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KTM 350 EXC-F AUS 2012, Repair Manual

The KTM 350 EXC-F AUS 2012 Repair Manual is a comprehensive guide that provides detailed instructions on maintaining and repairing this powerful off-road motorcycle. Free to download, this invaluable manual is easily accessible on our website, ensuring you have the necessary knowledge to keep your bike in top condition.

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TABLE OF CONTENTS

3

Checking the tire condition............................................. 82
Checking tire air pressure............................................... 82
Checking spoke tension.................................................. 83

10/REAR WHEEL .............................................................. 84

Removing the rear wheel ................................................ 84
Installing the rear wheel................................................. 84
Removing the rear brake disc.......................................... 85
Installing the rear brake disc .......................................... 85
Checking the chain tension ............................................ 85
Adjusting the chain tension ............................................ 86
Adjusting the chain guide............................................... 87
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 87
Checking for chain dirt accumulation .............................. 89
Cleaning the chain......................................................... 89

11/WIRING HARNESS, BATTERY ....................................... 90

Removing the main fuse................................................. 90
Installing the main fuse ................................................. 90
Changing the fuses of individual power consumers............ 90
Changing the fuse of the radiator fan (EXC-F SIX DAYS).... 91
Removing the battery ..................................................... 92
Installing the battery...................................................... 92
Charging the battery ...................................................... 92

13/BRAKE SYSTEM........................................................... 94

Checking the front brake linings...................................... 94
Changing the front brake linings ..................................... 94
Checking free travel of hand brake lever........................... 96
Adjusting the basic position of the hand brake lever
(XCF

‑

W)........................................................................ 96

Adjusting free travel of hand brake lever (All EXC

‑

F

models) ........................................................................ 96
Checking the front brake fluid level ................................. 97
Adding front brake fluid ................................................. 97
Changing the front brake fluid ........................................ 98
Checking the rear brake linings ....................................... 99
Changing the rear brake linings....................................... 99
Checking the free travel of foot brake lever..................... 101
Adjusting the basic position of the foot brake lever ......... 101
Checking the rear brake fluid level ................................ 102
Adding brake fluid to the rear brake circuit .................... 102
Changing the rear brake fluid........................................ 103

14/LIGHTING SYSTEM, INSTRUMENTS ........................... 105

Adjusting the speedometer functions............................. 105
Setting kilometers or miles ........................................... 105
Activating the additional functions ................................ 106
Setting the wheel circumference ................................... 106
Setting the clock ......................................................... 107
Checking the headlight setting...................................... 107
Adjusting the headlight range ....................................... 108

30/ENGINE..................................................................... 109

Removing the engine ................................................... 109
Installing the engine .................................................... 113

30/DISASSEMBLING THE ENGINE................................... 118

Preparations................................................................ 118
Removing the clutch push rod ...................................... 118
Removing the spacer ................................................... 118
Draining the engine oil................................................. 118
Removing the oil filter.................................................. 119
Removing the spark plug .............................................. 119
Removing the valve cover ............................................. 119
Removing the kick starter............................................. 120
Removing the alternator cover....................................... 120

Removing the torque limiter ......................................... 120
Positioning the engine at ignition top dead center........... 121
Removing the timing chain tensioner............................. 121
Removing the camshaft................................................ 121
Removing the cylinder head.......................................... 122
Removing the piston .................................................... 122
Removing the starter drive............................................ 123
Removing the suction pump ......................................... 124
Removing the water pump wheel................................... 125
Removing the clutch cover ........................................... 125
Removing the clutch discs............................................ 125
Removing the outer clutch hub ..................................... 126
Removing the intermediate kick starter gear................... 127
Removing the intermediate kick starter gear................... 127
Removing the shift shaft .............................................. 127
Removing the shift drum locating unit ........................... 127
Removing the locking lever........................................... 127
Removing the force pump ............................................ 128
Removing the primary gear ........................................... 128
Removing the timing chain........................................... 129
Removing the spacer ................................................... 129
Removing the left section of the engine case.................. 129
Removing the shift rails ............................................... 130
Removing the shift drum .............................................. 130
Removing the shift forks .............................................. 130
Removing the transmission shafts ................................. 130
Removing the crankshaft.............................................. 131

30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 132

Work on the right section of the engine case .................. 132
Working on the left section of the engine case................ 133
Work on the clutch cover.............................................. 134
Checking the oil pressure regulator valve........................ 135
Checking the lubrication system.................................... 136
Removing the crankshaft bearing inner race ................... 136
Installing the crankshaft bearing inner race.................... 136
Changing the connecting rod, conrod bearing and crank
pin............................................................................. 137
Checking the crankshaft run-out at the bearing pin ......... 138
Removing the drive wheel of the balancer shaft .............. 138
Installing the drive wheel of the balancer shaft............... 138
Cylinder - Nikasil

®

coating ............................................ 139

Checking/measuring the cylinder................................... 139
Checking/measuring the piston ..................................... 139
Measuring the piston/cylinder mounting clearance .......... 140
Checking the piston ring end gap .................................. 140
Changing the camshaft bearing..................................... 141
Checking the camshafts ............................................... 141
Checking the pivot points of the camshafts .................... 141
Removing the valves .................................................... 142
Checking the valves ..................................................... 143
Checking the valve springs ........................................... 144
Checking the valve spring seat ...................................... 144
Checking the cam levers .............................................. 144
Checking the cylinder head .......................................... 144
Installing the valves ..................................................... 145
Checking the freewheel ................................................ 146
Preassembling the kick starter shaft .............................. 146
Checking the electric starter drive ................................. 147
Checking the timing assembly ...................................... 148
Preparing the timing chain tensioner for installation ....... 149
Checking the clutch..................................................... 149
Checking the shift mechanism ...................................... 151

Summary of Contents for 350 EXC-F AUS 2012

Page 1: ...REPAIR MANUAL 2012 350 EXC F EU 350 EXC F AUS 350 EXC F SIX DAYS EU 350 XCF W USA 350 EXC F USA Art no 3206111en ...

Page 2: ......

Page 3: ...ically reserves the right to modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for deliv ery options deviations from illustrations and descriptions as well as fo...

Page 4: ... SIX DAYS 40 04 SHOCK ABSORBER SWINGARM 41 Adjusting the high speed compression damping of the shock absorber 41 Adjusting the low speed compression damping of the shock absorber 41 Adjusting the rebound damping of the shock absorber 42 Measuring rear wheel sag unloaded 42 Checking the static sag of the shock absorber 42 Checking the riding sag of the shock absorber 43 Adjusting the spring preload...

Page 5: ...g the torque limiter 120 Positioning the engine at ignition top dead center 121 Removing the timing chain tensioner 121 Removing the camshaft 121 Removing the cylinder head 122 Removing the piston 122 Removing the starter drive 123 Removing the suction pump 124 Removing the water pump wheel 125 Removing the clutch cover 125 Removing the clutch discs 125 Removing the outer clutch hub 126 Removing t...

Page 6: ...l circuit 181 Checking the engine oil level 181 Changing the engine oil and oil filter cleaning the oil screen 182 Adding engine oil 184 Checking the engine oil pressure 184 39 IGNITION SYSTEM 186 Ignition coil checking the secondary winding 186 Checking the spark plug connector 186 Alternator checking the stator winding 186 Removing the stator and ignition pulse generator 187 Installing the stato...

Page 7: ...TABLE OF CONTENTS 5 Page 4 of 7 XCF W 260 Page 5 of 7 XCF W 262 Page 6 of 7 XCF W 264 Page 7 of 7 XCF W 266 SUBSTANCES 268 AUXILIARY SUBSTANCES 270 SPECIAL TOOLS 272 STANDARDS 285 INDEX 286 ...

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

Page 9: ...Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Ensure that the vehicle is safe to operate after completing repair and maintenance work Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If ...

Page 10: ... The type label 1 is fixed to the front of the steering head 101477 10 EXC F USA The type label USA 1 is fixed to the front of the steering head 101478 10 EXC F USA The type label Canada 2 is fixed to the front of the front pipe 3 3 Key number All EXC F models 500125 10 EXC F EU AUS EXC F SIX DAYS The key number 1 for the steering lock is stamped onto the key connector ...

Page 11: ...D in a safe place 3 4 Engine number 101291 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 3 5 Fork part number B00265 01 The fork part number 1 is stamped on the inner side of the fork stub 3 6 Shock absorber part number 101292 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 12: ... Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the en...

Page 13: ... in an enclosed space without an effective exhaust extraction system Info Press the starter for a maximum of 5 seconds Wait for at least 5 seconds before trying again Shift transmission to neutral EXC F USA Turn the key in the ignition lock to the position Turn the emergency OFF switch to the position EXC F AUS Turn the emergency OFF switch to the position Press the electric starter button or pres...

Page 14: ...the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 101316 10 Turn adjusting screws 1 clockwise all the way Info Adjusting screws 1 are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 22 clicks ...

Page 15: ... fork legs Preliminary work Raise the motorcycle with the lift stand p 10 Loosen the fork protector p 14 101320 10 Main work Push dust boots 1 of both fork legs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time there is an ingress of dirt inside the boots If this dirt is not removed it may cause the oil seals to leak Warning Danger of accident...

Page 16: ...sition the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 5 8 Removing the fork legs Preliminary work Remove the headlight mask with the headlight p 78 Raise the motorcycle with the lift stand p 10 Remove the front wheel p 80 101322 10 Main work Remove screws 1 and take off the clamp Remove cable binder 2 Remove screws 3 an...

Page 17: ...amp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 101489 11 EXC F USA Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 101324 11 EXC F SIX DAYS Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom ...

Page 18: ...ork protector upwards Remove the screws on the right fork leg Remove the fork protector upwards 5 11 Installing the fork protector 101327 10 Main work Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6...

Page 19: ...The fork legs are disassembled 200736 10 Remove protective cover A Note down the present state of rebound damping 1 and compression damping 2 Note down of the present state of the spring preload Completely open the adjusters of the rebound damping and compression damping 201347 10 Clamp the fork leg in the area of lower triple clamp Clamping stand T1403S p 283 200737 10 Loosen Preload Adjuster 3 P...

Page 20: ... wrench T14032 p 283 Info The preload spacers 4 should be above the special tool 200739 10 Clamp the special tool in the bench vise Loosen Preload Adjuster 3 200740 10 Remove Preload Adjuster 3 with preload spacers 4 Remove adjustment tube 5 201348 10 Pull the spring downward Remove the special tool Remove the spring 201349 10 Drain the fork oil Info Pull out and push in the piston rod a few times...

Page 21: ...tor ring does not necessarily need to be disassembled for the further repair 200742 10 Remove lock ring 8 Info The lock ring has a coarsely finished end against which the screwdriver can be placed 201351 10 Warm up the outer tube in area B of the lower sliding bushing Guideline 50 C 122 F Jerk the outer tube out of the inner tube Info The lower sliding bushing 9 must be pulled out of its bearing s...

Page 22: ...sassemble the fork legs p 17 200746 10 Main work Remove fluid barrier 1 from the piston rod Clamping stand T14016S p 282 200747 10 Remove piston rod 2 from the cartridge 200748 10 Remove washer 3 and spring seat 4 from the cartridge 200749 10 Degrease the cartridge and clamp using the pecial tool Clamping stand T14015S p 282 Warm up the cartridge in the area of A Guideline 50 C 122 F Unscrew and r...

Page 23: ...mpletely 200699 10 Remove piston 8 Remove shim stack 9 completely 200700 10 Remove spring bk Remove tap rebound bl 200701 10 Remove spring bm Remove valve bn of the rebound damping together with the spring Take out the piston rod 5 15 Disassembling the compression damping fitting Info The steps are identical for both fork legs Preliminary work Disassemble the fork legs p 17 ...

Page 24: ...compression damping fitting Extract the compression damping fitting 5 16 Checking the fork legs Condition The fork legs must be disassembled 200728 10 Check the inner tube and axle clamp for damage If there is damage Change the inner tube 200684 10 Measure the outside diameter at several locations on the inner tube Outside diameter of the inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measu...

Page 25: ...gth Guideline Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 513 mm 20 2 in Weight of rider 75 85 kg 165 187 lb 513 mm 20 2 in Weight of rider 85 95 kg 187 209 lb 513 mm 20 2 in If the measured value is greater than the specified value Reduce the thickness of the preload spacer If the measured value is less than the specified value Increase the thickness of the preload spa...

Page 26: ...ocking Extract the compression damping fitting 5 18 Assembling the cartridge Info The steps are identical for both fork legs 200715 10 Clamp in the piston rod Clamping stand T14016S p 282 Mount valve 1 of the rebound damping with the spring and O ring Grease the O ring Lubricant T158 p 270 Mount spring 2 200718 10 Grease tap rebound 3 O ring Lubricant T158 p 270 Mount and tighten the tap rebound G...

Page 27: ...t with the collar facing downward Secure the nut by locking 200749 11 Degrease the cartridge and clamp using the special tool Clamping stand T14015S p 282 Mount and tighten screwsleeve 9 Guideline Screwsleeve M29x1 46 Nm 33 9 lbf ft Loctite 241 200748 11 Mount washer bk and spring seat bl 200747 11 Push piston rod bm into the cartridge 200746 11 Screw on fluid barrier bn to the stop Info The fluid...

Page 28: ...der facing downward Slide on lock ring 2 Grease and slide on seal ring 3 Lubricant T511 p 270 Info The sealing lip should face downward and the open side upward Slide on support ring 4 Remove the special tool 200670 10 Roughen clean and grease the edges of the sliding bushings using 600 grit sand paper Fork oil SAE 5 p 269 200671 10 Slide on lower sliding bushing 5 Mount upper sliding bushing 6 In...

Page 29: ...he spring force The adjustment tube extends more than 7 mm 0 276 in out from the car tridge and cannot be pressed inward against the spring force Screw on water excluder C to the stop Info The water excluder must be screwed on tightly against the stop Do not use a tool Mount the special tool on the cartridge Gripping tool T14026S1 p 282 Info The special tool must be used in order that the adjustme...

Page 30: ... on the hexagonal part Open end wrench T14032 p 283 Remove the special tool Gripping tool T14026S1 p 282 200743 10 Clamp the special tool in the bench vise Grease the thread of the piston rod Lubricant T159 p 270 Grease the upper edge E of the piston rod Lubricant T158 p 270 Screw the Preload Adjuster with preload spacer onto the piston rod Info The Preload Adjuster must be screwed in all the way ...

Page 31: ...ks Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Turn the adjusting screw of spring preload bl counterclockwise all the way Turn back clockwise the number of turns corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Alternative 2 Warning Danger of accidents Modifications to the suspension settings can ser...

Page 32: ... the front wheel p 80 Remove the fork legs p 14 Remove the front fender p 78 Remove the handlebar cushion Open the cable holder in front of the right radiator and detach the wiring harness 101335 10 Main work Remove screws 1 and hang the voltage regulator to the side Remove screw 2 Remove screw 3 take off the upper triple clamp with the han dlebar and set it aside Info Protect the motorcycle and i...

Page 33: ... and O ring 3 101337 10 Position the upper triple clamp with the steering Mount screw 4 but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 101338 10 Position the fork legs Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp Positio...

Page 34: ...ck that the wiring harness cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 35 Remove the motorcycle from the lift stand p 10 5 23 Removing the lower triple clamp EXC F EU AUS USA XCF W Preliminary work Remove the headlight mask with the headlight p 78 Raise the motorcycle with the lift stand p 10 Remove the front wheel p 80 Remove t...

Page 35: ...ing head bearing Check whether the top steering head seal 1 is correctly positioned Slide on protective ring 2 and O ring 3 101427 10 Position the upper triple clamp with the steering Mount screw 4 but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 101332 10 Position the fork legs In...

Page 36: ... Nm 14 8 lbf ft Secure the wiring harness with cable holder bk 101490 11 EXC F USA Tighten screws 9 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Secure the wiring harness with cable holder bk 101326 11 Position the brake caliper Mount and tighten screws bl Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder bm Position the brake line wiring harness and ...

Page 37: ...ay of the steering head bearing p 35 EXC F EU AUS USA XCF W Adjust the play of the steering head bearing p 36 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable EXC F SIX DAYS Adjust the play of the steering head bearing p 35 EXC F EU AUS US...

Page 38: ...nd p 10 101343 10 Main work Loosen screws 1 and 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws 1 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screw 2 Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Subsequent work Check the steering head be...

Page 39: ... the two screws 2 Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Fit and evenly tighten the fo...

Page 40: ...e routing Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the tank bearing If the throttle cable is not routed as specified Correct the throttle cable routing Subsequent work Install the fuel tank p 71 Mount the seat p 70 6 5 Checking the play in the throttle cable 400192 10 Check the throttle grip for smooth operation Move the handlebar ...

Page 41: ...n the throttle cable Preliminary work Remove the seat p 69 Remove the fuel tank p 70 Check the throttle cable routing p 38 101411 10 Main work Move the handlebar to the straight ahead position Push back sleeves 1 Loosen nut 2 Turn adjusting screw 3 in as far as possible Loosen nut 4 Turn adjusting screw 5 so that there is play in the throttle cable at the throttle grip Guideline Play in throttle c...

Page 42: ...68 10 Turn quick release 1 counterclockwise until it disengages Remove the engine guard 7 2 Installing the engine guard EXC F AUS EXC F SIX DAYS 101369 10 Attach the engine guard on the frame at the rear and swing up at the front Turn quick release 1 clockwise all the way ...

Page 43: ...rns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 8 2 Adjusting the low speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info The low speed setting can be seen during the slow to...

Page 44: ... sag unloaded Preliminary work Raise the motorcycle with the lift stand p 10 0 0 A A 400988 10 Main work Measure the distance as vertically as possible between the rear axle and a fixed point such as a mark on the side cover Make note of the value as measurement A Follow up work Remove the motorcycle from the lift stand p 10 8 5 Checking the static sag of the shock absorber 0 0 A A 0 0 B B 400989 ...

Page 45: ...y of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preliminary work Raise the motorcycle with the lift stand p 10 Remove shock absorber p 44 After removing the shock absorber clean it thoroughly 401026...

Page 46: ...hock absorber p 43 Adjust the rebound damping of the shock absorber p 42 8 9 Removing the shock absorber Preliminary work Raise the motorcycle with the lift stand p 10 101344 10 Main work Remove screw 1 and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw 2 push splash protector 3 to the side and remove the ...

Page 47: ... p 48 Check the damper p 50 Disassemble the rebound adjuster p 50 Remove the heim joint p 51 Install the heim joint p 52 Assemble the rebound adjuster p 53 Assemble the seal ring retainer p 53 Assemble the piston rod p 54 Assemble the damper p 55 Install the spring p 61 8 12 Removing the spring Condition The shock absorber has been demounted Clamp the shock absorber in a bench vise using soft jaws...

Page 48: ...stment elements of the rebound damping and compres sion damping Remove rubber cap 3 of the reservoir 201616 10 Slowly unscrew screw 4 The pressurized nitrogen is bled off 201617 10 Remove locking cap 5 201618 10 Press seal ring retainer 6 all the way in with the special tool Disassembly tool T1216 p 281 Remove lock ring 7 Info Do not scratch the inner surface Take out the damper 201619 10 Remove s...

Page 49: ...Remove the spring p 45 Disassemble the damper p 46 200761 10 Main work Clamp the piston rod with the fork in a bench vise Remove nut 1 Info If mount 2 is loosened apply counteractive force Remove rebound damping shim stack 3 Info Guide the rebound damping shim stack onto a screwdriver and put them aside together 200762 10 Remove piston 4 Remove compression damping shim stack 5 Info Guide the compr...

Page 50: ...ping shim stack 8 Info Guide the compression damping shim stack onto a screwdriver and put them aside together 200765 10 Remove rebound damping washer 9 Remove seal ring retainer bk 200766 10 Remove locking cap bl and bump rubber bm 8 15 Disassembling the seal ring retainer Preliminary work Remove the spring p 45 Disassemble the damper p 46 Disassemble the piston rod p 47 200785 10 Main work Remov...

Page 51: ... pilot bushing 1 onto the special tool Press drift T1504 p 283 Position the pilot bushing in the seal ring retainer using the special tool Press drift T1504 p 283 Support seal ring retainer 2 with the sleeve A of the special tool Press the pilot bushing all the way in Assembly tool T150S p 283 200798 10 Lubricate the special tool Shock absorber oil SAE 2 5 50180342S1 p 269 Calibration pin T1205 p ...

Page 52: ...od Diameter 17 95 mm 0 7067 in If the measured value is smaller than the specified value Replace the piston rod Measure the run out of the piston rod Piston rod Run out 0 02 mm 0 0008 in If the measured value is greater than the specified value Replace the piston rod Check the piston rod for damage and wear If there is damage or wear Replace the piston rod 200813 10 Check the piston rings for dama...

Page 53: ... the heim joint Condition The shock absorber has been demounted 200799 10 Clamp the shock absorber in a vise using soft jaws Remove the collar bushing of the heim joint Pin T120 p 280 Turn the shock absorber around and remove the second heim joint collar bushing 200800 10 Remove seal ring 1 on both sides 200801 10 Press the heim joint against a lock ring using the special tool Pressing tool T1207S...

Page 54: ...ng the heim joint 200803 10 Position new heim joint 1 and special tool Pressing tool T1206 p 281 Press in the heim joint all the way 200801 10 Press the heim joint against the lock ring using the special tool Pressing tool T1207S p 281 Mount the second lock ring 2 200800 11 Mount seal ring 3 on both sides 200804 10 Position both collar bushings 4 and press in ...

Page 55: ...crew sleeve 7 Guideline Screw sleeve M14x1 18 Nm 13 3 lbf ft Screw out the rebound damping adjusting screw 6 to the stop 200810 10 Grease the O ring of the rebound damping seat Lubricant T159 p 270 Mount and tighten rebound damping valve seat 8 Guideline Rebound damping valve seat M8x1 6 Nm 4 4 lbf ft Loctite 2701 Info The rebound damping valve seat must be pressed inward before tightening 8 22 As...

Page 56: ...iston rod with the fork in a bench vise Mount bump rubber 1 and locking cap 2 Position the special tool on the piston rod Mounting sleeve T1215 p 281 Grease the dust boot and slide seal ring retainer 3 onto the piston rod Lubricant T625 p 271 Remove the special tool 200767 10 Mount rebound damping washer 4 Mount the compression shim stack 5 with the smaller shims facing downward 200768 10 Grind pi...

Page 57: ...t sandpaper Clean the piston Mount the piston Guideline View A Top view of piston View B Bottom view of piston 200772 10 Mount rebound damping shim stack bl with the smaller shims facing upward Grease the threads of the mount Lubricant T152 p 271 Mount nut bm but do not tighten it yet 200776 10 Align both pistons using the special tool Centering sleeve T1214 p 281 Tighten the nut Guideline Piston ...

Page 58: ... has been assem bled 201619 11 Mount screw 3 but do not tighten yet 201620 10 Grease the O ring of the seal ring retainer Lubricant T158 p 270 Fill the damper cartridge approximately half way Shock absorber oil SAE 2 5 50180342S1 p 269 Carefully mount the piston rod 201618 11 Mount seal ring retainer 4 and slide it under the ring groove Mount lock ring 5 Info Do not scratch the inner surface Pull ...

Page 59: ...ping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Turn adjusting screw bl clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ou...

Page 60: ...ition the control lever as shown in the photo Control lever External tank 3 is set to Closed Damper 4 is set to Vacuum and Oil reservoir 5 is set to Vacuum Activate On Off switch 6 The suction process begins Pressure gauge 7 drops to the required value 0 bar Vacuum gauge 8 drops to the required value 4 mbar 201625 10 Determine distance A between the floating piston and reservoir hole with the spe ...

Page 61: ...bar 200268 10 When the pressure gauge reaches the required value turn control lever Damper 4 to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge increases to the required value 3 bar 200269 10 When the pressure gauge reaches the required value turn control lever Damper 4 to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar When the pressure gauge ...

Page 62: ...Keep the special tool in place in the bench vise Nitrogen filling tool T170S1 p 284 Connect the special tool to the pressure regulator of the filling cylinder Filling gas nitrogen Adjust the pressure regulator Guideline Gas pressure 10 bar 145 psi Position the shock absorber in the special tool The hexagonal part of tap handle A engages in the hexagon socket of the screw of the filling port Open s...

Page 63: ... ring to measurement Guideline Spring preload 8 mm 0 31 in Hook wrench T106S p 280 Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components Only make adjustments withi...

Page 64: ...his position Info Raise the wheel slightly to make it easier to remove the screw Swing back the shock absorber 305061 10 Remove spacers 2 on both sides 305062 10 Remove shaft seal rings 3 on both sides 305063 10 Mount special tool 4 Mounting tool heim joint 50329000044 p 272 Press out the heim joint by screwing in the screw 305064 10 Position the new heim joint Mount special tool 4 Mounting tool h...

Page 65: ...grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life 305061 10 Mount spacers 2 on both sides 305060 10 Position the shock absorber Mount and tighten screw 1 Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Info Raise the wheel slightly to make it easier to mount the screw Follow up work Remove the motorcycle fro...

Page 66: ...gs 1 305066 10 Remove screw 2 and take off the manifold 9 2 Installing the manifold 305065 10 Main work Position the manifold and mount springs 1 Spring hooks 50305017000 p 272 305066 10 Mount and tighten screw 2 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Subsequent work Install the main silencer p 65 Install the shock absorber p 44 Remove the motorcycle from the lift stand p 10 ...

Page 67: ...nt and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Reconnect spring 2 9 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 Do not touch hot components Info Over a period the fibers of the insulating material vanish into the air and the sile...

Page 68: ...and tighten the screws 0 0 1 1 0 0 2 2 0 0 4 4 0 0 6 6 0 0 bk bk 7 7 0 0 3 3 0 0 4 4 0 0 bk bk 0 0 5 5 0 0 9 9 0 0 8 8 101426 10 XCF W EXC F USA Remove screws 1 of connecting cap 2 Take off the connecting cap with the perforated pipe O ring 3 and glass fiber yarn filling 4 Remove screws 5 and silencer cap 6 with O ring 7 Remove screw 8 and remove insert 9 together with stuffing yarn bk Clean the p...

Page 69: ...d dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preliminary work Remove the air filter box lid p 67 101350 10 Main work Detach air filter holder 1 at the bottom and swing it to one side Remove the air...

Page 70: ...disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preliminary work Remove the air filter box lid p 67 Remove the air filter p 67 101352 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 270 Info Only press the air filter to dry it n...

Page 71: ... doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground wate...

Page 72: ...el is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according ...

Page 73: ...ontact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Preliminary work Remove the seat p 69 Remove the fuel tank p 70 Check the throttle cable...

Page 74: ...d See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into cont...

Page 75: ...anger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitabl...

Page 76: ...0 Position the fuel pump Mount fuel connection 2 with the gasket but do not tighten yet Guideline Fuel connection on fuel pump M8 10 Nm 7 4 lbf ft Mount and tighten nut 1 with the gasket Guideline Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Tighten fuel connection 2 Guideline Fuel connection on fuel pump M8 10 Nm 7 4 lbf ft 305314 10 Mount and tighten screws 3 Guideline Screw fuel pump EJOT 3 Nm ...

Page 77: ...or immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Preliminary work Drain the fuel from the fuel tank into a suitable ...

Page 78: ...at has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Condition The fuel tank is full The diagnostics tool is disconnected 305067 10 Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection v...

Page 79: ...6 52 9 psi If the specification is not reached Open the filler cap p 69 Check the tank air vent system 400928 01 Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 3 35 3 65 bar 48 6 52 9 psi If the specification is not reached Check that the fuel line is clear Change the fuel filter p 73 Change the fuel pump p 75 Stop the Function test of fuel pump control...

Page 80: ...ssis M6 10 Nm 7 4 lbf ft Info Make sure the holding lugs engage in the start number plate or headlight mask 12 3 Removing headlight mask with headlight 101401 10 Switch off all electrical equipment Remove screw 1 and take off clamp Loosen the rubber band 2 Push up the headlight mask and swing it forwards C00124 11 Pull out the electric plug connector 3 and remove the headlight mask with the headli...

Page 81: ... headlight mask and fix it with the rubber band 2 Info Ensure that the retaining lugs engage in the fender Position the brake line and wiring harness Put the clamp on mount and tighten screw 3 Subsequent work Check the headlight setting p 107 ...

Page 82: ...heel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 101388 10 Remove spacers 3 13 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cl...

Page 83: ...y due to worn brake disc s Change the worn brake disc s without delay A A 400257 10 Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement A Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in If the brake disc thickness is less...

Page 84: ...0 Check the front and rear tires for cuts run in objects and other damage If the tire exhibits cuts run in objects or other damage Change the tire Check the depth of the tread Info Note local national regulations concerning the minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum permissible depth Change the tire Check the tire age Info The tire s date o...

Page 85: ...l imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Tap each spoke with a screwdriver Info The sound frequency depends on the length and thickness of the spoke If there are different sound frequencies in spokes with the same length and thickness this ...

Page 86: ...le Take the rear wheel out of the swingarm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 101390 10 Remove spacers 4 14 2 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean t...

Page 87: ...ain work Remove screws 1 Take off the brake disc 14 4 Installing the rear brake disc 700075 10 Clean the contact surface of the brake disc Position the brake disc with the label facing outward Mount and tighten screws 1 Guideline Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Install the rear wheel p 84 14 5 Checking the chain tension Warning Danger of accidents Danger caused by incorrect ...

Page 88: ...hain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if neces sary Preliminary work Raise the motorcycle with the lift stand p 10 Check the chain tension p 85 101360 10 Main work Loosen nut 1 Loosen nuts 2 A...

Page 89: ...Insert nut 3 in hole B Position the chain guide Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the nut on screw 1 and tighten Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft 14 8 Checking the chain rear sprocket engine sprocket and chain guide Preliminary work Raise the motorcycle with the lift stand p 10 400227 01 Main work Shift gear to neutral...

Page 90: ...should also be changed New chains wear out faster on old worn sprockets 401343 01 Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M6 6 N...

Page 91: ...is very dirty Clean the chain p 89 14 10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environ...

Page 92: ...110 p 196 Info A reserve fuse 1 is located in the starter relay Replace a burned out fuse 2 only by an equivalent fuse Replace the protection cover Install the air filter box lid p 67 15 3 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preliminary work Switch off all power consumers and switch off the ...

Page 93: ...onsumer is functioning properly Close the fuse box cover Follow up work Mount the seat p 70 15 4 Changing the fuse of the radiator fan EXC F SIX DAYS Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Preliminary work Remove the seat p 69 Remove the fuel tank p 70 101400 10 Main work Remo...

Page 94: ...om Lift the battery up and out 15 6 Installing the battery 101394 10 Main work Insert battery into the battery compartment with the terminals facing to the front Battery YTX4L BS p 196 Reconnect rubber band 1 Connect positive cable 2 and negative cable 3 Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Info Contact disks A must be mounted between battery terminals 4 and cable sockets 5 with ...

Page 95: ...om starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free which means that the acid level does not need to be checked Preliminary work Switch off all power consumers and switch off the engine Remove the seat p 69 Disc...

Page 96: ...ording to the service schedule Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and appr...

Page 97: ... withdraw bolt 5 and take out the brake linings Clean the brake caliper and brake caliper support 0 0 7 7 0 0 6 6 100397 01 Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly 100398 10 Fit the brake linings insert the bolt and mount the locking split pins Operate the hand brake lever repeatedly until the brake linings are in contact ...

Page 98: ...ree travel of the hand brake lever p 96 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing screw 1 Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Tu...

Page 99: ... skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake accor...

Page 100: ... container 201595 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Cover the painted parts Remove screws 1 Remove cover 2 with membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 p 273 Brake fluid DOT 4 DOT 5 1 p 268 201596 10 Mount bleeder cover 3 Bleeder cover 00029013005 p...

Page 101: ...nimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 99 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings p 99 16 10 Changing the rear brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Warning Skin irritat...

Page 102: ...sed on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 101382 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 and the O ring Press the brake piston back to its basic position and make sure that no brake ...

Page 103: ...cording to specifications 101377 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 101 Reconnect spring 1 16 12 Adjusting the basi...

Page 104: ...t continue riding Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule 101379 10 Stand the vehicle upright Check the brake fluid level in the viewer 1 When in the viewer 1 an air bubble is visible Add brake fluid to the rear brake circuit p 102 16 14 Adding brake fluid to the rear brake ci...

Page 105: ... with water 16 15 Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous su...

Page 106: ...0029013100 p 272 Open bleeder screw 5 by approx one half turn Info Bleed until new brake fluid emerges from the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve 3 Open the bleeder screw again until no more brake fluid emerges Info This prevents overfilling of the brake fluid reservoir Tighten the bleeder screw Remove the hose of the bleeder bottle Attach the dust ...

Page 107: ...conds The settings are stored and the Setup menu is closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu is closed 17 2 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the uni...

Page 108: ...own risk and that the vehicle will no longer be approved for use on public roads once modified Preliminary work Remove the headlight mask with the headlight p 78 301287 10 Main work Expose connector CZ 1 301288 10 Sever the black brown cable 2 Insulate both cable ends Subsequent work Refit the headlight mask with the headlight p 78 Check the headlight setting p 107 17 4 Setting the wheel circumfer...

Page 109: ... set the following segments in the same way as the hours by pressing the button and the button Info The seconds can only be set to zero Press the button for 3 5 seconds The settings are stored and the Setup menu is closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu is closed 17 6 Checking the...

Page 110: ...sen screw 1 Adjust the headlight range of the headlight by moving it up or down Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider mark is applied under Checking the headlight setting Info A change in weight on the vehicle may require a correction of the headlight range Tighten screw 1 ...

Page 111: ...le with the lift stand p 10 Remove the main silencer p 65 Remove the seat p 69 Remove the fuel tank p 70 305069 10 Main work Remove screw 1 Disconnect the negative cable from the battery 305070 10 Loosen hose clip 2 305071 10 Detach connector 3 305072 10 Push back hose clamp 4 Pull off the vent hose ...

Page 112: ...ew 6 Repeat the operation on the opposite side 305074 10 Swing up the subframe and secure it 305075 10 Remove screw 7 Swing back the shock absorber 305076 10 Remove springs 8 Spring hooks 50305017000 p 272 305077 10 Remove screw 9 Remove the manifold ...

Page 113: ...pring bm 305081 10 Remove screw bn Remove screw bo Take off the engine sprocket cover 305082 10 Remove the connecting link of the chain Take off the chain 305083 10 Remove screws bp Take off the clutch slave cylinder and hang it to the side Info Do not kink the clutch line Do not activate the clutch lever if the clutch slave cylinder has been removed ...

Page 114: ... hose clip ck Take off the radiator hose 305087 10 Remove screw connections cl Remove the engine braces 305088 10 Remove nut cm Remove the swingarm pivot Pull the swingarm slightly toward the rear Remove screws cn Lift out the engine from the side Info You should have an assistant for this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments...

Page 115: ... 5 100 Nm 73 8 lbf ft 305087 11 Position the engine braces Mount and tighten screw caps 3 Guideline Screw engine brace M8 33 Nm 24 3 lbf ft Tighten screws 1 and nut 2 Guideline Engine attachment bolt M10 60 Nm 44 3 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft 305086 11 Mount the radiator hose Position and tighten hose clip 4 305085 11 Mount the throttle valve body Position and tighten hose...

Page 116: ... with connecting link bk 305081 11 Position the engine sprocket cover Mount and tighten screw bl Guideline Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Mount and tighten screw bm Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 305080 11 Mount spring bn 305079 11 Mount the radiator hose Position and tighten hose clip bo 305078 11 Position the cable Mount and tighten nut bp Position the c...

Page 117: ...rew bs Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 305073 11 Remove the fixation and position the subframe Info Watch out for the intake flange Mount and tighten screw bt Guideline Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Remove screw ck Mount and tighten screw ck Guideline Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Repeat the operation on the opposite side 30...

Page 118: ...er and fill up with engine oil Engine oil 1 20 l 1 27 qt Engine oil SAE 10W 50 p 268 Alternative engine oil for harsh oper ating conditions and increased per formance Engine oil SAE 10W 60 00062010035 p 268 Mount and tighten screw connection cp Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sur...

Page 119: ...30 ENGINE 117 Read out the fault memory using the KTM diagnostics tool Check the engine for leakage Check the engine oil level p 181 Check the coolant level p 179 ...

Page 120: ...e engine on the special tool Info Work with an assistant or a motorized hoist 19 2 Removing the clutch push rod 304919 10 Remove clutch push rod 1 19 3 Removing the spacer 304920 10 Remove spacer 1 of the countershaft Remove O ring 19 4 Draining the engine oil 304921 10 Remove plug 1 with oil screen and the O rings 304922 10 Remove oil drain plug 2 with the magnet Completely drain the engine oil ...

Page 121: ...il filter 3 out of the oil filter housing Circlip pliers reverse 51012011000 p 273 19 6 Removing the spark plug 304927 10 Remove the spark plug using special tool 1 Spark plug wrench 77229072000 p 279 19 7 Removing the valve cover 304928 10 Remove screws 1 Remove the valve cover with the valve cover seal 304929 10 Remove the spark plug shaft insert ...

Page 122: ...r Take off the kick starter 304933 10 Remove distance sleeve 2 19 9 Removing the alternator cover 304930 10 Remove screws 1 Remove the alternator cover 304931 10 Take off the alternator cover gasket 3 Dowels 2 remain in the engine case 19 10 Removing the torque limiter 304939 10 Remove torque limiter 1 ...

Page 123: ...ith the washer Info Check through the hole whether the position notch of the crankshaft is visi ble Mount and tighten screw 1 without the washer 19 12 Removing the timing chain tensioner 304945 10 Loosen screw 1 Remove screw 2 with the seal ring 304946 10 Pull out timing chain tensioner 3 Remove O ring 4 19 13 Removing the camshaft 304950 10 Loosen screws 1 from the outside to the inside and remov...

Page 124: ...e washers Remove the cylinder head 304958 10 Remove cylinder head gasket 3 19 15 Removing the piston 304959 10 Push the cylinder upward Info Only push the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer 1 Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info If no further work is to be performed on the cylin...

Page 125: ...tection cover 75029090000 p 276 Attach special tool 3 to the rotor Hold the special tool and pull off the rotor by turning in the screw Extractor 58012009000 p 273 Info Ensure that the spring washers remain in place 304965 10 Remove lock ring 4 Take off the starter idler gear with the washer 304966 10 Remove freewheel gear 5 304967 10 Remove screws 6 Remove the inside alternator cover ...

Page 126: ...ake off gasket 7 304969 10 Remove screws 8 Take off the starter motor 19 17 Removing the suction pump 304972 10 Remove screws 1 Take off oil pump cover 2 304973 10 Remove O ring 3 304974 10 Remove suction pump 4 304975 10 Remove needle roller 5 ...

Page 127: ...r pump cover 304977 10 Remove nut 2 Take off the two part water pump impeller 3 19 19 Removing the clutch cover 304978 10 Remove screws 1 Take off the clutch cover Remove the clutch cover seal 19 20 Removing the clutch discs 304981 10 Remove screws 1 Take off spring retainer 2 304982 10 Take off spring washer 3 ...

Page 128: ...moving the outer clutch hub 304988 10 Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut 1 Clutch holder 51129003000 p 273 Remove the nut with the lock washer Dispose of the lock washer 304989 10 Take off inner clutch hub 2 and washer 3 Info The washer usually sticks to the inner clutch hub Take off 4 304990 10 Take off needle bearing 5 and collar sleeve 6 ...

Page 129: ... ring Take off the washer Take off intermediate kick starter gear 1 19 24 Removing the shift shaft 304995 10 Push sliding plate 1 away from the shift drum locating unit 2 Remove shift shaft 3 with the washer 19 25 Removing the shift drum locating unit 304996 10 Remove screw 1 Push away locking lever 2 from shift drum locating unit 3 and remove the shift drum locating unit Relieve tension from the ...

Page 130: ...0 10 Remove lock ring 4 Take off washer 5 Remove oil pump gear 6 305001 10 Remove pin 7 Remove screws 8 Take off the oil pump cover 305002 10 Remove pin 9 Push oil pump shaft bk inward and take it out of the engine from the alternator side Remove force pump bl 19 28 Removing the primary gear 305018 10 Remove nut 1 Info Left handed thread Take off primary gear 2 ...

Page 131: ... 10 Remove spacer 1 of the crankshaft 19 31 Removing the left section of the engine case 305022 10 Remove screws 1 Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm 302681 10 Insert the special tool into the crankshaft Protection cover 75029090000 p 276 Mount special tool 2 with the appropriate screws Puller 77229048000 p 278 Info Use the dri...

Page 132: ...th upper spring 2 305026 10 Remove shift rail 3 together with upper spring 4 and the lower spring 19 33 Removing the shift drum 305027 10 Tilt shift forks 1 to the side Info Do not misplace the shift rollers Remove shift drum 2 19 34 Removing the shift forks 305028 10 Remove shift forks 1 Info Do not misplace shift rollers 2 19 35 Removing the transmission shafts 305030 10 Remove lock ring 1 ...

Page 133: ...SSEMBLING THE ENGINE 131 305031 10 Pull both transmission shafts 2 out of the bearing seats together 19 36 Removing the crankshaft 305032 10 Take out crankshaft 1 Take off the right section of the engine case ...

Page 134: ... bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer ring otherwise the bearings will be damaged when they are pressed in After the engine case section has...

Page 135: ...emoved using a suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer ring otherwise the bearings will be damaged when they ...

Page 136: ...bearing M5 6 Nm 4 4 lbf ft Loctite 243 400996 01 Blow out the oil channel with compressed air and check that it is clear 20 3 Work on the clutch cover 302692 10 Remove shaft seal ring 1 302693 10 Remove lock ring 2 Remove shaft seal ring 3 302694 10 Press out bearing 4 toward the inside 302693 10 Mount lock ring 2 Press the shaft seal ring 3 all the way in from the inside to the outside with the o...

Page 137: ...sed air and check that it is clear 20 4 Checking the oil pressure regulator valve 305033 10 Remove screw plug 1 with sealing washer 2 Remove pressure spring 3 and ball 4 200155 10 Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of pressure spring 23 5 mm 0 925 in If the measured value does not meet specifications Change the spring Check bal...

Page 138: ...nner race 302914 10 Fix the crankshaft in the vise Info Use soft jaws Warm up special tool 1 Guideline 150 C 302 F Tool for inner bearing race 58429037037 p 274 Push the warmed up special tool 1 onto the crankshaft bearing inner race press firmly together and pull jointly from the crankshaft Take off the compensating disk Repeat the operation on the opposite side 20 7 Installing the crankshaft bea...

Page 139: ...75029047000 p 276 Info Hold the lower crank web Remove the connecting rod and bearing 302918 10 Press the crank pin out of the lower crank web 302912 10 Press in the new crank pin 3 as far as possible Oil hole A is aligned with oil hole B If the oil holes are not correctly aligned the conrod bearing will not be sup plied with oil Use compressed air to check that the oil hole is clear 302913 10 Mou...

Page 140: ...low up work Check the crankshaft run out at the bearing pin p 138 20 9 Checking the crankshaft run out at the bearing pin 302915 10 Position the crankshaft on a roller block Turn the crankshaft slowly Check the crankshaft run out on both bearing pins Crankshaft run out at bearing pin 0 03 mm 0 0012 in If the crankshaft run out at the bearing pin is larger than the specification Align the crankshaf...

Page 141: ...025 mm 3 46503 3 46554 in Info The cylinder size 1 is marked on the cylinder collar 305004 10 Using a straightedge and the special tool check the sealing area of the cylinder head for distortion Feeler gauge 59029041100 p 274 Cylinder cylinder head distortion of sealing area 0 10 mm 0 0039 in If the measured value does not meet specifications Change the cylinder 20 14 Checking measuring the piston...

Page 142: ... cylinder mounting clearance 302699 10 Check measure the cylinder p 139 Check measure the piston p 139 The smallest piston cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter The largest piston cylinder mount ing clearance equals the largest cylinder bore diameter minus the smallest piston diameter Guideline Piston cylinder mounting clearance Si...

Page 143: ...n yet Guideline Screw camshaft drive sprocket M12x1 80 Nm 59 lbf ft Loc tite 243 cone degreased Repeat these steps for the second camshaft 20 18 Checking the camshafts 302713 10 Check the camshaft for damage and wear If there is damage or wear Change the camshaft If the surface of the cams is damaged check the oil supply to the camshaft and cam lever Check the autodecompressor for damage and wear ...

Page 144: ...are the Plastigauge clearance gauge with the specifications on the packaging Guideline Camshaft bearing sleeve bearing Radial clearance 0 020 0 054 mm 0 00079 0 00213 in Wear limit 0 065 mm 0 00256 in Info The width of the Plastigauge clearance gauge is a measure of the bearing play Take off the camshafts and clean the parts 20 20 Removing the valves 302710 10 Remove screw plugs 1 with the O ring ...

Page 145: ...277 Remove valve spring seat 5 300117 10 Mark the valves corresponding to their installation position Info Place the valves in a carton corresponding to their installation position and label them 20 21 Checking the valves 200193 10 Check the valve plate for run out Valve run out At the valve plate 0 05 mm 0 002 in If the measured value does not meet specifications Change the valve 302809 10 Check ...

Page 146: ...ue does not meet specifications Change the valve spring seat 20 24 Checking the cam levers 302718 10 Check the cam levers and cam lever shafts for damage and wear If there is damage or wear Change the cam levers and or cam lever shafts 20 25 Checking the cylinder head 302805 10 Check valve guides 1 using the special tool Limit plug gauge 77229026000 p 277 If the special tool is easy to insert in t...

Page 147: ... the tighter coil facing downward Mount the valve spring retainers 302711 10 Pre tension the valve spring using the special tool Valve spring compressor 59029019000 p 274 Insert for valve spring lever 77229060100 p 279 302719 10 Mount valve keys 3 Info When mounting the valve keys ensure that they are seated properly it is recommended to adhere the valve keys to the valves with a small amount of g...

Page 148: ... of starter wheel 1 If the freewheel gear does not turn clockwise or if it does not lock counterclock wise Change the free wheel 20 28 Preassembling the kick starter shaft 301000 10 Mount washer 1 and needle bearing 2 301001 10 Mount starter wheel 3 Mount washer 4 and lock ring 5 301002 10 Mount kick starter ratchet wheel 6 Marking 7 points to drill hole 8 301003 10 Position spring 9 and mount was...

Page 149: ...or wear Change the starter idler gear Check the gear mesh and bearing of torque limiter 2 for damage and wear If there is damage or wear Change the torque limiter Check the gear mesh and bearing of freewheel gear 3 for damage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel 4 for damage and wear If there is damage or wear Change the free wheel Check the gear...

Page 150: ...timing chain tensioning rail 2 for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail 3 for damage and wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide 4 for damage and wear If there is damage or wear Replace the timing chain securing guide Check camshaft gears 5 for damage a...

Page 151: ...echanism engages and the piston remains in place Final position of the piston after engagement 3 mm 0 12 in Info This position is necessary for installation If the timing chain tensioner is now pressed again and is only extended a maximum of half way it is prevented from extending completely This locks the detent mechanism and the timing chain tensioner can no longer be squeezed together This func...

Page 152: ...ge or wear Change the inner clutch hub Check the contact surfaces of the clutch facing disks in outer clutch hub bk for damage and wear If there is damage or wear Change the clutch facing discs and the outer clutch hub Check needle bearing bl and collar sleeve bm for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check the intermediate clutch discs bn for da...

Page 153: ...ng Check the shift rollers for damage and wear If there is damage or wear Change the shift rollers Check the springs of shift rails 4 for damage and wear If the spring is damaged or worn Change the spring of the shift rail Check the shift rails 4 for run out on a flat surface If there is run out Change the shift rail Check the shift rails for scoring wear and smooth operation in the shift forks If...

Page 154: ...with the guide pin facing downward and put the guide pin on the shift quadrant Mount pressure spring 2 Slide on spring guide 3 push return spring 4 with the offset end facing upward over the spring guide and lift the offset end over abutment bolt 5 Mount washer 6 20 35 Disassembling the main shaft 305011 10 Secure the main shaft with the toothed end facing downward in the vise Guideline Use soft j...

Page 155: ...ng 3 Remove stop disk 4 Remove 6th gear sliding gear 5 Remove stop disk 6 Remove lock ring 7 Remove 3rd gear idler gear 8 Remove needle bearing 9 Remove 4th gear idler gear bk Remove needle bearing bl Remove stop disk bm and lock ring bn Remove 5th gear sliding gear bo Remove lock ring bp Remove stop disk bq Remove the 2nd gear idler gear br Remove needle bearing bs 20 37 Checking the transmission...

Page 156: ...nd sliding gears 5 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears 4 sliding gears 5 and fixed gear 6 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 5 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 5 for smooth operation ...

Page 157: ...t jaws Mount needle bearing 1 Mount 6th gear idler gear 2 Mount stop disk 3 and lock ring 4 Mount 3rd 4th gear sliding gear 5 with the small gear wheel facing downward Mount lock ring 6 Mount stop disk 7 Mount needle bearing 8 Mount 5th gear idler gear 9 Mount 2nd gear fixed gear bk and stop disk bl Finally check all gear wheels for smooth operation 20 39 Assembling the countershaft Info Use new l...

Page 158: ...ount 5th gear sliding gear 5 with the shift groove facing up Mount lock ring 6 and stop disk 7 Mount needle bearing 8 Mount 4th gear idler gear 9 Mount needle bearing bk Mount 3rd gear idler gear bl Mount lock ring bm and stop disk bn Mount 6th gear sliding gear bo with the shift groove facing downward Mount stop disk bp Mount needle bearing bq Mount 1st gear idler gear br Mount stop disk bs Final...

Page 159: ...e bearing Engine oil SAE 10W 50 p 268 Slide both transmission shafts 1 into the bearing seats together 305030 11 Mount lock ring 2 21 3 Installing the shift forks 305029 10 Shift fork 1 has a smaller inside diameter mount this in the shift groove of the main shaft Mount shift fork 2 in the lower shift groove of the countershaft Mount shift fork 3 in the upper shift groove of the countershaft Slide...

Page 160: ...ply the sealing compound to the left section of the engine case Loctite 5910 Mount the special tool on the crankshaft Mounting sleeve 77229005000 p 276 305160 10 Mount the left section of the engine case If necessary strike it lightly with a rub ber mallet and turn the transmission shafts Info Do not use the screws to pull the two sections of the engine case together Mount screws 1 but do not tigh...

Page 161: ...e timing chain and timing chain securing guide Info If the timing chain was used before ensure it is running in the correct direction Mount and tighten screws 2 Guideline Screw timing chain secur ing guide M6 10 Nm 7 4 lbf ft Loctite 243 305019 11 Position timing chain guide rail 3 Mount and tighten screw 4 Guideline Screw timing chain guide rail M6 10 Nm 7 4 lbf ft Loctite 243 Position timing cha...

Page 162: ...octite 243 21 10 Installing the force pump 305002 11 Oil the oil pump shaft internal rotor and external rotor before assembly Position force pump 1 Info The rounded side of the force pump faces the engine case Mount oil pump shaft 2 from below Mount pin 3 305001 11 Position the oil pump cover Marking A faces upward Mount and tighten screws 4 Guideline Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctit...

Page 163: ...bl 21 11 Installing the suction pump 304975 11 Insert needle roller 1 304974 11 Position suction pump 2 Crank the oil pump gear and ensure that it can move easily 304973 10 Mount O ring 3 304972 11 Position oil pump cover 4 Mount and tighten screws 5 Guideline Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 ...

Page 164: ... lever Mount and tighten screw 3 Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 21 14 Installing the shift shaft 304995 11 Slide shift shaft 1 with the washer into the bearing seat Push sliding plate 2 away from the shift drum locating unit 3 Insert the shift shaft all the way Let the sliding plate engage in the shift drum locating unit Shift through the transmission 21 15 Ins...

Page 165: ...b 304990 11 Mount collar sleeve 1 and both needle bearings 2 304991 10 Slide the outer clutch hub onto the gearbox main shaft Turn oil pump gear 3 and kick starter gear 4 until the teeth of the outer clutch hub mesh 304989 11 Slide on washer 5 and inner clutch hub 6 304988 11 Position the new lock washer and mount nut 7 Tighten the nut holding the inner clutch hub with a special tool Guideline Nut...

Page 166: ...acing discs and intermediate discs into the outer clutch hub Mount pressure piece 1 304984 11 Position pressure cap 2 304983 11 Mount pretension ring 3 with the Top marking facing up 304982 11 Position spring washer 4 304985 10 Position spring retainer 5 with the I marking 304981 11 Install the screws 6 and tighten them diagonally Guideline Screw clutch spring M5 6 Nm 4 4 lbf ft ...

Page 167: ...cified value is not reached Change the clutch facing discs 21 19 Installing the clutch cover 304978 11 Put on the clutch cover gasket Info Ensure that the dowel pins are seated properly Position the clutch cover Mount screws 1 but do not tighten yet Guideline Screw clutch cover M6x25 10 Nm 7 4 lbf ft Mount screws 2 but do not tighten them yet Guideline Screw clutch cover M6x40 10 Nm 7 4 lbf ft Tig...

Page 168: ... starter motor Long life grease p 270 Position the starter motor Mount screws 1 but do not tighten yet Guideline Screw starter motor M6 10 Nm 7 4 lbf ft 304968 11 Put on gasket 2 304967 11 Position the inside alternator cover Mount and tighten screws 3 Guideline Screw inside alternator cover M6 6 Nm 4 4 lbf ft 304969 11 Mount screws 1 but do not tighten yet Guideline Screw starter motor M6 10 Nm 7...

Page 169: ...the special tool on the oiled piston Compress the piston rings using the spe cial tool Piston ring mounting tool 60029015000 p 275 The piston rings are pushed together all the way 303078 10 Position the piston on the cylinder using the special tool Push the piston carefully into the cylinder from above Info The piston rings should not catch or they will be damaged 302641 10 Ensure that piston mark...

Page 170: ...ol and press it forcefully to the piston Turn the special tool clockwise thereby pushing the piston pin retainer into the groove Insert piston pin lock ring 77229030000 p 277 Ensure that the piston pin retainer is seated properly on both sides 304962 10 Remove the cloth Keep the timing chain taut Push the cylinder down carefully and let the dowel pins engage 21 23 Installing the cylinder head 3049...

Page 171: ...Place the timing chain over the camshaft gear of the intake camshaft Markings A are aligned with the flat areas of the camshaft Lock ring B engages in groove C Ensure that bleeder 2 are seated properly Slip in exhaust camshaft 3 Place the timing chain over the camshaft gear and position the camshaft in the bearing seat Clean all oil jets thoroughly and blow out with compressed air Mount the camsha...

Page 172: ... valve timing p 170 Remove the special tool Adjustment bush bridge 77229050000 p 278 Insert timing chain tensioner 77229035000 p 278 21 26 Adjusting the valve timing Condition Camshaft gears were loosened 304944 10 Mount special tool 1 and tension the timing chain Insert timing chain tensioner 77229035000 p 278 304947 10 Remove screws 2 304949 10 Position the special tool Adjustment bush bridge 77...

Page 173: ...0000 p 278 304947 10 Mount and tighten screws 2 Guideline Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil 304944 10 Remove special tool 1 Insert timing chain tensioner 77229035000 p 278 21 27 Installing the timing chain tensioner Preliminary work Prepare the timing chain tensioner for installation p 149 304946 11 Main work Position timing chain tensioner 1 and inser...

Page 174: ...ing chain ten sioner M10x1 10 Nm 7 4 lbf ft 21 28 Checking the valve clearance 304941 10 Remove screw 1 Crank over the engine repeatedly 304940 10 Position the engine at ignition top dead center Markings A on the cylinder head are flush above the flat areas B of the camshafts 304942 10 Check the valve clearance at all valves between the camshaft and cam levers Guideline Valve clearance Intake at 2...

Page 175: ...afts p 169 Install the timing chain tensioner p 171 Subsequent work Check the valve clearance p 172 21 30 Installing the torque limiter 304939 10 Position torque limiter 1 21 31 Installing the alternator cover 304931 11 Position alternator cover gasket 1 304930 11 Position the alternator cover Mount screws 2 and tighten once all of the alternator cover screws have been mounted Guideline Screw alte...

Page 176: ...e 1 304932 11 Position the kick starter Mount and tighten screw 2 Guideline Screw kick starter M8 25 Nm 18 4 lbf ft Loctite 243 21 33 Installing the valve cover 304929 10 Grease the O rings and mount the spark plug shaft insert 303076 10 Apply a thin layer of sealing compound in area A Loctite 5910 304928 10 Position the valve cover with the gasket Mount and tighten screws 1 Guideline Screw valve ...

Page 177: ...ce it in the oil filter container 304925 11 Oil the O ring of the oil filter cover Mount oil filter cover 2 Mount and tighten screws 3 Guideline Screw oil filter cover M6 10 Nm 7 4 lbf ft 21 36 Installing the oil screen 305091 10 Mount and tighten the oil drain plug 1 with the magnet and the new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 304924 10 Push the oil screen ...

Page 178: ... before mounting Long life grease p 270 Position the O ring Mount spacer 1 with the bevel facing inward 21 38 Installing the clutch push rod 304919 10 Mount clutch push rod 1 21 39 Removing the engine from the work stand 304918 10 Remove the screw connection from the special tool Engine fixing arm 77229002000 p 276 Remove the engine from the work stand Info Work with an assistant or a motorized ho...

Page 179: ...nvironmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 101365 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 101366 10 Fill bleeding syringe 4 with the appropriate hydraulic fluid Bleed syringe 50329050000 p 273 Brake fluid DOT 4 DOT 5 1 p...

Page 180: ... of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant a...

Page 181: ...lant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 268 Alternative 2 Coolant mixed ready to use p 268 Mount the radiator cap 23 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot All...

Page 182: ...mmediately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 101410 10 Make sure that the screw 1 is tightened Stand the vehicle upright Pour coolant in up to measurement A above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 268 Coolant mixed ready t...

Page 183: ... Info The engine oil level can be checked when the engine is cold or warm Preliminary work Stand the motorcycle upright on a horizontal surface 101414 10 Condition The engine is cold Check the engine oil level The engine oil level is up to the middle A of the level viewer If the engine oil is not up to the middle of the level viewer Add engine oil p 184 Condition The engine is at operating tempera...

Page 184: ...S EXC F SIX DAYS Remove the engine guard p 40 Park the motorcycle on a level surface 101415 10 Main work Place a suitable container under the engine Remove oil drain plug 1 with the magnet and seal ring Info Do not remove screws A on both sides 101416 10 Remove plug 2 with oil screen 3 and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces 101417 10 Push th...

Page 185: ...ve the oil filler plug 7 with the O ring from the clutch cover and fill up with engine oil Engine oil 1 20 l 1 27 qt Engine oil SAE 10W 50 p 268 Alternative engine oil for harsh oper ating conditions and increased per formance Engine oil SAE 10W 60 00062010035 p 268 Info Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler plug...

Page 186: ...engine and check that it is oil tight 24 5 Checking the engine oil pressure 305068 10 Check the engine oil level p 181 Remove the chain adjuster release screw Mount and tighten special tool 1 Guideline Oil pressure adapter M10x1 10 Nm 7 4 lbf ft Oil pressure adapter 77329006000 p 279 Connect pressure gauge 2 without the t plate to the special tool Pressure testing tool 61029094000 p 275 Danger Dan...

Page 187: ...when the machine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Remove the special tools Mount and tighten the chain adjuster release screw Guideline Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft ...

Page 188: ...t 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 3 75 6 25 kΩ If the specification is not reached Change the spark plug connector 25 3 Alternator checking the stator winding Condition The stator is disconnected Preliminary work Remove the seat p 69 601211 10 Main work Stator winding measurement I check the resistance Measure the resistance between the specified points Stator conn...

Page 189: ...e Ω If the value displayed does not meet specifications Change the stator 25 4 Removing the stator and ignition pulse generator Condition The alternator cover has been removed 305319 10 Remove screw 1 Remove the retaining bracket 305320 10 Pull the cable sleeve from the alternator cover Take off cable retainer plate 2 305321 10 Remove screws 3 Remove the stator and ignition pulse generator from th...

Page 190: ...n the stator in the alternator cover Mount and tighten screws 2 Guideline Screw stator M5 6 Nm 4 4 lbf ft Loctite 243 305320 11 Position cable retainer plate 3 Position cable support sleeve in the alternator cover 305319 11 Position the ignition pulse generator with the cable retainer plate in the alternator cover Position the retaining bracket Mount and tighten screws 4 Guideline Screw crankshaft...

Page 191: ...been removed 700087 01 Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly to connector 1 of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 192: ...0 Select the model Select ECU Diagnostics Highlight the Injection management EXC control unit Press Continue Select Measured Values Highlight Fuel management general Press Continue Mark the Throttle position sensor voltage circuit A THAD and Throttle position sen sor signal circuit A ATP measured values and deselect the other parameters using Select live data Loosen screw 1 Set Throttle position s...

Page 193: ...y result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and perform an initialization run Guideline Initialization run 5 min ...

Page 194: ...scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 32 2nd gear 16 26 3rd gear 20 25 4th gear 22 23 5th gear 25 22 6th gear 26 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spar...

Page 195: ...7 985 mm 3 46362 3 46397 in Cylinder drill hole diameter Size I 88 000 88 012 mm 3 46456 3 46503 in Size II 88 012 88 025 mm 3 46503 3 46554 in Piston cylinder mounting clearance Size I 0 025 0 047 mm 0 00098 0 00185 in Size II 0 027 0 049 mm 0 00106 0 00193 in Wear limit 0 070 mm 0 00276 in Piston ring end gap Compression ring 0 40 mm 0 0157 in Oil scraper ring 0 80 mm 0 0315 in Connecting rod ax...

Page 196: ...e case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 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 timing chain guide rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timi...

Page 197: ... ft Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Plug oil pressure regulator valve M12x1 5 20 Nm 14 8 lbf ft Oil drain plug M14x1 5 15 Nm 11 1 lbf ft Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M18LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft Screw alternator cover...

Page 198: ... EXC F EU AUS EXC F SIX DAYS 14 52 13 52 Final drive XCF W 13 52 Final drive EXC F USA 14 45 Chain 5 8 x 1 4 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 482 10 mm 58 35 0 39 in Seat height unloaded 970 mm 38 19 in Ground clearance unloaded 345 mm 13 58 in Weight without fuel approx EXC F EU AUS EXC F SIX DAYS 108 5 kg 239 2 lb Weight without fuel approx...

Page 199: ...5 W 31 2 Tires Validity Front tire Rear tire All EXC F models 90 90 21 M C 54M M S TT Metzeler MEC 6 DAYS EXTREME 140 80 18 M C 70M M S TT Metzeler MEC 6 DAYS EXTREME XCF W 80 100 21 51M TT Dunlop GEOMAX MX51 110 100 18 64M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under http www ktm com 31 3 Capacity fuel Total fuel tank capacity approx XCF W EXC F USA 8 5 l...

Page 200: ... turns Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 513 mm 20 2 in Weight of rider 75 85 kg 165 187 lb 513 mm 20 2 in Weight of rider 85 95 kg 187 209 lb 513 mm 20 2 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 0 N mm 22 8 lb in Weight of rider 75 85 kg 165 187 lb 4 2 N mm 24 lb in Weight of rider 85 95 kg 187 209 lb 4 4 N mm 25 1 lb in Fork length 940 mm 37 01 i...

Page 201: ... 25 turns Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload 8 mm 0 31 in Spring rate Weight of rider 65 75 kg 143 165 lb 66 N mm 377 lb in Weight of rider 75 85 kg 165 187 lb 69 N mm 394 lb in Weight of rider 85 95 kg 187 209 lb 72 N mm 411 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 34 mm 1 34 in Riding sag 110 mm 4 33 in Fitted leng...

Page 202: ... XCF W M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem EXC F SIX D...

Page 203: ...en clean with a paintbrush Motorcycle cleaner p 271 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride a short distance until t...

Page 204: ...he brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake di...

Page 205: ... the motorcycle p 201 Change the engine oil and oil filter clean the oil screen p 182 Check the antifreeze and coolant level p 178 Drain the fuel from the tank into a suitable container Check the tire air pressure p 82 Remove the battery p 92 Charge the battery p 92 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subje...

Page 206: ...fluid level of the hydraulic clutch p 177 Check the front brake fluid level p 97 Check the free travel of the hand brake lever p 96 Check the steering head bearing play p 35 Check the valve clearance Check the clutch Change the shaft seal rings of the water pump Change the fuel screen p 72 Check the fuel pressure p 76 Check all hoses e g fuel cooling bleeding drainage and sleeves for cracking leak...

Page 207: ... plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator valve Change the suction oil pump Check the oil pumps and lubrication system Replace the timing ...

Page 208: ...1 2 E1 M10 K10 20A 4 1 2 3 G10 X300 1 AF 4 X2 2 1 4 10A F2 2 1 FN 2 X6 1 DT 36 X16 14 2 BR 4 X4 4 BR 4 X4 3 c BF 1 X43 1 BA 1 X44 1 DT 36 X16 34 BA 1 X45 1 a AF 4 X2 3 S21 BK 4 BK 4 2 1 4 3 FN 2 X6 2 b 14 34 bl bu bl ye bl bl bl bl wh rd wh rd wh rd bl bu bl bl ye bl wh rd bu rd wh rd wh rd br bl ye bl ye bl ye br wh rd bl bu rd 601641 01 ...

Page 209: ...WIRING DIAGRAM 207 Components A11 EFI control unit F2 Fuse G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button ...

Page 210: ...1 1 E8 3 B1 3 F1 1 F8 G 3 U 7 C1 K12 1 2 3 4 b d c c G20 2 3 EZ 3 1 K30 1 2 3 4 T20 CU 4 CU 4 EY 3 2 3 3 2 1 4 1 DY 4 X9 1 DT 36 X16 30 e DY 4 X9 3 EB 4 X10 3 2 2 EB 4 X3 3 2 5 1 EB 4 X10 4 4 EB 4 X3 4 1 AP 6 X295 6 30 wh rd gn wh bl wh bl br ye rd br br wh rd wh rd wh rd wh rd wh rd br gn wh pk wh pk ye rd wh bl wh bl br 601642 01 ...

Page 211: ...WIRING DIAGRAM 209 Components A11 EFI control unit G20 Alternator K12 Light relay K30 Power relay T20 Voltage regulator X295 Diagnostics connector ...

Page 212: ... 4 B1 4 E1 c c P24 2 1 10A F4 1 2 FN 2 X8 1 FO 2 X11 1 FO 2 X11 2 BS 2 X285 2 BS 2 X285 1 FN 2 X8 2 d 7 D8 7 D8 B32 1 GA 3 X29 1 5A F25 2 1 FQ 2 X58 1 FQ 2 2 B33 1 1 M14 BL 2 BL 2 2 1 BV 2 X59 1 BV 2 X59 2 CD 2 X60 1 d f CD 2 X60 2 FP 1 X61 1 FP 1 X62 1 br rd ye bu ye bu br br gn gn br rd ye bu gn ye bu br bl bl br br br bl bl br 601643 01 ...

Page 213: ...IAGRAM 211 Components B32 Fuel tank sensor B33 Temperature switch for radiator fan optional F4 Fuse F25 Fuse optional M14 Radiator fan optional P24 Low fuel warning lamp X285 Connector for radiator fan optional ...

Page 214: ...3 2 1 4 8 3 F8 7 F1 Up Down Mode 5 E1 5 E1 5 E1 3 B8 3 E8 c c B70 1 2 CW 2 S36 4 1 DA 4 2 3 1 1 CY 3 X50 3 AJ 3 X39 3 BG 3 X40 3 1 2 f c 2 2 10A F3 1 2 FN 2 X7 2 g FN 2 X7 1 d f 3 2 1 2 1 4 3 2 1 CZ 3 CX 2 DB 4 P13 br ye bu ye bu br br ye bu ye bu ye bu br br br br ye bu br ye ye ye ye gn gn br ye bu 601644 01 ...

Page 215: ...WIRING DIAGRAM 213 Components B70 Wheel speed sensor front F3 Fuse P13 Speedometer S36 Tripmaster switch optional ...

Page 216: ...2 1 P23 2 1 a BA 1 X47 1 3 FL 1 X49 1 AC 6 X48 2 FL 1 X12 1 f AH 2 X19 2 AH 2 X18 2 1 AH 2 X19 1 AH 2 X18 1 BV 2 X15 1 DI 2 X14 1 BV 2 X15 2 DI 2 X14 2 AJ 3 X17 2 AC 6 X48 1 c AJ 3 X17 3 FO 2 X13 2 AC 6 X48 5 BP 4 X22 1 2 BP 4 X22 3 4 DG 4 X46 1 2 DG 4 X46 3 4 4 FO 2 X13 1 6 DI 2 X31 2 DI 2 X31 1 FF 1 X21 1 FF 1 X24 1 FP 1 X1 1 g f c gr gr wh gn wh wh wh bu bu bu gn gn wh br wh gn wh gn br bl ye y...

Page 217: ...ents B76 Brake light switch front B77 Brake light switch rear E13 Low beam high beam E60 License plate lamp P15 Horn P23 High beam indicator light P35 Parking light P36 Brake tail light S22 Light switch horn button kill switch ...

Page 218: ...V 2 X42 1 BV 2 X42 2 AH 2 X51 1 AH 2 X51 2 BT 3 X52 1 c P41 1 CW 2 2 CW 2 P42 1 CW 2 2 CW 2 P45 2 CW 2 1 CW 2 P46 2 CW 2 1 CW 2 BT 3 X52 3 2 1 1 BG 3 X56 2 BG 3 X56 3 1 AJ 3 X57 2 AJ 3 X57 3 CX 2 X53 1 CX 2 X54 1 CX 2 X54 2 CX 2 X53 2 CX 2 X25 2 CX 2 X28 2 CX 2 X28 1 CX 2 X25 1 FO 2 X55 2 f ye rd ye rd bl pu bl ye bu or or br br br br br br br br br pu bl pu bl pu bl pu bl ye bu br pu 601646 01 ...

Page 219: ... DIAGRAM 217 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch ...

Page 220: ... X23 2 DT 36 X16 21 M51 1 2 DQ 2 X26 1 31 DT 36 X16 32 R30 2 1 1 AT 2 X27 2 10 11 4 DT 36 X16 7 FS 4 X20 2 DT 36 X16 24 FS 4 X20 1 h DT 36 X16 16 DQ 2 X26 2 1 X301 8 35 DT 36 X16 36 GA 3 X29 2 DT 36 X16 15 GA 3 X29 3 c FN 2 X5 2 3 D6 3 D6 M13 2 3 1 21 31 32 10 11 7 24 16 8 15 35 36 ye rd wh bl bu wh bu wh bu bl bu lbu pk gn rd bl gr or wh wh bu bl bu lbu pk gn rd bl bl gr or or or or or bl bl ye r...

Page 221: ...G DIAGRAM 219 Components A11 EFI control unit B51 Lambda sensor cylinder 1 F1 Fuse M13 Fuel pump M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P25 FI warning lamp MIL X295 Diagnostics connector ...

Page 222: ... X16 13 2 p B41 3 2 1 1 DX 3 X32 3 DT 36 X16 6 DX 3 X32 2 DT 36 X16 2 AP 6 X33 5 AP 6 X33 6 4 DV 2 X34 2 DT 36 X16 4 DV 2 X34 1 AX 2 X35 2 DT 36 X16 22 AX 2 X35 1 DT 36 X16 18 FL 1 X36 1 9 1 DT 36 X16 3 AL 2 X37 2 CM 2 X38 1 DT 36 X16 25 CM 2 X38 2 S51 EL 2 EL 2 1 2 1 2 DV 2 5 13 6 2 4 22 18 9 3 25 2 1 S55 ye bu pu ye rd bl br rd pu wh pu ye bu wh ye rd ye pu ye rd bl br rd pu wh pu ye bu wh ye rd...

Page 223: ...or cylinder 1 B26 Rollover sensor B37 Ignition pulse generator B41 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for riding mode optional S55 Map Select switch for basic setting optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 224: ... K10 20A 4 1 2 3 G10 X300 1 AF 4 X2 2 1 4 10A F2 2 1 FN 2 X6 1 DT 36 X16 14 2 BR 4 X4 4 BR 4 X4 3 c BF 1 X43 1 BA 1 X44 1 DT 36 X16 34 BA 1 X45 1 a AF 4 X2 3 FN 2 X6 2 b S23 BK 4 BK 4 BF 1 4 3 2 1 1 14 34 bl bu bl ye bl bl bl bl wh rd wh rd wh rd bl bu bl bl bl ye bl wh rd bu rd bu rd wh rd wh rd br bl ye bl ye bl ye br wh rd 601671 01 ...

Page 225: ...WIRING DIAGRAM 223 Components A11 EFI control unit F2 Fuse G10 Battery K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button ...

Page 226: ... 3 B1 3 F1 1 F8 G 3 U 7 C1 K12 1 2 3 4 b d c c G20 2 3 EZ 3 1 K30 1 2 3 4 T20 CU 4 CU 4 EY 3 2 3 3 2 1 4 1 DY 4 X9 1 DT 36 X16 30 e DY 4 X9 3 EB 4 X10 3 2 2 EB 4 X3 3 2 5 1 EB 4 X10 4 4 EB 4 X3 4 1 AP 6 X295 6 30 wh rd gn wh bl wh bl br ye rd br br wh rd wh rd wh rd wh rd wh rd br gn wh pk wh pk ye rd wh bl wh bl br 601672 01 ...

Page 227: ...WIRING DIAGRAM 225 Components A11 EFI control unit G20 Alternator K12 Light relay K30 Power relay T20 Voltage regulator X295 Diagnostics connector ...

Page 228: ... F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 3 8 2 F8 4 F1 2 B8 R 4 B1 4 E1 c c P24 2 1 10A F4 1 2 FN 2 X8 1 FO 2 X11 1 FO 2 X11 2 2 BS 2 X285 1 FN 2 X8 2 d 7 D8 7 D8 B32 1 GA 3 X29 1 d f br rd ye bu ye bu br br gn gn br rd ye bu gn ye bu br 601673 01 ...

Page 229: ...WIRING DIAGRAM 227 Components B32 Fuel tank sensor F4 Fuse P24 Low fuel warning lamp X285 Connector for radiator fan optional ...

Page 230: ...4 8 3 F8 7 F1 Up Down Mode 5 E1 5 E1 5 E1 3 B8 3 E8 c c B70 1 2 CW 2 S36 4 1 DA 4 2 3 1 1 CY 3 X50 3 AJ 3 X39 3 BG 3 X40 3 1 2 f c 2 2 10A F3 1 2 FN 2 X7 2 g FN 2 X7 1 d f 3 2 1 2 1 4 3 2 1 CZ 3 CX 2 DB 4 P13 br ye bu ye bu br br ye bu ye bu ye bu br br br br ye bu br ye ye ye ye gn gn br ye bu 601674 01 ...

Page 231: ...WIRING DIAGRAM 229 Components B70 Wheel speed sensor front F3 Fuse P13 Speedometer S36 Tripmaster switch optional ...

Page 232: ... 2 1 a BA 1 X47 1 3 FL 1 X49 1 AC 6 X48 2 FL 1 X12 1 f AH 2 X19 2 AH 2 X18 2 1 AH 2 X19 1 AH 2 X18 1 BV 2 X15 1 DI 2 X14 1 BV 2 X15 2 DI 2 X14 2 AJ 3 X17 2 AC 6 X48 1 c AJ 3 X17 3 FO 2 X13 2 AC 6 X48 5 BP 4 X22 1 2 BP 4 X22 3 4 DG 4 X46 1 2 DG 4 X46 3 4 4 FO 2 X13 1 6 DI 2 X31 2 DI 2 X31 1 FF 1 X21 1 FF 1 X24 1 FP 1 X1 1 g f c gr gr wh gn wh wh wh bu bu bu gn gn wh br wh gn wh gn br bl ye ye bu br...

Page 233: ...ents B76 Brake light switch front B77 Brake light switch rear E13 Low beam high beam E60 License plate lamp P15 Horn P23 High beam indicator light P35 Parking light P36 Brake tail light S22 Light switch horn button kill switch ...

Page 234: ... 1 BV 2 X42 2 AH 2 X51 1 AH 2 X51 2 BT 3 X52 1 c P41 1 CW 2 2 CW 2 P42 1 CW 2 2 CW 2 P45 2 CW 2 1 CW 2 P46 2 CW 2 1 CW 2 BT 3 X52 3 2 1 1 BG 3 X56 2 BG 3 X56 3 1 AJ 3 X57 2 AJ 3 X57 3 CX 2 X53 1 CX 2 X54 1 CX 2 X54 2 CX 2 X53 2 CX 2 X25 2 CX 2 X28 2 CX 2 X28 1 CX 2 X25 1 FO 2 X55 2 f ye rd ye rd bl pu bl ye bu or or br br br br br br br br br pu bl pu bl pu bl pu bl ye bu br pu 601676 01 ...

Page 235: ... DIAGRAM 233 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch ...

Page 236: ...M51 1 2 DQ 2 X26 1 31 DT 36 X16 32 R30 2 1 1 AT 2 X27 2 10 11 4 DT 36 X16 7 2 DT 36 X16 24 h DT 36 X16 16 DQ 2 X26 2 1 X301 8 35 DT 36 X16 36 GA 3 X29 2 DT 36 X16 15 GA 3 X29 3 c FN 2 X5 2 3 D6 3 D6 M13 2 3 1 21 31 32 10 11 7 24 16 8 15 35 36 3 FS 4 X20 1 ye rd wh bl bu wh bu wh bu bl bu lbu pk gn rd bl gr or wh wh bu bl bu lbu pk gn rd bl bl gr or or or or bl bl ye rd bl or br pu br pu br br br b...

Page 237: ...WIRING DIAGRAM 235 Components A11 EFI control unit F1 Fuse M13 Fuel pump M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P25 FI warning lamp MIL X295 Diagnostics connector ...

Page 238: ...3 2 p B41 3 2 1 1 DX 3 X32 3 DT 36 X16 6 DX 3 X32 2 DT 36 X16 2 AP 6 X33 5 AP 6 X33 6 4 DV 2 X34 2 DT 36 X16 4 DV 2 X34 1 AX 2 X35 2 DT 36 X16 22 AX 2 X35 1 DT 36 X16 18 FL 1 X36 1 9 1 DT 36 X16 3 AL 2 X37 2 CM 2 X38 1 DT 36 X16 25 CM 2 X38 2 S51 EL 2 EL 2 1 2 1 2 DV 2 2 1 S55 5 13 6 2 4 22 18 9 3 25 ye bu pu ye rd bl br rd pu wh pu ye bu wh ye rd ye pu ye rd bl br rd pu wh pu ye bu wh ye rd bl bu...

Page 239: ...or cylinder 1 B26 Rollover sensor B37 Ignition pulse generator B41 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for riding mode optional S55 Map Select switch for basic setting optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 240: ...6 14 2 BR 4 X4 4 BR 4 X4 3 d BF 1 X43 1 BA 1 X44 1 DT 36 X16 34 BA 1 X45 1 AF 4 X2 3 FN 2 X6 2 b S23 BK 4 BK 4 4 3 2 1 S10 CV 4 CV 4 4 3 1 2 BY 4 X62 4 GT 6 X61 6 BY 4 X62 3 10A F5 1 2 FN 2 X60 1 FN 2 X60 2 3 c a BA 1 X47 1 14 34 bl bu bl ye bl bl bl bl wh rd wh rd bl bu bl ye bl wh rd wh rd bl ye bl ye br wh rd bu rd bu rd wh rd ye br br br rd rd wh or ye br wh rd rd wh or wh or wh or ye br rd bl...

Page 241: ...WIRING DIAGRAM 239 Components A11 EFI control unit F2 Fuse F5 Fuse G10 Battery K10 Starter relay with main fuse M10 Starter motor S10 Ignition lock S23 Emergency OFF switch electric starter button ...

Page 242: ...2 1 2 3 4 b e d d G20 2 3 EZ 3 1 K30 1 2 3 4 T20 CU 4 CU 4 EY 3 2 3 3 2 1 4 1 DY 4 X9 1 DT 36 X16 30 f DY 4 X9 3 EB 4 X10 3 2 2 EB 4 X3 3 2 5 1 EB 4 X10 4 4 EB 4 X3 4 1 AP 6 X295 6 4 GT 6 X61 5 2 2 4 GS 6 X59 5 c a 30 wh rd gn wh bl wh bl br ye rd br br wh rd wh rd wh rd br gn wh pk wh pk ye rd wh bl wh bl br ye br wh bl wh pk br bl bl bl br ye br rd rd 601692 01 ...

Page 243: ...WIRING DIAGRAM 241 Components A11 EFI control unit G20 Alternator K12 Light relay K30 Power relay T20 Voltage regulator X295 Diagnostics connector ...

Page 244: ...E1 d d P24 2 1 10A F4 1 2 FN 2 X8 1 FO 2 X11 1 FO 2 X11 2 BS 2 X285 2 BS 2 X285 1 FN 2 X8 2 e 7 D7 7 D7 B32 1 GA 3 X29 1 5A F25 2 1 FQ 2 X63 1 FQ 2 X63 2 B33 1 1 M14 BL 2 BL 2 2 1 BV 2 X64 1 BV 2 X64 2 CD 2 X65 1 e g CD 2 X65 2 FP 1 X66 1 FP 1 X67 1 br rd ye bu ye bu br br gn gn br rd ye bu gn ye bu br bl bl br br br bl bl br 601733 01 ...

Page 245: ...IAGRAM 243 Components B32 Fuel tank sensor B33 Temperature switch for radiator fan optional F4 Fuse F25 Fuse optional M14 Radiator fan optional P24 Low fuel warning lamp X285 Connector for radiator fan optional ...

Page 246: ...4 8 3 F8 7 F1 Up Down Mode 5 E1 5 E1 5 E1 3 B8 3 E8 d d B70 1 2 CW 2 S36 4 1 DA 4 2 3 1 1 CY 3 X50 3 AJ 3 X39 3 BG 3 X40 3 1 2 g d 2 2 10A F3 1 2 FN 2 X7 2 h FN 2 X7 1 e g 3 2 1 2 1 4 3 2 1 CZ 3 CX 2 DB 4 P13 br ye bu ye bu br br ye bu ye bu ye bu br br br br ye bu br ye ye ye ye gn gn br ye bu 601694 01 ...

Page 247: ...WIRING DIAGRAM 245 Components B70 Wheel speed sensor front F3 Fuse P13 Speedometer S36 Tripmaster switch optional ...

Page 248: ...FL 1 X12 1 g AH 2 X19 2 AH 2 X18 2 1 AH 2 X19 1 AH 2 X18 1 BV 2 X15 1 DI 2 X14 1 BV 2 X15 2 DI 2 X14 2 AJ 3 X17 2 AC 6 X48 1 d AJ 3 X17 3 FO 2 X13 2 AC 6 X48 5 BP 4 X22 1 2 BP 4 X22 3 4 DG 4 X46 1 2 DG 4 X46 3 4 4 FO 2 X13 1 6 DI 2 X31 2 DI 2 X31 1 FF 1 X21 1 FF 1 X24 1 FP 1 X1 1 h g d 3 4 6 2 1 6 C2 S29 BC 6 BC 6 5 gr gr wh gn wh wh wh bu bu bu gn gn wh br wh gn wh gn br ye bu br br br ye bu br b...

Page 249: ...s B76 Brake light switch front B77 Brake light switch rear E13 Low beam high beam E60 License plate lamp P15 Horn P23 High beam indicator light P35 Parking light P36 Brake tail light S29 Light switch horn button turn signal switch ...

Page 250: ... 1 AH 2 X51 2 BT 3 X52 1 d P41 1 CW 2 2 CW 2 P42 1 CW 2 2 CW 2 P45 2 CW 2 1 CW 2 P46 2 CW 2 1 CW 2 BT 3 X52 3 2 1 1 BG 3 X56 2 BG 3 X56 3 1 AJ 3 X57 2 AJ 3 X57 3 CX 2 X53 1 CX 2 X54 1 CX 2 X54 2 CX 2 X53 2 CX 2 X25 2 CX 2 X28 2 CX 2 X28 1 CX 2 X25 1 FO 2 X55 2 g 5 C2 S29 BG 3 BG 3 2 3 1 ye rd ye rd bl pu bl ye bu or or br br br br br br br br br pu bl pu bl pu bl pu bl ye bu br pu 601696 01 ...

Page 251: ...Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 Light switch horn button turn signal switch ...

Page 252: ... CX 2 X23 2 DT 36 X16 21 M51 1 2 DQ 2 X26 1 31 DT 36 X16 32 R30 2 1 1 AT 2 X27 2 10 DT 36 X16 16 DQ 2 X26 2 1 X301 8 35 DT 36 X16 36 GA 3 X29 2 DT 36 X16 15 GA 3 X29 3 d FN 2 X5 2 3 D6 3 D6 M13 2 3 M20 2 1 DF 2 X58 1 DF 2 X58 2 1 21 31 32 10 16 8 15 35 36 ye rd wh bl bu wh bu wh bu bl bu lbu bl gr or wh wh bu bl bu lbu bl gr or or or or ye rd or br pu br pu br br br br br bu gr bu gr br br or or o...

Page 253: ...NG DIAGRAM 251 Components A11 EFI control unit F1 Fuse M13 Fuel pump M20 Fuel evaporation valve M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P25 FI warning lamp MIL X295 Diagnostics connector ...

Page 254: ... 1 1 DX 3 X32 3 DT 36 X16 6 DX 3 X32 2 DT 36 X16 2 AP 6 X33 5 AP 6 X33 6 4 DV 2 X34 2 DT 36 X16 4 DV 2 X34 1 AX 2 X35 2 DT 36 X16 22 AX 2 X35 1 DT 36 X16 18 FL 1 X36 1 9 1 DT 36 X16 3 AL 2 X37 2 CM 2 X38 1 DT 36 X16 25 CM 2 X38 2 S51 EL 2 EL 2 1 2 1 2 DV 2 2 1 S55 5 13 6 2 4 22 18 9 3 25 DT 36 X16 24 24 ye bu pu ye rd bl br rd pu wh pu ye bu wh ye rd ye pu ye rd bl br rd pu wh pu ye bu wh ye rd bl...

Page 255: ...or cylinder 1 B26 Rollover sensor B37 Ignition pulse generator B41 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for riding mode optional S55 Map Select switch for basic setting optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 256: ... F1 2 E1 M10 K10 20A 4 1 2 3 G10 X300 1 AF 4 X2 2 1 4 10A F2 2 1 FN 2 X6 1 DT 36 X16 14 2 BR 4 X4 4 BR 4 X4 3 c BF 1 X25 1 DT 36 X16 34 AF 4 X2 3 S21 BK 4 BK 4 2 1 4 3 FN 2 X6 2 b S20 1 BA 1 X302 14 34 bl bu bl ye bl bl bl bl wh rd wh rd wh rd bl bu bl bl ye bl wh rd bu rd wh rd wh rd br br wh rd bl bu rd 601681 01 ...

Page 257: ...WIRING DIAGRAM 255 Components A11 EFI control unit F2 Fuse G10 Battery K10 Starter relay with main fuse M10 Starter motor S20 Kill switch S21 Electric starter button ...

Page 258: ... B1 3 F1 1 F8 G 3 U 6 C1 K12 1 2 3 4 b d c c G20 2 3 EZ 3 1 K30 1 2 3 4 T20 CU 4 CU 4 EY 3 2 3 3 2 1 4 1 DY 4 X9 1 DT 36 X16 30 e DY 4 X9 3 EB 4 X10 3 2 2 EB 4 X3 3 2 5 1 EB 4 X10 4 4 EB 4 X3 4 1 AP 6 X295 6 30 wh rd gn wh bl wh bl br ye rd br br wh rd wh rd wh rd wh rd wh rd br gn wh pk wh pk ye rd wh bl wh bl br 601682 01 ...

Page 259: ...WIRING DIAGRAM 257 Components A11 EFI control unit G20 Alternator K12 Light relay K30 Power relay T20 Voltage regulator X295 Diagnostics connector ...

Page 260: ... M c c P24 2 1 10A F4 1 2 FN 2 X8 1 FO 2 X11 1 FO 2 X11 2 BS 2 X285 2 BS 2 X285 1 FN 2 X8 2 d 6 D8 6 D8 B32 1 GA 3 X29 1 d f 5A F25 2 1 FQ 2 X40 1 FQ 2 2 B33 1 1 M14 BL 2 BL 2 2 1 CD 2 X42 1 CD 2 X42 2 FP 1 X43 1 FP 1 X44 1 BV 2 X41 2 BV 2 X41 1 br rd ye bu ye bu br br gn gn br rd ye bu gn ye bu br bl br br bl bl br br bl 601743 01 ...

Page 261: ...IAGRAM 259 Components B32 Fuel tank sensor B33 Temperature switch for radiator fan optional F4 Fuse F25 Fuse optional M14 Radiator fan optional P24 Low fuel warning lamp X285 Connector for radiator fan optional ...

Page 262: ... 6 5 4 3 2 1 4 7 3 F8 6 F1 Up Down Mode 5 E1 5 E1 3 B8 3 E8 c c B70 1 2 CW 2 S36 4 1 DA 4 2 3 1 1 CY 3 X18 3 AJ 3 X39 3 BG 3 X28 3 1 2 c 2 2 10A F3 1 2 FN 2 X7 2 g FN 2 X7 1 d f 3 2 1 2 1 4 3 2 1 CZ 3 CX 2 DB 4 P13 br ye bu br ye bu ye bu br br br br ye ye ye ye gn gn br ye bu 601684 01 ...

Page 263: ...WIRING DIAGRAM 261 Components B70 Wheel speed sensor front F3 Fuse P13 Speedometer S36 Tripmaster switch optional ...

Page 264: ...5 4 3 2 1 5 7 4 E8 4 E8 P37 BG 3 BG 3 BS 2 BS 2 1 2 3 1 2 E11 1 1 1 P35 2 1 AJ 3 X17 2 c AJ 3 X17 3 2 BP 4 X22 3 4 DG 4 X19 1 2 DG 4 X19 3 4 DI 2 X31 2 DI 2 X31 1 FF 1 X21 1 FF 1 X24 1 FP 1 X1 1 g S30 2 1 FF 1 X13 1 FF 1 X12 1 wh br br bu wh gn bu br br br wh br wh gn ye wh ye wh 601685 01 ...

Page 265: ...WIRING DIAGRAM 263 Components E11 Low beam P35 Parking light P37 Tail light S30 Light switch ...

Page 266: ...1 1 2 DQ 2 X26 1 31 DT 36 X16 32 R30 2 1 1 AT 2 X27 2 10 11 4 DT 36 X16 7 2 DT 36 X16 24 h DT 36 X16 16 DQ 2 X26 2 1 X301 8 35 DT 36 X16 36 GA 3 X29 2 DT 36 X16 15 GA 3 X29 3 c FN 2 X5 2 3 D6 3 D6 M13 2 3 1 21 31 32 10 11 7 24 16 8 15 35 36 3 FS 4 X20 1 ye rd wh bl bu wh bu wh bu bl bu lbu pk gn rd bl gr or wh wh bu bl bu lbu pk gn rd bl bl gr or or or or bl ye rd bl or br pu br pu br br br br br ...

Page 267: ...WIRING DIAGRAM 265 Components A11 EFI control unit F1 Fuse M13 Fuel pump M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P25 FI warning lamp MIL X295 Diagnostics connector ...

Page 268: ...1 1 DX 3 X32 3 DT 36 X16 6 DX 3 X32 2 DT 36 X16 2 AP 6 X33 5 AP 6 X33 6 4 DV 2 X34 2 DT 36 X16 4 DV 2 X34 1 AX 2 X35 2 DT 36 X16 22 AX 2 X35 1 DT 36 X16 18 FL 1 X36 1 9 1 DT 36 X16 3 AL 2 X37 2 CM 2 X38 1 DT 36 X16 25 CM 2 X38 2 S51 EL 2 EL 2 1 2 1 2 DV 2 2 1 S55 5 13 6 2 4 22 18 9 3 25 ye bu pu ye rd bl br rd pu wh pu ye bu wh ye rd ye pu ye rd bl br rd pu wh pu ye bu wh ye rd bl bu bu bu bl bu b...

Page 269: ...or cylinder 1 B26 Rollover sensor B37 Ignition pulse generator B41 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for riding mode optional S55 Map Select switch for basic setting optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 270: ...n inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 285 SAE p 285 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Synthetic engine oi...

Page 271: ...ing to SAE p 285 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel ...

Page 272: ...ecommends Motorex products Supplier Motorex Protect Shine High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Lubricant T158 Guideline KTM recommends Lubcon products Supplier Lubcon Turmogrease PP 300 Lubricant T511 Guideline KTM recommends Lubcon products Supplier Lubcon Turmsi...

Page 273: ... Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil ...

Page 274: ...eder cover 201597 10 Art no 00029013005 Bleeder cover 201598 10 Art no 00029013006 Bleeding device 201491 10 Art no 00029013100 Spring hooks 400363 01 Art no 50305017000 Mounting tool heim joint 201428 01 Art no 50329000044 ...

Page 275: ...3 Bleed syringe 400058 01 Art no 50329050000 Circlip pliers reverse 400059 01 Art no 51012011000 Clutch holder 400289 01 Art no 51129003000 Lift stand 500071 01 Art no 54829055000 Extractor 400073 01 Art no 58012009000 ...

Page 276: ... 58429037037 Torque wrench with various accessories in set 200910 10 Art no 58429094000 Valve spring compressor 400101 01 Art no 59029019000 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Plastigauge measuring strips 400122 01 Art no 60029012000 ...

Page 277: ...ounting tool 400123 01 Art no 60029015000 Hose clamp pliers 400142 01 Art no 60029057000 Testing hose 201314 01 Art no 61029093000 Pressure testing tool 400149 01 Art no 61029094000 Engine assembly stand 200306 01 Art no 61229001000 ...

Page 278: ...crankshaft complete 400185 01 Art no 75029047000 Protection cover 400167 01 Art no 75029090000 Extractor camshaft gear 302768 10 Art no 77229001044 Engine fixing arm 301487 10 Art no 77229002000 Mounting sleeve 305092 10 Art no 77229005000 ...

Page 279: ...sing tool 302926 10 Art no 77229008000 Extrude plate base 302925 10 Art no 77229009000 Pliers for valve stem seals 302943 10 Art no 77229010000 Limit plug gauge 303164 10 Art no 77229026000 Insert piston pin lock ring 302721 10 Art no 77229030000 ...

Page 280: ...on cap 302921 10 Art no 77229031000 Separator plate 302922 10 Art no 77229032000 Insert timing chain tensioner 302769 10 Art no 77229035000 Puller 302723 10 Art no 77229048000 Adjustment bush bridge 302722 10 Art no 77229050000 ...

Page 281: ...ing lever 400129 01 Art no 77229060100 Spark plug wrench 400170 01 Art no 77229072000 Oil pressure adapter 400176 01 Art no 77329006000 Release device for timing chain tensioner 400181 01 Art no 77329051000 Pin wrench 200734 10 Art no T103 ...

Page 282: ...SPECIAL TOOLS 280 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Pin 201235 10 Art no T120 Mounting sleeve 200788 10 Art no T1204 Calibration pin 200790 10 Art no T1205 ...

Page 283: ...AL TOOLS 281 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Centering sleeve 200777 10 Art no T1214 Mounting sleeve 300568 10 Art no T1215 Disassembly tool 200816 10 Art no T1216 ...

Page 284: ...L TOOLS 282 Vacuum pump 200273 10 Art no T1240S Protecting sleeve 200635 10 Art no T1401 Clamping stand 200733 10 Art no T14015S Clamping stand 200688 10 Art no T14016S Gripping tool 200639 10 Art no T14026S1 ...

Page 285: ...ECIAL TOOLS 283 Assembly tool 200634 10 Art no T1402S Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S Press drift 200789 10 Art no T1504 Assembly tool 200791 10 Art no T150S ...

Page 286: ...SPECIAL TOOLS 284 Nitrogen filling tool 300574 10 Art no T170S1 ...

Page 287: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 288: ...w speed shock absorber adjusting 41 Coolant draining 179 refilling 180 Coolant level checking 178 179 Cooling system 178 Cylinder Nikasil coating 139 E Engine installing 113 removing 109 Engine work on individual parts cam levers checking 144 camshaft bearing changing 141 camshafts checking 141 clutch cover 134 clutch checking 149 connecting rod conrod bearing and crank pin changing 137 countersha...

Page 289: ...Engine disassembly alternator cover removing 120 camshaft removing 121 clutch cover removing 125 clutch discs removing 125 clutch push rod removing 118 crankshaft removing 131 cylinder head removing 122 engine oil draining 118 engine positioning at ignition top dead center 121 force pump removing 128 intermediate kick starter gear removing 127 kick starter removing 120 left section of the engine c...

Page 290: ...ling 90 removing 90 Main silencer glass fiber yarn filling changing 65 installing 65 removing 65 Manifold installing 64 removing 64 Motorcycle cleaning 201 raising with lift stand 10 removing from lift stand 10 O Oil circuit 181 Oil filter changing 182 Oil screen cleaning 182 P Play in throttle cable checking 38 Preparing for use after storage 203 R Rear sprocket checking 87 Rear wheel installing ...

Page 291: ...sis tightening torques 200 engine 192 engine tolerance wear limits 193 engine tightening torques 194 195 fork 198 shock absorber 199 Throttle cable play adjusting 39 Throttle cable routing checking 38 Throttle position sensor basic settings adjusting 190 circuit A checking the basic settings 190 Tire condition checking 82 Tire pressure checking 82 Type label 8 W Warranty 7 Winter operation checks ...

Page 292: ... 3206111en 3206111en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2011 Photo Mitterbauer ...

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