and wear.
– Change the gear wheel pair.
– Check the shift dogs of the idler gears and sliding gear  for damage and wear.
– Check tooth faces of idler gears , of sliding gear  and of fixed gear  for damage and wear.

– Check the tooth profiles of sliding gear  for damage and wear.
– Check the sliding gear for smooth operation in the profile of main shaft .
» If the sliding gear does not move easily:
– Change the sliding gear or the main shaft.
– Check sliding gear  for smooth operation in the profile of countershaft .
» If the sliding gear does not move easily:
– Change the sliding gear or the countershaft.
– Check stop disks  for damage and wear.
– Change the stop disk.
– Use new lock rings  in every repair job.
Assembling the main shaft

19.32
Info
Use new lock rings in every repair job.
– Oil all parts carefully before assembling.

– Check the transmission. ( p. 170)
304220-10
– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Mount needle bearing .
– Mount the sixth-gear idler gear .
– Mount stop disk  and lock ring .
– Mount third/fourth-gear sliding gear  with the small gear wheel facing up.
– Mount stop disk .
– Mount needle bearing .
– Mount the fifth-gear idler gear .
– Mount the second-gear fixed gear  and stop disk .
– Finally, check all gear wheels for smooth operation.
Assembling the countershaft

19.33
Info
Use new lock rings in every repair job.
– Oil all parts carefully before assembling.

– Check the transmission. ( p. 170)
304222-10
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Mount needle bearing  and the second-gear idler gear  on the countershaft with the protruding collar facing downward.
– Mount stop disk  and lock ring .
– Mount the fifth-gear sliding gear  with the shift groove facing upward.
– Install lock ring  and stop disk .
– Mount the needle bearing  and the fourth-gear idler gear .
– Mount needle bearing .
– Mount the third-gear idler gear .
– Install stop disk  and lock ring .
– Mount the sixth-gear sliding gear  with the shift groove facing downward.
– Mount stop disk .
– Mount the needle bearing  and the first-gear idler gear .
– Mount stop disk .
– Finally, check all gear wheels for smooth operation.
Work on the alternator cover

19.34
– Remove lock ring  and washer .
304292-10
– Remove starter idler gear  and needle bushing.
304293-10
– Press cable retainer  down slightly and remove it.
304294-10
– Remove the stator.
304295-10
– Remove shaft seal ring .

– Warm the alternator cover in an oven.
Guideline
150 °C (302 °F)
– Strike the alternator cover against a flat wooden plate; this causes the bearing  to
drop out of the bearing seat.
– Insert a new cold bearing into the bearing seat of the hot alternator cover; if neces-
sary, use a suitable press drift to push it all the way into place.
304296-10
Info
When pressing the bearing in, ensure that the alternator cover is level to
prevent damage.
Only press the bearing in via the outer ring; otherwise, the bearing will be
damaged when it is pressed in.
– After the alternator cover has cooled, check that the bearing is firmly seated.
Info
If the bearing is not firmly seated after cooling, it is likely that it will rotate
in the alternator cover when warm. In this case, the alternator cover must be
renewed.
– Press in the shaft seal ring  with the open side facing inward until it is flush.
– Position the stator.
Guideline
Screw, stator M6 10 Nm Loctite® 243™
(7.4 lbf ft)
– Position cable guide  in the alternator cover.
304295-11
– Mount cable retainer .
304294-10
– Oil the needle bushing of the starter idler gear.

– Mount the starter idler gear  with the needle bushing.
304293-10
– Mount washer  and lock ring .
304292-10
Checking the electric starter drive

19.35
304224-10
– Check the teeth and seating of the starter idler gears  for damage and wear.
– Replace the starter idler gears and/or needle bushing.
– Check the teeth and seating of the torque limiter  for damage and wear.
– Change the torque limiter and/or needle bushing.
– Check freewheel gear  and bearing when removed for damage and wear.

– Replace the freewheel gear and/or the bearing.
– Check the freewheel  when removed for damage and wear.
– Replace the freewheel.
– Check the toothing  of the starter motor for damage and wear.
– Replace the starter motor.
– Clamp the minus (negative) cable of a 12 volt power supply to the starter motor housing. Briefly connect the plus (positive) cable
of the power supply to the starter motor connection
» If the starter motor does not turn when you close the power circuit:
– Replace the starter motor.
– Replace the O-ring  of the starter motor.
Checking the freewheel

19.36
– Insert freewheel gear  into the freewheel hub, turning the freewheel gear clock-
wise; do not wedge.
– Check the locking action of the freewheel gear.
» If the freewheel gear does not turn clockwise or if it does not lock counterclock-
wise:
– Replace the freewheel.
304255-10
Removing the freewheel

19.37
304256-10
– Lightly strike the side of the rotor with a plastic hammer and remove freewheel
hub .
– Remove freewheel .
304257-10
Installing the freewheel

19.38
– Check freewheel hub  at the contact surface of the freewheel for damage and
wear.
– Change the freewheel hub.
– Degrease the flange surface of the rotor and the freewheel hub and coat thinly with
thread locker.
Loctite® 648™
– Oil the freewheel and mount in the freewheel hub.
304257-11
– Mount freewheel hub  on the rotor.

– Mount new screws  and tighten in a crisscross pattern.
Guideline
Screw, freewheel hub M6 13 Nm Loctite® 648™
(9.6 lbf ft)
304256-11
30/ASSEMBLING THE ENGINE 177
Installing the oil pumps

20.1
– Mount needle roller  and internal rotor  on the oil pump shaft.
Marking  of the internal rotor faces groove .
304218-10
– Position the right section of the engine case in the engine assembly stand.
Engine assembly stand (61229001000) ( p. 285)
– Oil the oil pump shaft, internal rotor, and external rotor before assembly.
– Mount oil pump shaft  with internal rotor  and external rotor .
The marking of the external rotor is not visible after mounting.
304216-11
– Mount the pressure pump housing.

– Mount screw  but do not tighten them yet.
Guideline
Screw, oil pump housing M6 10 Nm Loctite® 243™
(7.4 lbf ft)
304217-10
– Mount needle roller .
304215-11
– Oil the internal rotor and external rotor before mounting.

– Mount internal rotor  and external rotor .
The markings are not visible after assembly.
304214-11
– Mount intake pump housing .
Info
Ensure that the dowel pins are seated properly.
304213-11
– Mount and tighten screws . Fully tighten screws .

Guideline
Screw, oil pump housing M6 10 Nm Loctite® 243™
(7.4 lbf ft)
304212-11
Installing the transmission shafts

20.2
– Assemble the two transmission shafts and slide them into the bearing seats
together.
304210-10
– Mount washer  and lock ring  of the countershaft.
304209-11
– Tilt the engine.

– Mount shift forks  with the shift rollers.
– Mount shift forks  with the shift rollers.
– Mount shift forks  with the shift rollers.
Info
Use a small amount of grease to fix the shift rollers to the shift forks.
304211-10
– Swing shift forks to one side.
Info
Watch out for the shift rollers.
– Insert shift drum  into the bearing seat.

– Hang the shift forks into the shift grooves with the shift rollers.
304207-11
– Mount shift rails  with the springs.
Info
Fix the springs in the shift rails with grease.
– Check the transmission for smooth operation.
304206-11
– Mount oil spray tube .

The oil spray tube engages in the housing with anti-rotation lock .
Info
If necessary, turn the main shaft slightly.
304205-11
Installing the crankshaft

20.3
– Press crankshaft  into the bearing seat.

Connecting rod  (cylinder 1) is lying at the top.
304204-11
Installing the left engine case

20.4
– Mount dowels .
– Put on gasket .
– Mount special tool  on the countershaft.
304202-10
304199-11
– Attach the left engine case, using a plastic hammer if necessary to seat it properly.
Info
Do not tighten the engine case sections using the screws.
– Mount screws  but do not tighten them yet.

Guideline
Screw, engine case M6x75 10 Nm (7.4 lbf ft)
– Mount screws  but do not tighten them yet.
Guideline
– Mount screws  but do not tighten them yet.
Guideline
– Mount screws  but do not tighten them yet.
Guideline
– Mount screws  but do not tighten them yet.
Guideline
– Mount screws  but do not tighten them yet.
Guideline
304200-10
– Tighten the screws in the direction of the arrow.

Guideline
Screw, engine case M6 10 Nm (7.4 lbf ft)
– Set the crankshaft to top dead center of cylinder 1.

The position notch of the crankshaft is visible in the hole.
– Mount special tool .
– Mount the screw connection of the engine fixing arm.
304201-10
Installing the oil filter

20.5
– Tilt the engine sideways and fill the oil filter housing to about ⅓ full with engine
oil.
– Insert oil filter .
304198-11
– Lubricate the O-ring of the oil filter cover. Mount the oil filter cover.
Guideline
304197-11
Installing the timing chain of cylinder 2

20.6
– Thread in the timing chain tensioning rail  from above.

Guideline
Screw, timing chain ten- M8 20 Nm Loctite® 243™
sioning rail (14.8 lbf ft)
304196-11
– Thread in timing chain .
Info
When installing a used timing chain, note the original direction of travel and
– Insert balancer shaft .

– Position the timing chain and slide the balancer shaft all the way into the bearing.
304195-11
Installing the rotor

20.7
– Mount free wheel gear .
304194-11
– Mount starter idler gear .
304193-11
– Position the holder.

Guideline
Screw, freewheel holder M6 10 Nm Loctite® 243™
(7.4 lbf ft)
304192-11
– Position the rotor.
Tip
For easier mounting, turn the starter idler gear counterclockwise.
– Mount and tighten screw  with the washer.

Guideline
Rotor screw M16x1.5 150 Nm Loctite® 243™
(110.6 lbf ft)
304190-11
Info
– Mount torque limiter .
304189-11
Installing the alternator cover

20.8
– Mount dowels  and put alternator cover seal  in place.
304188-11
– Position the alternator cover.

– Mount screws  but do not tighten them yet.
Guideline
Screw, alternator cover M6x35 10 Nm (7.4 lbf ft)
– Fit screws  with washers, but do not tighten yet.
Guideline
304187-11 – Mount screws  but do not tighten them yet.
Guideline
– Mount screw  with the cable holder but to not tighten yet.
Guideline
– Tighten all screws in a crisscross pattern.
Guideline
Screw in alternator cover M6 10 Nm (7.4 lbf ft)
Installing the gear position sensor

20.9
– Mount the contact springs and contact bolt .

The rounded sides of the contact pins face the sensor.
304185-11
– Mount the gear position sensor with the O-ring.

Guideline
Screw, gear sensor M5 3 Nm Loctite® 243™
(2.2 lbf ft)
– Fasten the cable in holder .
304184-11
Installing the locking lever

20.10
– Position locking lever  with sleeve and spring.

Guideline
Screw, locking lever M5 6 Nm Loctite® 243™
(4.4 lbf ft)
304183-10
Installing the shift drum locating

20.11
– Press locking lever  down and position shift drum locating unit .
Info
The flat surfaces  of the shift drum locating are not symmetric.
– Release the locking lever.
304181-10
– Mount and tighten screw .

Guideline
Screw, shift drum locating M6 10 Nm Loctite® 243™
(7.4 lbf ft)
304180-11
Installing the shift shaft

20.12
– Preassemble the shift shaft. ( p. 168)

– Slide shift shaft  with the washer into the bearing seat.
– Push sliding plate  away from the shift drum locating .
– Insert the shift shaft all the way.
– Let the sliding plate engage in the shift drum locating.
– Shift through the transmission.
304179-11
Removing the oil pump gear wheel

20.13
– Mount washer  and pin .
304178-11
– Position oil pump gear wheel .
304177-10
– Mount washer  and lock washer .
304176-11
Installing the timing chain of cylinder 1

20.14
– Thread in the timing chain tensioning rail  from above.

Guideline
Screw, timing chain ten- M8 20 Nm Loctite® 243™
sioning rail (14.8 lbf ft)
304174-11
– Mount bearing ring  and spring washer .
304175-11
– Mount timing chain sprocket .
Info
Ensure that the spring washers are seated properly.
When installing a used timing chain sprocket, note the original direction of
travel and the cylinder to which it belongs.
– Mount spring washer .
304173-11
– Thread in timing chain .
Info
When installing a used timing chain, note the original direction of travel and
304172-11
– Mount balance weight  with the recess facing out.
304171-11
Installing the primary gear

20.15
– Ensure that the spring washer is seated properly.

– Mount primary gear .
304170-10
Installing the spread transmission

20.16
– Mount the preassembled spread transmission .

The crankshaft is at the top dead center position for cylinder 1 and
markings  and  are aligned.
– Remove locking tool .
304168-10
– Mount spring washer .
304163-11
– Mount and tighten nut  with the washer.

Guideline
Nut, balancer shaft M20x1.5 120 Nm Loctite® 243™
(88.5 lbf ft)
Info
304161-11
Installing the clutch cage

20.17
Alternative 1
Only the outer clutch hub is removed.
– Mount washer .
304167-11
– Turn the crankshaft counterclockwise until the flat area  of the trigger wheel
faces the toothing of the outer clutch hub.
– Install the clutch cage .
304154-11
– Press the outer clutch hub away from the primary gear and mount needle bear-
ing .
304155-11

– Position washer .
304153-11
Alternative 2
The engine has been disassembled.
– Mount washer  and needle bearing .
304160-11
– Mount outer clutch hub  with trigger wheel .

Holding lug  engages in the drilled hole.
304159-11
– Mount washer .
304158-11
– Mount and tighten nut  with the washer.

Guideline
Nut, primary gear M33LHx1.5 130 Nm Loctite® 243™
(95.9 lbf ft)
304157-11
– Position the crankshaft position sensor.

– Mount screws  but do not tighten them yet.
Guideline
Screw, pulse generator M6 10 Nm Loctite® 243™
(7.4 lbf ft)
– Position cable guide  in the engine case.
304156-11
– Release the special tool.

– Turn the crankshaft slightly and adjust the distance between the ignition pulse
generator and the trigger wheel using the special tool.
Guideline
Ignition pulse generator/trigger wheel 0.70 mm (0.0276 in)
- distance
304571-10 Feeler gauge (59029041100) ( p. 278)

– Tighten screws .
Guideline
Screw, pulse generator M6 10 Nm Loctite® 243™
(7.4 lbf ft)
– Position special tool .
Clutch holder (60029003000) ( p. 278)
– Mount and tighten nut .
Guideline
Nut, inner clutch hub M22x1.5 130 Nm Loctite® 243™
(95.9 lbf ft)
304152-11 Clutch holder (60029003000) ( p. 278)
Installing the clutch discs

20.18
– Mount support ring  and pretension ring .

The pretension ring rests on the inside of the support ring, with the outside
facing away from the support ring.
304149-10
– Oil the clutch facing discs well.

– Mount clutch facing disc  with the larger inside diameter.
– Alternately mount 10 intermediate discs and 11 identical clutch facing discs.
– The outer clutch facing disc  must be mounted offset by one mesh.
The first and last clutch facing discs differ from the others in color.
304151-10
– Mount push rod .
304147-11
– Position pressure cap .

– Mount screws  with washers and springs and tighten in a crisscross pattern.
Guideline
Screw, clutch spring M6 10 Nm (7.4 lbf ft)
304146-11
Installing the clutch cover

20.19
– Screw  of the vibration damper must not be released.
Info
In this case, the screw cannot be secured sufficiently again and this would
result in the danger of engine damage. If the screw of the vibration damper
was released, a new outer clutch cover with vibration damper must be used
or the old outer clutch cover without a vibration damper.
304143-10
– Mount dowel  and clutch cover gasket .
304142-11
– Turn the water pump shaft  so that the cut-out engages in the inner clutch
hub  of the balancer shaft.
304144-10
– Mount the clutch cover. Mount screw  but do not tighten them yet.
Guideline
Screw, clutch cover M6x35 10 Nm (7.4 lbf ft)
– Mount screw  but do not tighten them yet.
Guideline
– Mount screws  and tighten all screws in a crisscross pattern.
304141-11 Guideline
– Mount oil screen  with the Top marking  facing up.
304145-10
– Mount the oil screen cover with the gasket.

– Mount and tighten screws .
Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
304139-11
Installing the water pump impeller

20.20
– Mount the washer and water pump impeller.

– Use the special tool to hold the water pump impeller tight.
Holding spanner, water pump impeller (60029082000) ( p. 284)
Guideline
Screw, water pump wheel M6 10 Nm Loctite® 243™
(7.4 lbf ft)
304138-11 – Mount dowels .
– Replace the gasket.
– Mount the water pump cover.
Guideline
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
304137-11
Installing cylinder 1 with the cylinder head

20.21
– Position the new cylinder base gasket .
304061-10
– Mount a cable binder at the end of the timing chain.

– Thread the timing chain and timing chain tensioning rail  into the cylinder.
– Carefully slide the cylinder down and position the connecting rod in the piston.
304062-10

– Mount piston pin .
304063-10
– Position the piston pin retainer.
Info
For clarity, the following steps are illustrated using a disassembled piston.
– Insert the special tool and firmly press it toward the piston.
Insert for piston ring lock (60029036000) ( p. 280)
– Turn the special tool counterclockwise, thereby pressing the piston pin retainer into
the groove.
– Ensure that the piston pin retainer is correctly seated on both sides.
400366-10
– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let the
dowel pins engage.
– Mount nut  with the washers and tighten in a crisscross pattern.
Guideline
Nut, cylinder head (exte- M10 Step 1 Only applies when
rior) 23 Nm using:
(17 lbf ft) Box wrench
Step 2 attachment
304064-10
34 Nm 13 mm
(25.1 lbf ft) (60029081000)
( p. 283)
Lubricated with
engine oil
Nut, cylinder head on M10 Step 1 Lubricated with
chain shaft 25 Nm engine oil
(18.4 lbf ft)
Step 2
38 Nm
(28 lbf ft)
Box wrench attachment 13 mm (60029081000) ( p. 283)

– Mount and tighten nuts  with the washers.
Guideline
Nut, cylinder head M6 8 Nm (5.9 lbf ft)
304065-10
Installing the timing gears of cylinder 1

20.22
– Remove the cable binder from the timing chain.

– Position timing gears  in the chain shaft.
The timing chain lies on the inside.
304069-10
– Position the timing chain on the timing gears using a wire hook .
Info
Hold the timing gears with a finger passed through the drilled hole of the
bearing bolt.
304070-10
– Grease the O-ring of bearing bolt .

– Mount the bearing bolt with the bearing.
304071-10

Guideline
Screw, bearing bolt of timing gears M10 30 Nm
(22.1 lbf ft)
304072-10
Installing the timing chain tensioner of cylinder 1

20.23
– Mount timing chain tensioner .
Info
The housing and the tension piston of the timing chain tensioner are
pressed together; if they can be separated, the timing chain tensioner must
be changed.
304073-10
– Mount and tighten screw  with the washer.

Guideline
Plug, timing-chain tensioner M16x1.5 20 Nm
(14.8 lbf ft)
304074-10
Installing the camshafts of cylinder 1

20.24
– Insert intake camshaft .
Info
The intake camshaft is labeled with INRE.
– Insert exhaust camshaft .

Markings  must be flush with the edge of the cylinder head.
Info
304075-10 The exhaust camshaft is labeled with EXRE.
– Thoroughly clean all oil jets and blow them out with compressed air.
– Position the camshaft bearing bridge.
– Mount screws  and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
Screw, camshaft bearing support M8 Step 1
10 Nm (7.4 lbf ft)
Step 2
304076-10 18 Nm
(13.3 lbf ft)

20.25
– Remove special tool .

– Keep the timing chain tensioned.
– Turn the crankshaft counterclockwise by the specified value.
Guideline
1 turn
304090-10
– Turn the crankshaft counterclockwise by the specified value .

Guideline
75°
– Screw in special tool .
304091-10
Installing cylinder 2 with the cylinder head

20.26
– Position the new cylinder base gasket .
304077-10
– Mount a cable binder at the end of the timing chain.

– Thread the timing chain and timing chain tensioning rail  into the cylinder.
– Carefully slide the cylinder down and position the connecting rod in the piston.
304078-10

– Mount piston pin .
304079-10
– Position the piston pin retainer.
Info
For clarity, the following steps are illustrated using a disassembled piston.
– Insert the special tool and firmly press it toward the piston.
Insert for piston ring lock (60029036000) ( p. 280)
– Turn the special tool counterclockwise, thereby pressing the piston pin retainer into
the groove.
– Ensure that the piston pin retainer is correctly seated on both sides.
400366-10
– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let the
dowel pins engage.
– Mount nut  with the washers and tighten in a crisscross pattern.
304080-10
Guideline
Nut, cylinder head (exte- M10 Step 1 Only applies when
rior) 23 Nm using:
(17 lbf ft) Box wrench
Step 2 attachment
34 Nm 13 mm
(25.1 lbf ft) (60029081000)
( p. 283)
Lubricated with
engine oil
Nut, cylinder head on M10 Step 1 Lubricated with
chain shaft 25 Nm engine oil
(18.4 lbf ft)
Step 2
38 Nm
(28 lbf ft)
Box wrench attachment 13 mm (60029081000) ( p. 283)

– Mount and tighten nuts  with the washers.
Guideline
Nut, cylinder head M6 8 Nm (5.9 lbf ft)
304081-10
Installing the timing gears of cylinder 2

20.27
– Remove the cable binder from the timing chain.

– Position timing gears  in the chain shaft.
The timing chain lies on the inside.
304082-10
– Position the timing chain on the timing gears using a wire hook .
Info
Hold the timing gears with a finger passed through the drilled hole of the
bearing bolt.
304083-10
– Grease the O-ring of bearing bolt .

– Mount the bearing bolt with the bearing.
304084-10

Guideline
Screw, bearing bolt of timing gears M10 30 Nm
(22.1 lbf ft)
304085-10
Installing the timing chain tensioner of cylinder 2

20.28
– Mount timing chain tensioner .
Info
The housing and the tension piston of the timing chain tensioner are
pressed together; if they can be separated, the timing chain tensioner must
be changed.
304086-10
– Mount and tighten screw  with the washer.

Guideline
(14.8 lbf ft)
304087-10
Installing the camshafts of cylinder 2

20.29
– Insert intake camshaft .
Info
The intake camshaft is labeled with INFR.
– Insert exhaust camshaft .

Markings  must be flush with the edge of the cylinder head.
Info
304088-10 The exhaust camshaft is labeled with EXFR.
– Thoroughly clean all oil jets and blow them out with compressed air.
– Position the camshaft bearing bridge.
– Mount screws  and tighten them from the outside to the inside.
Guideline
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
Screw, camshaft bearing support M8 Step 1
10 Nm (7.4 lbf ft)
Step 2
304089-10 18 Nm
(13.3 lbf ft)
Checking the valve clearance of cylinder 1

20.30
– Set the engine to ignition top dead center of cylinder 1. ( p. 128)

– On all valves, check the valve clearance between the camshaft and bucket tappet.
Guideline
Valve clearance
Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098…
0.0118 in)
Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…
0.0059 in)
Feeler gauge (59029041100) ( p. 278)

304093-10
» If valve clearance does not meet specifications:
– Adjust the valve clearance of cylinders 1. ( p. 199)
Adjusting the valve clearance of cylinders 1

20.31
– Remove the camshafts of cylinder 1. ( p. 128)

– Remove bucket tappet .
– Remove shims  and set them down according to the installation position.
– Correct the shims as indicated by the results of the valve clearance check.
– Insert suitable shims.
– Mount the bucket tappet.
– Install the camshafts of cylinder 1. ( p. 195)
– Check the valve clearance of cylinder 1. ( p. 199)
304094-10

20.32
– Remove special tool .

– Turn the crankshaft counterclockwise by the specified value.
Guideline
1 turn
304096-10
– Turn the crankshaft counterclockwise by the specified value .

Guideline
75°
– Screw in special tool .
304097-10
Checking the valve clearance of cylinders 2

20.33
– On all valves, check the valve clearance between the camshaft and bucket tappet.
Guideline
Valve clearance
Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098…
0.0118 in)
Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…
0.0059 in)
Feeler gauge (59029041100) ( p. 278)

304095-10
» If valve clearance does not meet specifications:

– Adjust the valve clearance of cylinders 2. ( p. 200)
Adjusting the valve clearance of cylinders 2

20.34
– Remove the camshafts of cylinder 2. ( p. 132)

– Remove bucket tappet .
– Remove shims  and set them down according to the installation position.
– Correct the shims as indicated by the results of the valve clearance check.
– Insert suitable shims.
– Install the camshafts of cylinder 2. ( p. 198)
– Check the valve clearance of cylinder 2. ( p. 199)
304098-10
– Remove special tool .

– Mount and tighten screw  with the washer.
Guideline
304099-10
– Mount and tighten screw .

Guideline
Screw in alternator cover M24x1.5 8 Nm (5.9 lbf ft)
304100-10
Installing the spark plugs

20.35
– Mount the spark plug using the special tool.

Guideline
Spark plug M12x1.25 18 Nm
(13.3 lbf ft)
Spark plug wrench (75029172000) ( p. 286)
303989-10
Installing the valve cover of cylinder 1

20.36
– Mount and grease O-rings .

303993-10
– Mount spark plug shaft insert  with gasket.
303988-11
– Position the valve cover with the valve cover seal.

Guideline
Screw, valve cover M6 10 Nm (7.4 lbf ft)
303987-11
Installing the valve cover of cylinder 2

20.37
– Mount and grease O-rings .

303992-10
– Mount spark plug shaft insert  with gasket.
303991-10
– Position the valve cover with the valve cover seal.

Guideline
Screw, valve cover M6 10 Nm (7.4 lbf ft)
303990-11
Installing the ignition coils

20.38
– Mount ignition coils .
303986-10
Installing the starter motor

20.39
– Grease the O-ring of the starter motor.

– Position the starter motor.
Guideline
Screw, starter motor M6 10 Nm (7.4 lbf ft)
303985-10
Preparing the engine for installation

20.40
– Position the ground wire.

Guideline
303983-11
– Position the radiator hose.

Guideline
303982-11
– Mount hose clamps  using the special tool.

Hose clamp pliers (60029057000) ( p. 283)
303981-11
– Mount membrane .
303980-10
– Position the SAS hose.

Guideline
303979-11

Guideline
303978-11
– Mount the vent hose.

– Mount hose clamp  using the special tool.
Hose clamp pliers (60029057000) ( p. 283)
303977-11
Removing the engine from the engine assembly stand

20.41
– Remove the fittings from the special tool.

– Dismount the engine from the work stand.
Info
Have an assistant help you or use a crane.
303976-11
32/CLUTCH 205
Checking/rectifying the fluid level of the hydraulic clutch

21.1
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the coolant level does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
B00672-10 Hydraulic fluid (15) ( p. 273)
Changing the hydraulic clutch fluid

21.2
Warning
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
304314-10
– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000) ( p. 277)
Hydraulic fluid (15) ( p. 273)
– On the slave cylinder, remove bleeder screw and mount bleeding syringe .
304315-10
– Inject the liquid into the system until it escapes from hole  of the master cylinder
without bubbles.
– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim 4 mm (0.16 in)
304316-10
35/WATER PUMP, COOLING SYSTEM 206
Draining the coolant

22.1
Warning
Danger of scalding During 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 poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
– Reset the fuel tank. ( p. 63)

– Place a suitable container under the radiator.
– Remove radiator cap .
– Remove screw .
– Completely drain the coolant.
– Mount screw  with a new seal ring and tighten it.
Guideline
B00680-10
– Place a suitable container under the engine.

– Completely drain the coolant.
– Mount screw  with a new seal ring and tighten it.
Guideline
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
B00676-11
Filling/bleeding the cooling system

22.2
Warning

– Ensure that the drain plug on the radiator and the water pump cover are tightened.
– Remove bleeder screw .
700629-10
– Position the vehicle as shown and secure it against rolling. Height difference 
must be reached.
Guideline
Height difference  50 cm (19.7 in)
Info
To make sure that all of the air can escape from the cooling system, raise
A
0 the front of the vehicle. A poorly bled cooling system is less effective at
cooling and the engine can overheat.
400677-10
– Remove the radiator cap and pour in coolant until it emerges without bubbles at
the vent hole, and then immediately mount and tighten the bleeder screw .
Alternative 1
Coolant ( p. 272)
Alternative 2
Coolant (mixed ready to use) ( p. 272)
– Fill the radiator completely with coolant. Mount the radiator cap.
B00682-10 – Lean the vehicle on the side stand.
Danger

– Stop the engine and allow it to cool down.
– When the engine is cool, check the coolant level in the radiator and add coolant if
necessary.
– Position the fuel tank. ( p. 63)
Checking the antifreeze and coolant level

22.3
Warning
Warning
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove radiator cap  and plug  from the compensating tank.

– Check the coolant antifreeze.
−25… −45 °C (−13… −49 °F)
» If the coolant antifreeze does not meet specifications:
– Correct the coolant antifreeze.
– Check the coolant level in the compensating tank.
The coolant level must be between the upper marking  and lower marking .
B00677-10
» If the coolant level in the compensating tank does not meet specifications, but
the tank is not empty:
– Add coolant to the upper marking.
Alternative 1
Coolant ( p. 272)
Alternative 2
» If there is no coolant in the compensating tank:
– Check the cooling system for leaks.
Info
Do not start up the motorcycle!

– Mount cap  of the compensating tank.
– Check the coolant level in the radiator.
The radiator must be completely filled.
» If the coolant level does not meet specifications:
– Correct the coolant level and determine the reason for the coolant loss.
Alternative 1
Coolant ( p. 272)
Alternative 2
B00678-10
» If more coolant needed to be added than the specified value:
> 0.50 l (> 0.53 qt.)
– Mount radiator cap .
Checking the coolant level in the compensating tank

22.4
Warning
Warning
Condition
The engine is cold.
The radiator is completely full.
– Stand the motorcycle on a horizontal surface.
– Check the coolant level in the compensating tank .

The coolant level must be between the upper marking  and lower marking .
» If the coolant level in the compensating tank does not meet specifications, but
the tank is not empty:
– Remove the compensating tank cap.
– Add coolant to the upper marking.
Alternative 1
B00679-10 Coolant ( p. 272)
Alternative 2
– Mount the cap of the compensating tank.
» If there is no coolant in the compensating tank:
– Check the cooling system for leaks.
Info
Do not start up the motorcycle!

38/LUBRICATION SYSTEM 210
Oil circuit
23.1
bbn
0n
0o
bbo
0
2 0l 0
bbl 9
bbk
0k
3
0
b0m
bm 8
0 0
7
4
0 bbr
0r
bbp
0p
b0q
bq
b0s
bs
bbt
0t
ccm
0m 1
0
0
5 6
0
ccn
0n
c0o
co
ccl
0l
c0k
ck
401183-60
Oil circuit of force pump

1 Force pump
2 Oil tank
3 Oil screen
4 Oil check valve
5 Oil pressure regulator valve
6 Oil filter
7 Ring duct
8 Main bearing
9 Conrod bearing
10 Oil jet (cylinder 2)
11 Oil jets for piston cooling (cylinder 2)
12 Timing chain tensioner (cylinder 2)
13 Camshaft (cylinder 2)
14 Oil pressure sensor
15 Distributor duct
16 Oil jets for piston cooling (cylinder 1)
17 Timing chain tensioner (cylinder 1)

18 Oil jet (cylinder 1)
19 Camshaft (cylinder 1)
20 Oil spray tube
21 Oil jet for clutch lubrication
Oil circuit of suction pump
22 Suction pump
23 Oil screen
24 Oil sump
Checking the engine oil level

23.2
Danger

stand).
Info
After switching off the engine, wait one minute before checking the level.
– Check the engine oil level at oil level viewer .

The engine oil level must be between the upper marking  and lower mark-
B00683-11 ing .
» If the engine oil level is not at the specified level:
– Add engine oil. ( p. 215)
Changing the engine oil and filter, cleaning the oil screens
23.3
– Drain the engine oil and filter, clean the oil screens. ( p. 211)
– Fill up with engine oil. ( p. 214)
B00119-01
Draining the engine oil and filter, cleaning the oil screens
23.4
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Info
Drain the engine oil only when the engine is warm.

– Remove the oil drain plug  with the magnet and seal ring.
– Fully drain the engine oil out of the engine.
700611-10
– Remove screws  and cover .
700610-10
– Pull oil screen  out of the engine case with pliers.
700612-10

– Remove oil drain plug .
– Fully drain the engine oil out of the oil tank.
– Remove screws  and move oil line  to one side.
700613-10
– Pull oil screen  out of the oil tank.
700615-10
– Remove screw connection  and move oil line to one side.

– Remove screws. Remove the oil filter cover  with the O-ring.
– Pull oil filter  out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 277)
– Completely drain the engine oil.
– Clean all oil screens and oil drain plugs with a magnet.
– Clean all sealing surfaces.
700617-10
– Insert oil filter .

– Lubricate the O-ring of the oil filter cover.
– Mount the oil filter cover . Mount and tighten the screws.
Guideline
– Position the oil line. Mount and tighten screw connection .
Guideline
700618-10 Nut, oil line M16x1.5 25 Nm
(18.4 lbf ft)
– Check seal ring  of the oil screen for damage and correct seating.
– Insert oil screen  into the oil tank.
700614-10
– Position oil line . Mount and tighten screws .

Guideline
– Mount oil drain plug  with the magnet and new seal and tighten.
Guideline
Oil drain plug with magnet M12x1.5 25 Nm
(18.4 lbf ft)
700613-10
– Mount oil drain plug  with the magnet and new seal ring and tighten.
Guideline
(25.8 lbf ft)
700611-10
– Slide oil screen  into the engine case with the TOP marking facing up.
– Check the form ring in cover  for damage and correct seating.
– Position the cover. Mount and tighten the screws.
Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
700616-10
Draining the engine oil

23.5
Warning
Warning

– Remove the oil drain plug  with the magnet and seal ring.
– Fully drain the engine oil out of the engine.
700611-10

– Remove oil drain plug .
– Fully drain the engine oil out of the oil tank.
– Mount the oil drain plug  with the magnet and seal ring and tighten it.
Guideline
(25.8 lbf ft)
– Mount the oil drain plug  with the magnet and gasket and tighten it.
304122-10
Guideline
(18.4 lbf ft)
Filling up with engine oil

23.6
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
– The oil must be added in two steps.

Engine oil 3.80 l External tem- Engine oil
(1.004 US gal) perature: ≥ 0 °C (SAE 10W/50)
(≥ 32 °F) ( p. 272)
External tem- Engine oil
perature: < 0 °C (SAE 5W/40)
(< 32 °F) ( p. 272)
– Remove plug  and add engine oil to the top marking .
B00683-10 – Mount the plug.
Danger

– Check the lubrication system for leaks.

stand).
– Remove the plug.
– Add engine oil to the top marking .
– Mount the plug.
Adding engine oil

23.7
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
The engine oil level must be corrected when the engine is warm.
– Remove plug  and add engine oil to the top marking .

Condition
External temperature: ≥ 0 °C (≥ 32 °F)
Engine oil (SAE 10W/50) ( p. 272)
Condition
External temperature: < 0 °C (< 32 °F)
Engine oil (SAE 5W/40) ( p. 272)
B00683-10
Info
For optimal performance of the engine oil, do not mix different types of
engine oil.
We recommend changing the engine oil, if necessary.
– Mount the plug.
Checking the engine oil pressure

23.8
Warning
Warning
– Remove screw  and the washer.
304317-10
– Mount and tighten the oil pressure adapter with the washer.
– Mount and tighten the banjo bolt with the washers.
Guideline
Banjo bolt M10x1 8 Nm (5.9 lbf ft)
Oil pressure adapter (60029006000) ( p. 279)

– Connect the pressure testing tool to the special tool without the t-plate.
Pressure testing tool (61029094000) ( p. 285)
304318-10
Danger
– Start the engine and let it warm up.

– Check the engine oil pressure.
Engine oil pressure
Coolant temperature: ≥ 70 °C ≥ 0.8 bar (≥ 12 psi)
(≥ 158 °F)
Engine speed: 1,500 rpm
Coolant temperature: ≥ 70 °C 2.4… 3.5 bar (35… 51 psi)
(≥ 158 °F)
» If the specifications have not been met:
– Change the oil filter.
– Check the oil pumps for wear.
– Check that all oil holes are free of blockages.
Warning
Danger of burns Some vehicle components get very hot when the machine
is driven.
– Wear appropriate protective clothing and safety gloves. In case of burns,
rinse immediately with lukewarm water.

Guideline
(14.8 lbf ft)
Checking the oil jet for the clutch lubrication

23.9
– Take off the engine sprocket cover.
305053-10
– Take off the clutch slave cylinder and hang it to the side.
Info
Do not actuate the clutch lever while the slave cylinder of the clutch is
removed.
Do not bend the clutch line.
305054-10
– Take off adapter  of the clutch slave cylinder.
305055-10
– Remove screw .
– Take off the chain securing guide.
305056-10
– Take off adapter  of the clutch slave cylinder.
Info
Do not misplace the locking pin of the clutch push rod.
305057-10
– Remove screw  with the washer.
305058-10
– Remove oil jet .

– Blow out oil jet with compressed air and check that it is clear.
– Mount and tighten oil jet.
Guideline
(3 lbf ft)
305059-10
– Mount and tighten screw  with the washer.

Guideline
Plug, clutch lubrication M10 15 Nm
(11.1 lbf ft)
305058-10
– Mount adapter  of the clutch slave cylinder.

The locking pin engages in the cut-out.
305057-10
– Position the chain securing guide.

Guideline
(18.4 lbf ft)
305056-10
– Mount adapter  of the clutch slave cylinder.
305055-10
– Position the clutch slave cylinder with the O-ring.

Guideline
305054-10
– Position the engine sprocket cover.

Guideline
305053-10
41/THROTTLE VALVE BODY 219
Throttle position sensor circuit A - check in zero position

24.1
Condition
The ignition is on.
The diagnostics tool is connected and active.
– Select model.
– Select "Adjustment".
– Select "Throttle position sensor circuit A adjustment".
400687-60
– Read the information screen on the KTM diagnostics tool and use "Continue" to start
the zero balance.
Info
The throttle stepper motor moves the throttle valve in circuit A to the "zero"
position (throttle valve fully closed position).
Throttle position sensor circuit A voltage "(THAD)"

In "zero" position 0.56… 0.64 V
» If the displayed value does not correspond to the nominal value:
– Adjust the position of the throttle position sensor in circuit A. ( p. 219)
Throttle position sensor circuit A - adjusting the position

24.2
Condition
The ignition is on.
– Remove the throttle valve body. ( p. 220)
– Plug in the connector of the throttle valve body.
400680-10
– Select model.
– Select "Adjustment".

– Select "Throttle position sensor circuit A adjustment".
– Read the information screen on the KTM diagnostics tool and use "Continue" to start the zero balance.
Info
The throttle stepper motor moves the throttle valve in circuit A to the "zero" position (throttle valve fully closed position).

» If the displayed value does not correspond to the nominal value:
– Loosen screw .
– Adjust the throttle valve sensor by turning to the specified value.
Guideline
– Tighten screw .
– Open and close the throttle grip fully ten times.
– Check the voltage again and readjust if necessary.
– Install the throttle valve body. ( p. 220)
Removing the throttle valve body

24.3
– Remove the air filter box. ( p. 59)

– Push back rubber caps .
– Loosen nuts .
– Unscrew the adjusting screws and take them out of the holder.
– Detach the throttle cable wires.
– Remove the throttle valve body.
304386-10
Installing the throttle valve body

24.4
– Adjust the position of the throttle position sensor in circuit A. ( p. 219)

– Attach the throttle cable wires to the throttle valve body.
– Move the handlebar to the straight-ahead position.
– Position the adjusting screws and lock nuts until the necessary play exists in the
throttle cable.
Guideline
400192-10
– Tighten nuts .
– Mount rubber caps .
– Install the air filter box. ( p. 60)
304386-11
Flashing the EFI control unit

24.5
Condition
The ignition is on.
– Select model.
– Select "ECU Flashing".
– Read the safety information and set up the required conditions.
400687-60
– Confirm the instruction by clicking on "OK".
– Press "Select file" and select the new mapping.
Info
"The BLZ file and the exhaust system must match!"
– Press the "ECU flash process" button.

– Read the safety notice and confirm with "OK".
The new mapping is loaded.
Requesting the EFI control unit activation code

24.6
Condition
An exchanged EFI control unit is connected.
The ignition is on.
The "ECU Flashing" process is complete.
– Select model.
– Select "Change VIN - New identity".
400687-60
– Read the information page on the KTM diagnostics tool and, using "Continue", start
the coding process.
– Overwrite the entry under the "Please enter VIN:" heading.
– Select "Code form".
– Press "Print".
The protocol is being printed out.
– Fill out the protocol and send to "diagnostic@ktm.com".
Coding the EFI control unit

24.7
Condition
The ignition is on.
For a used control unit
– Request the EFI control unit activation code. ( p. 221)
– Select model.
– Select "Change VIN - New identity".
400687-60
– Read the information page on the KTM diagnostics tool and, using "Continue", start
the coding process.
– Overwrite the entry under the "Please enter VIN:" heading.
– Select "Code entry".
– "Please enter the Code"
The new VIN is written to the EFI control unit.
– Switch to the main menu.
– Select "Show identification".
– Compare the old VIN to the new VIN.
The new VIN is shown.
IMMOBILIZER BLINK CODE 223
Blink code of immobilizer indi-

cator lamp
12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short
Possible cause All ignition keys inactive ( p. 223)
All ignition keys inactive

– Activate/deactivate the ignition key. ( p. 109)

cator lamp
Possible cause ICU antenna - value not plausible ( p. 224)
ICU antenna - coil antenna has an open ( p. 224)
Last measure if none of the doc- – Change the immobilizer control unit.
umented causes leads to elimi-
nation of the fault
ICU antenna - value not plausible

Condition
ICU antenna is disconnected.
ICU antenna - checking the resistance
– Measure the resistance between the specified points.
ICU antenna, connector EL pin 1 – ICU antenna, connector EL pin 2
ICU antenna 18.6… 19.8 Ω

– Change the ICU antenna.
» If the specifications have been met:
400685-10 – Check the next possible cause:
ICU antenna - coil antenna has an open ( p. 224)
ICU antenna - coil antenna has an open

Condition
The ICU is disconnected.
ICU antenna is connected.
ICU antenna - checking the coil antenna for opens
– Measure the resistance between the specified points.
Immobilizer control unit, connector DO pin 1 – Immobilizer control unit,
connector DO pin 2
ICU antenna 18.6… 19.8 Ω
– Check connector DO pin 1 and pin 2.
– Check connector DV pin 1 and pin 2.
400657-10
– Check the cable from connector DO pin 1 to connector DV pin 1 for opens.
– Check the cable from connector DO pin 2 to connector DV pin 2 for opens.
– Disconnect connector DV of the ICU antenna. Check the cables from connec-
tor DO pin 1 and pin 2 to connector DV pin 1 and pin 2 for mutual short circuits.
» If the specifications have been met:
– Change the immobilizer control unit.

cator lamp
Possible cause Malfunction in transponder of black ignition key ( p. 225)
Malfunction in transponder of black ignition key

– Use spare black ignition key.
– Order a new black ignition key according to the key number on the KEYCODECARD.

cator lamp
Possible cause Black ignition key inactive ( p. 226)
Black ignition key inactive


cator lamp
Possible cause Malfunction, ICU encryption for black ignition key ( p. 227)
Last measure if none of the doc- – Activate/deactivate the ignition key. ( p. 109)
umented causes leads to elimi-
nation of the fault
Malfunction, ICU encryption for black ignition key

– Use the black ignition key belonging to the vehicle.
Last measure if none of the documented causes leads to elimination of the fault

cator lamp
Possible cause ICU is not activated ( p. 228)
ICU is not activated

– Activate the immobilizer control unit. ( p. 111)

cator lamp
Possible cause Malfunction, encryption query from EFI control unit to immobilizer control unit ( p. 229)
Malfunction, encryption query from EFI control unit to immobilizer control unit
– Code the EFI control unit. ( p. 221)

cator lamp
Possible cause Malfunction in CAN bus communication ( p. 230)
Malfunction in CAN bus communication

– Read out the trouble code memory using the KTM diagnostics tool.

cator lamp
60 Immobilizer indicator lamp flashes 6x short
Possible cause E²PROM malfunction ( p. 231)
E²PROM malfunction
– Change the immobilizer control unit.
TECHNICAL DATA - ENGINE 232
Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled

Displacement 999 cm³ (60.96 cu in)
Stroke 62.4 mm (2.457 in)
Bore 101 mm (3.98 in)
Compression ratio 11.5:1
Control DOHC, 4 valves per cylinder, chain-driven
Valve - diameter
Exhaust 33 mm (1.3 in)
Intake 38 mm (1.5 in)
Valve clearance
Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098… 0.0118 in)
Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing Sleeve bearing
Conrod bearing Sleeve bearing
Piston Forged light alloy
Piston ring 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication Dry sump lubrication system with two rotor pumps
Primary transmission 35:67
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission 6-gears, claw-shifted
Transmission ratio
1st gear 12:35
2nd gear 15:32
3rd gear 18:30
4th gear 20:27
5th gear 24:27
6th gear 27:26
Mixture preparation Electronic fuel injection
Ignition system Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Alternator 12 V, 450 W
Spark plug NGK LKAR8BI9
Spark plug electrode gap 0.8 mm (0.031 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Idle speed (990 Supermoto T EU, 990 Supermoto T FR, 1,400… 1,500 rpm
990 Supermoto T AUS/UK)
Idle speed (990 Supermoto T USA) 1,400… 1,600 rpm
Cold start device Electric starter
Capacity- engine oil

26.1
Engine oil 3.80 l (1.004 US gal) External temperature: ≥ 0 °C Engine oil (SAE 10W/50)
(≥ 32 °F) ( p. 272)
External temperature: < 0 °C Engine oil (SAE 5W/40)
(< 32 °F) ( p. 272)
TECHNICAL DATA - ENGINE 233
Capacity - coolant
26.2
Coolant 2.30 l (2.43 qt.) Coolant ( p. 272)

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 234

Intake: New condition 1.0 mm (0.039 in)
Intake: Wear limit 1.20… 1.80 mm (0.0472… 0.0709 in)
Exhaust: New condition 1.0 mm (0.039 in)
Exhaust: Wear limit 1.50… 2.00 mm (0.0591… 0.0787 in)
Valve guide - diameter
Valve spring - length
External: New condition 42.00 mm (1.6535 in)
External: Wear limit 41.20 mm (1.622 in)
Internal: New condition 37.80 mm (1.4882 in)
Internal: Wear limit 37.00 mm (1.4567 in)
Valve - run-out
On the valve stem ≤ 0.05 mm (≤ 0.002 in)
On the valve plate: New condition ≤ 0.016 mm (≤ 0.00063 in)
On the valve plate: Wear limit ≤ 0.030 mm (≤ 0.00118 in)
Camshaft - bearing pin 23.960… 23.980 mm (0.94331… 0.94409 in)
Camshaft bearing - radial clearance
Cylinder head - bearing hole of camshaft 24.000… 24.021 mm (0.94488… 0.94571 in)
Piston - diameter
Size I 100.943… 100.957 mm (3.97413… 3.97468 in)
Size II 100.953… 100.967 mm (3.97452… 3.97507 in)
Piston - piston pin hole diameter
Wear limit 22.030 mm (0.86732 in)
Piston pin - diameter
Wear limit 21.980 mm (0.86535 in)
Cylinder - bore diameter
Size I 101.000… 101.012 mm (3.97637… 3.97684 in)
Size II 101.013… 101.025 mm (3.97688… 3.97735 in)
Cylinder/cylinder head - distortion of sealing area ≤ 0.10 mm (≤ 0.0039 in)
Piston ring - groove clearance ≤ 0.08 mm (≤ 0.0031 in)
Piston ring end gap
Ring 1 ≤ 0.40 mm (≤ 0.0157 in)
Ring 2 ≤ 0.40 mm (≤ 0.0157 in)
Ring 3 ≤ 0.40 mm (≤ 0.0157 in)
Piston ring
Width, first ring (L-ring) 0.850… 0.880 mm (0.03346… 0.03465 in)
Width, first ring (L-ring) 1.200… 1.270 mm (0.04724… 0.05 in)
Width, second ring (tapered compression piston ring) 1.220… 1.240 mm (0.04803… 0.04882 in)
Width, oil scraper ring 2.470… 2.490 mm (0.09724… 0.09803 in)
Connecting rod - upper conrod eye diameter
Wear limit 22.040 mm (0.86771 in)
Connecting rod - radial clearance of lower conrod bearing

Connecting rod - axial clearance of lower conrod bearing
Connecting rod - large end width 21.948… 22.000 mm (0.86409… 0.86614 in)
Crankshaft - axial clearance
Crankshaft - crank pin diameter
Yellow 41.978… 41.989 mm (1.65267… 1.65311 in)
Blue 41.990… 42.000 mm (1.65315… 1.65354 in)
Red 42.001… 42.011 mm (1.65358… 1.65397 in)
Crankshaft - crank pin width 44.30… 44.35 mm (1.7441… 1.7461 in)
Crankshaft - main bearing diameter
Yellow 49.965… 49.975 mm (1.96712… 1.96752 in)
Blue 49.976… 49.985 mm (1.96756… 1.96791 in)
Red 49.986… 49.995 mm (1.96795… 1.9683 in)
Crankshaft - support bearing diameter 27.985… 28.000 mm (1.10177… 1.10236 in)
Crankshaft - support bearing radial clearance
Crankshaft run-out at bearing pin ≤ 0.03 mm (≤ 0.0012 in)
Crankshaft - main bearing radial clearance
Clutch facing disc - thickness ≥ 2.6 mm (≥ 0.102 in)
Intermediate disk - thickness
Clutch discs - total package thickness
Clutch spring - length ≥ 29.00 mm (≥ 1.1417 in)
Clutch cage - contact surface of clutch facing discs ≤ 0.5 mm (≤ 0.02 in)
Shift shaft - play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in)
Transmission shaft - axial play 0.05… 0.15 mm (0.002… 0.0059 in)
Shift fork
Thickness at leaf 4.85… 4.95 mm (0.1909… 0.1949 in)
Clearance in the sliding gear groove: New condition 0.10… 0.25 mm (0.0039… 0.0098 in)
Clearance in the sliding gear groove: Wear limit 0.40 mm (0.0157 in)
Sliding gear - shift fork groove width 5.02… 5.12 mm (0.1976… 0.2016 in)
Oil pressure regulator valve - minimum spring length 42.00 mm (1.6535 in)
Oil pumps
Clearance, external rotor/engine case or oil pump housing 0.20… 0.40 mm (0.0079… 0.0157 in)
Clearance between external rotor and internal rotor 0.10… 0.20 mm (0.0039… 0.0079 in)
Axial clearance: New condition 0.04… 0.09 mm (0.0016… 0.0035 in)
Axial clearance: Wear limit 0.25 mm (0.0098 in)
Engine oil pressure
Coolant temperature: ≥ 70 °C (≥ 158 °F) ≥ 0.8 bar (≥ 12 psi)
Coolant temperature: ≥ 70 °C (≥ 158 °F) 2.4… 3.5 bar (35… 51 psi)
Oil consumption ≤ 0.6 l/1.000 km (≤ 0.6 qt./600 mi)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 237
Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) –

Screw, oil spray tube M4 6 Nm (4.4 lbf ft) Loctite® 243™
Oil jet M5 4 Nm (3 lbf ft) Loctite® 243™
Remaining engine screws M5 6 Nm (4.4 lbf ft) –
Screw, bearing retainer M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, connecting angle on valve cover M5 3 Nm (2.2 lbf ft) Loctite® 243™
Screw, gear sensor M5 3 Nm (2.2 lbf ft) Loctite® 243™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™
Nut, cylinder head M6 8 Nm (5.9 lbf ft) –
Plug, vacuum connection M6 5 Nm (3.7 lbf ft) Loctite® 243™
Remaining engine screws M6 10 Nm (7.4 lbf ft) –
Screw in alternator cover M6 10 Nm (7.4 lbf ft) –
Screw, bearing bolt in alternator cover M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, freewheel holder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, freewheel hub M6 13 Nm (9.6 lbf ft) Loctite® 648™
Screw, oil pump housing M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, pulse generator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, starter motor M6 10 Nm (7.4 lbf ft) –
Screw, stator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™
Vacuum connection M6 2.5 Nm (1.84 lbf ft) Loctite® 243™
Oil jet M6x0.75 4 Nm (3 lbf ft) Loctite® 243™
Screw, camshaft bearing support M8 Step 1 –
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
Screw, clutch cover M8 15 Nm (11.1 lbf ft) –
Screw, cylinder head M8 Step 1 Loctite® 243™
18 Nm (13.3 lbf ft)
Step 2
23 Nm (17 lbf ft)
Screw, timing chain guide rail M8 15 Nm (11.1 lbf ft) Loctite® 243™
Screw, timing chain tensioning rail M8 20 Nm (14.8 lbf ft) Loctite® 243™
Stud, exhaust flange M8 15 Nm (11.1 lbf ft) –
Nut, cylinder head (exterior) M10 Step 1 Only applies when using:
23 Nm (17 lbf ft) Box wrench attachment
Step 2 13 mm (60029081000)
34 Nm (25.1 lbf ft) ( p. 283)
Lubricated with engine oil
Nut, cylinder head on chain shaft M10 Step 1 Lubricated with engine oil
25 Nm (18.4 lbf ft)
Step 2
38 Nm (28 lbf ft)
Plug, clutch lubrication M10 15 Nm (11.1 lbf ft) –
Screw, bearing bolt of timing gears M10 30 Nm (22.1 lbf ft) –
Stud, cylinder head in engine case M10 20 Nm (14.8 lbf ft) –
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 238
Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) –

Screw, conrod bearing M10x1 Step 1 –
25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
60°
Spark plug M12x1.25 18 Nm (13.3 lbf ft) –
Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –
Plus, cylinder head (2nd cylinder) M12x1.5 25 Nm (18.4 lbf ft) –
Plug, oil filter housing M14x1.5 15 Nm (11.1 lbf ft) Loctite® 243™
Bleeder flange, alternator cover M16x1.5 10 Nm (7.4 lbf ft) Loctite® 243™
Plug, timing-chain tensioner M16x1.5 20 Nm (14.8 lbf ft) –
Rotor screw M16x1.5 150 Nm (110.6 lbf ft) Loctite® 243™
Nut, balancer shaft M20x1.5 120 Nm (88.5 lbf ft) Loctite® 243™
Nut, engine sprocket M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Screw-in fitting, cooling system M20x1.5 10 Nm (7.4 lbf ft) Loctite® 577
Nut, inner clutch hub M22x1.5 130 Nm (95.9 lbf ft) Loctite® 243™
Oil drain plug with magnet M22x1.5 35 Nm (25.8 lbf ft) –
Screw in alternator cover M24x1.5 8 Nm (5.9 lbf ft) –
Nut, primary gear M33LHx1.5 130 Nm (95.9 lbf ft) Loctite® 243™
TECHNICAL DATA - CHASSIS 239
Frame Lattice frame made of chrome molybdenum steel tubing,

powder-coated
Fork WP Suspension Up Side Down 4860 ROMA PA
Shock absorber WP Suspension 4618 BAVP DCC
Suspension travel
Front 160 mm (6.3 in)
Rear 180 mm (7.09 in)
Brake system
Front Double disc brake with radially screwed four-piston brake
calipers, float-mounted brake discs
Rear Single disc brake with dual-piston brake caliper, rigid-mounted
brake disc
Brake discs - diameter
Front 305 mm (12.01 in)
Rear 240 mm (9.45 in)
Brake discs - wear limit
Front 4.5 mm (0.177 in)
Brake disc - wear limit
Rear 4.5 mm (0.177 in)
Tire air pressure, solo
Tire air pressure with passenger/full payload
Secondary drive ratio 17:41
Chain 5/8 x 5/16” X‑ring
Steering head angle 65.6°
Wheelbase 1,505±15 mm (59.25±0.59 in)
Seat height, unloaded 855 mm (33.66 in)
Ground clearance, unloaded 195 mm (7.68 in)
Weight without fuel, approx. 198 kg (437 lb.)
Maximum permissible front axle load 160 kg (353 lb.)
Maximum permissible rear axle load 250 kg (551 lb.)
Maximum permissible total weight 400 kg (882 lb.)
Battery YTZ14S Battery voltage: 12 V

Nominal capacity: 11.2 Ah
maintenance-free
Fuse 75011088010 10 A
Fuse 75011088015 15 A
Fuse 58011109130 30 A
Lighting equipment
29.1
Low beam/high beam H4/socket P43t 12 V

60/55 W
Parking light W5W/socket W2.1x9.5d 12 V
5W
Instrument lights and indicator lamps LED
Turn signal RY10W/socket BAU15s 12 V
10 W
Tail light (990 Supermoto T EU, WR5W/socket W2.1x9.5d 12 V
990 Supermoto T FR, 5W
TECHNICAL DATA - CHASSIS 240
Tail light (990 Supermoto T USA) W5W/socket W2.1x9.5d 12 V

5W
Brake light (990 Supermoto T EU, PR21W/socket BAW15s 12 V
990 Supermoto T FR, 21 W
Brake light (990 Supermoto T USA) P21W/socket BA15s 12 V
21 W
License plate lamp W5W/socket W2.1x9.5d 12 V
5W
Capacity - fuel
29.2
Total fuel tank capacity, 19 l (5 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 273)
approx.
Fuel reserve, approx. 3.7 l (3.9 qt.)

TECHNICAL DATA - FORK 241
Fork part number 14.18.7K.43

Fork WP Suspension Up Side Down 4860 ROMA PA
Compression damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Rebound damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Spring preload - Preload Adjuster
Comfort 5 turns
Standard 5 turns
Sport 3 turns
Full payload 3 turns
Spring length with preload spacer(s) 384 mm (15.12 in)
Spring rate
Soft 6.5 N/mm (37.1 lb/in)
Medium (standard) 7.0 N/mm (40 lb/in)
Hard 7.5 N/mm (42.8 lb/in)
Fork length 877 mm (34.53 in)
Air chamber length 100±20 mm (3.94±0.79 in)
Fork oil per fork leg 737 ml (24.92 fl. oz.) Fork oil (SAE 5) ( p. 273)
TECHNICAL DATA - SHOCK ABSORBER 242
Shock absorber part number 15.18.7K.43

Shock absorber WP Suspension 4618 BAVP DCC
Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring preload
Comfort 10 mm (0.39 in)
Spring rate
Soft 140 N/mm (799 lb/in)
Medium (standard) 150 N/mm (857 lb/in)
Spring length 200 mm (7.87 in)
Static sag 20 mm (0.79 in)
Fitted length 372 mm (14.65 in)
Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 273)
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 243
Remaining frame bolts EJOT Delta PT 50x12 1.2 Nm (0.89 lbf ft) –
Remaining frame bolts EJOT PT K50x12 T20 1.2 Nm (0.89 lbf ft) –
Remaining frame bolts EJOT PT K50x18 T20 2 Nm (1.5 lbf ft) –
Screw, brake line holder EJOT PT K60x20 2 Nm (1.5 lbf ft) –
Screw, chain sliding piece EJOT PT K60x20 2 Nm (1.5 lbf ft) –
Screw, combination instrument EJOT Delta PT 50x12 1 Nm (0.7 lbf ft) –
Screw, rear side part EJOT Altracs 50x16 Initial screw connection –
3.3 Nm (2.43 lbf ft)
Subsequent screw connec-
tion
2 Nm (1.5 lbf ft)
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite® 243™
Remaining chassis nuts M5 5 Nm (3.7 lbf ft) –
Remaining chassis screws M5 5 Nm (3.7 lbf ft) –
Screw, brake line holder M5 2 Nm (1.5 lbf ft) –
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft) –
Screw, closure flange, fuel tank M5 3.3 Nm (2.43 lbf ft) –
Screw, engine oil level viewer M5 3.3 Nm (2.43 lbf ft) –
Screw, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, mask spoiler M5 1.2 Nm (0.89 lbf ft) –
Screw, windshield M5 3.3 Nm (2.43 lbf ft) –
Nut, tail light M6 8 Nm (5.9 lbf ft) –
Screw, cable guide M6 2 Nm (1.5 lbf ft) –
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, fuel pump M6 6 Nm (4.4 lbf ft) –
Screw, fuel tap M6 6 Nm (4.4 lbf ft) –
Screw, holder on ABS unit M6 6 Nm (4.4 lbf ft) –
Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, seat bracket, fuel tank M6 3.3 Nm (2.43 lbf ft) –
Screw, splash protector M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, spoiler M6 3.3 Nm (2.43 lbf ft) –
Screw, wheel speed sensor M6 6 Nm (4.4 lbf ft) Loctite® 243™
Nut, manifold on cylinder head M8 Tightening sequence: –
Tighten the nuts uniformly.
Do not bend the metal.
Screw, bag carrier M8 15 Nm (11.1 lbf ft) Loctite® 243™
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, exhaust clamp on distributor M8 35 Nm (25.8 lbf ft) –
pipe
Screw, exhaust clamp on main silencer M8 20 Nm (14.8 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, handrail M8 20 Nm (14.8 lbf ft) –
Screw, ignition lock (ratchet screw) M8 Loctite® 243™
Screw, mask holder M8 15 Nm (11.1 lbf ft) Loctite® 243™
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 244
Screw, spring holder on side stand M8 25 Nm (18.4 lbf ft) Loctite® 243™
bracket
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 20 Nm (14.8 lbf ft) –
Remaining frame bolts M10 45 Nm (33.2 lbf ft) –
Screw connection, engine mounting M10 45 Nm (33.2 lbf ft) –
bracket
Screw, handlebar support M10 20 Nm (14.8 lbf ft) –
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite® 243™
Screw, side stand bracket M10 45 Nm (33.2 lbf ft) Loctite® 243™
Banjo bolt, brake line M10x1 15 Nm (11.1 lbf ft) –
Brake light switch M10x1 15 Nm (11.1 lbf ft) –
Screw connection, rear hub shock M10x1.25 50 Nm (36.9 lbf ft) Loctite® 243™
absorber/rear sprocket
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, lower subframe M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, upper subframe M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft) –
Screw connection, suction line M14x1.5 45 Nm (33.2 lbf ft) Loctite® 577
Screw, bottom shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased
Screw, top shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased
Nut, oil line M16x1.5 25 Nm (18.4 lbf ft) –
Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased
Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) –
Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased
CLEANING/CONSERVATION 245
Cleaning motorcycle
33.1
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-
cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
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.
– Close off the exhaust system to keep water from entering.

– Remove coarse dirt particles with a gentle spray of water.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a
paintbrush.
Motorcycle cleaner ( p. 275)
Info
Clean the vehicle using warm water containing normal motorcycle cleaner
401061-01 and a soft sponge.
If the vehicle was operated in road salt, clean it with cold water. Warm
water would enhance the corrosive effects of salt.
– After the motorcycle has been thoroughly cleaned with a gentle jet of water, it
should be dried with compressed air and a cloth.
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– After cleaning, ride the vehicle a short distance until the engine warms up, apply-
ing the brakes occasionally.
Info
The heat produced causes water at inaccessible positions in the engine and
on the brakes to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Clean the chain. ( p. 79)
– Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 274)
– Treat all painted parts with a mild paint polish.
High-luster polish for paint ( p. 274)
– Oil the ignition/steering lock, tank lock, and seat lock.
Universal oil spray ( p. 275)
CLEANING/CONSERVATION 246
Checks and maintenance measures for winter operation

33.2
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres-
sive road salt.
If the vehicle was operated in road salt, clean it with cold water after use. Warm water would enhance the corrosive effects of
salt.
– Clean the motorcycle. ( p. 245)

– Clean the brakes.
Info
After EVERY trip on salted roads, thoroughly clean the brake calipers and
brake linings after they have cooled down while they are installed; use cold
water and dry them well.
After riding on salted roads, thoroughly wash the motorcycle with cold water
and dry it well.
401060-01
– Treat the engine, the swingarm, and all other bare or galvanized parts (except brake
discs) with a wax-based anti-corrosion substance.
Info
To prevent serious reduction of the braking efficiency, make sure no anti-
corrosion substance gets on to the brake discs.
– Clean the chain. ( p. 79)

STORAGE 247
Storage
34.1
Info
If you want to garage the motorcycle for a longer period, take the following actions.
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.
– Make sure the fuel tanks are as empty as possible so that you can fill up with fresh
fuel when you put the motorcycle back into operation.
– Clean the motorcycle. ( p. 245)
– Change the engine oil and filter, clean the oil screens. ( p. 211)
– Check the antifreeze and coolant level. ( p. 207)
– Check the tire air pressure. ( p. 72)
– Remove the battery. ( p. 83)
– Recharge the battery. ( p. 84)
401058-01
Guideline
Storage temperature of battery without 0… 35 °C (32… 95 °F)
direct sunshine
– Store the vehicle in a dry location that is not subject to large fluctuations in tem-
perature.
Info
KTM recommends raising the motorcycle.

– Raise the motorcycle with the front wheel stand. ( p. 9)
– Cover the motorcycle with a tarp or cover that is permeable to air.
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.
Preparing for use after storage

34.2
– Take the motorcycle off of the front wheel stand. ( p. 9)

– Recharge the battery. ( p. 84)
– Install the battery. ( p. 83)
– Refuel.
– Perform checks and maintenance measures when preparing for use.
– Take a test ride.
401059-01
SERVICE SCHEDULE 248
Service schedule
35.1
K10N K75A K150A K300A

Check that the electrical equipment is functioning properly. • • • •
Read out the trouble code memory using the KTM diagnostics tool. • • • •
Check the measured service values with the KTM diagnostics tool. • • •
Change the engine oil and filter, clean the oil screens. ( p. 211) • • • •
Check the oil jet for the clutch lubrication. ( p. 216) • • •
Check the front brake linings. ( p. 88) • • • •
Check the front brake discs. ( p. 73) • • • •
Check the rear brake linings. ( p. 92) • • • •
Check the rear brake disc. ( p. 80) • • • •
Check that brake lines are undamaged and free of leaks. • • • •
Check the rear brake fluid level. ( p. 95) • • • •
Check the free travel of the foot brake lever. ( p. 94) • • • •
Check the shock absorber and fork for leaks. Perform a fork and shock absorber service if
• • • •
needed and depending on vehicle use.
Check the swingarm bearings. • • •
Check the wheel bearing for play. • • •
Check the tire condition. ( p. 72) • • • •
Check the tire air pressure. ( p. 72) • • • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 78) • • •
Check the chain tension. ( p. 77) • • • •
Lubricate all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth opera-
• • • •
tion.
Clean the dust boots of the fork legs. ( p. 14) • • •
Check the front brake fluid level. ( p. 90) • • • •
Bleed the fork legs. ( p. 14) • • •
Check the steering head bearing play. ( p. 26) • • • •
Change the spark plugs. • •
Check the valve clearance. • •
Check all hoses (e.g. fuel, cooling, bleeding, drainage, ...) and sleeves for cracking, leaks, and
• •
incorrect routing.
Check the antifreeze and coolant level. ( p. 207) • • • •
Check the wiring harness of the throttle valve body for damage and correct routing. • •
Check the cables for damage and kink-free routing. • •
Check the control cables for damage, kink-free routing and adjustment. • • • •
Change the air filter. Clean the air filter box. • •
Check the fuel pressure. • • •
Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics
• • •
tool.
Check the CO adjustment with the KTM diagnostics tool. • • •
Check/rectify the fluid level of the hydraulic clutch. ( p. 205) • • •
Check the fasteners for tightness. • • • •
Change the coolant. •
Change the front brake fluid. ( p. 91) • •
Change the rear brake fluid. ( p. 96) • •
Check the clutch. • •
Check the headlight setting. ( p. 102) • • • •
Check the radiator fan operation. • • • •
Final inspection: Check the vehicle of roadworthiness and take a test ride. • • • •
Read out the fault memory after a test ride using the KTM diagnostics tool. • • • •
Make the service entries in the KTM DEALER.NET and service record. • • • •
K10N: Once after 1,000 km (621.4 mi)
SERVICE SCHEDULE 249
K75A: Every 7,500 km (4,660 mi) or every year

K150A: Every 15,000 km (9,321 mi) or every 2 years
K300A: Every 30,000 km (18,641 mi) or every 4 years
250 1 2 3 4 5 6 7 8
305041-01
-P10 -A50
/2.A6 /2.A4
A A
6
1
ED/32 EF/14 EF/14
6
-X29 -X8 -X8
ye-rd
ye-rd
br
B B
wh-rd a /2.B1
bl-rd b /2.C1
wh-rd
wh-rd
wh-rd
wh-rd
wh-rd
ye-rd
bl-rd
bl-rd
rd
br
br
br
bl
bl
bl
bl
C -X4 C
-X3 AU/2 -X79 -X83 -X7
2
1
AF/4 FJ/2 FP/1 EB/4
3
2
2
1
1
BI/2
1
1
1
2
2
3
-X86
-M10 -K10 -G10 -T20 -G20 -F6 -X82 -X290 CR/1 -K11
1
3
30A
1 1
-X291 EE/1
1
2 2
10A
M
U CR/1
1
3 3 G
EE/1 CR/1
1
EM/3
EN/3
CR/1 -X81 -X292
1
-X85
3
4
4
2
1
AF/4 FJ/2 FP/1 EB/4
1
2
3
4
4
D -X3 -X79 -X84 -X7 D
rd-bu
gn-or
rd-bu
ye-rd
gn
gn
br
rd
rd
rd
rd
br
bl
bl
br
-X301 -X302
E E
WIRING DIAGRAM
rd c /11.E1
bl d /11.F1
br e /2.F1
Page 1 of 11
gn-or f /7.F1
F F
990 Supermoto T ABS 2011

1/11
1 2 3 4 5 6 7 8
36.1
WIRING DIAGRAM 251
Components:
A50 Alarm system (optional)
F6 Fuse
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
K11 Start auxiliary relay
M10 Starter motor
P10 Combination instrument
T20 Voltage regulator
X290 Socket
X291 Connector for accessory, ground ACC 1 (not assigned)
X292 Connector for accessory plus terminal 30 ACC 1 (not assigned)
252 1 2 3 4 5 6 7 8
305042-01
-A11 -A50 -P10
/6.A1 /1.A6 /1.A5
A /4.A3 /3.A3 A
14
2
2
CO/34 EF/14 ED/32
2
14
-X10 -X8 -X29
bu-gr
ye-or
ye-or
B B
/1.B8 a wh-rd
/1.C8 b bl-rd
wh-rd
wh-rd
wh-rd
bu-gr
ye-or
bl-bu
bl-bu
bl-gn
bl-rd
rd
rd
br
rd
C -X1 -X72 -X13 C
BR/4 AU/2 -X12 AM/3 -X14 -X15 -X73 -X6 -X78
4
2
1
1
EB/4 AI/2 EB/4 FJ/2 EB/4 FJ/2
4
2
1
1
BK/4 BI/2 AR/3
1
1
1
1
2
4
2
3
4
-S23 -S11 -K40 -M13 -R10 -K30 -F5 -K12 -F1
/8.D4 /5.D7
10A
10A
M
/5.D7
BK/4 BI/2 AR/3
3
4
4
2
2
3
3
2
1
1
EB/4 AI/2 EB/4 FJ/2 EB/4 FJ/2
1
2
2
3
4
4
D BR/4 AU/2 -X12 AM/3 -X14 -X15 -X73 -X6 -X78 D
1
2
-X1 -X72 3 -X13

wh-or
wh-or
wh-or
ye-or
ye-or
bl-gn
bl-ye
bl-ye
bl-ye
gn
br
br
or
br
E bl-ye g /4.E1 E
WIRING DIAGRAM
gn h /3.E1
/1.F8 e br br e /3.F1
Page 2 of 11
or i /6.F1
F F

2/11
1 2 3 4 5 6 7 8
36.2
WIRING DIAGRAM 253
Components:
A11 EFI control unit
F1 Fuse
F5 Fuse
K12 Light relay
K30 Power relay
K40 Fuel pump relay
M13 Fuel pump
R10 Diode
S11 Ignition/steering lock
S23 Emergency OFF switch, electric starter button
254 1 2 3 4 5 6 7 8
305043-01
-P10
/2.A6
A /4.A5 A
8
ED/32
8
-X29
bu
B B
ye j /4.B1
wh-gn
wh-gn
wh-gn
gn
gn
bu
bu
gn
ye
ye
ye
gr
gr
C -X21 -X23 -X25 -X22 C
-X76 -X26 AD/12 -X30 -X77 -X24 AH/2 AH/2 AJ/3
7
8
2
1
FJ/2 FF/1 BW/3 FJ/2 DI/2
3
2
2
1
1
BD/12 AK/2 AK/2 BG/3
1
1
1
7
2
8
10
4
2
3
-F3 -P15 -S24 -E13 -F2 -P35 -B76 -B77 -P36
/4.C1 LO HI P.light
10A
15A
P
12
11 BD/12 AK/2 AK/2 BG/3

2
2
5
3
2
1
1
1
FJ/2 FF/1 BW/3 FJ/2 DI/2
1
1
2
2
D -X76 -X28 AD/12 -X30 -X77 -X24 AH/2 AH/2 AJ/3 D
1
1
2
3
-X21 -X23 -X25 -X22
ye-bu
ye-bu
ye-bu
ye-bu
gn
gn
ye
ye
br
br
br
br
ye-bu k /4.E1
E E
WIRING DIAGRAM
/2.E8 h gn gn h /5.E1
/2.F8 e br br e /4.F1
Page 3 of 11
F F

3 /11
1 2 3 4 5 6 7 8
36.3
WIRING DIAGRAM 255
Components:
B76 Front brake light switch
B77 Rear brake light switch
E13 Low beam, high beam
F2 Fuse
F3 Fuse
P15 Horn
P35 Parking light
P36 Brake/tail light
S24 Light switch, horn button, headlight flasher switch, turn signal switch
256 1 2 3 4 5 6 7 8
305044-01
-A50 -P10
/2.A4 /3.A3
A /5.A4 A
10
17
10
11
7
9
9
4
EF/14 EF/14 ED/32
11
7
9
10
17
10
9
4
-X8 -X8 -X29
bu-rd
bu-rd
pu
gn
pu
rd
bl
bl
B B
/3.B8 j ye
wh-pu
wh-pu
wh-bl
wh-bl
pu
pu
pu
ye
rd
br
br
br
br
bl
bl
bl
C -X21 -X71 -X33 -X34 -X36 -X37 -X38 C
AD/12 DN/8 CX/2 CX/2 BS/2 CX/2 CX/2 -X35
9
3
8
6
2
2
1
1
DI/2
2
BD/12 DO/8 CW/2 CW/2 BV/2 CW/2 CW/2
1
2
2
9
3
8
6
2
-S24 -K21 -P41 -P42 -B36 -X19 -P45 -P46 -E60 -X18
/3.C3 CV/4 BY/4
3
4
2
1
LR
G
BY/4 CV/4
2
3
4
BD/12 DO/8 CW/2 CW/2 BV/2 -X18 CW/2 CW/2 -X19
7
5
6
1
1
1
DI/2
1
D AD/12 DN/8 CX/2 CX/2 BS/2 CX/2 CX/2 -X35 D
1
1
7
2
5
6
-X21 -X71 -X33 -X34 -X36 -X37 -X38

ye-bu
ye-bu
bl-ye
bl-ye
wh
wh
pu
pu
br
br
br
br
br
bl
bl
/3.E8 k ye-bu
E /2.E8 g bl-ye bl-ye g /8.E1 E

WIRING DIAGRAM
/3.F8 e br br e /5.F1
Page 4 of 11
F F

4/11
1 2 3 4 5 6 7 8
36.4
WIRING DIAGRAM 257
Components:
B36 Alarm system switch (optional)
E60 License plate lamp
K21 Hazard warning flasher relay
P41 Front left turn signal
P42 Front right turn signal
P45 Rear left turn signal
P46 Rear right turn signal
S24 Light switch, horn button, headlight flasher switch, turn signal switch
258 1 2 3 4 5 6 7 8
305045-01
-P10
/4.A5
A /7.A1 A
14
18
23
7
6
ED/32 ED/32 ED/32 ED/32 ED/32
18
14
6
23
-X29 -X29 -X29 -X29 -X29
bu-br
gn-gr
br-rd
gr
br
B B
wh-bl
wh-bl
gn-gr
br-rd
bl-rd
bl-rd
br
gr
C -X16 -X40 -X13 C
-X74 -X75 AU/2 -X17 CW/2 AM/3
2
1
FJ/2 FJ/2 AV/2
2
1
BI/2 CX/2 AR/3
1
1
2
2
2
-F7 -X294 -F4 -M14 -B33 -B25 -X31 -B35 -B32

t° /2.D3 R
CR/1 AY/1
1
1
10A
10A
M t°
P
CR/1
1
/2.D3
-X293 BJ/1
1
BI/2 CX/2 -X32
2
1
1
1
FJ/2 FJ/2 AV/2 FP/1

1
1
2
D -X74 -X75 AU/2 -X17 CW/2 -X42 D
1
2
-X16 -X40
bu-br
gn-gr
gn-gr
gn
gn
br
br
br
bl
bl
E E
WIRING DIAGRAM
/3.E8 h gn gn h /11.E1
/4.F8 e br br e /7.F1
Page 5 of 11
F F

5 /11
1 2 3 4 5 6 7 8
36.5
WIRING DIAGRAM 259
Components:
B25 Ambient air temperature sensor
B32 Fuel level indicator
B33 Temperature switch - radiator fan
B35 Oil pressure sensor
F4 Fuse
F7 Fuse
M14 Radiator fan
X293 Connector for accessory, ground ACC 2 (not assigned)
X294 Connector for accessory plus terminal 15 ACC 2 (not assigned)
WIRING DIAGRAM 260
Page 6 of 11
36.6
A
F
B
/2.F8 i
/7.A2
/2.A2
-A11
or
1
1
pu 5 5 bl-gr bl-gr 5 5
bl-bu 9 9 ye-or ye-or 6 6
wh 4 4 bu-or bu-or 3 3
pu 16 16 gn-or gn-or 23 23
gr 12 12 wh-rd wh-rd 7 7
gn 8 8 gn gn 11 11
bu 3 3 bu-pk bu-pk 4 4
ye 11 11 ye-gn ye-gn 22 22
rd 7 7 wh-gn wh-gn 12 12
gr 15 15 br-gr br-gr 21 21
-X44
CP/16
CQ/16
-X43
-X10
CO/34
2
2
gn-rd 10 10 rd-pu rd-pu 2 2

wh 6 6 bl-rd bl-rd 10 10
-X44
CP/16
CQ/16
-X43
-X2
AO/26
3
3
-B10
wh 2 2 1 1 bu
-X47
AR/3
AM/3
3 3 bl
-X47
AM/3
AR/3
-B11
4
4
gn-rd 1 1 2 2 bu
-X48
AM/3
AR/3
3 3 bl
-X48
AR/3
AM/3
-M62
gr 1 1
2 2
5
5
rd
M
ye 3 3
bu 4 4
-X50
CA/4
CE/4
-M61
gn 1 1
gr 2 2
M
pu 3 3
wh 4 4
6
6
-X49
AE/4
-M52
bl-bu 1 1 2 2 or
-X45
CL/2
CL/2
-X45
-M51
7
pu 1 1 2 2 or
-X46
CL/2
CL/2
-X46
or 13 13 or
bl 2 2 bl
bu 14 14 bu
-X43
CQ/16
CP/16
-X44
bu
8
8
or
bl
i /8.F1
m /7.F1
l /7.F1
6/11
305046-01
A
F
B
D
C
WIRING DIAGRAM 261
Components:
B10 Throttle position sensor circuit A
B11 Throttle position sensor circuit B
M51 Injector (cylinder 1)
M52 Injector (cylinder 2)
M61 Motor drive circuit A
M62 Motor drive circuit B
262
1 2 3 4 5 6 7 8
305047-01
-P10 -A11
/5.A4 /6.A1
A /8.A3 /8.A5 A
16
14
15
18
19
24
11
12
26
32
25
21
5
8
9
6
4
ED/32 CO/34 AO/26 AO/26 AO/26 AO/26 CO/34 AO/26 AO/26 CO/34
11
21
12
18
32
5
8
9
16
14
15
19
24
26
25
4
-X29 -X10 -X2 -X2 -X2 -X2 -X10 -X2 -X2 -X10
wh-bu
wh-bu
br-pu
rd-pu
br-pu
rd-bu
bu-br
ye-br
bl-gn
bl-gn
bl-ye
bl-br
wh
wh
pk
ye
gr
br
br
B B
rd-pu
rd-bu
bu-br
br-pu
br-pu
ye-br
bl-gn
bl-gn
bl-ye
bl-br
pk
pk
ye
ye
gr
C -X60 -X61 -X55 -X62 C
-X56 AM/3 AR/3 DN/8 AL/2
7
3
8
6
4
2
1
1
EC/3
3
1
AR/3 AM/3 DO/8 AT/2
1
1
7
2
3
8
6
4
3 -X281
-B21 -B34 -B30 -A20 -B38 BA/1
1
2nd
t° t°
3rd
N
-X300 BF/1
1
-X280
AM/3 DO/8 AT/2
3
5
2
2
1
1
EC/3
2
D -X56 AR/3 DN/8 AL/2 D
1
2
2
3
5
-X61 -X55 -X62
gn-or
bu
bu
pk
br
br
br
br
br
br
bl
bl
E E
WIRING DIAGRAM
/6.F8 l bl bl l /9.F1
/6.F8 m bu bu m /9.F1
/5.F8 e br br e /8.F1
Page 7 of 11
/1.F8 f gn-or
F F
7/11
1 2 3 4 5 6 7 8
36.7
WIRING DIAGRAM 263
Components:
A20 Control unit of electric starter lock
B21 Engine coolant temperature sensor (cylinder 1)
B30 Side stand switch
B34 Gear position sensor
B38 Clutch switch
X281 Connector, ignition curve
264 1 2 3 4 5 6 7 8
305048-01
-P10 -A11
/7.A1 /7.A2
A /11.A1 /9.A1 A
16
19
17
20
ED/32 CO/34 AO/26
16
19
17
20
-X29 -X10 -X2
wh-bu
bu-or
bl-bu
lbu
B B
wh-bu
wh-bu
wh-bu
bu-or
bl-bu
bl-bu
bl-bu
gn
gn
C -X57 -X58 C
DO/8 DV/2 -X59
8
6
2
1
AT/2
2
1
DN/8 EL/2
1
2
5
8
6
2
-A21 -T10 -R30
/2.D2
AP/6
1
2
3
6
4
-X295
DN/8 EL/2
7
3
4
1
D DO/8 DV/2 D
1
7
2
3
4
-X57 -X58
wh-bu
wh-bu
bl-gn
bl-gn
bl-bu
bl-bu
bl-ye
lbu
or
br
br
or
E /4.E8 g bl-ye E
WIRING DIAGRAM
lbu n /11.E1
bl-bu o /11.E1
wh-bu p /11.E1
/7.F8 e br
Page 8 of 11
/6.F8 i or or i /10.F1
F F

8/11
1 2 3 4 5 6 7 8
36.8
WIRING DIAGRAM 265
Components:
A21 Immobilizer control unit
R30 CAN bus terminating resistor
T10 Antenna, ignition lock
X295 Diagnostics connector
266 1 2 3 4 5 6 7 8
305049-01
-A11
/8.A5
A /10.A1 A
13
14
23
24
22
7
3
4
1
AO/26 AO/26 AO/26 AO/26 AO/26 AO/26 AO/26
1
7
13
14
23
24
4
22
-X2 -X2 -X2 -X2 -X2 -X2 -X2
wh-ye
ye-bu
gn-gr
ye-rd
bl-bu
bu
pu
rd
bl
B B
wh-ye
ye-bu
gn-gr
ye-rd
bl-bu
pu
rd
C -X64 C
-X39 -X65 -X66 -X67 -X41 AL/2
1
AP/6 DP/3 DP/3 DP/3 CM/2
5
2
AT/2
1
1
2
2
2
5
3
-B26 -B13 -B42 -B41 -B12 -B37
t°
p p p
3
6
4
2
1
1
AP/6 DP/3 DP/3 DP/3 CM/2
1
1
2
2
6
4
D -X39 -X65 -X66 -X67 -X41 D

bu
bu
bu
bu
bu
bl
bl
bl
bl
bl
bl
E E
WIRING DIAGRAM
/7.F8 l bl bl l /10.F1
/7.F8 m bu
Page 9 of 11
F F

9 /11
1 2 3 4 5 6 7 8
36.9
WIRING DIAGRAM 267
Components:
B12 Intake air temperature sensor
B13 Ambient air pressure sensor
B26 Rollover sensor
B37 Crankshaft position sensor
B41 Manifold absolute pressure sensor (cylinder 1)
B42 Manifold absolute pressure sensor (cylinder 2)
268 1 2 3 4 5 6 7 8
305050-01
-A11
/9.A1
A A
13
15
31
29
26
20
33
11
12
CO/34 CO/34 CO/34 CO/34 AO/26 CO/34 AO/26 CO/34 AO/26
31
11
12
13
15
29
26
20
33
-X10 -X10 -X10 -X10 -X2 -X10 -X2 -X10 -X2
wh-pu
wh-br
wh-or
wh-bl
gn-rd
rd-gr
br-rd
bl-or
or
B B
wh-pu
wh-br
wh-or
wh-bl
gn-rd
rd-gr
br-rd
bl-or
C -X54 -X52 -X51 C

-X68 CK/2 -X53 -X63 CA/4 CA/4
4
2
2
1
DF/2 AS/2 AS/2

2
1
FE/2 CE/4 CE/4
1
2
4
4
2
-M20 -M21 -R51 -R52 -B51 -B52

L L
t° t°
FE/2 CE/4 CE/4

2
3
2
1
1
DF/2 AS/2 AS/2
1
2
D -X68 CK/2 -X53 -X63 CA/4 CA/4 D
1
2
3
-X54 -X52 -X51
or
or
or
or
or
or
or
bl
bl
E E
WIRING DIAGRAM
/9.F8 l bl
Page 10 of 11
/8.F8 i or
F F

10/11
1 2 3 4 5 6 7 8
36.10
WIRING DIAGRAM 269
Components:
B51 Lambda sensor (cylinder 1)
B52 Lambda sensor (cylinder 2)
M20 Fuel evaporation valve (USA version only)
M21 Exhaust air injection valve
R51 Ignition coil (cylinder 1)
R52 Ignition coil (cylinder 2)
WIRING DIAGRAM 270
Page 11 of 11
36.11
A
F
B
/1.E8
/8.E8
/8.E8
/8.E8
/5.E8
/1.F8 d
p
c
o
n
h
wh-bu
bl-bu
lbu
gn
rd
bl
1
1
-F8
1 10A 2
gn 1 2 gn-rd
FJ/2
FJ/2
-X5
-X5
/8.A3
-P10
bl-ye 15 15
2
2
gn 22 22
bl-or 3 3
ED/32
-X29
3
3
-A30
bl-or 9 9 bl-or bl-or 8 8
gn 8 8 gn gn 15 15
4
4
bl-ye 3 3 bl-ye bl-ye 17 17
gn-rd 5 5 gn-rd gn-rd 4 4
lbu 4 4 lbu lbu 5 5
bl-bu 7 7 bl-bu bl-bu 2 2

wh-bu 2 2 wh-bu wh-bu 11 11
bl-gr 6 6 bl-gr bl-gr 3 3

gr 1 1 gr gr 12 12
EQ/10
ER/10
-X11
-X9
-X80
GE/18
5
5
-B70
1 1 bl-gr
2 2 gr
FI/2
DM/2
-X69
6
6
-B71
1 1 wh-bl wh-bl 14 14
2 2 wh wh 13 13
FI/2
DM/2
-X70
-F21
2 30A 1 9
2 1 9
7
rd rd rd
EA/2
EA/2
-X20
-X20
-F22
2 30A 1 18
rd 2 1 or or 18
EA/2
EA/2
-X27
-X27
bl bl 10 10
bl bl 1 1
-X80
GE/18
8
8
1111
/
305051-01
A
F
B
D
C
WIRING DIAGRAM 271
Components:
A30 ABS control unit
B70 Front wheel speed sensor
B71 Wheel speed sensor, rear
F8 Fuse
F21 Fuse, ABS hydraulic unit
F22 Fuse, ABS return pump
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
SUBSTANCES 272
Brake fluid DOT 4 / DOT 5.1

According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
−49 °F) 50 % distilled water
Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
– Anti Freeze
Engine oil (SAE 10W/50)

According to
– JASO T903 MA ( p. 290)
– SAE ( p. 290) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Fully synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
Engine oil (SAE 5W/40)

According to
– JASO T903 MA ( p. 290)
– SAE ( p. 290) (SAE 5W/40)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
Synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
SUBSTANCES 273
Fork oil (SAE 5)

According to
– SAE ( p. 290) (SAE 5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Racing Fork Oil
Hydraulic fluid (15)

According to
– ISO VG (15)
Guideline
– Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre-
Supplier
Motorex®
– Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 290) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.
Super unleaded (ROZ 95/RON 95/PON 91)

According to
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
AUXILIARY SUBSTANCES 274
Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean
Chain lube for road use

Guideline
Supplier
Motorex®
– Chainlube Road
Cleaning and preserving materials for metal, rubber and plastic

Guideline
Supplier
Motorex®
– Protect & Shine
High viscosity grease

Guideline
– KTM recommends SKF® products.
Supplier
SKF®
– LGHB 2
High-luster polish for paint

Guideline
Supplier
Motorex®
– Moto Polish
Long-life grease
Guideline
Supplier
Motorex®
– Bike Grease 2000
Lubricant (T511)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmsilon® GTI 300 P
Lubricant (T158)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmogrease® PP 300
AUXILIARY SUBSTANCES 275
Lubricant (T152)
Guideline
– KTM recommends Bel‑Ray® products.
Supplier
Bel‑Ray®
– Molylube® Anti‑Seize
Lubricant (T159)
Guideline
– KTM recommends Bel‑Ray® products.
Supplier
Bel‑Ray®
– MC‑11®
Lubricant (T625)
Guideline
– KTM recommends Molykote® products.
Supplier
Molykote®
– 33 Medium
Motorcycle cleaner
Guideline
Supplier
Motorex®
– Moto Clean 900
Universal oil spray

Guideline
Supplier
Motorex®
– Joker 440 Synthetic
SPECIAL TOOLS 276
Bleeder cover
Art. no.: 00029013000
201490-10
Bleeding device
Art. no.: 00029013100
201491-10
Cable connector unlocking set

Art. no.: 00029014000
201489-10
Crankshaft locking bolt

Art. no.: 113080802
400035-01
Bearing puller
Art. no.: 15112017000
400037-01
SPECIAL TOOLS 277
Bleed syringe
Art. no.: 50329050000
400058-01
Circlip pliers reverse

Art. no.: 51012011000
400059-01
Mounting sleeve
Art. no.: 58529005000
400095-01
Valve spring compressor

Art. no.: 59029019000
400101-01
Extractor
Art. no.: 59029021044
400103-01
SPECIAL TOOLS 278
Limit plug gauge

Art. no.: 59029026006
400104-01
Feeler gauge
Art. no.: 59029041100
35
30
25
20
15
12
10
5
400110-01
Engine fixing arm

Art. no.: 60029002000
400114-01
Clutch holder
Art. no.: 60029003000
400115-01
Mounting sleeve
Art. no.: 60029005000
400116-01
SPECIAL TOOLS 279
Oil pressure adapter

Art. no.: 60029006000
303966-10
Puller for rotor

Art. no.: 60029009000
400118-01
Insert for crankshaft

Art. no.: 60029009110
400119-01
Graduated disc
Art. no.: 60029010000
400120-01
Plastigauge measuring strips

Art. no.: 60029012000
400122-01
SPECIAL TOOLS 280
Piston ring mounting tool

Art. no.: 60029015000
400123-01
Insert for bearing puller

Art. no.: 60029018000
Feature
23… 28 mm (0.91… 1.1 in)
400125-01
Pressure piece
Art. no.: 60029031000
400127-01
Puller, 2-arm
Art. no.: 60029033000
400128-01
Insert for piston ring lock

Art. no.: 60029036000
400160-01
SPECIAL TOOLS 281
Insert for valve spring lever

Art. no.: 60029041000
304249-10
Pressing tool
Art. no.: 60029043010
400130-01
Pressing tool
Art. no.: 60029043020
400131-01
Pressing tool
Art. no.: 60029043030
400132-01
Press drift
Art. no.: 60029043060
304290-10
SPECIAL TOOLS 282
Pressing tool
Art. no.: 60029044050
400135-01
Step bearing tool

Art. no.: 60029046028
400136-01
Holder for clamping wheel

Art. no.: 60029050000
400137-01
Holding spanner, clamping wheel

Art. no.: 60029051000
400138-01
Floor jack attachment

Art. no.: 60029055100
303963-10
SPECIAL TOOLS 283
Hose clamp pliers

Art. no.: 60029057000
400142-01
Pliers for spring band clamp

Art. no.: 60029057100
400085-01
Arms for puller

Art. no.: 60029058000
400143-01
Multi-tooth wrench socket 10 mm; ½" drive

Art. no.: 60029075000
400145-01
Box wrench attachment 13 mm

Art. no.: 60029081000
400146-01
SPECIAL TOOLS 284
Holding spanner, water pump impeller

Art. no.: 60029082000
400147-01
Special socket 13 mm; ½" drive

Art. no.: 60029083000
400148-01
Pressure damper tool

Art. no.: 61029010000
201578-01
Adapter
Art. no.: 61029055120
700270-01
Front wheel stand

Art. no.: 61029055300
500078-01
SPECIAL TOOLS 285
Rear wheel stand

Art. no.: 61029055400
500077-01
Testing hose
Art. no.: 61029093000
201314-01
Pressure testing tool

Art. no.: 61029094000
400149-01
Engine assembly stand

Art. no.: 61229001000
200306-01
Press drift/press sleeve

Art. no.: 61229044000
200319-01
SPECIAL TOOLS 286
Work stand
Art. no.: 62529055000
400151-01
Work stand adapter

Art. no.: 75029036000
400161-01
Spark plug wrench

Art. no.: 75029172000
400170-01
Pin wrench
Art. no.: T103
200734-10
Depth micrometer
Art. no.: T107S
300577-10
SPECIAL TOOLS 287
Pin
Art. no.: T120
201235-10
Calibration pin
Art. no.: T1205
200790-10
Pressing tool
Art. no.: T1206
200583-10
Pressing tool
Art. no.: T1207S
200585-01
Vacuum pump
Art. no.: T1240S
200273-10
SPECIAL TOOLS 288
Protecting sleeve
Art. no.: T1401
200635-10
Support tool
Art. no.: T14026
200639-10
Assembly tool
Art. no.: T1402S
200634-10
Open-end wrench
Art. no.: T14032
200640-10
Clamping stand
Art. no.: T1403S
200637-10
SPECIAL TOOLS 289
Press drift
Art. no.: T1504
200789-10
Assembly tool
Art. no.: T150S
200791-10
Mounting sleeve
Art. no.: T1515
300569-10
Hook wrench
Art. no.: T157S
200899-10
Nitrogen filling tool

Art. no.: T170S1
300574-10
STANDARDS 290
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. With 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 vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX 291
Blink code
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 223-231
Air filter Brake disc, rear

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Air filter box
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Brake discs, front
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Antifreeze
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Brake fluid
Assembling the engine
front brake, adding . .. . . . . . . . . . . . . . . . . . . . . . . . 90
alternator cover, installing . . . . . . . . . . . . . . . . . . . . 183
front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 91
camshafts of cylinder 1, installing . . . . . . . . . . . . . . . 195
rear brake, adding . .. . . . . . . . . . . . . . . . . . . . . . . . 95
camshafts of cylinder 2, installing . . . . . . . . . . . . . . . 198
rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 96
clutch cage, installing . . . . . . . . . . . . . . . . . . . . . . . 187
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 190 Brake fluid level
clutch discs, installing . . . . . . . . . . . . . . . . . . . . . . 189 front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 90
crankshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 179 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 95
cylinder 1, installing with cylinder head . . . . . . . . . . . 192 Brake light bulb
cylinder 2, installing with cylinder head . . . . . . . . . . . 196 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
engine, preparing for installation . . . . . . . . . . . . . . . . 202 Brake linings
engine, removing from engine assembly stand . . . . . . 204 front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 88
engine, setting to ignition top dead center, front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 88
cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 195, 199 rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 93
gear position sensor, installing . . . . . . . . . . . . . . ... 184 rear brake, checking .. . . . . . . . . . . . . . . . . . . . . . . . 92
ignition coils, installing . . . . . . . . . . . . . . . . . . . ... 202
left engine case, installing . . . . . . . . . . . . . . . . . ... 179 C
locking lever, installing . . . . . . . . . . . . . . . . . . . ... 184 Chain
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . ... 181 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
oil pump gear wheel, removing . . . . . . . . . . . . . . ... 185 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
oil pumps, installing . . . . . . . . . . . . . . . . . . . . . ... 177 Chain guide
primary gear, installing . . . . . . . . . . . . . . . . . . . ... 186 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . ... 182
Chain tension
shift drum locating, installing . . . . . . . . . . . . . . . ... 184
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . ... 185
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
spark plugs, installing . . . . . . . . . . . . . . . . . . . . ... 200
spread transmission, installing . . . . . . . . . . . . . . ... 187 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
starter motor, installing . . . . . . . . . . . . . . . . . . . ... 202 Clutch
timing chain of cylinder 1, installing . . . . . . . . . . ... 185 fluid level, checking/correcting . . . . . . . . . . . . . . . . . 205
timing chain of cylinder 2, installing . . . . . . . . . . ... 182 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
timing chain tensioner of cylinder 1, installing . . . ... 194 Clutch lever
timing chain tensioner of cylinder 2, installing . . . ... 198 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 29
timing gears of cylinder 1, installing . . . . . . . . . . ... 194
Combination instrument
timing gears of cylinder 2, installing . . . . . . . . . . ... 197
clock, setting . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 98
transmission shafts, installing . . . . . . . . . . . . . . ... 178
kilometers or miles, setting . . ... . . . . . . . . . . . . . . . 98
valve clearance of cylinders 1, adjusting . . . . . . . ... 199
TRIP 1 display, setting/resetting .. . . . . . . . . . . . . . . . 98
valve clearance of cylinders 1, checking . . . . . . . . ... 199
TRIP 2 display, setting/resetting .. . . . . . . . . . . . . . . . 98
valve clearance of cylinders 2, adjusting . . . . . . . ... 200
wheel circumference, setting . ... . . . . . . . . . . . . . . . 99
valve clearance of cylinders 2, checking . . . . . . . . ... 199
valve cover of cylinder 1, installing . . . . . . . . . . . ... 200 Coolant
valve cover of cylinder 2, installing . . . . . . . . . . . ... 201 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
water pump impeller, installing . . . . . . . . . . . . . ... 192 Coolant level
B checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
compensating tank, checking . . . . . . . . . . . . . . . . . . 208
Battery
Cooling system
connecting . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
installing . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . . . 158
recharging . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
removing . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INDEX 292
E engine, setting to ignition top dead center, cylinder 2 . 131

gear position sensor, removing . . . . . . . . . . . . . . . . . 141
EFI control unit
ignition coil, removing . . . . . . . . . . . . . . . . . . . . . . . 127
activation code, requesting . . . . . . . . . . . . . . . . . . . 221
left engine case, removing . . . . . . . . . . . . . . . . . . . . 144
coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 141
flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
oil filter, removing . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine oil pump gear wheel, removing . . . . . . . . . . . . . . . . . 140
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 oil pumps, removing . . . . . . . . . . . . . . . . . . . . . . . . 146
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 preparing engine for disassembly . . . . . . . . . . . . . . . 125
Engine - Work on individual parts primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 139
alternator cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 shift drum locating, removing . . . . . . . . . . . . . . . . . . 141
conrod bearing, changing . . . . . . . . . . . . . . . . . . . . . 152 shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 140
countershaft, assembling . . . . . . . . . . . . . . . . . . . . . 172 spark plugs, removing . . . . . . . . . . . . . . . . . . . . . . . 128
countershaft, dismantling . . . . . . . . . . . . . . . . . . . . 169 spread transmission, removing . . . . . . . . . . . . . . . . . 138
cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . 158 starter motor, removing . . . . . . . . . . . . . . . . . . . . . . 126
cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 timing chain of cylinder 1, removing . . . . . . . . . . . . . 139
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . 159 timing chain of cylinder 2, removing . . . . . . . . . . . . . 143
cylinder head, mounting on cylinder . . . . . . . . . . . . . 162 timing chain tensioner of cylinder 1, removing . . . . . . 129
cylinder head, removing from cylinder . . . . . . . . . . . . 156 timing chain tensioner of cylinder 2, removing . . . . . . 132
cylinder, checking/measuring . . . . . . . . . . . . . . . . . . 159 timing gears of cylinder 1, removing . . . . . . . . . . . . . 129
electric starter drive, checking . . . . . . . . . . . . . . . . . 174 timing gears of cylinder 2, removing . . . . . . . . . . . . . 133
freewheel, checking . . . . . . . . . . . . . . . . . . . . . . . . 175 transmission shafts, removing . . . . . . . . . . . . . . . . . 145
freewheel, installing . . . . . . . . . . . . . . . . . . . . . . . . 175 valve cover of cylinder 1, removing . . . . . . . . . . . . . . 127
freewheel, removing . . . . . . . . . . . . . . . . . . . . . . . . 175 valve cover of cylinder 2, removing . . . . . . . . . . . . . . 127
left engine case section . . . . . . . . . . . . . . . . . . . . . . 147 water pump impeller, removing . . . . . . . . . . . . . . . . . 134
left main bearing, installing . . . . . . . . . . . . . . . . . . . 151 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
left main bearing, removing . . . . . . . . . . . . . . . . . . . 149
Engine oil
main bearing shells, selecting . . . . . . . . . . . . . . . . . 150
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 215
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 171
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 211
main shaft, disassembling . . . . . . . . . . . . . . . . . . . . 169
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211, 214
oil pressure regulator valve, checking . . . . . . . . . . . . 157
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 214
oil pumps, checking . . . . . . . . . . . . . . . . . . . . . . . . 157
piston ring end gap, checking . . . . . . . . . . . . . . . . . . 161 Engine oil level
piston, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
piston, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Engine oil pressure
piston, measuring . . . . . . . . . . . . . . . . . . . . . . . . . . 160 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
piston/cylinder mounting clearance, checking . . . . . . . 161 Engine sprocket
radial clearance of lower conrod bearing, checking . . . 153 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
right engine case section . . . . . . . . . . . . . . . . . . . . . 148
Exhaust manifold
right main bearing, installing . . . . . . . . . . . . . . . . . . 151
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
right main bearing, removing . . . . . . . . . . . . . . . . . . 150
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
shift mechanism, checking . . . . . . . . . . . . . . . . . . . 167
shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . 168 F
spread transmission, preassembling . . . . . . . . . . . . . 165 Filler cap
support bearing of crankshaft, changing . . . . . . . . . . . 154 closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
timing assembly, checking . . . . . . . . . . . . . . . . . . . . 164 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
transmission, checking . . . . . . . . . . . . . . . . . . . . . . 170
Foot brake lever
water pump bearing, changing . . . . . . . . . . . . . . . . . 155
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 94
Engine disassembly free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 94
alternator cover, removing . . . . . . . . . . . . . . . . . . . . 141
Fork
camshafts of cylinder 1, removing . . . . . . . . . . . . . . . 128
compression damping, adjusting . . . . . . . . . . . . . . . . . 13
camshafts of cylinder 2, removing . . . . . . . . . . . . . . . 132
fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 14
clutch cage, removing . . . . . . . . . . . . . . . . . . . . . . . 136
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 13
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 135
clutch discs, removing . . . . . . . . . . . . . . . . . . . . . . 135 Fork legs
crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 144 assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
cylinder head of cylinder 1, removing with cylinder . . . 130 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
cylinder head of cylinder 2, removing with cylinder . . . 133 dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
engine, clamping into engine assembly stand . . . . . . . 125 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 14
engine, setting to ignition top dead center, cylinder 1 . 128 fork, servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INDEX 293
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Main silencer

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 with distributor pipe, installing . . . . . . . . . . . . . . . . . . 54
Fork part number ............................... 8 with distributor pipe, removing . . . . . . . . . . . . . . . . . . 52
Front fender Mask spoiler

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Front wheel Motorcycle

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 lifting with lift stand . . . . . . . . . . . . . . . . . . . . . . . . . 10
raising with the front wheel stand . . . . . . . . . . . . . . . .. 9
Fuel filter
raising with the rear wheel stand . . . . . . . . . . . . . . . . .. 9
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
taking off of the front wheel stand . . . . . . . . . . . . . . . .. 9
Fuel pressure taking off of the rear wheel stand . . . . . . . . . . . . . . . .. 9
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 work stand, removing from . . . . . . . . . . . . . . . . . . . . . 10
Fuel tank
O
installing . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
reinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Oil filter
removing . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oil jet for clutch lubrication

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Fuse
individual power consumers, changing . . . . . . . . . . . . . 86 Oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
H
Oil screens
Hand brake lever cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 90
P
Headlight
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Parking light bulb
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Headlight adjustment Play in throttle cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Headlight bulb Preparing for use

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Headlight trim R
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Rear hub shock absorber
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
I checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Ignition curve Rear sprocket

adjusting to fuel quality . . . . . . . . . . . . . . . . . . . . . . . 87 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
plug-in connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Rear wheel
Ignition key installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
activating/deactivating . . . . . . . . . . . . . . . . . . . . . . . 109 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Immobilizer control unit S

activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Seat
K mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248-249
L
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
License plate lamp Servicing the fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Shock absorber
Lower triple clamp bleeding and filling . . . . . . . . . . . . . . . . . . . . . . . . . . 43
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 compression damping, high-speed, adjusting . . . . . . . . 30
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 compression damping, low-speed, adjusting . . . . . . . . . 30
M damper, assembling . . . . . . . . . . . . . . . . . . . . . . . . . 41
damper, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Main fuse
dismantling shock absorber . . . . . . . . . . . . . . . . . . . . 34
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INDEX 294
heim joint, installing . . . . . . . . . . . . . . . . . . . . . . . . . 39 page 03 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

heim joint, removing . . . . . . . . . . . . . . . . . . . . . . . . . 38 page 04 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 page 05 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
nitrogen, filling damper with . . . . . . . . . . . . . . . . . . . 45 page 06 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
pilot bushing, changing . . . . . . . . . . . . . . . . . . . . . . . 37 page 07 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
piston rod, assembling . . . . . . . . . . . . . . . . . . . . . . . 40 page 08 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
piston rod, disassembling . . . . . . . . . . . . . . . . . . . . . 35 page 09 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 31 page 10 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 page 11 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
seal ring retainer, assembling . . . . . . . . . . . . . . . . . . . 39 Work rules ................................... 6
seal ring retainer, disassembling . . . . . . . . . . . . . . . . . 36
servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 31
spring, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
spring, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 8
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
for making checks . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering head bearing
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
T
Tail light bulbs
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Technical data
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239-240
chassis tightening torques . . . . . . . . . . . . . . . . . 243-244
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232-233
engine - tolerance, wear limits . . . . . . . . . . . . . . 234-236
engine tightening torques . . . . . . . . . . . . . . . . . 237-238
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Throttle position sensor circuit A
in zero position, checking . . . . . . . . . . . . . . . . . . . . 219
position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 219
Throttle valve body
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Winter operation
checks and maintenance measures . . . . . . . . . . . . . . 246
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 250-271
page 01 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
page 02 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
*3206109en*
3206109en
06/2011
Photo: Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com

990 Supermoto T EU 990 Supermoto T FR 990 Supermoto T AUS/UK 990 Supermoto T USA

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990 Supermoto T EU 990 Supermoto T FR 990 Supermoto T AUS/UK 990 Supermoto T USA

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REPAIR MANUAL 2011

Only use ORIGINAL KTM SPARE PARTS.

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria

ISO 9001(12 100 6061)

MEANS OF REPRESENTATION ............................................ 5

Indicates an unexpected reaction (e.g. of a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

Name® Identifies a protected name.

Brand™ Identifies a trademark.

Fuel, oils, etc.

Spare parts, accessories

Chassis number/type label

(990 Supermoto T EU, 990 Supermoto T FR, 990 Supermoto T AUS/UK)

(990 Supermoto T USA)

(990 Supermoto T USA)

The Code number  key number can be found on the KEYCODECARD.

Fork part number

Shock absorber part number

Raising the motorcycle with the rear wheel stand

– Mount the lifting bushings on the swingarm.

Taking the motorcycle off of the rear wheel stand

– Secure the motorcycle against falling over.

Raising the motorcycle with the front wheel stand

– Raise the motorcycle with the rear wheel stand. ( p. 9)

– Raise the front of the motorcycle.

Taking the motorcycle off of the front wheel stand

– Secure the motorcycle against falling over.

Lifting the motorcycle with the lift stand

– Mount special tool .

Removing the motorcycle from the work stand

– Secure the motorcycle against falling over.

– Position the footrest rubber with the holder.

– Press the emergency OFF switch into the position .

Starting the motorcycle to make checks

– Press the emergency OFF switch into the position .

Adjusting the compression damping of the fork

– Turn adjusting screws  clockwise all the way.

Adjusting the rebound damping of the fork

– Turn adjusting screws  clockwise all the way.

Bleeding the fork legs

– Lean the motorcycle on the side stand.

Cleaning the dust boots of the fork legs

– Push dust boot  of both fork legs downwards.

Removing fork legs

– Lift the motorcycle with the lift stand. ( p. 10)

– Take the speed sensor cable out of the clamp .

– Loosen screws  and .

Installing the fork legs

– Push the fork legs into the triple clamps.

– Check the wheel bearing for damage and wear.

– Clean screw  and the wheel spindle.

Servicing the fork

Disassembling the fork legs

– Release Preload Adjuster .

– Slide the outer tube down.

– Clamp the special tool in the vise. Release Preload Adjuster .

– Remove Preload Adjuster  with preload spacers .

– Pull the spring downwards. Remove the special tool.