REPAIR MANUAL 2022

250 EXC TPI

250 EXC SIX DAYS TPI
250 XC‑W TPI
300 EXC TPI
300 EXC SIX DAYS TPI
300 XC-W TPI
300 EXC TPI ERZBERGRODEO
300 XC‑W TPI ERZBERGRODEO

52
Item no. 3206472en

73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

Zac Martin, [email protected],

Za
c
M
ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73
52
 INTRODUCTION

Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION

The vehicle will only be able to meet the demands placed on it in the long run if the specified service work is per-
formed regularly and properly.

This repair manual was written to correspond to the latest state of this model series. We reserve the right to make
changes in the interest of technical advancement without updating this repair manual at the same time.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic.

All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.

© 2022 KTM Sportmotorcycle GmbH, Mattighofen Austria

All rights reserved

52
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

73
of the copyright owner.

01
ISO 9001(12 100 6061)

8/
KTM applies quality assurance processes that lead to the highest possible product quality as

21
defined in the ISO 9001 international quality management standard.

16
Issued by: TÜV Management Service

l.c r:
,0
ai d fo
KTM Sportmotorcycle GmbH

om
Stallhofnerstraße 3
5230 Mattighofen, Austria
gm e
@ ens

This document is valid for the following models:

tin ic
ar | L

250 EXC TPI EU (F7303V7)

250 EXC SIX DAYS TPI EU (F7303V2)
lm r
ie fü

250 XC‑W TPI US (F7375V4)

an ert

300 EXC TPI EU (F7403V7)

300 EXC SIX DAYS TPI EU (F7403V2)
yd zi
ar en

300 EXC SIX DAYS TPI CN (F7487V2)

300 EXC SIX DAYS TPI ASEAN (F7488V2)
ch Liz

300 XC‑W TPI US (F7475V3)

300 EXC TPI ERZBERGRODEO EU (F7403V3)
300 XC‑W TPI ERZBERGRODEO US (F7475V6)
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

*3206472en*
3206472en

04/2022
 INDEX

6.18 Lubricating the steering head

INDEX

1 MEANS OF REPRESENTATION ...................... 7

bearing ........................................... 38
1.1 Symbols used .................................... 7 6.19 Removing the lower triple clamp
1.2 Formats used..................................... 7 (All standard models) ....................... 38
2 SAFETY ADVICE............................................ 8 6.20 Installing the lower triple clamp
(All standard models) ....................... 39
2.1 Repair Manual ................................... 8 6.21 Removing the lower triple clamp (All
2.2 Safety advice..................................... 8 special models)................................ 41
2.3 Degrees of risk and symbols ................ 8 6.22 Installing the lower triple clamp (All
2.4 Work rules......................................... 8 special models)................................ 42
6.23 Checking the steering head bearing
3 IMPORTANT NOTES.................................... 10 play ................................................ 44
3.1 Manufacturer warranty, implied 6.24 Adjusting the steering head bearing
warranty.......................................... 10 play ................................................ 45
3.2 Fuel, auxiliary substances ................. 10 6.25 Changing the steering head bearing
3.3 Spare parts, technical accessories ..... 10 (All standard models) ....................... 46
3.4 Figures ........................................... 10 6.26 Changing the steering head bearing

52
(All special models).......................... 47
4 SERIAL NUMBERS ..................................... 11

73
7 HANDLEBAR, CONTROLS............................ 49

01
4.1 Vehicle identification number............ 11
7.1 Handlebar position........................... 49
4.2 Type label ....................................... 11

8/
7.2 Adjusting the handlebar position ....... 49
4.3 Engine number ................................ 11

21
7.3 Adjusting the basic position of the
4.4 Fork part number ............................. 11
clutch lever ..................................... 51

16
4.5 Shock absorber article number .......... 12
7.4 Checking the rubber grip .................. 51

l.c r:
,0
ai d fo
5 MOTORCYCLE ............................................ 13 7.5 Checking the throttle cable routing .... 52

om
7.6 Checking the play in the throttle
5.1 Raising the motorcycle with a lift
cable .............................................. 53
gm e
stand .............................................. 13
@ ens

7.7 Adjusting the play in the throttle

5.2 Removing the motorcycle from the
cable .............................................. 53
lift stand ......................................... 13
tin ic

7.8 Setting the characteristic map of the

5.3 Starting the vehicle .......................... 13
ar | L

throttle response .............................. 54

5.4 Starting the motorcycle to check the
function .......................................... 14 8 FRAME ...................................................... 56
lm r
ie fü

6 FORK, TRIPLE CLAMP ................................ 15 8.1 Checking the frame .......................... 56

an ert

8.2 Removing the engine guard (All

6.1 Adjusting the compression damping
special models)................................ 56
yd zi

of the fork ....................................... 15

8.3 Installing the engine guard (All
ar en

6.2 Adjusting the rebound damping of

special models)................................ 56
the fork........................................... 15
ch Liz

8.4 Changing the footrests...................... 56

6.3 Adjusting the spring preload of the
fork ................................................ 16 9 SHOCK ABSORBER, LINK FORK.................. 60
6.4 Bleeding the fork legs....................... 16
9.1 Adjusting the high-speed
6.5 Cleaning the dust boots of the fork
compression damping of the shock
za

legs ................................................ 17
absorber.......................................... 60
6.6 Removing the fork legs ..................... 18
,

9.2 Adjusting the low-speed

in

6.7 Installing the fork legs ...................... 18 compression damping of the shock
t

6.8 Removing the fork protector .............. 19

ar

absorber.......................................... 60
6.9 Installing the fork protector............... 20
M

9.3 Adjusting the rebound damping of

6.10 Servicing the fork............................. 20 the shock absorber ........................... 61
c

6.11 Disassembling the fork legs............... 20

Za

9.4 Measuring the dimension of the rear

6.12 Disassembling the cartridge .............. 23 wheel unloaded................................ 62
6.13 Disassembling the tap compression ... 26 9.5 Checking the static sag of the shock
6.14 Checking the fork legs ...................... 27 absorber.......................................... 62
6.15 Assembling the tap compression ....... 29 9.6 Checking the riding sag of the shock
6.16 Assembling the cartridge .................. 29 absorber.......................................... 63
Zac Martin, [email protected],

6.17 Assembling the fork legs................... 33

2
 INDEX

9.7 Adjusting the spring preload of the 12.7 Changing the fuel screen ................ 106
shock absorber ................................ 63 12.8 Changing the fuel filter................... 107
9.8 Adjusting the riding sag .................... 64 12.9 Changing the fuel pump ................. 110
9.9 Removing the shock absorber ............ 65 12.10 Checking the fuel pressure.............. 113
9.10 Installing the shock absorber............. 65
13 MASK, FENDER........................................ 116
9.11 Servicing the shock absorber............. 66
9.12 Removing the spring......................... 66 13.1 Removing front fender .................... 116
9.13 Disassembling the damper ................ 67 13.2 Installing front fender..................... 116
9.14 Disassembling the seal ring 13.3 Removing the headlight mask with
retainer ........................................... 69 the headlight ................................. 117
9.15 Disassembling the piston rod ............ 69 13.4 Installing the headlight mask with
9.16 Replacing the pilot bushing .............. 71 the headlight ................................. 117
9.17 Checking the damper ....................... 72
14 WHEELS .................................................. 119
9.18 Changing the heim joint.................... 73
9.19 Assembling seal ring retainer ............ 74 14.1 Checking tire pressure .................... 119
9.20 Assembling the piston rod................. 75 14.2 Checking the tire condition ............. 119
14.3 Checking the wheel bearing for

52
9.21 Assembling the damper .................... 76
9.22 Bleeding and filling the damper ........ 79 play .............................................. 120

73
9.23 Filling damper with nitrogen ............. 82 14.4 Checking the brake discs ................ 120

01
9.24 Installing the spring ......................... 83 14.5 Checking the rim run-out ................ 121

8/
9.25 Checking the link fork ...................... 84 14.6 Checking spoke tension .................. 122

21
9.26 Checking the shock absorber heim 14.7 Front wheel ................................... 123
joint for play.................................... 84 14.7.1 Removing the front wheel ........... 123

16
9.27 Changing the heim joint on the link 14.7.2 Installing the front wheel ............ 124

l.c r:
,0
fork ................................................ 85 14.7.3 Changing the front brake disc ..... 125

ai d fo
om
9.28 Checking the fork bearing for play ..... 87 14.7.4 Changing the front wheel
9.29 Removing the link fork...................... 87 bearing ..................................... 126
gm e
14.8 Rear wheel .................................... 127
@ ens

9.30 Installing the link fork ...................... 88

9.31 Changing the link fork bearing........... 90 14.8.1 Removing the rear wheel ............ 127
tin ic

14.8.2 Installing the rear wheel ............. 128

10 EXHAUST SYSTEM ..................................... 93
ar | L

14.8.3 Changing the rear brake disc....... 129

10.1 Removing the manifold..................... 93 14.8.4 Changing the rear wheel
lm r

bearing ..................................... 130

ie fü

10.2 Installing the manifold ..................... 94

10.3 Removing the main silencer .............. 96 14.8.5 Checking the chain for dirt ......... 132
an ert

10.4 Installing the main silencer............... 96 14.8.6 Cleaning the chain ..................... 132
14.8.7 Checking the chain tension......... 133
yd zi

10.5 Changing the glass fiber yarn filling

ar en

of the main silencer ......................... 97 14.8.8 Checking the chain, rear

sprocket, engine sprocket, and
ch Liz

11 AIR FILTER ................................................ 98 chain guide ............................... 133

11.1 Removing the air filter box cover ....... 98 14.8.9 Adjusting the chain tension ........ 136
11.2 Installing the air filter box cover ........ 98 14.8.10 Changing the drivetrain kit.......... 136
11.3 Removing the air filter ...................... 99 15 WIRING HARNESS, BATTERY.................... 140
za

11.4 Installing the air filter....................... 99

11.5 Cleaning the air filter and air filter 15.1 Ignition curve plug-in connector ...... 140
,
in

box ............................................... 100 15.2 Changing main fuse ....................... 140

t

11.6 Preparing air filter box cover for 15.3 Changing the fuses of individual
ar

securing........................................ 100 electrical power consumers ............. 142

M

15.4 Disconnecting the negative cable

12 FUEL TANK, SEAT, TRIM .......................... 101
c

of the 12-V battery......................... 143

Za

12.1 Opening the fuel tank filler cap ....... 101 15.5 Connecting the negative cable of
the 12-V battery............................. 143
12.2 Closing the fuel tank filler cap......... 101
15.6 Removing the 12-V battery.............. 143
12.3 Removing the seat ......................... 102
15.7 Installing the 12-V battery .............. 145
12.4 Mounting the seat .......................... 102
15.8 Charging the 12-V battery ............... 147
12.5 Removing the fuel tank................... 103
15.9 Checking the charging voltage ......... 148
Zac Martin, [email protected],

12.6 Installing the fuel tank ................... 104

3
 INDEX

15.10 Checking the open-circuit current .... 149 18.6 Engine disassembly........................ 188
15.11 Checking the starter relay ............... 149 18.6.1 Clamping engine into the engine
15.12 Diagnostics connector .................... 150 work stand ................................ 188
18.6.2 Removing the shift lever ............. 189
16 BRAKE SYSTEM ....................................... 151
18.6.3 Removing the clutch push rod..... 189
16.1 Checking the front brake linings ...... 151 18.6.4 Draining the gear oil................... 189
16.2 Changing the brake linings of the 18.6.5 Removing the spacer.................. 189
front brake .................................... 151 18.6.6 Removing the alternator cover ..... 190
16.3 Checking the free travel of the 18.6.7 Removing injection valves........... 190
hand brake lever ............................ 153 18.6.8 Removing the cylinder head ........ 191
16.4 Adjusting the free travel of the 18.6.9 Removing the cylinder................ 191
handbrake lever (EU/CN/ASEAN) ..... 154 18.6.10 Removing the piston .................. 193
16.5 Adjusting the basic position of the 18.6.11 Removing the water pump
hand brake lever (US)..................... 154 cover ........................................ 194
16.6 Checking the front brake fluid 18.6.12 Removing the clutch cover.......... 194
level ............................................. 154
18.6.13 Removing the clutch discs .......... 195
16.7 Adding front brake fluid.................. 155

52
18.6.14 Removing the clutch basket ........ 196
16.8 Changing the front brake fluid ......... 156
18.6.15 Removing the balancer shaft....... 197

73
16.9 Checking the brake linings of the
18.6.16 Removing the shift shaft............. 198

01
rear brake...................................... 158
18.6.17 Removing the shift drum
16.10 Changing the rear brake linings ....... 158

8/
locating unit.............................. 198
16.11 Checking the free travel of foot

21
18.6.18 Removing the locking lever ......... 199
brake lever .................................... 160
18.6.19 Removing the rotor..................... 199

16
16.12 Adjusting the basic position of the
18.6.20 Removing the starter motor......... 200

l.c r:
foot brake lever.............................. 161

,0
ai d fo
16.13 Checking the rear brake fluid 18.6.21 Removing the reed valve

om
level ............................................. 162 housing..................................... 201
18.6.22 Removing the left section of the
gm e
16.14 Adding rear brake fluid ................... 162
@ ens
engine case ............................... 201
16.15 Changing the rear brake fluid .......... 163
18.6.23 Removing the shift rails.............. 201
17 LIGHTING SYSTEM, INSTRUMENTS .......... 166
tin ic

18.6.24 Removing the shift drum ............ 202

ar | L

17.1 Changing the headlight bulb ........... 166 18.6.25 Removing the shift forks............. 202
17.2 Changing the turn signal bulb 18.6.26 Removing the transmission
lm r

shafts ....................................... 202

ie fü

(EU/CN/ASEAN)............................. 166
17.3 Checking the headlight setting ........ 167 18.6.27 Removing the crankshaft ............ 203
an ert

17.4 Adjusting the headlight range.......... 168 18.7 Working on individual parts............. 204
18.7.1 Working on the right section of
yd zi

17.5 Changing the combination

the engine case ......................... 204
ar en

instrument battery.......................... 168

17.6 Combination instrument overview .... 169 18.7.2 Working on the left section of
ch Liz

the engine case ......................... 205

17.7 Activation and test ......................... 169
18.7.3 Removing the crankshaft
17.8 Setting kilometers or miles.............. 169
bearing inner race...................... 206
17.9 Adjusting combination instrument
18.7.4 Installing the crankshaft bearing
function ........................................ 170
inner race ................................. 207
za

17.10 Setting the clock............................ 171

18.7.5 Changing the connecting rod,
17.11 Adjusting the wheel
,

conrod bearing, and crank pin..... 207

in

circumference ............................... 171

18.7.6 Checking the crankshaft run-out
t
ar

17.12 Viewing the lap time....................... 172 at the bearing pin ...................... 209
M

18 ENGINE ................................................... 174 18.7.7 Checking/measuring the

cylinder .................................... 209
c

18.1 Cleaning the pressure sensor hose ... 174

Za

18.7.8 Cleaning the pressure sensor

18.2 Cleaning the protection cap of the cylinder connection.................... 210
pressure sensor.............................. 174 18.7.9 Removing the exhaust control ..... 210
18.3 Cleaning the hose connections of 18.7.10 Checking the exhaust control ...... 214
the pressure sensor ........................ 175 18.7.11 Installing the exhaust control ...... 216
18.4 Removing the engine...................... 176 18.7.12 Cylinder - Nikasil® coating .......... 223
Zac Martin, [email protected],

18.5 Installing the engine....................... 182

4
 INDEX

18.7.13 Checking/measuring the piston.... 223 18.8.26 Installing the spacer................... 261
18.7.14 Checking the piston ring end 18.8.27 Gear oil drain plug, installing ...... 262
gap........................................... 224 18.8.28 Installing the clutch push rod ..... 262
18.7.15 Measuring the piston/cylinder 18.8.29 Installing the shift lever.............. 262
mounting clearance.................... 225 18.8.30 Removing the engine from the
18.7.16 Disassemble the reed valve engine work stand...................... 263
housing..................................... 225
18.7.17 Checking the reed valve 19 CLUTCH ................................................... 264
housing, reed valve and intake 19.1 Checking/correcting the fluid level
flange ....................................... 226 of the hydraulic clutch.................... 264
18.7.18 Assembling the reed valve 19.2 Changing the hydraulic clutch
housing..................................... 227 fluid ............................................. 265
18.7.19 Working on the clutch cover........ 228 19.3 Checking the clutch ....................... 266
18.7.20 Checking the clutch ................... 231
18.7.21 Preassembling shift shaft ........... 232 20 WATER PUMP, COOLING SYSTEM ............. 275
18.7.22 Checking the shift mechanism .... 233 20.1 Cooling system .............................. 275
18.7.23 Disassembling the main shaft ..... 234 20.2 Checking the antifreeze and

52
18.7.24 Disassembling the coolant level .................................. 275

73
countershaft .............................. 235 20.3 Checking the coolant level .............. 276
18.7.25 Checking the transmission .......... 235

01
20.4 Draining the coolant ....................... 276
18.7.26 Assembling the main shaft.......... 237 20.5 Refilling with coolant ..................... 277

8/
18.7.27 Assembling the countershaft ....... 238 20.6 Changing the coolant...................... 279

21
18.7.28 Checking the electric starter 20.7 Changing the coolant pipe .............. 280

16
drive......................................... 239

l.c r:
21 EXHAUST CONTROL ................................. 285

,0
18.8 Assembling the engine ................... 239

ai d fo
18.8.1 Installing the crankshaft ............. 239

om
21.1 Checking/adjusting the basic
18.8.2 Installing the transmission setting of the exhaust control .......... 285
gm e
shafts ....................................... 240
@ ens

18.8.3 Installing the shift forks.............. 240 22 LUBRICATION SYSTEM............................. 286

18.8.4 Installing the shift drum ............. 241 22.1 Changing the gear oil...................... 286
tin ic

18.8.5 Installing the shift rails .............. 241 22.2 Checking the gear oil level .............. 287
ar | L

18.8.6 Installing the left section of the 22.3 Adding the gear oil......................... 287
engine case ............................... 241
lm r

22.4 Checking 2-stroke oil level .............. 288

ie fü

18.8.7 Installing the reed valve 22.5 Opening 2-stroke oil tank cap.......... 288
housing..................................... 242
an ert

22.6 Adding 2-stroke oil......................... 289

18.8.8 Installing the starter motor.......... 243
22.7 Closing 2-stroke oil tank cap ........... 289
yd zi

18.8.9 Installing the rotor ..................... 244

22.8 Priming oil pump ........................... 289
ar en

18.8.10 Installing the locking lever .......... 244

22.9 Changing the oil pump, cleaning
ch Liz

18.8.11 Installing the shift drum the oil screen................................. 291

locating unit.............................. 245
22.10 Cleaning the oil screen in the oil
18.8.12 Installing the shift shaft ............. 245 tank.............................................. 295
18.8.13 Installing the balancer shaft........ 245
18.8.14 Installing the clutch basket......... 246 23 IGNITION SYSTEM.................................... 299
za

18.8.15 Installing the clutch discs........... 247 23.1 Checking the ignition system........... 299
,

18.8.16 Installing the clutch cover .......... 250 23.2 Ignition coil - checking the primary
in

18.8.17 Installing the water pump winding......................................... 300

t
ar

cover ........................................ 251 23.3 Checking the spark plug

M

18.8.18 Installing the piston ................... 251 connector...................................... 301

18.8.19 Installing the cylinder................. 253 23.4 Alternator – checking the stator
c
Za

18.8.20 Checking the X-distance ............. 255 winding......................................... 301

18.8.21 Adjusting the X-distance............. 256 23.5 Checking the crankshaft speed
18.8.22 Adjusting the Z-distance............. 257 sensor........................................... 302
18.8.23 Installing the cylinder head......... 260 23.6 Changing the spark plug ................. 303
18.8.24 Installing injection valves ........... 261 23.7 Changing the spark plug and spark
18.8.25 Installing the alternator cover...... 261 plug connector............................... 304
Zac Martin, [email protected],

23.8 Removing the stator ....................... 304

5
 INDEX

23.9 Installing the stator ........................ 305 30.11 Page 3 of 6 (US)............................ 346
30.12 Page 4 of 6 (US)............................ 348
24 ELECTRIC STARTER SYSTEM .................... 306
30.13 Page 5 of 6 (US)............................ 350
24.1 Checking the starter motor .............. 306 30.14 Page 6 of 6 (US)............................ 352
30.15 Page 1 of 8 (CN)............................ 354
25 THROTTLE VALVE BODY ........................... 307
30.16 Page 2 of 8 (CN)............................ 356
25.1 Adjusting the idle speed ................. 307 30.17 Page 3 of 8 (CN)............................ 358
25.2 Programming ambient air 30.18 Page 4 of 8 (CN)............................ 360
pressure........................................ 307 30.19 Page 5 of 8 (CN)............................ 362
25.3 Cold start button............................ 308 30.20 Page 6 of 8 (CN)............................ 364
26 TECHNICAL DATA..................................... 309 30.21 Page 7 of 8 (CN)............................ 366
30.22 Page 8 of 8 (CN)............................ 368
26.1 Engine .......................................... 309
26.1.1 All 250 models.......................... 309 31 SUBSTANCES .......................................... 370
26.1.2 All 300 models.......................... 309 32 AUXILIARY SUBSTANCES ......................... 372
26.2 Tolerance, engine wear limits .......... 310
33 SPECIAL TOOLS ....................................... 374

52
26.3 Engine tightening torques ............... 311
26.4 Capacities ..................................... 312 34 STANDARDS ............................................ 393

73
26.4.1 Gear oil..................................... 312

01
26.4.2 Engine oil ................................. 312 35 GLOSSARY OF TECHNICAL TERMS............ 394

8/
26.4.3 Coolant ..................................... 312 36 LIST OF ABBREVIATIONS.......................... 395

21
26.4.4 Fuel ......................................... 312
INDEX ............................................................. 396
26.5 Chassis ......................................... 313

16
26.6 Electrical system............................ 314

l.c r:
,0
ai d fo
26.7 Tires ............................................. 314

om
26.8 Fork.............................................. 314
26.9 Shock absorber .............................. 315
gm e
@ ens

26.10 Chassis tightening torques .............. 316

27 CLEANING, CARE ..................................... 319
tin ic
ar | L

27.1 Cleaning the motorcycle ................. 319

27.2 Checks and maintenance steps for
lm r
ie fü

winter operation............................. 320

an ert

28 STORAGE ................................................. 321

yd zi

28.1 Storage ......................................... 321

ar en

28.2 Preparing for use after storage......... 322

ch Liz

29 SERVICE SCHEDULE ................................ 323

29.1 Additional information .................... 323
29.2 Required work ............................... 323
29.3 Recommended work ....................... 324
za

30 WIRING DIAGRAM .................................... 326

,
in

30.1 Page 1 of 8 (EU/ASEAN) ................ 326

t
ar

30.2 Page 2 of 8 (EU/ASEAN) ................ 328

30.3 Page 3 of 8 (EU/ASEAN) ................ 330
M

30.4 Page 4 of 8 (EU/ASEAN) ................ 332

c
Za

30.5 Page 5 of 8 (EU/ASEAN) ................ 334

30.6 Page 6 of 8 (EU/ASEAN) ................ 336
30.7 Page 7 of 8 (EU/ASEAN) ................ 338
30.8 Page 8 of 8 (EU/ASEAN) ................ 340
30.9 Page 1 of 6 (US)............................ 342
30.10 Page 2 of 6 (US)............................ 344
Zac Martin, [email protected],

6
 MEANS OF REPRESENTATION 1

1.1 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.

52
73
Indicates the result of a testing step.

01
8/
21
Indicates a voltage measurement.

16
l.c r:
,0
ai d fo
Indicates a current measurement.

om
gm e
@ ens

Indicates a resistance measurement.

tin ic
ar | L

Indicates the end of an activity including potential rework.

lm r
ie fü
an ert

1.2 Formats used

yd zi
ar en

The typographical formats used in this document are explained below.

ch Liz

Proprietary name Indicates a proprietary name.

Name® Indicates a protected name.

za

Brand™ Indicates a brand available on the open market.

,
t in

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
ar

are explained in the glossary.

M
c
Za

Zac Martin, [email protected],

7
 2 SAFETY ADVICE

2.1 Repair Manual

Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips
to help you repair and service your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are
available.

2.2 Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.

Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.

52
73
2.3 Degrees of risk and symbols

01
8/
Danger

21
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.

16
l.c r:
,0
Warning

ai d fo
om
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
gm e
@ ens

Caution
tin ic

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
ar | L

Note
lm r

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
ie fü

not taken.
an ert

Note
yd zi

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
ar en
ch Liz

2.4 Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
za

using the number in parentheses. Example: bearing puller (15112017000)

Unless otherwise noted, normal conditions apply to all tasks and descriptions.
,
t in

Ambient temperature 20 °C (68 °F)

ar

Ambient air pressure 1,013 mbar (14.69 psi)

M

Relative air humidity 60 ± 5 %

c
Za

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instruc-
tions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
Zac Martin, [email protected],

8
 SAFETY ADVICE 2

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za

Zac Martin, [email protected],

9
 3 IMPORTANT NOTES

3.1 Manufacturer warranty, implied warranty

The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con-
firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

3.2 Fuel, auxiliary substances

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.

3.3 Spare parts, technical accessories

52
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other
products and any resulting damage or loss.

73
The latest news KTM PowerParts on your vehicle can be found on the KTM website.

01
International KTM Website: KTM.COM

8/
21
3.4 Figures

16
The figures contained in the manual may depict special equipment.

l.c r:
,0
ai d fo
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not

om
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za
Zac Martin, [email protected],

10
 SERIAL NUMBERS 4

4.1 Vehicle identification number

The vehicle identification number 1 is stamped on the right side
of the steering head.

401945-10

4.2 Type label

Type label 1 is fixed to the front of the steering head.

52
73
01
8/
21
16
l.c r:
401946-10

,0
ai d fo
om
4.3 Engine number
gm e
@ ens

The engine number 1 is located on the left side of the engine

over the engine sprocket.
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H01047-10
ar en
ch Liz

4.4 Fork part number

The fork part number 1 is stamped on the inside of the axle
clamp.
, za
in
t
ar
M
c
Za

401947-10
Zac Martin, [email protected],

11
 4 SERIAL NUMBERS

4.5 Shock absorber article number

Shock absorber article number 1 is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.

401948-10

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

12
 MOTORCYCLE 5

5.1 Raising the motorcycle with a lift stand

Note
Danger of damage The parked vehicle can roll away or fall
over.
– Park the vehicle on a firm and level surface.

– Raise the motorcycle at the frame underneath the engine.

Lift stand (78129955100) ( p. 382)

401942-01 Neither wheel is in contact with the ground.

– Secure the motorcycle against falling over.

5.2 Removing the motorcycle from the lift stand

52
Note

73
Danger of damage The parked vehicle can roll away or fall over.

01
– Park the vehicle on a firm and level surface.

8/
21
– Remove the motorcycle from the lift stand.

16
– Remove the lift stand.

l.c r:
,0
– To park the motorcycle, press side stand 1
to the ground

ai d fo
om
with your foot and lean the motorcycle on it.
gm e
Info
@ ens

When you are riding, the side stand must be folded up

and secured with the rubber strap.
tin ic
ar | L

401943-10
lm r
ie fü

5.3 Starting the vehicle

an ert

Danger
yd zi

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
ar en

– Always make sure there is sufficient ventilation when running the engine.
ch Liz

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
za

– Always run the engine warm at a low speed.

,
in

– Take the motorcycle off side stand 1 and secure the side
t
ar

stand with rubber strap 2

.
M

– Shift the transmission to neutral position.

c

Condition
Za

Ambient temperature: < 10 °C (< 50 °F)

– Pull the cold start button fully out and turn it by a ¼ turn.

Info
401944-10 If the engine is warm, the cold start button must be
deactivated.
Zac Martin, [email protected],

13
 5 MOTORCYCLE

– Press the start button.

Info
Do not open the throttle.
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at start-
ing.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
400733-01 battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.

5.4 Starting the motorcycle to check the function

52
Danger

73
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

01
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.

8/
21
– Shift the transmission to neutral position.

16
l.c r:
– Press the start button.

,0
ai d fo
om
Info
gm e
Press the start button for a maximum of 5 seconds.
@ ens

Wait for 30 seconds before a further attempt at start-

ing.
tin ic

At temperatures below 15 °C (60 °F), several attempts

ar | L

at starting may be necessary to warm-up the lithium-ion

battery and thereby increase the starting power.
lm r

During the starting process, the malfunction indicator

ie fü

400733-01
lamp lights up.
an ert

Do not open the throttle.

yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za
Zac Martin, [email protected],

14
 FORK, TRIPLE CLAMP 6

6.1 Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

– Turn white adjuster 1 clockwise as far as it will go.

Info
Adjuster 1 is located at the upper end of the left fork
leg.
The compression damping is located in left fork
leg COMP (white adjuster). The rebound damping is
located in right fork leg REB (red adjuster).

S04824-10 – Turn counterclockwise by the number of clicks corresponding

to the fork type.

52
Guideline

73
Compression damping

01
Comfort 18 clicks

8/
Standard 15 clicks

21
Sport 12 clicks

16
l.c r:
Info

,0
ai d fo
Turn clockwise to increase damping; turn counterclock-

om
wise to reduce damping during compression.
gm e
@ ens

6.2 Adjusting the rebound damping of the fork

tin ic
ar | L

Info
lm r
ie fü

The hydraulic rebound damping determines the fork suspension behavior.

an ert

– Turn red adjuster 1 clockwise as far as it will go.

yd zi
ar en

Info
ch Liz

Adjuster 1 is located at the upper end of the right

fork leg.
The rebound damping is located in right fork leg REB
(red adjuster). The compression damping is located in
left fork leg COMP (white adjuster).
za

– Turn counterclockwise by the number of clicks corresponding

,

S04824-11
in

to the fork type.

t

Guideline
ar
M

Rebound damping
Comfort 18 clicks
c
Za

Standard 15 clicks
Sport 12 clicks
Zac Martin, [email protected],

15
 6 FORK, TRIPLE CLAMP

Info
Turn clockwise to increase the damping; turn counter-
clockwise to reduce damping when the shock absorber
rebounds.

6.3 Adjusting the spring preload of the fork

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
– Turn T-grips 1 counterclockwise all the way.
Marking +0 aligns with the right T-grip on both fork legs.

Info

52
Make the adjustment by hand only. Do not use a tool.
Make the same adjustment on both fork legs.

73
01
– Turn the T-grip clockwise.

8/
S04314-10
Guideline

21
Spring preload – preload adjuster

16
Comfort +0

l.c r:
,0
Standard +0

ai d fo
om
Sport +3
The T-grip engages noticeably at the numerical values.
gm e
@ ens

Info
tin ic

Adjust the spring preload to the numerical values only

ar | L

as the preload will not engage between the numerical

values.
lm r

Turn clockwise to increase the spring preload; turn

ie fü

counterclockwise to reduce the spring preload.

an ert

Adjusting the spring preload has no influence on the

absorption setting of the rebound.
yd zi

Basically, however, you should set the rebound damp-

ar en

ing higher with a higher spring preload.

ch Liz

Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)
za

6.4 Bleeding the fork legs

,
in

Preparatory work
t
ar

– Raise the motorcycle with a lift stand. ( p. 13)

M
c
Za
Zac Martin, [email protected],

16
 FORK, TRIPLE CLAMP 6

Main work
– Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.

S04824-13

Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)

6.5 Cleaning the dust boots of the fork legs

Preparatory work

52
– Raise the motorcycle with a lift stand. ( p. 13)

73
– Remove the fork protector. ( p. 19)

01
Main work

8/
– Push dust boots 1 of both fork legs downward.

21
16
Info

l.c r:
,0
The dust boots remove dust and coarse dirt particles

ai d fo
from the inside fork tubes. Over time, dirt can accumu-

om
late behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
gm e
@ ens

K00070-10
Warning
tin ic
ar | L

Danger of accidents Oil or grease on the brake discs

reduces the braking effect.
lm r

– Always keep the brake discs free of oil and grease.

ie fü

– Clean the brake discs with brake cleaner when nec-

an ert

essary.
yd zi
ar en

– Clean and oil the dust boots and inner fork tubes of both fork
legs.
ch Liz

Universal oil spray ( p. 373)

– Press the dust boots back into their installation position.
– Remove excess oil.
za

Finishing work
,

– Install the fork protector. ( p. 20)

in

– Remove the motorcycle from the lift stand. ( p. 13)

t
ar
M
c
Za

Zac Martin, [email protected],

17
 6 FORK, TRIPLE CLAMP

6.6 Removing the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the front wheel. ( p. 123)
– Remove the headlight mask with the headlight. ( p. 117)
Main work
– Remove screws 1 and take off the clamp.
– Remove the cable tie.
– Remove screws 2 and take off the brake caliper.
– Hang the brake caliper and the brake line loosely to the side.

E00375-10

52
(All standard models)

73
– Loosen screws 3. Remove the left fork leg.

01
– Loosen screws 4. Remove the right fork leg.

8/
21
16
l.c r:
,0
ai d fo
om
S04894-10
gm e
@ ens

(All special models)

– Loosen screws 3. Remove the left fork leg.
tin ic

– Loosen screws 4. Remove the right fork leg.

ar | L
lm r
ie fü
an ert
yd zi
ar en

S04893-10
ch Liz

6.7 Installing the fork legs

Main work
– Position the fork legs.
Bleeder screws 1 are positioned toward the front.
,za

Info
t in

The rebound damping is located in right fork leg REB

ar

(red adjuster). The compression damping is located in

M

left fork leg COMP (white adjuster).

Grooves are milled into the side of the upper end of the
c
Za

S04824-13 fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
Zac Martin, [email protected],

18
 FORK, TRIPLE CLAMP 6

(All standard models)

– Tighten screws 2.
Guideline
Screw, top triple M8 20 Nm
clamp (14.8 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom M8 15 Nm
S04894-11
triple clamp (11.1 lbf ft)

(All special models)

– Tighten screws 2.
Guideline
Screw, top triple M8 17 Nm
clamp (12.5 lbf ft)

52
– Tighten screws 3.

73
Guideline

01
Screw, bottom M8 15 Nm
S04893-11

8/
triple clamp (11.1 lbf ft)

21
– Position the brake caliper, and mount and tighten screws 4.

16
Guideline

l.c r:
,0
Screw, front M8 25 Nm (18.4 lbf ft)

ai d fo
om
brake caliper
gm e Loctite®243™
– Mount the cable ties.
@ ens

– Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws 5 .
tin ic
ar | L

E00375-11
lm r

Finishing work
ie fü

– Install the front wheel. ( p. 124)

an ert

– Install the headlight mask with the headlight. ( p. 117)

–
yd zi

Check the headlight setting. ( p. 167)

ar en
ch Liz

6.8 Removing the fork protector

– Remove screws 1 and take off the clamp.
– Remove screws 2 and take off the left fork protector.
za

– Remove screws 3 and take off the right fork protector.

,
tin
ar
M
c
Za

V00332-10
Zac Martin, [email protected],

19
 6 FORK, TRIPLE CLAMP

6.9 Installing the fork protector

– Position the fork protector on the left fork leg. Mount and
tighten screws 1 .
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Position the brake line, wiring harness, and clamp. Mount and
tighten screws 2 .
– Position the fork protector on the right fork leg. Mount and
V00332-11 tighten screws 3 .
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

52
73
6.10 Servicing the fork

01
Condition

8/
The fork legs have been removed.

21
– Disassemble the fork legs. ( p. 20)

16
– Disassemble the cartridge. ( p. 23)

l.c r:
,0
– Disassemble the tap compression. ( p. 26)

ai d fo
om
– Check the fork legs. ( p. 27)
– Assemble the tap compression. ( p. 29)
gm e
@ ens

– Assemble the cartridge. ( p. 29)

– Assemble the fork legs. ( p. 33)
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

T03875-10
za

6.11 Disassembling the fork legs

,
t in

Info
ar

The operations are the same on both fork legs.

M
c

Condition
Za

The fork legs have been removed.

Zac Martin, [email protected],

20
 FORK, TRIPLE CLAMP 6

– Note down the current state of compression

damping 1 COMP (white adjuster on the left fork leg).
– Note down the current state of rebound damping 2 REB (red
adjuster on the right fork leg).
– Open the adjusters of the rebound and compression damping
completely.

T03839-10

– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 391)
– Remove screw 3. Remove the adjuster.

52
73
01
T03840-10

8/
– Loosen screw cap 4.

21
Ring wrench (T14017) ( p. 390)

16
l.c r:
,0
Info

ai d fo
om
The screw cap cannot be removed yet.
gm e
@ ens
tin ic

T03841-10
ar | L

– Unclamp the fork leg and push the outside fork tube down-
ward.
lm r
ie fü

– Pull the spring downward and push the open end wrench onto
the hexagonal part.
an ert

– Hold the hexagonal part and loosen the Preload Adjuster with
yd zi

special tool 5
, but do not take it off yet.
ar en

Special socket (T14087) ( p. 391)

ch Liz

T03849-10

– Pull the spring downward. Remove the open end wrench.

–
za

Remove the screw cap.

,
in
t
ar
M
c
Za

T03850-10
Zac Martin, [email protected],

21
 6 FORK, TRIPLE CLAMP

– Remove the spring.

– Drain the fork oil.

Info
Pull out and push in the piston rod a few times to
pump the cartridge empty.

B04513-10

– Clamp the fork leg with the axle clamp.

Guideline
Use soft jaws.
– Unscrew and remove compression holder 6.
Info

52
Place a collecting container underneath as some oil will

73
usually still run out.

01
B04514-10

8/
– Remove the cartridge.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

B04515-10
ar | L

– Remove dust boot 7.

lm r

– Remove fork protection ring A.

ie fü
an ert

Info
The fork protection ring does not necessarily need to be
yd zi

removed for repair work.

ar en
ch Liz

T03291-12

– Remove lock ring 8.

za

Info
,
in

The lock ring has a beveled end where a screwdriver

can be used.
t
ar
M
c
Za

B03527-14
Zac Martin, [email protected],

22
 FORK, TRIPLE CLAMP 6

– Warm up the outside fork tube in area B of the lower sliding

bushing.
Guideline
50 °C (122 °F)
– Pull the outside fork tube off the inside fork tube with a jerk.

Info
Lower sliding bushing 9 must be drawn from its bear-
B03528-15 ing seat.

– Remove upper sliding bushing bk.

Info
Without using a tool, pull the stack slightly apart by
hand.

52
– Take off lower sliding bushing 9.

73
– Take off support ring bl.

01
– Take off seal ring bm.
T03282-12

8/
– Take off lock ring 8.

21
– Take off dust boot 7.

16
– Take off lift indicator bn.

l.c r:
,0
– Unclamp the fork leg.

ai d fo
om
gm e
@ ens

6.12 Disassembling the cartridge

Preparatory work
tin ic

– Disassemble the fork legs. ( p. 20)

ar | L

Right cartridge
lm r

– Clamp the piston rod using the special tool.

ie fü
an ert

Clamping stand (T14016S) ( p. 390)

–
yd zi

Remove adjusting tube 1.

ar en

– Remove fluid barrier 2 from the piston rod.

ch Liz

B04517-10

– Take piston rod 3 out of the cartridge.

, za
tin
ar
M
c
Za

B04532-10
Zac Martin, [email protected],

23
 6 FORK, TRIPLE CLAMP

– Take spring seat 4 and washer 5 off the cartridge.

B04519-10

– Degrease the piston rod.

– Clamp the piston rod using the special tool.
Clamping stand (T14016S) ( p. 390)

52
73
01
B04528-10

8/
– Remove nut 6.

21
– Completely remove shim stack 7.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

B04529-10
ar | L

– Remove piston 8.
lm r

– Completely remove shim stack 9.

ie fü
an ert
yd zi
ar en
ch Liz

B04530-10

– Remove spring bk.

za

– Warm up the piston rod in area A.

Guideline
,
in

50 °C (122 °F)
t
ar

– Remove tap rebound bl.

M
c
Za

B04531-10
Zac Martin, [email protected],

24
 FORK, TRIPLE CLAMP 6

– Remove spring bm.

– Remove valve bn of the rebound damping with the spring.
– Unclamp the piston rod.

B04539-10

– Remove piston ring bo.

52
73
01
B04538-10

8/
Left cartridge

21
– Clamp the piston rod using the special tool.

16
Clamping stand (T14016S) ( p. 390)

l.c r:
,0
–

ai d fo
Remove adjusting tube 1.

om
– Remove fluid barrier 2 from the piston rod.
gm e
@ ens
tin ic

B04517-10
ar | L

– Take piston rod 3 out of the cartridge.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

T03833-10

– Take spring seat 4 and washer 5 off the cartridge.

, za
in
t
ar
M
c
Za

B04533-10
Zac Martin, [email protected],

25
 6 FORK, TRIPLE CLAMP

– Degrease the piston rod.

– Clamp the piston rod using the special tool.
Clamping stand (T14016S) ( p. 390)
– Remove piston ring 6.

B05419-10

– Warm up the piston rod in area A.

Guideline
50 °C (122 °F)
– Remove piston 7 with setting needle 8.

52
73
01
B04535-10

8/
– 8 out of the piston.
Pull setting needle

21
– Remove O-rings 9 and bk.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

B04536-10
ar | L

– Remove spring bl.

lm r

– Unclamp the piston rod.

ie fü
an ert
yd zi
ar en
ch Liz

B04537-10

6.13 Disassembling the tap compression

, za

Info
in

The procedures are the same on both fork legs.

t
ar
M

Preparatory work
c

– Disassemble the fork legs. ( p. 20)

Za
Zac Martin, [email protected],

26
 FORK, TRIPLE CLAMP 6

Main work
– Mount the tap compression on a suitable hexagon socket and
clamp into a vise.
– Remove nut 1.
– Remove spring 2.
– Remove washer 3.

B04504-10

– Remove O-ring 4.
– Remove piston 5.
– Remove shim stack 6.

52
73
01
B04506-10

8/
– Remove O-ring 7 from the tap compression.

21
– Extract the tap compression.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

B04507-10
ar | L

6.14 Checking the fork legs

lm r
ie fü

Condition
an ert

The fork legs have been disassembled.

yd zi

– Check the inside fork tube and the axle clamp for damage.
ar en

» If damage is found:
ch Liz

– Change the inside fork tube.

, za
in

B03581-10
t
ar
M
c
Za

Zac Martin, [email protected],

27
 6 FORK, TRIPLE CLAMP

– Measure the outside diameter of the inside fork tube at several

places.
Outside diameter of the 47.975 … 48.005 mm
inside fork tube (1.88878 … 1.88996 in)
» If the measured value is less than the specified value:
– Change the inside fork tube.

B03582-10

– Measure the run-out of the inside fork tube.

Run-out of the inside fork ≤ 0.20 mm (≤ 0.0079 in)
tube
» If the measured value is greater than the specified value:
– Change the inside fork tube.

52
73
01
B03583-10

8/
– Check the outside fork tube for damage.

21
» If damage is found:

16
– Change the outside fork tube.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

B03584-10
ar | L

– Check the surface of the sliding bushings.

lm r

» When bronze-colored layer A becomes visible under glid-

ie fü

ing layerB :
an ert

– Change the guiding bushes.

yd zi
ar en
ch Liz

200665-10

– Check the spring length.

za

Guideline
Spring length with preload 474 mm (18.66 in)
,
in

spacer(s)
t
ar

» If the measured value is greater than the specified value:

M

– Reduce the thickness of the preload spacers.

c

» If the measured value is less than the specified value:

Za

– Increase the thickness of the preload spacers.

B04555-10

Info
There may only be one preload spacer installed,
or none at all.
Zac Martin, [email protected],

28
 FORK, TRIPLE CLAMP 6

6.15 Assembling the tap compression

Info
The operations are the same on both fork legs.

– Mount the tap compression on a suitable hexagon socket and

clamp into a vise.
– Mount O-ring 1.
– Grease the O-ring.
Lubricant (T158) ( p. 372)
– Mount shim stack 2.
B04508-10
Info
Mount the smaller shims at the bottom.

52
– 3.

73
Mount piston
Guideline

01
View A of piston from above

8/
21
View B of piston from below

16
– Mount O-ring 4.

l.c r:
,0
– Grease the piston O-ring.

ai d fo
om
Fork oil (SAE 4) (48601166S1) ( p. 371)
B04509-10
gm e
@ ens

– Mount washer 5.
– Mount spring 6 with the tighter coil facing downward.
tin ic

–
ar | L

Mount and tighten nut 7.

Guideline
lm r
ie fü

Nut, tap compression M6x0.5 5 Nm (3.7 lbf ft)

an ert

Info
yd zi

Washer 5 must be free to move against the spring

ar en

B04505-10
force.
ch Liz

– Extract the tap compression.

6.16 Assembling the cartridge

za

Right cartridge
,
in

– Clamp in the piston rod.

t
ar

Clamping stand (T14016S) ( p. 390)

M

– Mount valve 1 of the rebound damping with the spring

c

and O-ring.
Za

– Grease the O-ring.

Lubricant (T158) ( p. 372)
B04545-10 – Mount spring 2.
Zac Martin, [email protected],

29
 6 FORK, TRIPLE CLAMP

– Mount and grease O-ring 3 in tap rebound 4.

Lubricant (T158) ( p. 372)
– Mount and tighten the tap rebound.
Guideline
Tap rebound M9x1 18 Nm (13.3 lbf ft)
Loctite®2701™

B04546-10

– 5.
Position spring
– Mount shim stack 6.

Info
Mount the smaller shims at the bottom.

52
– Press the shim stack downward against the spring force.

73
Info

01
B04547-10
The shim stack must be pressed downward over the

8/
collar.

21
– 7.

16
Mount and lubricate piston ring

l.c r:
,0
Fork oil (SAE 4) (48601166S1) ( p. 371)

ai d fo
om
gm e
@ ens
tin ic
ar | L

B05418-11
lm r
ie fü

– Mount piston 8 with the piston ring.

an ert

Guideline
View A of piston from above
yd zi
ar en

View B of piston from below

ch Liz

B04548-10
za

– Mount shim stack 9.

,
in

Info
t
ar

Align the triangular plate exactly with the piston

M

opening.
c

– bk with the collar facing down-

Za

Mount and tighten nut

ward.
Guideline
B04549-10
Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft)
The lower shim stack is free to move against the
Zac Martin, [email protected],

spring force.
– Lock the nut by center punching it.

30
 FORK, TRIPLE CLAMP 6

– Mount washer bl and spring seat bm.

D04749-10

– Slide piston rod bn into the cartridge.

52
73
01
B04532-11

8/
– Mount fluid barrier bo all the way on.

21
16
Info

l.c r:
The fluid barrier must be tightened all the way. Do

,0
ai d fo
not use a tool.

om
– Mount adjusting tube bp for the rebound damping in the
gm e
@ ens
cartridge.
The adjusting tube protrudes approx. 5 mm (0.197 in)
tin ic

B04550-10 out of the cartridge and can be pressed in against the

spring force.
ar | L

The adjusting tube protrudes more than 7 mm

lm r

(0.275 in) from the cartridge and cannot be pressed

ie fü

in against the spring force.

an ert

Left cartridge
yd zi

– Clamp in the piston rod.

ar en

Clamping stand (T14016S) ( p. 390)

ch Liz

– Mount spring 1.
za

B04537-11
,
in

– Mount and lubricate O-ring 2 for setting needle 3.

t
ar

Lubricant (T158) ( p. 372)

M

– 4 for piston 5.
c

Mount and lubricate O-ring

Za

Lubricant (T158) ( p. 372)

B04551-10
Zac Martin, [email protected],

31
 6 FORK, TRIPLE CLAMP

– 3 in the piston.
Insert setting needle
– Mount and tighten piston 5.
Guideline
Compression M9x1 18 Nm (13.3 lbf ft)
piston Loctite®2701™

B04552-10

– Mount and lubricate piston ring 6.

Fork oil (SAE 4) (48601166S1) ( p. 371)

52
73
01
B05419-10

8/
– Mount washer 7 and spring seat 8.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

D04750-10
ar | L

– Slide piston rod 9 into the cartridge.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

T03833-11

– Mount fluid barrier bk all the way on.

za

Info
,
in

The fluid barrier must be tightened all the way. Do

not use a tool.
t
ar
M

– Mount adjusting tube bl for the rebound damping in the

cartridge.
c
Za

The adjusting tube protrudes approx. 3 mm (0.118 in)

B04550-11 out of the cartridge and can be pressed in against the
spring force.
The adjusting tube protrudes more than 5 mm
(0.197 in) from the cartridge and cannot be pressed
in against the spring force.
Zac Martin, [email protected],

32
 FORK, TRIPLE CLAMP 6

6.17 Assembling the fork legs

Info
The operations are the same on both fork legs.

Preparatory work
– Check the fork legs. ( p. 27)
– Assemble the tap compression. ( p. 29)
– Assemble the cartridge. ( p. 29)
Main work
– Clamp the inside fork tube using an axle clamp.
Guideline
Use soft jaws.
– Mount the special tool.

52
Protecting sleeve (T1401) ( p. 390)

73
– Position lift indicator 1.

01
T03287-10 – Grease and push on dust boot 2.

8/
21
Lubricant (T14034) ( p. 372)

16
Info

l.c r:
,0
ai d fo
Always change the dust boot, seal ring, lock ring, and

om
support ring.
Mount the sealing lip with the spring expander facing
gm e
@ ens
down.

– Push on lock ring 3.

tin ic

–
ar | L

Grease and push on seal ring 4.

Lubricant (T14034) ( p. 372)
lm r
ie fü
an ert

Info
Sealing lip downward, open side upward.
yd zi
ar en

– Remove the special tool.

ch Liz

– Push on support ring 5.

– 6.
Push on lower sliding bushing
– Mount upper sliding bushing 7.
za

Info
,

Without using a tool, pull the stack slightly apart by

in

hand.
t
ar
M

T03288-10
c
Za

Zac Martin, [email protected],

33
 6 FORK, TRIPLE CLAMP

– Warm up the outside fork tube in area A of the lower sliding

bushing.
Guideline
50 °C (122 °F)
– Slide on the outside fork tube.
– Hold the lower sliding bushing with the longer side of the spe-
cial tool.
Mounting tool (T14040S) ( p. 391)
B03537-10

– Press the outside fork tube all the way in.

– Position the support ring.
– Hold the seal ring with shorter side of the special tool.
Mounting tool (T14040S) ( p. 391)
– Press the outside fork tube all the way in.

52
73
01
8/
T03289-10

21
– Mount lock ring 3.

16
The lock ring engages audibly.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

T03290-10

– Mount dust boot 2.

lm r
ie fü

– Mount fork protection ring B.

an ert
yd zi
ar en
ch Liz

T03291-10
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

34
 FORK, TRIPLE CLAMP 6

– Slide the cartridge all the way into the inside fork tube.
The hexagonal part of the cartridge engages in the inside
fork tube guide.

Info
When assembling, ensure that the cartridges are not
mixed up.
The cartridge with the holes is installed on the left.
The cartridge without the holes is installed on the right.

52
73
01
D04748-10

8/
– Mount and tighten tap compression 8.

21
Guideline

16
Compression damp- M29x1 35 Nm (25.8 lbf ft)

l.c r:
,0
ing fitting

ai d fo
om
Info
gm e
@ ens

When assembling, ensure that the tap compressions are

not mixed up.
tin ic

T03835-10 The red tap compression is installed on the right.

ar | L

– Mount special tool 9 on the piston rod.

lm r
ie fü

Support tool (T14026S1) ( p. 390)

an ert

Info
yd zi

The special tool must be used to prevent the adjust-

ar en

ing tube from being lifted and thus to prevent oil from
ch Liz

reaching the piston rod.

– Clamp the fork vertically.

T03836-10
– Fill with fork oil.
Fork oil per fork leg 636 ± 10 ml Fork oil (SAE 4)
za

(21.5 (48601166S1)
,

± 0.34 fl. oz.) ( p. 371)

in
t
ar

Info
M

Pull out the piston rod and push back in a number of

c

times to bleed the cartridge.

Za

Zac Martin, [email protected],

35
 6 FORK, TRIPLE CLAMP

– Remove pin C of the special tool.

Support tool (T14026S1) ( p. 390)
– Pull out the piston rod. Mount the spring. Mount the pin again.
Guideline
Spring rate
Weight of rider: 65 … 4.2 N/mm (24 lb/in)
75 kg (143 … 165 lb.)
B04543-10 Weight of rider: 75 … 4.4 N/mm (25.1 lb/in)
85 kg (165 … 187 lb.)
Weight of rider: 85 … 4.6 N/mm (26.3 lb/in)
95 kg (187 … 209 lb.)

– Pull the spring downward.

– Remove the special tool.
Support tool (T14026S1) ( p. 390)

52
– bk.

73
Mount screw cap

01
Info

8/
When assembling, ensure that the screw caps are

21
mounted correctly.
T03851-10
Rebound damping side – right fork leg, screw cap with

16
marking REB, red adjuster.

l.c r:
,0
Compression damping side – left fork leg, screw cap

ai d fo
om
gm e with marking COMP, white adjuster.

– Pull the spring downward.

@ ens

– Mount the open end wrench on the hexagonal part.

tin ic

– Hold the open end wrench. Tighten the Preload Adjuster with
ar | L

special tool bl
.
Guideline
lm r
ie fü

Preload adjuster on M12x1 25 Nm (18.4 lbf ft)

piston rod
an ert
yd zi

Special socket (T14087) ( p. 391)

T03849-11
ar en

– Push the outside fork tube upward.

ch Liz

– Clamp the outside fork tube in the area of the lower triple
clamp.
Clamping stand (T1403S) ( p. 391)
za

– Grease the O-ring of the screw cap.

,

Lubricant (T158) ( p. 372)

in

–
t

Mount and tighten screw cap bk.

ar

T03841-11
Guideline
M

Screw cap on the M51x1.5 40 Nm (29.5 lbf ft)

c

outside fork tube

Za

Ring wrench (T14017) ( p. 390)

Zac Martin, [email protected],

36
 FORK, TRIPLE CLAMP 6

– Mount the adjuster.

– Mount and tighten screw bm.
Guideline
Screw, adjuster M4x0.5 2.5 Nm
(1.84 lbf ft)

T03840-11

Alternative 1
– Turn compression adjuster bn and rebound adjuster bo
clockwise all the way.
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline

52
Rebound damping

73
Comfort 18 clicks

01
T03839-11 Standard 15 clicks

8/
Sport 12 clicks

21
Compression damping

16
Comfort 18 clicks

l.c r:
,0
Standard 15 clicks

ai d fo
om
Sport 12 clicks
–
gm e
Set the spring preload according to the fork type.
@ ens

Guideline
Spring preload – preload adjuster
tin ic

Comfort +0
ar | L

Standard +0
lm r
ie fü

Sport +3
an ert

Alternative 2
yd zi

Warning
ar en

Danger of accident Modifications to the suspen-

ch Liz

sion setting may seriously alter the handling char-

acteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
za

characteristic and overload components.

– Only make adjustments within the
,
in

recommended range.
t
ar

– Ride slowly to start with after making adjust-

ments to get the feel of the new handling char-
M

acteristic.
c
Za

– Set the adjusters to the positions determined upon

removal.
Zac Martin, [email protected],

37
 6 FORK, TRIPLE CLAMP

6.18 Lubricating the steering head bearing

(All standard models)
– Remove the lower triple clamp. ( p. 38)
– Install the lower triple clamp. ( p. 39)

Info
The steering head bearing is cleaned and lubri-
cated in the course of removal and installation of
the lower triple clamp.

H02387-01 (All special models)

– Remove the lower triple clamp. ( p. 41)
– Install the lower triple clamp. ( p. 42)

Info
The steering head bearing is cleaned and lubri-

52
cated in the course of removal and installation of

73
the lower triple clamp.

01
8/
21
6.19 Removing the lower triple clamp (All standard models)

16
Preparatory work

l.c r:
,0
– Raise the motorcycle with a lift stand. ( p. 13)

ai d fo
om
– Remove the front wheel. ( p. 123)
– Remove the headlight mask with the headlight. ( p. 117)
gm e
@ ens

– Remove the fork legs. ( p. 18)

– Remove front fender. ( p. 116)
tin ic

– Remove the handlebar cushion.

ar | L

Main work
lm r

– Remove screws 1and hang the combination instrument

ie fü

holder to the side.

an ert
yd zi
ar en
ch Liz

S03514-10

– Remove screw 2.
za

– Loosen screw 3. Take off the upper triple clamp with the
,

handlebar and hang them to the side.

tin
ar

Info
M

Cover the components to protect them against damage.

Do not kink the cables and lines.
c
Za

E00921-10
Zac Martin, [email protected],

38
 FORK, TRIPLE CLAMP 6

– Remove O-ring 4. Remove protective ring 5.

– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

E00922-10

6.20 Installing the lower triple clamp (All standard models)

Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 372)

52
– Insert the lower triple clamp with the steering stem. Mount

73
upper steering head bearing.

01
– Check whether upper steering head seal 1 is correctly posi-

8/
tioned.

21
– Mount protective ring 2 and O-ring 3.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r

V00359-10
ie fü

– Position the upper triple clamp with the handlebar.

an ert

– Position the clutch line and the wiring harness.

yd zi

– Mount screw 4, but do not tighten yet.

ar en
ch Liz
za

E00921-11

– Position the combination instrument holder, and mount and

,
in

tighten screws 5.
t
ar

Guideline
M

Remaining screws, M6 10 Nm (7.4 lbf ft)

chassis
c
Za

S03514-11
Zac Martin, [email protected],

39
 6 FORK, TRIPLE CLAMP

– Position the fork legs.

Bleeder screws 6 are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjuster). The compression damping is located in
left fork leg COMP (white adjuster).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
S04824-14 be flush with the upper edge of the upper triple clamp.

– Tighten screws 7.
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp

52
73
01
S04894-12

8/
–

21
Tighten screw 4.
Guideline

16
l.c r:
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)

,0
ai d fo
head

om
gm e
@ ens
tin ic

S04879-10
ar | L

– Tighten screw 8.
lm r
ie fü

Guideline
an ert

Screw, top steering M8 20 Nm (14.8 lbf ft)

stem
yd zi
ar en
ch Liz

S04880-10

– Tighten screws 9.
za

Guideline
,
in

Screw, top triple M8 20 Nm (14.8 lbf ft)

clamp
t
ar
M
c
Za

S04894-13
Zac Martin, [email protected],

40
 FORK, TRIPLE CLAMP 6

– Position the brake caliper, and mount and tighten screws bk.
Guideline
Screw, front M8 25 Nm (18.4 lbf ft)
brake caliper Loctite®243™
– Mount the cable ties.
– Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws bl.

E00375-13

Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 116)
– Install the front wheel. ( p. 124)
– Install the headlight mask with the headlight. ( p. 117)
– Check that the wiring harness, throttle cables, and brake and

52
clutch lines can move freely and are routed correctly.

73
– Check the steering head bearing for play. ( p. 44)

01
– Remove the motorcycle from the lift stand. ( p. 13)

8/
– Check the headlight setting. ( p. 167)

21
16
6.21 Removing the lower triple clamp (All special models)

l.c r:
,0
ai d fo
om
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
gm e
@ ens

– Remove the front wheel. ( p. 123)

– Remove the headlight mask with the headlight. ( p. 117)
tin ic

– Remove the fork legs. ( p. 18)

ar | L

– Remove front fender. ( p. 116)

–
lm r

Remove the handlebar cushion.

ie fü

Main work
an ert

– Remove screws 1 and hang the combination instrument

yd zi

holder to the side.

ar en
ch Liz
za

S03515-10

– 2.
,

Remove screw
in

– Remove screw 3
. Take off the upper triple clamp with the
t
ar

handlebar and hang them to the side.

M

Info
c
Za

Cover the components to protect them against damage.

Do not kink the cables and lines.

E00924-10
Zac Martin, [email protected],

41
 6 FORK, TRIPLE CLAMP

– Remove O-ring 4. Remove protective ring 5.

– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

E00925-10

6.22 Installing the lower triple clamp (All special models)

Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 372)

52
– Insert the lower triple clamp with the steering stem. Mount

73
upper steering head bearing.

01
– Check whether upper steering head seal 1 is correctly posi-

8/
tioned.

21
– Mount protective ring 2 and O-ring 3.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r

B01218-10
ie fü

– Position the upper triple clamp with the handlebar.

an ert

– Mount screw 4, but do not tighten yet.

yd zi

– Position the clutch line and the wiring harness.

ar en
ch Liz
za

E00927-10

– Position the combination instrument holder, and mount and

,
in

tighten screws 5.
t
ar

Guideline
M

Remaining screws, M6 10 Nm (7.4 lbf ft)

chassis
c
Za

S03515-11
Zac Martin, [email protected],

42
 FORK, TRIPLE CLAMP 6

– Position the fork legs.

Bleeder screws 6 are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjuster). The compression damping is located in
left fork leg COMP (white adjuster).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
S04824-14 be flush with the upper edge of the upper triple clamp.

– Tighten screws 7.
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp

52
73
01
S04893-12

8/
–

21
Tighten screw 4.
Guideline

16
l.c r:
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)

,0
ai d fo
head

om
gm e
@ ens
tin ic

S03523-10
ar | L

– Mount and tighten screw 8.

lm r
ie fü

Guideline
an ert

Screw, top M8 17 Nm (12.5 lbf ft)

steering stem Loctite®243™
yd zi
ar en
ch Liz

S03509-11

– Tighten screws 9.
za

Guideline
,
in

Screw, top triple M8 17 Nm (12.5 lbf ft)

clamp
t
ar
M
c
Za

S04893-13
Zac Martin, [email protected],

43
 6 FORK, TRIPLE CLAMP

– Position the brake caliper, and mount and tighten screws bk.
Guideline
Screw, front M8 25 Nm (18.4 lbf ft)
brake caliper Loctite®243™
– Mount the cable ties.
– Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws bl
.

E00375-13

Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 116)
– Install the front wheel. ( p. 124)
– Install the headlight mask with the headlight. ( p. 117)
– Check that the wiring harness, throttle cables, and brake and

52
clutch lines can move freely and are routed correctly.

73
– Check the steering head bearing for play. ( p. 44)

01
– Remove the motorcycle from the lift stand. ( p. 13)

8/
– Check the headlight setting. ( p. 167)

21
16
6.23 Checking the steering head bearing play

l.c r:
,0
ai d fo
om
Warning
gm e
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
@ ens

ages components.
– Correct incorrect steering head bearing play immediately.
tin ic
ar | L

Info
lm r
ie fü

If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
an ert
yd zi

Preparatory work
ar en

– Raise the motorcycle with a lift stand. ( p. 13)

ch Liz

Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
za

» If there is detectable play:

,
in

– Adjust the steering head bearing play. ( p. 45)

t

– Move the handlebar to and fro over the entire steering range.
ar
M

H01167-01 It must be possible to move the handlebar easily over the

entire steering range. There should be no detectable detent
c
Za

positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 45)
– Check the steering head bearing and change if neces-
sary.
Zac Martin, [email protected],

44
 FORK, TRIPLE CLAMP 6

– Check the steering stop bolts for correct adjustment and lock-
ing.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)

6.24 Adjusting the steering head bearing play

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
(All standard models)
– Loosen screws 1 and 2.
– Loosen and retighten screw 3.
Guideline

52
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head

73
– Using a plastic hammer, tap lightly on the upper triple

01
S04881-10 clamp to avoid stresses.

8/
– Tighten screws 1.

21
Guideline

16
Screw, top triple M8 20 Nm

l.c r:
,0
clamp (14.8 lbf ft)

ai d fo
om
– Tighten screw 2.
gm e
Guideline
@ ens

Screw, top steering M8 20 Nm

stem (14.8 lbf ft)
tin ic
ar | L

(All special models)

– Loosen screws 1. Remove screw 2.
lm r
ie fü

– Loosen and retighten screw 3.

an ert

Guideline
yd zi

Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)

ar en

head
–
ch Liz

Using a plastic hammer, tap lightly on the upper triple

clamp to avoid stresses.
S03478-10
– Tighten screws 1.
Guideline
za

Screw, top triple M8 17 Nm

clamp (12.5 lbf ft)
,
in

– Mount and tighten screw 2.

t
ar

Guideline
M

Screw, top M8 17 Nm (12.5 lbf ft)

c

steering stem Loctite®243™

Za

Finishing work
– Check the steering head bearing for play. ( p. 44)
– Remove the motorcycle from the lift stand. ( p. 13)
Zac Martin, [email protected],

45
 6 FORK, TRIPLE CLAMP

6.25 Changing the steering head bearing (All standard models)

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the front wheel. ( p. 123)
– Remove the headlight mask with the headlight. ( p. 117)
– Remove the fork legs. ( p. 18)
– Remove front fender. ( p. 116)
– Remove the handlebar cushion.
– Remove the lower triple clamp. ( p. 38)
Main work
– Remove lower bearing ring 1 with special tool 2.
Tool bracket (58429089000) ( p. 380)
Pressing tool (58429092000) ( p. 380)

52
73
01
8/
R02802-10

21
– Press the new bearing ring up to the stop with special tool 3.

16
Tool bracket (58429089000) ( p. 380)

l.c r:
,0
ai d fo
Pressing tool (58429091000) ( p. 380)

om
gm e
@ ens
tin ic
ar | L

R02803-10

–
lm r

Remove upper bearing ring 4 with special tool 2.

ie fü

Tool bracket (58429089000) ( p. 380)

an ert

Pressing tool (58429092000) ( p. 380)

yd zi
ar en
ch Liz

R02804-10

–
za

Remove lower steering head bearing 5.

– Remove the seal ring.
,
in

– Grease and mount the new seal ring.

t
ar

– Press on the new bearing with a suitable tube as far as it will

M

go.
c
Za

Info
Only press the bearing in via the inner ring.
B03410-10

Finishing work
– Install the lower triple clamp. ( p. 39)
Zac Martin, [email protected],

– Mount the handlebar cushion.

46
 FORK, TRIPLE CLAMP 6

– Install front fender. ( p. 116)

– Install the front wheel. ( p. 124)
– Install the headlight mask with the headlight. ( p. 117)
– Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
– Check the steering head bearing for play. ( p. 44)
– Remove the motorcycle from the lift stand. ( p. 13)
– Check the headlight setting. ( p. 167)

6.26 Changing the steering head bearing (All special models)

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the front wheel. ( p. 123)
– Remove the headlight mask with the headlight. ( p. 117)

52
– Remove the fork legs. ( p. 18)

73
– Remove front fender. ( p. 116)

01
– Remove the handlebar cushion.

8/
– Remove the lower triple clamp. ( p. 41)

21
Main work

16
– Remove lower bearing ring 1 with special tool 2.

l.c r:
,0
ai d fo
Tool bracket (58429089000) ( p. 380)

om
Pressing tool (58429092000) ( p. 380)
gm e
@ ens
tin ic
ar | L

R02802-10
lm r

–
ie fü

Press the new bearing ring up to the stop with special tool 3.
an ert

Tool bracket (58429089000) ( p. 380)

Pressing tool (58429091000) ( p. 380)
yd zi
ar en
ch Liz

R02803-10
za

– Remove upper bearing ring 4 with special tool 2.

,
in

Tool bracket (58429089000) ( p. 380)

t

Pressing tool (58429092000) ( p. 380)

ar
M
c
Za

R02804-10
Zac Martin, [email protected],

47
 6 FORK, TRIPLE CLAMP

– Press the new bearing ring up to the stop with special tool 3.
Tool bracket (58429089000) ( p. 380)
Pressing tool (58429091000) ( p. 380)

R02805-10

– Remove lower steering head bearing 5.

– Remove the seal ring.
– Grease and mount the new seal ring.
– Press on the new bearing with a suitable tube as far as it will
go.

52
Info

73
Only press the bearing in via the inner ring.

01
R01337-10

8/
Finishing work

21
– Install the lower triple clamp. ( p. 42)

16
– Mount the handlebar cushion.

l.c r:
,0
– Install front fender. ( p. 116)

ai d fo
–

om
Install the front wheel. ( p. 124)
– Install the headlight mask with the headlight. ( p. 117)
gm e
@ ens

– Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
tin ic

– Check the steering head bearing for play. ( p. 44)

ar | L

– Remove the motorcycle from the lift stand. ( p. 13)

– Check the headlight setting. ( p. 167)
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

48
 HANDLEBAR, CONTROLS 7

7.1 Handlebar position

(All standard models)
On the upper triple clamp, there are 2 holes at a distance
A
of to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance
of B from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This
allows the handlebar to be mounted in the most comfortable
position for the rider.

52
73
01
8/
21
M00993-10

16
(All special models)

l.c r:
,0
On the upper triple clamp, there are 2 holes at a distance

ai d fo
A
of to each other.

om
Hole distance A 15 mm (0.59 in)
gm e
@ ens

The holes on the handlebar support are placed at a distance

of B from the center.
tin ic

Hole distance B 3.5 mm (0.138 in)

ar | L

The handlebar can be mounted in four different positions. This

lm r
ie fü

allows the handlebar to be mounted in the most comfortable

position for the rider.
an ert
yd zi
ar en
ch Liz

M00987-10
, za

7.2 Adjusting the handlebar position

tin
ar

Warning
M

Danger of accidents A repaired handlebar poses a safety risk.

c
Za

If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
– Change the handlebar if the handlebar is damaged or bent.
Zac Martin, [email protected],

49
 7 HANDLEBAR, CONTROLS

(All standard models)

– Remove screws 1 . Take off the handlebar clamps.
Remove the handlebar and lay it to one side.

Info
Cover the components to protect them against dam-
age.
Do not kink the cables and lines.

– Remove screws 2. Take off the handlebar supports.

– Place the handlebar supports in the required position.
Mount and tighten screws 2 .
Guideline
Screw, handle- M10 40 Nm (29.5 lbf ft)
bar support Loctite®243™

52
Info
Position the left and right handlebar supports

73
evenly.

01
M00993-11
– Position the handlebar.

8/
21
Info

16
Make sure the cables and wiring are positioned cor-

l.c r:
,0
rectly.

ai d fo
om
– Position the handlebar clamps. Mount screws 1 and
gm e
tighten evenly.
@ ens

Guideline
Screw, handlebar M8 20 Nm
tin ic

clamp (14.8 lbf ft)

ar | L
lm r

Info
ie fü

Make sure the gap widths are even.

an ert

(All special models)

yd zi

– Remove screws
ar en

1 . Take off the handlebar clamps.

Remove the handlebar and lay it to one side.
ch Liz

Info
Cover the components to protect them against dam-
age.
Do not kink the cables and lines.
za

–
,

Remove screws 2. Take off the handlebar supports.

in

– Place the handlebar supports in the required position.

t
ar

Mount and tighten screws 2 .

M

Guideline
c

Screw, handle- M10 40 Nm (29.5 lbf ft)

Za

bar support Loctite®243™

Info
Position the left and right handlebar supports
evenly.
Zac Martin, [email protected],

M00987-11
– Position the handlebar.

50
 HANDLEBAR, CONTROLS 7

Info
Make sure the cables and wiring are positioned cor-
rectly.

– Position the handlebar clamps. Mount screws 1 and

tighten evenly.
Guideline
Screw, handlebar M8 20 Nm
clamp (14.8 lbf ft)

Info
Make sure the gap widths are even.

7.3 Adjusting the basic position of the clutch lever

52
– Adjust the basic position of the clutch lever to your hand size

73
by turning adjusting screw 1.

01
8/
Info

21
Turn the adjusting screw counterclockwise to decrease
the distance between the clutch lever and the handle-

16
bar.

l.c r:
,0
Turn the adjusting screw clockwise to increase the

ai d fo
distance between the clutch lever and the handlebar.

om
S04872-11 The range of adjustment is limited.
gm e
Turn the adjusting screw by hand only, and do not
@ ens

apply any force.

Do not make any adjustments while riding.
tin ic
ar | L
lm r
ie fü

7.4 Checking the rubber grip

an ert

– Check the rubber grips on the handlebar for damage, wear,

and looseness.
yd zi
ar en

Info
ch Liz

The rubber grips are vulcanized onto a sleeve on the

left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
za

401197-01
» If a rubber grip is damaged or worn:
,
in

– Change the rubber grip.

t
ar
M
c
Za

Zac Martin, [email protected],

51
 7 HANDLEBAR, CONTROLS

– Check that screw 1 is firmly seated.

Guideline
Screw, fixed M4 5 Nm (3.7 lbf ft)
grip Loctite®243™

Diamond A must be positioned visibly as shown in the fig-

ure.

E00889-10

7.5 Checking the throttle cable routing

Warning
Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor-
rectly.

52
If the throttle cable is kinked, trapped or blocked, the speed can no longer be controlled.

73
– Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-

01
tion.

8/
21
Preparatory work
– Remove the seat. ( p. 102)

16
– Remove the fuel tank. ( p. 103)

l.c r:
,0
ai d fo
Main work

om
– Check the throttle cable routing.
gm e
@ ens
Both throttle cables must be routed, side by side, on the
back of the handlebars, above the fuel tank bracket on the
right of the frame to the throttle valve body. Both throttle
tin ic

cables must be secured behind the rubber strap of the fuel

ar | L

tank support.
lm r

» If the throttle cable is not routed as specified:

ie fü

– Correct the throttle cable routing.

an ert
yd zi
ar en
ch Liz
, za
in

E01230-01
t

Finishing work
ar

– Install the fuel tank. ( p. 104)

M

– Mount the seat. ( p. 102)

c
Za
Zac Martin, [email protected],

52
 HANDLEBAR, CONTROLS 7

7.6 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Turn handlebar as far as possible to the right. Turn the throttle
grip back and forth slightly and determine the play in throttle
cable .A
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
– Adjust the play in the throttle cable. ( p. 53)

400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.

52
– Use effective exhaust extraction when starting or

73
running the engine in an enclosed space.

01
– Start the engine and let it run at idle speed. Move the handle-

8/
bar to and fro over the entire steering range.

21
The idle speed must not change.

16
» If the idle speed changes:

l.c r:
,0
ai d fo
– Adjust the play in the throttle cable. ( p. 53)

om
gm e
@ ens

7.7 Adjusting the play in the throttle cable

tin ic

Info
ar | L

If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be
lm r

removed.
ie fü
an ert

Preparatory work
– Remove the seat. ( p. 102)
yd zi

–
ar en

Remove the fuel tank. ( p. 103)

– Check the throttle cable routing. ( p. 52)
ch Liz

Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1.
za

– Loosen nut 2 .
– Turn adjusting screw 3 in as far as possible.
,
in

– Loosen nut 4.
t
ar

– Turn adjusting screw 5 in as far as possible.

M

S04897-10 – Turn adjusting screw 3 so that there is play in the throttle

c

cable at the throttle grip.

Za

Guideline
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
– Unscrew the adjusting screw 5until the smooth operation or
play in throttle cable is worsened.
Zac Martin, [email protected],

– Turn adjusting screw 5 approx. two turns further.

– Tighten nut 4.

53
 7 HANDLEBAR, CONTROLS

– Tighten nut 2.
– Slide on sleeve 1.
– Check the throttle grip for smooth operation.
Finishing work
– Check the play in the throttle cable. ( p. 53)

7.8 Setting the characteristic map of the throttle response

Info
On the throttle grip, the characteristic map of the throttle response is changed by changing the guide
plate.
A guide plate with a different characteristic map is supplied.

Main work

52
– Push back sleeve 1.

73
– Remove screws 2 and half-shells 3.

01
– Detach the throttle cables and take off the grip tube.

8/
21
16
l.c r:
,0
ai d fo
S04898-10

om
– Remove guide plate 4 from handle tube 5.
gm e
– Position the required guide plate on the grip tube.
@ ens

Guideline
tin ic

The label OUTSIDE must be visible. Marking A must be

ar | L

positioned at marking B.
lm r

Grey guide plate (79002014000)

ie fü

Alternative 1
an ert

Black guide plate (79002014100)

yd zi
ar en

Info
ch Liz

The gray guide plate opens the throttle valve more

slowly.
The black guide plate opens the throttle valve more
quickly.
The gray guide plate is mounted upon delivery.
, za
tin

102246-10
ar
M
c
Za
Zac Martin, [email protected],

54
 HANDLEBAR, CONTROLS 7

– Clean the outside of the handlebar and the inside of the grip
tube. Mount the grip tube on the handlebar.
– Attach the throttle cables to the guide plate and route cor-
rectly.
– Position half-shells 3, mount and tighten screws 2.
Guideline
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
– Slide on sleeve 1 and check the throttle grip for ease of
movement.

52
73
01
S04899-10

8/
Finishing work

21
– Check the play in the throttle cable. ( p. 53)

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

55
 8 FRAME

8.1 Checking the frame

– Check the frame for damage, cracks, and deformation.
» If the frame shows signs of damage, cracks, or deforma-
tion:
– Change the frame.
Guideline
Repairs on the frame are not permitted.

401347-01

8.2 Removing the engine guard (All special models)

– Remove screws 1 and engine guard.

52
73
01
8/
21
16
l.c r:
H01638-10

,0
ai d fo
om
8.3 Installing the engine guard (All special models)
gm e
– Attach the engine guard on the frame at the rear and swing up
@ ens

at the front.
–
tin ic

Mount and tighten screws 1.

ar | L

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
lm r
ie fü

chassis
an ert
yd zi

H01638-10
ar en
ch Liz

8.4 Changing the footrests

Condition
The frame protectors have been removed on the left and right.
Left footrest
za

– Raise the motorcycle with a lift stand. ( p. 13)

,
in

– Remove pin 1 and take off the washer.

t
ar
M
c
Za

R00755-10
Zac Martin, [email protected],

56
 FRAME 8

– Press the spring with special tool 2.

Footrest spring plier (79029083000) ( p. 383)

The special tool is applied to area A on the footrest.

– Remove pin 3.

R01338-10

– Position the new footrest and pin.

Info
Only insert the pin to the extent that the spring can
still be mounted.

52
73
01
R00757-10

8/
– Position spring as shown.

21
Spring B engages in area C.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

R01339-10

– Press the spring with special tool 2.

za

Footrest spring plier (79029083000) ( p. 383)

,
in

The special tool is applied to area A on the footrest.

t

–
ar

Mount pin 3.
M
c
Za

R01338-10
Zac Martin, [email protected],

57
 8 FRAME

– Mount the washer and splint 1.

– Remove the motorcycle from the lift stand. ( p. 13)

R00755-10

Right footrest
– Remove pin 1 and take off the washer.

52
73
01
R01227-10

8/
– Press the spring with special tool 2.

21
Footrest spring plier (79029083000) ( p. 383)

16
l.c r:
The special tool is applied to area A on the footrest.

,0
ai d fo
– Remove pin 3.

om
gm e
@ ens
tin ic

R01228-10
ar | L

– Position the new footrest and pin.

lm r
ie fü

Info
Only insert the pin to the extent that the spring can
an ert

still be mounted.
yd zi
ar en
ch Liz

R01229-10
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

58
 FRAME 8

– Position spring as shown.

Spring B engages in area C.

52
73
01
R01230-10

8/
– Press the spring with special tool 2.

21
Footrest spring plier (79029083000) ( p. 383)

16
l.c r:
,0
The special tool is applied to area A on the footrest.

ai d fo
–

om
Mount pin 3.
gm e
@ ens
tin ic

R01228-10
ar | L

– Mount the washer and splint 1.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

R01227-10
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

59
 9 SHOCK ABSORBER, LINK FORK

9.1 Adjusting the high-speed compression damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided.

Info
The effect of the high speed compression adjuster can be seen in the fast compression of the shock
absorber.

– Using an open end wrench, turn adjusting screw 1 clockwise

all the way.

52
Info

73
Do not loosen fitting 2!

01
– Turn counterclockwise by the number of turns corresponding

8/
to the shock absorber type.

21
Guideline

16
S04870-11
High-speed compression damping

l.c r:
,0
Comfort 2.5 turns

ai d fo
om
Standard 2 turns
Sport 1 turn
gm e
@ ens

Info
tin ic

Turn clockwise to increase damping; turn counterclock-

ar | L

wise to reduce damping.

lm r
ie fü
an ert

9.2 Adjusting the low-speed compression damping of the shock absorber

yd zi
ar en

Caution
ch Liz

Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided.
za

Info
,
in

The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
t

absorber.
ar
M
c
Za
Zac Martin, [email protected],

60
 SHOCK ABSORBER, LINK FORK 9

– Turn adjusting screw 1 clockwise with a screwdriver as far as

the last perceptible click.

Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
S04870-10
Low-speed compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

Info
Turn clockwise to increase damping; turn counterclock-

52
wise to reduce damping.

73
01
8/
9.3 Adjusting the rebound damping of the shock absorber

21
16
Caution

l.c r:
,0
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

ai d fo
om
The shock absorber is filled with highly compressed nitrogen.
gm e
– Please follow the description provided.
@ ens

– Turn adjusting screw 1 clockwise up to the last perceptible

tin ic

click.
ar | L

– Turn counterclockwise by the number of clicks corresponding

lm r

to the shock absorber type.

ie fü

Guideline
an ert

Rebound damping
yd zi

Comfort 18 clicks
ar en

Standard 15 clicks
ch Liz

S04871-10
Sport 12 clicks

Info
Turn clockwise to increase the damping; turn counter-
za

clockwise to reduce damping when the shock absorber

rebounds.
,
t in
ar
M
c
Za

Zac Martin, [email protected],

61
 9 SHOCK ABSORBER, LINK FORK

9.4 Measuring the dimension of the rear wheel unloaded

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
– Position the sag gage in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090100)
Pin, sag scale (00029990010)
– Note the value as dimension A.

52
73
01
8/
21
16
l.c r:
,0
402415-10

ai d fo
om
Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)
gm e
@ ens
tin ic

9.5 Checking the static sag of the shock absorber

ar | L

– Measure dimension A of rear wheel unloaded. ( p. 62)

lm r

– Hold the motorcycle upright with aid of an assistant.

ie fü

– Measure the distance again between the rear axle and mark-
an ert

ing SAG on the rear fender using the sag gage.

yd zi

– Note the value as dimension B.

ar en

Info
ch Liz

The static sag is the difference between

measurements A and B .

– Check the static sag.

za

Static sag 37 mm (1.46 in)

,
in

» If the static sag is less or more than the specified value:

t

– Adjust the spring preload of the shock absorber.

ar

( p. 63)
M
c
Za

402416-10
Zac Martin, [email protected],

62
 SHOCK ABSORBER, LINK FORK 9

9.6 Checking the riding sag of the shock absorber

– Measure dimension A of rear wheel unloaded. ( p. 62)
– With another person holding the motorcycle, the rider, wear-
ing full protective clothing, sits on the seat in a normal sitting
position (feet on footrests) and bounces up and down a few
times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear
axle and marking SAG on the rear fender using the sag gage.
– Note the value as dimension C.
Info
The riding sag is the difference between
measurements A and C.

52
– Check riding sag.

73
Riding sag 110 mm (4.33 in)

01
» If the riding sag differs from the specified measurement:

8/
– Adjust the riding sag. ( p. 64)

21
402417-10

16
9.7 Adjusting the spring preload of the shock absorber

l.c r:
,0
ai d fo
om
Caution
gm e
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
@ ens

The shock absorber is filled with highly compressed nitrogen.

tin ic

– Please follow the description provided.

ar | L
lm r
ie fü

Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring
an ert

length.
yd zi
ar en

Preparatory work
– Raise the motorcycle with a lift stand. (
ch Liz

p. 13)
– Remove the shock absorber. ( p. 65)
– After removing the shock absorber, clean it thoroughly.
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

63
 9 SHOCK ABSORBER, LINK FORK

Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under ten-
sion.
Hook wrench (90129051000) ( p. 383)

Info
If the spring cannot be fully released, the spring must
be removed to accurately measure the spring length.

– Measure the total spring length while the spring is not under
tension.
– Tension the spring by turning adjusting ring 2 to specified
dimension A .
Guideline
Spring preload 9 mm (0.35 in)

52
73
Info

01
402405-10 Depending on the static sag and/or the riding sag, it

8/
may be necessary to increase or decrease the spring

21
preload.

16
– Tighten screw 1.

l.c r:
,0
Guideline

ai d fo
om
Screw, shock M5 5 Nm (3.7 lbf ft)
absorber adjusting
gm e
ring
@ ens

Finishing work
tin ic

– Install the shock absorber. ( p. 65)

ar | L

– Remove the motorcycle from the lift stand. ( p. 13)

lm r
ie fü
an ert

9.8 Adjusting the riding sag

yd zi

Preparatory work
ar en

– Raise the motorcycle with a lift stand. ( p. 13)

ch Liz

– Remove the shock absorber. ( p. 65)

– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
za

Guideline
,

Spring rate
in

Weight of rider: 65 … 57 … 63 N/mm (325 …

t
ar

75 kg (143 … 165 lb.) 360 lb/in)

M

Weight of rider: 75 … 60 … 66 N/mm (343 …

c

85 kg (165 … 187 lb.) 377 lb/in)

Za

B00292-10 Weight of rider: 85 … 63 … 69 N/mm (360 …

95 kg (187 … 209 lb.) 394 lb/in)

Info
The spring rate is shown on the outside of the spring.
Zac Martin, [email protected],

64
 SHOCK ABSORBER, LINK FORK 9

Finishing work
– Install the shock absorber. ( p. 65)
– Remove the motorcycle from the lift stand. ( p. 13)
– Check the static sag of the shock absorber. ( p. 62)
– Check the riding sag of the shock absorber. ( p. 63)
– Adjust the rebound damping of the shock absorber. ( p. 61)

9.9 Removing the shock absorber

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
– Remove screw 1 and lower the rear wheel with the link fork
as far as possible without blocking the rear wheel. Secure the
rear wheel in this position.

52
– Remove screw 2 , push splash protector 3 to the side, and

73
remove the shock absorber.

01
8/
21
S03479-10

16
l.c r:
,0
9.10 Installing the shock absorber

ai d fo
om
Main work
– Push splash protector 1
gm e
to the side and position the shock
@ ens

absorber. Mount and tighten screw 2 .

Guideline
tin ic

Screw, top M12 80 Nm (59 lbf ft)

ar | L

shock absorber Loctite®2701™

lm r

–
ie fü

Mount and tighten screw 3.

Guideline
an ert

S03479-11
Screw, bottom M12 80 Nm (59 lbf ft)
yd zi

shock absorber Loctite®2701™

ar en
ch Liz

Info
The heim joint for the shock absorber on the link fork
is Teflon coated. It must not be lubricated with grease,
nor with any other lubricants. Lubricants dissolve the
Teflon coating, thereby drastically reducing the service
za

life.
,
in

Finishing work
t
ar

– Remove the motorcycle from the lift stand. ( p. 13)

M
c
Za

Zac Martin, [email protected],

65
 9 SHOCK ABSORBER, LINK FORK

9.11 Servicing the shock absorber

Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided.

Condition
The shock absorber has been removed.
– Remove the spring. ( p. 66)
– Disassemble the damper. ( p. 67)
– Disassemble the piston rod. ( p. 69)
– Disassemble the seal ring retainer. ( p. 69)
– Check the damper. ( p. 72)

52
– Change the heim joint. ( p. 73)

73
– Assemble the seal ring retainer. ( p. 74)

01
– Assemble the piston rod. ( p. 75)

8/
– Assemble the damper. ( p. 76)

21
– Install the spring. ( p. 83)

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

B03061-01
lm r
ie fü

9.12 Removing the spring

an ert

Condition
The shock absorber has been removed.
yd zi
ar en

– Clamp the shock absorber into the vise.

ch Liz

Guideline
Use soft jaws.
– Measure and note the spring length while the spring is under
tension.
za

– Loosen screw 1.
,

– Turn the adjusting ring until the spring is completely without

in

tension.
t
ar

B04460-10
Hook wrench (90129051000) ( p. 383)
M
c
Za
Zac Martin, [email protected],

66
 SHOCK ABSORBER, LINK FORK 9

– Remove lock ring 2.

– Remove spring retainer 3.
– Remove washer 4.

B04461-10

– Remove the spring.

– Remove washer 5.

52
73
01
B04463-10

8/
21
9.13 Disassembling the damper

16
Preparatory work

l.c r:
,0
– Remove the spring. ( p. 66)

ai d fo
om
Main work
– Make a note of the present state of rebound 1 and compres-
gm e
@ ens

sion damping 2 .
– Open the adjusters of the rebound and compression damping
tin ic

completely.
ar | L
lm r
ie fü
an ert

B04467-10
yd zi

– Slowly open screw 3.

ar en

The nitrogen pressure dissipates.

ch Liz

– Remove the screw with the O-ring.

, za
in

B04465-11
t
ar
M
c
Za

Zac Martin, [email protected],

67
 9 SHOCK ABSORBER, LINK FORK

– Remove locking cap 4.

B04469-10

– Push in seal ring retainer 5.

– Remove lock ring 6.
Info
Check inner surface; do not scratch. If necessary,
remove any burrs with sandpaper.

52
73
01
B04470-10

8/
– Remove the piston rod.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

T03852-10
ar | L

– Remove adjusting ring 7 with the clamping ring.

lm r

– Drain the oil.

ie fü
an ert
yd zi
ar en
ch Liz

B04476-10

– Remove compression adjuster 8. Remove the washer, spring,

and piston.
, za
in
t
ar
M
c
Za

B04477-10
Zac Martin, [email protected],

68
 SHOCK ABSORBER, LINK FORK 9

9.14 Disassembling the seal ring retainer

Preparatory work
– Remove the spring. ( p. 66)
– Disassemble the damper. ( p. 67)
– Disassemble the piston rod. ( p. 69)
Main work
– Remove rebound rubber 1.
– Remove washer 2.

B04492-10

52
– 3.
Remove seal ring

73
– Remove washer 4 from seal ring 3.

01
8/
21
16
l.c r:
,0
ai d fo
om
B04493-10
gm e
@ ens

– Remove washer 5.
– Remove O-ring 6.
tin ic

– Remove dust boot 7.

ar | L
lm r
ie fü
an ert
yd zi
ar en

B04494-10
ch Liz

9.15 Disassembling the piston rod

Preparatory work
– Remove the spring. ( p. 66)
– Disassemble the damper. ( p. 67)
za

Main work
,
in

– Clamp the piston rod with the fork in the bench vise.
t
ar

Guideline
M

Use soft jaws.

c

– Remove nut 1.
Za

– Remove piston 2.

T03858-10
Zac Martin, [email protected],

69
 9 SHOCK ABSORBER, LINK FORK

– Remove compression shim stack 3.

Info
Guide the compression shim stack onto a screwdriver
and put them to one side together.

– Remove bushing 4.

T03859-10

– Remove nut5.
– Remove washer 6.

52
73
01
B04481-10

8/
– Remove rebound shim stack 7.

21
16
Info

l.c r:
Guide the rebound shim stack onto a screwdriver and

,0
ai d fo
put them to one side together.

om
– Remove piston 8.
gm e
@ ens
tin ic

B04482-10
ar | L

– Remove compression shim stack 9.

lm r
ie fü

Info
an ert

Guide the compression shim stack onto a screwdriver

and put them to one side together.
yd zi
ar en

– Remove rebound washer bk.

ch Liz

B04483-10

– Remove seal ring retainer bl.

za

– Remove locking cap bm and rubber buffer bn.

,
in
t
ar
M
c
Za

B04484-10
Zac Martin, [email protected],

70
 SHOCK ABSORBER, LINK FORK 9

9.16 Replacing the pilot bushing

Preparatory work
– Remove the spring. ( p. 66)
– Disassemble the damper. ( p. 67)
– Disassemble the piston rod. ( p. 69)
– Disassemble the seal ring retainer. ( p. 69)
Main work
– Press pilot bushing 1 out of seal ring retainer 2 using the
special tool.
Pressing tool (T1504) ( p. 391)

52
200796-10

73
– Slide the new pilot bushing 1 onto the special tool.

01
Pressing tool (T1504) ( p. 391)

8/
21
– Position the pilot bushing in the seal ring retainer using the
special tool.

16
l.c r:
Pressing tool (T1504) ( p. 391)

,0
ai d fo
–

om
Support seal ring retainer 2 with the sleeve A of the spe-
cial tool. Press the pilot bushing all the way in.
gm e
@ ens
200797-10
Mounting tool (T150S) ( p. 392)

– Lubricate the special tool.

tin ic
ar | L

Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 371)

Calibrating unit (T1205) ( p. 389)
lm r
ie fü

– Support seal ring retainer 2 with the sleeve A of the spe-

an ert

cial tool.
yd zi

Mounting tool (T150S) ( p. 392)

ar en

– Press the special tool through the new pilot bushing.

ch Liz

200798-10
Calibrating unit (T1205) ( p. 389)
The pilot bushing is to be calibrated.
Finishing work
za

– Assemble the seal ring retainer. ( p. 74)

,
tin
ar
M
c
Za

Zac Martin, [email protected],

71
 9 SHOCK ABSORBER, LINK FORK

9.17 Checking the damper

Condition
The damper has been disassembled.
– Measure the inside diameter on both ends and in the middle of
the damper cartridge.
Damper cartridge
Diameter ≤ 46.10 mm (≤ 1.815 in)
» If the measured value is greater than the specified value:
– Replace the damper cartridge.
– Check the damper cartridge for damage and wear.
B04497-10
» If there is damage or wear:
– Replace the damper cartridge.
– Check the heim joint for damage and wear.

52
» If there is damage or wear:

73
– Replace the heim joint.

01
– Measure the diameter of the piston rod.

8/
Piston rod

21
Diameter ≥ 17.95 mm (≥ 0.7067 in)

16
» If the measured value is smaller than the specified value:

l.c r:
,0
– Replace the piston rod.

ai d fo
om
– Measure the run-out of the piston rod.
gm e
Piston rod
@ ens

B04498-10
Run-out ≤ 0.03 mm (≤ 0.0012 in)
tin ic

» If the measured value is greater than the specified value:

ar | L

– Replace the piston rod.

– Check the piston rod for damage and wear.
lm r
ie fü

» If there is damage or wear:

an ert

– Replace the piston rod.

yd zi

– Check the piston rings for damage and wear.

ar en

» If damage or a bronze-colored surface is visible:

ch Liz

– Replace the piston rings.

,za
in

B04499-10
t
ar
M
c
Za
Zac Martin, [email protected],

72
 SHOCK ABSORBER, LINK FORK 9

9.18 Changing the heim joint

– Clamp the shock absorber into the vise.
Guideline
Use soft jaws.
– Remove both collar bushings 1 of the heim joint with a spe-
cial tool.
Drift (T120) ( p. 388)

B04455-10

– Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) ( p. 389)
– Remove second lock ring 2.

52
73
01
8/
21
B04456-10

16
– Place special tool A underneath and press out heim joint 3

l.c r:
B.

,0
using special tool

ai d fo
om
Pressing tool (T1207S) (
gm e p. 389)
@ ens
tin ic
ar | L

B04457-10
lm r
ie fü

– Position new heim joint 3 and the special tool.

an ert

Guideline
yd zi

Use soft jaws.

ar en

Pressing tool (T1206) ( p. 389)

ch Liz

– Press the heim joint all the way in.

B04459-11
za

– Press the heim joint against the lock ring using the special
,

tool.
tin

Pressing tool (T1207S) ( p. 389)

ar
M

– Mount second lock ring 2.

c
Za

B04456-10
Zac Martin, [email protected],

73
 9 SHOCK ABSORBER, LINK FORK

– Position both collar bushings 1 and press in.

B04458-11

9.19 Assembling seal ring retainer

– Mount dust boot 1 with the special tool.
Mounting sleeve (T1204) ( p. 388)
– Grease the sealing lip of the dust boot.

52
Lubricant (T625) ( p. 372)

73
01
8/
21
B04496-10

16
– Grease the O-ring groove.

l.c r:
,0
Lubricant (T158) ( p. 372)

ai d fo
om
– Mount O-ring2.
gm e
– Mount washer 3.
@ ens
tin ic
ar | L

B04495-10
lm r
ie fü

– Position washer 4 on seal ring 5.

an ert

– Grease the seal ring and mount with the washer facing down-
ward.
yd zi
ar en

Lubricant (T14034) ( p. 372)

ch Liz

B04493-11
za

– Mount washer 6.
,
in

– Mount rebound rubber 7.

t
ar
M
c
Za

B04492-11
Zac Martin, [email protected],

74
 SHOCK ABSORBER, LINK FORK 9

9.20 Assembling the piston rod

Preparatory work
– Assemble the seal ring retainer. ( p. 74)
Main work
– Clamp the piston rod with the fork in the bench vise.
Guideline
Use soft jaws.
– Mount rubber buffer 1 and locking cap 2.
– Position special tool on the piston rod.
Mounting sleeve (T1554) ( p. 392)
B04485-10 – Grease the dust boot and slide the seal ring retainer 3 onto
the piston rod.
Lubricant (T625) ( p. 372)

52
– Remove the special tool.

73
– 4.

01
Mount rebound washer
– 5 with the smaller washers

8/
Mount compression shim stack
facing downward.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens

B04486-10

– Clean piston 6.
tin ic

–
ar | L

Mount the piston.

Guideline
lm r
ie fü

View A of piston from above

an ert

View B of piston from below

yd zi
ar en
ch Liz

B04487-10

– Mount rebound shim stack 7 with the smaller washers facing

upward.
– Mount washer 8.
, za
tin
ar
M
c

B04488-10
Za

Zac Martin, [email protected],

75
 9 SHOCK ABSORBER, LINK FORK

– Mount and tighten nut 9 with the collar facing upward.

Guideline
Nut, damper piston M12x1 40 Nm (29.5 lbf ft)

B04489-10

– Mount bushingbk with the groove facing downward.

– Mount compression shim stack bl with the smaller washers
facing downward.

52
73
01
T03860-10

8/
– bm with the groove facing upward.
Position piston

21
– Mount and tighten nut bn.

16
Guideline

l.c r:
,0
Nut, piston rod M10x1 30 Nm (22.1 lbf ft)

ai d fo
om
gm e Loctite®2701™
@ ens
tin ic

T03861-10
ar | L

9.21 Assembling the damper

lm r
ie fü

Preparatory work
an ert

– Assemble the seal ring retainer. ( p. 74)

– Assemble the piston rod. ( p. 75)
yd zi
ar en
ch Liz
,za
in
t
ar
M
c
Za
Zac Martin, [email protected],

76
 SHOCK ABSORBER, LINK FORK 9

Main work
– Lubricate the O-rings of the compression adjuster.
Lubricant (T158) ( p. 372)
– Lubricate the thread.
Lubricant (T159) ( p. 372)
– Mount the piston with the spring and washer.
– Mount and tighten compression adjuster 1.
Guideline
Compression adjuster M31x1 35 Nm (25.8 lbf ft)

52
73
01
B05415-10

8/
– Mount adjusting ring 2 with the clamping ring.

21
16
Info

l.c r:
,0
The adjusting ring cannot be mounted after the piston

ai d fo
rod has been mounted.

om
gm e
@ ens
tin ic

B04475-10
ar | L

– Fill the damper cartridge about half full.

lm r
ie fü

Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 371)

–
an ert

Lubricate O-ring 3 of the seal ring retainer.

yd zi

Lubricant (T158) ( p. 372)

ar en

– Mount the piston rod carefully.

ch Liz

T03853-10

– Mount seal ring retainer 4 and slide it under the ring groove.
za

– Mount lock ring 5.

,
in

Info
t
ar

Do not scratch the inside surface.

M

– Pull out the piston rod until the seal ring retainer is flush with
c

the lock ring.

Za

B04474-10
Zac Martin, [email protected],

77
 9 SHOCK ABSORBER, LINK FORK

– Mount locking cap 6 of the damper cartridge.

– Bleed and fill the damper. ( p. 79)
– Fill the damper with nitrogen. ( p. 82)

B04473-10

Alternative 1
– Turn adjusting screw 7 clockwise with a screwdriver up
to the last perceptible click.
– Turn counterclockwise by the number of clicks correspond-
ing to the shock absorber type.
Guideline

52
Low-speed compression damping

73
Comfort 18 clicks

01
B04468-10 Standard 15 clicks

8/
Sport 12 clicks

21
– Using an open end wrench, turn adjusting screw 8 clock-

16
wise all the way.

l.c r:
,0
– Turn counterclockwise by the number of turns correspond-

ai d fo
ing to the shock absorber type.

om
Guideline
gm e
High-speed compression damping
@ ens

Comfort 2.5 turns

tin ic

Standard 2 turns
ar | L

Sport 1 turn
lm r

– Turn adjusting screw 9 clockwise up to the last percepti-

ie fü

ble click.
an ert

– Turn counterclockwise by the number of clicks correspond-

ing to the shock absorber type.
yd zi
ar en

Guideline
ch Liz

Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

78
 SHOCK ABSORBER, LINK FORK 9

Alternative 2

Warning
Danger of accident Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
characteristic and overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.

– Position adjusting screws 78

, , and 9 in the location

52
determined during disassembly.

73
01
9.22 Bleeding and filling the damper

8/
21
Info

16
Before working with the vacuum pump, it is essential that you carefully read through the Owner's Manual

l.c r:
,0
included for the vacuum pump.

ai d fo
om
Open the adjusters of the rebound and compression damping completely.
gm e
–
@ ens
Clamp the damper as shown.
Guideline
tin ic

Use soft jaws.

ar | L

Info
lm r
ie fü

The filling port must be located at the highest position.

an ert

The piston rod moves in and out during filling; do not

immobilize it by holding it with your hand.
yd zi

B04500-10
ar en

– Remove the screw from the filling port.

–
ch Liz

Mount adapter 1 on the damper.

Info
Hand-tighten only without using a tool.
za

– Connect adapter 1 to connector 2 of the vacuum pump.

,
in

Vacuum pump (T1240S) ( p. 389)

t
ar
M
c
Za

Zac Martin, [email protected],

79
 9 SHOCK ABSORBER, LINK FORK

– Adjust the control lever as shown.

Control lever External tank3 is set to Closed, Damper 4
is set to Vacuum and Oil reservoir5 is set to Vacuum.
– Activate On/Off switch 6.
The suction process begins.
Pressure gauge 7 drops to the required value.
< 0 bar
200271-10
Vacuum gauge 8 drops to the required value.
4 mbar

– Determine distance A between the floating piston and reser-

voir hole with the special tool.
Depth micrometer (T107S) ( p. 388)
The floating piston is located in the lowermost position.

52
73
01
8/
21
B04501-10

16
When the vacuum gauge reaches the required value, turn con-
trol lever Oil reservoir 5
to Equalize pressure.

l.c r:
,0
ai d fo
Guideline

om
4 mbar
gm e
@ ens
The pressure gauge rises to the specified value.
0 bar
tin ic
ar | L

200267-10
lm r
ie fü

– When the pressure gauge reaches the specified value, turn

control lever Damper 4 to Pressure.
an ert

Guideline
yd zi

0 bar
ar en

Oil is pumped into the damper.

ch Liz

The pressure gauge rises to the specified value.

3 bar
200268-10
za

– When the pressure gauge reaches the specified value, turn

,

control lever Damper 4 to Vacuum.

in
t

Guideline
ar

3 bar
M

The pressure gauge drops to the specified value.

c
Za

0 bar

200269-10
Zac Martin, [email protected],

80
 SHOCK ABSORBER, LINK FORK 9

– When the pressure gauge reaches the specified value, turn

5
control lever Oil reservoir to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the specified value.
8 mbar

200270-10

– When the vacuum gauge reaches the required value, turn con-
5
trol lever Oil reservoir to Equalize Pressure.
Guideline
8 mbar
The pressure gauge drops to the specified value.

52
0 bar

73
01
200267-10

8/
– When the pressure gauge reaches the specified value, turn

21
control lever Damper 4 to Pressure.

16
Guideline

l.c r:
,0
0 bar

ai d fo
om
Oil is pumped into the damper.
The pressure gauge rises to the specified value.
gm e
@ ens

3 bar
tin ic

200268-10
ar | L

– When the pressure gauge reaches the specified value, turn

control lever Damper 4 to Vacuum.
lm r
ie fü

Guideline
an ert

3 bar
yd zi

The pressure gauge drops to the specified value.

ar en

0 bar
ch Liz

– When the pressure gauge reaches the required value, activate

200269-10 switch On/Off.
Guideline
0 bar
za

The vacuum pump is switched off.

,
in

– Slide the O-ring to the end of the special tool by the specified
t
ar

value (distance A minus specified value B ).

M

Guideline
c

5 mm
Za

Depth micrometer (T107S) ( p. 388)

– Slide the floating piston into the reservoir to the shortened
position using the special tool.
B04502-10
Zac Martin, [email protected],

81
 9 SHOCK ABSORBER, LINK FORK

Info
The floating piston must be positioned at exactly this
point when the piston rod is fully extended, otherwise
damage will occur during compression of the shock
absorber.

– Remove the special tool.

– Remove adapter 1 from connector 2 of the vacuum pump.
Info
Hold the damper so that the filling port is at the high-
est point.

– Remove the adapter.

– Mount and tighten screw 9.
Guideline

52
B04503-10
Filling port screw M10x1 14 Nm (10.3 lbf ft)

73
01
8/
9.23 Filling damper with nitrogen

21
– Mount screw 1 with the O-ring and screw it in approx. 2 full

16
turns, but do not tighten it fully yet.

l.c r:
,0
ai d fo
Info

om
The piston rod is fully extended.
gm e
@ ens
tin ic
ar | L

B04465-10
lm r

– Fix the special tool in the vise.

ie fü

Filling tool (T170S1) ( p. 392)

an ert

Filling adapter (T1565) ( p. 392)

yd zi

– Connect the special tool to the pressure regulator of the filling

ar en

cylinder.
ch Liz

Filling gas - nitrogen

– Adjust the pressure regulator.
B05327-10
Guideline
za

Gas pressure 10 bar (145 psi)

–
,

Position the damper in the special tool.

in

The hexagonal part of tap handle A engages in the

t
ar

hexagon socket of the filling port screw.

M

– Open filler tap B.

c

– Fill the damper for at least 15 seconds.

Za

Guideline
Gas pressure 10 bar (145 psi)
Zac Martin, [email protected],

82
 SHOCK ABSORBER, LINK FORK 9

Info
Watch the pressure regulator dial.
Ensure that the damper is filled to the specified pres-
sure.

– Screw the filling port shut with tap handle A.

– Close spigot B and take the damper out of the special tool.
– Tighten the filling port screw.
Guideline
Screw, filling port, M5 3 Nm (2.2 lbf ft)
reservoir

9.24 Installing the spring

– Clamp the shock absorber into the vise.

52
Guideline

73
Use soft jaws.

01
– Ensure that adjusting ring 1 is mounted with the clamping

8/
ring.

21
– Mount washer 2.

16
l.c r:
,0
ai d fo
om
B04464-10

– Measure the total spring length while the spring is not under
gm e
@ ens

tension.
– Position the spring.
tin ic

Guideline
ar | L

Spring rate
lm r

Weight of rider: 65 … 57 … 63 N/mm (325 …

ie fü

75 kg (143 … 165 lb.) 360 lb/in)

an ert

Weight of rider: 75 … 60 … 66 N/mm (343 …

85 kg (165 … 187 lb.) 377 lb/in)
yd zi

B04462-10
ar en

Weight of rider: 85 … 63 … 69 N/mm (360 …

95 kg (187 … 209 lb.) 394 lb/in)
ch Liz

– Mount washer 3.
– Mount spring retainer 4.
– Mount lock ring 5.
za

Alternative 1
– Tension the spring by turning the adjusting ring to the pre-
,
in

scribed value.
t

Guideline
ar
M

Spring preload 9 mm (0.35 in)

c

Hook wrench (90129051000) ( p. 383)

Za

Zac Martin, [email protected],

83
 9 SHOCK ABSORBER, LINK FORK

Alternative 2

Warning
Danger of accident Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
characteristic and overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.

– Tension the spring to the length measured during disas-

52
sembly by turning the adjusting ring.

73
Hook wrench (90129051000) ( p. 383)

01
– Tighten screw 6.

8/
Guideline

21
Screw, shock M5 5 Nm (3.7 lbf ft)

16
absorber adjusting

l.c r:
,0
ring

ai d fo
om
gm e
@ ens

B04460-11
tin ic
ar | L

9.25 Checking the link fork

lm r

– Check the link fork for damage, cracks, and deformation.

ie fü

» If the link fork shows signs of damage, cracks, or deforma-

an ert

tion:
yd zi

– Change the link fork.

ar en

Guideline
ch Liz

Repairs on the link fork are not permitted.

401341-01
za

9.26 Checking the shock absorber heim joint for play

,
in

Preparatory work
t
ar

– Raise the motorcycle with a lift stand. ( p. 13)

M

– Place a load on the front of the vehicle.

c

The rear wheel is not in contact with the ground.

Za
Zac Martin, [email protected],

84
 SHOCK ABSORBER, LINK FORK 9

Main work
– Check the upper heim joint.
– Move the link fork up and down.
» If there is detectable play:
– Change the heim joint. ( p. 73)

R05830-10

– Check the lower heim joint.

– Move the link fork up and down.
» If there is detectable play:
– Change the heim joint on the link fork. ( p. 85)

52
73
01
R05829-10

8/
Finishing work

21
– Remove the motorcycle from the lift stand. ( p. 13)

16
l.c r:
,0
ai d fo
9.27 Changing the heim joint on the link fork

om
Preparatory work
gm e
@ ens

– Raise the motorcycle with a lift stand. ( p. 13)

Main work
tin ic

– Remove screw 1 and lower the rear wheel with the link fork
ar | L

as far as possible without blocking the rear wheel. Secure the

rear wheel in this position.
lm r
ie fü

Info
an ert

Raise the link fork slightly to be able to remove the

yd zi

screw more easily.

ar en

– Swing the shock absorber to the rear.

ch Liz

R02806-10

– Remove spacers 2 on both sides.

, za
tin
ar
M
c

R02815-10
Za

Zac Martin, [email protected],

85
 9 SHOCK ABSORBER, LINK FORK

– Mount special tool 3.

Pressing tool (79629000044) ( p. 383)
– Press out the heim joint by screwing in the screw.

R05843-10

– Position the new heim joint.

– Mount special tool 3.
Pressing tool (79629000044) ( p. 383)
– Press in the heim joint by screwing in the screw.

52
73
01
R02817-10

8/
– Mount spacers 2 on both sides.

21
16
Info

l.c r:
The heim joint for the shock absorber on the link fork

,0
ai d fo
is Teflon coated. It must not be lubricated with grease,

om
nor with any other lubricants. Lubricants dissolve the
Teflon coating, thereby drastically reducing the service
gm e
@ ens
life.
tin ic

R02815-10
ar | L

– Position the shock absorber.

–
lm r

Mount and tighten screw 1.

ie fü

Guideline
an ert

Screw, bottom M12 80 Nm (59 lbf ft)

yd zi

shock absorber Loctite®2701™

ar en

Info
ch Liz

Raise the link fork slightly to be able to mount the

R02806-10 screw more easily.

Finishing work
za

– Remove the motorcycle from the lift stand. ( p. 13)

,
in
t
ar
M
c
Za
Zac Martin, [email protected],

86
 SHOCK ABSORBER, LINK FORK 9

9.28 Checking the fork bearing for play

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Place a load on the front of the vehicle.
The rear wheel is not in contact with the ground.
Main work
– Move the link fork up and down.
» If there is detectable play:
– Change the link fork bearing. ( p. 90)
– Move the link fork from one side to the other.
» If there is detectable play:
– Change the link fork bearing. ( p. 90)

H01898-01

52
Finishing work

73
– Remove the motorcycle from the lift stand. ( p. 13)

01
8/
21
9.29 Removing the link fork

16
Preparatory work

l.c r:
,0
– Raise the motorcycle with a lift stand. ( p. 13)

ai d fo
–

om
Remove the rear wheel. ( p. 127)
Main work
gm e
@ ens

– Remove screws 1 with the washers.

– Remove the cable ties.
tin ic

– Push the right frame protector to the front and take off at the
ar | L

bottom.
–
lm r

Take off the left frame protector.

ie fü
an ert
yd zi

Z00159-10
ar en

– Take the brake line out of the guide.

ch Liz
, za
tin
ar

R02831-10
M
c
Za

Zac Martin, [email protected],

87
 9 SHOCK ABSORBER, LINK FORK

– Push the brake caliper forward, slip it out, and hang it to the
side.

Info
Cover the components to protect them against damage.

R02832-10

– Remove connecting link 2 of the chain.

Info
Cover the components to protect them against damage.

– Take off the chain.

52
73
01
R02833-10

8/
– Remove screw 3.

21
– Push the link fork down and away from the shock absorber.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R02835-10
ar | L

– Remove nut 4.
lm r

– Remove the swingarm pivot.

ie fü

– Take off the link fork.

an ert
yd zi
ar en
ch Liz

Z00160-10

9.30 Installing the link fork

za

Main work
,
in

– Position the link fork. Mount the swingarm pivot.

t

–
ar

Mount and tighten nut 1.

M

Guideline
c

Nut, fork pivot M16x1.5 100 Nm

Za

(73.8 lbf ft)

Z00160-11
Zac Martin, [email protected],

88
 SHOCK ABSORBER, LINK FORK 9

– Lift the link fork and position the shock absorber.

– Mount and tighten screw 2.
Guideline
Screw, bottom M12 80 Nm (59 lbf ft)
shock absorber Loctite®2701™

R02835-11

– Mount the chain.

– Connect the chain with connecting link 3.
Guideline
The closed side of the chain joint lock must face in the
direction of travel.

52
73
01
R02834-10

8/
– Position the brake caliper.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R02832-11
ar | L

– Position the brake line in the guide.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

R01254-10

– Insert the right frame protector from below and push it to the
rear.
za

– Position the left frame protector.

,
in

– Mount and tighten screws 4 with the washers.

t
ar

Guideline
M

Screw, frame protec- M5 3 Nm (2.2 lbf ft)

tor
c
Za

– Mount the cable ties.

Z00159-11

Finishing work
– Install the rear wheel. ( p. 128)
– Check the chain tension. ( p. 133)
Zac Martin, [email protected],

89
 9 SHOCK ABSORBER, LINK FORK

– Remove the motorcycle from the lift stand. ( p. 13)

9.31 Changing the link fork bearing

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the rear wheel. ( p. 127)
– Remove the link fork. ( p. 87)
Left fork bearing
– Remove collar bushings 1.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens

R02757-10
tin ic

–
ar | L

Remove bushing 2.
lm r
ie fü
an ert
yd zi
ar en
ch Liz

R02758-10

– Remove radial shaft seal rings 3 using a suitable tool.

– Remove stop disks 4.
za

– Press out bearing 5 using a suitable tool.

,
in

– Using a suitable tool, press in new bearing 5.

t
ar

– Position the stop disks 4.

M

– Press in radial shaft seal rings 3.

c
Za

R02759-10
Zac Martin, [email protected],

90
 SHOCK ABSORBER, LINK FORK 9

– Mount bushing 2.

R02758-10

– Grease the radial shaft seal rings.

Long-life grease ( p. 372)
– Position the collar bushings 1 with the shoulder facing
inward.

52
73
01
R02763-10

8/
Right fork bearing

21
– Remove collar bushings 6.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

R02760-10

– Remove bushing 7.
, za
in
t
ar
M
c
Za

R02761-10
Zac Martin, [email protected],

91
 9 SHOCK ABSORBER, LINK FORK

– Remove radial shaft seal rings 8 using a suitable tool.

– Press out bearing 9 using a suitable tool.
– Using a suitable tool, press in new bearing 9.
– Press in radial shaft seal rings 8.

R02762-10

– Mount bushing 7.

52
73
01
R02761-10

8/
– Grease the radial shaft seal rings.

21
Long-life grease ( p. 372)

16
– 6 with the shoulder facing

l.c r:
Position the collar bushings

,0
ai d fo
inward.

om
gm e
@ ens
tin ic

R02764-10
ar | L

Finishing work
– Install the link fork. ( p. 88)
lm r
ie fü

– Install the rear wheel. ( p. 128)

an ert

– Check the chain tension. ( p. 133)

– Remove the motorcycle from the lift stand. ( p. 13)
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

92
 EXHAUST SYSTEM 10

10.1 Removing the manifold

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

(EU/CN/ASEAN)
– Remove the fuel tank. ( p. 103)
– Remove the cable tie(s) and expose the cable.

52
73
R02818-10

01
– Open the cable holder.

8/
–

21
Expose the cable.

16
l.c r:
,0
ai d fo
om
gm e
@ ens

Z00170-10
tin ic

–
ar | L

Disconnect plug-in connector 1 of the lambda sensor.

– Expose the cable.
lm r
ie fü
an ert
yd zi
ar en
ch Liz

Z00171-10

– Remove springs 2.
Spring hook (50305017000C1) ( p. 387)
, za
tin
ar
M
c
Za

Z00172-10
Zac Martin, [email protected],

93
 10 EXHAUST SYSTEM

– Remove screw 3.
– Take off the manifold in a forward direction.

Z00173-10

(US)
– Remove springs 1.
Spring hook (50305017000C1) ( p. 387)

52
73
01
Z00174-10

8/
– Remove screw 2.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00175-10
ar | L

– Remove screw 3.
lm r

– Take off the manifold in a forward direction.

ie fü
an ert
yd zi
ar en
ch Liz

Z00176-10

10.2 Installing the manifold

za

(EU/CN/ASEAN)
,
in

– Position the manifold and mount springs 1.

t
ar

Spring hook (50305017000C1) ( p. 387)

M
c
Za

Z00177-10
Zac Martin, [email protected],

94
 EXHAUST SYSTEM 10

– Mount and tighten screw 2.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

Z00178-10

– Join plug-in connector 3 of the lambda sensor.

52
73
01
Z00179-10

8/
– Position the cables.

21
– Secure the cable with the cable holders.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00170-10
ar | L

– Route the cable without tension and secure it with a cable

tie.
lm r
ie fü

– Install the fuel tank. ( p. 104)

an ert
yd zi
ar en
ch Liz

R02818-10

(US)
– Position the manifold and mount springs 1.
za

Spring hook (50305017000C1) ( p. 387)

,
in
t
ar
M
c
Za

Z00174-10
Zac Martin, [email protected],

95
 10 EXHAUST SYSTEM

– Mount screw 2, but do not tighten yet.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

Z00180-10

– Mount and tighten screw 3.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Tighten screw 2.

52
Guideline

73
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

01
Z00181-10

8/
21
10.3 Removing the main silencer

16
l.c r:
,0
Warning

ai d fo
om
Danger of burns The exhaust system gets very hot when the vehicle is driven.
gm e
– Allow the exhaust system to cool down before performing any work on the vehicle.
@ ens

– Remove screws 1.
tin ic

– 2 and the
ar | L

Pull off the main silencer with exhaust sleeve

spring ring from the manifold.
lm r
ie fü
an ert
yd zi
ar en
ch Liz

S03484-10

10.4 Installing the main silencer

– Mount the main silencer with rubber sleeve 1 and the spring
za

rings.
– Mount and tighten screws 2.
,
in

Guideline
t
ar

Remaining screws, M6 10 Nm (7.4 lbf ft)

M

chassis
c
Za

S03484-11
Zac Martin, [email protected],

96
 EXHAUST SYSTEM 10

10.5 Changing the glass fiber yarn filling of the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

Info
Over time, the fibers of the glass fiber yarn filling escape and the damper "burns" out.
Not only is the noise level higher, but the performance characteristics change.

Preparatory work
– Remove main silencer. ( p. 96)
Main work
– Remove screws 1. Pull out inner tube 2 with O-ring 3.

52
– Pull glass fiber yarn filling 4 from the inner tube.

73
– Clean the parts that need to be reinstalled and check for dam-

01
age.
– 4 on the inner tube.

8/
Mount new glass fiber yarn filling

21
– Push outer tube 5 over the inner tube with the new glass
fiber yarn filling and the O-ring.

16
–

l.c r:
Mount and tighten all screws 1.

,0
ai d fo
Guideline

om
Screws on main M5 7 Nm (5.2 lbf ft)
gm e
silencer
@ ens
tin ic
ar | L
lm r
ie fü

V01636-10
an ert

Finishing work
yd zi

– Install the main silencer. ( p. 96)

ar en
ch Liz
, za
tin
ar
M
c
Za

Zac Martin, [email protected],

97
 11 AIR FILTER

11.1 Removing the air filter box cover

Preparatory work
– Remove the seat. ( p. 102)
Condition
The air filter box cover is secured.
– Remove screw 1.

S03526-10

– Pull off the air filter box cover in area A laterally and take it
off at the front.

52
73
01
8/
21
16
l.c r:
,0
S03526-11

ai d fo
om
11.2 Installing the air filter box cover
gm e
@ ens
Main work
– Insert the air filter box cover in area A and clip it into
tin ic

area B.
ar | L
lm r
ie fü
an ert
yd zi
ar en

S03526-12

Condition
ch Liz

The air filter box cover is secured.

– Mount and tighten screw 1.
Guideline
za

Screw, air filter box EJOT PT® 3 Nm (2.2 lbf ft)

cover K60x20-Z
,
t in
ar

S03526-10
M

Finishing work
c
Za

– Mount the seat. ( p. 102)

Zac Martin, [email protected],

98
 AIR FILTER 11

11.3 Removing the air filter

Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Only operate the vehicle if it is equipped with an air filter.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Preparatory work
– Remove the seat. ( p. 102)
– Remove the air filter box cover. ( p. 98)

52
Main work

73
– Detach retaining tab 1. Remove air filter with air filter sup-

01
port.
– Remove air filter from air filter support.

8/
21
16
l.c r:
,0
ai d fo
om
S03482-10
gm e
@ ens

11.4 Installing the air filter

tin ic

Main work
ar | L

– Mount the clean air filter on the air filter support.

– Grease the air filter in area A.
lm r
ie fü

Long-life grease ( p. 372)

an ert
yd zi
ar en
ch Liz

H02459-01

– Insert air filter and position retaining pin 1 in bushing B.

The air filter is correctly positioned.
–
za

Insert retaining tab 2.

Retaining pin 3 is secured with retaining tab 2.
,
t in

Info
ar

If the air filter is not mounted correctly, dust and dirt

M

may enter the engine and result in damage.

c
Za

S03483-10

Finishing work
– Install the air filter box cover. ( p. 98)
– Mount the seat. ( p. 102)
Zac Martin, [email protected],

99
 11 AIR FILTER

11.5 Cleaning the air filter and air filter box

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work
– Remove the seat. ( p. 102)
– Remove the air filter box cover. ( p. 98)
– Remove the air filter. ( p. 99)

52
Main work
– Wash the air filter thoroughly in special cleaning liquid and

73
allow it to dry properly.

01
Air filter cleaner ( p. 372)

8/
21
Info

16
Only press the air filter to dry it, never wring it out.

l.c r:
,0
ai d fo
– Oil the dry air filter with a high-grade air filter oil.

om
102191-01

Oil for foam air filter ( p. 373)

gm e
@ ens

– Clean the air filter box.

– Clean the intake flange and check it for damage and tightness.
tin ic
ar | L

Finishing work
– Install the air filter. ( p. 99)
lm r
ie fü

– Install the air filter box cover. ( p. 98)

– Mount the seat. ( p. 102)
an ert
yd zi
ar en

11.6 Preparing air filter box cover for securing

ch Liz

Preparatory work
– Remove the seat. ( p. 102)
– Remove the air filter box cover. ( p. 98)
Main work
za

– Drill a hole at marking A.

,
in

Guideline
t
ar

Diameter 6 mm (0.24 in)

M
c
Za

S03499-10

Finishing work
– Install the air filter box cover. ( p. 98)
Zac Martin, [email protected],

– Mount the seat. ( p. 102)

100
 FUEL TANK, SEAT, TRIM 12

12.1 Opening the fuel tank filler cap

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.

52
– Immediately consult a doctor if you swallow fuel.

73
– Do not inhale fuel vapors.

01
– In case of skin contact, rinse the affected area with plenty of water.

8/
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

21
– Change your clothing in case of fuel spills on them.

16
– Keep fuels correctly in a suitable canister, and out of the reach of children.

l.c r:
,0
Note

ai d fo
om
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
gm e
@ ens

– Press release button 1 , turn the fuel tank filler cap counter-
tin ic

clockwise, and lift it off.

ar | L
lm r
ie fü
an ert
yd zi
ar en

E00929-10
ch Liz

12.2 Closing the fuel tank filler cap

– Mount the fuel tank filler cap and turn it clockwise until
release button 1 engages.
, za

Info
tin

Route fuel tank breather hose 2 without kinks.

ar
M
c
Za

E00930-10
Zac Martin, [email protected],

101
 12 FUEL TANK, SEAT, TRIM

12.3 Removing the seat

– Remove screw 1 on the left side.

S03480-10

– Raise the rear of the seat, pull the seat back, and lift it off.

52
73
01
8/
21
H02218-10

16
12.4 Mounting the seat

l.c r:
,0
ai d fo
– Mount the front of the seat on the two collar bushings of the

om
fuel tank, lower the seat at the rear, and push the seat forward.
gm e
– Make sure the seat is latched in place correctly.
@ ens
tin ic
ar | L
lm r
ie fü
an ert

H02218-11

– Mount and tighten screw 1 on the left side.

yd zi
ar en

Guideline
ch Liz

Screw, seat fixing M6 10 Nm (7.4 lbf ft)

, za
in

S03480-10
t
ar
M
c
Za
Zac Martin, [email protected],

102
 FUEL TANK, SEAT, TRIM 12

12.5 Removing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.

52
– Immediately consult a doctor if you swallow fuel.

73
– Do not inhale fuel vapors.

01
– In case of skin contact, rinse the affected area with plenty of water.

8/
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

21
– Change your clothing in case of fuel spills on them.

16
– Keep fuels correctly in a suitable canister, and out of the reach of children.

l.c r:
,0
ai d fo
Preparatory work

om
– Remove the seat. ( p. 102)
gm e
Main work
@ ens

– Unplug connector 1 of the fuel pump.

tin ic

– Remove tube 2 from the fuel tank breather.

ar | L
lm r
ie fü
an ert
yd zi

S04895-10
ar en

– Clean the quick release coupling thoroughly with compressed

ch Liz

air.

Info
Under no circumstances should dirt enter into the fuel
za

line. Dirt in the fuel line clogs the injection valve!

,

– Disconnect the quick release coupling.

tin
ar

E00880-10
Info
M

Remaining fuel may flow out of the fuel hose.

c
Za

– Mount wash cap set 3.

Wash cap set (81212016100)
Zac Martin, [email protected],

103
 12 FUEL TANK, SEAT, TRIM

– Remove screws 4 with the collar bushings.

(EU/CN/ASEAN)
– Hang the horn and horn bracket to one side.

E00881-10

– Remove screw 5 with the rubber bushing.

52
73
01
E00882-10

8/
– Pull both spoilers off laterally from the radiator mount and lift

21
off the fuel tank.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

E00883-10
ar | L

12.6 Installing the fuel tank

lm r
ie fü

Danger
an ert

Fire hazard Fuel is highly flammable.

yd zi
ar en

The fuel in the fuel tank expands when warm and can escape if overfilled.
ch Liz

– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
za

– Observe the specifications for refueling.

,
in

Warning
t

Danger of poisoning Fuel is poisonous and a health hazard.

ar

–
M

Avoid skin, eye and clothing contact with fuel.

– Immediately consult a doctor if you swallow fuel.
c
Za

– Do not inhale fuel vapors.

– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Zac Martin, [email protected],

104
 FUEL TANK, SEAT, TRIM 12

Main work
– Check the throttle cable routing. ( p. 52)
– Position the fuel tank and fit the two spoilers to the sides in
front of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or dam-
aged.

E00883-11

– Mount and tighten screw 1 with the rubber bushing.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

52
73
(EU/CN/ASEAN)
– Position the horn with the horn bracket.

01
8/
21
E00882-11

16
– Mount and tighten screws 2 with the collar bushings.

l.c r:
,0
Guideline

ai d fo
om
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
gm e
@ ens
tin ic
ar | L
lm r

E00881-11
ie fü

– Remove the wash cap set.

an ert

– Clean the quick release coupling thoroughly with compressed

air.
yd zi
ar en

Info
ch Liz

Under no circumstances should dirt enter into the fuel

line. Dirt in the fuel line clogs the injection valve!

– Spray silicone spray onto a lint-free cleaning cloth and lightly

lubricate the O-ring of the quick-release coupling.
za

Silicone spray ( p. 373)

,
in

– Join quick release coupling 3.

t
ar

Info
M

Route the cable and fuel line at a safe distance from

c
Za

the exhaust system.

– Attach fuel tank breather hose 4.

– Plug in connector 5 for the fuel pump.
S04896-10
Zac Martin, [email protected],

105
 12 FUEL TANK, SEAT, TRIM

Finishing work
– Mount the seat. ( p. 102)

12.7 Changing the fuel screen

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

52
Warning

73
Danger of poisoning Fuel is poisonous and a health hazard.

01
– Avoid skin, eye and clothing contact with fuel.

8/
– Immediately consult a doctor if you swallow fuel.

21
– Do not inhale fuel vapors.

16
– In case of skin contact, rinse the affected area with plenty of water.

l.c r:
,0
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

ai d fo
om
– Change your clothing in case of fuel spills on them.
gm e
Note
@ ens

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
tin ic
ar | L

– Clean quick release coupling 1 thoroughly with compressed

lm r

air.
ie fü
an ert

Info
Under no circumstances should dirt enter into the fuel
yd zi

line. Dirt in the fuel line clogs the injection valve!

ar en
ch Liz

– Disconnect the quick release coupling.

Info
Remaining fuel may flow out of the fuel hose.
za

– Pull fuel screen 2 out of the connecting piece.

,

– Insert the new fuel screen all the way into the connecting
in

piece.
t
ar

– Spray silicone spray onto a lint-free cleaning cloth and lightly

M

lubricate the O-ring of the quick-release coupling.

c

Silicone spray ( p. 373)

Za

– Join the quick release coupling.

E00911-10
Zac Martin, [email protected],

106
 FUEL TANK, SEAT, TRIM 12

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Start the engine and check the response.

12.8 Changing the fuel filter

Danger
Fire hazard Fuel is highly flammable.

52
The fuel in the fuel tank expands when warm and can escape if overfilled.

73
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

01
– Switch off the engine for refueling.

8/
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

21
– If any fuel is spilled, wipe it off immediately.

16
– Observe the specifications for refueling.

l.c r:
,0
ai d fo
om
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
gm e
@ ens

– Avoid skin, eye and clothing contact with fuel.

– Immediately consult a doctor if you swallow fuel.
tin ic

– Do not inhale fuel vapors.

ar | L

– In case of skin contact, rinse the affected area with plenty of water.
lm r

– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
ie fü

– Change your clothing in case of fuel spills on them.

an ert

– Keep fuels correctly in a suitable canister, and out of the reach of children.
yd zi

Note
ar en

Environmental hazard Improper handling of fuel is a danger to the environment.

ch Liz

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Preparatory work
– Drain the fuel from the fuel tank into a suitable container.
za

– Remove the seat. ( p. 102)

–
,

Remove the fuel tank. ( p. 103)

tin

Main work
ar

– Remove screws 1.
M

– Detach the front side cover in area A to the front and take it
c

off.
Za

R05743-10
Zac Martin, [email protected],

107
 12 FUEL TANK, SEAT, TRIM

– Remove nut 2 with the gasket.

– Remove fuel connection 3 with the O-rings.

Z00224-10

– Remove screws 4.

52
73
01
R05745-10

8/
– Pull out the fuel pump.

21
– Remove hose clamps 5.

16
– Remove fuel filter 6.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

R05749-10

– Press locking mechanism 7.

za

– Pull back fuel pump housing 8.

,
in
t
ar
M
c
Za

D05070-10
Zac Martin, [email protected],

108
 FUEL TANK, SEAT, TRIM 12

– Change fuel screen 9.

– Mount the fuel pump housing.

D05071-10

– Mount new fuel filter 6.

Arrow B points away from the fuel pump.
– Mount hose clamps 5.
Hose clamp pliers (60029057000) ( p. 381)

52
73
01
D05072-10

8/
– Position the fuel pump.

21
– Mount nut 2 with gasket, but do not tighten yet.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05747-10
ar | L

– Mount and tighten screws 4.

lm r

Guideline
ie fü

Screw, fuel pump EJOT PT® 2.3 Nm (1.7 lbf ft)

an ert
yd zi
ar en
ch Liz

R05745-10
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

109
 12 FUEL TANK, SEAT, TRIM

– Grease O-rings C lightly.

Multi-purpose grease (00062010051) ( p. 373)

Info
Make sure that no grease gets into the fuel connection.

– Mount fuel connection 3 with the O-rings but do not tighten

yet.
– Tighten nut 2.
Guideline
Nut, fuel pump M12 15 Nm (11.1 lbf ft)
mounting
– Tighten fuel connection 3.
Guideline

52
Fuel connection on M8 15 Nm (11.1 lbf ft)
fuel pump

73
01
Z00224-11

8/
– A and position.
Attach side covers in area

21
– Mount and tighten screws 1.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05743-10
ar | L

Finishing work
– Install the fuel tank. (
lm r

p. 104)
ie fü

– Mount the seat. ( p. 102)

an ert
yd zi
ar en

12.9 Changing the fuel pump

ch Liz

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
za

– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
,

– Switch off the engine for refueling.

in

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
t
ar

– If any fuel is spilled, wipe it off immediately.

M

– Observe the specifications for refueling.

c
Za
Zac Martin, [email protected],

110
 FUEL TANK, SEAT, TRIM 12

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Preparatory work

52
– Drain the fuel from the fuel tank into a suitable container.

73
– Remove the seat. ( p. 102)

01
– Remove the fuel tank. ( p. 103)

8/
Main work

21
– Remove screws 1.

16
– Detach the front side cover in area A to the front and take it

l.c r:
off.

,0
ai d fo
om
gm e
@ ens
tin ic

R05743-10
ar | L

– Remove nut 2 with the gasket.

– Remove fuel connection 3 with the O-rings.
lm r
ie fü
an ert
yd zi
ar en
ch Liz

Z00224-10

– Remove screws 4.
, za
t in
ar
M
c
Za

R05745-10
Zac Martin, [email protected],

111
 12 FUEL TANK, SEAT, TRIM

– Remove the fuel pump.

52
73
01
R05746-10

8/
– Position the new fuel pump.

21
– Mount nut 2 with gasket, but do not tighten yet.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05747-10
ar | L

– Mount and tighten screws 4.

lm r

Guideline
ie fü

Screw, fuel pump EJOT PT® 2.3 Nm (1.7 lbf ft)

an ert

The connector points downwards.

yd zi
ar en
ch Liz

R05745-10
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

112
 FUEL TANK, SEAT, TRIM 12

– Grease O-rings B lightly.

Multi-purpose grease (00062010051) ( p. 373)

Info
Make sure that no grease gets into the fuel connection.

– Mount fuel connection 3 with the O-rings but do not tighten

yet.
– Tighten nut 2.
Guideline
Nut, fuel pump M12 15 Nm (11.1 lbf ft)
mounting
– Tighten fuel connection 3.
Guideline

52
Fuel connection on M8 15 Nm (11.1 lbf ft)
fuel pump

73
01
Z00224-10

8/
– A and position.
Attach side covers in area

21
– Mount and tighten screws 1.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05743-10
ar | L

Finishing work
– Install the fuel tank. (
lm r

p. 104)
ie fü

– Mount the seat. ( p. 102)

an ert
yd zi
ar en

12.10 Checking the fuel pressure

ch Liz

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
za

– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
,

– Switch off the engine for refueling.

in

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
t
ar

– If any fuel is spilled, wipe it off immediately.

M

– Observe the specifications for refueling.

c
Za

Zac Martin, [email protected],

113
 12 FUEL TANK, SEAT, TRIM

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.

Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The diagnostics tool is disconnected.
– Clean the quick release coupling thoroughly with compressed

52
air.

73
01
Info
Under no circumstances should dirt enter into the fuel

8/
line. Dirt in the fuel line clogs the injection valve!

21
16
– Press on the small metal plate and disconnect quick release
coupling . 1

l.c r:
,0
ai d fo
om
R05752-10
Info
Remaining fuel may flow out of the fuel hose.
gm e
@ ens

– Mount special tool 2.

tin ic

Pressure testing tool (61029094000) ( p. 382)

ar | L

– Mount special tool 3 with nozzle code 0,60.

lm r
ie fü

Testing hose (61029093000) ( p. 381)

an ert

– Position the hose end in a fuel can.

yd zi

Guideline
ar en

Minimum size, fuel can 10 l (2.6 US gal)

400926-10
ch Liz

– Connect the diagnostics tool and start it.

– Select "Actuator test" > "Fuel pump".
Guideline
Maximum duration of the 3 min
za

actuator test
,
in

– Check the fuel pressure with the fuel tank filler cap closed.
t
ar

Fuel pressure
M

When the fuel pump is 3.35 … 3.65 bar (48.6 …

c

active 52.9 psi)

Za

» If the specification is not reached:

– Open the fuel tank filler cap. ( p. 101)
– Check the fuel tank breather.
400927-01
Zac Martin, [email protected],

114
 FUEL TANK, SEAT, TRIM 12

– Check the fuel pressure with the fuel tank filler cap open.
Fuel pressure
When the fuel pump is 3.35 … 3.65 bar (48.6 …
active 52.9 psi)
» If the specification is not reached:
– Check that the fuel line is clear.
– Change the fuel filter. ( p. 107)
400928-01
– Change the fuel pump. ( p. 110)
– Stop the "Actuator test" > "Fuel pump" by pressing the "Quit" but-
ton.
– Remove the special tools.
– Join the quick release coupling.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

115
 13 MASK, FENDER

13.1 Removing front fender

Preparatory work
– Remove the headlight mask with the headlight. ( p. 117)
Main work
– Remove screws 1.

V00340-10

– Remove screws 2. Take off front fender.

52
73
01
8/
21
16
l.c r:
,0
V00341-10

ai d fo
om
13.2 Installing front fender
gm e
@ ens
Main work
– Position front fender. Mount and tighten screws 1.
tin ic

Guideline
ar | L

Remaining screws, M6 10 Nm (7.4 lbf ft)

chassis
lm r
ie fü
an ert
yd zi
ar en

V00341-11

– 2.
ch Liz

Mount and tighten screws

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
,za
t in
ar

V00340-11
M

Finishing work
c
Za

– Install the headlight mask with the headlight. ( p. 117)

– Check the headlight setting. ( p. 167)
Zac Martin, [email protected],

116
 MASK, FENDER 13

13.3 Removing the headlight mask with the headlight

– Detach the brake line and wiring harness from the headlight
mask.
– Loosen rubber strap 1. Slide the headlight mask up and
swing it forward.

E00899-10

(EU/CN/ASEAN)
– Detach plug-in connectors 2 and take off the headlight
mask with the headlight.

52
73
01
8/
21
E00900-10

16
(US)
–

l.c r:
Disconnect plug-in connector 2 and take off the head-

,0
ai d fo
light mask together with the headlight.

om
gm e
@ ens
tin ic
ar | L

E00357-10
lm r
ie fü

13.4 Installing the headlight mask with the headlight

an ert

Main work
yd zi

(EU/CN/ASEAN)
ar en

– Join plug-in connectors 1.

ch Liz
, za
in

E00900-11
t

(US)
ar

– Join plug-in connector 1.

M
c
Za

Zac Martin, [email protected],

E00357-11

117
 13 MASK, FENDER

– Position the headlight mask and secure it with rubber

straps2 .
The holding lugs engage in the fender.
– Position the brake line and wiring harness in the brake line
guide.

E00899-11

Finishing work
– Check the headlight setting. ( p. 167)

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

118
 WHEELS 14

14.1 Checking tire pressure

Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.

– Remove protection cap.

– Check tire pressure when the tires are cold.
Street tire pressure (EU/CN/ASEAN)
front 2.0 bar (29 psi)
rear 2.0 bar (29 psi)

Offroad tire pressure

front 1.0 bar (15 psi)
400695-01
rear 1.0 bar (15 psi)

52
» If the tire pressure does not meet specifications:

73
– Correct tire pressure.

01
– Mount the protection cap.

8/
21
16
14.2 Checking the tire condition

l.c r:
,0
ai d fo
om
Info
Only mount tires approved and/or recommended by KTM.
gm e
Other tires could have a negative effect on handling characteristics.
@ ens

The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the
motorcycle.
tin ic

Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
ar | L
lm r

– Check the front and rear tires for cuts, embedded objects, and
ie fü

other damage.
an ert

» If the tires have cuts, run-in objects, or other damage:

–
yd zi

Change the tires.

ar en

– Check the tread depth.

ch Liz

Info
Adhere to the legally required minimum tread depth.
400602-10
Minimum tread depth ≥ 2 mm (≥ 0.08 in)
za

» If the tread depth is less than the minimum tread depth:

,
in

– Change the tires.

t
ar

– Check the tire age.

M
c
Za

Zac Martin, [email protected],

H01144-01

119
 14 WHEELS

Info
The tire date of manufacture is usually contained in the
tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of
manufacture and the last two digits the year of manu-
facture.
KTM recommends that the tires be changed after 5
years at the latest, regardless of the actual state of
wear.

» If the tires are more than 5 years old:

– Change the tires.

14.3 Checking the wheel bearing for play

Preparatory work

52
– Raise the motorcycle with a lift stand. ( p. 13)

73
– Place a load on the rear of the vehicle.

01
The front wheel is not in contact with the ground.

8/
Main work

21
– Move the front wheel from side to side.

16
Info

l.c r:
,0
Hold fork leg to check it.

ai d fo
om
» If there is detectable play:
gm e
@ ens

– Change front wheel bearing. ( p. 126)

tin ic

H01899-01
ar | L

– Place a load on the front of the vehicle.

The rear wheel is not in contact with the ground.
lm r
ie fü

– Move the rear wheel from side to side.

an ert

Info
yd zi

Hold the link fork to check it.

ar en
ch Liz

» If there is detectable play:

– Change the rear wheel bearing. ( p. 130)
H01896-01

Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)
, za
in

14.4 Checking the brake discs

t
ar
M

Warning
c
Za

Danger of accidents Worn-out brake discs reduce the braking effect.

– Make sure that worn-out brake discs are replaced immediately.
Zac Martin, [email protected],

120
 WHEELS 14

– Check the front and rear brake disc thickness at multiple

points for the dimension .A
Info
Wear reduces the thickness of the brake disc around
the contact surface of the brake linings.

Brake discs - wear limit (All standard models)

front 2.5 mm (0.098 in)
400257-10
rear 3.5 mm (0.138 in)
Brake discs - wear limit (All special models)
front 2.5 mm (0.098 in)
rear 3.7 mm (0.146 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc. ( p. 125)

52
– Change the rear brake disc. ( p. 129)

73
– Check the front and rear brake discs for damage, cracking, and
deformation.

01
» If the brake disc exhibits damage, cracking, or deforma-

8/
tion:

21
– Change the front brake disc. ( p. 125)

16
– Change the rear brake disc. ( p. 129)

l.c r:
,0
ai d fo
om
14.5 Checking the rim run-out
gm e
@ ens

Warning
tin ic

Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec-
ar | L

ondary damage.
lm r

The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
ie fü

is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
an ert

result.
–
yd zi

Check spoke tension regularly, and in particular on a new vehicle.

ar en
ch Liz

Info
A loose spoke can unbalance the wheel and other spokes may loosen within a short period.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

121
 14 WHEELS

– Check for lateral and radial run-out of the rims.

Lateral runout
Outside the rim joint < 1.8 mm (< 0.071 in)

Radial runout
Outside the rim joint < 1.8 mm (< 0.071 in)
» If the measured value is greater than the specified value:
– Center the rim.

Info
Center the rim by pulling the spoke nipple on
the other side of the rim run-out. If there is sig-
nificant deformation, change the rim.

– Correct the spoke tension.

52
73
01
400998-01

8/
21
14.6 Checking spoke tension

16
l.c r:
Warning

,0
ai d fo
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec-

om
ondary damage.
gm e
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
@ ens

is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
tin ic
ar | L

– Check spoke tension regularly, and in particular on a new vehicle.

lm r
ie fü

– Strike each spoke briefly using a screwdriver blade.

an ert

Info
yd zi

The frequency of the sound depends on the spoke

ar en

length and spoke diameter.

If you hear different tone frequencies from different
ch Liz

spokes of equal length and diameter, this is an indica-

tion of different spoke tensions.

400694-01 You should hear a high note.

za

» If the spoke tension differs:

–
,

Correct the spoke tension.

in

– Check the spoke torque.

t
ar

Guideline
M

Spoke nipple, front M4.5 6 Nm (4.4 lbf ft)

c

wheel
Za

Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft)

wheel

Torque wrench kit (58429094000) ( p. 380)

Zac Martin, [email protected],

122
 WHEELS 14

14.7 Front wheel

14.7.1 Removing the front wheel

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
– Manually press the brake caliper toward the brake disc to push
back the brake pistons.

Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.

V00363-10

52
– Loosen screw 1 by several rotations.

73
– Loosen screws 2.

01
– Press on screw 1 to push the wheel spindle out of the axle
clamp.

8/
21
– Remove screw 1.

16
l.c r:
,0
ai d fo
om
V00364-10 gm e
@ ens

Warning
Danger of accidents Damaged brake discs reduce the
tin ic

braking effect.
ar | L

– Always lay the wheel down in such a way that the

lm r

brake disc is not damaged.

ie fü
an ert

– Hold the front wheel and remove the wheel spindle. Take the
front wheel out of the fork.
yd zi

V00365-10
ar en

Info
ch Liz

Do not actuate the hand brake lever when the front

wheel is removed.

(All Standard and SIX DAYS models)

– Remove spacers 3 .
, za
tin
ar
M
c
Za

H00934-10
Zac Martin, [email protected],

123
 14 WHEELS

(All ERZBERGRODEO models)

– Remove spacer 3
and brake disc guard 4.

H01890-10

14.7.2 Installing the front wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.

52
– Clean the brake discs with brake cleaner when necessary.

73
(All Standard and SIX DAYS models)

01
– Check the wheel bearing for damage and wear.

8/
» If the wheel bearing is damaged or worn:

21
– Change front wheel bearing. ( p. 126)

16
– Clean and grease shaft seal rings 1 and contact sur-

l.c r:
,0
faces A
of the spacers.

ai d fo
om
Long-life grease ( p. 372)
gm e
– Insert the spacers.
@ ens

H00935-10
– Clean and grease the wheel spindle.
tin ic

Long-life grease ( p. 372)

ar | L

– Jack up the front wheel into the fork, position it, and insert
lm r

the wheel spindle.

ie fü

The brake linings are correctly positioned.

an ert

(All ERZBERGRODEO models)

yd zi

– Check the wheel bearing for damage and wear.

ar en

» If the wheel bearing is damaged or worn:

ch Liz

– Change front wheel bearing. ( p. 126)

– Clean and grease shaft seal rings 1 and contact sur-
faces A
of the spacers.
Long-life grease ( p. 372)
za

S01631-10
– Insert the spacer and brake disc guard.
,
in

– Clean and grease the wheel spindle.

t
ar

Long-life grease ( p. 372)

M

– Position the front wheel and insert the wheel spindle.

c

The brake linings are correctly positioned.

Za
Zac Martin, [email protected],

124
 WHEELS 14

– Align the brake disc guard so that distance B and C are

equal in size.

S01633-10

– Mount and tighten screw 2.

Guideline
Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft)
spindle
– Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.

52
– Remove the motorcycle from the lift stand. ( p. 13)

73
– Operate the front brake and compress the fork a few times

01
V00364-11 firmly.

8/
The fork legs straighten.

21
– Tighten screws 3.

16
Guideline

l.c r:
,0
Screw, fork stub M8 15 Nm (11.1 lbf ft)

ai d fo
om
gm e
@ ens

14.7.3 Changing the front brake disc

tin ic

Info
ar | L

If the brake discs are changed, the brake linings must also be changed.
lm r
ie fü

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
an ert

– Remove the front wheel. ( p. 123)

yd zi
ar en

Main work
(All Standard and ERZBERGRODEO models)
ch Liz

– Remove screws 1
. Take off the brake disc.
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward.
– Mount and tighten screws 1.
za

Guideline
,
in

Screw, front M6 14 Nm (10.3 lbf ft)

t

D00187-10 brake disc Loctite®243™

ar
M
c
Za

Zac Martin, [email protected],

125
 14 WHEELS

(All SIX DAYS models)

– Remove screws 1. Take off the brake disc.
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward.
– Mount and tighten screws 1.
Guideline
Screw, front M6 14 Nm (10.3 lbf ft)
brake disc Loctite®243™
D02131-10

Finishing work
– Install the front wheel. ( p. 124)

14.7.4 Changing the front wheel bearing

Preparatory work

52
– Raise the motorcycle with a lift stand. ( p. 13)

73
– Remove the front wheel. ( p. 123)

01
Main work

8/
– Remove radial shaft seal rings 1 and 2.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens

D00195-10
tin ic

– Press out bearing 3 using a suitable tool.

ar | L

Info
lm r
ie fü

Spacing tube4 can be pushed aside.

an ert

– Remove spacing tube 4.

yd zi
ar en
ch Liz

D00197-10

– Press out bearing 5 using a suitable tool.

– Press in new bearing 5 all the way using a suitable tool.
za

Info
,
in

Only press the bearing in via the outer bearing race,

t

otherwise the bearing will be damaged when it is

ar

pressed in.
M
c
Za

D00199-10
Zac Martin, [email protected],

126
 WHEELS 14

– Clean, grease, and mount spacing tube 4.

Long-life grease ( p. 372)
– Press in new bearing 3 all the way using a suitable tool.
Info
Only press the bearing in via the outer bearing race,
otherwise the bearing will be damaged when it is
pressed in.
D00198-10

– Grease new radial shaft seal rings 2 and 1 and press in

until they are flush.

52
73
01
D00196-10

8/
Finishing work

21
– Install the front wheel. ( p. 124)

16
l.c r:
,0
ai d fo
14.8 Rear wheel

om
gm e
14.8.1 Removing the rear wheel
@ ens

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
tin ic
ar | L

Main work
– Manually press the brake caliper toward the brake disc to push
lm r
ie fü

back the brake piston.

an ert

Info
yd zi

Make sure that you do not press the brake caliper

ar en

against the spokes when pushing back the brake piston.

ch Liz

– Remove nut 1.
– Take off chain adjuster 2 . Pull out wheel spindle 3 far
enough to allow the rear wheel to be pushed forward.
– Push the rear wheel forward as far as possible. Remove the
za

chain from the rear sprocket.

,
in

Info
t

Cover the components to protect them against damage.

ar
M
c

Warning
Za

Danger of accidents Damaged brake discs reduce the

V00366-10
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.
Zac Martin, [email protected],

127
 14 WHEELS

– Hold the rear wheel and remove the wheel spindle. Take the
rear wheel out of the link fork.

Info
Do not operate the foot brake lever when the rear wheel
is removed.

– Remove spacers 4.

H03002-10

52
73
14.8.2 Installing the rear wheel

01
Warning

8/
Danger of accidents Oil or grease on the brake discs reduces the braking effect.

21
– Always keep the brake discs free of oil and grease.

16
– Clean the brake discs with brake cleaner when necessary.

l.c r:
,0
ai d fo
om
Main work
– Check the wheel bearing for damage and wear.
gm e
@ ens

» If the wheel bearing is damaged or worn:

– Change the rear wheel bearing. ( p. 130)
tin ic

– Clean and grease shaft seal rings 1 and contact surfaces A

ar | L

of the spacers.
lm r

Long-life grease ( p. 372)

ie fü

– Insert the spacers.

an ert

H03001-10
– Clean and grease the wheel spindle.
yd zi
ar en

Long-life grease ( p. 372)

ch Liz

– Position rear wheel and insert wheel spindle 2.

– Mount the chain.
The brake linings are correctly positioned.
, za
tin
ar
M

V00367-10
c
Za
Zac Martin, [email protected],

128
 WHEELS 14

– Position chain adjuster 3. Mount nut 4, but do not tighten

it yet.
– Make sure that chain adjusters 3 are fitted correctly on
adjusting screws . 5
– Check the chain tension. ( p. 133)
– Tighten nut 4.
Guideline
Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft)
dle

Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters 3can be turned by 180°.

52
– Operate the foot brake lever repeatedly until the brake lin-

73
ings are in contact with the brake disc and there is a pressure
point.

01
V00368-10

8/
Finishing work

21
– Remove the motorcycle from the lift stand. ( p. 13)

16
l.c r:
,0
ai d fo
14.8.3 Changing the rear brake disc

om
gm e
Info
@ ens

If the brake discs are changed, the brake linings must also be changed.
tin ic

Preparatory work
ar | L

– Raise the motorcycle with a lift stand. ( p. 13)

lm r

– Remove the rear wheel. ( p. 127)

ie fü

Main work
an ert

(All standard models)

yd zi

– Remove screws 1. Take off the brake disc.

ar en

– Clean the contact surface of the brake disc.

ch Liz

– Position the brake disc with the label facing outward.

– Mount and tighten screws 1.
Guideline
Screw, rear M6 14 Nm (10.3 lbf ft)
za

D00220-10 brake disc Loctite®243™

,
in

(All special models)

t

– Remove screws 1. Take off the brake disc.

ar

–
M

Clean the contact surface of the brake disc.

– Position the brake disc with the label facing outward.
c
Za

– Mount and tighten screws 1.

Guideline
Screw, rear M6 14 Nm (10.3 lbf ft)
brake disc Loctite®243™
D02133-10
Zac Martin, [email protected],

129
 14 WHEELS

Finishing work
– Install the rear wheel. ( p. 128)
– Remove the motorcycle from the lift stand. ( p. 13)

14.8.4 Changing the rear wheel bearing

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the rear wheel. ( p. 127)
Main work
– Remove radial shaft seal ring 1.
– Remove lock ring 2 .

52
73
01
R00607-10

8/
– Remove radial shaft seal ring 3.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

D00211-10
ar | L

– Using a suitable tool, press bearing 4 out from the inside to

the outside.
lm r
ie fü

– Remove spacing tube 5.

an ert
yd zi
ar en
ch Liz

R00609-10

– Using a suitable tool, press bearing 6 out from the inside to

the outside.
za

– Check spacer washer 7 for damage and wear.

,
in

» If the spacer washer is damaged or worn:

t
ar

– Replace the spacer washer.

M
c
Za

D00214-10
Zac Martin, [email protected],

130
 WHEELS 14

– Press new bearing 4 all the way in from the outside to the
inside.

Info
Only press the bearing in via the outer bearing race,
otherwise the bearing will be damaged when it is
pressed in.

Z00155-10

– Mount lock ring 2.

The lock ring engages audibly.
– Grease new radial shaft seal ring 1 and press it in until it is
flush.

52
73
01
Z00156-10

8/
– Clean, grease, and mount spacing tube 5.

21
Long-life grease ( p. 372)

16
–

l.c r:
Position spacer washer 7.

,0
ai d fo
– Press new bearing 6 all the way in from the outside to the

om
inside.
gm e
@ ens

Info
Only press the bearing in via the outer bearing race,
tin ic

Z00157-10
otherwise the bearing will be damaged when it is
ar | L

pressed in.
lm r
ie fü

– Grease new radial shaft seal ring 3 and press it in until it is

flush.
an ert
yd zi
ar en
ch Liz

D00211-10
za

Finishing work
– Install the rear wheel. (
,

p. 128)
in

– Remove the motorcycle from the lift stand. ( p. 13)

t
ar
M
c
Za

Zac Martin, [email protected],

131
 14 WHEELS

14.8.5 Checking the chain for dirt

– Check the chain for heavy soiling.
» If the chain is very dirty:
– Clean the chain. ( p. 132)

400678-01

14.8.6 Cleaning the chain

Warning
Danger of accidents Lubricants on the tires reduces the road grip.

52
– Remove lubricants from the tires using a suitable cleaning agent.

73
01
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.

8/
21
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

16
l.c r:
,0
Note

ai d fo
om
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
gm e
the applicable regulations.
@ ens
tin ic

Info
ar | L

The service life of the chain depends largely on its maintenance.

lm r
ie fü

Preparatory work
an ert

– Raise the motorcycle with a lift stand. ( p. 13)

yd zi

Main work
ar en

– Rinse off loose dirt with a soft jet of water.

ch Liz

– Remove old grease residue with chain cleaner.

Chain cleaner ( p. 372)
– After drying, apply chain spray.
Off-road chain spray ( p. 373)
, za
in

400725-01
t
ar

Finishing work
M

– Remove the motorcycle from the lift stand. ( p. 13)

c
Za
Zac Martin, [email protected],

132
 WHEELS 14

14.8.7 Checking the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
– Pull the chain at the end of the chain sliding piece upward to

52
measure chain tension .A

73
01
Info

8/
Lower chain section 1 must be taut.

21
When the chain guard is mounted, it must be possible
to pull up the chain at least to the point where it makes

16
contact with chain guard B .

l.c r:
,0
Chain wear is not always even, so you should repeat

ai d fo
this measurement at different chain positions.

om
gm e
Chain tension 55 … 58 mm (2.17 …
@ ens

2.28 in)
tin ic

» If the chain tension does not meet the specification:

ar | L

– Adjust the chain tension. ( p. 136)

lm r
ie fü
an ert

E00885-10
yd zi

Finishing work
ar en

– Remove the motorcycle from the lift stand. ( p. 13)

ch Liz

14.8.8 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
za

– Raise the motorcycle with a lift stand. ( p. 13)

Main work
,
in

– Shift the transmission into neutral.

t
ar

– Check the chain, rear sprocket, and engine sprocket for wear.
M

» If the chain, rear sprocket or engine sprocket is worn:

c

– Change the drivetrain kit. ( p. 136)

Za

Info
The engine sprocket, rear sprocket, and chain
should always be replaced together.
400227-01
Zac Martin, [email protected],

133
 14 WHEELS

– Pull on the top section of the chain with the specified

weight A.
Guideline
Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.)
ment
– Measure distance B of 18 chain rollers in the lower chain
section.

Info
Chain wear is not always even, so you should repeat
this measurement at different chain positions.

Maximum distance Bfrom 272 mm (10.71 in)

18 chain rollers at the
longest chain section
» If distance B is greater than the specified measurement:

52
– Change the drivetrain kit. ( p. 136)

73
01
400987-10 Info

8/
When a new chain is mounted, the rear sprocket

21
and engine sprocket should also be changed.
New chains wear out faster on old, worn sprock-

16
ets.

l.c r:
,0
ai d fo
– Check the chain sliding guard for wear.

om
» If the lower edge of the chain pins is in line with, or below,
gm e
the chain sliding guard:
@ ens

– Change the chain sliding guard.

–
tin ic

Check that the chain sliding guard is firmly seated.

ar | L

» If the chain sliding guard is loose:

– Tighten screws on the chain sliding guard.
lm r
ie fü

Guideline
an ert

Screw, chain M6 10 Nm (7.4 lbf ft)

sliding guard Loctite®243™
yd zi
ar en
ch Liz
, za
in

E00886-10
t
ar
M
c
Za
Zac Martin, [email protected],

134
 WHEELS 14

– Check chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below
the chain sliding piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten screw on the chain sliding piece.
Guideline
Screw, chain slid- M8 15 Nm
ing piece (11.1 lbf ft)

52
73
01
E00887-10

8/
– Check the chain guide for wear.

21
16
Info

l.c r:
Wear can be seen on the front of the chain guide.

,0
ai d fo
om
» If the light part of the chain guide is worn:
gm e
– Change the chain guide.
@ ens
tin ic

400985-01
ar | L

– Check that the chain guide is firmly seated.

lm r

» If the chain guide is loose:

ie fü

– Tighten the screws on the chain guide.

an ert

Guideline
yd zi

Remaining screws, M6 10 Nm
ar en

chassis (7.4 lbf ft)

ch Liz

E00333-01

Finishing work
– Remove the motorcycle from the lift stand. (
za

p. 13)
,
in
t
ar
M
c
Za

Zac Martin, [email protected],

135
 14 WHEELS

14.8.9 Adjusting the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Check the chain tension. ( p. 133)

52
Main work
– Loosen nut 1.

73
– Loosen nuts 2.

01
– Adjust the chain tension by turning adjusting screws 3 left

8/
and right.

21
Guideline

16
Chain tension 55 … 58 mm (2.17 …

l.c r:
,0
2.28 in)

ai d fo
om
Turn adjusting screws 3 on the left and right so that the
markings on the left and right chain adjusters are in the
gm e
@ ens

same position relative to reference marks A

. The rear
wheel is then correctly aligned.
tin ic

– Tighten nuts 2.
ar | L

– Make sure that chain adjusters 4 are fitted correctly on

lm r

adjusting screws 3
.
ie fü

– Tighten nut 1.
an ert

Guideline
yd zi

E00330-10
Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft)
ar en

dle
ch Liz

Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
za

Chain adjusters 4 can be turned by 180°.

,
in

Finishing work
t
ar

– Remove the motorcycle from the lift stand. ( p. 13)

M
c
Za

14.8.10 Changing the drivetrain kit

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the seat. ( p. 102)
– Remove the air filter box cover. ( p. 98)
Zac Martin, [email protected],

136
 WHEELS 14

Main work
– Remove screw 1.
– Remove screw 2.
– Take the engine sprocket cover off to the front.

Z00166-10

– Have an assistant operate the rear brake.

– Remove screw 3 with washer.

52
73
01
Z00167-10

8/
– Remove connecting link 4 of the chain.

21
16
Info

l.c r:
Cover the components to protect them against damage.

,0
ai d fo
om
– Take off the chain.
gm e
– Remove the rear wheel. ( p. 127)
@ ens
tin ic

Z00168-10
ar | L

– Remove engine sprocket 5.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

Z00169-10

(All standard models)

– Remove fittings 6. Take off the rear sprocket.
za

– Position the new rear sprocket. Mount and tighten the fit-
,
in

tings.
t

Guideline
ar

Nut, rear M8 35 Nm (25.8 lbf ft)

M

sprocket screw Loctite®2701™

c
Za

R01252-10
Zac Martin, [email protected],

137
 14 WHEELS

(All special models)

– Remove fittings 6. Take off the rear sprocket.
– Position the new rear sprocket. Mount and tighten the fit-
tings.
Guideline
Nut, rear M8 35 Nm (25.8 lbf ft)
sprocket screw Loctite®2701™

R01349-10

– Slide new engine sprocket 5 onto the countershaft.

– Install the rear wheel. ( p. 128)

52
73
01
Z00169-10

8/
– Mount the new chain.

21
– Connect the chain with connecting link 4.

16
Guideline

l.c r:
,0
The closed side of the chain joint lock must face in the

ai d fo
om
gm edirection of travel.
@ ens
tin ic

R02828-10
ar | L

– Have an assistant operate the rear brake.

–
lm r

Mount and tighten screw 3 with the washer.

ie fü

Guideline
an ert

Screw, drive M10 60 Nm (44.3 lbf ft)

yd zi

chain engine Loctite®2701™

ar en

sprocket
ch Liz

Z00167-10

– Position the engine sprocket cover.

–
za

Mount and tighten screw 1.

Guideline
,
in

Remaining screws, M6 10 Nm (7.4 lbf ft)

t
ar

chassis
M

– Mount and tighten screw 2.

c

Guideline
Za

Z00166-10
Screw, engine M8 15 Nm (11.1 lbf ft)
sprocket cover

Finishing work
– Install the air filter box cover. ( p. 98)
–
Zac Martin, [email protected],

Mount the seat. ( p. 102)

– Check the chain tension. ( p. 133)

138
 Za
c
M
ar
tin
, za
–

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
Remove the motorcycle from the lift stand. (

l.c r:
om
p. 13)

,0
16
21

139
8/
01
73
52
WHEELS 14

Zac Martin, [email protected],

 15 WIRING HARNESS, BATTERY

15.1 Ignition curve plug-in connector

Plug-in connector 1 of the ignition timing map adjustment is
located on the frame under the fuel tank.

Info
The ignition timing map connector has no function in the
homologated (restricted) condition of the motorcycle.

Possible states
• Soft – The plug-in connector of the ignition timing map
adjustment is disconnected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing
map adjustment is joined to achieve higher performance.

52
73
01
8/
21
S03501-10

16
15.2 Changing main fuse

l.c r:
,0
ai d fo
om
Warning
gm e
Fire hazard Incorrect fuses overload the electrical system.
@ ens

– Only use fuses with the required ampere value.

–
tin ic

Do not bypass or repair fuses.

ar | L
lm r

Info
ie fü

The main fuse protects all electrical power consumers of the vehicle.
an ert

Preparatory work
yd zi

– Remove the seat. (

ar en

p. 102)
ch Liz

Main work
– Pull EFI control unit 1 upward off the rubber lugs 2 and
hang to the side.
,za
tin
ar
M

S04883-11
c
Za
Zac Martin, [email protected],

140
 WIRING HARNESS, BATTERY 15

– Pull starter relay 3 from the holder.

S04889-10

– 4.
Take off protection caps
– Remove faulty main fuse 5.

Info
A faulty fuse has a burned-out fuse wire A .
A spare fuse 6is located in the starter relay.

52
73
– Insert a new main fuse.

01
Fuse (58011109120) ( p. 314)

8/
– Check that the electrical system is functioning properly.

21
Tip

16
Insert a spare fuse so that it is available if needed.

l.c r:
,0
ai d fo
om
– Attach the protection caps 4.
–
gm e
Mount starter relay 3 onto the holder and route the cable.
@ ens
tin ic

S04892-10
ar | L

– Mount the EFI control unit 1 on the rubber lugs 2.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

S04883-11

Finishing work
– Mount the seat. (
za

p. 102)
,
in
t
ar
M
c
Za

Zac Martin, [email protected],

141
 15 WIRING HARNESS, BATTERY

15.3 Changing the fuses of individual electrical power consumers

Info
The fuse box containing the fuses of individual electrical power consumers is located under the seat.

Preparatory work
– Remove the seat. ( p. 102)
Main work
– Open fuse box cover 1.
– Remove the faulty fuse.
Guideline
(EU/CN/ASEAN)
Fuse 1 - 10 A - EFI control unit, lambda sensor, oil
pump, combination instrument, electronic fuel injection,
diagnostics connector

52
S03498-10 Fuse 2 - 10 A - horn, brake light, radiator fan (optional),

73
turn signal (optional)

01
Fuse 3 ‑ 10 A ‑ high beam, low beam, position light, tail
light, license plate lamp

8/
21
Fuse 4 - 5 A - fuel pump

16
(US)

l.c r:
,0
Fuse 1 - 10 A - EFI control unit, oil pump, combination

ai d fo
instrument, electronic fuel injection, diagnostics con-

om
nector
gm e
Fuse 2 - 10 A - radiator fan (optional)
@ ens

Fuse 3 - 10 A - low beam, position light, tail light

tin ic

Fuse 4 - 5 A - fuel pump

ar | L

Fuses res - 10 A - spare fuse

lm r
ie fü

Info
an ert

A faulty fuse has a burned-out fuse wire A.

yd zi
ar en

Warning
ch Liz

Fire hazard Incorrect fuses overload the electrical sys-

tem.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
za

– Insert the spare fuse with the correct rating.

,
in

Fuse (75011088010) ( p. 314)

t
ar

Fuse (75011088005) ( p. 314)

M
c

Tip
Za

Put a spare fuse in the fuse box so that it is available if

needed.

– Check the function of the electrical power consumer.

– Close the fuse box cover 1.
Zac Martin, [email protected],

142
 WIRING HARNESS, BATTERY 15

Finishing work
– Mount the seat. ( p. 102)

15.4 Disconnecting the negative cable of the 12-V battery

Preparatory work
– Remove the seat. ( p. 102)
Main work
– Disconnect negative cable 1 of the 12-V battery.

52
R01414-10

73
01
15.5 Connecting the negative cable of the 12-V battery

8/
Main work

21
– Connect negative cable 1 of the 12-V battery.

16
Guideline

l.c r:
,0
Screw, battery termi- M5 2.5 Nm

ai d fo
om
nal gm e (1.84 lbf ft)
@ ens
tin ic

R01414-10
ar | L

Finishing work
lm r

– Mount the seat. ( p. 102)

ie fü
an ert

15.6 Removing the 12-V battery

yd zi
ar en

Note
ch Liz

Environmental hazard 12 V batteries contain environmentally hazardous materials.

– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
za

Note
Environmental hazard Hazardous substances cause environmental damage.
,
in

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
t
ar

the applicable regulations.

M

Preparatory work
c
Za

– Remove the seat. ( p. 102)

Zac Martin, [email protected],

143
 15 WIRING HARNESS, BATTERY

Main work

Warning
Risk of injury 12 V batteries contain harmful sub-
stances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V bat-
teries.
S04883-10 – Only charge 12 V batteries in well-ventilated
rooms.
– Maintain a minimum clearance from inflammable
materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if
the charge is already below the minimum voltage.

52
Minimum voltage before 9 V
the start of the charge

73
– Dispose of 12 V batteries with less than the mini-

01
mum voltage correctly.

8/
21
– Disconnect negative cable 1 from the 12-V battery.

16
– Pull back positive terminal cover 2 and disconnect the posi-

l.c r:
,0
tive cable from the 12-V battery.

ai d fo
om
– Pull EFI control unit 3 upward off rubber lugs 4 and hang
to the side.
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert

S04884-10
yd zi

– Pull off starter relay 5

and fuse box 6 from the battery
ar en

compartment and hang to the side.

ch Liz
, za
in

S04884-11
t
ar
M
c
Za
Zac Martin, [email protected],

144
 WIRING HARNESS, BATTERY 15

– Detach wiring harness 7, disconnect relays 8 and plug 9,

and hang to the side.

S04884-12

– Remove screw bk and detach the battery compartment.

– Lift out the 12-V battery.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

S04886-10
ar | L

15.7 Installing the 12-V battery

lm r
ie fü

Main work
an ert

– Insert the 12 V battery into the battery compartment with the

terminals facing forward and secure with holding bracket 1.
yd zi
ar en

12-V battery (HJTZ5S-FP-C) ( p. 314)

ch Liz

– Mount and tighten screw 2.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
, za
t in
ar
M
c
Za

S04887-10
Zac Martin, [email protected],

145
 15 WIRING HARNESS, BATTERY

– Place relays 3and connector 4

on the battery compart-
ment and attach the wiring harness 5
.

S04884-13

– Attach starter relay 6 and fuse box 7 to the battery com-

partment.

52
73
01
S04884-14

8/
– Secure EFI control unit 8 with the rubber lugs 9.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

S04884-15
ar | L

– Connect positive cable bk to the 12-V battery.

lm r

Guideline
ie fü

Screw, battery termi- M5 2.5 Nm

an ert

nal (1.84 lbf ft)

yd zi
ar en

Info
Contact disk A must be mounted under screw and bl
ch Liz

cable lug bmwith the claws toward the battery termi-

nal.

– Slide positive terminal cover bn over the positive terminal.

za

– Connect negative cable bo to the 12-V battery.

Guideline
,
in

Screw, battery termi- M5 2.5 Nm

t
ar

nal (1.84 lbf ft)

M
c
Za

S04888-10

Finishing work
– Mount the seat. ( p. 102)
Zac Martin, [email protected],

146
 WIRING HARNESS, BATTERY 15

15.8 Charging the 12-V battery

Warning
Risk of injury 12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V batteries.
– Only charge 12 V batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
– Dispose of 12 V batteries with less than the minimum voltage correctly.

Note

52
Danger of damage An incorrectly selected charging mode will damage the 12-V battery.

73
– Always select a charging mode that is compatible with the type of battery.

01
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.

8/
21
– Do not dispose of 12 V batteries as household waste.
–

16
Dispose of 12 V batteries at a collection point for used batteries.

l.c r:
,0
Note

ai d fo
om
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
gm e
the applicable regulations.
@ ens
tin ic

Info
ar | L

Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
lm r
ie fü

Rapid recharging with a high charging current shortens the service life of the battery.
an ert

If the charging current, charging voltage, or charging time is exceeded, the 12-V battery will be destroyed.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
yd zi

If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
ar en

and suffer a loss of capacity, destroying the battery.

ch Liz

The 12-V battery is maintenance-free.

Preparatory work
– Remove the seat. ( p. 102)
– Disconnect the negative cable of the 12-V battery. ( p. 143)
za

Main work
,
in

– Connect a battery charger to the 12-V battery. Adjust the bat-

t

tery charger.
ar
M

EU battery charger XCharge‑professional (00029095050)

( p. 375)
c
Za

Alternative 1
US battery charger XCharge‑professional
(00029095051) ( p. 375)
311910-10
Zac Martin, [email protected],

147
 15 WIRING HARNESS, BATTERY

Alternative 2
UK battery charger XCharge‑professional
(00029095052) ( p. 376)

Info
Follow the instructions of the charger and the manual.

– Disconnect the battery charger after charging the 12-V battery.

Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery 3 months
regularly when the motorcy-
cle is not being used

Finishing work
– Connect the negative cable of the 12-V battery. (

52
p. 143)
– Mount the seat. ( p. 102)

73
01
8/
15.9 Checking the charging voltage

21
Condition

16
The 12-V battery must be fully functional and completely charged.

l.c r:
,0
Preparatory work

ai d fo
om
– Remove the seat. (
gm e p. 102)
Main work
@ ens

– Carry out the start procedure. ( p. 13)

– Measure the voltage between the specified points.
tin ic

Measuring point plus (+) – Measuring point Ground (−)

ar | L

Charging voltage
lm r
ie fü

5,000 rpm 13.5 … 15.0 V

an ert

» If the displayed value is less than the specified value:

– Check the plug-in connections from the alternator to
yd zi

H01812-10
the voltage regulator.
ar en

– Check the plug-in connections from the voltage regula-

ch Liz

tor to the wiring harness.

– Check the stator winding of the alternator. ( p. 301)
» If the displayed value is greater than the specified value:
– Change voltage regulator.
za

Finishing work
,
in

– Mount the seat. ( p. 102)

t
ar
M
c
Za
Zac Martin, [email protected],

148
 WIRING HARNESS, BATTERY 15

15.10 Checking the open-circuit current

Preparatory work
– Remove the seat. ( p. 102)
Main work
– Disconnect the negative cable of the 12-V battery.
– Measure the current between the 12-V battery ground (−) and
the negative cable.

Info
The value of the open-circuit current only applies to
vehicles in their original state without additional electri-
cal power consumers.
H01813-10

Maximum open-circuit cur- < 1.0 mA

rent

52
» If the measured value is greater than the specified value:

73
– Disconnect the voltage regulator from the wiring har-
ness and perform the measurement again.

01
8/
21
15.11 Checking the starter relay

16
Preparatory work

l.c r:
,0
ai d fo
– Remove the seat. ( p. 102)

om
– Disconnect the negative cable of the 12-V battery. ( p. 143)
gm e
Main work
@ ens

– Pull off the EFI control unit 1 upward and hang to the side.
tin ic
ar | L
lm r
ie fü
an ert
yd zi

R05750-10
ar en

– Pull the starter relay off the bracket.

ch Liz

– Unplug connector 2.
– Disconnect cables 3 and 4 on the starter relay.
, za
tin
ar

R05751-10
M
c
Za

Zac Martin, [email protected],

149
 15 WIRING HARNESS, BATTERY

– Connect the starter relay to a 12-V power supply as shown in

the figure.
– Measure the resistance between the specified points.
Resistance of open circuit 0Ω
» If the value displayed does not meet specifications:
– Change the starter relay.

601201-10

Finishing work
– Connect the negative cable of the 12-V battery. ( p. 143)
– Mount the seat. ( p. 102)

15.12 Diagnostics connector

52
Diagnostics connector 1is located under the seat below the EFI

73
control unit.

01
8/
21
16
l.c r:
,0
ai d fo
om
H00933-12
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

150
 BRAKE SYSTEM 16

16.1 Checking the front brake linings

Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately.

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the brake linings of the front brake.
( p. 151)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the brake linings of the front brake.

52
E00342-10
( p. 151)

73
01
16.2 Changing the brake linings of the front brake

8/
21
16
Warning

l.c r:
Danger of accidents Incorrect servicing will cause the brake system to fail.

,0
ai d fo
– Ensure that service work and repairs are performed professionally.

om
gm e
Warning
@ ens

Skin irritation Brake fluid causes skin irritation.

– Keep brake fluid out of the reach of children.
tin ic

– Wear suitable protective clothing and safety glasses.

ar | L

– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
lm r
ie fü

– Consult a doctor immediately if brake fluid has been swallowed.

– Rinse the affected area with plenty of water in the event of contact with the skin.
an ert

– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
yd zi

with the eyes.

ar en

– If brake fluid spills on to your clothing, change the clothing.

ch Liz

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
, za

Warning
in

Danger of accidents Oil or grease on the brake discs reduces the braking effect.
t
ar

– Always keep the brake discs free of oil and grease.

M

– Clean the brake discs with brake cleaner when necessary.

c
Za

Zac Martin, [email protected],

151
 16 BRAKE SYSTEM

Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info

52
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.

73
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.

01
Only use clean brake fluid from a sealed container.

8/
21
– Move the brake fluid reservoir mounted on the handlebar to a

16
horizontal position.

l.c r:
–

,0
Remove screws 1.

ai d fo
– Take off cover 2 with membrane 3.

om
– Manually press the brake caliper toward the brake disc to push
gm e
back the brake pistons. Ensure that brake fluid does not flow
@ ens

out of the brake fluid reservoir, extract some if necessary.

tin ic

Info
ar | L

E01226-10
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
lm r
ie fü

pistons.
an ert

– Remove cotter pin 4, pull out pin 5, and remove the brake
yd zi

linings.
ar en

– Clean the brake caliper and the brake caliper bracket.

ch Liz
za

E00344-10
,
in

– Check that spring plate 6 in the brake caliper and brake pad
t
ar

sliding plate 7 in the brake caliper bracket are seated cor-

M

rectly.
c
Za

100397-01
Zac Martin, [email protected],

152
 BRAKE SYSTEM 16

– Insert the new brake linings, insert the pin, and mount the cot-
ter pins.

Info
Always change the brake linings in pairs.

– Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
E00345-10

– Correct the brake fluid level to level A.

Guideline
Level A (brake fluid level 5 mm (0.2 in)
below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 370)

52
– Position the cover with the membrane. Mount and tighten the

73
screws.

01
E01226-11
Info

8/
Use water to immediately clean up any brake fluid that

21
has overflowed or spilled.

16
l.c r:
,0
ai d fo
om
16.3 Checking the free travel of the hand brake lever gm e
@ ens

Warning
Danger of accidents The brake system fails in the event of overheating.
tin ic
ar | L

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
lm r
ie fü
an ert

(EU/CN/ASEAN)
– Push the hand brake lever to the handlebar and check free
yd zi

travel . A
ar en

Free travel of hand brake ≥ 3 mm (≥ 0.12 in)

ch Liz

lever
» If the free travel does not match the specification:
– Adjust the free travel of the handbrake lever.
( p. 154)
za

S04873-12
,
in

(US)
–
t

Push the hand brake lever forward and check free

ar

travel .A
M

Free travel of hand brake ≥ 3 mm (≥ 0.12 in)

c

lever
Za

» If the free travel does not match the specification:

– Adjust the basic position of the hand brake lever.
( p. 154)
S04873-11
Zac Martin, [email protected],

153
 16 BRAKE SYSTEM

16.4 Adjusting the free travel of the handbrake lever (EU/CN/ASEAN)

– Check the free travel of the hand brake lever. ( p. 153)
– Adjust the free travel of the handbrake lever with adjustment
screw 1 .

Info
Turn the adjusting screw clockwise to reduce free
travel. The pressure point moves away from the
handlebar.
Turn the adjusting screw counterclockwise to increase
S04873-13 free travel. The pressure point moves towards the han-
dlebar.
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.

52
73
01
16.5 Adjusting the basic position of the hand brake lever (US)

8/
– Check the free travel of the hand brake lever. ( p. 153)

21
– Adjust the basic position of the hand brake lever to your hand

16
size by turning adjusting screw 1 .

l.c r:
,0
ai d fo
om
Info
Turn the adjusting screw clockwise to increase the
gm e
distance between the hand brake lever and the han-
@ ens

dlebar.
Turn the adjusting screw counterclockwise to decrease
tin ic

S04873-13 the distance between the hand brake lever and the han-
ar | L

dlebar.
The range of adjustment is limited.
lm r
ie fü

Turn the adjusting screw by hand only, and do not

apply any force.
an ert

Do not make any adjustments while riding.

yd zi
ar en
ch Liz

16.6 Checking the front brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
za

If the brake fluid level drops below the specified marking or the specified value, the brake system is
,
in

leaking or the brake linings are worn down.

t
ar

– Check the brake system and do not continue riding until the problem is eliminated.
M

Warning
c
Za

Danger of accidents Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
Zac Martin, [email protected],

154
 BRAKE SYSTEM 16

– Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
– Check the brake fluid level in level viewer 1.
» If the brake fluid level has dropped below marking A in
the level viewer:
– Add the front brake fluid. ( p. 155)

S03517-10

16.7 Adding front brake fluid

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is

52
leaking or the brake linings are worn down.

73
– Check the brake system and do not continue riding until the problem is eliminated.

01
Warning

8/
21
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.

16
– Wear suitable protective clothing and safety glasses.

l.c r:
,0
ai d fo
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

om
– Consult a doctor immediately if brake fluid has been swallowed.
gm e
– Rinse the affected area with plenty of water in the event of contact with the skin.
@ ens

– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
tin ic

–
ar | L

If brake fluid spills on to your clothing, change the clothing.

lm r

Warning
ie fü

Danger of accidents Old brake fluid reduces the braking effect.

an ert

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
yd zi
ar en

Note
ch Liz

Environmental hazard Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
za

Info
,

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
in

designed for DOT 5 brake fluid.

t
ar

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
M

Only use clean brake fluid from a sealed container.

c
Za

Preparatory work
– Check the front brake linings. ( p. 151)
Zac Martin, [email protected],

155
 16 BRAKE SYSTEM

Main work
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
– Remove screws 1.
– Take off cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Level A (brake fluid level 5 mm (0.2 in)
below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 370)

– Position the cover with the membrane. Mount and tighten the
screws.

Info

52
Immediately clean up any brake fluid that has over-
flowed or spilled using water.

73
01
E01225-10

8/
21
16.8 Changing the front brake fluid

16
l.c r:
Warning

,0
ai d fo
Skin irritation Brake fluid causes skin irritation.

om
– Keep brake fluid out of the reach of children.
gm e
–
@ ens
Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
tin ic

– Consult a doctor immediately if brake fluid has been swallowed.

ar | L

– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
lm r
ie fü

with the eyes.

an ert

– If brake fluid spills on to your clothing, change the clothing.

yd zi

Note
ar en

Environmental hazard Hazardous substances cause environmental damage.

ch Liz

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
za

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
,
in

Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
t

Only use clean brake fluid from a sealed container.

ar
M
c
Za
Zac Martin, [email protected],

156
 BRAKE SYSTEM 16

– Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
– Cover the painted parts.
– Remove screws 1.
– Take off cover 2 with membrane.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 376)
Z00164-10
Brake fluid DOT 4 / DOT 5.1 ( p. 370)

– Mount bleeder cover 3.

Bleeder cover (00029013005) ( p. 374)
– Connect the bleeding device.
Bleeding device (00029013100) ( p. 374)

52
73
01
Z00165-10

8/
21
– Open shut-off valve 4.

16
Info

l.c r:
,0
ai d fo
Follow the instructions in the Owner's Manual of the

om
bleeding device.
gm e
– Ensure that the inflation pressure is set at pressure gauge A .
@ ens

Correct the inflation pressure on pressure regulator B if nec-

essary.
tin ic

Guideline
ar | L

201494-10

Inflation pressure 2 … 2.5 bar (29 … 36 psi)

lm r
ie fü

– Pull off protection cap 5 of the bleeder screw. Connect the

an ert

bleeder bottle hose.

yd zi

Bleeding device (00029013100) ( p. 374)

ar en

– Open bleeder screw 6 by approx. one half turn.

ch Liz

Info
Drain until fresh brake fluid emerges in the bleeder bot-
tle hose without bubbles.
R02780-10
za

– Tighten the bleeder screw.

–
,

Close shut-off valve 4.

in

– Open the bleeder screw again until brake fluid stops emerging.
t
ar
M

Info
c

Overfilling the brake fluid reservoir is prevented.

Za

– Tighten the bleeder screw. Remove the bleeder bottle hose.

Mount the protection cap.
– Disconnect the bleeding device. Remove the bleeder cover.
Zac Martin, [email protected],

157
 16 BRAKE SYSTEM

– Add brake fluid up to level C.

Guideline
Level C (brake fluid level 5 mm (0.2 in)
below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 370)

– Position the cover with the membrane. Mount and tighten the
screws.
309386-10
Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.

– Check the hand brake lever for a firm pressure point.

52
16.9 Checking the brake linings of the rear brake

73
Warning

01
Danger of accidents Worn-out brake linings reduce the braking effect.

8/
– Ensure that worn-out brake linings are replaced immediately.

21
16
– Check the brake linings for minimum thickness A.

l.c r:
,0
ai d fo
Minimum thickness A ≥ 1 mm (≥ 0.04 in)

om
» If the minimum thickness is less than specified:
gm e
@ ens

– Change the rear brake linings. ( p. 158)

– Check the brake linings for damage and cracking.
tin ic

» If damage or wear is encountered:

ar | L

– Change the rear brake linings. ( p. 158)

lm r

E00349-10
ie fü
an ert

16.10 Changing the rear brake linings

yd zi
ar en

Warning
ch Liz

Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally.

Warning
Skin irritation Brake fluid causes skin irritation.
za

– Keep brake fluid out of the reach of children.

,
in

– Wear suitable protective clothing and safety glasses.

t

– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
ar

– Consult a doctor immediately if brake fluid has been swallowed.

M

– Rinse the affected area with plenty of water in the event of contact with the skin.
c
Za

– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Zac Martin, [email protected],

158
 BRAKE SYSTEM 16

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.

Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.

Note
Environmental hazard Hazardous substances cause environmental damage.

52
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with

73
the applicable regulations.

01
8/
Info

21
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not

16
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.

l.c r:
,0
ai d fo
Only use clean brake fluid from a sealed container.

om
gm e
– Position the vehicle vertically.
@ ens

– Remove screw cap 1 with membrane 2 and the O-ring.

– Press the brake piston back into the basic position and ensure
tin ic

that brake fluid does not flow out of the brake fluid reservoir;
ar | L

extract some if necessary.

lm r
ie fü

Info
an ert

Make sure that you do not press the brake caliper

against the spokes when pushing back the brake piston.
yd zi

S03488-10
ar en

– Remove cotter pin 3, pull out pin 4, and remove the brake
ch Liz

linings.
– Clean the brake caliper and the brake caliper bracket.
, za
t in
ar

E00351-10
M
c
Za

Zac Martin, [email protected],

159
 16 BRAKE SYSTEM

– Check that spring plate 5

in the brake caliper and brake pad
sliding plate 6
in the brake caliper bracket are seated cor-
rectly.

E00352-10

– Insert the new brake linings, insert the pin, and mount the cot-
ter pins.

Info
Always change the brake linings in pairs.

– Operate the foot brake lever repeatedly until the brake lin-

52
ings are in contact with the brake disc and there is a pressure

73
point.

01
E00353-01

8/
– Correct brake fluid level to marking A.

21
Brake fluid DOT 4 / DOT 5.1 ( p. 370)

16
–

l.c r:
Mount screw cap 1 with membrane 2 and O-ring.

,0
ai d fo
om
Info
gm e
Use water to immediately clean up any brake fluid that
@ ens

has overflowed or spilled.

tin ic

S03487-10
ar | L

16.11 Checking the free travel of foot brake lever

lm r
ie fü

Warning
an ert

Danger of accidents The brake system fails in the event of overheating.

yd zi
ar en

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
ch Liz

– Set the free travel on the foot brake lever in accordance with the specification.

– Disconnect spring 1.
– Move the foot brake lever back and forth between the end stop
za

and the contact to the foot brake cylinder piston and check
,

free travel A
.
tin

Guideline
ar

Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)

M

» If the free travel does not meet specifications:

c
Za

– Adjust the basic position of the foot brake lever.

402026-10
( p. 161)
– Reconnect spring 1.
Zac Martin, [email protected],

160
 BRAKE SYSTEM 16

16.12 Adjusting the basic position of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.

– Detach spring 1.

52
73
01
402026-10

8/
Loosen nut 2
and, with push rod 3, turn it back until you

21
have maximum free travel.
– To adjust the basic position of the foot brake lever to individ-

16
ual requirements, loosen nut 4 and turn screw 5 accord-

l.c r:
,0
ingly.

ai d fo
om
Info
gm e
The range of adjustment is limited.
@ ens

E00346-10 – Turn push rod 3 accordingly until you have free travel A . If
tin ic

necessary, adjust the basic position of the foot brake lever.

ar | L

Guideline
lm r

Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)

ie fü

–
an ert

Hold screw 5 and tighten nut 4.

Guideline
yd zi
ar en

Nut, foot brake lever M8 20 Nm (14.8 lbf ft)

stop
ch Liz

– Hold push rod 3 and tighten nut 2.

Guideline
Remaining nuts, M6 10 Nm (7.4 lbf ft)
chassis
za

– Attach spring 1.
,
t in
ar
M
c
Za

Zac Martin, [email protected],

161
 16 BRAKE SYSTEM

16.13 Checking the rear brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated.

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.

– Stand the vehicle upright.

– 1.

52
Check the brake fluid level in the viewer
» If the fluid has dropped below marking A in the level

73
viewer:

01
– Add rear brake fluid. ( p. 162)

8/
21
16
l.c r:
,0
S03518-10

ai d fo
om
16.14 Adding rear brake fluid
gm e
@ ens

Warning
tin ic

Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
ar | L

If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
lm r
ie fü

– Check the brake system and do not continue riding until the problem is eliminated.
an ert

Warning
yd zi

Skin irritation Brake fluid causes skin irritation.

ar en

– Keep brake fluid out of the reach of children.

ch Liz

– Wear suitable protective clothing and safety glasses.

– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
za

– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
,

with the eyes.

in

–
t

If brake fluid spills on to your clothing, change the clothing.

ar
M

Warning
c

Danger of accidents Old brake fluid reduces the braking effect.

Za

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
Zac Martin, [email protected],

162
 BRAKE SYSTEM 16

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

Preparatory work
– Check the brake linings of the rear brake. ( p. 158)
Main work
– Stand the vehicle upright.

52
– Remove screw cap 1 with membrane 2 and the O-ring.

73
– Add brake fluid to level A.

01
Brake fluid DOT 4 / DOT 5.1 ( p. 370)

8/
– Mount and tighten the screw cap with the membrane and O-

21
ring.

16
S03487-10

l.c r:
Info

,0
ai d fo
Clean up overflowed or spilled brake fluid immediately

om
with water.
gm e
@ ens

16.15 Changing the rear brake fluid

tin ic
ar | L

Warning
lm r
ie fü

Skin irritation Brake fluid causes skin irritation.

an ert

– Keep brake fluid out of the reach of children.

– Wear suitable protective clothing and safety glasses.
yd zi

–
ar en

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
ch Liz

– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
za

Note
,
in

Environmental hazard Hazardous substances cause environmental damage.

t
ar

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
M
c
Za

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Only use clean brake fluid from a sealed container.
Zac Martin, [email protected],

163
 16 BRAKE SYSTEM

– Cover the painted parts.

– Remove screw cap 1 with the membrane and the O-ring.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 376)
Brake fluid DOT 4 / DOT 5.1 ( p. 370)

Z00182-01

– Mount bleeder cover 2.

Bleeder cover (00029013006) ( p. 374)
– Connect the bleeding device.
Bleeding device (00029013100) ( p. 374)

52
73
01
Z00183-01

8/
– Open shut-off valve 3.

21
16
Info

l.c r:
Follow the instructions in the Owner's Manual of the

,0
ai d fo
bleeding device.

om
– Ensure that the inflation pressure is set at pressure gauge A .
gm e
@ ens

Correct the inflation pressure on pressure regulator B if nec-

essary.
tin ic

201494-12 Guideline
ar | L

Inflation pressure 2 … 2.5 bar (29 … 36 psi)

lm r

– 4 of the bleeder screw. Connect the

ie fü

Pull off protection cap

bleeder bottle hose.
an ert

Bleeding device (00029013100) ( p. 374)

yd zi

– 5 by approx. one half turn.

ar en

Open bleeder screw

ch Liz

Info
Drain until fresh brake fluid emerges in the bleeder bot-
tle hose without bubbles.
R02783-10
– Tighten the bleeder screw.
za

– Close shut-off valve 3.

,
in

– Open the bleeder screw again until brake fluid stops emerging.
t
ar

Info
M

Overfilling the brake fluid reservoir is prevented.

c
Za

– Tighten the bleeder screw. Remove the bleeder bottle hose.

Mount the protection cap.
– Disconnect the bleeding device. Remove the bleeder cover.
Zac Martin, [email protected],

164
 BRAKE SYSTEM 16

– Position the vehicle vertically.

– Correct the brake fluid to marking C.
Brake fluid DOT 4 / DOT 5.1 ( p. 370)
– Mount and tighten the screw cap with the membrane and O-
ring.

Info
Use water to immediately clean up any brake fluid that
Z00184-01 has overflowed or spilled.

– Check the foot brake lever for a firm pressure point.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

165
 17 LIGHTING SYSTEM, INSTRUMENTS

17.1 Changing the headlight bulb

Note
Damage to reflector Grease on the reflector reduces the light intensity.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
– Clean and degrease the bulbs before mounting.
– Do not touch the bulbs with your bare hands.

Preparatory work
– Remove the headlight mask with the headlight. ( p. 117)
Main work
– Turn protection cap 1
together with the underlying bulb
socket counterclockwise all the way and remove it.
– Pull bulb socket 2 of the position light out of the reflector.

52
73
01
8/
21
E00358-10

16
Pull out headlight bulb 3.

l.c r:
–

,0
Insert the new headlight bulb.

ai d fo
om
Headlight (HS1/socket BX43t) ( p. 314)
–
gm e
Insert the protection cap with the bulb socket into the reflector
@ ens

and turn it clockwise all the way.

tin ic

Info
ar | L

E00359-10
Ensure that O-ring 4 is seated properly.
lm r

– Insert the bulb socket of the position light into the reflector.
ie fü

Finishing work
an ert

– Install the headlight mask with the headlight. ( p. 117)

yd zi

– Check the headlight setting. ( p. 167)

ar en
ch Liz

17.2 Changing the turn signal bulb (EU/CN/ASEAN)

Note
za

Damage to reflector Grease on the reflector reduces the light intensity.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
,
in

– Clean and degrease the bulbs before mounting.

t
ar

– Do not touch the bulbs with your bare hands.

M
c
Za
Zac Martin, [email protected],

166
 LIGHTING SYSTEM, INSTRUMENTS 17

Main work
– Remove the screw on the rear of the turn signal housing.
– Carefully remove turn signal glass 1.
– Lightly squeeze orange cap 2 in the area of the holding lugs
and take it off.
– Press the turn signal bulb lightly into the socket, turn it coun-
terclockwise by about 30°, and take it out of the socket.

Info
Do not touch the reflector with your fingers and keep it
free from grease.

– Press the new turn signal bulb carefully into the socket and
turn it clockwise until it stops.
Turn signal (R10W / socket BA15s) ( p. 314)
– Mount the orange cap.

52
– Position the turn signal glass.

73
– Insert the screw and first turn counterclockwise until it

01
E00360-10 engages in the thread with a small jerk. Tighten the screw
lightly.

8/
21
Finishing work
– Check that the turn signal system is functioning properly.

16
l.c r:
,0
ai d fo
om
17.3 Checking the headlight setting
gm e
–
@ ens
Park the vehicle on a horizontal surface in front of a light-
colored wall and make a mark at the height of the center of
the low beam headlight.
tin ic

–
ar | L

Make another mark at a distance B under the first marking.

Guideline
lm r
ie fü

Distance B 5 cm (2 in)
an ert

– Position the vehicle vertically at a distance A away from the

wall.
yd zi

400726-10
ar en

Guideline
ch Liz

Distance A 5 m (16 ft)

– The rider now sits down on the motorcycle.

– Switch on the low beam.
– Check the headlight setting.
za

The boundary between light and dark must be exactly on the

,

lower mark for a motorcycle with rider.

tin

» If the boundary between light and dark does not meet

ar

specifications:
M

– Adjust the headlight range. ( p. 168)

c
Za

Zac Martin, [email protected],

167
 17 LIGHTING SYSTEM, INSTRUMENTS

17.4 Adjusting the headlight range

Preparatory work
– Check the headlight setting. ( p. 167)
Main work
– Loosen screw 1.
– Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on the
lower mark for a motorcycle with rider (instructions on how
to apply the mark: Checking the headlight setting).

V00369-10 Info
If you have a payload, you may have to correct the
headlight range.

52
– Tighten screw 1.

73
01
17.5 Changing the combination instrument battery

8/
21
Preparatory work

16
– Remove the headlight mask with the headlight. ( p. 117)

l.c r:
,0
Main work

ai d fo
– Remove screws

om
1.
– Pull the combination instrument upward out of the holder.
gm e
@ ens
tin ic
ar | L
lm r
ie fü

E00901-10
an ert

– Using a coin, turn protection cap 2 all the way counterclock-

yd zi

wise and take it off.

ar en

– Remove combination instrument battery 3.

ch Liz

– Insert the combination instrument battery with the label facing

outward.
Combination instrument battery (CR 2430) ( p. 314)
– Check the O-ring of the protection cap for correct seating.
za

V00371-10
,
in

– Position protection cap 2 and turn all the way clockwise

t
ar

using a coin.
M

– Press any button on the combination instrument.

c

The combination instrument is activated.

Za

– Position the combination instrument in the holder.

– Mount and tighten the screws with washers.

V00372-10
Zac Martin, [email protected],

168
 LIGHTING SYSTEM, INSTRUMENTS 17

Finishing work
– Install the headlight mask with the headlight. ( p. 117)
– Check the headlight setting. ( p. 167)
– Set kilometers or miles. ( p. 169)
– Adjust combination instrument function. ( p. 170)
– Set the clock. ( p. 171)

17.6 Combination instrument overview

– The button is used to select menus and make settings.
– The button is used to select menus and make settings.

Info
When the vehicle is delivered, only the SPEED/H and
SPEED/ODO display modes are activated.

52
73
01
V00799-01

8/
21
17.7 Activation and test

16
Activating combination instrument

l.c r:
,0
The combination instrument is activated when one of the buttons

ai d fo
is pressed or an impulse comes from the wheel speed sensor.

om
Display test
gm e
To enable you to check that the display is functioning properly, all
@ ens

display segments light up briefly.

tin ic
ar | L
lm r

400313-01
ie fü

WS (wheel size)
an ert

After the display function check, the wheel circumference WS is

displayed briefly.
yd zi
ar en

Info
ch Liz

The number 2205 equals the circumference of the 21"

front wheel with standard tires.

The display then changes to the last selected mode.

za

400314-01
,
in

17.8 Setting kilometers or miles

t
ar

Info
M

If you change the unit, the value ODO is retained and converted accordingly.
c

The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Za

Condition
The motorcycle is stationary.
Zac Martin, [email protected],

169
 17 LIGHTING SYSTEM, INSTRUMENTS

– Repeatedly press the button briefly until H appears at the

bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
– Repeatedly press the button briefly until Km/h/Mph flashes.
Adjusting the Km/h
– Press the button .
400329-01 Adjusting the Mph
– Press the button .
– Wait 3 - 5 seconds.
The settings are stored.

Info
If no button is pressed for 10–12 seconds, or if an
impulse comes from the wheel speed sensor, the

52
settings are automatically saved and the setup menu is

73
closed.

01
8/
21
17.9 Adjusting combination instrument function

16
Info

l.c r:
,0
ai d fo
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

om
gm e
Condition
@ ens

The motorcycle is stationary.

–
tin ic

Repeatedly press the button briefly until H appears at the

bottom right of the display.
ar | L

– Press the button for 2–3 seconds.

lm r
ie fü

The Setup menu is displayed and the active functions are

shown.
an ert

Info
yd zi
ar en

If no button is pressed for 10–12 seconds, the settings

are automatically saved.
ch Liz

400318-01 If no button is pressed for 20 seconds, or if an impulse

comes from the wheel speed sensor, the settings are
automatically saved and the setup menu is closed.

– Repeatedly press the button briefly until the desired func-

za

tion flashes.
,

The selected function flashes.

in

Activating the function

t
ar

– Press the button .

M

The symbol continues to appear in the display and the

c

next function appears.

Za

Deactivating a function
– Press the button .
The symbol disappears in the display and the next
function appears.
Zac Martin, [email protected],

170
 LIGHTING SYSTEM, INSTRUMENTS 17

17.10 Setting the clock

Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The hour display flashes.
– Adjust hour display with the button and/or button .
– Wait 3 - 5 seconds.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the
400330-01 hours by pressing the button and the button .

Info

52
The seconds can only be set to zero.
If no button is pressed for 15–20 seconds, or if an

73
impulse comes from the wheel speed sensor, the

01
settings are automatically saved and the setup menu is
closed.

8/
21
16
l.c r:
17.11 Adjusting the wheel circumference

,0
ai d fo
om
Note
gm e
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for oper-
@ ens

ation on public roads in the homologated version.

– After the conversions, only use the vehicle on closed circuits that are not open to public road traffic.
tin ic

– Inform the rider and owner that the public road approval and insurance coverage are no longer valid.
ar | L

– If you are requested to carry out these conversions, insist on a shop order signed by your customer, in which
lm r

you also inform the customer that these conversions will be carried out at the customer’s own risk and that
ie fü

the vehicle will thereafter no longer be approved for use on public roads.
an ert

Condition
yd zi

The motorcycle is stationary.

ar en

Preparatory work
ch Liz

– Remove the headlight mask with the headlight. ( p. 117)

Main work
– Open cable holder 1 and expose the cable.
– Disconnect plug-in connector CZ.
, za
t in
ar
M
c
Za

D06394-10
Zac Martin, [email protected],

171
 17 LIGHTING SYSTEM, INSTRUMENTS

– Repeatedly press the button briefly until H appears at the

bottom right of the display.
– Press the button for 2–3 seconds.
– Repeatedly press the button until the WS indicator flashes.
– Press the button briefly.

Info
The wheel circumference is displayed in millimeters.
400315-01
Enlarging the wheel circumference
– Press the button .
Reducing the wheel circumference
– Press the button .

Info
If no button is pressed for 20 seconds, or if no

52
impulse comes from the wheel speed sensor, the
settings are automatically saved and the Setup

73
menu is closed.

01
– Join plug-in connector CZ.

8/
–

21
Position the cable in the cable holder.
– 1.

16
Engage cable holder

l.c r:
,0
ai d fo
om
gm e
@ ens

D06395-10
tin ic

Finishing work
ar | L

– Remove the headlight mask with the headlight. ( p. 117)

lm r
ie fü
an ert

17.12 Viewing the lap time

yd zi
ar en

Info
ch Liz

This function can only be opened if lap times have actually been timed.

Condition
The motorcycle is stationary.
za

– Repeatedly press the button briefly until LAP appears at the

bottom right of the display.
,
in

– Briefly press the button .

t
ar

LAP 1 appears on the left side of the display.

M

– The laps 1 - 10 can be viewed with the button .

– Press and hold the button for 3 - 5 seconds.
c
Za

The lap times are deleted.

– Briefly press the button .
400321-01
Next display mode
Zac Martin, [email protected],

172
 LIGHTING SYSTEM, INSTRUMENTS 17

Info
When an impulse is received from the wheel speed sen-
sor, the left side of the display changes back to the
SPEED mode.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

173
 18 ENGINE

18.1 Cleaning the pressure sensor hose

– Push back hose clamps 1.
– Pull off pressure sensor hose 2.

R05731-10

– Clean hose 2thoroughly and blow out with compressed air.

52
73
01
8/
21
R02849-10

16
– Mount pressure sensor hose 2.

l.c r:
,0
– Position hose clamps 1 .

ai d fo
om
gm e
@ ens
tin ic
ar | L

R05731-10
lm r
ie fü

18.2 Cleaning the protection cap of the pressure sensor

an ert

– Push back hose clamp 1.

yd zi
ar en

– Remove protection cap 2.

ch Liz

– Clean the protection cap thoroughly and blow out with com-
pressed air.
– Mount protection cap2.
– Position hose clamp 1.
,za
in

R05730-10
t
ar
M
c
Za
Zac Martin, [email protected],

174
 ENGINE 18

18.3 Cleaning the hose connections of the pressure sensor

Preparatory work
(All special models)
– Remove the engine guard. ( p. 56)
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the seat. ( p. 102)
– Disconnect the negative cable of the 12-V battery. ( p. 143)
– Drain the coolant. ( p. 276)
– Remove the fuel tank. ( p. 103)
– Remove the manifold. ( p. 93)
– Remove the air filter box cover. ( p. 98)
– Remove the engine. ( p. 176)
Main work
– Clean the pressure sensor cylinder connection. ( p. 210)

52
– Push back hose clamp 1.

73
– Pull off hose 2.

01
– Pull off the pressure sensor hose.

8/
21
16
l.c r:
,0
ai d fo
om
R05754-10
gm e
@ ens

– Clean the hose connection with a drill without applying force.

Guideline
tin ic

Metal drill 2 mm (0.08 in)

ar | L
lm r

Info
ie fü

Do not use compressed air, as otherwise the pressure

an ert

sensor will be damaged.

yd zi
ar en

R05755-10
ch Liz

Finishing work
– Install the engine. ( p. 182)
– Remove the motorcycle from the lift stand. ( p. 13)
(All special models)
– Install the engine guard. ( p. 56)
za

– Refill with coolant. ( p. 277)

,
in

– Prime the oil pump. ( p. 289)

t

– Mount the seat. ( p. 102)

ar

–
M

Go for a short test ride.

– Check the engine for leaks.
c
Za

– Check the gear oil level. ( p. 287)

– Check the coolant level. ( p. 276)
Zac Martin, [email protected],

175
 18 ENGINE

18.4 Removing the engine

Preparatory work
(All special models)
– Remove the engine guard. ( p. 56)
– Raise the motorcycle with a lift stand. ( p. 13)
– Remove the seat. ( p. 102)
– Disconnect the negative cable of the 12-V battery. ( p. 143)
– Drain the coolant. ( p. 276)
– Remove the fuel tank. ( p. 103)
– Remove the manifold. ( p. 93)
– Remove the air filter box cover. ( p. 98)
Main work
– Remove screws 1 and the washers.
– Take off the main silencer.

52
73
01
8/
21
16
Z00189-10

l.c r:
,0
– Remove screw 2 and the washers.

ai d fo
om
– Remove the cable ties.
– Push the right frame protector to the front and take off at the
gm e
@ ens
bottom.
tin ic
ar | L
lm r
ie fü

Z00190-10
an ert

– Remove screws 3 and the washers.

yd zi

– Remove the cable tie.

ar en

– Take off the left frame protector.

ch Liz
za

Z00191-10
,
in

– Loosen screw4.
t
ar

– Remove screw 5.
M

– Repeat these steps on the opposite side.

c
Za

Z00192-10
Zac Martin, [email protected],

176
 ENGINE 18

– Loosen hose clip 6.

Z00193-10

– Lift the subframe slightly and secure it.

Info
Pay attention to the oil pump hose.

52
73
01
Z00194-10

8/
– Remove screw 7.

21
– Remove screw 8.

16
– Take off the engine sprocket cover.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00195-10
ar | L

– Remove screws 9.
lm r

– Take off the slave cylinder of the clutch and hang to the side.
ie fü
an ert

Info
Do not kink the clutch line.
yd zi

Do not activate the clutch lever while the slave cylinder

ar en

of the clutch is removed.

ch Liz

Z00196-10

– Have an assistant operate the rear brake.

–
za

Remove screw bk with washer.

,
in
t
ar
M
c
Za

Z00197-10
Zac Martin, [email protected],

177
 18 ENGINE

– Remove connecting link bl of the chain.

Info
Cover the components to protect them against damage.

– Take off the chain.

Z00198-10

– Remove engine sprocket bm.

52
73
01
Z00199-10

8/
– Disconnect spark plug connector bn.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00200-10
ar | L

– Push back protection cap bo.

lm r

– Disconnect the connector of the coolant temperature sensor.

ie fü
an ert
yd zi
ar en
ch Liz

Z00201-10

– Push back protection caps bp.

za

– Disconnect connector.
,
in
t
ar
M
c
Za

Z00202-10
Zac Martin, [email protected],

178
 ENGINE 18

– Pull off vent hose bq.

Z00203-10

– Remove the cable tie.

52
73
01
Z00204-10

8/
– Disconnect plug-in connector br.

21
– Disconnect plug-in connector bs.

16
– Expose the cable.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00205-10
ar | L

– Push back hose clamp bt.

lm r

– Pull off the pressure sensor hose.

ie fü
an ert
yd zi
ar en
ch Liz

Z00206-10

– Loosen hose clip ck.

za

– Pull off the radiator hose.

,
in
t
ar
M
c
Za

Z00207-10
Zac Martin, [email protected],

179
 18 ENGINE

– Loosen hose clip cl.

– Pull off the radiator hose.

Z00208-10

– Disconnect oil pump connector cm.

52
73
01
Z00209-10

8/
– Remove the cable tie.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00210-10
ar | L

– Push back protection cap cn and remove the nut.

lm r

– Hang the positive cable to the side.

ie fü
an ert
yd zi
ar en
ch Liz

Z00211-10

– Remove spring co.

, za
in
t
ar
M
c
Za

Z00212-10
Zac Martin, [email protected],

180
 ENGINE 18

– Remove fitting cp.

– Slip the foot brake lever out toward the rear.

Z00213-10

– Remove screws cq and cr.

– Take off the engine braces.

52
73
01
Z00214-10

8/
– Remove nut cs.

21
– Remove the swingarm pivot.

16
– Carefully pull the link fork back, and secure it.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00215-10
ar | L

– Remove screws ct.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

Z00216-10

(EU/ASEAN)
– Pull fuel vapor valve A off the holder and hang it to the
za

side.
,
in
t
ar
M
c
Za

D07636-10
Zac Martin, [email protected],

181
 18 ENGINE

– Pry out the engine sideways to the left.

Info
The help of an assistant is useful in this step.
Make sure that the motorcycle is sufficiently secured
against falling over.
Cover the components to protect them against damage.
Pay attention to the oil pump.

Z00217-10

18.5 Installing the engine

Main work
– Position the engine in the frame.

Info

52
The help of an assistant is useful in this step.

73
Make sure that the motorcycle is sufficiently secured
against falling over.

01
Cover the components to protect them against damage.

8/
Pay attention to the oil pump.

21
Z00217-10

16
– Mount screws 1, but do not tighten yet.

l.c r:
,0
Guideline

ai d fo
om
Engine bracket screw
gm e M10 60 Nm (44.3 lbf ft)
@ ens
tin ic
ar | L

Z00216-11
lm r
ie fü

(EU/ASEAN)
an ert

– Mount fuel vapor valve A on the holder.

yd zi

Info
ar en

Make sure the cables and wiring are positioned cor-

ch Liz

rectly.

D07636-11
za

– Position the link fork.

,
in

– Mount the swingarm pivot.

t
ar

– Mount nut 2, but do not tighten yet.

M

Guideline
c

Nut, fork pivot M16x1.5 100 Nm

Za

(73.8 lbf ft)

Z00215-11
Zac Martin, [email protected],

182
 ENGINE 18

– Position the engine braces.

– Mount and tighten screws 3.
Guideline
Screw, engine M8x15 25 Nm (18.4 lbf ft)
brace Loctite®2701™
– Mount and tighten screws 4.
Guideline
Z00214-11 Screw, engine M8x20 25 Nm (18.4 lbf ft)
brace Loctite®243™
– Tighten screws 1 and nut 2.
Guideline
Engine bracket screw M10 60 Nm (44.3 lbf ft)
Nut, fork pivot M16x1.5 100 Nm
(73.8 lbf ft)

52
– Slip in the foot brake lever and position it.

73
– Mount and tighten fitting 5.

01
Guideline

8/
Nut, foot brake lever M8 20 Nm (14.8 lbf ft)

21
16
Push rod B engages in the foot brake cylinder.

l.c r:
The dust boot is correctly positioned.

,0
ai d fo
om
D07653-10
gm e
@ ens

– Mount spring 6.
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en

Z00212-11
ch Liz

– Position the positive cable on the starter motor.

– Mount and tighten the nut.
Guideline
Remaining nuts, M6 10 Nm (7.4 lbf ft)
za

chassis
– 7.
,

Position protection cap

in
t
ar
M

Z00211-11
c
Za

Zac Martin, [email protected],

183
 18 ENGINE

– Mount the cable ties.

Z00210-10

– Plug in oil pump connector 8.

52
73
01
Z00209-11

8/
– Mount the radiator hose.

21
– Position and tighten hose clip 9.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00208-11
ar | L

– Mount the radiator hose.

–
lm r

Position and tighten hose clip bk.

ie fü
an ert
yd zi
ar en
ch Liz

Z00207-11

– Position pressure sensor hose.

–
za

Position hose clamp bl.

,
in
t
ar
M
c
Za

Z00206-11
Zac Martin, [email protected],

184
 ENGINE 18

– Join plug-in connectors bm and bn.

Z00205-11

– Route the cable without tension and secure with the cable ties.

52
73
01
Z00204-10

8/
– Mount vent hose bo.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00203-11
ar | L

– Plug in the connectors.

–
lm r

Position protection caps bp.

ie fü
an ert
yd zi
ar en
ch Liz

Z00202-10

– Plug in the connector of the coolant temperature sensor.

–
za

Position protection cap bq.

,
in
t
ar
M
c
Za

Z00201-11
Zac Martin, [email protected],

185
 18 ENGINE

– Plug in spark plug connector br.

Z00200-11

– Slide engine sprocket bs onto the countershaft.

52
73
01
Z00199-11

8/
– Mount the chain.

21
– Connect the chain with connecting link bt.

16
Guideline

l.c r:
,0
The closed side of the chain joint lock must face in the

ai d fo
om
direction of travel.
gm e
@ ens
tin ic

R02884-10
ar | L

– Have an assistant operate the rear brake.

–
lm r

Mount and tighten screw ck with the washer.

ie fü

Guideline
an ert

Screw, drive M10 60 Nm (44.3 lbf ft)

yd zi

chain engine Loctite®2701™

ar en

sprocket
ch Liz

Z00197-11

– Position the clutch slave cylinder with the gasket.

–
za

Mount and tighten screws cl.

Guideline
,
in

Screw, clutch slave M6 10 Nm (7.4 lbf ft)

t
ar

cylinder
M
c
Za

Z00196-11
Zac Martin, [email protected],

186
 ENGINE 18

– Position the engine sprocket cover.

– Mount and tighten screw cm.
Guideline
Screw, clutch slave M6 10 Nm (7.4 lbf ft)
cylinder
– Mount and tighten screw cn.
Guideline
Z00195-11
Screw, engine M8 15 Nm (11.1 lbf ft)
sprocket cover

– Remove the locking piece and position the subframe.

Info
Watch out for the intake flange.

– Position hose clip co but do not tighten yet.

52
73
01
Z00193-11

8/
21
– Mount and tighten screw cp.

16
Guideline

l.c r:
,0
Screw, sub- M8 30 Nm (22.1 lbf ft)

ai d fo
frame bottom Loctite®2701™

om
– Remove screw cq.
gm e
@ ens

– Mount and tighten screw cq.

Guideline
tin ic

Screw, sub- M8 35 Nm (25.8 lbf ft)

ar | L

Z00192-11
frame top Loctite®2701™
lm r
ie fü

– Repeat these steps on the opposite side.

– Tighten hose clip co.
an ert

– Position the left frame protector.

yd zi
ar en

– Mount and tighten screws cr with the washers.

ch Liz

Guideline
Screw, frame protec- M5 3 Nm (2.2 lbf ft)
tor
– Mount the cable ties.
, za
in

Z00191-11
t

– Insert the right frame protector from below and push it to the
ar

rear.
M

– Mount and tighten screw cs with washers.

c
Za

Guideline
Screw, frame protec- M5 3 Nm (2.2 lbf ft)
tor
– Mount the cable ties.
– Install the manifold. ( p. 94)
Zac Martin, [email protected],

Z00190-11

187
 18 ENGINE

– Mount the main silencer with exhaust sleeve ct.

– Mount and tighten screws dk with the washers.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Connect the negative cable of the 12-V battery. ( p. 143)
– Install the fuel tank. ( p. 104)
Z00218-10
– Install the air filter box cover. ( p. 98)
– Mount the seat. ( p. 102)
– Remove filler plug dl with the O-ring, and fill up with gear
oil.
Gear oil 0.80 l Engine oil
(0.85 qt.) (15W/50)
( p. 370)

52
– Mount and tighten filler plug dl with the O-ring.

73
01
Z00219-10

8/
21
Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)

16
(All special models)

l.c r:
,0
– Install the engine guard. (

ai d fo
p. 56)

om
– Refill with coolant. ( p. 277)
gm e
– Prime the oil pump. ( p. 289)
@ ens

– Mount the seat. ( p. 102)

– Go for a short test ride.
tin ic

–
ar | L

Check the engine for leaks.

– Check the gear oil level. ( p. 287)
lm r
ie fü

– Check the coolant level. ( p. 276)

an ert
yd zi

18.6 Engine disassembly

ar en
ch Liz

18.6.1 Clamping engine into the engine work stand

– Mount special tool 1 on engine work stand 2.
Engine work stand (61229001000) ( p. 382)
Holder and fitting for work stand (55429002000)
za

( p. 378)
,
in

– Mount the engine on special tool 1.

t
ar
M
c

E02129-10
Za
Zac Martin, [email protected],

188
 ENGINE 18

18.6.2 Removing the shift lever

– Remove screw 1 with the washers. Take off the shift lever.

E02130-10

18.6.3 Removing the clutch push rod

– Remove clutch push rod 1.

52
73
01
8/
21
16
E02131-10

l.c r:
,0
ai d fo
18.6.4 Draining the gear oil

om
– Remove gear oil drain plug 1 with the magnet and seal ring.
gm e
@ ens

– Let the gear oil drain fully.

tin ic
ar | L
lm r
ie fü
an ert

E02132-10
yd zi
ar en

18.6.5 Removing the spacer

ch Liz

– Remove spacer 1.
, za
t in
ar
M

E02133-10
c
Za

Zac Martin, [email protected],

189
 18 ENGINE

– Take off O-ring 2.

E02134-10

18.6.6 Removing the alternator cover

– Remove screws 1. Take off the alternator cover.

52
73
01
8/
21
E02135-10

16
– Remove the dowels 2 and alternator cover gasket 3.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

G03865-10
lm r
ie fü

18.6.7 Removing injection valves

an ert

– Remove screws 1.
yd zi

– Take off the injection valves on both sides.

ar en
ch Liz
za

G03866-10
,
t in
ar
M
c
Za
Zac Martin, [email protected],

190
 ENGINE 18

18.6.8 Removing the cylinder head

– Remove spark plug 1.

G03867-10

– Loosen screws 2 in a crisscross pattern and remove them.

– Remove the cylinder head.

52
73
01
8/
G03868-10

21
(All 250 models)

16
– Remove O-rings 3 and 4.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

D04408-10
lm r
ie fü

(All 300 models)

– Remove O-rings 3 and 4.
an ert
yd zi
ar en
ch Liz

D04409-10
za

18.6.9 Removing the cylinder

,
in

(All 250 models)

t
ar

– Remove screws 1 and 2.

M

– Take off both covers.

c
Za

G03870-10
Zac Martin, [email protected],

191
 18 ENGINE

– Remove retainer 3 of ball socket 4.

– Pull off the ball socket.
– Remove the gaskets on both sides.

G03871-10

– Remove nuts 5.
Info
Raise the cylinder slightly to be able to remove the
front nuts.

– Carefully slide the cylinder up and take it off.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03916-10
ar | L

– Take off gasket 6.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

D04417-10

(All 300 models)

– Remove screws
za

1 and 2.
– Take off both covers.
,
in
t
ar
M
c
Za

G03914-10
Zac Martin, [email protected],

192
 ENGINE 18

– Remove retainer 3 of ball socket 4.

– Pull off the ball socket.
– Remove the gaskets on both sides.

G03915-10

– Remove nuts 5.
Info
Raise the cylinder slightly to be able to remove the
front nuts.

– Carefully slide the cylinder up and take it off.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

T03847-11
ar | L

– Take off gasket 6.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

D04425-10

18.6.10 Removing the piston

za

(All 250 models)

,
in

– Uncover the crankcase.

t

– Remove piston ring lock 1.

ar

–
M

Remove the piston pin.

– Take off the piston.
c
Za

D04430-10
Zac Martin, [email protected],

193
 18 ENGINE

(All 300 models)

– Uncover the crankcase.
– Remove piston ring lock 1.
– Remove the piston pin.
– Take off the piston.

D04431-10

– Remove upper conrod bearing 2.

52
73
01
D04432-10

8/
21
18.6.11 Removing the water pump cover

16
– Remove screws 1.

l.c r:
,0
– Take off the water pump cover.

ai d fo
– Remove the form ring.

om
gm e
@ ens
tin ic
ar | L

E02136-10
lm r
ie fü

18.6.12 Removing the clutch cover

an ert

– Remove screws 1.
yd zi

– Take off the cap.

ar en
ch Liz
za

E02137-10
,
in

– Remove adjusting spring 2 with the auxiliary spring and

t
ar

spring insert.
M
c
Za

E02138-10
Zac Martin, [email protected],

194
 ENGINE 18

– Remove screws 3.

E02139-10

– Take off the clutch cover at the top and slip out the linkage.

Info
Ensure that the kick starter shaft remains in the engine
case.

52
73
01
E02140-01

8/
– Remove dowels 4 and clutch cover gasket 5.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03889-10
ar | L

– Remove screws 6.
lm r

– Take off the bearing support with the linkage and angle lever.
ie fü
an ert
yd zi
ar en
ch Liz

G03890-10

18.6.13 Removing the clutch discs

za

– Remove screws 1.
,
in

– Take off spring retainer 2.

t
ar
M
c
Za

G03891-10
Zac Martin, [email protected],

195
 18 ENGINE

– Take off spring washer 3.

G03892-10

– Take off pretension ring 4.

52
73
01
G03893-10

8/
– Take off clutch pressure cap 5.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03894-10
ar | L

– Remove clutch disc pack 6 completely.

lm r

– Remove clutch throw-out 7.

ie fü
an ert
yd zi
ar en
ch Liz

G03895-10

18.6.14 Removing the clutch basket

za

– Hold the primary gear wheel using special tool 1.

,
in

Gear segment (56012004000) ( p. 378)

t
ar

– Remove nut 2 with the washer.

M
c

Info
Za

LH thread!

G03896-10
Zac Martin, [email protected],

196
 ENGINE 18

– Bend up the lock washer.

– Hold the inner clutch hub with the special tool. Loosen
nut 3 .
Holding wrench (51129003000) ( p. 377)
– Remove the nut with the lock washer.

G03897-10

– Take off inner clutch hub 4 and washer 5.

Info
The washer usually sticks to the inner clutch hub.

– Take off clutch basket 6.

52
73
01
G03898-10

8/
– Take off needle bearing 7 and collar bushing 8.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03899-10
ar | L

18.6.15 Removing the balancer shaft

lm r
ie fü

– Position the special tool.

an ert

– Hold the balancer shaft in place using the special tool 1.

yd zi

Gear segment (56012004000) ( p. 378)

ar en

– Remove screw 2 with the washer.

ch Liz

G03900-10
za

– Remove primary gear wheel 3.

,
tin
ar
M
c
Za

G03901-10
Zac Martin, [email protected],

197
 18 ENGINE

– Remove balancer shaft drive wheel 4.

G03902-10

– Remove woodruff key 5.

52
73
01
G03903-10

8/
– Remove balancer shaft 6.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

D04465-10
ar | L

18.6.16 Removing the shift shaft

lm r
ie fü

– Push sliding plate 1 away from shift drum locating unit 2.

an ert

Remove shift shaft 3 with washer.

yd zi
ar en
ch Liz

G03910-10
za

18.6.17 Removing the shift drum locating unit

,
in

– Remove screw 1.
t
ar

– Push locking lever 2 away from shift drum locating unit 3

M

and take off the shift drum locating unit.

c

– Relieve tension from the locking lever.

Za

G03911-10
Zac Martin, [email protected],

198
 ENGINE 18

18.6.18 Removing the locking lever

– Remove screw 1 with the washer.
– Take off locking lever 2 with the sleeve and spring.

G03912-10

18.6.19 Removing the rotor

– Hold the rotor with special tool 1.
Holding wrench (A44029012000) ( p. 388)

52
– Remove nut 2 with washer.

73
01
8/
21
16
D04474-10

l.c r:
,0
– Mount special tool 3, hold, and pull off the rotor by screwing
ai d fo
om
in the screw.gm e
Puller (58012009000) ( p. 379)
@ ens
tin ic
ar | L
lm r
ie fü

D04475-10
an ert

– Remove screws 4.
yd zi

– Take off the crankshaft speed sensor.

ar en
ch Liz
za

D04476-10
,
in

– Take off Bendix 5.

t
ar
M
c
Za

D04477-10
Zac Martin, [email protected],

199
 18 ENGINE

18.6.20 Removing the starter motor

– Remove screw 1.
– Take off cover 2.

G03935-10

– Remove screws 3.
– Pull the starter motor out of the engine case as far as possible.

Info

52
It is not possible to completely remove the starter
motor.

73
01
8/
G03936-10

21
– Remove screw 4.

16
–

l.c r:
Remove spacer 5 using the special tool.

,0
ai d fo
om
Footrest spring plier (58429083000) (
gm e p. 379)
@ ens
tin ic
ar | L

D04480-10
lm r
ie fü

– Remove the starter motor.

an ert
yd zi
ar en
ch Liz

G04008-10
za

– Remove O-ring 6.
,
tin
ar
M
c
Za

D04484-10
Zac Martin, [email protected],

200
 ENGINE 18

18.6.21 Removing the reed valve housing

– Remove screws 1.
– Take off intake flange and gasket.

D04485-10

– Remove reed valve housing 2.

– Take off the gasket.

52
73
01
8/
D04486-10

21
16
18.6.22 Removing the left section of the engine case

l.c r:
,0
– Remove screws 1.
ai d fo
om
– Tilt the left section of the engine case upward and remove the
fitting of the engine fixing arm.
gm e
@ ens

– Loosen the left section of the engine case by striking it lightly

with a plastic hammer and remove it.
tin ic
ar | L

Info
Do not pry it apart with screwdrivers, since the sealing
lm r
ie fü

areas are easily damaged.

D04488-10
an ert
yd zi

18.6.23 Removing the shift rails

ar en

– Remove shift rails 1.

ch Liz
, za
t in
ar

D04491-10
M
c
Za

Zac Martin, [email protected],

201
 18 ENGINE

18.6.24 Removing the shift drum

– 1 to the side.
Tilt shift forks
– Remove shift drum 2.

D04492-10

18.6.25 Removing the shift forks

– Remove shift forks 1.
Info

52
Do not misplace the shift rollers.

73
01
8/
21
16
D04493-10

l.c r:
,0
ai d fo
18.6.26 Removing the transmission shafts

om
– Remove lock ring 1.
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert

G04009-10
yd zi
ar en

– Pull both transmission shafts 2 out of the bearing seats

together.
ch Liz

Info
The stop disks of the transmission shafts usually stick
to the bearings.
,za
tin

D04495-10
ar
M
c
Za
Zac Martin, [email protected],

202
 Za
c
M
18.6.27 Removing the crankshaft

ar
tin

G04035-10
B04429-10
D04496-10

, za

–
–
–

ch Liz
ar en
yd zi
an ert
Remove O-ring

ie fü
Remove crankshaft

lm r
2.
1.

Remove distance sleeve

ar | L
tin ic 3.
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

203
8/
01
73
52
ENGINE 18

Zac Martin, [email protected],

 18 ENGINE

18.7 Working on individual parts

18.7.1 Working on the right section of the engine case

– Remove all dowels.
– Remove radial shaft seal ring 1 of the crankshaft.
– 2.
Remove lock ring
– Remove screws 3. Remove the bearing retainers.
– Clean the section of the engine case thoroughly.
– Warm the section of the engine case in an oven.
Guideline
180 °C (356 °F)
– Knock the section of the engine case against a level wooden
board. This will cause the bearings to drop out of the bearing
seats.

52
73
Info
Any bearings that remain in the section of the engine

01
case must be removed using a suitable tool.

8/
21
16
G04033-10

l.c r:
,0
ai d fo
– Blow out lubrication bore 4 with compressed air and check

om
that it is clear.
gm e
– Insert the new cold bearings in the bearing seats of the heated
@ ens

section of the engine case; if necessary, use a suitable press-

ing tool to push them all the way in and make them flush.
tin ic
ar | L

Info
When pressing in, ensure that the section of the engine
lm r

case lies flat in order to prevent damage.

ie fü

D04499-10 Only press the bearings in using the outer bearing race;
an ert

otherwise, the bearings will be damaged when they are

pressed in.
yd zi
ar en

– After the section of the engine case has cooled, check that the
ch Liz

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
za

warm. In this case, the engine case must be renewed.

,
in

– Press in radial shaft seal ring 1 of the crankshaft with the

t

open side facing in so that it is flush.

ar

– Mount lock ring 2.

M

– Mount and tighten screws 3 with the bearing retainers.

c
Za

Guideline
Screw, bearing M5 6 Nm (4.4 lbf ft)
retainer Loctite®243™
– Mount the dowels.
Zac Martin, [email protected],

204
 ENGINE 18

18.7.2 Working on the left section of the engine case

– Remove all dowels.
– Press radial shaft seal ring 1 of the crankshaft from the out-
side to facing inward using special tool 2 .
Pressing tool (60029046128) ( p. 381)
– Remove radial shaft seal ring 3 from the shift shaft and 4
from the countershaft.
– Remove radial shaft seal ring 5 of the balancer shaft.

52
73
01
8/
21
B04432-10

16
Remove lock ring 6.

l.c r:
–

,0
Clean the section of the engine case thoroughly.

ai d fo
– Warm the section of the engine case in an oven.

om
Guideline
gm e
@ ens
180 °C (356 °F)
– Knock the section of the engine case against a level wooden
tin ic

board. This will cause the bearings to drop out of the bearing
ar | L

seats.
B04433-10
lm r
ie fü

Info
Any bearings that remain in the section of the engine
an ert

case must be removed using a suitable tool.

yd zi

–
ar en

Blow out lubrication bore 7 with compressed air and check

that it is clear.
ch Liz
, za
tin

D04500-10
ar
M
c
Za

Zac Martin, [email protected],

205
 18 ENGINE

– Insert the new cold bearings in the bearing seats of the heated
section of the engine case; if necessary, use a suitable press-
ing tool to push them all the way in and make them flush.

Info
When pressing in, ensure that the section of the engine
case lies flat in order to prevent damage.
Only press the bearings in using the outer bearing race;
otherwise, the bearings will be damaged when they are
pressed in.

– After the section of the engine case 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 replaced.

52
–

73
Position radial shaft seal ring 1 for the crankshaft on special
tool2 .

01
B04439-10

8/
Pressing tool (50429005000) ( p. 376)

21
– Press in the radial shaft seal ring of the crankshaft from the

16
outside to the inside with the open side facing inward.
–

l.c r:
6.

,0
Mount lock ring

ai d fo
om
– Press in radial shaft seal ring 3
of the shift shaft so it is
flush with the open side facing inward.
gm e
@ ens

– Press in radial shaft seal ring 4

of the countershaft so it is
flush with the open side facing in.
tin ic

– Press in radial shaft seal ring 5

of the balancer shaft so it is
ar | L

flush with the open side facing in.

lm r
ie fü
an ert

B04440-10
yd zi

18.7.3 Removing the crankshaft bearing inner race

ar en

– Fixate the crankshaft in the vice with special tool 1.

ch Liz

Guideline
Use soft jaws.

Separator plate (54829009000) ( p. 377)

za

– Warm up special tool 2.

,
in

Guideline
t

180 °C (356 °F)

ar

B04438-10
M

Puller (58429037043) ( p. 379)

c

–
Za

Push the warmed up special tool 2onto the crankshaft bear-

ing inner race, press firmly together, and pull jointly from the
crankshaft.
Zac Martin, [email protected],

206
 ENGINE 18

18.7.4 Installing the crankshaft bearing inner race

– Fixate the crankshaft in the vice with special tool 1.
Guideline
Use soft jaws.

Separator plate (54829009000) ( p. 377)

– Heat the crankshaft bearing inner race in special tool 2 and
mount together.
Guideline
B04438-10
120 °C (248 °F)

Puller (58429037043) ( p. 379)

– Ensure that the new crankshaft bearing inner race is flush.

52
18.7.5 Changing the connecting rod, conrod bearing, and crank pin

73
Main work

01
– Position crankshaft 1 in the press using special tool 2.

8/
Separator plate (54829009000) ( p. 377)

21
–

16
Press the crank pin out of the upper crankweb with a suitable
tool.

l.c r:
,0
ai d fo
om
Info
Hold the lower crankweb.
gm e
@ ens
312225-10
– Remove the connecting rod and bearing.
tin ic

– Press the crank pin out of the lower crankweb.

ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

312226-10

– Lubricate the new crank pin 3 and push in up to the stop.

, za
tin
ar
M
c
Za

312219-10
Zac Martin, [email protected],

207
 18 ENGINE

– Mount new bearing 4 with washers 5 and connecting

rod 6
.

Info
Thoroughly oil the bearing.

312220-10

– Position special tool 7 on the press.

Crankshaft pressing tool (75029047000) ( p. 382)
Insert for crankshaft pressing tool (54829108000)
( p. 377)
– Insert the crankweb with the connecting rod and bearing. Posi-

52
tion the second crankweb.

73
01
312227-10

8/
– Position special tool 8 with the heel pointing down.

21
Insert for crankshaft pressing tool (54829108000)

16
( p. 377)

l.c r:
,0
–

ai d fo
Press in the upper crankweb as far as possible.

om
Info
gm e
@ ens

The press mandrel must be positioned over the crank

pin.
tin ic

312228-10
– Take the crankshaft out of the special tool and check that the
ar | L

connecting rod can move freely.

lm r

– A
ie fü

Measure axial play between the connecting rod and the

crankwebs using the special tool.
an ert

Feeler gauge (59029041100) ( p. 381)

yd zi
ar en

Connecting rod - axial play of 0.60 … 0.70 mm (0.0236

lower conrod bearing … 0.0276 in)
ch Liz

» If the measured value is less than the specification:

– Correct it so the dimension is equal to the specified
B04452-10 value.
za

Finishing work
– Check the crankshaft run-out at the bearing pin. ( p. 209)
,
in
t
ar
M
c
Za
Zac Martin, [email protected],

208
 ENGINE 18

18.7.6 Checking the crankshaft run-out at the bearing pin

– Position the crankshaft on a roller block.
– Turn the crankshaft slowly.
– Check the crankshaft run-out on both bearing pins.
Crankshaft - run-out at bear- ≤ 0.03 mm (≤ 0.0012 in)
ing pin
» If the crankshaft run-out at the bearing pin is larger than
the specification:
– Align the crankshaft.
B04454-10

18.7.7 Checking/measuring the cylinder

– Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:

52
– Change the cylinder and piston.

73
– Measure the bore diameter at several locations on
‑ and ‑axes using a micrometer to identify oval wear.

01
the X Y
Guideline

8/
21
Cylinder - drill hole diameter (All 250 models)

16
Size I 66.400 … 66.412 mm
(2.61417 … 2.61464 in)

l.c r:
,0
ai d fo
Size II 66.412 … 66.425 mm

om
gm e (2.61464 … 2.61515 in)
Cylinder - drill hole diameter (All 300 models)
@ ens

Size I 72.000 … 72.012 mm

(2.83464 … 2.83511 in)
tin ic

Size II 72.012 … 72.025 mm

ar | L

(2.83511 … 2.83562 in)

lm r
ie fü

Info
an ert

T03855-10
The cylinder size 1 is labeled on the right side of the
cylinder.
yd zi
ar en

– Using a straightedge and the special tool, check the sealing

ch Liz

surface of the cylinder head for distortion.

Feeler gauge (59029041100) ( p. 381)

Cylinder/cylinder head - dis- ≤ 0.10 mm (≤ 0.0039 in)

tortion of sealing surface
za

» If the measured value does not meet specifications:

,
in

– Change the cylinder.

t
ar

T03856-10
M
c
Za

Zac Martin, [email protected],

209
 18 ENGINE

18.7.8 Cleaning the pressure sensor cylinder connection

– Clean pressure connection 1thoroughly and blow out with
compressed air.

R02885-10

18.7.9 Removing the exhaust control

(All 250 models)
– Remove screw 1.

52
73
01
8/
21
16
D07463-10

l.c r:
,0
– Remove screw 2 with the bushing and spring.
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü

D07465-10
an ert

– Remove adjusting lever 3 and thrust bearing 4 with

yd zi

bushing 5 .
ar en
ch Liz
za

D07466-10
,
in

– Take off gear segment 6.

t
ar
M
c
Za

D07468-10
Zac Martin, [email protected],

210
 ENGINE 18

– Remove screw 7.
– Take off the retaining bracket.

D07445-10

– Remove control shaft 8.

52
73
01
D07469-10

8/
– Remove screw 9 with the washer.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

D07470-10
ar | L

– Take off gear segment bk.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

D07471-10

– Remove screw bl.

za

– Take off the retaining bracket.

,
in
t
ar
M
c
Za

D07447-10
Zac Martin, [email protected],

211
 18 ENGINE

– Remove control shaft bm.

D07472-10

– Remove screws bn.

– Take off the exhaust flange.

52
73
01
G04047-10

8/
– Remove O-rings bo.

21
– Remove the control flap evenly from the grooves on both

16
sides.

l.c r:
,0
ai d fo
Info

om
If the control flap is wedged, the cylinder may be
gm e
damaged.
@ ens
tin ic

D07449-10
ar | L

(All 300 models)

– Remove screw 1.
lm r
ie fü
an ert
yd zi
ar en
ch Liz

G04037-10

– Remove screw 2 with the bushing and spring.

, za
in
t
ar
M
c
Za

G04038-10
Zac Martin, [email protected],

212
 ENGINE 18

– Remove adjusting lever 3 and thrust bearing 4 with

bushing 5 .

G04039-10

– Take off gear segment 6.

52
73
01
G04040-10

8/
– Remove screws 7.

21
– Take off the retaining bracket.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G04041-10
ar | L

– Remove control shaft 8.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

G04042-10

– Remove screw 9 with the washer.

, za
in
t
ar
M
c
Za

G04043-10
Zac Martin, [email protected],

213
 18 ENGINE

– Take off gear segment bk.

G04044-10

– Remove screws bl.

– Take off the retaining bracket.

52
73
01
G04045-10

8/
– Remove control shaft bm.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G04046-10
ar | L

– Remove screws bn.

lm r

– Take off the exhaust flange.

ie fü
an ert
yd zi
ar en
ch Liz

G04047-10

– Remove O-rings bo.

za

– Take off the control flap.

,
tin
ar
M
c
Za

G04048-10

18.7.10 Checking the exhaust control

Condition
Zac Martin, [email protected],

The exhaust control and the centrifugal force controller are removed.

214
 ENGINE 18

52
73
01
G04036-10

8/
– Check control shafts 1 for damage and wear.

21
» If there is damage or wear:

16
– Change the control shaft.

l.c r:
,0
– Check gear segments 2 for damage and wear.

ai d fo
om
» If there is damage or wear:
–
gm e
Change the gear segments.
@ ens

– Check bearing sleeves 3 for damage and wear.

» If there is damage or wear:
tin ic

– Change the bearing sleeves.

ar | L

– Check control flap 4 for damage and wear.

lm r
ie fü

» If there is damage or wear:

– Change the control flap.
an ert

– Check spring 5 for damage and wear.

yd zi
ar en

» If there is damage or wear:

– Change the spring.
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

215
 18 ENGINE

52
73
01
R04649-10

8/
– Check pins 6 of the control lever for damage and wear.

21
» If there is damage or wear:

16
– Change the control lever.

l.c r:
,0
– Check ball head 7 on the linkage for damage and wear.

ai d fo
om
» If there is damage or wear:
–
gm e
Change the linkage.
@ ens

– Check centrifugal force controller 8 for damage and wear.

» If there is damage or wear:
tin ic

– Change centrifugal force controller.

ar | L

– Check axial bearing 9 for damage and wear.

lm r
ie fü

» If there is damage or wear:

– Change the axial bearing.
an ert
yd zi
ar en

18.7.11 Installing the exhaust control

ch Liz

(All 250 models)

– Mount and grease O-rings 1.
Long-life grease ( p. 372)
,za
t in
ar
M

D04837-10
c
Za
Zac Martin, [email protected],

216
 ENGINE 18

– Mount the control shafts.

The control shaft with marking L is installed on the
left.

D07473-10

– Mount the retaining brackets.

– Mount and tighten screws 2.
Guideline
Screw, retain- M5 6 Nm (4.4 lbf ft)
ing bracket of Loctite®2701™
exhaust control

52
73
01
D07451-10

8/
– Mount and grease O-rings 3.

21
Long-life grease ( p. 372)

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

D04839-10
ar | L

– Mount and grease bearing sleeves 4.

lm r

Long-life grease (
ie fü

p. 372)
an ert
yd zi
ar en
ch Liz

D04838-10

– Set the control flap to the open position in the grooves.

–
za

Mount O-rings 5.
,
in
t
ar
M
c
Za

D07449-11
Zac Martin, [email protected],

217
 18 ENGINE

– Degrease the sealing surface and coat thinly with sealing

compound.
Loctite® 5910
– Position the exhaust flange.
The control flap is still in the open position.
– Mount and tighten screws 6.
Guideline
G04047-11 Screw, exhaust M6 8 Nm (5.9 lbf ft)
flange

Info
Do not forget the spring hangers.

– Position gear segment 7.

52
73
01
8/
21
16
l.c r:
,0
D07468-11

ai d fo
om
– Position adjusting lever 8 and thrust bearing 9 with
bushing bk .
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in

D07467-10
t
ar
M
c
Za
Zac Martin, [email protected],

218
 ENGINE 18

– Position the spring with the short leg toward the outside.
– Mount screw bl with the bushing and spring but do not
tighten yet.
Guideline
Screw, control M6 10 Nm (7.4 lbf ft)
flap, exhaust Loctite®243™
control
– Attach the spring.
The short leg of spring A rests on the right on top
pin B .
The long leg of spring C rests on the left on bottom
pin D .
– Tighten the screw.
Guideline
Screw, control M6 10 Nm (7.4 lbf ft)

52
flap, exhaust Loctite®243™

73
control

01
D07464-10

8/
– Mount screw bm, but do not tighten yet.

21
16
Info

l.c r:
,0
The screw is tightened when the Z-distance is

ai d fo
adjusted.

om
gm e
@ ens
tin ic

D07463-11
ar | L

– Position gear segment bn.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

D07471-11

– Mount and tighten screw bo with the washer.

za

Guideline
Screw, control M6 10 Nm (7.4 lbf ft)
,
in

flap, exhaust Loctite®243™

t
ar

control
M
c
Za

D07470-11
Zac Martin, [email protected],

219
 18 ENGINE

(All 300 models)

– Mount and grease O-rings 1.
Long-life grease ( p. 372)

D04837-10

– Mount the control shafts.

The control shaft with marking L is installed on the
left.

52
73
01
G04050-10

8/
– Mount the retaining brackets.

21
– Mount and tighten screws 2.

16
Guideline

l.c r:
,0
Screw, retain- M5 6 Nm (4.4 lbf ft)

ai d fo
om
ing bracket of Loctite®2701™
exhaust control
gm e
@ ens
tin ic

G04049-10
ar | L

– Mount and grease O-rings 3.

lm r
ie fü

Long-life grease ( p. 372)

an ert
yd zi
ar en
ch Liz

D04839-10

– Mount and grease bearing sleeves 4.

za

Long-life grease ( p. 372)

,
in
t
ar
M
c
Za

D04838-10
Zac Martin, [email protected],

220
 ENGINE 18

– Set the control flap to the open position.

– Mount O-rings 5.

G04048-11

– Degrease the sealing surface and coat thinly with sealing

compound.
Loctite® 5910
– Position the exhaust flange.
The control flap is still in the open position.

52
– Mount and tighten screws 6.

73
Guideline

01
G04047-11 Screw, exhaust M6 8 Nm (5.9 lbf ft)
flange

8/
21
Info

16
Do not forget the spring hangers.

l.c r:
,0
ai d fo
om
– Position gear segment
gm e 7.
@ ens
tin ic
ar | L
lm r
ie fü
an ert

G04040-11
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za

Zac Martin, [email protected],

221
 18 ENGINE

– Position adjusting lever 8 and thrust bearing 9 with

bushing bk .

52
73
01
G04051-10

8/
– Position the spring with the short leg toward the outside.

21
– Mount screw bl with the bushing and spring but do not

16
tighten yet.

l.c r:
,0
Guideline

ai d fo
om
Screw, control M6 10 Nm (7.4 lbf ft)
flap, exhaust Loctite®243™
gm e
control
@ ens

– Attach the spring.

tin ic

The short leg of spring A rests on the right on top

ar | L

pin B .
lm r

The long leg of spring C rests on the left on bottom

ie fü

pin D .
an ert

– Tighten the screw.

yd zi

Guideline
ar en

Screw, control M6 10 Nm (7.4 lbf ft)

flap, exhaust Loctite®243™
ch Liz

control
G04052-10

– Mount screw bm, but do not tighten yet.

za

Info
,
in

The screw is tightened when the Z-distance is

t

adjusted.
ar
M
c
Za

G04037-11
Zac Martin, [email protected],

222
 ENGINE 18

– Position gear segment bn.

G04044-11

– Mount and tighten screw bo with the washer.

Guideline
Screw, control M6 10 Nm (7.4 lbf ft)
flap, exhaust Loctite®243™
control

52
73
01
G04043-11

8/
21
18.7.12 Cylinder - Nikasil® coating

16
Nikasil® is a surface protection layer for a coating procedure devel-
oped by MAHLE GmbH. The name is derived from the two materi-

l.c r:
,0
als used in this procedure – a layer of nickel into which is embed-

ai d fo
om
ded the particularly hard silicone carbide.
The most important advantages of the Nikasil® coating are very
gm e
good heat conductivity, resulting in much improved performance,
@ ens

low wear, and a lightweight cylinder.

tin ic
ar | L

D04518-10
lm r
ie fü

18.7.13 Checking/measuring the piston

an ert

– Check the piston bearing surface for damage.

yd zi

» If the piston bearing surface is damaged:

ar en

– Replace the piston and, if necessary, the cylinder.

ch Liz

– Check that the piston rings move easily in the piston ring
grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.
za

D04518-10 Tip
,
in

An old piston ring can be used to clean the pis-

t

ton ring groove.

ar
M

– Check the piston rings for damage.

c

» If the piston ring is damaged:

Za

– Change the piston ring.

Info
Mount the piston ring with the marking facing
upward.
Zac Martin, [email protected],

– Check the piston pins for discoloration or signs of wear.

223
 18 ENGINE

» If the piston pin shows severe discoloration/signs of wear:

– Change the piston pin.
– Place the upper conrod bearing and piston pin in the connect-
ing rod and check the seating for play.
» If the piston pin seating has excessive play:
– Change the connecting rod, conrod bearing, and crank
pin.
– Measure the piston at the piston skirt, at right angles to the
piston pin, at a distance .A
Guideline
Distance A 50 mm (1.97 in)
Piston - diameter (All 250 models)
Size I 66.340 … 66.350 mm
(2.61181 … 2.6122 in)
Size II 66.351 … 66.360 mm

52
D06846-10 (2.61224 … 2.61259 in)

73
Piston - diameter (All 300 models)

01
Size I 71.925 … 71.934 mm
(2.83169 … 2.83204 in)

8/
21
Size II 71.935 … 71.944 mm
(2.83208 … 2.83244 in)

16
l.c r:
,0
Info

ai d fo
om
gm e Piston dimensions 1 are marked on the piston head.
@ ens
tin ic

18.7.14 Checking the piston ring end gap

ar | L

– Remove the piston ring from the piston.

– Place the piston ring in the cylinder and align with the piston.
lm r
ie fü

Guideline
an ert

Below the upper edge of the 20 mm (0.79 in)

cylinder
yd zi
ar en

– Measure end gap A with a feeler gauge.

ch Liz

Guideline
Piston ring end gap
D04519-10
Ring 1 ≤ 0.60 mm (≤ 0.0236 in)
Ring 2 ≤ 0.60 mm (≤ 0.0236 in)
za

» If the end gap is greater than the specified value:

,

– Check/measure the cylinder. ( p. 209)

tin

» If cylinder wear lies within the specified tolerance:

ar

– Change the piston ring.

M

– Mount the piston ring with the marking facing toward the pis-
c

ton head.
Za
Zac Martin, [email protected],

224
 ENGINE 18

18.7.15 Measuring the piston/cylinder mounting clearance

– Check/measure the cylinder. ( p. 209)
– Check/measure the piston. ( p. 223)
– The smallest piston/cylinder mounting clearance equals the
smallest cylinder bore diameter minus the largest piston diam-
eter. The largest piston/cylinder mounting clearance equals the
largest cylinder bore diameter minus the smallest piston diam-
eter.
Guideline
Piston/cylinder - mounting clearance (All 250 models)
D04518-10
New condition 0.050 … 0.074 mm
(0.00197 … 0.00291 in)
Wear limit 0.10 mm (0.0039 in)
Piston/cylinder - mounting clearance (All 300 models)
New condition 0.066 … 0.088 mm

52
(0.0026 … 0.00346 in)

73
Wear limit 0.10 mm (0.0039 in)

01
8/
21
18.7.16 Disassemble the reed valve housing

16
– Remove screws 1.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

311407-10
lm r
ie fü

– Remove the reed valve housing 2 from the support plate.

an ert
yd zi
ar en
ch Liz

311409-10
za

– Remove screws 3 on both sides.

,
in

– Take off clamping plate 4 on both sides.

t
ar

– Remove the outer reed valve 5 on both sides.

M
c
Za

G01317-10
Zac Martin, [email protected],

225
 18 ENGINE

– Remove screws 6.
– Separate the reed valve holders. Remove holding strip 7.

G01318-10

– Take off the inner reed valve 8 from both reed valve holders.

52
73
01
G01319-10

8/
21
18.7.17 Checking the reed valve housing, reed valve and intake flange

16
Condition
Reed valve housing has been removed.

l.c r:
,0
ai d fo
– Check intake flange 1 for damage and wear.

om
» If there is damage or wear:
gm e
@ ens

– Change the intake flange.

– Check reed valve 2 for damage and wear.
tin ic

» If there is damage or wear:

ar | L

– Change the reed valve.

lm r

– Check the reed valve housing for damage and wear.

ie fü

» If there is damage or wear:

an ert

– Change the reed valve housing.

yd zi
ar en
ch Liz
, za
in

308688-10
t
ar
M
c
Za
Zac Martin, [email protected],

226
 ENGINE 18

18.7.18 Assembling the reed valve housing

– Position the inner reed valve 1 on both reed valve holders.
The recesses are located on the right side.

G01321-10

– Position holding strip 2.

The holding lugs engage in the drilled holes.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

G01322-10
lm r
ie fü

– Position the membrane holder.

an ert
yd zi
ar en
ch Liz

G01323-10
za

– Mount screws 3 and screw in all the way.

,
in

Info
t
ar

Mount the screws at right angles to prevent damage.

M

–
c

Loosen screws 3 and tighten again.

Za

Guideline
Screw, inner mem- EJOTDELTA PT® 1 Nm (0.7 lbf ft)
brane sheets 35x25
G01324-10

Distance A is equal on both sides.

Zac Martin, [email protected],

227
 18 ENGINE

– Position the outer reed valve 4 on both sides.

The recesses are located on the right side.

G01328-10

– Position the clamping plates on both sides.

After installation, the TOP marking must be visible as
shown.
– Mount screws 5 on both sides and screw in all the way.
– Loosen screws 5 and tighten again.
Guideline

52
Screw, outer mem- EJOTDELTA PT® 1 Nm (0.7 lbf ft)

73
brane sheets 30x6

01
G01326-11

8/
– Position gasket 6.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

311410-10
ar | L

– Position the reed valve housing in the support plate.

lm r

The outer recess is located on the right in the direction of

ie fü

travel when installed.

an ert

– Mount and tighten screws 7.

yd zi

Guideline
ar en

Screw, membrane EJOTDELTA PT® 1 Nm (0.7 lbf ft)

support plate 30x12
ch Liz

311407-11

18.7.19 Working on the clutch cover

za

Info
,
in

Remove the outer clutch cover to avoid damage.

t
ar
M
c
Za
Zac Martin, [email protected],

228
 ENGINE 18

– Remove nut 1.
– Take off the water pump impeller.

G03947-10

– Remove form washer 2.

52
73
01
G03948-10

8/
– Remove centrifugal force controller 3.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03949-10
ar | L

– Remove radial shaft seal ring 4.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

G03950-10

– Press out bearing 5 toward the inside.

za

– Press the new bearing all the way in to the stop from the
inside.
,
in
t
ar
M
c
Za

G03951-10
Zac Martin, [email protected],

229
 18 ENGINE

– Press in the new radial shaft seal ring 4 so that it is flush.

– Ensure that the bearing can turn freely and does not touch the
radial shaft seal ring.

G03950-10

– Mount centrifugal force controller 3.

52
73
01
G03949-10

8/
– Position form washer 2.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03948-10
ar | L

– Mount the water pump impeller.

–
lm r

Mount and tighten nut 1.

ie fü

Guideline
an ert

Cap nut, water M6 5 Nm (3.7 lbf ft)

yd zi

pump impeller Loctite®243™

ar en
ch Liz

G03947-10
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

230
 ENGINE 18

18.7.20 Checking the clutch

52
73
01
8/
21
304690-10

– Check clutch throw-out 1 for damage and wear.

16
» If there is damage or wear:

l.c r:
,0
ai d fo
– Change the clutch push rod.

om
– Place the clutch push rod 2 on a flat surface and check for run-out.
gm e
» If there is run-out:
@ ens

– Change the clutch push rod.

tin ic

– Check spring retainer 3 for damage and wear.

ar | L

» If there is damage or wear:

– Change the spring retainer.
lm r
ie fü

– Check pretension ring 4 for damage and wear.

an ert

» If there is damage or wear:

yd zi

– Change the pretension ring.

ar en

– Check spring washer 5 for damage and wear.

ch Liz

» If there is damage or wear:

– Change the spring washer.
– Check the contact surface of clutch pressure cap 6 for damage and wear.
» If there is damage or wear:
za

– Change the clutch pressure cap.

,

– Check clutch center 7 for damage and wear.

tin

» If there is damage or wear:

ar

– Change the clutch center.

M

– Check damping rubber pieces 8 for damage and wear.

c
Za

» If there is damage or wear:

– Change the damping rubber pieces.
– Check inner clutch hub 9 for damage and wear.
» If there is damage or wear:
– Change the inner clutch hub.
Zac Martin, [email protected],

– Check the thrust surfaces of the clutch facing discs in clutch basket bk for damage and wear.

231
 18 ENGINE

» If there is damage or wear:

– Change the clutch facing discs and the clutch basket.
– Check needle bearing bl and collar bushing bm for damage and wear.
» If there is damage or wear:
– Change the needle bearing and collar bushing.
– Check intermediate discs bn for damage and wear.
» If the intermediate discs are not flat or have punctiform outbreaks:
– Change all intermediate discs.
– Check clutch facing discs bo for discoloration and scoring.
» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs bo.
Clutch facing disc - thickness ≥ 1.9 mm (≥ 0.075 in)

52
» If the clutch facing disc does not meet specifications:
– Change all clutch facing discs.

73
01
8/
18.7.21 Preassembling shift shaft

21
– Secure the short end of the shift shaft in the bench vise.

16
Guideline

l.c r:
,0
Use soft jaws.

ai d fo
om
– Mount sliding plate 1 with the guide pin facing downward
gm e
and put the guide pin on the shift quadrant.
@ ens

– Mount pressure spring 2.

–
tin ic

Slide on spring guide 3, push return spring 4, with the off-

set end facing upward, over the spring guide and lift the offset
ar | L

312211-10
end over abutment bolt 5 .
lm r

–
ie fü

Mount stop disk 6.

an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za
Zac Martin, [email protected],

232
 ENGINE 18

18.7.22 Checking the shift mechanism

52
73
01
8/
21
B04450-10

– Check shift forks 1 on plate A for damage and wear (visual check).

16
» If there is damage or wear:

l.c r:
,0
ai d fo
– Change the shift fork.

om
– Check shift grooves B of shift drum 2 for wear.
gm e
» If the shift groove is worn:
@ ens

– Change the shift drum.

tin ic

– Check the seat of the shift drum in bearings 3.

ar | L

» If the shift drum is not seated correctly:

– Change the shift drum and/or the bearing.
lm r
ie fü

– Check bearing 3 for stiffness and wear.

an ert

» If the bearings are stiff or are worn:

yd zi

– Change the bearings.

ar en

– Check the shift rollers for damage and wear.

ch Liz

» If there is damage or wear:

– Change the shift rollers.
– Check shift rail 4 for run-out on a flat surface.
» If there is run-out:
za

– Change the shift rail.

–
,

Check the shift rails for scoring, wear and smooth operation in the shift forks.
in

» If there is scoring or corrosion, or if the shift rail in the shift forks is stiff:
t
ar

– Change the shift rail.

M

– Check sliding plate 5 in contact areas C for wear.

c

» If the sliding plate is worn:

Za

– Change the sliding plate.

– Check return surface D on the sliding plate for wear.
» If deep notches are present:
– Change the sliding plate.
Zac Martin, [email protected],

– Check guide pin E for looseness and wear.

233
 18 ENGINE

» If the guide pin is loose and/or worn:

– Change the sliding plate.

– Preassemble the shift shaft. ( p. 232)

– Check clearance F between the sliding plate and the shift
quadrant.
Shift shaft - sliding 0.40 … 0.80 mm (0.0157
plate/shift quadrant play … 0.0315 in)
» If the measured value does not meet specifications:
– Change the sliding plate.

312212-10

18.7.23 Disassembling the main shaft

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert

B04445-12
yd zi

– Secure the main shaft with the toothed end facing downward in the vise.
ar en

Guideline
ch Liz

Use soft jaws.

– Remove stop disk 1 and second-gear fixed gear 2.
– Remove fifth-gear idler gear3 and needle bearing 4.
– Remove stop disk 5.
za

– Remove lock ring 6.

,
in

– Remove third/fourth-gear sliding gear 7.

t
ar

– Remove lock ring 8.

M

– Remove stop disk 9.

c

– Remove sixth-gear idler gear bk.

Za

– Remove needle bearing bl.

Zac Martin, [email protected],

234
 ENGINE 18

18.7.24 Disassembling the countershaft

52
73
01
8/
21
B04446-10

– Secure the countershaft in the bench vise with the toothed end facing downward.

16
Guideline

l.c r:
,0
ai d fo
Use soft jaws.

om
– Remove stop disk 1 and first-gear idler gear 2.
gm e
@ ens

– Remove needle bearing 3 and stop disk 4.

– Remove sixth-gear sliding gear 5.
tin ic

– Remove lock ring 6.

ar | L

– Remove stop disk 7.

lm r
ie fü

– Remove third-gear idler gear 8 and needle bearing 9.

– Remove fourth-gear idler gear bk.
an ert

– Remove needle bearing bl.

yd zi
ar en

– Remove stop disk bm and lock ring bn.

–
ch Liz

Remove fifth-gear sliding gear bo.

– Remove lock ring bp.
– Remove stop disk bq.
– Remove second-gear idler gear br and needle bearing bs.
, za
in

18.7.25 Checking the transmission

t
ar

Condition
M

The transmission has been disassembled.

c
Za

Zac Martin, [email protected],

235
 18 ENGINE

52
73
01
D06845-10

8/
– Check needle bearings 1 for damage and wear.

21
» If there is damage or wear:

16
– Change the needle bearings.

l.c r:
,0
– Check the pivot points of main shaft 2 and countershaft 3 for damage and wear.

ai d fo
om
» If there is damage or wear:
–
gm e
Change the main shaft and/or countershaft.
@ ens

– Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
» If there is damage or wear:
tin ic

– Change the main shaft and/or countershaft.

ar | L

– Check the pivot points of idler gears 4 for damage and wear.
lm r
ie fü

» If there is damage or wear:

– Change the gear wheel pair.
an ert

– Check the shift dogs of idler gears 4 and sliding gears 5 for damage and wear.
yd zi
ar en

» If there is damage or wear:

– Change the gear wheel pair.
ch Liz

– Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
» If there is damage or wear:
– Change the gear wheel pair.
–
za

Check the tooth profiles of sliding gears 5 for damage and wear.
» If there is damage or wear:
,
in

– Change the gear wheel pair.

t
ar

– Check sliding gears 5 for smooth operation in the profile of main shaft 2.
M

» If the sliding gear does not move freely:

c

– Change the sliding gear or the main shaft.

Za

– Check sliding gears 5 for smooth operation in the profile of countershaft 3.

» If the sliding gear does not move freely:
– Change the sliding gear or the countershaft.
– Check stop disks 7 for damage and wear.
Zac Martin, [email protected],

» If there is damage or wear:

– Change the stop disks.

236
 ENGINE 18

– Use new lock rings 8 with every repair.

18.7.26 Assembling the main shaft

Info
Use new lock rings with every repair.

Preparatory work
– Check the transmission. ( p. 235)
– Carefully lubricate all parts before assembling.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

B04445-11
lm r
ie fü

Main work
– Secure the main shaft in the vise with the gear teeth facing downward.
an ert

Guideline
yd zi

Use soft jaws.

ar en

–
ch Liz

Mount needle bearing 1.

– Mount sixth-gear idler gear 2.
– Mount stop disk 3 and lock ring 4.
– Mount third/fourth-gear sliding gear 5.
za

– Mount lock ring 6 and stop disk 7.

,

–
in

Mount needle bearing 8.

t

– Mount fifth-gear idler gear 9.

ar

–
M

Mount second-gear fixed gear bk and stop disk bl.

– Finally, check all the gear wheels for smooth operation.
c
Za

Zac Martin, [email protected],

237
 18 ENGINE

18.7.27 Assembling the countershaft

Info
Use new lock rings with every repair.

Preparatory work
– Check the transmission. ( p. 235)
– Carefully lubricate all parts before assembling.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens

B04446-11
tin ic

Main work
ar | L

– Secure the countershaft in the bench vise with the toothed end facing downward.
lm r

Guideline
ie fü

Use soft jaws.

an ert

– Mount needle bearing 1 and second-gear idler gear 2 onto the countershaft with the protruding collar fac-
yd zi

ing downward.
ar en

– Mount stop disk 3 and lock ring 4.

ch Liz

– Mount fifth-gear sliding gear 5 with the shift groove facing up.
– Mount lock ring 6 and stop disk 7.
– Mount needle bearing 8 and fourth-gear idler gear 9.
– Mount needle bearing bk.
za

– Mount third-gear idler gear bl.

,
in

– Mount stop disk bm and lock ring bn.

t
ar

– Mount sixth-gear sliding gear bo with the shift groove facing downward.
M

– Mount stop disk bp.

c

– Mount needle bearing bq and first-gear idler gear br.

Za

– Mount stop disk bs.

– Finally, check all the gear wheels for smooth operation.
Zac Martin, [email protected],

238
 ENGINE 18

18.7.28 Checking the electric starter drive

Condition
Bendix has been removed.

52
73
01
8/
21
16
l.c r:
,0
D04546-10

ai d fo
– Check the gear teeth of rotor 1 for damage and wear.

om
» If there is damage or wear:
gm e
–
@ ens
Change the rotor.
– Check the gear teeth and bearing of the Bendix 2 for smooth operation, damage, and wear.
tin ic

» If damaged or worn, or if the Bendix does not move easily:

ar | L

– Change the Bendix.

lm r

– Check gear teeth of starter motor 3 for damage and wear.

ie fü

» If there is damage or wear:

an ert

– Change starter motor.

yd zi

– Connect negative cable of a 12-V power supply to the housing of the starter motor. Connect positive cable of
ar en

the power supply briefly with the connector of the starter motor.
ch Liz

» If the starter motor does not turn when the circuit is closed:
– Change starter motor.

18.8 Assembling the engine

, za
in

18.8.1 Installing the crankshaft

t

–
ar

Mount O-ring 1.
M
c
Za

Zac Martin, [email protected],

B04429-11

239
 18 ENGINE

– Position the right section of the engine case in the engine work
stand.
Engine work stand (61229001000) ( p. 382)
Holder and fitting for work stand (55429002000)
( p. 378)
– Warm up the crankshaft bearing.
Guideline
100 °C (212 °F)
D04496-11
– Slide crankshaft 2 all the way into the bearing seat of the
right section of the engine case.

18.8.2 Installing the transmission shafts

– Oil all bearings.

52
Engine oil (15W/50) ( p. 370)

73
– Assemble the two transmission shafts 1 and slide them into

01
the bearing seats together.

8/
21
16
l.c r:
,0
D04495-11

ai d fo
om
– Mount lock ring 2.
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert

G04009-11
yd zi
ar en

18.8.3 Installing the shift forks

ch Liz

– Arrange shift forks 1, 2, and 3 as shown.

, za
t in
ar
M

B04441-10
c
Za
Zac Martin, [email protected],

240
 ENGINE 18

– Position shift forks 1, 2, and 3 in the sliding gears.

D04493-11

18.8.4 Installing the shift drum

– Push shift drum 1 into the bearing seat.
– Position shift forks 2 in the shift grooves.
Info

52
Do not misplace the shift rollers.

73
01
8/
21
D04492-11

16
18.8.5 Installing the shift rails

l.c r:
,0
ai d fo
– Mount shift rails 1.

om
gm e
@ ens
tin ic
ar | L
lm r
ie fü

D04491-10
an ert

18.8.6 Installing the left section of the engine case

yd zi
ar en

– Clean and degrease the sealing surface.

ch Liz

– Thinly coat the sealing surface A

of the right section of the
engine case with sealing compound.
Loctite® 5910
– Check that dowels 1 are seated correctly.
za
,
t in
ar

D04490-11
M
c
Za

Zac Martin, [email protected],

241
 18 ENGINE

– Mount the left section of the engine case.

Info
Do not use the screws to pull the two sections of the
engine case together.

– Mount screws 2 and, once all screws of the left section of

the engine case have been mounted, tighten.
Guideline
D04488-12 Screw, engine case M6x45 10 Nm (7.4 lbf ft)
– Mount screws 3 and, once all screws of the left section of
the engine case have been mounted, tighten.
Guideline
Screw, engine case M6x60 10 Nm (7.4 lbf ft)
– Secure the engine in the engine work stand.

52
– Grease the radial shaft seal ring and mount distance

73
sleeve4 .

01
8/
21
16
l.c r:
,0
ai d fo
om
D04487-11
gm e
@ ens

18.8.7 Installing the reed valve housing

tin ic

Info
ar | L

If the reed valve housing is removed and installed with the engine installed, the oil pump must be actu-
ated.
lm r
ie fü

– Position the gasket.

an ert

– Position reed valve housing 1 in the engine case opening.

yd zi
ar en
ch Liz
za

D04486-11

– Position the intake flange with the gasket.

,
in

– Mount and tighten screws 2.

t
ar

Guideline
M

Screw, intake M6 6 Nm (4.4 lbf ft)

c

flange/reed valve
Za

housing

D04485-11
Zac Martin, [email protected],

242
 ENGINE 18

18.8.8 Installing the starter motor

– Grease and mount O-ring 1.
Long-life grease ( p. 372)

D04484-11

– Grease O-ring 2.
Long-life grease ( p. 372)
– Position the starter motor in the engine case.

52
73
01
8/
D04483-10

21
– Mount screws 3 but do not tighten yet.

16
l.c r:
Guideline

,0
ai d fo
Screw, starter motor M6 10 Nm (7.4 lbf ft)

om
gm e
@ ens
tin ic
ar | L

G04011-10
lm r
ie fü

– Mount spacer 4 flush in the engine case.

–
an ert

Mount and tighten screw 5.

Guideline
yd zi
ar en

Screw, starter M6 10 Nm (7.4 lbf ft)

motor bearing Loctite®243™
ch Liz

bush

D04549-10
za

– Tighten screws 3.
,
in

Guideline
t

Screw, starter motor M6 10 Nm (7.4 lbf ft)

ar
M
c
Za

G04011-10
Zac Martin, [email protected],

243
 18 ENGINE

– Position cover 6.
– Mount and tighten screw 7.
Guideline
Screw, starter motor M6 8 Nm (5.9 lbf ft)
protection cap

D04478-11

18.8.9 Installing the rotor

– Grease and mount Bendix 1.
Lubricant (T625) ( p. 372)

52
73
01
8/
21
D04477-11

16
– Position the crankshaft speed sensor.

l.c r:
–

,0
Mount and tighten screws 2.

ai d fo
Guideline

om
Screw, M5 6 Nm (4.4 lbf ft)
gm e
crankshaft Loctite®243™
@ ens

speed sensor
tin ic
ar | L

D04476-11
lm r
ie fü

– Ensure that the woodruff key is seated correctly.

an ert

– Degrease the cone.

– Mount the rotor and hold it with special tool 3.
yd zi
ar en

Holding wrench (55429012000) ( p. 378)

ch Liz

– Mount and tighten nut 4 with the washer.

Guideline
Nut, rotor M12x1 60 Nm (44.3 lbf ft)
D04474-11
, za

18.8.10 Installing the locking lever

t in

– 1 with the sleeve and spring 2.

ar

Position locking lever

–
M

Mount and tighten screw 3 with the washer.

c

Guideline
Za

Screw, locking M5 6 Nm (4.4 lbf ft)

lever Loctite®243™
Zac Martin, [email protected],

G04034-10

244
 ENGINE 18

18.8.11 Installing the shift drum locating unit

– Press locking lever 1 to the left and position the shift drum
locating unit.

Info
The flat surfaces A of the shift drum locating unit are
not symmetric.

– Relieve tension from the locking lever.

D04473-10

– Mount and tighten screw 2.

Guideline
Screw, shift M6 10 Nm (7.4 lbf ft)
drum locating Loctite®243™

52
73
01
8/
D04470-11

21
16
18.8.12 Installing the shift shaft

l.c r:
,0
– Slide shift shaft 1 with the washer into the bearing seat.
ai d fo
om
– Push sliding plate 2 away from shift drum locating unit3.
gm e
Insert the shift shaft all the way.
@ ens

– Let the sliding plate engage in the shift drum locating unit.
– Shift through the transmission.
tin ic
ar | L
lm r
ie fü

D04469-11
an ert

18.8.13 Installing the balancer shaft

yd zi
ar en

– Mount balancer shaft 1.

ch Liz
, za
tin

D04465-11
ar
M
c
Za

Zac Martin, [email protected],

245
 18 ENGINE

– Mount woodruff key 2.

G03903-11

– Mount balancer shaft drive wheel 3.

52
73
01
G03939-10

8/
– 4.
Mount primary gear wheel

21
Align markings A and B.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

G03940-10
ar | L

– Hold the primary gear wheel using special tool 5.

lm r
ie fü

Gear segment (56012004000) ( p. 378)

–
an ert

Mount and tighten screw 6 with the washer.

Guideline
yd zi
ar en

Screw, balancer M8 30 Nm (22.1 lbf ft)

shaft Loctite®243™
ch Liz

G03941-10

18.8.14 Installing the clutch basket

za

– Mount collar bushing 1.

,
in

– Oil and mount needle bearing 2.

t
ar

Engine oil (15W/50) ( p. 370)

M
c
Za

G03942-10
Zac Martin, [email protected],

246
 ENGINE 18

– Slide clutch basket 3 onto the gearbox main shaft.

G03945-10

– Slide on washer 4 and inner clutch hub 5.

52
73
01
G03898-11

8/
– Position the new lock washer and mount nut 6
. Tighten the

21
nut, holding the inner clutch hub with a special tool.

16
Guideline

l.c r:
,0
Nut, inner M18x1.5 100 Nm (73.8 lbf ft)

ai d fo
clutch hub Loctite®243™

om
gm e
Holding wrench (51129003000) ( p. 377)
@ ens

– Secure the nut with the lock washer.

tin ic

G03897-11
ar | L

– Hold the primary gear wheel using special tool 7.

lm r

Gear segment (56012004000) (

ie fü

p. 378)
–
an ert

Mount and tighten nut 8 with the washer.

Guideline
yd zi
ar en

Nut, primary M18LHx1.5 150 Nm (110.6 lbf ft)

gear wheel Loctite®243™
ch Liz

– Crank the engine to ensure that it can move easily.

G03944-10

18.8.15 Installing the clutch discs

za

– Thoroughly oil the clutch facing discs.

,
in

– Mount intermediate clutch disc A with marking S.

t
ar

Guideline
M

Thickness of intermediate 1.0 mm (0.039 in)

clutch disc A
c
Za

– Alternately place the clutch facing and 7 intermediate discs

into the clutch basket.
Guideline
311602-10
Thickness of intermediate 1.4 mm (0.055 in)
clutch discs
Zac Martin, [email protected],

247
 18 ENGINE

– Place intermediate clutch disc B into the clutch basket.

Guideline
Thickness of intermediate 1.0 mm (0.039 in)
clutch discB
– Mount clutch throw-out 1.

G03895-11

– Position clutch pressure cap 2.

52
73
01
8/
21
16
l.c r:
,0
G03894-11

ai d fo
om
– Mount pretension ring 3 with marking Top facing up.
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert

G03893-11
yd zi

– Position spring washer 4.

ar en
ch Liz
, za
in

G03892-11
t
ar
M
c
Za
Zac Martin, [email protected],

248
 ENGINE 18

– Position spring retainer 5 with marking I.

G03943-10

– Mount screws 6 and tighten in a crisscross pattern.

Guideline
Screw, clutch spring M5 6 Nm (4.4 lbf ft)
retainer

52
73
01
G03891-11

8/
– Using a straightedge and the special tool, check the spring

21
washer for distortion.

16
Feeler gauge (59029041100) ( p. 381)

l.c r:
,0
ai d fo
Spring washer distortion 0 … 0.10 mm (0 …

om
0.0039 in)
gm e
» If the specified value is not reached:
@ ens

– Remove screws 6 and mount the spring retainer with

marking II.
tin ic

–
ar | L

Using a straightedge and the special tool, check the spring

washer for distortion.
lm r
ie fü

Feeler gauge (59029041100) ( p. 381)

an ert

Spring washer distortion 0 … 0.10 mm (0 …

0.0039 in)
yd zi
ar en

» If the specified value is not reached:

ch Liz

– Remove screws 6 and mount the spring retainer with

marking III.
G03946-10
– Using a straightedge and the special tool, check the spring
washer for distortion.
za

Feeler gauge (59029041100) ( p. 381)

,

Spring washer distortion 0 … 0.10 mm (0 …

in

0.0039 in)
t
ar

» If the specified value is not reached:

M

– Change the clutch facing discs.

c
Za

Zac Martin, [email protected],

249
 18 ENGINE

18.8.16 Installing the clutch cover

– Position the bearing support with the angle lever and the link-
age.
– Mount and tighten screws 1.
Guideline
Screw, exhaust M5 6 Nm (4.4 lbf ft)
control bearing Loctite®243™
support

D04445-11

– Mount dowels 2.
– Mount clutch cover gasket 3.

52
73
01
8/
G03922-10

21
– Position the clutch cover and thread in the linkage.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

E02140-11
lm r
ie fü

– Mount screws 4, but do not tighten yet.

an ert

Guideline
Screw, clutch cover M6x25 10 Nm (7.4 lbf ft)
yd zi
ar en

– Mount screw 5, but do not tighten yet.

ch Liz

Guideline
Screw, clutch cover M6x30 10 Nm (7.4 lbf ft)
– Mount screws 6 and tighten all screws in a crisscross pat-
E02141-10 tern.
za

Guideline
,

Screw, outer clutch M6x60 8 Nm (5.9 lbf ft)

in

cover
t
ar
M
c
Za
Zac Martin, [email protected],

250
 ENGINE 18

– Mount adjusting spring 7 with the auxiliary spring and spring

insert.
Recess A in the spring insert engages in angle lever B.

52
73
01
G03927-10

8/
– Position the cap.

21
– Mount and tighten screws 8.

16
Guideline

l.c r:
,0
Screw, exhaust con- M5 5 Nm (3.7 lbf ft)

ai d fo
om
trol cap gm e
@ ens
tin ic

E02137-11
ar | L

18.8.17 Installing the water pump cover

lm r
ie fü

– Mount the molded ring.

an ert

– Position the water pump cover.

– 1.
yd zi

Mount and tighten screws

ar en

Guideline
ch Liz

Screw, water pump M6 10 Nm (7.4 lbf ft)

cover
– Mount and tighten screw 2 with the seal ring.
E02136-11
Guideline
za

Screw, water pump M6 10 Nm (7.4 lbf ft)

cover
,
t in
ar
M

18.8.18 Installing the piston

c
Za

Info
If the piston change is carried out with the engine installed, the oil pump must be actuated.
Zac Martin, [email protected],

251
 18 ENGINE

(All 250 models)

– Oil the upper conrod bearing and position it in the con-
necting rod.
– Position the piston.
Piston marking 1 must face the exhaust side.

D04433-10

– Cover the engine case opening with a cloth.

– Slide piston pin 2 into the connecting rod by hand.

52
73
01
D04435-10

8/
(All 300 models)

21
– Oil the upper conrod bearing and position it in the con-

16
necting rod.
–

l.c r:
Position the piston.

,0
ai d fo
Piston marking 1 must face the exhaust side.

om
gm e
@ ens
tin ic

D04434-10
ar | L

– Cover the engine case opening with a cloth.

–
lm r

Slide piston pin 2 into the connecting rod by hand.

ie fü
an ert
yd zi
ar en
ch Liz

D04436-10

– Position the piston ring locks in the 6 o'clock or 12 o'clock

position.
za

– Ensure that the piston ring lock is in the correct position on

,

both sides.
in
t

– Remove the cloth.

ar
M
c
Za

302973-10
Zac Martin, [email protected],

252
 ENGINE 18

18.8.19 Installing the cylinder

Info
If the cylinder change is carried out with the engine installed, the oil pump must be actuated.

(All 250 models)

– Place new cylinder base gasket 1 in position.
Info
If neither the piston, cylinder, crankshaft, or engine
case need to be changed, the same gasket thick-
ness can be used as before.

– Oil the cylinder and piston.

D04417-12

– Position the piston ring.

52
The anti-rotation lock engages in piston ring end 2.

73
01
8/
21
16
l.c r:
,0
ai d fo
D04420-10

om
– Slide the cylinder over the piston.
gm e
@ ens

– Push the cylinder down carefully.

tin ic
ar | L
lm r
ie fü
an ert

T03842-10
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

253
 18 ENGINE

– Mount nuts 3 on both sides and tighten in a crisscross

pattern.
Guideline
Nut, cylinder base M10 35 Nm
(25.8 lbf ft)

52
73
01
T03843-10

8/
(All 300 models)

21
– Place new cylinder base gasket 1 in position.

16
l.c r:
Info

,0
ai d fo
If neither the piston, cylinder, crankshaft, or engine

om
case need to be changed, the same gasket thick-
gm e
ness can be used as before.
@ ens

– Oil the cylinder and piston.

tin ic

D04425-11
ar | L

– Position the piston ring.

lm r

The anti-rotation lock engages in piston ring end 2.

ie fü
an ert
yd zi
ar en
ch Liz

D04426-10

– Slide the cylinder over the piston.

za

– Push the cylinder down carefully.

,
in
t
ar
M
c
Za

G04054-10
Zac Martin, [email protected],

254
 ENGINE 18

– Mount nuts 3 on both sides and tighten in a crisscross

pattern.
Guideline
Nut, cylinder base M10 35 Nm
(25.8 lbf ft)

52
73
01
T03844-10

8/
21
18.8.20 Checking the X-distance

16
Info

l.c r:
,0
The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and

ai d fo
om
the piston is at top dead center.
The X-distance must be checked very carefully. If the X-distance is too large, the compression ratio
gm e
decreases and the engine loses power. If the X-distance is too small, the engine knocks and overheats.
@ ens

(All 250 models)

tin ic

– Apply special tool

ar | L

1 to the cylinder.
Setting gauge (54829001100) ( p. 377)
lm r
ie fü

– Position the piston at top dead center.

an ert

– Check the X-distance using the special tool.

yd zi

Feeler gauge (59029041100) ( p. 381)

ar en

X distance (upper edge of 0 … 0.10 mm (0 …

ch Liz

T03845-10
piston to upper edge of 0.0039 in)
cylinder)
» If the specified value is not reached:
– Adjust the X-distance. ( p. 256)
za

(All 300 models)

,
in

– Apply special tool 1 to the cylinder.

t
ar

Setting gauge (54829001100) ( p. 377)

M

– Position the piston at top dead center.

c

– Check the X-distance using the special tool.

Za

Feeler gauge (59029041100) ( p. 381)

X distance (upper edge of 0 … 0.10 mm (0 …

G04055-10
piston to upper edge of 0.0039 in)
cylinder)
Zac Martin, [email protected],

255
 18 ENGINE

» If the specified value is not reached:

– Adjust the X-distance. ( p. 256)

18.8.21 Adjusting the X-distance

Info
The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses.

Preparatory work
– Check the X-distance. ( p. 255)
Main work
(All 250 models)
– Remove nuts 1.
– Carefully slide the cylinder up and take it off.

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L

T03846-10
lm r
ie fü

– Replace cylinder base gasket 2 with a cylinder base gas-

ket of the required X-distance.
an ert
yd zi

Info
ar en

Multiple cylinder base gaskets can be combined.

ch Liz

D04417-11
, za
t in
ar
M
c
Za
Zac Martin, [email protected],

256
 ENGINE 18

(All 300 models)

– Remove nuts 1.
– Carefully slide the cylinder up and take it off.

52
73
01
T03847-10

8/
– Replace cylinder base gasket 2 with a cylinder base gas-

21
ket of the required X-distance.

16
l.c r:
Info

,0
ai d fo
Multiple cylinder base gaskets can be combined.

om
gm e
@ ens
tin ic

D04425-12
ar | L

Finishing work
– Install the cylinder. (
lm r

p. 253)
ie fü
an ert

18.8.22 Adjusting the Z-distance

yd zi
ar en

Info
ch Liz

The Z-distance is the distance from the lower edge of the control flap to the upper edge of the cylinder,
measured in the middle of the exhaust port.

– Counterhold screw 1 and loosen nut 2.

, za
t in
ar
M
c
Za

T03872-10
Zac Martin, [email protected],

257
 18 ENGINE

– Adjust the Z-distance using the depth micrometer.

Guideline
Z distance (height of control 49.0 mm (1.929 in)
flap) (All 250 models)
Z distance (height of control 49.5 mm (1.949 in)
flap) (All 300 models)
– Move control flap 3 up and position the depth micrometer.
D04520-10

– Adjust the Z-distance by turning screw 1.

– Hold screw 1 and tighten nut 2.
Guideline
Nut, adjusting screw, M6 8 Nm (5.9 lbf ft)
power valve

52
– Check the Z dimension.

73
Guideline
Z distance (height of control 49.0 mm (1.929 in)

01
T03872-10
flap) (All 250 models)

8/
Z distance (height of control 49.5 mm (1.949 in)

21
flap) (All 300 models)

16
– 4.

l.c r:
Loosen screw

,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü

G03955-10

– 5.
an ert

Mount gasket
– Grease and mount ball socket 6.
yd zi
ar en

Info
ch Liz

The linkage is preset and must not be adjusted.

za

G03952-10
,
in
t
ar
M
c
Za
Zac Martin, [email protected],

258
 ENGINE 18

– Remove vacuum connection 7.

– Mount and tighten appropriate screw A M6.
Guideline
Appropriate screw M6 1 Nm (0.7 lbf ft)
Gear segment is locked.

Info
If the screw is tightened to more than 1 Nm, damage
may be caused to the cylinder or to the gear segment.

– Tighten screw 4.
Guideline
Screw, exhaust M6 8 Nm (5.9 lbf ft)
control thrust Loctite®243™
bearing

52
73
01
G03953-10

8/
– Remove appropriate screw A.

21
– Mount and tighten vacuum connection 7.

16
Guideline

l.c r:
,0
ai d fo
Vacuum con- M6 2 Nm (1.5 lbf ft)

om
nection, housing Loctite®243™
breather
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

G03953-11

– Mount retainer 8.
, za
in
t
ar
M
c
Za

G03956-10
Zac Martin, [email protected],

259
 18 ENGINE

– Position the gasket.

– Position both covers.
– Mount and tighten screws 9 and bk.
Guideline
Screw, exhaust con- M5 4 Nm (3 lbf ft)
trol cover

G03957-10

18.8.23 Installing the cylinder head

(All 250 models)
– Mount O-rings 1 and 2.
Info

52
Ensure that the pins are seated correctly.

73
01
8/
21
D04408-11

16
(All 300 models)
– Mount O-rings

l.c r:
1 and 2.

,0
ai d fo
om
Info
gm e
Ensure that the pins are seated correctly.
@ ens
tin ic
ar | L

D04409-11
lm r
ie fü

– Put the cylinder head in place.

an ert

– Mount screws 3 with the washers and tighten them in a

crisscross pattern.
yd zi

Guideline
ar en

Screw, cylinder head M8 27 Nm (19.9 lbf ft)

ch Liz

Info
Use new washers.
G03868-11
za

– Mount and tighten spark plug 4.

,
in

Guideline
t
ar

Spark plug M14x1.25 25 Nm (18.4 lbf ft)

M
c
Za

G03867-11
Zac Martin, [email protected],

260
 ENGINE 18

18.8.24 Installing injection valves

– Position injection valves on both sides.
– Mount and tighten screws 1.
Guideline
Screw, injection M5 5 Nm (3.7 lbf ft)
valve holder Loctite®243™

G03866-10

18.8.25 Installing the alternator cover

– Mount dowels 1and put alternator cover gasket 2 in place.

52
73
01
8/
21
16
G03865-11

l.c r:
,0
– Position the alternator cover.

ai d fo
om
– Mount and tighten screws
gm e 3.
Guideline
@ ens

Screw, alternator M6x20 8 Nm (5.9 lbf ft)

cover
tin ic

–
ar | L

Mount and tighten screws 4.

Guideline
lm r
ie fü

E02135-11
Screw, alternator M6x25 8 Nm (5.9 lbf ft)
cover
an ert
yd zi
ar en

18.8.26 Installing the spacer

ch Liz

– Before mounting, grease spacer 1 in area A and O-ring 2.

Long-life grease ( p. 372)
– Position the O-ring in the cut-out of the spacer.
, za
t in
ar
M

312160-10
c
Za

Zac Martin, [email protected],

261
 18 ENGINE

– Grease the radial shaft seal ring.

Long-life grease ( p. 372)
– Push spacer 1 with the O-ring onto the countershaft with a
twisting motion.
The cut-out with the O-ring must face inward.
The radial shaft seal ring rests against the spacer along its
entire circumference.

E02133-10

18.8.27 Gear oil drain plug, installing

– Mount and tighten gear oil drain plug 1 with the magnet and
a new seal ring.
Guideline
Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft)

52
with magnet

73
01
8/
21
E02132-10

16
18.8.28 Installing the clutch push rod

l.c r:
,0
ai d fo
– Mount clutch push rod 1.

om
gm e
@ ens
tin ic
ar | L
lm r
ie fü

E02131-10
an ert

18.8.29 Installing the shift lever

yd zi
ar en

– Position the shift lever. Mount and tighten screw 1 with the
ch Liz

washers.
Guideline
Screw, shift M6 14 Nm (10.3 lbf ft)
lever Loctite®243™
, za
tin
ar

E02130-10
M
c
Za
Zac Martin, [email protected],

262
 ENGINE 18

18.8.30 Removing the engine from the engine work stand

– Remove the fitting from the special tool.
Holder and fitting for work stand (55429002000)
( p. 378)
– Remove the engine from the engine work stand.

E02129-01

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za

Zac Martin, [email protected],

263
 19 CLUTCH

19.1 Checking/correcting the fluid level of the hydraulic clutch

Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.

Note
Environmental hazard Hazardous substances cause environmental damage.

52
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with

73
the applicable regulations.

01
8/
Info

21
The fluid level rises with increasing wear of the clutch facing discs.

16
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.

l.c r:
,0
ai d fo
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

om
Only use clean brake fluid from a sealed container.
gm e
@ ens

– Move the clutch fluid reservoir mounted on the handlebar to a

horizontal position.
tin ic

– Remove screws 1.
ar | L

– Remove cover 2 with membrane 3.

lm r

– Check the fluid level.

ie fü

Fluid level below container 4 mm (0.16 in)

an ert

rim
yd zi

» If the level of the fluid does not meet specifications:

ar en

E01223-10
– Correct the fluid level of the hydraulic clutch.
ch Liz

Brake fluid DOT 4 / DOT 5.1 ( p. 370)

– Position the cover with the membrane. Mount and tighten the
screws.
za

Info
,

Clean up overflowed or spilled brake fluid immediately

in

with water.
t
ar
M
c
Za
Zac Martin, [email protected],

264
 CLUTCH 19

19.2 Changing the hydraulic clutch fluid

Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.

Note
Environmental hazard Hazardous substances cause environmental damage.

52
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with

73
the applicable regulations.

01
8/
Info

21
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not

16
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

l.c r:
,0
ai d fo
Only use clean brake fluid from a sealed container.

om
–
gm e
Move the clutch fluid reservoir mounted on the handlebar to a
@ ens

horizontal position.
– Remove screws 1.
tin ic

– Take off cover 2 with membrane 3.

ar | L
lm r
ie fü
an ert
yd zi

E01223-10
ar en

– Fill bleeding syringe 4 with the appropriate hydraulic fluid.

ch Liz

Syringe (50329050000) ( p. 376)

Brake fluid DOT 4 / DOT 5.1 ( p. 370)
– On the clutch slave cylinder, remove bleeder protection cap,
release the bleeder screw 5 and mount bleeding syringe 4
.
, za
t in
ar

S04882-10
M
c
Za

Zac Martin, [email protected],

265
 19 CLUTCH

– Now press the fluid into the system until it emerges from the
hole 6 of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir
to prevent overflow.
– Remove the bleeding syringe. Tighten the bleeder screw.
Mount protection cap.
– Correct the fluid level of the hydraulic clutch.
Guideline
E01224-10 Fluid level below container 4 mm (0.16 in)
rim
– Position cover with membrane. Mount and tighten screws.

Info
Clean up overflowed or spilled brake fluid immediately
with water.

52
73
19.3 Checking the clutch

01
8/
Danger

21
Fire hazard Fuel is highly flammable.

16
l.c r:
The fuel in the fuel tank expands when warm and can escape if overfilled.

,0
ai d fo
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

om
– Switch off the engine for refueling.
gm e
@ ens

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
tin ic

– Observe the specifications for refueling.

ar | L

Warning
lm r
ie fü

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid skin, eye and clothing contact with fuel.
an ert

– Immediately consult a doctor if you swallow fuel.

yd zi

– Do not inhale fuel vapors.

ar en

– In case of skin contact, rinse the affected area with plenty of water.
ch Liz

– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
za

Main work
,

– Drain the fuel from the fuel tank into a suitable container.
in

– Lay the vehicle on its side on the work stand.

t
ar
M

Info
c

Cover the components to protect them against damage.

Za

Remaining fuel may flow out of the fuel tank.

R05713-10
Zac Martin, [email protected],

266
 CLUTCH 19

– Detach spring 1.

R05715-10

– Remove screws 2.
– Take off the clutch cover with the gasket.

52
73
01
R05716-10

8/
– Loosen screws 3 in a crisscross pattern and remove them.

21
– Take off spring retainer 4.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05717-10
ar | L

– Take off spring washer 5.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

R05720-10

– Take off pretension ring 6.

, za
in
t
ar
M
c
Za

R05721-10
Zac Martin, [email protected],

267
 19 CLUTCH

– Take off clutch pressure cap 7.

R05722-10

– Take off clutch throw-out 8 with clutch push rod 9.

52
73
01
R05723-10

8/
– Remove sleeves bk.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05724-10
ar | L

– Remove clutch discs bl completely.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

R05725-10

– Bend up the lock washer.

–
za

Hold the inner clutch hub with the special tool. Loosen
nut bm .
,
in

Holding wrench (51129003000) ( p. 377)

t
ar

– Remove the nut with the lock washer.

M
c
Za

R05727-10
Zac Martin, [email protected],

268
 CLUTCH 19

– Take off inner clutch hub bn and washer bo.

Info
The washer usually sticks to the inner clutch hub.

– Take off clutch basket bp.

R05728-10

– Take off needle bearing bq and collar bushing br.

Info
The needle bearing and collar bushing may be in the
clutch basket.

52
73
01
R05729-10

8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

D02006-11

– Check clutch throw-out 8 for damage and wear.

za

» If there is damage or wear:

– Change the clutch throw-out.
,
in

– Place the clutch push rod 9 on a flat surface and check for run-out.
t
ar

» If there is run-out:
M

– Change the clutch push rod.

c

– Check spring retainer 4 for damage and wear.

Za

» If there is damage or wear:

– Change the spring retainer.
– Check pretension ring 6 for damage and wear.
» If there is damage or wear:
Zac Martin, [email protected],

– Change the pretension ring.

– Check spring washer 5 for damage and wear.

269
 19 CLUTCH

» If there is damage or wear:

– Change the spring washer.
– Check the contact surface of clutch pressure cap 7 for damage and wear.
» If there is damage or wear:
– Change the clutch pressure cap.
– Check clutch center bs for damage and wear.
» If there is damage or wear:
– Change the clutch center.
– Check damping rubber pieces bt for damage and wear.
» If there is damage or wear:
– Change the damping rubber pieces.
– Check inner clutch hub bn for damage and wear.
» If there is damage or wear:
– Change the inner clutch hub.

52
– Check the thrust surfaces of the clutch facing discs in clutch basket bp for damage and wear.

73
» If there is damage or wear:

01
– Change the clutch facing discs and the clutch basket.

8/
– Check needle bearing bq and collar bushing br for damage and wear.

21
» If there is damage or wear:

16
– Change the needle bearings and collar bushing.

l.c r:
,0
– Check intermediate clutch discs ck for damage and wear.

ai d fo
om
» If the intermediate clutch discs are not level and are pitted:
–
gm e
Change all intermediate clutch discs.
@ ens

– Check clutch facing discs cl for discoloration and scoring.

» If there is discoloration or scoring:
tin ic

– Change all clutch facing discs.

ar | L

– Check the thickness of clutch facing discs cl.

lm r
ie fü

Clutch facing disc - thickness ≥ 1.9 mm (≥ 0.075 in)

an ert

» If the clutch facing disc does not meet specifications:

yd zi

– Change all clutch facing discs.

ar en

– Mount collar bushing br and needle bearing bq.

ch Liz
, za
t in
ar

R05729-10
M
c
Za
Zac Martin, [email protected],

270
 CLUTCH 19

– Mount clutch basket bp.

– Mount washer bo and inner clutch hub bn.

R05728-10

– Position the new lock washer and mount nut bm. Hold the
inner clutch hub with the special tool and tighten the nut.
Guideline
Nut, inner M18x1.5 100 Nm (73.8 lbf ft)
clutch hub Loctite®243™

52
Holding wrench (51129003000) ( p. 377)

73
– Secure the nut with a lock washer.

01
R05727-10

8/
– Mount sleeves bk.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05726-10
ar | L

– Thoroughly oil the clutch facing discs.

–
lm r

Mount intermediate clutch disc A with marking S.

ie fü

Guideline
an ert

Thickness of intermediate 1.0 mm (0.039 in)

A
yd zi

clutch disc
ar en

– Alternately place the clutch facing and 7 intermediate discs

ch Liz

into the clutch basket.

Guideline
311602-10
Thickness of intermediate 1.4 mm (0.055 in)
clutch discs
za

– Place intermediate clutch disc B into the clutch basket.

Guideline
,
in

Thickness of intermediate 1.0 mm (0.039 in)

t
ar

clutch disc B
M
c
Za

Zac Martin, [email protected],

271
 19 CLUTCH

– Mount clutch throw-out 8 with clutch push rod 9.

R05723-10

– Position clutch pressure cap 7.

52
73
01
R05722-10

8/
– Mount pretension ring 6 with marking Top facing up.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

R05721-10
ar | L

– Position spring washer 5.

lm r
ie fü
an ert
yd zi
ar en
ch Liz

R05720-10

– Position spring retainer 4 with marking I.

za

– Mount screws 3 and tighten in a crisscross pattern.

Guideline
,
in

Screw, clutch spring M5 6 Nm (4.4 lbf ft)

t
ar

retainer
M
c
Za

R05718-10
Zac Martin, [email protected],

272
 CLUTCH 19

– Using a straightedge and the special tool, check the spring

washer for distortion.
Feeler gauge (59029041100) ( p. 381)

Spring washer distortion 0 … 0.10 mm (0 …

0.0039 in)
» If the specified value is not reached:
– Remove screws 3 and mount the spring retainer with
marking II.
– Using a straightedge and the special tool, check the spring
washer for distortion.
Feeler gauge (59029041100) ( p. 381)

Spring washer distortion 0 … 0.10 mm (0 …

0.0039 in)
» If the specified value is not reached:

52
– Remove screws 3 and mount the spring retainer with

73
marking III.

01
R05719-10
– Using a straightedge and the special tool, check the spring

8/
washer for distortion.

21
Feeler gauge (59029041100) ( p. 381)

16
Spring washer distortion 0 … 0.10 mm (0 …

l.c r:
,0
ai d fo
0.0039 in)

om
» If the specified value is not reached:
gm e
– Change the clutch facing discs.
@ ens

– Position the clutch cover with the gasket.

tin ic

– Mount and tighten screws 2.

ar | L

Guideline
lm r

Screw, outer clutch M6 8 Nm (5.9 lbf ft)

ie fü

cover
an ert
yd zi
ar en

R05716-10
ch Liz

– Attach spring 1.
, za
in
t
ar
M

R05715-10
c
Za

Zac Martin, [email protected],

273
 19 CLUTCH

– Place vehicle in upright position and lean on the side stand.

R05714-10

Finishing work
– Check the gear oil level. ( p. 287)

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

274
 WATER PUMP, COOLING SYSTEM 20

20.1 Cooling system

Water pump 1in the engine ensures forced circulation of the
coolant.
The pressure resulting from the warming of the cooling system is
regulated by a valve in radiator cap 2
. This ensures that operat-
ing the vehicle at the specified coolant temperature will not result
in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
S03527-11 The lower the speed, the less the cooling effect. Dirty cooling fins
also reduce the cooling effect.

20.2 Checking the antifreeze and coolant level

Warning

52
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

73
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the

01
cooling system are at operating temperature.

8/
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses

21
or other components of the cooling system.

16
– In the event of scalding, rinse the area affected immediately with lukewarm water.

l.c r:
,0
Warning

ai d fo
om
Danger of poisoning Coolant is harmful to health.
gm e
– Keep coolant out of the reach of children.
@ ens

– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
tin ic

– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
ar | L

– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
lm r
ie fü

– Change clothing if coolant spills onto your clothing.

an ert

Condition
yd zi

The engine is cold.

ar en

– Stand the motorcycle upright on a horizontal surface.

ch Liz

– Remove the radiator cap.

– Check the coolant antifreeze.
−25 … −45 °C (−13 … −49 °F)
za

» If the antifreeze in the coolant does not match the speci-

fied value:
,
in

– Correct the coolant antifreeze.

t

– Check the coolant level in the radiator.

ar

400243-10
M

Coolant level A above the 10 mm (0.39 in)

radiator fins
c
Za

» If the coolant level does not match the specified value:

– Correct the coolant level.
Coolant ( p. 370)
– Mount the radiator cap.
Zac Martin, [email protected],

275
 20 WATER PUMP, COOLING SYSTEM

20.3 Checking the coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning
Danger of poisoning Coolant is harmful to health.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.

52
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.

73
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

01
– Change clothing if coolant spills onto your clothing.

8/
21
Condition

16
The engine is cold.

l.c r:
,0
– Stand the motorcycle upright on a horizontal surface.

ai d fo
– Remove the radiator cap.

om
– Check the coolant level in the radiator.
gm e
@ ens

Coolant level A above the 10 mm (0.39 in)

radiator fins
tin ic

» If the coolant level does not match the specified value:

ar | L

– Correct the coolant level.

lm r
ie fü

400243-10 Coolant ( p. 370)

an ert

– Mount the radiator cap.

yd zi
ar en

20.4 Draining the coolant

ch Liz

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
za

cooling system are at operating temperature.

,

– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
in

or other components of the cooling system.

t
ar

– In the event of scalding, rinse the area affected immediately with lukewarm water.
M
c
Za
Zac Martin, [email protected],

276
 WATER PUMP, COOLING SYSTEM 20

Warning
Danger of poisoning Coolant is harmful to health.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.

Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.

52
– Completely drain the coolant.

73
– Mount and tighten screw 1 with a new seal ring.

01
Guideline

8/
Screw, water pump M6 10 Nm (7.4 lbf ft)

21
cover

16
l.c r:
,0
ai d fo
S03527-10

om
20.5 Refilling with coolant
gm e
@ ens

Warning
tin ic

Danger of poisoning Coolant is harmful to health.

ar | L

– Keep coolant out of the reach of children.

lm r

– Do not allow coolant to come into contact with the skin, the eyes and clothing.
ie fü

– Consult a doctor immediately if coolant is swallowed.

an ert

– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
yd zi

– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
ar en

– Change clothing if coolant spills onto your clothing.

ch Liz

Main work
– Make sure that screw 1 is tightened.
– Position the motorcycle upright.
, za
tin
ar
M
c

S03528-10
Za

Zac Martin, [email protected],

277
 20 WATER PUMP, COOLING SYSTEM

– Pour coolant in up to level A above the radiator fins.

Guideline
10 mm (0.39 in)

Coolant 1.2 l (1.3 qt.) Coolant ( p. 370)

400243-10

– Push protection cap 2 upward over the coolant temperature

sensor.

52
73
01
E00904-10

8/
– Unplug connector 3.

21
– Remove coolant temperature sensor 4with the O-ring and

16
wait until the coolant escapes without bubbles.

l.c r:
,0
– Mount and tighten coolant temperature sensor 4 with the O-

ai d fo
om
ring.
Guideline
gm e
@ ens

Screw, cylinder head M10x1.25 12 Nm (8.9 lbf ft)

temperature sensor
tin ic

E00905-10
– Plug in connector 3.
ar | L

– Position protection cap 2.

lm r
ie fü

– Pour coolant in up to level A above the radiator fins.

an ert

Guideline
10 mm (0.39 in)
yd zi
ar en

Coolant ( p. 370)
ch Liz

400243-10
za

– Mount radiator cap 5.

,
in

Danger
t
ar

Danger of poisoning Exhaust gases are toxic and inhal-

M

ing them may result in unconsciousness and death.

c

– Always make sure there is sufficient ventilation

Za

when running the engine.

– Use effective exhaust extraction when starting or
E00906-10
running the engine in an enclosed space.

– Allow the engine to warm up and cool down again.

Zac Martin, [email protected],

278
 WATER PUMP, COOLING SYSTEM 20

Finishing work
– Check the coolant level. ( p. 276)

20.6 Changing the coolant

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning
Danger of poisoning Coolant is harmful to health.

52
– Keep coolant out of the reach of children.

73
– Do not allow coolant to come into contact with the skin, the eyes and clothing.

01
– Consult a doctor immediately if coolant is swallowed.

8/
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.

21
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

16
– Change clothing if coolant spills onto your clothing.

l.c r:
,0
ai d fo
om
Condition
The engine is cold.
gm e
@ ens

– Remove screw 1. Take off radiator cap 2.

– Place an appropriate container under the water pump cover.
tin ic

– Completely drain the coolant.

ar | L

– Mount and tighten screw 1 with a new seal ring.

lm r
ie fü

Guideline
Screw, water pump M6 10 Nm (7.4 lbf ft)
an ert

cover
yd zi

– Position the motorcycle upright.

ar en

S03527-10
– Completely fill the radiator with coolant.
ch Liz

Coolant ( p. 370)

– Push protection cap 3 upward over the coolant temperature

sensor.
, za
tin
ar
M
c
Za

S04256-10
Zac Martin, [email protected],

279
 20 WATER PUMP, COOLING SYSTEM

– Unplug connector 4.
– Remove coolant temperature sensor 5
with the O-ring and
wait until the coolant escapes without bubbles.
– Mount and tighten coolant temperature sensor 5 with the O-
ring.
Guideline
Screw, cylinder head M10x1.25 12 Nm (8.9 lbf ft)
temperature sensor
S04259-10
– Plug in connector4.
– Mount protection cap 3.
– Mount radiator cap 2.

Danger
Danger of poisoning Exhaust gases are toxic and inhal-

52
ing them may result in unconsciousness and death.
–

73
Always make sure there is sufficient ventilation
when running the engine.

01
– Use effective exhaust extraction when starting or

8/
S04255-10
running the engine in an enclosed space.

21
16
– Allow the engine to warm up and cool down again.

l.c r:
,0
– Check the cooling system for leaks.

ai d fo
– Check the coolant level. ( p. 276)

om
gm e
@ ens

20.7 Changing the coolant pipe

tin ic

Preparatory work
ar | L

– Drain the coolant. ( p. 276)

–
lm r

Remove the seat. ( p. 102)

ie fü

– Remove the fuel tank. ( p. 103)

an ert

Main work
yd zi

– Pull off overflow hose 1.

ar en
ch Liz
za

R05732-10
,
in

– Remove screws 2.
t
ar

– Remove radiator shield on both sides.

M
c
Za

R05733-10
Zac Martin, [email protected],

280
 WATER PUMP, COOLING SYSTEM 20

– Loosen hose clips 3.

– Pull off the radiator hoses.

52
73
01
R05734-10

8/
– Remove the hose clips 4.

21
– Detach radiator 5 and remove to the side.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

R05735-10

– Loosen hose clips 6.

za

– Pull off the radiator hose.

,
in
t
ar
M
c
Za

R05736-10
Zac Martin, [email protected],

281
 20 WATER PUMP, COOLING SYSTEM

– Remove coolant pipe 7 using special tool 8.

Mounting tool (79129081000) ( p. 383)

R05737-10

– Pull off connecting piece 9 to the side and remove.

Info
The connecting piece can only be removed from the left
side.

52
73
01
R05738-10

8/
– Mount new connecting piece 9 in the frame.

21
16
Info

l.c r:
The connecting piece can only be mounted on the left

,0
ai d fo
side.

om
gm e
@ ens
tin ic

R05738-11
ar | L

– Mount new coolant pipe 7 with special tool 8 and tighten.

lm r

Guideline
ie fü

Screw-in fitting, M24x1.5 18 Nm (13.3 lbf ft)

an ert

cooling system Loctite®243™

yd zi

Mounting tool (79129081000) ( p. 383)

ar en
ch Liz

R05737-10

– Mount the radiator hose.

–
za

Position and tighten hose clips 6.

,
in
t
ar
M
c
Za

R05736-10
Zac Martin, [email protected],

282
 WATER PUMP, COOLING SYSTEM 20

– Detach the radiator 5 and position.

– Position and tighten hose clips 4.

52
73
01
R05739-10

8/
– Mount the radiator hoses.

21
– Position and tighten hose clips 3.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

R05734-10

– Position the radiator shield on both sides.

za

– Mount and tighten screws 2.

,

Guideline
in

Remaining screws, M6 10 Nm (7.4 lbf ft)

t
ar

chassis
M
c
Za

R05733-10
Zac Martin, [email protected],

283
 20 WATER PUMP, COOLING SYSTEM

– Mount overflow hose 1.

R05732-10

Finishing work
– Install the fuel tank. ( p. 104)
– Mount the seat. ( p. 102)
– Refill with coolant. ( p. 277)
– Check the coolant level. ( p. 276)

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

284
 EXHAUST CONTROL 21

21.1 Checking/adjusting the basic setting of the exhaust control

– Measure distance A between the housing and the adjusting
screw.
Basic setting, exhaust control (All 250 models)
Basic setting 2.7 … 2.9 mm (0.106 …
0.114 in)
Basic setting, exhaust control (All 300 models)
Basic setting 2.3 … 2.5 mm (0.091 …
0.098 in)
R05753-10
» If the measured value is less than the specified value:
– Correct the adjusting screw to the specified value using
the special tool.
Socket wrench (55529021000) ( p. 378)

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za

Zac Martin, [email protected],

285
 22 LUBRICATION SYSTEM

22.1 Changing the gear oil

Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Drain the gear oil while the engine is at operating temperature.

52
Preparatory work

73
(All special models)

01
– Remove the engine guard. ( p. 56)

8/
– Park the motorcycle on a level surface.

21
– Position an appropriate container under the engine.

16
Main work

l.c r:
– Remove gear oil drain plug

,0
1 with magnet.

ai d fo
–

om
Let the gear oil drain fully.
– Thoroughly clean the gear oil drain plug with magnet.
gm e
@ ens

– Clean the sealing surface on the engine.

– Mount and tighten gear oil drain plug 1 with the magnet and
tin ic

a new seal ring.

ar | L

Guideline
E00913-10
lm r

Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft)

ie fü

with magnet
an ert

– Remove filler plug 2 with the O-ring, and fill up with gear oil.
yd zi

Gear oil 0.80 l Engine oil

ar en

(0.85 qt.) (15W/50)

ch Liz

( p. 370)
– Mount and tighten the filler plug together with the O-ring.

Danger
za

Danger of poisoning Exhaust gases are toxic and inhal-

401955-11 ing them may result in unconsciousness and death.
,
in

– Always make sure there is sufficient ventilation

t
ar

when running the engine.

M

– Use effective exhaust extraction when starting or

running the engine in an enclosed space.
c
Za

– Start the engine and check it for leaks.

Finishing work
– Check the gear oil level. ( p. 287)
(All special models)
Zac Martin, [email protected],

– Install the engine guard. ( p. 56)

286
 LUBRICATION SYSTEM 22

22.2 Checking the gear oil level

Info
The gear oil level must be checked when the engine is cold.

Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Detach the foot brake lever spring.
– Remove gear oil level monitoring screw 1.
– Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add the gear oil. ( p. 287)

52
E00912-10 – Mount and tighten the gear oil level monitoring screw.

73
Guideline

01
Screw, gear oil level M6 8 Nm (5.9 lbf ft)

8/
monitoring

21
– Attach the foot brake lever spring.

16
l.c r:
,0
ai d fo
22.3 Adding the gear oil

om
gm e
Info
@ ens

Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Gear oil must only be topped up when the engine is cold.
tin ic
ar | L

Preparatory work
lm r

– Park the motorcycle on a level surface.

ie fü

Main work
an ert

– Detach the foot brake lever spring.

yd zi

– Remove gear oil level monitoring screw 1.

ar en
ch Liz
za

E00912-10
,

– Remove filler plug 2 with the O-ring.

t in

– Add gear oil until it emerges from the drill hole of the gear oil
ar

level monitoring screw.

M

Engine oil (15W/50) ( p. 370)

c
Za

– Mount and tighten the gear oil level monitoring screw.

Guideline
Screw, gear oil level M6 8 Nm (5.9 lbf ft)
monitoring
401955-11

– Mount and tighten filler plug 2 with the O-ring.

Zac Martin, [email protected],

– Attach the foot brake lever spring.

287
 22 LUBRICATION SYSTEM

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Start the engine and check it for leaks.

Finishing work
– Check the gear oil level. ( p. 287)

22.4 Checking 2-stroke oil level

52
Warning

73
Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank.

01
If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.

8/
– As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the

21
tank is depleted.

16
– At the next opportunity add 2-stroke oil before you refuel.

l.c r:
,0
– Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully

ai d fo
om
depleted in error. gm e
@ ens

Preparatory work
– Stand the motorcycle upright on a horizontal surface.
tin ic

Main work
ar | L

– Check the 2-stroke oil level in the oil tank.

lm r
ie fü

Info
For a full tank of fuel, the 2-stroke oil tank must be
an ert

filled up to at least the upper abutting edge A .

yd zi
ar en

The 2-stroke oil tank must be completely filled if possible.

ch Liz

» If the 2-stroke oil level is too low:

S03500-10
– Add 2-stroke oil. ( p. 289)
za

22.5 Opening 2-stroke oil tank cap

,

–
in

Fold loop 1upward.

t

– Turn the 2-stroke oil tank cap counterclockwise and pull it up.
ar
M
c
Za

E00861-10
Zac Martin, [email protected],

288
 LUBRICATION SYSTEM 22

22.6 Adding 2-stroke oil

Warning
Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank.
If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
– As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the
tank is depleted.
– At the next opportunity add 2-stroke oil before you refuel.
– Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully
depleted in error.

– Open 2-stroke oil tank cap. ( p. 288)

– Fill the 2-stroke oil tank up to the lower edge A of the filler
neck.

52
Guideline

73
Only use 2-stroke oil which is appropriate for separate lubri-
cation.

01
8/
2-stroke oil tank con- 0.6 l (0.6 qt.) Engine oil, 2-stroke

21
tent approx. ( p. 370)

16
– Close 2-stroke oil tank cap. ( p. 289)
M01516-10

l.c r:
,0
ai d fo
om
22.7 Closing 2-stroke oil tank cap
gm e
@ ens

– Put the 2-stroke oil tank cap on and turn it clockwise.

– Fold loop 1down.
tin ic

The 2-stroke oil tank cap engages.

ar | L
lm r
ie fü
an ert
yd zi
ar en

E00861-11
ch Liz

22.8 Priming oil pump

Warning
Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank.
za

If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
,
in

– As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the
t
ar

tank is depleted.
M

– At the next opportunity add 2-stroke oil before you refuel.

c

– Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully
Za

depleted in error.

Condition
The engine is off.
Preparatory work
Zac Martin, [email protected],

– Remove the seat. ( p. 102)

289
 22 LUBRICATION SYSTEM

– Stand the motorcycle upright on a horizontal surface.

– Check 2-stroke oil level. ( p. 288)
Main work
– Pull the EFI control unit 1 upward off the rubber plugs and
hang to the side.
– Pull diagnostics connector 2 off the holder.

52
73
01
8/
21
S04900-10

16
– Put throttle grip 3 into full throttle position and secure.

l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r

S04874-11
ie fü

– Plug in wake-up connector 4 for priming the oil pump to the

an ert

diagnostics connector .5
yd zi

The combination instrument lighting is activated.

ar en
ch Liz

Info
The connector is included as part of the motorcycle's
separate enclosure.

– Wait for at least five seconds.

za

– Release the fixing means from the throttle grip.

The oil pump is timed.
,
in
t
ar

Info
M

The oil pump is actuated at various speeds.

The procedure is clearly audible.
c
Za

– Wait until you can no longer hear the oil pump operating.
– Disconnect the wake-up connector from the diagnostics con-
nector.
S04854-11
Zac Martin, [email protected],

290
 LUBRICATION SYSTEM 22

– Check whether air bubbles are visible in the hose 6.

» If air bubbles are visible:
– Repeat the entire procedure until air bubbles are no
longer visible.
– Mount the diagnostics connector on the holder.
– Mount the EFI control unit on the rubber lugs.

S03513-10

Finishing work
– Mount the seat. ( p. 102)

22.9 Changing the oil pump, cleaning the oil screen

52
Note

73
Environmental hazard Hazardous substances cause environmental damage.

01
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

8/
21
Condition

16
Oil tank is empty.

l.c r:
,0
Preparatory work

ai d fo
– Remove main silencer. (

om
p. 96)
– Remove the seat. ( p. 102)
gm e
@ ens

– Remove the fuel tank. ( p. 103)

– Remove the air filter box cover. ( p. 98)
tin ic

– Raise the motorcycle with a lift stand. ( p. 13)

ar | L

Main work
lm r

– Remove screw 1 with washer.

ie fü

– Remove the cable ties and take off the frame protector.
an ert
yd zi
ar en
ch Liz

S04901-10

– Remove screws 2.
za

– Loosen screws 3.
,
t in
ar
M
c
Za

S04902-10
Zac Martin, [email protected],

291
 22 LUBRICATION SYSTEM

– Loosen clamps 4 of the throttle valve body.

– Disconnect plug-in connector 5 of the rear brake light
switch.
– Lift the subframe slightly and secure it.

Info
Pay attention to intake flange 6.
– Pull throttle valve body 7 towards the rear, out of the intake
flange, and hang it to the side.

52
73
01
S04903-10

8/
– Push back hose clamp 8.

21
– Pull off the tube from the throttle valve body.

16
l.c r:
,0
Info

ai d fo
Residual oil may escape from the hose.

om
gm e
@ ens
tin ic

D06402-10
ar | L

– Unplug connector 9.
lm r
ie fü
an ert
yd zi
ar en
ch Liz

D06397-10

– Push back hose clamp bk.

, za
in
t
ar
M
c
Za

D06398-10
Zac Martin, [email protected],

292
 LUBRICATION SYSTEM 22

– Remove screw bl.

– Pull off the hose from the oil tank.

Info
Residual oil may escape from the oil tank.

– Remove the oil pump with the hose.

D06399-10

– Open hose clamp bm using a screwdriver and pull off the

angle piece.

52
73
01
D06400-10

8/
– Remove oil screen bn and clean it.

21
– Check the oil screen for damage.

16
» If the oil screen is damaged:

l.c r:
,0
– Change the oil screen.

ai d fo
om
gm e
@ ens
tin ic

D06401-10
ar | L

– Insert the oil screen and mount the angle piece with a new
hose clamp.
lm r
ie fü

Hose clamp pliers (60029057000) ( p. 381)

an ert
yd zi
ar en
ch Liz

D06400-11

– Position the new oil pump with the hose.

–
za

Mount the hose from the oil tank.

– Mount and tighten screw bl.
,
in

Guideline
t
ar

Screw, oil pump M6 7 Nm (5.2 lbf ft)

M
c
Za

D06399-10
Zac Martin, [email protected],

293
 22 LUBRICATION SYSTEM

– Position hose clamp bk.

D06398-10

– Plug in connector 9.

52
73
01
D06397-10

8/
– Mount hose on the throttle valve body.

21
– Position hose clamp 8.

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

D06402-10
ar | L

– Mount throttle valve body 7.

lm r

– Remove the locking piece and position the subframe.

ie fü
an ert

Info
Pay attention to intake flange 6.
yd zi
ar en

– Join plug-in connector 5 of the rear brake light switch.

ch Liz

– Position and tighten clamps 4 of the throttle valve body.

Guideline
Screw, intake M6 6 Nm (4.4 lbf ft)
flange/reed valve
za

housing
,
in
t
ar
M
c
Za

S04904-10
Zac Martin, [email protected],

294
 LUBRICATION SYSTEM 22

– Mount and tighten screws 2.

Guideline
Screw, sub- M8 30 Nm (22.1 lbf ft)
frame bottom Loctite®2701™
– Remove screws 3.
– Mount and tighten screws 3.
Guideline
S04902-10 Screw, sub- M8 35 Nm (25.8 lbf ft)
frame top Loctite®2701™

– Position the frame protector.

– Mount and tighten screw 1 with the washer.
Guideline
Screw, frame protec- M5 3 Nm (2.2 lbf ft)
tor

52
– Mount the cable ties.

73
01
8/
S04901-10

21
Finishing work

16
– Remove the motorcycle from the lift stand. ( p. 13)

l.c r:
,0
– Install the air filter box cover. ( p. 98)

ai d fo
– Install the fuel tank. ( p. 104)

om
– Add 2-stroke oil. ( p. 289)
gm e
@ ens

– Prime the oil pump. ( p. 289)

– Mount the seat. ( p. 102)
tin ic

– Install the main silencer. ( p. 96)

ar | L
lm r
ie fü

22.10 Cleaning the oil screen in the oil tank

an ert

Note
yd zi

Environmental hazard Hazardous substances cause environmental damage.

ar en

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
ch Liz

the applicable regulations.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
za

– Remove main silencer. ( p. 96)

– Remove the seat. ( p. 102)
,
in

– Remove the fuel tank. ( p. 103)

t
ar

– Remove the air filter box cover. ( p. 98)

M
c
Za

Zac Martin, [email protected],

295
 22 LUBRICATION SYSTEM

Main work
– Remove screw 1 with washer.
– Remove the cable ties and take off the frame protector.

S04901-10

– Remove screws 2.
– Loosen screws 3.

52
73
01
S04902-10

8/
– Loosen clamps 4 of the throttle valve body.

21
– Disconnect plug-in connector 5 of the rear brake light

16
switch.

l.c r:
,0
– Lift the subframe slightly and secure it.

ai d fo
om
Info
gm e
Pay attention to intake flange 6.
@ ens

– Pull throttle valve body 7 towards the rear, out of the intake
tin ic

flange, and hang it to the side.

ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz

S04903-10

– Open hose clamp 8 using a screwdriver.

za

– Pull off the angle piece and collect the 2-stroke oil in a suit-
able container.
,
in
t
ar
M
c
Za

S03504-10
Zac Martin, [email protected],

296
 LUBRICATION SYSTEM 22

– Remove oil screen 9 and clean it.

– Check the oil screen for damage.
» If the oil screen is damaged:
– Change the oil screen.

S03505-10

– Insert the oil screen and mount the angle piece with a new
hose clamp.
Hose clamp pliers (60029057000) ( p. 381)

52
73
01
S03506-10

8/
– Mount throttle valve body 7.

21
– Remove the locking piece and position the subframe.

16
l.c r:
,0
Info

ai d fo
Pay attention to intake flange 6.

om
gm e
– Join plug-in connector 5 of the rear brake light switch.
@ ens

– Position and tighten clamps 4 of the throttle valve body.

tin ic

Guideline
ar | L

Screw, intake M6 6 Nm (4.4 lbf ft)

flange/reed valve
lm r
ie fü

housing
an ert
yd zi
ar en
ch Liz

S04904-10

– Mount and tighten screws 2.

za

Guideline
Screw, sub- M8 30 Nm (22.1 lbf ft)
,
in

frame bottom Loctite®2701™

t
ar

– Remove screws 3.
M

– Mount and tighten screws 3.

c
Za

Guideline
S04902-10 Screw, sub- M8 35 Nm (25.8 lbf ft)
frame top Loctite®2701™
Zac Martin, [email protected],

297
 22 LUBRICATION SYSTEM

– Position the frame protector.

– Mount and tighten screw 1 with washer.
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis
– Mount the cable ties.

S04901-10

Finishing work
– Install the air filter box cover. ( p. 98)
– Install the fuel tank. ( p. 104)
– Add 2-stroke oil. ( p. 289)
– Prime the oil pump. ( p. 289)
– Mount the seat. ( p. 102)

52
– Install the main silencer. ( p. 96)

73
– Remove the motorcycle from the lift stand. ( p. 13)

01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

298
 IGNITION SYSTEM 23

23.1 Checking the ignition system

Warning
Risk of injury The ignition system is under high voltage.
– To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection
cable during and immediately after measuring.

– Shift the transmission to neutral position.

– Unplug the spark plug connector and remove it from the igni-
tion wire.
– Remove the spark plug.
Guideline
Close the spark plug thread in the cylinder head, e.g., with a
suitable spare spark plug.

52
– Hold the free end of the ignition wire at distance A from
ground.

73
E02171-01 Guideline

01
Distance A 5 mm (0.2 in)

8/
21
– Press the start button.

16
Info

l.c r:
,0
Do not open the throttle.

ai d fo
om
– Check the ignition spark.
gm e
@ ens
» If no ignition spark is visible:
– Check the emergency OFF switch.
tin ic

– Check the wiring harness to the emergency OFF switch.

ar | L

– Check the stop button.

–
lm r

Check the ground connection of the EFI control unit

ie fü

and ignition coil.

an ert

– Check the cable from the EFI control unit to the igni-
tion coil.
yd zi
ar en

Info
ch Liz

The EFI control unit cannot be tested using

simple methods but only using an ignition test
bench.

– Ignition coil - check the primary winding. ( p. 300)

za

– Check the crankshaft speed sensor. ( p. 302)

– Check the stator winding of the alternator. ( p. 301)
,
in

– Mount the spark plug connector on the ignition wire again.

t
ar

Mount the spark plug in the spark plug connector. Hold the
M

spark plug to ground.

c

– Press the start button.

Za

Info
Do not open the throttle.

– Check the ignition spark.

E02172-01 » If no ignition spark is visible:
Zac Martin, [email protected],

– Check the spark plug connector. ( p. 301)

299
 23 IGNITION SYSTEM

– Change the spark plug. ( p. 303)

23.2 Ignition coil - checking the primary winding

Warning
Risk of injury The ignition system is under high voltage.
– To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection
cable during and immediately after measuring.

Condition
Ignition coil cylinder 1 is disconnected.
Ignition coil cylinder 1 - check the primary winding resistance.
– Measure the resistance between the specified
points.
Ignition coil pin 1 (-) – Ignition coil pin 2 (+)

52
Ignition coil

73
Primary winding resis- 0.337 … 0.412 Ω

01
R02908-10 tance at: 20 °C (68 °F)

8/
» If the displayed value does not correspond to the nomi-

21
nal value:

16
– Change the ignition coil.

l.c r:
,0
Condition

ai d fo
om
Ignition coil cylinder 1 is connected.
– Connect the special tool to the multimeter.
gm e
@ ens

Peak voltage adapter (58429042000) ( p. 379)

tin ic

Info
ar | L

When using the peak voltage adapter, adjust the

lm r

measuring range of the multimeter to DCV.

ie fü

– Start the motorcycle to check the function. ( p. 14)

an ert

Ignition coil cylinder 1 - check the primary winding voltage.

yd zi

– Measure the voltage between the specified points.

ar en

Ignition coil pin 1 (-) – Ignition coil pin 2 (+)

ch Liz

Info
Connect the black measuring lead to pin 2 and the
red measuring lead to pin 1 of the ignition coil.
za

Ignition coil
,

Voltage, primary wind- 200 … 250 V

in

ing
t
ar

» If the displayed value does not correspond to the nomi-

M

nal value:
c

– Change the ignition coil.

Za
Zac Martin, [email protected],

300
 IGNITION SYSTEM 23

23.3 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.
– Measure the resistance between the specified points.
Measuring point 1 – Measuring point 2

Spark plug connector

Resistance at: 20 °C 4.3 … 5.7 kΩ
(68 °F)
» If the specification is not reached:
– Change the spark plug connector.
R02857-10

23.4 Alternator – checking the stator winding

52
Condition

73
The stator is disconnected.

01
Preparatory work
– Remove the seat. (

8/
p. 102)

21
Main work

16
Stator winding measurement I - check the resistance.
– Measure the resistance between the specified points.

l.c r:
,0
ai d fo
Stator, connector EZ pin 1 – Stator, connector EZ pin 2

om
Alternator
gm e
@ ens

Stator winding resistance 0.368 … 0.552 Ω

at: 20 °C (68 °F)
tin ic

» If the indicated value does not correspond to the setpoint

ar | L

601211-10
value:
– Change the stator.
lm r
ie fü

Stator winding measurement II - check the resistance.

–
an ert

Measure the resistance between the specified points.

Stator, connector EZ pin 1 – Stator, connector EZ pin 3
yd zi
ar en

Alternator
ch Liz

Stator winding resistance 0.368 … 0.552 Ω

at: 20 °C (68 °F)
» If the indicated value does not correspond to the setpoint
value:
– Change the stator.
, za
tin
ar
M
c
Za

Zac Martin, [email protected],

301
 23 IGNITION SYSTEM

601211-10 H01812-10

Stator winding - checking the short circuit to ground (terminal 31).

– Measure the resistance between the specified points.
Stator, connector EZ pin 1 – Measuring point Ground (−)

Resistance ∞Ω
» If the indicated value does not correspond to the setpoint value:

52
– Change the stator.

73
Finishing work
– Mount the seat. ( p. 102)

01
8/
21
23.5 Checking the crankshaft speed sensor

16
l.c r:
Condition

,0
ai d fo
Crankshaft speed sensor is disconnected.

om
– Measure the resistance between the specified points.
gm e
Crankshaft speed sensor, connector AT pin 1 –
@ ens

Crankshaft speed sensor, connector AT pin 2

tin ic

Crankshaft speed sensor

ar | L

Resistance at: 20 °C 80 … 120 Ω

(68 °F)
lm r
ie fü

» If the specification is not reached:

an ert

– Change the crankshaft speed sensor.

400585-10
yd zi
ar en
ch Liz
, za
t in

400585-10 H01812-10
ar

– Measure the resistance between the specified points.

M

Crankshaft speed sensor, connector AT pin 1 – Measuring point Ground (−)

c
Za

Resistance ∞Ω
» If the specification is not reached:
– Change the crankshaft speed sensor.
– Connect the special tool to the multimeter.
Zac Martin, [email protected],

302
 IGNITION SYSTEM 23

Peak voltage adapter (58429042000) ( p. 379)

Info
When using the peak voltage adapter, adjust the measuring range of the multimeter to DCV.

– Start the motorcycle to check the function. ( p. 14)

Crankshaft speed sensor – check the resistance.
– Measure the voltage between the specified points.
Crankshaft speed sensor, connector AT pin 1 –
Crankshaft speed sensor, connector AT pin 2
Crankshaft speed sensor
Voltage at starting engine 2…4V
speed
» If the specification is not reached:
400585-10
– Change the crankshaft speed sensor.

52
73
01
23.6 Changing the spark plug

8/
– Disconnect spark plug connector 1.

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic

Z00161-10
ar | L

– Remove spark plug 2 using a suitable tool.

lm r

– Mount and tighten the new spark plug using a suitable tool.
ie fü

Guideline
an ert

Spark plug M14x1.25 25 Nm (18.4 lbf ft)

yd zi
ar en
ch Liz

Z00162-10

– Plug in spark plug connector 1.

, za
tin
ar
M
c
Za

Z00161-10
Zac Martin, [email protected],

303
 23 IGNITION SYSTEM

23.7 Changing the spark plug and spark plug connector

– Disconnect spark plug connector 1.

Z00161-10

– Remove spark plug 2 using a suitable tool.

– Mount and tighten the new spark plug using a suitable tool.
Guideline
Spark plug M14x1.25 25 Nm (18.4 lbf ft)

52
73
01
8/
21
Z00162-10

16
– Remove spark plug connector 1.

l.c r:
,0
– Mount new spark plug connector 1.

ai d fo
om
gm e
@ ens
tin ic
ar | L

Z00163-10
lm r
ie fü

– Plug in spark plug connector 1.

an ert
yd zi
ar en
ch Liz

Z00161-10
za

23.8 Removing the stator

,
in
t

Condition
ar

The alternator cover has been removed.

M
c
Za
Zac Martin, [email protected],

304
 IGNITION SYSTEM 23

– Remove screws 1.
– 2.
Remove retaining bracket
– Remove rubber grommet 3 from the alternator cover.
– Remove the stator from the alternator cover.

R02907-10

23.9 Installing the stator

– Position the stator in the alternator cover.
– Position rubber grommet 1 in the alternator cover.
– Mount and tighten screws 2.

52
Guideline

73
Screw, stator M5 6 Nm (4.4 lbf ft)
Loctite®2701™

01
– Mount retaining bracket 3.

8/
21
R02907-11

16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

305
 24 ELECTRIC STARTER SYSTEM

24.1 Checking the starter motor

Condition
The starter motor has been removed.
– Connect negative cable of a 12-V power supply to the housing
of the starter motor. Connect positive cable of the power sup-
ply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is
closed:
– Change starter motor.

R02772-10

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
,za
tin
ar
M
c
Za
Zac Martin, [email protected],

306
 THROTTLE VALVE BODY 25

25.1 Adjusting the idle speed

Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
– Set the idle speed to the specified value.

– Run the engine until warm.

The cold start button is deactivated – A further ¼ turn
returns the cold start button back to the basic position.
( p. 308)

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation

52
when running the engine.

73
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

01
8/
– Adjust the idle speed by turning idle speed adjusting

21
screw 1.

16
Guideline

l.c r:
,0
Idle speed 1,400 … 1,500 rpm

ai d fo
om
Tachometer (45129075000) ( p. 376)
gm e
S03529-11
@ ens

Info
Turn clockwise to decrease the idle speed.
tin ic

Turn counterclockwise to increase the idle speed.

ar | L

Make the setting in small steps.

lm r

An incorrect idle speed can have a negative impact on

ie fü

overall engine running.

an ert
yd zi
ar en

25.2 Programming ambient air pressure

ch Liz

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
za

– Use effective exhaust extraction when starting or running the engine in an enclosed space.
,
tin

Info
ar

If the vehicle is ridden with the engine running at various heights above sea level, the ambient pressure is
M

programmed on an ongoing basis.

c

If the vehicle is transported over great differences in height, the ambient pressure must be reprogrammed.
Za

Zac Martin, [email protected],

307
 25 THROTTLE VALVE BODY

– Start the vehicle at the new height above sea level and switch
off the engine again.
– Wait for at least five seconds.
– Start the vehicle again and check the response of the vehicle.
» If the response has not improved:
– Repeat the procedure.

H02349-01

25.3 Cold start button

The cold start button 1 is fitted on the side of the throttle valve
body.
If the engine is cold and the ambient temperature is low, the
electronic fuel injection system extends the injection time. To help

52
the engine burn the increased fuel quantity, it must be supplied
with additional oxygen by pulling the cold start button.

73
01
Info

8/
If the engine is warm, the cold start button must be deacti-

21
vated.

16
Possible states

l.c r:
,0
• The cold start button is activated – The cold start button is

ai d fo
om
pulled out all the way and turned by a ¼ turn.
• The cold start button is deactivated – A further ¼ turn returns
gm e
@ ens
the cold start button back to the basic position.
tin ic
ar | L
lm r

S03529-10
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za
Zac Martin, [email protected],

308
 TECHNICAL DATA 26

26.1 Engine

26.1.1 All 250 models

Design 1-cylinder 2-stroke engine, water-cooled, with reed
intake, exhaust control and transfer duct injection
Displacement 249 cm³ (15.19 cu in)
Stroke 72 mm (2.83 in)
Hole 66.4 mm (2.614 in)
Idle speed 1,400 … 1,500 rpm
Exhaust control - setting measurement 2.7 + 0.2
−0 mm (0.106 +− 00.008 in)
Exhaust valve, beginning of adjustment 5,500 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing

52
Piston Cast aluminum

73
Piston rings 2 half keystone rings

01
Engine lubrication Separate lubrication

8/
X distance (upper edge of piston to upper edge of 0 … 0.10 mm (0 … 0.0039 in)

21
cylinder)

16
Z distance (height of control flap) 49.0 mm (1.929 in)

l.c r:
,0
Primary transmission 26:73

ai d fo
om
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission 6 gear transmission, claw shifted
gm e
@ ens

Transmission ratio
first-gear 14:32
tin ic

second-gear 16:26
ar | L

third-gear 20:25
lm r

fourth-gear 22:23
ie fü

fifth-gear 25:22
an ert

sixth-gear 26:20
yd zi

Alternator 12 V, 196 W
ar en

Ignition system Contactless controlled fully electronic ignition with

ch Liz

digital ignition adjustment

Spark plug NGK BR 7 ES
Spark plug electrode gap 0.6 mm (0.024 in)
Cooling Water cooling, permanent circulation of coolant by
za

water pump
Starting aid Electric starter system
,
t in
ar

26.1.2 All 300 models

M

Design 1-cylinder 2-stroke engine, water-cooled, with reed

c

intake, exhaust control and transfer duct injection

Za

Displacement 293.15 cm³ (17.8892 cu in)

Stroke 72 mm (2.83 in)
Hole 72 mm (2.83 in)
Idle speed 1,400 … 1,500 rpm
Zac Martin, [email protected],

309
 26 TECHNICAL DATA

Exhaust valve, beginning of adjustment 5,500 rpm

Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Piston Cast aluminum
Piston rings 2 rectangular rings
Engine lubrication Separate lubrication
X distance (upper edge of piston to upper edge of 0 … 0.10 mm (0 … 0.0039 in)
cylinder)
Z distance (height of control flap) 49.5 mm (1.949 in)
Primary transmission 26:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission 6 gear transmission, claw shifted
Transmission ratio

52
first-gear 14:32

73
second-gear 16:26

01
third-gear 20:25

8/
fourth-gear 22:23

21
fifth-gear 25:22

16
sixth-gear 26:20

l.c r:
,0
Alternator 12 V, 196 W

ai d fo
om
Ignition system Contactless controlled fully electronic ignition with
digital ignition adjustment
gm e
@ ens

Spark plug NGK BR 7 ES

Spark plug electrode gap 0.6 mm (0.024 in)
tin ic

Cooling Water cooling, permanent circulation of coolant by

ar | L

water pump
Starting aid Electric starter system
lm r
ie fü
an ert

26.2 Tolerance, engine wear limits

yd zi

Piston - diameter (All 250 models)

ar en

Size I 66.340 … 66.350 mm (2.61181 … 2.6122 in)

ch Liz

Size II 66.351 … 66.360 mm (2.61224 … 2.61259 in)

Piston - diameter (All 300 models)
Size I 71.925 … 71.934 mm (2.83169 … 2.83204 in)
Size II 71.935 … 71.944 mm (2.83208 … 2.83244 in)
za

Cylinder - drill hole diameter (All 250 models)

,
in

Size I 66.400 … 66.412 mm (2.61417 … 2.61464 in)

t
ar

Size II 66.412 … 66.425 mm (2.61464 … 2.61515 in)

M

Cylinder - drill hole diameter (All 300 models)

c

Size I 72.000 … 72.012 mm (2.83464 … 2.83511 in)

Za

Size II 72.012 … 72.025 mm (2.83511 … 2.83562 in)

Piston/cylinder - mounting clearance (All 250 models)
New condition 0.050 … 0.074 mm (0.00197 … 0.00291 in)
Wear limit 0.10 mm (0.0039 in)
Piston/cylinder - mounting clearance (All 300 models)
Zac Martin, [email protected],

310
 TECHNICAL DATA 26

New condition 0.066 … 0.088 mm (0.0026 … 0.00346 in)

Wear limit 0.10 mm (0.0039 in)
Piston ring end gap
Ring 1 ≤ 0.60 mm (≤ 0.0236 in)
Ring 2 ≤ 0.60 mm (≤ 0.0236 in)
Cylinder/cylinder head - distortion of sealing surface ≤ 0.10 mm (≤ 0.0039 in)
Connecting rod - axial play of lower conrod bearing 0.60 … 0.70 mm (0.0236 … 0.0276 in)
Crankshaft - run-out at bearing pin ≤ 0.03 mm (≤ 0.0012 in)
Clutch facing disc - thickness ≥ 1.9 mm (≥ 0.075 in)
Shift shaft - sliding plate/shift quadrant play 0.40 … 0.80 mm (0.0157 … 0.0315 in)

26.3 Engine tightening torques

Screw, inner membrane sheets EJOTDELTA PT® 35x25 1 Nm (0.7 lbf ft)

52
Screw, membrane support plate EJOTDELTA PT® 30x12 1 Nm (0.7 lbf ft)

73
Screw, outer membrane sheets EJOTDELTA PT® 30x6 1 Nm (0.7 lbf ft)

01
Screw, angle lever, exhaust control M5 6 Nm (4.4 lbf ft)
Loctite®243™

8/
21
Screw, bearing retainer M5 6 Nm (4.4 lbf ft)
Loctite®243™

16
Screw, clutch spring retainer M5 6 Nm (4.4 lbf ft)

l.c r:
,0
ai d fo
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)

om
Loctite®243™
gm e
Screw, exhaust control bearing M5 6 Nm (4.4 lbf ft)
@ ens

support Loctite®243™
Screw, exhaust control cap M5 5 Nm (3.7 lbf ft)
tin ic

Screw, exhaust control cover M5 4 Nm (3 lbf ft)

ar | L

Screw, injection valve holder M5 5 Nm (3.7 lbf ft)

lm r

Loctite®243™
ie fü

Screw, locking lever M5 6 Nm (4.4 lbf ft)

an ert

Loctite®243™
yd zi

Screw, retaining bracket of exhaust M5 6 Nm (4.4 lbf ft)

ar en

control Loctite®2701™
ch Liz

Screw, stator M5 6 Nm (4.4 lbf ft)

Loctite®2701™
Cap nut, water pump impeller M6 5 Nm (3.7 lbf ft)
Loctite®243™
za

Drain plug, water pump cover M6 10 Nm (7.4 lbf ft)

Screw, alternator cover M6 8 Nm (5.9 lbf ft)
,
in

Screw, clutch cover M6 10 Nm (7.4 lbf ft)

t
ar

Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)

M

Screw, control flap, exhaust con- M6 10 Nm (7.4 lbf ft)

c

trol Loctite®243™
Za

Screw, engine case M6 10 Nm (7.4 lbf ft)

Screw, exhaust control thrust bear- M6 8 Nm (5.9 lbf ft)
ing Loctite®243™
Screw, exhaust flange M6 8 Nm (5.9 lbf ft)
Screw, gear oil level monitoring M6 8 Nm (5.9 lbf ft)
Zac Martin, [email protected],

311
 26 TECHNICAL DATA

Screw, intake flange/reed valve M6 6 Nm (4.4 lbf ft)

housing
Screw, kick starter intermediate M6 10 Nm (7.4 lbf ft)
gear pin Loctite®243™
Screw, outer clutch cover M6 8 Nm (5.9 lbf ft)
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor M6 10 Nm (7.4 lbf ft)
Screw, starter motor bearing bush M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, starter motor protection cap M6 8 Nm (5.9 lbf ft)
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
Vacuum connection, cylinder M6 4 Nm (3 lbf ft)

52
Loctite®2701™

73
Screw, balancer shaft M8 30 Nm (22.1 lbf ft)

01
Loctite®243™

8/
Screw, cylinder head M8 27 Nm (19.9 lbf ft)

21
Nut, cylinder base M10 35 Nm (25.8 lbf ft)

16
Screw, drive chain engine sprocket M10 60 Nm (44.3 lbf ft)

l.c r:
,0
Loctite®2701™

ai d fo
Stud, cylinder base M10 12 Nm (8.9 lbf ft)

om
Screw, cylinder head temperature M10x1.25 12 Nm (8.9 lbf ft)
gm e
sensor
@ ens

Nut, rotor M12x1 60 Nm (44.3 lbf ft)

tin ic

Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)
ar | L

Spark plug M14x1.25 25 Nm (18.4 lbf ft)

Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)
lm r
ie fü

Loctite®243™
an ert

Nut, primary gear wheel M18LHx1.5 150 Nm (110.6 lbf ft)

Loctite®243™
yd zi
ar en

26.4 Capacities
ch Liz

26.4.1 Gear oil

Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 370)
za

26.4.2 Engine oil

,
in

2-stroke oil tank content approx. 0.6 l (0.6 qt.) Engine oil, 2-stroke ( p. 370)
t
ar
M

26.4.3 Coolant
c
Za

Coolant 1.2 l (1.3 qt.) Coolant ( p. 370)

26.4.4 Fuel
Total fuel tank capacity, approx. 9 l (2.4 US gal) Super unleaded (ROZ 95)
( p. 371)
Zac Martin, [email protected],

312
 TECHNICAL DATA 26

Fuel reserve, approx. 1.5 l (1.6 qt.)

26.5 Chassis
Frame Central tube frame made of chrome molybdenum steel
tubing
Fork WPXPLOR OC
Suspension travel
front 300 mm (11.81 in)
Suspension travel
rear 310 mm (12.2 in)
Fork offset 22 mm (0.87 in)
Shock absorber WP XPLOR PDS
Brake system Disc brakes, floating brake calipers

52
Brake discs - diameter
front 260 mm (10.24 in)

73
rear 220 mm (8.66 in)

01
Brake discs - wear limit (All standard models)

8/
front 2.5 mm (0.098 in)

21
rear 3.5 mm (0.138 in)

16
Brake discs - wear limit (All special models)

l.c r:
,0
ai d fo
front 2.5 mm (0.098 in)

om
rear 3.7 mm (0.146 in)
gm e
Street tire pressure (EU/CN/ASEAN)
@ ens

front 2.0 bar (29 psi)

tin ic

rear 2.0 bar (29 psi)

ar | L

Offroad tire pressure

front 1.0 bar (15 psi)
lm r
ie fü

rear 1.0 bar (15 psi)

an ert

Secondary ratio (All 250 models) 14:52 (13:52)

yd zi

Secondary ratio (All 300 models) 14:50 (13:50)

ar en

Chain 5/8 x 1/4"

ch Liz

Rear sprockets available 45, 48, 49, 50, 51, 52

Steering head angle 63.5°
Wheelbase 1,482 ± 10 mm (58.35 ± 0.39 in)
Seat height unloaded 960 mm (37.8 in)
za

Ground clearance unloaded 370 mm (14.57 in)

,

Weight without fuel, approx. 104 kg (229 lb.)

in

Maximum permissible front axle load 145 kg (320 lb.)

t
ar

Maximum permissible rear axle load 190 kg (419 lb.)

M

Maximum permissible overall weight 335 kg (739 lb.)

c
Za

Zac Martin, [email protected],

313
 26 TECHNICAL DATA

26.6 Electrical system

12-V battery HJTZ5S-FP-C Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
Combination instrument battery CR 2430 Battery voltage: 3 V
Fuse 75011088005 5A
Fuse 75011088010 10 A
Fuse 58011109120 20 A
Headlight HS1/socket BX43t 12 V
35/35 W
Position light W5W / socket W2.1x9.5d 12 V
5W
Indicator lamps W2.3W / socket W2x4.6d 12 V

52
2.3 W

73
Turn signal (EU/CN/ASEAN) R10W / socket BA15s 12 V

01
10 W
Brake/tail light LED

8/
21
License plate lamp LED
(EU/CN/ASEAN)

16
l.c r:
,0
ai d fo
26.7 Tires

om
Validity Front tire Rear tire
gm e
@ ens

(All standard EXC models) 90/90 - 21 M/C 54R M+S TT 140/80 - 18 M/C 70R M+S TT
MAXXIS Maxx Enduro MAXXIS Maxx Enduro
tin ic

(All special models) 90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT
ar | L

Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME

lm r

(US) 80/100 - 21 51M TT 110/100 - 18 64M TT

ie fü

Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81

an ert

The tires specified represent one of the possible series production tires. For alternative manufacturers, if any,
contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the
yd zi

respective technical specifications must be observed. Additional information is available in the Service section
ar en

under:
ch Liz

KTM.COM

26.8 Fork
Fork article number 0797C164V401000
za

Fork WPXPLOR OC
,
in

Compression damping
t
ar

Comfort 18 clicks
M

Standard 15 clicks
c

Sport 12 clicks
Za

Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring preload – preload adjuster
Zac Martin, [email protected],

314
 TECHNICAL DATA 26

Comfort +0
Standard +0
Sport +3
Spring length with preload spacer(s) 474 mm (18.66 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.2 N/mm (24 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.4 N/mm (25.1 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.6 N/mm (26.3 lb/in)
Fork length 928 mm (36.54 in)

Fork oil per fork leg 636 ± 10 ml (21.5 ± 0.34 fl. oz.) Fork oil (SAE 4) (48601166S1)
( p. 371)

26.9 Shock absorber

52
Shock absorber article number 0797C463V305000

73
Shock absorber WP XPLOR PDS

01
Low-speed compression damping

8/
Comfort 18 clicks

21
Standard 15 clicks

16
Sport 12 clicks

l.c r:
,0
High-speed compression damping

ai d fo
om
Comfort 2.5 turns
Standard 2 turns
gm e
@ ens

Sport 1 turn
Rebound damping
tin ic

Comfort 18 clicks
ar | L

Standard 15 clicks
lm r

Sport 12 clicks
ie fü

Spring preload 9 mm (0.35 in)

an ert

Spring rate
yd zi

Weight of rider: 65 … 75 kg (143 … 165 lb.) 57 … 63 N/mm (325 … 360 lb/in)

ar en

Weight of rider: 75 … 85 kg (165 … 187 lb.) 60 … 66 N/mm (343 … 377 lb/in)

ch Liz

Weight of rider: 85 … 95 kg (187 … 209 lb.) 63 … 69 N/mm (360 … 394 lb/in)

Spring length 225 mm (8.86 in)
Gas pressure 10 bar (145 psi)
Static sag 37 mm (1.46 in)
za

Riding sag 110 mm (4.33 in)

,
in

Fitted length 415 mm (16.34 in)

t
ar

Shock absorber fluid ( p. 371) SAE 2.5

M
c
Za

Zac Martin, [email protected],

315
 26 TECHNICAL DATA

26.10 Chassis tightening torques

Remaining screws, chassis EJOT PT® K60x25‑Z 2 Nm (1.5 lbf ft)
Screw, intake air temperature sen- EJOTDELTA PT® 45x12-Z 0.7 Nm (0.52 lbf ft)
sor
Screw, oil fill level sensor G 3/4 " 7 Nm (5.2 lbf ft)
Screw, oil pump holder on oil tank EJOTDELTA PT 45x12-Z 0.7 Nm (0.52 lbf ft)
Screw, pressure regulator EJOT PT® K60x25‑Z 2.3 Nm (1.7 lbf ft)
Screw, emergency OFF switch M4 0.4 Nm (0.3 lbf ft)
(EU/CN/ASEAN)
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)

52
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)

73
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft)

01
Screw, brake line guide for link M5 5 Nm (3.7 lbf ft)

8/
fork

21
Screw, ground wire in tail section M5 5 Nm (3.7 lbf ft)

16
Screw, light switch M5 1 Nm (0.7 lbf ft)

l.c r:
,0
(EU/CN/ASEAN)

ai d fo
Screw, shock absorber adjusting M5 5 Nm (3.7 lbf ft)

om
ring
gm e
Screw, turn signal switch M5 1 Nm (0.7 lbf ft)
@ ens

(EU/CN/ASEAN)
Nut, cable on starter motor M6 4 Nm (3 lbf ft)
tin ic
ar | L

Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
lm r
ie fü

Screw, ball joint of push rod on M6 10 Nm (7.4 lbf ft)

foot brake cylinder Loctite®243™
an ert

Screw, battery support bracket M6 6 Nm (4.4 lbf ft)

yd zi

Screw, brake lever M6 5 Nm (3.7 lbf ft)

ar en

Screw, cable on starter relay M6 6 Nm (4.4 lbf ft)

ch Liz

Screw, chain guide M6 10 Nm (7.4 lbf ft)

Screw, chain sliding guard M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch lever M6 5 Nm (3.7 lbf ft)
za

Screw, front brake disc M6 14 Nm (10.3 lbf ft)

,
in

Loctite®243™
t

Screw, manifold on silent block M6 6 Nm (4.4 lbf ft)

ar

Screw, rear brake disc M6 14 Nm (10.3 lbf ft)

M

Loctite®243™
c
Za

Screw, seat fixing M6 10 Nm (7.4 lbf ft)

Screw, silent block on frame M6 6 Nm (4.4 lbf ft)
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
Fuel connection on fuel pump M8 15 Nm (11.1 lbf ft)
Nut, foot brake lever M8 20 Nm (14.8 lbf ft)
Zac Martin, [email protected],

316
 TECHNICAL DATA 26

Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft)

Nut, pull switch (US) M8 0.8 Nm (0.59 lbf ft)
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft)
(All standard models)
Screw, bottom triple clamp (All M8 15 Nm (11.1 lbf ft)
special models)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft)
Screw, engine brace M8x15 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, engine brace M8x20 25 Nm (18.4 lbf ft)

52
Loctite®243™

73
Screw, engine sprocket cover M8 15 Nm (11.1 lbf ft)

01
Screw, fork stub M8 15 Nm (11.1 lbf ft)

8/
Screw, front brake caliper M8 25 Nm (18.4 lbf ft)

21
Loctite®243™

16
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)

l.c r:
,0
Screw, manifold M8 15 Nm (11.1 lbf ft)

ai d fo
om
Screw, side stand attachment M8x20 33 Nm (24.3 lbf ft)
(EU/CN/ASEAN) Loctite®2701™
gm e
@ ens

Screw, side stand attachment (US) M8x26 33 Nm (24.3 lbf ft)

Loctite®2701™
tin ic

Screw, subframe bottom M8 30 Nm (22.1 lbf ft)

ar | L

Loctite®2701™
Screw, subframe top M8 35 Nm (25.8 lbf ft)
lm r
ie fü

Loctite®2701™
an ert

Screw, top steering stem (All stan- M8 20 Nm (14.8 lbf ft)

dard models)
yd zi

Screw, top steering stem (All spe- M8 17 Nm (12.5 lbf ft)

ar en

cial models) Loctite®243™

ch Liz

Screw, top triple clamp (All stan- M8 20 Nm (14.8 lbf ft)

dard models)
Screw, top triple clamp (All special M8 17 Nm (12.5 lbf ft)
models)
za

Engine bracket screw M10 60 Nm (44.3 lbf ft)

Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)
,
in

Remaining screws, chassis M10 45 Nm (33.2 lbf ft)

t
ar

Screw, handlebar support M10 40 Nm (29.5 lbf ft)

M

Loctite®243™
c

Nut, fuel pump M12 15 Nm (11.1 lbf ft)

Za

Screw, bottom shock absorber M12 80 Nm (59 lbf ft)

Loctite®2701™
Screw, top shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft)
Zac Martin, [email protected],

317
 26 TECHNICAL DATA

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft)
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
Screw-in fitting, cooling system M24x1.5 18 Nm (13.3 lbf ft)
Loctite®243™

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za
Zac Martin, [email protected],

318
 CLEANING, CARE 27

27.1 Cleaning the motorcycle

Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

52
73
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.

01
Avoid direct sunshine when cleaning the motorcycle.

8/
21
– Close off exhaust system to keep water from entering.

16
– Remove the coarse dirt particles with a gentle water jet.

l.c r:
,0
– Spray the heavily soiled parts with a normal commercial motor-

ai d fo
om
cycle cleaner and clean using a brush.
Motorcycle cleaner ( p. 373)
gm e
@ ens

Info
tin ic

Use warm water containing normal motorcycle cleaner

ar | L

401061-01 and a soft sponge.

Never apply motorcycle cleaner to a dry vehicle; always
lm r
ie fü

rinse the vehicle with water first.

an ert

– After rinsing the motorcycle with a gentle spray of water, allow

it to dry thoroughly.
yd zi

–
ar en

Remove the closure of the exhaust system.

ch Liz

Warning
Danger of accidents Moisture and dirt impair the
brake system.
– Brake carefully several times to dry out and remove
za

dirt from the brake linings and the brake discs.

,
in

– After cleaning, ride the vehicle a short distance until the

t
ar

engine warms up.

M

Info
c

The heat produced causes water at inaccessible loca-

Za

tions in the engine and on the brake system to evapo-

rate.

– After the motorcycle has cooled down, lubricate all moving

parts and pivot points.
– Clean the chain. ( p. 132)
Zac Martin, [email protected],

319
 27 CLEANING, CARE

– Treat bare metal (except for brake discs and the exhaust sys-
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 373)
– Treat all plastic parts and powder-coated parts with a mild
cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 373)
(EU/CN/ASEAN)
– Oil the steering lock.
Universal oil spray ( p. 373)

27.2 Checks and maintenance steps for winter operation

52
Info

73
If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precau-

01
tions against aggressive road salt.

8/
If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water

21
enhances the corrosive effects of salt.

16
– Clean the motorcycle. ( p. 319)

l.c r:
,0
ai d fo
– Clean the brakes.

om
Info
gm e
@ ens

After EVERY trip on salted roads, thoroughly clean the

brake calipers and brake linings, after they have cooled
tin ic

down and without removing them, with cold water and

ar | L

dry them carefully.

After riding on salted roads, thoroughly clean the vehi-
lm r

cle with cold water and dry it well.

ie fü

401060-01

–
an ert

Treat engine, link fork, and all other bare or zinc-plated parts
(except the brake discs) with a wax-based corrosion inhibitor.
yd zi
ar en

Info
ch Liz

Corrosion inhibitor must not come in contact with the

brake discs as this would greatly reduce the braking
force.

– Clean the chain. ( p. 132)

, za
in
t
ar
M
c
Za
Zac Martin, [email protected],

320
 STORAGE 28

28.1 Storage

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.

Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them per-

52
formed.

73
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

01
avoid long workshop waiting times at the start of the new season.

8/
21
– Clean the motorcycle. ( p. 319)

16
– Change the gear oil. ( p. 286)

l.c r:
,0
– Check the antifreeze and coolant level. ( p. 275)

ai d fo
om
– When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
gm e
@ ens

Fuel additive ( p. 372)

– Refuel.
tin ic

– Add 2-stroke oil. ( p. 289)

ar | L

401058-01
– Check tire pressure. ( p. 119)
lm r
ie fü

– Remove the 12-V battery. ( p. 143)

– Charge the 12-V battery.
an ert

Guideline
yd zi

Ideal charging and storage 10 … 20 °C (50 … 68 °F)

ar en

temperature of the lithium-

ch Liz

ion battery
– Store the vehicle in a dry location that is not subject to large
fluctuations in temperature.

Info
za

KTM recommends jacking up the motorcycle.

,
in

– Raise the motorcycle with a lift stand. ( p. 13)

t
ar

– Cover the vehicle with a tarp or similar cover that is permeable

M

to air.
c
Za

Zac Martin, [email protected],

321
 28 STORAGE

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. Because
the engine will not warm up sufficiently, the water
vapor produced during combustion will condense, caus-
ing engine parts and the exhaust system to rust.

28.2 Preparing for use after storage

– Remove the motorcycle from the lift stand. ( p. 13)
– Install the 12-V battery. ( p. 145)
– Perform checks and maintenance measures when preparing for
use.
– Make a test ride.

52
73
01
8/
401059-01

21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
tin
ar
M
c
Za
Zac Martin, [email protected],

322
 SERVICE SCHEDULE 29

29.1 Additional information

Any further work that results from the compulsory work or from the recommended work must be ordered sepa-
rately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.

29.2 Required work

Every 10 operating hours when used for motorsports
Every 40 operating hours
Every 20 operating hours
After 5 operating hours
After 1 operating hour

52
Read out the fault memory using the KTM diagnostics tool. ○ ○ ● ● ●

73
Check that the electrical system is functioning properly. ○ ● ● ●

01
Check and charge the 12-V battery. ● ● ●

8/
Check the front brake linings. ( p. 151) ● ● ●

21
Check the brake linings of the rear brake. ( p. 158) ● ● ●

16
Check the brake discs. ( p. 120) ● ● ●

l.c r:
,0
Check the brake lines for damage and leakage. ● ● ●

ai d fo
Check the rear brake fluid level. ( p. 162) ● ● ●

om
Check the free travel of the foot brake lever. ( p. 160) ● ● ●
gm e
@ ens

Check the frame. ( p. 56) ● ● ●

Check the link fork. ( p. 84) ● ● ●
tin ic

Check the fork bearing for play. ( p. 87) ● ●

ar | L

Check the shock absorber heim joint for play. ( p. 84) ● ●

lm r

Check the tire condition. ( p. 119) ○ ● ● ●

ie fü

Check tire pressure. ( p. 119) ○ ● ● ●

an ert

Check the wheel bearing for play. ( p. 120) ● ● ●

yd zi

Check the wheel hubs. ● ● ●

ar en

Check the rim run-out. ( p. 121) ○ ● ●

ch Liz

Check the spoke tension. ( p. 122) ○ ● ● ●

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 133) ● ● ●
Check the chain tension. ( p. 133) ○ ● ● ●
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth ● ● ●
za

operation.
,

Check/correct the fluid level of the hydraulic clutch. ( p. 264) ● ● ●

in

Check the front brake fluid level. ( p. 154) ● ● ●

t
ar

Check the free travel of the hand brake lever. ( p. 153) ● ● ●

M

Check the steering head bearing for play. ( p. 44) ○ ● ●

c
Za

Change the spark plug and spark plug connector. ( p. 304) ●

Check the reed valve housing, reed valve, and intake flange. ( p. 226) ● ●
Change the gear oil. ( p. 286) ○ ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, ○ ● ● ●
leaks, and incorrect routing.
Zac Martin, [email protected],

323
 29 SERVICE SCHEDULE

Every 10 operating hours when used for motorsports

Every 40 operating hours
Every 20 operating hours
After 5 operating hours
After 1 operating hour
Check the antifreeze and coolant level. ( p. 275) ○ ● ● ●
Check the cables for damage and for routing without kinks. ● ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set cor- ○ ● ● ●
rectly.
Clean the air filter and air filter box. ( p. 100) ● ● ●
Change the glass fiber yarn filling of the main silencer. ( p. 97) ● ●
Service the fork. ( p. 20) ●
Perform the shock absorber service. ( p. 66) ●
Check the tightness of the easily accessible, safety-relevant screws and nuts. ○ ● ● ●

52
Change the fuel screen. ( p. 106) ○ ● ● ●

73
Check the fuel pressure. ( p. 113) ● ● ●

01
Check the headlight setting. ( p. 167) ○ ● ● ●

8/
Check the idle speed. ● ● ●

21
Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ●

16
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ○ ● ● ●

l.c r:
,0
Make a service entry in KTM Dealer.net. ○ ○ ● ● ●

ai d fo
om
○ One-time interval
● Periodic interval
gm e
@ ens

29.3 Recommended work

tin ic
ar | L

Every 40 operating hours when used for motorsports

Every 10 operating hours when used for motorsports
lm r
ie fü

every 48 months
an ert

every 12 months
Every 80 operating hours
yd zi

Every 40 operating hours

ar en

After 20 operating hours

ch Liz

After 10 operating hours

Change the front brake fluid. ( p. 156) ● ●
Change the rear brake fluid. ( p. 163) ● ●
● ●
za

Change the hydraulic clutch fluid. ( p. 265)

Lubricate the steering head bearing. ( p. 38) ● ●
,
in

Clean the pressure sensor hose. ( p. 174) ● ● ● ●

t
ar

Service the fork. ( p. 20) ○

M

Perform the shock absorber service. ( p. 66) ○

c

Check the electric starter drive. ( p. 239) ● ●

Za

Change the fuel filter. ( p. 107) ● ●

Change the piston and check the cylinder. ● ●
Change the oil pump; clean the oil screen. ( p. 291) ●
Clean the oil screen in the oil tank. ( p. 295) ●
Clean the protection cap of the pressure sensor. ( p. 174) ● ● ● ●
Zac Martin, [email protected],

324
 SERVICE SCHEDULE 29

Every 40 operating hours when used for motorsports

Every 10 operating hours when used for motorsports
every 48 months
every 12 months
Every 80 operating hours
Every 40 operating hours
After 20 operating hours
After 10 operating hours
Change the coolant. ( p. 279) ●
Perform minor engine service. (Check the exhaust control for functioning ● ● ● ●
and smooth operation. Check the clutch.)
Perform major engine service including removing and installing the engine. ● ●
(Change the connecting rod, conrod bearing, and crank pin. Clean the
hose connections of the pressure sensor. Check the transmission and shift
mechanism. Change all engine bearings.)

52
○ One-time interval

73
● Periodic interval

01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
,za
t in
ar
M
c
Za

Zac Martin, [email protected],

325
Zac Martin, [email protected],

326
30.1

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 1 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02091-01
52
 S21
A11

K10
G10

M10
Components:

Battery

Start button
Starter motor
EFI control unit

Za
c
M
ar
Starter relay with main fuse

tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

327
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

328
30.2

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 2 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02092-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
F2 Fuse
F3 Fuse
G20 Alternator
K12 Light relay
K30 Power relay
K50 Radiator fan relay (if installed)
M14 Radiator fan (if installed)
T20 Voltage regulator

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

329
Zac Martin, [email protected],

330
30.3

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 3 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02093-01
52
 S33
P35
P15
P13
E75
Components:

Horn
Position light
Headlight unit

Za
c
M
Combination instrument

Combination switch, left

ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

331
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

332
30.4

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 4 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02094-01
52
 P36
B77
B76
Components:

Brake/tail light

Za
c
M
Rear brake light switch
Front brake light switch

ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

333
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

334
30.5

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 5 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02095-01
52
 WIRING DIAGRAM 30

Components:
E60 License plate lamp
K20 Turn signal relay
P21 Turn signal indicator lamp
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S33 Combination switch, left

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

335
Zac Martin, [email protected],

336
30.6

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 6 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02096-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B32 Fuel level sensor
B46 Oil level sensor
B51 Lambda sensor
F1 Fuse
M20 Fuel vapor valve
P13 Combination instrument
P27 Oil level warning lamp
R51 Ignition coil

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

337
Zac Martin, [email protected],

338
30.7

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 7 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02097-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B70 Front wheel speed sensor
F4 Fuse
M13 Fuel pump
M35 Oil pump
M51/1 Injection valve 1
M51/2 Injection valve 2
P13 Combination instrument
R30 CAN-bus terminating resistor 1
X295 Diagnostics connector

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

339
Zac Martin, [email protected],

340
30.8

Za
c
30 WIRING DIAGRAM

M
ar
tin
, za
Page 8 of 8 (EU/ASEAN)

ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02098-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B12 Intake air temperature sensor
B13 Ambient air pressure sensor
B21 Coolant temperature sensor
B26 Tilt sensor
B37 Crankshaft speed sensor
B43 Throttle valve position sensor
B47 Crankcase pressure sensor
S53 Map Select switch (if installed)
Cable colors:
bl Black
br Brown
bu Blue

52
gn Green

73
gr Gray

01
lbu Light blue

8/
or Orange

21
pk Pink

16
pu Violet

l.c r:
,0
rd Red

ai d fo
om
wh White
ye Yellow
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

341
Zac Martin, [email protected],

342
30.9

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 1 of 6 (US)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02099-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
G10 Battery
K10 Starter relay with main fuse
M10 Starter motor
S21 Start button
S20 Stop button

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

343
Zac Martin, [email protected],

344
30.10

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 2 of 6 (US)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02100-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
F2 Fuse
F3 Fuse
G20 Alternator
K12 Light relay
K30 Power relay
K50 Radiator fan relay (if installed)
M14 Radiator fan (if installed)
T20 Voltage regulator

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

345
Zac Martin, [email protected],

346
30.11

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 3 of 6 (US)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02101-01
52
 S30
P36
P35
E75
Components:

Light switch
Position light
Headlight unit

Brake/tail light

Za
c
M
ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

347
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

348
30.12

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 4 of 6 (US)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02102-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B32 Fuel level sensor
B46 Oil level sensor
F1 Fuse
P13 Combination instrument
P27 Oil level warning lamp
R51 Ignition coil

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

349
Zac Martin, [email protected],

350
30.13

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 5 of 6 (US)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02103-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B70 Front wheel speed sensor
F4 Fuse
M13 Fuel pump
M35 Oil pump
M51/1 Injection valve 1, cylinder 1
M51/2 Injection valve 2, cylinder 1
P13 Combination instrument
R30 CAN-bus terminating resistor 1
X295 Diagnostics connector

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

351
Zac Martin, [email protected],

352
30.14

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 6 of 6 (US)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02104-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B12 Intake air temperature sensor
B13 Ambient air pressure sensor
B21 Coolant temperature sensor
B26 Tilt sensor
B37 Crankshaft speed sensor
B43 Throttle valve position sensor
B47 Crankcase pressure sensor
S53 Map Select switch (if installed)
Cable colors:
bl Black
br Brown
bu Blue

52
gn Green

73
gr Gray

01
lbu Light blue

8/
or Orange

21
pk Pink

16
pu Violet

l.c r:
,0
rd Red

ai d fo
om
wh White
ye Yellow
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

353
Zac Martin, [email protected],

354
30.15

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 1 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02105-01
52
 S21
A11

K10
G10

M10
Components:

Battery

Start button
Starter motor
EFI control unit

Za
c
M
ar
Starter relay with main fuse

tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

355
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

356
30.16

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 2 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02106-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
F2 Fuse
F3 Fuse
G20 Alternator
K12 Light relay
K30 Power relay
K50 Radiator fan relay (if installed)
M14 Radiator fan (if installed)
T20 Voltage regulator

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

357
Zac Martin, [email protected],

358
30.17

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 3 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02107-01
52
 S33
P35
P15
P13
E75
Components:

Horn
Position light
Headlight unit

Za
c
M
Combination instrument

Combination switch, left

ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

359
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

360
30.18

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 4 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02108-01
52
 P36
B77
B76
Components:

Brake/tail light

Za
c
M
Rear brake light switch
Front brake light switch

ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

361
8/
01
73
52
WIRING DIAGRAM 30

Zac Martin, [email protected],

Zac Martin, [email protected],

362
30.19

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 5 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02109-01
52
 WIRING DIAGRAM 30

Components:
E60 License plate lamp
K20 Turn signal relay
P21 Turn signal indicator lamp
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S33 Combination switch, left

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

363
Zac Martin, [email protected],

364
30.20

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 6 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02110-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B32 Fuel level sensor
B46 Oil level sensor
B51 Lambda sensor
F1 Fuse
P13 Combination instrument
P27 Oil level warning lamp
R51 Ignition coil

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

365
Zac Martin, [email protected],

366
30.21

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 7 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02111-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B70 Front wheel speed sensor
F4 Fuse
M13 Fuel pump
M35 Oil pump
M51/1 Injection valve 1
M51/2 Injection valve 2
P13 Combination instrument
R30 CAN-bus terminating resistor 1
X295 Diagnostics connector

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
za
,
t in
ar
M
c
Za

Zac Martin, [email protected],

367
Zac Martin, [email protected],

368
30.22

Za
c
30 WIRING DIAGRAM

M
ar
tin
Page 8 of 8 (CN)

, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Y02112-01
52
 WIRING DIAGRAM 30

Components:
A11 EFI control unit
B12 Intake air temperature sensor
B13 Ambient air pressure sensor
B21 Coolant temperature sensor
B26 Tilt sensor
B37 Crankshaft speed sensor
B43 Throttle valve position sensor
B47 Crankcase pressure sensor
S53 Map Select switch (if installed)
Cable colors:
bl Black
br Brown
bu Blue

52
gn Green

73
gr Gray

01
lbu Light blue

8/
or Orange

21
pk Pink

16
pu Violet

l.c r:
,0
rd Red

ai d fo
om
wh White
ye Yellow
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

369
 31 SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1

Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade

52
and unsuitable antifreeze causes corrosion, deposits and frothing.
–

73
Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec-
tion and lubrication properties.

01
– Only use coolant that complies with the requirements stated (see specifications on the container) and that

8/
has the relevant properties.

21
Antifreeze protection to at least −25 °C (−13 °F)

16
l.c r:
,0
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs

ai d fo
to be diluted.

om
The use of premixed coolant is recommended.
gm e
@ ens

Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.
tin ic
ar | L

Recommended supplier
MOTOREX®
lm r
ie fü

– COOLANT M3.0
an ert

Engine oil (15W/50)

yd zi

Standard/classification
ar en

– JASO T903 MA2 ( p. 393)

ch Liz

– SAE ( p. 393) (15W/50)

Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
za

Recommended supplier
MOTOREX®
,
in

– Top Speed 4T
t
ar

Engine oil, 2-stroke

M

Standard/classification
c

– JASO FD ( p. 393)
Za

Guideline
– Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
Zac Martin, [email protected],

370
 SUBSTANCES 31

Recommended supplier
MOTOREX®
– Cross Power 2T

Fork oil (SAE 4) (48601166S1)

Standard/classification
– SAE ( p. 393) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.

Shock absorber fluid (SAE 2.5) (50180751S1)

Standard/classification
– SAE ( p. 393) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit

52
the corresponding properties.

73
01
Super unleaded (ROZ 95)

8/
Standard/classification

21
– DIN EN 228 (ROZ 95)

16
Guideline
– Only use super unleaded fuel that matches or is equivalent to the specified standard.

l.c r:
,0
ai d fo
– Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.

om
Info
gm e
@ ens

Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15,
E25, E85, E100).
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

371
 32 AUXILIARY SUBSTANCES

Air filter cleaner

Recommended supplier
MOTOREX®
– Racing Bio Dirt Remover

Chain cleaner
Recommended supplier
MOTOREX®
– Chain Clean

Fuel additive
Recommended supplier
MOTOREX®
– Fuel Stabilizer

52
High viscosity grease

73
Recommended supplier

01
SKF®
– LGHB 2

8/
21
Long-life grease

16
Recommended supplier

l.c r:
,0
MOTOREX®

ai d fo
om
– Bike Grease 2000 gm e
@ ens

Lubricant (T158)
Recommended supplier
tin ic

Lubcon®
ar | L

– Turmogrease® PP 300
lm r
ie fü

Lubricant (T14034)
an ert

Recommended supplier
WP Performance Systems
yd zi

– WP Racing Grease IPR 2

ar en
ch Liz

Lubricant (T625)
Recommended supplier
Molykote®
– 33 Medium
za

Lubricant (T159)
,
in

Recommended supplier
t
ar

Bel‑Ray®
– MC‑11®
M
c
Za
Zac Martin, [email protected],

372
 AUXILIARY SUBSTANCES 32

Motorcycle cleaner
Recommended supplier
MOTOREX®
– Moto Clean

Multi-purpose grease (00062010051)

Recommended supplier
Klüber Lubrication®
– CENTOPLEX 2 EP

Off-road chain spray

Recommended supplier
MOTOREX®
– Chainlube Offroad

52
Oil for foam air filter

73
Recommended supplier

01
MOTOREX®
– Racing Bio Liquid Power

8/
21
Preserving materials for paints, metal and rubber

16
Recommended supplier

l.c r:
,0
MOTOREX®

ai d fo
om
– Moto Protect gm e
@ ens

Silicone spray
Recommended supplier
tin ic

MOTOREX®
ar | L

– Silicone Spray
lm r
ie fü

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

Recommended supplier
MOTOREX®
yd zi

– Quick Cleaner
ar en
ch Liz

Universal oil spray

Recommended supplier
MOTOREX®
– Joker 440 Synthetic
za
,
tin
ar
M
c
Za

Zac Martin, [email protected],

373
 33 SPECIAL TOOLS

Bleeder cover
Art. no.: 00029013005

H00504-01

Bleeder cover
Art. no.: 00029013006

52
73
01
8/
21
16
H00505-01

l.c r:
,0
ai d fo
Bleeding device

om
Art. no.: 00029013100
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00518-01
ar en

Cable connector unlocking kit

ch Liz

Art. no.: 00029014000

,za
in
t
ar
M

H02257-01
c
Za
Zac Martin, [email protected],

374
 SPECIAL TOOLS 33

Break out box

Art. no.: 00029095001

H01895-01

Adapter and template M3C

Art. no.: 00029095013

52
73
01
8/
21
16
H02568-01

l.c r:
,0
ai d fo
EU battery charger XCharge‑professional

om
Art. no.: 00029095050
gm e
@ ens

Feature
EU safety plug
tin ic

Nominal voltage 230 V

ar | L

Mains fuse 16 A
lm r
ie fü

Power cable length 5 m (16 ft)

approx.
an ert

Charger cable length 5 m (16 ft)

yd zi

H01065-01
approx.
ar en
ch Liz

US battery charger XCharge‑professional

Art. no.: 00029095051
Feature
US plug
za

Nominal voltage 120 V

,

Mains fuse 32 A
in
t

Power cable length 5 m (16 ft)

ar

approx.
M

Charger cable length 5 m (16 ft)

c

H01065-01
approx.
Za

Zac Martin, [email protected],

375
 33 SPECIAL TOOLS

UK battery charger XCharge‑professional

Art. no.: 00029095052
Feature
UK safety plug
Nominal voltage 230 V
Mains fuse 16 A
Power cable length 5 m (16 ft)
approx.
Charger cable length 5 m (16 ft)
H01065-01
approx.

Tachometer
Art. no.: 45129075000

52
73
01
8/
21
16
l.c r:
H00525-01

,0
ai d fo
om
Syringe
gm e
Art. no.: 50329050000
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

500689-01
ar en
ch Liz

Pressing tool
Art. no.: 50429005000
za
,
tin
ar
M
c

H00568-01
Za
Zac Martin, [email protected],

376
 SPECIAL TOOLS 33

Holding wrench
Art. no.: 51129003000

H00575-01

Setting gauge
Art. no.: 54829001100

52
73
01
8/
21
16
H00583-01

l.c r:
,0
ai d fo
Separator plate

om
Art. no.: 54829009000
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00584-01
ar en

Insert for crankshaft pressing tool

ch Liz

Art. no.: 54829108000

, za
tin
ar
M

H00994-01
c
Za

Zac Martin, [email protected],

377
 33 SPECIAL TOOLS

Holder and fitting for work stand

Art. no.: 55429002000

H01175-01

Holding wrench
Art. no.: 55429012000

52
73
01
8/
21
16
H01176-01

l.c r:
,0
ai d fo
Socket wrench

om
Art. no.: 55529021000
gm e
@ ens

Feature
Square 5 mm (0.2 in)
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H02866-01
ar en

Gear segment
ch Liz

Art. no.: 56012004000

,za
in
t
ar
M

H00588-01
c
Za
Zac Martin, [email protected],

378
 SPECIAL TOOLS 33

Puller
Art. no.: 58012009000

H00592-01

Puller
Art. no.: 58429037043
Feature

52
Inside diameter 43.9 mm (1.728 in)

73
01
8/
21
16
H00598-01

l.c r:
,0
ai d fo
Peak voltage adapter

om
Art. no.: 58429042000
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00599-01
ar en

Footrest spring plier

ch Liz

Art. no.: 58429083000

, za
t in
ar
M

H00601-01
c
Za

Zac Martin, [email protected],

379
 33 SPECIAL TOOLS

Tool bracket
Art. no.: 58429089000

H00603-01

Pressing tool
Art. no.: 58429091000

52
73
01
8/
21
16
H00604-01

l.c r:
,0
ai d fo
Pressing tool

om
Art. no.: 58429092000
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00605-01
ar en

Torque wrench kit

ch Liz

Art. no.: 58429094000

Feature
Torque 3 … 15 Nm (2.2 … 11.1 lbf ft)
za

Open ended bit 3.9 mm (0.154 in)

Open ended bit 4.9 mm (0.193 in)
,
in

Open ended bit 5.5 mm (0.217 in)

t
ar

Open ended bit 6.0 mm (0.236 in)

M

H00606-01
Open ended bit 6.8 mm (0.268 in)
c

Bit diameter 5.9 mm (0.232 in)

Za
Zac Martin, [email protected],

380
 SPECIAL TOOLS 33

Feeler gauge
Art. no.: 59029041100
Feature
5 piece 0.10 … 0.25 mm (0.0039 …
0.0098 in)

H00616-01

Pressing tool
Art. no.: 60029046128

52
73
01
8/
21
16
Z01544-10

l.c r:
,0
ai d fo
Hose clamp pliers

om
Art. no.: 60029057000
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00650-01
ar en

Testing hose
ch Liz

Art. no.: 61029093000

, za
in
t
ar
M

H00659-01
c
Za

Zac Martin, [email protected],

381
 33 SPECIAL TOOLS

Pressure testing tool

Art. no.: 61029094000

H00660-01

Engine work stand

Art. no.: 61229001000

52
73
01
8/
21
16
H00662-01

l.c r:
,0
ai d fo
Crankshaft pressing tool

om
Art. no.: 75029047000
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00714-01
ar en

Lift stand
ch Liz

Art. no.: 78129955100

Feature
Height 315 … 425 mm (12.4 … 16.73 in)
za

Load ≤ 150 kg (≤ 331 lb.)

,
tin
ar
M

H00980-01
c
Za
Zac Martin, [email protected],

382
 SPECIAL TOOLS 33

Footrest spring plier

Art. no.: 79029083000

H00804-01

Mounting tool
Art. no.: 79129081000
Feature

52
Hexagonal driver 13 mm (0.51 in)

73
01
8/
21
16
H02653-01

l.c r:
,0
ai d fo
Pressing tool

om
Art. no.: 79629000044
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H01750-01
ar en

Hook wrench
ch Liz

Art. no.: 90129051000

, za
t in
ar
M

H00831-01
c
Za

Zac Martin, [email protected],

383
 33 SPECIAL TOOLS

Diagnostics tablet
Art. no.: 00029XC2001

H02645-01

Hand strap
Art. no.: 00029XC2002

52
73
01
8/
21
16
H02883-01

l.c r:
,0
ai d fo
Battery charger

om
Art. no.: 00029XC2003
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H02882-01
ar en

VCI
ch Liz

Art. no.: 00029XC2004

,za
in
t
ar
M

H02646-01
c
Za
Zac Martin, [email protected],

384
 SPECIAL TOOLS 33

VCI attachment
Art. no.: 00029XC2005

H03078-01

Protective film
Art. no.: 00029XC2006

52
73
01
8/
21
16
500361-01

l.c r:
,0
ai d fo
Diagnostics cable extension

om
Art. no.: 00029XC2007
gm e
@ ens

Feature
Length approx. 1.15 m (3.77 ft)
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H02880-01
ar en

USB cable
ch Liz

Art. no.: 00029XC2008

Feature
Length approx. 5 m (16 ft)
, za
t in
ar
M

H02879-01
c
Za

Zac Martin, [email protected],

385
 33 SPECIAL TOOLS

12-V power supply cable

Art. no.: 00029XC2009

H02881-01

RideRecorder trigger
Art. no.: 00029XC2010

52
73
01
8/
21
16
H02648-01

l.c r:
,0
ai d fo
Case

om
Art. no.: 00029XC2011
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H03082-01
ar en

Docking station
ch Liz

Art. no.: 00029XC2012

, za
in
t
ar
M

H03077-01
c
Za
Zac Martin, [email protected],

386
 SPECIAL TOOLS 33

Wall attachment
Art. no.: 00029XC2013

H03080-01

Battery
Art. no.: 00029XC2014

52
73
01
8/
21
16
H03079-01

l.c r:
,0
ai d fo
Input stylus

om
Art. no.: 00029XC2015
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H03083-01
ar en

Spring hook
ch Liz

Art. no.: 50305017000C1

, za
in
t
ar
M

500454-01
c
Za

Zac Martin, [email protected],

387
 33 SPECIAL TOOLS

Holding wrench
Art. no.: A44029012000

502386-01

Depth micrometer
Art. no.: T107S

52
73
01
8/
21
16
H00842-01

l.c r:
,0
ai d fo
Drift

om
Art. no.: T120
gm e
@ ens

Feature
Diameter 8 mm (0.31 in)
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00844-01
ar en

Mounting sleeve
ch Liz

Art. no.: T1204

Feature
Diameter 25.5 … 30.5 mm (1.004 … 1.201 in)
, za
in
t
ar
M

H00878-01
c
Za
Zac Martin, [email protected],

388
 SPECIAL TOOLS 33

Calibrating unit
Art. no.: T1205
Feature
Diameter 18 mm (0.71 in)

H00879-01

Pressing tool
Art. no.: T1206
Feature

52
Diameter 15 … 30 mm (0.59 … 1.18 in)

73
01
8/
21
16
H00880-01

l.c r:
,0
ai d fo
Pressing tool

om
Art. no.: T1207S
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00881-01
ar en

Vacuum pump
ch Liz

Art. no.: T1240S

, za
in
t
ar
M

H00890-01
c
Za

Zac Martin, [email protected],

389
 33 SPECIAL TOOLS

Protecting sleeve
Art. no.: T1401
Feature
Diameter 48 mm (1.89 in)

H00894-01

Clamping stand
Art. no.: T14016S
Feature

52
Diameter 12 mm (0.47 in)

73
01
8/
21
16
H01036-01

l.c r:
,0
ai d fo
Ring wrench

om
Art. no.: T14017
gm e
@ ens

Feature
Hexagonal part 50 mm (1.97 in)
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H00904-01
ar en

Support tool
ch Liz

Art. no.: T14026S1

Feature
M12
za

Diameter 17 mm (0.67 in)

,
in
t
ar
M

H00916-01
c
Za
Zac Martin, [email protected],

390
 SPECIAL TOOLS 33

Clamping stand
Art. no.: T1403S
Feature
Diameter 48 mm (1.89 in)
Diameter 60 mm (2.36 in)

H00896-01

Mounting tool
Art. no.: T14040S
Feature

52
Diameter 48 mm (1.89 in)

73
01
8/
21
16
H00922-01

l.c r:
,0
ai d fo
Special socket

om
Art. no.: T14087
gm e
@ ens

Feature
Drive 1/2 in
tin ic

External diameter 44 mm (1.73 in)

ar | L

Internal diameter 29.5 mm (1.161 in)

lm r
ie fü
an ert
yd zi

H01737-01
ar en

Pressing tool
ch Liz

Art. no.: T1504

Feature
Diameter 18 mm (0.71 in)
, za
in
t
ar
M

H00899-01
c
Za

Zac Martin, [email protected],

391
 33 SPECIAL TOOLS

Mounting tool
Art. no.: T150S

H00852-01

Mounting sleeve
Art. no.: T1554
Feature

52
Diameter 18 mm (0.71 in)

73
01
8/
21
16
H00903-01

l.c r:
,0
ai d fo
Filling adapter

om
Art. no.: T1565
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi

H02354-01
ar en

Filling tool
ch Liz

Art. no.: T170S1

, za
in
t
ar
M

H00855-01
c
Za
Zac Martin, [email protected],

392
 STANDARDS 34

JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2
standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor-
cycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high
performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.

SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils
according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.

JASO FD

52
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of
racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even

73
under extreme operating conditions.

01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za

Zac Martin, [email protected],

393
 35 GLOSSARY OF TECHNICAL TERMS

TPI Injection into transfer ducts (Trans- Electronic fuel injection in which two injection valves
fer Port Injection) in the transfer ducts of the cylinders are used
PA Preload adjuster Device on the suspension components that enables
the adjustment of the spring preload

52
73
01
8/
21
16
l.c r:
,0
ai d fo
om
gm e
@ ens
tin ic
ar | L
lm r
ie fü
an ert
yd zi
ar en
ch Liz
, za
t in
ar
M
c
Za
Zac Martin, [email protected],

394
 cf.
ca.

no.
i.a.
e.g.
etc.

poss.
Art. no.
circa

number
possibly
compare

et cetera
inter alia
Za
for example

c
Article number

M
ar
tin
, za
ch Liz
ar en
yd zi
an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21

395
8/
01
73
52
LIST OF ABBREVIATIONS 36

Zac Martin, [email protected],

 INDEX

of the front brake, changing . . . . . . . . . . . . 151

INDEX

1 of the rear brake, changing . . . . . . . . . . . . 158

12-V battery rear brake, checking . . . . . . . . . . . . . . . . . 158
charging . . . . . . . . . . . . . . . . . . . . . . . . . 147 C
installing . . . . . . . . . . . . . . . . . . . . . . . . . 145
Capacity
negative cable, connecting . . . . . . . . . . . . . 143
coolant . . . . . . . . . . . . . . . . . . . . . . 278, 312
negative cable, disconnecting . . . . . . . . . . . 143
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
removing . . . . . . . . . . . . . . . . . . . . . . . . . 143
Gear oil . . . . . . . . . . . . . . . . . . 188, 286, 312
2 Cartridge
2-stroke oil level of fork legs, disassembling . . . . . . . . . . . . . . 23
checking . . . . . . . . . . . . . . . . . . . . . . . . . 288 of the fork legs, assembling . . . . . . . . . . . . . 29
2-stroke oil tank cap Chain
closing . . . . . . . . . . . . . . . . . . . . . . . . . . 289 checking . . . . . . . . . . . . . . . . . . . . . . . . . 133
opening . . . . . . . . . . . . . . . . . . . . . . . . . . 288 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 132
Chain guide

52
A
checking . . . . . . . . . . . . . . . . . . . . . . . . . 133

73
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 100 Chain tension

01
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 99 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 136

8/
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 99 checking . . . . . . . . . . . . . . . . . . . . . . . . . 133

21
Air filter box Characteristic map of the throttle response

16
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 100 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 54

l.c r:
,0
Air filter box cover Charging voltage

ai d fo
om
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 98 checking . . . . . . . . . . . . . . . . . . . . . . . . . 148
preparing for securing . . . . . . . . . . . . . . . . 100 Clutch
gm e
@ ens

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 98 checking . . . . . . . . . . . . . . . . . . . . . . . . . 266

Alternator fluid level, checking/correcting . . . . . . . . . . 264
tin ic

stator winding, checking . . . . . . . . . . . . . . 301 fluid, changing . . . . . . . . . . . . . . . . . . . . . 265

ar | L

Ambient pressure Clutch lever

basic position, adjusting . . . . . . . . . . . . . . . 51
lm r

programming . . . . . . . . . . . . . . . . . . . . . . 307
ie fü

Antifreeze Cold start button . . . . . . . . . . . . . . . . . . . . . . . 308

an ert

checking . . . . . . . . . . . . . . . . . . . . . . . . . 275 Combination instrument

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 170
yd zi

Auxiliary substances . . . . . . . . . . . . . . . . . . . . . 10
ar en

clock, setting . . . . . . . . . . . . . . . . . . . . . . 171

B
combination instrument battery, changing . . 168
ch Liz

Brake disc kilometers or miles, setting . . . . . . . . . . . . 169

of rear brake, changing . . . . . . . . . . . . . . . 129 overview . . . . . . . . . . . . . . . . . . . . . . . . . 169
of the front brake, changing . . . . . . . . . . . . 125 Compression damping
Brake discs fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 15
za

checking . . . . . . . . . . . . . . . . . . . . . . . . . 120 Coolant

,

Brake fluid changing . . . . . . . . . . . . . . . . . . . . . . . . . 279

in

of front brake, adding . . . . . . . . . . . . . . . . 155 draining . . . . . . . . . . . . . . . . . . . . . . . . . 276

t
ar

of rear brake, adding . . . . . . . . . . . . . . . . . 162 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 277

M

of rear brake, changing . . . . . . . . . . . . . . . 163 Coolant level

c

of the front brake, changing . . . . . . . . . . . . 156 checking . . . . . . . . . . . . . . . . . . . . . . 275-276

Za

Brake fluid level Coolant pipe

of front brake, checking . . . . . . . . . . . . . . . 154 changing . . . . . . . . . . . . . . . . . . . . . . . . . 280
rear brake, checking . . . . . . . . . . . . . . . . . 162
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 275
Brake linings
Crankshaft speed sensor
front brake, checking . . . . . . . . . . . . . . . . 151
Zac Martin, [email protected],

checking . . . . . . . . . . . . . . . . . . . . . . . . . 302

396
 INDEX

Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . 223 Engine assembly

D alternator cover, installing . . . . . . . . . . . . . 261
balancer shaft, installing . . . . . . . . . . . . . . 245
Diagnostics connector . . . . . . . . . . . . . . . . . . . 150
clutch basket, installing . . . . . . . . . . . . . . 246
Drivetrain kit clutch cover, installing . . . . . . . . . . . . . . . 250
changing . . . . . . . . . . . . . . . . . . . . . . . . . 136 clutch discs, installing . . . . . . . . . . . . . . . 247
E clutch push rod, installing . . . . . . . . . . . . . 262
crankshaft, installing . . . . . . . . . . . . . . . . . 239
Engine
cylinder head, installing . . . . . . . . . . . . . . 260
assembling . . . . . . . . . . . . . . . . . . . . . . . 239
cylinder, installing . . . . . . . . . . . . . . . . . . 253
disassembling . . . . . . . . . . . . . . . . . . . . . 188
engine, removing from the engine work stand 263
installing . . . . . . . . . . . . . . . . . . . . . . . . . 182
gear oil drain plug, installing . . . . . . . . . . . 262
removing . . . . . . . . . . . . . . . . . . . . . . . . . 176
left section of the engine case, installing . . . 241
technical data – engine . . . . . . . . . . . . . . . 309
locking lever, installing . . . . . . . . . . . . . . . 244
working on individual parts . . . . . . . . . . . . 204
piston, installing . . . . . . . . . . . . . . . . . . . 251
Engine – work on the individual parts reed valve housing, installing . . . . . . . . . . . 242

52
connecting rod, conrod bearing, and crank pin, rotor, installing . . . . . . . . . . . . . . . . . . . . . 244
changing . . . . . . . . . . . . . . . . . . . . . . . . . 207

73
shift drum locating unit, installing . . . . . . . 245
crankshaft run-out at the bearing pin, checking 209
shift drum, installing . . . . . . . . . . . . . . . . . 241

01
main shaft, disassembling . . . . . . . . . . . . . 234
shift forks, installing . . . . . . . . . . . . . . . . . 240

8/
piston ring end gap, checking . . . . . . . . . . . 224
shift lever, installing . . . . . . . . . . . . . . . . . 262

21
piston/cylinder, measuring the mounting
shift rails, installing . . . . . . . . . . . . . . . . . 241
clearance . . . . . . . . . . . . . . . . . . . . . . . . 225

16
shift shaft, installing . . . . . . . . . . . . . . . . . 245
reed valve housing, disassembling . . . . . . . . 225

l.c r:
,0
spacer, installing . . . . . . . . . . . . . . . . . . . 261
shift shaft, preassembling . . . . . . . . . . . . . 232

ai d fo
starter motor, installing . . . . . . . . . . . . . . . 243

om
transmission, checking . . . . . . . . . . . . . . . 235
transmission shafts, installing . . . . . . . . . . 240
gm e
Engine - working on the individual parts water pump cover, installing . . . . . . . . . . . 251
@ ens

piston, checking . . . . . . . . . . . . . . . . . . . . 223 X-distance, adjusting . . . . . . . . . . . . . . . . . 256

piston, measuring . . . . . . . . . . . . . . . . . . . 223 X-distance, checking . . . . . . . . . . . . . . . . . 255
tin ic

shift mechanism, checking . . . . . . . . . . . . 233 Z-distance, setting . . . . . . . . . . . . . . . . . . 257

ar | L

Engine – working on the individual parts Engine disassembly

lm r

checking the electric starter drive . . . . . . . . 239 alternator cover, removing . . . . . . . . . . . . . 190
ie fü

clutch cover . . . . . . . . . . . . . . . . . . . . . . . 228 balancer shaft, removing . . . . . . . . . . . . . . 197

an ert

clutch, checking . . . . . . . . . . . . . . . . . . . . 231 clutch basket, removing . . . . . . . . . . . . . . . 196

countershaft, assembling . . . . . . . . . . . . . . 238
yd zi

clutch cover, removing . . . . . . . . . . . . . . . 194

countershaft, disassembling . . . . . . . . . . . . 235
ar en

clutch discs, removing . . . . . . . . . . . . . . . 195

crankshaft bearing inner race, installing . . . . 207 clutch push rod, removing . . . . . . . . . . . . . 189
ch Liz

crankshaft bearing inner race, removing . . . . 206 crankshaft, removing . . . . . . . . . . . . . . . . . 203

cylinder - Nikasil® coating . . . . . . . . . . . . . 223 cylinder head, removing . . . . . . . . . . . . . . . 191
cylinder, checking/measuring . . . . . . . . . . . 209 cylinder, removing . . . . . . . . . . . . . . . . . . 191
exhaust control, checking . . . . . . . . . . . . . 214 engine, clamping into the engine work stand 188
za

exhaust control, installing . . . . . . . . . . . . . 216 gear oil, draining . . . . . . . . . . . . . . . . . . . 189

exhaust control, removing . . . . . . . . . . . . . 210 injection valves, installing . . . . . . . . . . . . . 261
,
in

intake flange, checking . . . . . . . . . . . . . . . 226 Injection valves, removing . . . . . . . . . . . . . 190

t

main shaft, assembling . . . . . . . . . . . . . . . 237

ar

left section of the engine case, removing . . . 201

reed valve housing, assembling . . . . . . . . . . 227
M

locking lever, removing . . . . . . . . . . . . . . . 199

reed valve housing, checking . . . . . . . . . . . 226 piston, removing . . . . . . . . . . . . . . . . . . . . 193
c

reed valve, checking . . . . . . . . . . . . . . . . . 226

Za

reed valve housing, removing . . . . . . . . . . . 201

section of the engine case, left . . . . . . . . . . 205 rotor, removing . . . . . . . . . . . . . . . . . . . . . 199
section of the engine case, right . . . . . . . . . 204 shift drum locating unit, removing . . . . . . . 198
stator, installing . . . . . . . . . . . . . . . . . . . . 305 shift drum, removing . . . . . . . . . . . . . . . . . 202
stator, removing . . . . . . . . . . . . . . . . . . . . 304 shift forks, removing . . . . . . . . . . . . . . . . . 202
shift lever, removing . . . . . . . . . . . . . . . . . 189
Zac Martin, [email protected],

397
 INDEX

shift rails, removing . . . . . . .. . . . . . . . . . 201 Fuel filter

shift shaft, removing . . . . . . .. . . . . . . . . . 198 changing . . . . . . . . . . . . . . . . . . . . . . . . . 107
spacer, removing . . . . . . . . .. . . . . . . . . . 189 Fuel pressure
starter motor, removing . . . . .. . . . . . . . . . 200 checking . . . . . . . . . . . . . . . . . . . . . . . . . 113
transmission shafts, removing . . . . . . . . . . 202
Fuel pump
water pump cover, removing . .. . . . . . . . . . 194
changing . . . . . . . . . . . . . . . . . . . . . . . . . 110
Engine guard
Fuel screen
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
changing . . . . . . . . . . . . . . . . . . . . . . . . . 106
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel tank
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 11
installing . . . . . . . . . . . . . . . . . . . . . . . . . 104
Engine sprocket removing . . . . . . . . . . . . . . . . . . . . . . . . . 103
checking . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fuel tank filler cap
Exhaust control closing . . . . . . . . . . . . . . . . . . . . . . . . . . 101
basic setting, checking/adjusting . . . . . . . . 285 opening . . . . . . . . . . . . . . . . . . . . . . . . . . 101
F Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . 10

52
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuse

73
Foot brake lever changing for individual electrical power

01
basic position, adjusting . . . . . . . . . . . . . . 161 consumers . . . . . . . . . . . . . . . . . . . . . . . . 142

8/
free travel, checking . . . . . . . . . . . . . . . . . 160 main fuse, changing . . . . . . . . . . . . . . . . . 140

21
Footrests G

16
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gear oil

l.c r:
,0
Fork adding . . . . . . . . . . . . . . . . . . . . . . . . . . 287

ai d fo
om
article number . . . . . . . . . . . . . . . . . . . . . . 11 changing . . . . . . . . . . . . . . . . . . . . . . . . . 286
Fork bearing Gear oil level
gm e
@ ens

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 87 checking . . . . . . . . . . . . . . . . . . . . . . . . . 287

Fork legs H
tin ic

assembling . . . . . . . . . . . . . . . . . . . . . . . . 33
ar | L

Hand brake lever

Assembling the tap compression . . . . . . . . . . 29
basic position, adjusting . . . . . . . . . . . . . . 154
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 16
lm r

free travel, adjusting . . . . . . . . . . . . . . . . . 154

ie fü

cartridge, assembling . . . . . . . . . . . . . . . . . 29
free travel, checking . . . . . . . . . . . . . . . . . 153
cartridge, disassembling . . . . . . . . . . . . . . . 23
an ert

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Handlebar position . . . . . . . . . . . . . . . . . . . . . . 49

yd zi

disassembling . . . . . . . . . . . . . . . . . . . . . . 20 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ar en

dust boots, cleaning . . . . . . . . . . . . . . . . . . 17 Headlight

ch Liz

fork, servicing . . . . . . . . . . . . . . . . . . . . . . 20 range, adjusting . . . . . . . . . . . . . . . . . . . . 168

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Headlight bulb
of tap compression, disassembling . . . . . . . . 26 changing . . . . . . . . . . . . . . . . . . . . . . . . . 166
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Headlight mask with headlight
spring preload, adjusting . . . . . . . . . . . . . . . 16
za

installing . . . . . . . . . . . . . . . . . . . . . . . . . 117
Fork protector removing . . . . . . . . . . . . . . . . . . . . . . . . . 117
,
in

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Headlight setting
t

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ar

checking . . . . . . . . . . . . . . . . . . . . . . . . . 167
Frame
M

Heim joint
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 56
c

on the link fork, changing . . . . . . . . . . . . . . 85

Za

Front fender
High-speed compression damping
installing . . . . . . . . . . . . . . . . . . . . . . . . . 116
shock absorber, adjusting . . . . . . . . . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . 116
Front wheel I
installing . . . . . . . . . . . . . . . . . . . . . . . . . 124 Idle speed
Zac Martin, [email protected],

removing . . . . . . . . . . . . . . . . . . . . . . . . . 123 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 307

398
 INDEX

Ignition coil Preparing for use

primary winding, checking . . . . . . . . . . . . . 300 after storage . . . . . . . . . . . . . . . . . . . . . . 322
Ignition system R
checking . . . . . . . . . . . . . . . . . . . . . . . . . 299
Rear sprocket
Ignition timing map checking . . . . . . . . . . . . . . . . . . . . . . . . . 133
plug-in connector . . . . . . . . . . . . . . . . . . . 140
Rear wheel
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . 10 installing . . . . . . . . . . . . . . . . . . . . . . . . . 128
L removing . . . . . . . . . . . . . . . . . . . . . . . . . 127

Link fork Rebound damping

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 84 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 15
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 88 shock absorber, adjusting . . . . . . . . . . . . . . 61
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Refueling
Link fork bearing 2-stroke oil . . . . . . . . . . . . . . . . . . . . . . . 289
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Riding sag

52
Lower triple clamp adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 64

73
installing . . . . . . . . . . . . . . . . . . . . . . . 39, 42 Rim run-out
removing . . . . . . . . . . . . . . . . . . . . . . . 38, 41 checking . . . . . . . . . . . . . . . . . . . . . . . . . 121

01
Low-speed compression damping Rubber grip

8/
shock absorber, adjusting . . . . . . . . . . . . . . 60 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 51

21
M S

16
l.c r:
,0
Main fuse Seat

ai d fo
changing . . . . . . . . . . . . . . . . . . . . . . . . . 140 mounting . . . . . . . . . . . . . . . . . . . . . . . . 102

om
Main silencer removing . . . . . . . . . . . . . . . . . . . . . . . . . 102
gm e
glass fiber yarn filling, changing . . . . . . . . . . 97 Service schedule . . . . . . . . . . . . . . . . . . . 323-325
@ ens

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Servicing the fork . . . . . . . . . . . . . . . . . . . . . . . 20

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Servicing the shock absorber . . . . . . . . . . . . . . . 66
tin ic
ar | L

Manifold Shock absorber

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 94 article number . . . . . . . . . . . . . . . . . . . . . . 12
lm r
ie fü

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 93 damper, assembling . . . . . . . . . . . . . . . . . . 76

Manufacturer warranty . . . . . . . . . . . . . . . . . . . . 10 damper, bleeding and filling . . . . . . . . . . . . 79
an ert

damper, checking . . . . . . . . . . . . . . . . . . . . 72
Motorcycle
yd zi

damper, disassembling . . . . . . . . . . . . . . . . 67
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 319
ar en

damper, filling with nitrogen . . . . . . . . . . . . 82

from lift stand, removing . . . . . . . . . . . . . . . 13
ch Liz

heim joint, changing . . . . . . . . . . . . . . . . . . 73

raising with lift stand . . . . . . . . . . . . . . . . . 13
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 65
O pilot bushing, replacing . . . . . . . . . . . . . . . . 71
Oil pump piston rod, assembling . . . . . . . . . . . . . . . . 75
changing . . . . . . . . . . . . . . . . . . . . . . . . . 291 piston rod, disassembling . . . . . . . . . . . . . . 69
za

priming . . . . . . . . . . . . . . . . . . . . . . . . . . 289 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 65

,

riding sag, checking . . . . . . . . . . . . . . . . . . 63

in

Oil screen
seal ring retainer, assembling . . . . . . . . . . . . 74
t

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 291
ar

seal ring retainer, disassembling . . . . . . . . . . 69

Open-circuit current
M

shock absorber, servicing . . . . . . . . . . . . . . . 66

checking . . . . . . . . . . . . . . . . . . . . . . . . . 149 spring preload, adjusting . . . . . . . . . . . . . . . 63
c
Za

P spring, installing . . . . . . . . . . . . . . . . . . . . 83
spring, removing . . . . . . . . . . . . . . . . . . . . . 66
Play in throttle cable
static sag, checking . . . . . . . . . . . . . . . . . . 62
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 53
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Shock absorber heim joint
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Zac Martin, [email protected],

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

399
 INDEX

Spark plug W
changing . . . . . . . . . . . . . . . . . . . . . . . . . 303
Wheel bearing
Spark plug and spark plug connector checking . . . . . . . . . . . . . . . . . . . . . . . . . 120
changing . . . . . . . . . . . . . . . . . . . . . . . . . 304 of the front wheel, changing . . . . . . . . . . . . 126
Spark plug connector of the rear wheel, changing . . . . . . . . . . . . 130
checking . . . . . . . . . . . . . . . . . . . . . . . . . 301 Winter operation
Speedometer checks and maintenance steps . . . . . . . . . . 320
wheel circumference, adjusting . . . . . . . . . 171 Wiring diagram ................... 326-369
Spoke tension Page 1 of 6 ................... . . . . 342
checking . . . . . . . . . . . . . . . . . . . . . . . . . 122 Page 1 of 8 ................... 326, 354
Starter motor Page 2 of 6 ................... . . . . 344
checking . . . . . . . . . . . . . . . . . . . . . . . . . 306 Page 2 of 8 ................... 328, 356
Page 3 of 6 ................... . . . . 346
Starter relay
Page 3 of 8 ................... 330, 358
checking . . . . . . . . . . . . . . . . . . . . . . . . . 149
Page 4 of 6 ................... . . . . 348

52
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Page 4 of 8 ................... 332, 360

73
Steering head bearing Page 5 of 6 ................... . . . . 350
changing . . . . . . . . . . . . . . . . . . . . . . . . 46-47 Page 5 of 8 ................... 334, 362

01
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 38 Page 6 of 6 ................... . . . . 352

8/
Steering head bearing play Page 6 of 8 ................... 336, 364

21
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Page 7 of 8 ................... 338, 366

16
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Page 8 of 8 ................... 340, 368

l.c r:
,0
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Work rules ............................ 8

ai d fo
om
T
gm e
Tap compression
@ ens

of fork legs, assembling . . . . . . . . . . . . . . . . 29

of fork legs, disassembling . . . . . . . . . . . . . . 26
tin ic
ar | L

Technical accessories . . . . . . . . . . . . . . . . . . . . 10
Technical data
lm r
ie fü

capacities . . . . . . . . . . . . . . . . . . . . . . . . 312
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 313
an ert

chassis tightening torques . . . . . . . . . . . . . 316

yd zi

electrical system . . . . . . . . . . . . . . . . . . . 314

ar en

engine – tolerance, wear limits . . . . . . . . . . 310

ch Liz

engine tightening torques . . . . . . . . . . . . . 311

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
shock absorber . . . . . . . . . . . . . . . . . . . . . 315
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
za

Throttle cable routing

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 52
,
in

Tire condition
t
ar

checking . . . . . . . . . . . . . . . . . . . . . . . . . 119
M

Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . 119
c
Za

Turn signal bulb

changing . . . . . . . . . . . . . . . . . . . . . . . . . 166
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
V
Vehicle identification number . . . . . . . . . . . . . . . 11
Zac Martin, [email protected],

400
 04/2022
3206472en
Za
c
M
ar
tin
, za

KTM.COM
ch Liz
ar en

5230 Mattighofen/Austria
yd zi

KTM Sportmotorcycle GmbH

*3206472en*

an ert
ie fü
lm r
ar | L
tin ic
@ ens
gm e
ai d fo
l.c r:
om
,0
16
21
8/
01
73

Photo: Mitterbauer/KISKA/KTM
52

Zac Martin, [email protected],