KTM 390 Duke 2014 COL 2013, Repair Manual

Page 1: ...REPAIR MANUAL 2013 390 Duke EU 390 Duke AUS 390 Duke MAL 390 Duke 2014 COL Art no 3206167en ...

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

Page 4: ... SEAT TRIM 38 11 1 Opening the filler cap 38 11 2 Closing the filler cap 38 11 3 Removing the seat 38 11 4 Mounting the seat 39 11 5 Removing the passenger seat 39 11 6 Mounting the passenger seat 39 11 7 Removing the fuel tank cover 39 11 8 Installing the fuel tank cover 42 11 9 Removing the fuel tank 44 11 10 Installing the fuel tank 45 11 11 Removing the front spoiler 47 11 12 Fitting front spo...

Page 5: ...ging the balancer shaft bearing 111 16 4 7 Work on the cylinder head 112 16 4 8 Checking the cylinder head 113 16 4 9 Checking the pivot point of the camshafts 113 16 4 10 Checking measuring the cylinder 114 16 4 11 Checking the piston ring end gap 114 16 4 12 Checking measuring the piston 115 16 4 13 Checking the piston cylinder mounting clearance 115 16 4 14 Checking the oil pump 115 16 4 15 Che...

Page 6: ...erance wear limits 157 21 3 Engine tightening torques 158 21 4 Capacities 159 21 4 1 Engine oil 159 21 4 2 Coolant 159 21 4 3 Fuel 159 21 5 Chassis 159 21 6 Electrical system 160 21 7 Tires 160 21 8 Fork 160 21 9 Shock absorber 160 21 10 Chassis tightening torques 161 22 CLEANING PROTECTIVE TREATMENT 163 22 1 Cleaning the motorcycle 163 22 2 Checks and maintenance steps for winter operation 164 23...

Page 7: ...page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Identifies a proprietary name Name Identifies a prot...

Page 8: ... are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will...

Page 9: ...a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 Spare parts accessories Only use spare parts and accessories approved and or recommended by KTM KTM accepts no liability for other products and any resulting damage or loss The current KTM Po...

Page 10: ...abel 2 is on the right of the frame behind the steering head 4 2 Key number B00755 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 4 3 Engine number 101876 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket ...

Page 11: ...d lift the motorcycle 5 2 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 101884 10 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand 1 Remove the support of the wheel stand 5 3 Raising the motorcycle with the front wh...

Page 12: ...5 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 101889 01 Secure the motorcycle against falling over Remove the front wheel stand 101887 10 Mount cap 1 5 5 Raising the motorcycle with the work stand Note Danger of damage The parked vehicle may roll away or fall over Always...

Page 13: ...ide of the vehicle Work stand 62529055000 p 192 308231 10 Position the motorcycle upright align the special tool and raise the motorcycle 5 6 Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 308231 11 Secure the motorcycle against falling over Remove special tool 1 ...

Page 14: ... at low engine speeds B00782 10 Sit on the vehicle take the weight off of the side stand and move up all the way Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the position After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time Shift gear ...

Page 15: ...st gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Info Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again B00782 10 Turn the emergency OFF switch to the ...

Page 16: ...ry work Raise the motorcycle with the work stand p 10 Tie the rear of the vehicle down Dismount the front fender p 48 308235 10 Main work Remove screw 1 Remove the cable binder Pull off the ABS sensor and hang it to one side 308236 10 Remove screws 2 Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake...

Page 17: ...ired position using the fork rings 308238 11 Tighten screws 1 Guideline Screw top triple clamp M8 11 Nm 8 1 lbf ft Tighten screws 2 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 308240 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing Clean and grease the shaft seal rings 3 and contact surfaces A of the spacers Long life grea...

Page 18: ... brake lever Unload the rear of the vehicle Remove the motorcycle from the work stand p 11 308235 11 Position the ABS sensor Mount and tighten screw 6 Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Route the cable and secure with a cable binder 308241 10 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws 7 Guideline Screw fork st...

Page 19: ...8 10 Release the fork leg and clamp it with the fork stub Info Use soft jaws 201509 10 Push the outer tube downward Hold screw cap 1 Loosen nut 2 Remove the screw cap 201510 10 Detach the outer tube from the inner tube Info Place a container underneath to catch any oil that may run out 201511 10 Unclamp the inner tube Drain the oil ...

Page 20: ...201514 10 Remove seal ring 5 Remove support ring 6 201515 10 Unclamp the outer tube Heat up the outer tube in the area of sliding bushing 7 Guideline 50 C 122 F Strike the lower edge of the outer fork tube on a wooden board Sliding bushing 7 must fall out of its seat 6 5 Checking the fork legs Condition The fork legs have been disassembled 201516 10 Check the inner tube and the axle clamp for dama...

Page 21: ... leg 200632 10 Check the outer tube for damage If damage is found Change the fork leg 201517 10 Check the surface of the sliding bushings If the dark layer A is worn off Change the fork leg 6 6 Assembling the fork legs Info These operations are the same on both fork legs Preparatory work Check the fork legs p 18 202092 10 Main work Clamp in the inner tube with the axle clamp Guideline Use soft jaw...

Page 22: ...e outer tube in the lower sliding bushing area A Guideline 50 C 122 F Slide the outer tube onto the inner tube Hold the sliding bushing with the longer shoulder of the special tool Mounting tool T528S p 197 Push the sliding bushing all the way into the outer tube 202094 10 Position the support ring Hold the seal ring with the shorter shoulder of the special tool Mounting tool T528S p 197 Push the ...

Page 23: ...nclamp the fork and bounce a number of times Then add the remaining quantity 201522 10 Push the outer tube upward Mount screw cap 6 Unclamp the fork leg in the area of the lower triple clamp Clamping stand T612S p 197 Tighten the screw cap Guideline Screw cap on outer tube M47x1 5 30 Nm 22 1 lbf ft 6 7 Removing the lower triple clamp Preparatory work Raise the motorcycle with the work stand p 10 T...

Page 24: ...ch connectors 3 and 4 308245 10 Detach connectors 5 and 6 308246 10 Remove the connector holder Disconnect connector 7 308247 10 Remove the combination instrument 308248 10 Remove screws 8 Remove the headlight mask 308249 10 Remove screw 9 ...

Page 25: ...move washer bl Remove steering head bearing bm Remove the lower triple clamp with the steering stem 6 8 Installing the lower triple clamp 308254 11 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 187 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing 1 Mount washer 2 with the cut out facing downward 308253...

Page 26: ...line Nut steering head M30x1 5 Nm 3 7 lbf ft Castle nut wrench drive 90129050000 p 195 308252 10 Secure the cable in the bracket 308251 10 Position the upper triple clamp with the handlebar 308250 10 Mount screw 4 with the washer but do not tighten it yet Guideline Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Holding lugs A reach into the drilled holes 308248 11 Position the headlight mask Mo...

Page 27: ...ight mask up Mount and tighten screws bm Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 308242 11 Mount expanding rivets bn on both sides Install the fork legs p 15 308255 10 Loosen screws bo Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screw 4 Guideline Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Tighten screws bo Guideline Screw top triple clamp...

Page 28: ...ht ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the play of the steering head bearing p 26 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 cl...

Page 29: ...r triple clamp to avoid strains Tighten screw 2 Guideline Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Tighten screws 1 Guideline Screw top triple clamp M8 11 Nm 8 1 lbf ft Finishing work Check the steering head bearing play p 26 Remove the motorcycle from the work stand p 11 ...

Page 30: ...hange If the idle speed changes Check the throttle cable routing 7 2 Adjusting the play in the throttle cable B00728 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the throttle cable by turning adjusting screw 3 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut 2 Slide on sleeve 1 7 3 Checking the clutch lever play 10191...

Page 31: ...e play 101915 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the clutch level A by turning adjusting screw 3 Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut 2 Slide on sleeve 1 ...

Page 32: ...and stability 101886 10 Adjust the spring preload by turning adjusting ring 1 Guideline Spring preload Standard 3 clicks Full payload 10 clicks Hook wrench T106S p 196 Info The spring preload can be set to 10 different positions 8 2 Removing the shock absorber Preparatory work Raise the motorcycle with the work stand p 10 308258 10 Main work Remove screw 1 Info Protect the link fork and attachment...

Page 33: ...ecial tool Spring compressor T14050S p 196 Info Use the ring of the special tool with the smallest possible inside diameter It must be pressed directly onto the spring Compress the spring Remove spring retainer 1 Release the spring Remove the shock absorber from the special tool Remove the spring 8 5 Installing the spring 201697 10 Mount the spring The tight coil of the spring is at the bottom Cla...

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

Page 35: ...he exhaust system to cool down Do not touch hot components 308293 10 Remove nuts 1 with the washers Swing the radiator forward slightly 308294 10 Remove the cable binder expose the connector 2 of the lambda probe and detach 308295 10 Loosen exhaust clamp 3 308296 10 Remove the nuts 4 308297 10 Remove the exhaust manifold toward the front ...

Page 36: ...ange M8 22 Nm 16 2 lbf ft 308295 11 Position and tighten exhaust clamp 2 Guideline Exhaust clamp 10 Nm 7 4 lbf ft Tighten nuts 1 Guideline Nut exhaust flange M8 22 Nm 16 2 lbf ft 308294 11 Plug in connector 3 Secure the connector with a cable binder 308293 11 Position the radiator Mount and tighten nuts 4 with the washers Guideline Nut radiator M6 5 Nm 3 7 lbf ft ...

Page 37: ...ork Remove screw 1 with washers 308300 10 Remove screw 2 with the sleeve Hang the brake fluid reservoir to the side Info Ensure that brake fluid does not escape 308301 10 Remove screw 2 with washers 308302 10 Remove screw 4 Info Do not misplace the sleeves 308303 10 Take off the main silencer toward the bottom ...

Page 38: ...rrectly 308301 11 Mount and tighten screw 2 with the washers Guideline Screw main silencer M6 11 Nm 8 1 lbf ft 308300 11 Position the brake fluid reservoir Mount and tighten screw 3 with the sleeve Guideline Screw brake fluid reservoir of rear brake M6 9 Nm 6 6 lbf ft 308299 11 Mount and tighten screw 4 with the washers Guideline Screw main silencer M6 11 Nm 8 1 lbf ft Finishing work Install the e...

Page 39: ...ssenger seat p 39 Remove the seat p 38 308260 10 Main work Remove screws 1 Pull the air filter box lid forward and move to the side 308261 10 Remove air filter 2 Clean the air filter box 10 2 Installing the air filter 308261 11 Main work Position air filter 1 308260 11 Mount air filter box lid Info Make sure the air filter box lid is seated correctly Mount and tighten screws 2 Guideline Screw air ...

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

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

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

Page 43: ...filler cap 3 308277 10 Remove screws 4 with the washers 308278 10 Remove screws 5 Remove screws 6 308279 10 Remove cap 7 from the compensating tank 308280 10 Remove screws 8 308281 10 Lift the fuel tank cover Detach the side covers on both sides ...

Page 44: ...fueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that i...

Page 45: ...279 11 Mount plug 3 of the compensating tank 308276 11 Mount filler cap 4 308284 10 Individually remove special screws 5 and replace with screws 6 Info Always replace the screws individually or the fuel tank will become dis torted and it will no longer be possible to mount the screws When all screws have been replaced tighten the screws crosswise Guideline Screw fuel tank cover M5 4 Nm 3 lbf ft ...

Page 46: ...low the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediat...

Page 47: ...line and remove the fuel tank 11 10 Installing the fuel tank Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instru...

Page 48: ...ntact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system 308291 11 Main work Connect the fuel line Position hose clamp 1 308290 11 Remove tool 2...

Page 49: ...39 Mount the passenger seat p 39 11 11 Removing the front spoiler 101895 10 Remove screws 1 101896 10 Remove screws 2 Take off the front spoiler 11 12 Fitting front spoiler 101895 10 Position the front spoiler Mount screws 1 but do not tighten yet 101896 10 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Tighten screw 1 Guideline Remaining screws chassis M6 10 Nm ...

Page 50: ...emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed cont...

Page 51: ...t of fuel pump control actuator test by pressing the Quit but ton Remove the special tools 308292 10 Connect the fuel line and position hose clamp 1 Remove the tool 11 16 Changing the fuel filter Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicl...

Page 52: ... the fuel from the fuel tank into a suitable container 304887 10 Main work Take fuel filter 1 out of the holder 304888 10 Remove hose clamp 2 and pull off the fuel hose Push back hose clamp 3 and remove the fuel filter 304890 10 Position the fuel filter Connection A faces to the left Position the fuel hoses and mount hose clamp 2 Position hose clamps 3 304887 10 Position fuel filter 1 in the holde...

Page 53: ...with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Preparatory work Remove the passenger seat p...

Page 54: ...he vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especi...

Page 55: ...ing the front wheel Preparatory work Raise the motorcycle with the rear wheel stand p 9 Raise the motorcycle with the front wheel stand p 9 B01391 10 Main work Remove screws 1 and push the fender to the side Remove screw 2 and pull wheel speed sensor 3 out of the hole Loosen screws 4 and screw 5 Unscrew screw 5 about six turns and press your hand on the screw to push the wheel spindle out of the a...

Page 56: ...rews 5 Take the motorcycle off of the front wheel stand p 10 Pull the front brake and push down hard on the fork several times to align the fork legs Tighten screws 6 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 9 12 4 3 Removing the brake disc of the front brake Preparatory work Raise the motorcycle with the rear wheel stand p 9 R...

Page 57: ...12 5 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 them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reache...

Page 58: ...eel speed sensor 5 into the hole Mount and tighten screw 6 Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 9 12 5 3 Removing the brake disc of the rear brake Preparatory work Raise the motorcycle with the rear wheel stand p 9 Remove the rear wheel p 55 307350 10 Main work Remove screws 1 Take off the ABS sensor wheel 307...

Page 59: ... motorcycle on the side stand Shift gear to neutral In the area of chain sliding guard press the chain upward toward the swingarm and determine chain tension A Info The upper chain section B must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 5 7 mm 0 2 0 28 in If the chain tension does not meet specifications Adjust the chain...

Page 60: ...ing the chain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rear sprocket and chain should always be replaced together 1 2 3 18 19 20 0 0 0 B B 0 0 A A 401288 10 Shift gear to neutral Pull the lower chain section with specified weight A Guideline Weight...

Page 61: ...tion the chain guard and tighten screw 1 Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw 2 Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft 12 5 8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of...

Page 62: ...in time the rear sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with the rear wheel stand p 9 Remove the rear wheel p 55 101925 10 Main work Check bearing 1 If the bearing is damaged or worn Change the bearing Check the rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in...

Page 63: ...rminal cover 1 Disconnect the negative cable 2 of the battery 101904 10 Pull back the positive terminal cover 3 Disconnect the positive cable 4 of the battery Detach rubber band 5 Pull the battery up and out of the battery holder Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehicle is ther...

Page 64: ...e eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environment Do not discard batteries with the household waste Dispose of faulty batteries in an environmentally compatible manner Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries Info Even ...

Page 65: ...deline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Finishing work Mount the seat p 39 Mount the passenger seat p 39 Set the clock p 76 13 6 Checking the charging voltage Condition The battery must be fully functional and completely charged Preparatory work Remove the passenger seat p 39 Remove the se...

Page 66: ...Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 10 A ABS control unit Fuse 8 10 A combination instrument control unit Fuse 9 10 A auxiliary equipment Info A defective fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed a...

Page 67: ...t a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger o...

Page 68: ... 4 307306 10 Remove pin 5 Take off springs 6 307307 10 Remove brake linings 7 Clean the brake caliper 307308 10 Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir Suction it off if necessary Info Protect the components against damage 307307 10 Position brake linings 7 Info Always change the brake linings in pairs ...

Page 69: ... brake fluid Change the brake fluid of the front and rear brake according to the service schedule C00200 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in viewer 1 If the brake fluid is below the MIN marking Add front brake fluid p 67 14 4 Adding front brake fluid Warning Danger of accidents Failure of the brake system If the brake f...

Page 70: ... and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulatio...

Page 71: ...the bleeder cover 307303 10 Correct the brake fluid level to level A Guideline Level A 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 186 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water Check the hand brake lever for a firm pressure point 14 6 Checking the rear brake linings Warning Danger of accidents Reduced braking ...

Page 72: ...ed and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no lo...

Page 73: ...he free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications 101897 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contac...

Page 74: ... 2 in Info The range of adjustment is limited Hold screw 3 and tighten nut 2 Attach spring 1 14 10 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Warning Danger of accidents Reduced br...

Page 75: ...e disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 101899 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 186 Refit screw cap with membrane Info Clean up overflowed or spilt brake fluid immedi...

Page 76: ...e Filling pressure 2 2 5 bar 29 36 psi 308268 10 Pull off dust cap 4 of the bleeder screw Connect the bleeder bottle hose Bleeding device 00029013100 p 189 Open bleeder screw 5 by approximately one half turn Info Drain until fresh brake fluid emerges in the bleeder bottle hose without bub bles Tighten the bleeder screw Close shut off valve 3 Open the bleeder screw again until no more brake fluid e...

Page 77: ...the engine speed above which the shift warning light starts to flash Set the speed with the MODE and SET buttons Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds The display RPM 1 goes out and the set speed is stored 15 3 Adjusting the shift speed RPM 2 Condition The ignition is on The motorcycle is stationary 401308 ...

Page 78: ... service interval display can only be reset It is not possible to individu ally adjust the distance or time to the next required service 15 6 Checking the headlight setting 0 0 A A 0 0 B B 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the first mar...

Page 79: ...otorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range 101908 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 101907 10 Moun...

Page 80: ...mounting Preparatory work Switch off all power consumers and switch off the engine 101907 10 Main work Remove expanding rivets 1 308243 10 Remove screws 2 Lift the headlight mask slightly and swing forward B00762 10 Remove screws 3 Take off cover 4 B00763 10 Pull the socket with bulb 5 out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 1...

Page 81: ... that the lighting is functioning properly 15 9 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine 101907 10 Main work Remove expanding rivets 1 101908 10 Remove s...

Page 82: ...ousing Headlight H4 socket P43t p 160 Info Insert the headlight bulb so that the catches latch into the recesses Attach retaining clamp 5 B00760 10 Connect plug in connection 4 Mount protection cap 3 101908 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 101907 10 Mount expanding rivets 1 on both sides Check that the lighting is functioni...

Page 83: ...nnect the negative cable of the battery p 62 Drain the coolant p 148 Remove the exhaust manifold p 33 308304 10 Main work Push back the rubber cap Remove nut 1 with washers Hang the cable to one side 308305 10 Bend up the lock washer 2 Detach the clutch cable 308306 10 Remove nut 3 Detach the clutch cable 308307 10 Disconnect connector 4 308308 10 Push back hose clamp 5 Pull off the vent hose ...

Page 84: ...t cover 308311 10 Remove screws 9 and take off the lock washer 308312 10 Remove nut bk with washer Take off chain adjuster bl Push the rear wheel into the foremost position 308313 10 Pull the engine sprocket off of the countershaft and remove it 308314 10 Remove screw bm Pull off the shift linkage and hang it to one side ...

Page 85: ...g connectors bo and bp 308317 10 Expose the cable and unplug connector bq 308318 10 Release hose clip br Push the throttle valve body upward out of the intake flange 308319 10 Remove screws bs Remove fitting bt Remove both engine fixing arms 308320 10 Push back hose clamps ck and cl Pull off the radiator hoses ...

Page 86: ...iator pipe and hang it to one side 308323 10 Remove screws co Take off the retaining bracket 308324 10 Position the floor jack under the engine and fix it using the special tool Floor jack attachment 75029055000 p 192 308325 10 Remove fitting cp Remove fitting cq Remove the cable binder Hang ground wire cr to the side ...

Page 87: ...000 p 192 308326 10 Main work Position the engine in the frame Info It is useful to draw on the help of an assistant Protect the frame and attachments against damage 308325 11 Position ground wire 1 and secure it with a cable binder Mount fitting 2 but do not tighten yet Guideline Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft Mount fitting 3 but do not tighten yet Guideline Fitting engine ...

Page 88: ...Nm 7 4 lbf ft 308321 11 Mount the radiator hose Position hose clamp 6 308320 11 Mount the radiator hoses Position hose clamps 7 and 8 308327 10 Tighten fittings 2 and 3 Guideline Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft 308319 11 Position both engine fixing arms Mount and tighten screws 9 Guideline Screw engine bearer on frame M8 30 Nm 22 1 lbf ft Mount and tighten fitting bk Guidelin...

Page 89: ...tors bn and bo Position the cable and secure with cable binders 308315 11 Mount and tighten nut bp with the washer Guideline Remaining nuts chassis M5 3 Nm 2 2 lbf ft Position the rubber cap 308314 11 Position the shift linkage Mount and tighten screw bq Guideline Screw shift activation M6 11 Nm 8 1 lbf ft Loctite 243 308313 10 Position the engine sprocket in the chain and slide onto the countersh...

Page 90: ...t 308311 11 Mount the lock washer and turn it slightly The lock washer engages in the gear teeth of the countershaft Mount and tighten screws bt Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft 308310 11 Position the engine sprocket cover Mount and tighten screws ck Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft Mount and tighten screw cl Guideline Remaining nuts chassis M6 15 Nm 11 1 ...

Page 91: ...he clutch cover and fill up with engine oil Engine oil 1 6 l 1 7 qt Engine oil SAE 15W 50 p 186 Mount and tighten the oil filler plug with the O ring Finishing work Install the exhaust manifold p 34 Reconnect the negative cable of the battery p 62 Set the clock p 76 Mount the seat p 39 Mount the passenger seat p 39 Take the motorcycle off of the rear wheel stand p 9 Fill bleed the cooling system p...

Page 92: ...and 61229001000 p 192 Mount the engine on special tool Info Have an assistant help you or use a crane 16 3 2 Draining the engine oil 307957 10 Remove oil drain plug 1 with the O ring 307958 10 Remove oil screen 2 with the O ring Completely drain the engine oil 307959 10 Remove screw plug 3 with the O ring and oil screen 16 3 3 Removing the chain securing guide 307960 10 Remove screws 1 Take off th...

Page 93: ... the valve cover with the valve cover seal 307962 10 Take off gasket 2 307963 10 Remove the spark plug shaft insert 3 16 3 5 Removing the spark plug 307966 10 Remove the spark plug using special tool 1 Spark plug wrench 77229172000 p 193 16 3 6 Removing the clutch cover 307972 10 Remove screws 1 ...

Page 94: ... 2 Take off clutch cover gasket 3 16 3 7 Setting the engine to ignition top dead center 307967 10 Remove screw plug 1 307968 10 Remove screw plug 2 307969 10 Turn the crankshaft counterclockwise until markings A align with the edge of the cylinder head Castle nut wrench drive 90129021000 p 194 Markings B and C align ...

Page 95: ... 307978 10 Remove screw 1 with the O ring 307979 10 Turn the timing chain tensioner screw clockwise The timing chain tensioner is locked Remove screw 2 Remove the timing chain tensioner with the gasket 16 3 9 Removing the camshaft 307981 10 Release screws 1 from the outside to the inside and remove them Remove the camshaft bearing bridge Remove dowels ...

Page 96: ...ft 3 16 3 10 Removing the cylinder head 307985 10 Remove screws 1 307986 10 Release screws 2 in a crisscross pattern and remove them with the washers Take off the cylinder head 307987 10 Take off the cylinder head gasket 3 Remove dowels 4 307988 10 Remove timing chain guide rail 5 ...

Page 97: ... cylinder Info If no other work is required on the cylinder and the piston you can leave the piston in the cylinder 307991 10 Take off cylinder base gasket 2 Remove dowels 3 16 3 12 Removing the starter motor 307997 10 Remove screws 1 Take off the starter motor 16 3 13 Removing the timing chain 307998 10 Feed out timing chain 1 Info If the timing chain is to be reused mark the direction of travel ...

Page 98: ...water pump cover with the gasket 308001 10 Remove locating pins 2 308002 10 Remove nut 3 with washer Take off the water pump impeller 4 16 3 15 Removing the alternator cover 308003 10 Remove screws 1 Take off the alternator cover 308004 10 Remove dowels 2 Take off alternator cover gasket 3 ...

Page 99: ...t special tool 3 on the rotor Info Left handed thread Hold it tight using the special tool and pull off the rotor by turning the screw in Puller for rotor 90229009000 p 196 Remove the spring washer 16 3 17 Removing the starter drive 308007 10 Take off torque limiter 1 Remove starter idler gear 2 308008 10 Remove screw 3 Remove the retaining bracket 308009 10 Remove freewheel gear 4 ...

Page 100: ...with washers Castle nut wrench drive 90129022000 p 194 Take off drive wheel of the balancer shaft Remove the spring washer 16 3 19 Removing the gear position sensor 308014 10 Remove screws 1 Take off the retaining bracket Remove screws 2 Pull off the ignition pulse generator 308015 10 Remove screws 3 Take off the gear position sensor and ignition pulse generator with the cable ...

Page 101: ...n 3 and the contact spring 16 3 20 Removing the suction pump 308017 10 Remove screws 1 Take off the oil pump housing of the suction pump 308018 10 Remove dowels 2 308019 10 Remove external rotor 3 and internal rotor 4 308020 10 Take off pin 5 ...

Page 102: ...1 in a crisscross pattern and remove together with the washers and the clutch springs Take off pressure cap 2 308024 10 Remove pull rod 3 Remove clutch discs 4 308025 10 Take off support ring and pretension ring 5 308026 10 Hold the clutch basket using the special tool Clutch holder 51129003000 p 189 Remove nut 6 with washer Info Left handed thread ...

Page 103: ...washer usually sticks to the inner clutch hub Take off clutch basket 9 308028 10 Remove collar sleeve bk 16 3 23 Removing the primary gear 308030 10 Remove nut 1 with washer 308031 10 Remove washer 2 308032 10 Remove the timing chain sprocket 3 308033 10 Remove primary gear 4 ...

Page 104: ...rce pump 308035 10 Remove lock ring 1 Take off washer 2 Remove the oil pump gear 3 308036 10 Remove pin 4 Take off the washer 308037 10 Remove screws 5 Take off the pressure pump housing 308038 10 Remove dowels 6 308039 10 Remove external rotor 7 Remove internal rotor 8 ...

Page 105: ... 3 26 Removing the shift drum locating 308045 10 Remove screw 1 Press locking lever 2 away from shift drum locating 3 and take off the shift drum locating Release the locking lever 16 3 27 Removing the locking lever 308046 10 Remove screw 1 Take off locking lever 2 together with the washers and spring 16 3 28 Removing the oil filter 308047 10 Remove screws 1 Remove the oil filter cover 2 with the ...

Page 106: ...iers reverse 51012011000 p 189 16 3 29 Removing the left engine case 308055 10 Remove special tool 1 Engine blocking screw 61229015000 p 192 308056 10 Remove screw 2 308057 10 Remove screws 3 Swing the left section of the engine case up and remove the fitting of the engine fixing arm ...

Page 107: ...gine case by screwing in the screw Info Do not wedge the engine case section The washer of the main shaft usually sticks to the bearing Take off the left section of the engine case Remove the special tool 309196 10 Remove dowels 6 16 3 30 Removing the shift rails 308059 10 Remove shift rail 1 together with upper spring and the lower spring Remove shift rail 2 16 3 31 Removing the shift drum 308060...

Page 108: ... 33 Removing the transmission shafts 308063 10 Pull both transmission shafts 1 out of the bearing seats together 16 3 34 Removing the balancer shaft 308064 10 Remove screw 1 Take off the lock washer Remove balancer shaft 2 16 3 35 Removing the crankshaft 308065 10 Remove crankshaft 1 ...

Page 109: ...ft to push the bearing all the way to the stop or so that it is flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer ring otherwise the bearings will be damaged when they are pressed in After the engine case section has cooled check that the bearings are firmly seated Info If the bearings are not firmly seat...

Page 110: ... is flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer ring otherwise the bearings will be damaged when they are pressed in After the engine case section has cooled check that the bearings are firmly seated Info If the bearings are not firmly seated after cooling it is likely that they will rotate in the e...

Page 111: ...ll the way with the open side facing inward Mounting sleeve 90129043000 p 195 308076 10 Press shaft seal ring 2 all the way in with the open side facing inward Mounting sleeve 90129043000 p 195 308075 10 Mount lock ring 1 16 4 4 Checking the radial play of the lower conrod bearing Condition The conrod bearing is bulging ...

Page 112: ... not twist the connecting rod Remove the conrod bearing cover again Compare the Plastigauge clearance gauge with the specifications on the packaging Guideline Connecting rod radial play of lower conrod bearing New condition 0 045 0 068 mm 0 00177 0 00268 in Wear limit 0 080 mm 0 00315 in Info The width of the Plastigauge clearance gauge is equivalent to the bearing play Clean the parts 16 4 5 Chan...

Page 113: ...heck the radial play of the lower conrod bearing p 109 308110 01 Position and oil the bearing shells Position the connecting rod and conrod bearing cover according to markings 3 Mount and tighten screws 1 Guideline Screw conrod bearing M8x1 34 Nm 25 1 lbf ft 16 4 6 Changing the balancer shaft bearing 308070 10 Mount special tools 1 Disassembly tool balancer shaft bearing 90129056000 p 196 308071 1...

Page 114: ... valve spring Remove valve spring retainer 4 Remove valve spring valve stem seal 5 and valve spring seat 6 Info Place the valve into a box according to the installation position and label the box Check the cylinder head p 113 Mount valve spring seat 6 and the new valve stem seal 5 Mount the valve spring Mount valve spring retainer 4 308105 01 Pretension the valve spring using the special tool Valv...

Page 115: ... 0 10 mm 0 0039 in If the measured value does not equal the specified value Change the cylinder head 302808 10 Check sealing seat A of the valves Valve sealing seat width Intake 0 90 1 10 mm 0 0354 0 0433 in Valve sealing seat width Exhaust 0 90 1 10 mm 0 0354 0 0433 in If the measured value does not equal the specified value Machine the valve seat Blow compressed air through all oil holes and che...

Page 116: ...aged Change the cylinder and piston Measure the cylinder diameter at several places in the X and Y axes using a micrometer to check for oval wear Guideline Cylinder bore diameter 88 982 88 998 mm 3 50322 3 50385 in 308079 10 Check the sealing area of the cylinder head for distortion using a straight edge and the special tool Feeler gauge 59029041100 p 190 Cylinder cylinder head distortion of seali...

Page 117: ...oloration or signs of wear If the piston pin has strong discoloration signs of wear Change the piston pin Insert the piston pin into the connecting rod and check the bearing for play If the piston pin bearing has too much play Change the connecting rod and the piston pin 308099 01 Measure the piston at the piston skirt at right angles to the piston pin at a distance B Guideline Distance B 9 mm 0 3...

Page 118: ...nge the oil pump and if necessary the oil pump housing 16 4 15 Checking the oil pressure regulator valve 308084 01 Remove washer 1 Remove spring 2 Measure the length of spring 2 Oil pressure regulator valve minimum spring length 26 00 mm 1 0236 in If the measured length is less than the specification Change the spring Check control piston 3 for damage and wear If there is damage or wear Change the...

Page 119: ...amage or wear Change the clutch pressure cap Check the contact surfaces of the clutch facing discs in the outer clutch hub 5 for wear Contact surface clutch facing discs in clutch basket 0 5 mm 0 02 in If the contact surface is very worn Change the clutch facing discs and the outer clutch hub Check clutch facing discs 6 for discoloration and scoring If there is discoloration or scoring Change all ...

Page 120: ...t drum and or the bearing Check bearing 3 for stiffness and wear If the bearing is stiff or worn Change the bearing Check shift rail 4 on a flat surface for run out If there is run out Change the shift rail Check the shift rail for scoring signs of corrosion and stiffness in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate 5 i...

Page 121: ...ith the guide pin facing down and attach the guide pin to the shift quadrant Mount preload spring 2 Push on spring guide 3 push return spring 4 over the spring guide with the offset end facing upward and lift the offset end over abutment bolt 5 Mount washer 6 16 4 19 Disassembling the main shaft 308096 01 Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Re...

Page 122: ...st gear idler gear 2 Remove collar bushing 3 Remove the 6th gear sliding gear 4 Remove lock ring 5 Remove collar bushing 6 Remove the 3rd gear idler gear 7 Remove washer 8 Remove the 4th gear idler gear 9 Remove fifth gear sliding gear bk Remove the second gear idler gear bl Remove collar bushing bm 16 4 21 Checking the transmission Condition The transmission has been disassembled ...

Page 123: ...mage or wear Change the gear wheel pair Check the tooth faces of idler gears 4 sliding gears 5 and fixed gear 6 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 5 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 5 for smooth operation in the profile of main shaft 2 If the sliding gear do...

Page 124: ...t collar bushing 2 Mount lock ring 3 Mount third fourth gear sliding gear 4 with the small gear wheel facing up Mount lock ring 5 Mount collar bushing 6 Mount fifth gear idler gear 7 Mount second gear fixed gear 8 and stop disk 9 Finally check all gear wheels for smooth operation 16 4 23 Assembling the countershaft Info Use new lock rings in every repair job Preparatory work Oil all parts carefull...

Page 125: ...r sliding gear 3 with the shift groove facing upward Mount fourth gear idler gear 4 Mount washer 5 Mount third gear idler gear 6 Mount collar bushing 7 Mount lock ring 8 Mount sixth gear sliding gear 9 with the shift groove facing downward Mount collar bushing bk Mount first gear idler gear bl Mount stop disk bm Replace O ring bn of the countershaft Finally check all gear wheels for smooth operati...

Page 126: ...ming chain guide rail 2 for damage and wear If there is damage or wear Change the timing chain guide rail Check timing chain tensioning rail 3 for damage and wear If there is damage or wear Change the timing chain tensioning rail Check timing chain sprocket 4 for damage and wear If there is damage or wear Change the timing chain sprocket Check camshaft gears 5 for damage and wear If there is damag...

Page 127: ...ge or wear Change the starter idler gear Check the teeth and seating of the torque limiter 2 for damage and wear If there is damage or wear Change the torque limiter Check the toothing and bearing of freewheel gear 3 for damage and wear If there is damage or wear Replace the freewheel gear and or the bearing Check toothing 4 of the starter motor for damage and wear If there is damage or wear Repla...

Page 128: ...eplace the freewheel 16 5 Assembling the engine 16 5 1 Installing the crankshaft 308065 10 Oil the bearing Slide crankshaft 1 into the bearing seat 16 5 2 Installing the balancer shaft 308069 10 Mount special tool 1 Mounting sleeve 90129005000 p 194 308064 11 Mount balancer shaft 2 with the bearing Info If necessary heat the engine case Position the retaining bracket Mount and tighten screw 3 Guid...

Page 129: ...er mount it in the shift groove of the main shaft Mount shift fork 2 in the lower shift groove of the countershaft Mount shift fork 3 in the upper shift groove of the countershaft 16 5 5 Installing the shift drum 308060 11 Slide shift drum 1 into the bearing seat Hang shift forks 2 into the shift drum 16 5 6 Installing the shift rails 308059 10 Oil all parts carefully before assembling Mount shift...

Page 130: ...ngine case Loctite 5910 309200 10 Mount the engine case section If necessary tap lightly with a rubber mallet while turning the transmission shafts Info Do not tighten the engine case sections using the screws Mount screws 3 but do not tighten them yet Guideline Screw engine case M6x75 12 Nm 8 9 lbf ft Mount screws 4 and tighten all screws in a crisscross pattern Guideline Screw engine case M6x35 ...

Page 131: ...e oil filter housing approx full with engine oil Fill oil filter 1 with engine oil and insert it in the oil filter housing 308047 11 Oil the O ring of the oil filter cover Install the oil filter cover 2 Mount and tighten screws 3 Guideline Screw oil filter cover M5 8 Nm 5 9 lbf ft 16 5 9 Installing the locking lever 308046 11 Mount locking lever 1 with the sleeve washers and spring Mount and tight...

Page 132: ... screw 4 Guideline Screw shift drum locating M6 12 Nm 8 9 lbf ft Loctite 243 16 5 11 Installing the shift shaft 308044 11 Slide shift shaft 1 with the washer into the bearing seat Push sliding plate 2 away from the shift drum locating 3 Insert the shift shaft all the way Let the sliding plate engage in the shift drum locating Shift through the transmission 16 5 12 Installing the oil pump 308041 10...

Page 133: ...il holes are clear and fill with a small amount of oil Position the oil pump Mount and tighten screws 5 Guideline Screw oil pump M6 12 Nm 8 9 lbf ft Loctite 243 308036 11 Position the washer Position pin 6 308035 11 Position the oil pump gear 7 Position washer 8 Mount lock ring 9 Crank the oil pump gear and check for stiffness 16 5 13 Installing the primary gear 308034 11 Mount woodruff key 1 3080...

Page 134: ...r Guideline Nut primary gear timing chain sprocket M16x1 5 120 Nm 88 5 lbf ft Loctite 243 16 5 14 Installing the clutch cage 308028 11 Mount collar sleeve 1 308029 10 Slide clutch basket 2 onto the main shaft Turn oil pump gear 3 until the gear teeth of the clutch basket engage 308027 11 Slide on washer 4 and inner clutch hub 5 ...

Page 135: ...away from the support ring 308054 10 Oil the clutch facing discs thoroughly Mount the clutch facing disc 9 with the largest inside diameter Alternately mount all of the other intermediate clutch discs and clutch facing discs 308024 11 Mount pull rod bk 308023 11 Position pressure cap bl Mount screws bm with the washers and springs and tighten them in a crisscross pat tern Guideline Screw clutch sp...

Page 136: ...8021 10 Mount internal rotor 2 and external rotor 3 Marking A of the external rotor is not visible after assembly 308018 11 Mount dowels 4 308017 11 Oil the oil pump Position the oil pump housing Mount and tighten screws 5 Guideline Screw oil pump M6 12 Nm 8 9 lbf ft Loctite 243 ...

Page 137: ...he retaining bracket Info Ensure that the cable is correctly routed Position the ignition pulse generator Mount and tighten screws 3 Guideline Screw ignition pulse gen erator M5 6 Nm 4 4 lbf ft Loctite 243 Mount and tighten screws 4 Guideline Screw retaining bracket M5 6 Nm 4 4 lbf ft Loctite 243 16 5 18 Installing the balancer shaft drive wheel 308050 10 Mount the spring washer Mount drive wheel ...

Page 138: ...and B align Mount wedge 5 308010 11 Mount and tighten screw 6 Guideline Screw balancer shaft gear M8 20 Nm 14 8 lbf ft Loctite 243 16 5 19 Installing the starter drive 308009 11 Position freewheel gear 1 308008 11 Position the retaining bracket Mount and tighten screw 2 Guideline Screw freewheel gear retaining bracket M6 12 Nm 8 9 lbf ft Loctite 243 308007 11 Mount starter idler gear 3 Mount torqu...

Page 139: ...ernator cover 308004 11 Mount the dowels 1 Seal the cable guide Loctite 5910 Mount the alternator cover gasket 2 308003 11 Position the alternator cover Install the screws 3 and tighten them diagonally Guideline Screw alternator cover M6 12 Nm 8 9 lbf ft 16 5 22 Installing the water pump cover 308002 11 Mount water pump impeller 1 Mount and tighten nut 2 with the washer Guideline Nut water pump im...

Page 140: ...ft Loctite 243 307998 11 Position timing chain 2 in the engine case according to the direction of travel 16 5 24 Installing the starter motor 307997 10 Grease the O ring Position the starter motor Long life grease p 187 Mount and tighten screws 1 Guideline Screw starter motor M6 12 Nm 8 9 lbf ft 16 5 25 Installing the piston 307992 10 Shift the joint of the piston rings by 120 Place the special to...

Page 141: ...ings should not become caught otherwise they may be dam aged 307994 10 Ensure that piston marking A faces the outfeed side 307995 10 Thinly apply sealing compound to area B Loctite 5910 Position the cylinder base gasket 307991 11 Mount dowels 1 and position the cylinder base gasket 2 307990 11 Feed the timing chain through the chain shaft Mount piston pin 3 ...

Page 142: ...rectly on both sides Remove the cloth Keep the timing chain tensioned Push the cylinder down carefully and let the dow els engage 16 5 26 Installing the cylinder head 307989 10 Position timing chain guide rail 1 Pins A engage in recess B The timing chain guide rail engages in recess C 307987 11 Mount dowels 2 Put on cylinder head gasket 3 Mount the cylinder head 307986 11 Mount screws 4 with the w...

Page 143: ...chain over the camshaft gear of the intake camshaft Markings A of the camshafts align with the edge of the cylinder head 307981 11 Thoroughly clean all oil jets and blow through with compressed air Mount the dowels Position the camshaft bearing bridge Mount screws 2 and tighten from the inside to the outside Guideline Screw camshaft bearing bridge M6 11 Nm 8 1 lbf ft 16 5 28 Installing the timing ...

Page 144: ...4 lbf ft 16 5 29 Checking the valve clearance 307965 10 Remove the special tool Engine blocking screw 61229015000 p 192 Crank the engine several times Set the engine to ignition top dead center p 92 Check the valve clearance at all valves between the camshaft and cam lever Guideline Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Valve clearance intake cold 0 08 0 12 mm 0 0031 0 0047 in...

Page 145: ...2 Nm 8 9 lbf ft 16 5 30 Adjusting the valve clearance Preparatory work Remove the timing chain tensioner p 93 Remove the camshaft p 93 307977 10 Main work Swing up cam lever 1 Correct the shims 2 as indicated by the results of the valve clearance check Finishing work Install the camshafts p 141 Install the timing chain tensioner p 141 Check the valve clearance p 142 16 5 31 Installing the clutch c...

Page 146: ...lutch cover M6 12 Nm 8 9 lbf ft 16 5 32 Installing the spark plug 307966 10 Mount and tighten the spark plug using special tool 1 Guideline Spark plug M12 15 Nm 11 1 lbf ft Spark plug wrench 77229172000 p 193 16 5 33 Installing the valve cover 307963 11 Grease the O rings and mount spark plug shaft insert 1 307962 10 Mount gasket 2 ...

Page 147: ...ews 3 with the gaskets Guideline Screw valve cover M6 12 Nm 8 9 lbf ft 16 5 34 Installing the chain securing guide 307960 10 Position the chain securing guide Mount and tighten screws 1 Guideline Screw chain securing guide M6 11 Nm 8 1 lbf ft Loctite 243 16 5 35 Installing the oil screen 307959 11 Mount and tighten screw plug 1 with the O ring and oil screen Guideline Oil screen screw plug small M...

Page 148: ...ine Oil drain plug M24x1 5 15 Nm 11 1 lbf ft 16 5 36 Removing the engine from the engine assembly stand 307956 10 Remove the fitting from special tools 1 and 2 Engine fixing arm 90129002060 p 194 Engine fixing arm 90129002050 p 193 Remove the engine from the engine assembly stand Info Have an assistant help you or use a crane ...

Page 149: ... same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle B Guideline Adjusting angle B shift rod linkage shift lever 75 Tighten nuts 1 Info After the nuts have been tightened the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells Check the shift lever ...

Page 150: ...Stand the motorcycle upright Place a suitable container under the engine Remove screw 1 Remove the radiator cap Completely drain the coolant Mount screw 1 with a new seal ring and tighten it Guideline Plug water pump drain hole M6 8 Nm 5 9 lbf ft 18 2 Filling bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the...

Page 151: ...em components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated area...

Page 152: ...immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that ...

Page 153: ...18 WATER PUMP COOLING SYSTEM 151 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 148 Mount the radiator cap ...

Page 154: ...il must be between the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 155 19 3 Checking the engine oil pressure Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Env...

Page 155: ... an enclosed space without an effective exhaust extraction system Start the engine Check the engine oil pressure Engine oil pressure Coolant temperature 70 C 158 F Engine speed 1 500 rpm 0 7 bar 10 psi Coolant temperature 70 C 158 F Engine speed 5 000 rpm 2 4 bar 35 psi If the specification is not reached Check oil pumps for wear Check all oil channels for free flow Switch off the engine Warning D...

Page 156: ...ug 1 with the O ring Remove oil screen 2 with the O ring Remove screw plug 3 with oil screen 4 Completely drain the engine oil Thoroughly clean the oil drain plugs and oil screens Position oil screen 2 and mount and tighten oil drain plug 1 with the O ring Guideline Oil drain plug M24x1 5 15 Nm 11 1 lbf ft Mount and tighten screw plug 3 with oil screen 4 and the O ring Guideline Oil screen screw p...

Page 157: ...l level p 152 19 5 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 101921 10 Main work Remove the oil filler plug 1 with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 15W 50 p 186 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil I...

Page 158: ...tor Stator winding measurement II check the resistance Measure the resistance between the specified points Stator connector HB pin 1 Stator connector HB pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 Ω If the displayed value does not equal the setpoint value Change the stator L00082 10 304934 10 Stator winding check the short circuit to ground terminal 31 Measure the resistance betwe...

Page 159: ...rd gear 19 27 4th gear 21 24 5th gear 23 22 6th gear 25 21 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Alternator 12 V 238 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 550 1 650 rpm Star...

Page 160: ...impeller M6 10 Nm 7 4 lbf ft Loctite 243 Plug water pump drain hole M6 8 Nm 5 9 lbf ft Screw alternator cover M6 12 Nm 8 9 lbf ft Screw bearing retainer M6 12 Nm 8 9 lbf ft Loctite 243 Screw camshaft bearing bridge M6 11 Nm 8 1 lbf ft Screw chain securing guide M6 11 Nm 8 1 lbf ft Loctite 243 Screw clutch cover M6 12 Nm 8 9 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6x40 12 ...

Page 161: ... balancer shaft M28 60 Nm 44 3 lbf ft 21 4 Capacities 21 4 1 Engine oil Engine oil 1 6 l 1 7 qt Engine oil SAE 15W 50 p 186 21 4 2 Coolant Coolant 1 1 l 1 2 qt Coolant p 186 Coolant mixed ready to use p 186 21 4 3 Fuel Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 186 Fuel reserve approx 1 5 l 1 6 qt 21 5 Chassis Frame Lattice frame of steel tubes powder coa...

Page 162: ...ocket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED 21 7 Tires Front tires Rear tires 110 70 R 17 M C 54S TL MRF revz FC 150 60 R 17 M C 66S TL MRF revz C Additional information is available in the Service section under http www ktm com 21 8 Fork Fork part number 90101000044 Fork WP Suspension Fork length 736 mm 28 98 in Fo...

Page 163: ...hassis M6 10 Nm 7 4 lbf ft Screw air filter box M6 6 Nm 4 4 lbf ft Screw bottom of rear part M6 11 Nm 8 1 lbf ft Screw brake fluid reservoir of rear brake M6 9 Nm 6 6 lbf ft Screw cable holder side stand switch M6 9 Nm 6 6 lbf ft Loctite 243 Screw chain sliding guard M6 9 Nm 6 6 lbf ft Loctite 243 Screw compensating tank M6 11 Nm 8 1 lbf ft Screw foot brake cylinder M6 9 Nm 6 6 lbf ft Loctite 243 ...

Page 164: ... caliper M8x1 27 Nm 19 9 lbf ft Loctite 243 Fitting side stand M10 34 Nm 25 1 lbf ft Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft Nut mirror M10 16 Nm 11 8 lbf ft Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Fitting bottom shock absorber M10x1 25 45 Nm 33 2 lbf ft Fitting handlebar support M10x1 25 21 Nm 15 5 lbf ft Nut rear sprocket screw M1...

Page 165: ...leaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake syst...

Page 166: ...3 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the...

Page 167: ...ature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subject to large fluctuations in tem perature Info KTM recommends jacking up the motorcycle Raise the motorcycle with the rear wheel stand p 9 Raise the motorcycle with the front wheel stand p 9 Cover the motorcycle with a tarp or similar cover that is permeable to air Info Do not use non porous...

Page 168: ...ain and check for smooth operation Clean the dust boots of the fork legs p 14 Check the brake fluid level of the front brake p 67 Check the steering head bearing play p 26 Change the spark plugs Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and correct routing Check the antifreeze and coolant level p 149 Check the cables for damage a...

Page 169: ...167 ...

Page 170: ... 4 1 4 4 46 GK 56 X31 46 2 2 15A F4 13 4 IG 18 X7 4 HA 4 X3 3 HA 4 X6 3 e f 30A F1 1 10 IG 18 X7 13 13 d EF 14 X55 14 6 C5 S23 4 2 3 5 AP 6 AP 6 AP 6 AP 6 X305 2 AK 2 X1 1 13 14 BH 6 X5 4 BH 6 X5 2 BH 6 X5 5 BH 6 X5 3 b 1 4 IG 18 X7 1 c IG 18 X7 10 a ye bu gn rd gn rd bu gr wh or wh gn bl bl rd rd wh gn wh gn ye rd gn rd gn rd gn rd rd bu gr ye rd bl ye ye rd ye rd ye bu wh or wh or wh br bl ye wh...

Page 171: ...nit A50 Alarm system optional A60 Vehicle control unit F1 Fuse F4 Fuse G10 Battery K11 Start auxiliary relay 1 K17 Start auxiliary relay 2 K18 Start auxiliary relay 3 K19 Starter relay M10 Starter motor S23 Emergency OFF switch electric starter button ...

Page 172: ...2 2 1 49 GK 56 X31 49 1 2 15A F5 14 5 IG 18 X7 5 HA 4 X11 3 HA 4 X11 4 GP 2 X12 2 GP 2 X12 1 S11 GY 2 GY 2 2 1 15A F6 15 6 IG 18 X7 6 GP 2 X13 2 EF 14 X55 12 a a GP 2 X13 1 e g f 12 AN 4 X10 2 AN 4 X10 1 IG 18 X7 14 IG 18 X7 12 10A F9 18 9 IG 18 X7 9 IG 18 X7 18 AQ 1 X294 1 AQ 1 X293 1 bu gn wh bu gn pk bu br bu gn wh bu bu or gn pk ye gr ye gr bu br bu br wh bl wh bl wh bl bu or wh br wh rd wh rd...

Page 173: ...tional F3 Fuse F5 Fuse F6 Fuse F9 Fuse K30 Power relay K40 Fuel pump relay K50 Radiator fan relay M13 Fuel pump M14 Radiator fan S11 Ignition steering lock X293 Connector for accessory ground ACC 2 not assigned X294 Connector for accessory plug terminal 15 ACC 2 not assigned ...

Page 174: ...20 X54 1 EF 14 X55 8 X304 T20 BI 2 HC 3 1 2 3 2 1 G20 2 3 HB 3 1 f BV 2 BV 2 1 2 B36 EF 14 X55 4 BS 2 X52 1 BS 2 X52 2 EF 14 X55 7 35 1 GP 2 X24 2 35 2 3 AP 6 X295 6 36 36 47 GK 56 X31 47 48 GK 56 X31 48 1 f 8 7 4 1 AU 2 X14 2 IG 18 X7 11 h i wh wh pu bl ye bu bu gn ye bu wh bl wh bl wh bl pu ye bu bu gn bu ye bl ye wh wh wh wh bl ye bl ye wh bl ye bl ye bu ye 390 Duke 2013 390 Duke COL 2014 30820...

Page 175: ...RING DIAGRAM 173 Components A11 EFI control unit A50 Alarm system optional B36 Alarm system switch optional F2 Fuse G20 Alternator P10 Combination instrument T20 Voltage regulator X295 Diagnostics connector ...

Page 176: ... GK 56 X31 11 11 B26 CU 4 CU 4 1 2 4 3 GK 56 X31 42 1 43 GK 56 X31 43 GZ 20 4 GJ 20 X54 4 GL 4 X20 1 B10 3 1 2 53 53 B51 t L 4 2 3 1 GV 4 GV 4 2 4 M51 1 2 GQ 2 X15 2 AN 4 X10 3 AN 4 X10 4 AN 4 X18 4 1 AN 4 X18 3 3 AN 4 X19 1 AN 4 X19 2 GX 4 X17 4 2 p t B45 4 2 1 3 wh br bl ye bl ye bl ye wh br bl ye bl ye wh br wh bl bl rd bu rd ye gn wh rd br gn gn pk ye bu gn rd bl ye bu rd bl gn wh br wh bl bl ...

Page 177: ...l unit B10 Throttle position sensor circuit A B26 Rollover sensor B30 Side stand switch B32 Fuel tank sensor B45 Temperature and manifold absolute pressure sensor B51 Lambda sensor cylinder 1 M51 Injection valve cylinder 1 P10 Combination instrument ...

Page 178: ...0 GR 2 X23 2 30 GR 2 X23 1 GJ 20 X54 14 f f AL 2 X26 1 d AP 6 X48 1 2 3 4 5 6 GZ 20 9 13 GZ 20 14 BH 6 1 2 3 4 5 6 5 D5 B37 1 2 4 AN 4 5 D3 B34 N 1st 6th 4th 2nd 5th 3rd 5 6 AP 6 4 1 2 3 3 AN 4 GK 56 X31 55 1 55 R51 2 1 AT 2 X29 2 BH 6 X49 6 5 4 3 2 1 3 6 2 GN 6 X28 2 GK 56 X31 45 45 wh or bl ye bl ye bl bu wh gr bl ye lbu lbu ye gn gn rd wh rd ye gn wh ye wh ye bu pk ye gn wh gn ye wh rd gn bl wh...

Page 179: ...1 EFI control unit A60 Vehicle control unit B21 Coolant temperature sensor cylinder 1 B34 Gear position sensor B37 Ignition pulse generator B38 Clutch switch M65 Idle speed actuator P10 Combination instrument R51 Ignition coil cylinder 1 ...

Page 180: ...1 CU 4 X32 1 f AH 2 X34 2 GO 2 X35 1 GJ 20 X54 3 GZ 20 3 GS 6 X33 1 GS 6 X33 2 5 4 B76 2 1 1 C4 S23 1 6 1 2 1 2 AP 6 AP 6 AH 2 AH 2 FG 1 FG 1 7 C2 S24 4 5 1 2 GT 6 1 AN 4 GT 6 6 GT 6 3 GT 6 GY 2 1 GY 2 2 AG 3 X36 3 AG 3 X36 2 1 AK 2 X37 1 AK 2 X37 2 BH 6 X5 1 BH 6 X5 6 BW 3 X40 1 2 BW 3 X40 3 4 GN 6 X4 4 BP 4 X41 4 DG 4 X38 4 1 1 pu bl rd br br ye rd bl rd bl bu bu bl ye wh br bu bl ye bl pu bl ye...

Page 181: ...ch front B77 Brake light switch rear E13 Low beam high beam E60 License plate lamp P10 Combination instrument P15 Horn P35 Parking light P36 Brake tail light S23 Emergency OFF switch electric starter button S24 Light switch horn button high beam flasher button turn signal switch ...

Page 182: ...1 GU 2 CU 4 X32 3 GO 2 X44 2 GO 2 X45 2 f f GO 2 X45 1 GO 2 X44 1 GJ 20 X54 7 4 GO 2 X46 2 GO 2 X47 2 GJ 20 X54 6 GO 2 X46 1 GO 2 X47 1 GZ 20 7 GZ 20 6 GZ 20 18 GJ 20 X54 18 GU 2 X50 2 1 1 GO 2 X51 2 GZ 20 16 GJ 20 X54 16 EF 14 X55 9 EF 14 X55 10 6 C2 S24 4 3 2 AN 4 AN 4 B35 9 10 2 or gr bu pk pk br gn gn gr gr gr gr gn gn gn bu pk bl ye pk br or bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ...

Page 183: ...l A60 Vehicle control unit B35 Oil pressure sensor P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S24 Light switch horn button high beam flasher button turn signal switch ...

Page 184: ...F 14 X55 11 2 1 GJ 20 X54 5 3 15 8 12 20 19 19 12 15 GZ 20 5 1 3 8 20 f GN 6 X4 5 GN 6 X28 5 X300 51 GK 56 X31 52 50 50 51 52 10 10 6 X301 X302 X303 11 6 3 5 5 bl bl bl wh gr bu or br rd wh ye bl pu bu or br rd wh ye bl pu bl ye bl ye bl ye bl ye bl ye wh gr bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye bl ye 390 Duke 2013 390 Duke COL 2014 308208 01 ...

Page 185: ...25 WIRING DIAGRAM 183 Components A11 EFI control unit A50 Alarm system optional A60 Vehicle control unit P10 Combination instrument ...

Page 186: ... 1 14 1 GE 18 X25 13 DM 2 X30 2 3 1 GE 18 X25 12 DM 2 X27 2 X306 1 GE 18 X25 10 h i 2 GE 18 X25 11 10A F7 16 7 IG 18 X7 7 IG 18 X7 16 GE 18 X25 4 b 10A F8 17 8 IG 18 X7 8 IG 18 X7 17 GK 56 X31 9 11 11 9 17 17 17 GZ 20 20 GJ 20 X54 20 15 GN 6 X4 6 6 8 wh bu wh bl bl bu wh rd bu pk wh rd wh bu wh bl bl bu wh rd bu pk wh rd rd wh rd bl ye bl ye bl ye bl ye bu ye bu ye gn gr gn gr rd gr rd gr rd gr ye...

Page 187: ... A60 Vehicle control unit B70 Wheel speed sensor front B71 Wheel speed sensor rear F7 Fuse F8 Fuse F21 ABS fuse F22 ABS fuse P10 Combination instrument Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 188: ...otorex COOLANT G48 Engine oil SAE 15W 50 According to JASO T903 MA p 198 SAE p 198 SAE 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Partially synthetic engine oil Supplier Motorex Formula 4T Fork oil SAE 4 48601166S1 According to SAE p 198 SAE 4 Guide...

Page 189: ...Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Gr...

Page 190: ...ner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 191: ...leeder cover 201490 10 Art no 00029013000 Bleeding device 201491 10 Art no 00029013100 Bleed syringe 400058 01 Art no 50329050000 Circlip pliers reverse 400059 01 Art no 51012011000 Clutch holder 400289 01 Art no 51129003000 ...

Page 192: ... 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 Piston ring mounting tool 400123 01 Art no 60029015000 Adapter C00194 01 Art no 61029055130 ...

Page 193: ...Rear wheel stand 500077 01 Art no 61029055400 Front wheel stand B00756 01 Art no 61029055500 Testing hose 201314 01 Art no 61029093000 Pressure testing tool 400149 01 Art no 61029094000 Adapter B00757 01 Art no 61029955620 ...

Page 194: ...embly stand 200306 01 Art no 61229001000 Engine blocking screw 200312 01 Art no 61229015000 Work stand 400151 01 Art no 62529055000 Floor jack attachment 400184 01 Art no 75029055000 Oil pressure adapter 400169 01 Art no 75029094000 ...

Page 195: ...00104 01 Art no 77029026000 Insert for valve spring lever 303272 10 Art no 77029041100 Spark plug wrench 304549 10 Art no 77229172000 Insert for piston pin retainer 400160 01 Art no 77329030100 Engine fixing arm 304419 10 Art no 90129002050 ...

Page 196: ... 304418 10 Art no 90129002060 Mounting sleeve 201612 01 Art no 90129005000 Pressure screw for crankshaft 304527 10 Art no 90129020000 Castle nut wrench drive 304430 10 Art no 90129021000 Castle nut wrench drive 304469 10 Art no 90129022000 ...

Page 197: ...4541 10 Art no 90129043000 Case separating tool 308111 01 Art no 90129048100 Castle nut wrench drive 305037 10 Art no 90129050000 Castle nut wrench drive 305037 10 Art no 90129050100 Key for steering head bearing 304951 10 Art no 90129051000 ...

Page 198: ...CIAL TOOLS 196 Disassembly tool balancer shaft bearing 304565 10 Art no 90129056000 Puller for rotor 308102 01 Art no 90229009000 Hook wrench 301085 01 Art no T106S Spring compressor 201648 10 Art no T14050S ...

Page 199: ...28 SPECIAL TOOLS 197 Mounting tool 200634 10 Art no T528S Clamping stand 200638 10 Art no T612S ...

Page 200: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 201: ...44 water pump cover installing 137 Auxiliary substances 7 B Battery connecting minus cable 62 disconnecting minus cable 62 installing 61 recharging 62 removing 61 Brake disc front brake changing 54 front brake removing 54 rear brake installing 56 rear brake removing 56 Brake discs checking 53 Brake fluid front brake adding 67 front brake changing 68 rear brake adding 73 rear brake changing 73 Brak...

Page 202: ...ton checking 115 piston cylinder mounting clearance checking 115 pistons measuring 115 pivot points of camshafts checking 113 radial play of lower conrod bearing checking 109 right engine case section 108 shaft seal ring of water pump changing 108 shift mechanism checking 118 shift shaft preassembling 119 stator changing 124 timing assembly checking 124 transmission checking 120 Engine assembly le...

Page 203: ...Service interval display reinstalling 76 Service schedule 166 Shift lever adjusting 147 Shift speed RPM 1 adjusting 75 Shift speed RPM 2 adjusting 75 Shock absorber installing 30 removing 30 spring preload adjusting 30 spring installing 31 spring removing 31 Spare parts 7 Starting 12 to make checks 13 Steering head bearing play adjusting 26 checking 26 Storage 165 T Technical data capacity coolant...

Page 204: ... 3206167en 3206167en 07 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...