2024 KTM 250-300 EXC TBI Repair Manual

250 EXC
250 EXC SIX DAYS

250 XC‑W
300 EXC
300 EXC SIX DAYS
300 XC-W
300 EXC HARDENDURO
300 XC-W HARDENDURO
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INTRODUCTION
250 EXC EU
250 EXC SIX DAYS EU
250 XC‑W US
300 EXC EU
300 EXC BR 300 EXC SIX DAYS BR
300 EXC SIX DAYS EU 300 EXC SIX DAYS CN
300 EXC SIX DAYS ASEAN 300 XC‑W US
300 EXC HARDENDURO EU
300 EXC HARDENDURO CN
300 XC‑W HARDENDURO US
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INDEX
6.18 Assembling the piston rod................. 32

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

6.19 Assembling the cartridge .................. 34
1.1 Symbols used .................................... 7
6.20 Assembling the fork legs................... 36
1.2 Formats used..................................... 7
6.21 Lubricating the steering head
2 SAFETY ADVICE............................................ 8 bearing ........................................... 39
6.22 Removing the lower triple clamp........ 39
2.1 Repair Manual ................................... 8
6.23 Installing the lower triple clamp ........ 40
2.2 Safety advice..................................... 8
6.24 Changing the steering head bearing ... 42
2.3 Degrees of risk and symbols ................ 8
6.25 Checking the steering head bearing
2.4 Work rules......................................... 8 play ................................................ 43
3 IMPORTANT NOTES.................................... 10 6.26 Adjusting the steering head bearing
play ................................................ 44
3.1 Manufacturer warranty, implied
warranty.......................................... 10 7 HANDLEBAR, CONTROLS............................ 46
3.2 Fuel, auxiliary substances ................. 10 7.1 Handlebar position........................... 46
3.3 Spare parts, technical accessories ..... 10 7.2 Adjusting the handlebar position ....... 46
3.4 Figures ........................................... 10 7.3 Adjusting the basic position of the
4 SERIAL NUMBERS ..................................... 11 clutch lever ..................................... 48
7.4 Checking the rubber grip .................. 48
4.1 Vehicle identification number............ 11 7.5 Checking the throttle cable routing .... 49
4.2 Type label ....................................... 11 7.6 Checking the play in the throttle
4.3 Engine number ................................ 11 cable .............................................. 50
4.4 Fork part number ............................. 11 7.7 Adjusting the play in the throttle
4.5 Shock absorber article number .......... 12 cable .............................................. 50
7.8 Setting the characteristic map of the
5 MOTORCYCLE ............................................ 13
throttle response .............................. 51
5.1 Raising the motorcycle with a lift
8 FRAME ...................................................... 53
stand .............................................. 13
5.2 Removing the motorcycle from the 8.1 Checking the frame .......................... 53
lift stand ......................................... 13 8.2 Changing the footrests...................... 53
5.3 Starting the vehicle .......................... 13 8.3 Removing the frame protector ........... 55
5.4 Starting the motorcycle to check the 8.4 Installing the frame protector ............ 55
function .......................................... 14 8.5 Removing the engine guard
6 FORK, TRIPLE CLAMP ................................ 15 (All XC-W and special models)........... 55
8.6 Installing the engine guard
6.1 Adjusting the compression damping (All XC-W and special models)........... 55
of the fork ....................................... 15
6.2 Adjusting the rebound damping of 9 SHOCK ABSORBER, LINK FORK.................. 56
the fork........................................... 15 9.1 Adjusting the high-speed
6.3 Bleeding the fork legs....................... 16 compression damping of the shock
6.4 Cleaning the dust boots of the fork absorber.......................................... 56
legs ................................................ 16 9.2 Adjusting the low-speed
6.5 Removing the fork legs ..................... 17 compression damping of the shock
6.6 Installing the fork legs ...................... 17 absorber.......................................... 56
6.7 Removing the fork protector .............. 18 9.3 Adjusting the rebound damping of
6.8 Installing the fork protector............... 18 the shock absorber ........................... 57
6.9 Servicing the fork............................. 19 9.4 Measuring the dimension of the rear
wheel unloaded................................ 57
6.10 Disassembling the fork legs............... 19
9.5 Checking the static sag of the shock
6.11 Disassembling the cartridge .............. 22
absorber.......................................... 58
6.12 Disassembling the piston rod ............ 24
9.6 Checking the rider sag of the shock
6.13 Disassembling the pressure stage absorber.......................................... 59
unit ................................................ 26
9.7 Adjusting the spring preload of the
6.14 Disassembling the gasket support ...... 27 shock absorber ................................ 59
6.15 Checking the fork legs ...................... 28 9.8 Adjusting the rider sag...................... 60
6.16 Assembling the gasket support .......... 30 9.9 Removing the shock absorber ............ 61
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6.17 Assembling the pressure stage unit.... 31
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INDEX
9.10 Installing the shock absorber............. 62 13.4 Installing the headlight mask with
9.11 Servicing the shock absorber............. 63 the headlight ................................. 109
9.12 Removing the spring......................... 64 14 WHEELS .................................................. 111
9.13 Disassembling the damper ................ 65
9.14 Disassembling the piston rod ............ 66 14.1 Checking tire pressure .................... 111
9.15 Checking the damper ....................... 67 14.2 Checking the tire condition ............. 111
9.16 heim joint, changing ........................ 68 14.3 Checking the wheel bearing for
9.17 Assembling the piston rod................. 70 play .............................................. 112
9.18 Assembling the damper .................... 71 14.4 Checking the brake discs ................ 112
9.19 Bleeding and filling the damper ........ 73 14.5 Checking the rim run-out ................ 113
9.20 Filling the damper with nitrogen ........ 76 14.6 Checking spoke tension .................. 114
9.21 Installing the spring ......................... 77 14.7 Front wheel ................................... 115
9.22 Checking the link fork ...................... 79 14.7.1 Removing the front wheel ........... 115
9.23 Checking the shock absorber heim 14.7.2 Installing the front wheel ............ 116
joint for play.................................... 79 14.7.3 Changing the front brake disc ..... 117
9.24 Checking the fork bearing for play ..... 79 14.7.4 Changing the front wheel
9.25 Removing the link fork...................... 80 bearing ..................................... 118
9.26 Installing the link fork ...................... 81 14.8 Rear wheel .................................... 119
9.27 Changing the link fork bearing........... 82 14.8.1 Removing the rear wheel ............ 119
14.8.2 Installing the rear wheel ............. 120
10 EXHAUST SYSTEM ..................................... 86 14.8.3 Changing the rear brake disc....... 121
10.1 Removing the main silencer .............. 86 14.8.4 Changing the rear wheel
bearing ..................................... 122
10.2 Installing the main silencer............... 86
14.8.5 Checking the chain for dirt ......... 124
10.3 Removing the manifold..................... 86
14.8.6 Cleaning the chain ..................... 124
10.4 Installing the manifold ..................... 88
14.8.7 Checking the chain tension......... 125
10.5 Changing the glass fiber yarn filling
of the main silencer ......................... 89 14.8.8 Checking the chain, rear
sprocket, engine sprocket, and
11 AIR FILTER ................................................ 91 chain guide ............................... 125
14.8.9 Adjusting the chain tension ........ 128
11.1 Removing the air filter box cover ....... 91
14.8.10 Changing the drivetrain kit.......... 128
11.2 Installing the air filter box cover ........ 91
11.3 Removing the air filter ...................... 92 15 WIRING HARNESS, BATTERY.................... 132
11.4 Installing the air filter....................... 92
15.1 Changing the main fuse .................. 132
11.5 Cleaning the air filter and air filter
15.2 Disconnecting the negative cable
box ................................................. 93
of the 12-V battery......................... 132
11.6 Preparing air filter box cover for
15.3 Connecting the negative cable of
securing.......................................... 93
the 12-V battery............................. 133
12 FUEL TANK, SEAT, TRIM ............................ 94 15.4 Removing the 12-V battery.............. 133
15.5 Installing the 12-V battery .............. 134
12.1 Opening the fuel tank filler cap ......... 94
15.6 Charging the 12-V battery ............... 135
12.2 Closing the fuel tank filler cap........... 94
15.7 Checking the charging voltage ......... 136
12.3 Removing the seat ........................... 95
15.8 Checking the open-circuit current .... 137
12.4 Mounting the seat ............................ 95
15.9 Checking the starter relay ............... 138
12.5 Removing the fuel tank..................... 96
15.10 Checking the wiring harness............ 139
12.6 Installing the fuel tank ..................... 97
15.11 Diagnostics connector .................... 139
12.7 Changing the fuel screen .................. 99
15.12 OCU ............................................. 139
12.8 Changing the fuel filter................... 100
12.9 Changing the fuel pump ................. 103 16 BRAKE SYSTEM ....................................... 140
12.10 Checking the fuel pressure.............. 105
16.1 Checking that the brake linings of
13 MASK, FENDER........................................ 108 the front brake are secured ............. 140
16.2 Changing the brake linings of the
13.1 Removing front fender .................... 108 front brake .................................... 140
13.2 Installing front fender..................... 108 16.3 Checking the free travel of the
13.3 Removing the headlight mask with hand brake lever ............................ 142
the headlight ................................. 109
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INDEX
16.4 Adjusting the free travel of the 18.4.3 Removing the crankshaft
handbrake lever ............................. 143 bearing inner race...................... 187
16.5 Checking the front brake fluid 18.4.4 Installing the crankshaft bearing
level ............................................. 143 inner race ................................. 188
16.6 Adding front brake fluid.................. 144 18.4.5 Changing the connecting rod,
16.7 Changing the front brake fluid ......... 145 conrod bearing and crank pin...... 188
16.8 Checking that the brake linings of 18.4.6 Checking the crankshaft run-out
the rear brake are secured............... 147 at the bearing pin ...................... 190
16.9 Changing the rear brake linings ....... 147 18.4.7 Checking/measuring the
16.10 Checking the free travel of foot cylinder .................................... 190
brake lever .................................... 149 18.4.8 Removing the exhaust control ..... 190
16.11 Adjusting the basic position of the 18.4.9 Checking the exhaust control ...... 192
foot brake lever.............................. 150 18.4.10 Installing the exhaust control ...... 193
16.12 Checking the rear brake fluid 18.4.11 Checking/measuring the piston.... 196
level ............................................. 151 18.4.12 Checking the piston ring end
16.13 Adding rear brake fluid ................... 151 gap........................................... 197
16.14 Changing the rear brake fluid .......... 152 18.4.13 Measuring the piston/cylinder
mounting clearance.................... 197
17 LIGHTING SYSTEM, INSTRUMENTS .......... 155
18.4.14 Disassemble the reed valve
17.1 Changing the headlight bulb ........... 155 housing..................................... 198
17.2 Changing the turn signal bulb (All 18.4.15 Checking the reed valve
EXC models).................................. 155 housing, reed valve and intake
17.3 Checking the headlight setting ........ 156 flange ....................................... 199
17.4 Adjusting the headlight range.......... 157 18.4.16 Assemble the reed valve
housing..................................... 199
17.5 Changing the combination
instrument battery.......................... 157 18.4.17 Working on the clutch cover........ 201
17.6 Combination instrument overview .... 158 18.4.18 Checking the clutch ................... 204
17.7 Activation and test ......................... 158 18.4.19 Preassembling shift shaft ........... 205
17.8 Setting kilometers or miles.............. 158 18.4.20 Checking the shift mechanism .... 206
17.9 Adjusting combination instrument 18.4.21 Disassembling the main shaft ..... 207
function ........................................ 159 18.4.22 Disassembling the
17.10 Setting the clock............................ 160 countershaft .............................. 207
17.11 Adjusting the wheel 18.4.23 Checking the transmission .......... 208
circumference ............................... 160 18.4.24 Assembling the main shaft.......... 210
17.12 Viewing the lap time....................... 161 18.4.25 Assembling the countershaft ....... 210
18.4.26 Checking the electric starter
18 ENGINE ................................................... 162 drive......................................... 212
18.1 Removing the engine...................... 162 18.5 Engine assembly ............................ 212
18.2 Installing the engine....................... 168 18.5.1 Assembling the engine case ........ 212
18.3 Engine disassembly........................ 174 18.5.2 Preparing the engine for
18.3.1 Clamping engine into the engine assembly................................... 214
work stand ................................ 174 18.5.3 Assembling the alternator side .... 216
18.3.2 Removing the cylinder head and 18.5.4 Assembling the clutch side ......... 217
the cylinder ............................... 174 18.5.5 Installing the cylinder and
18.3.3 Draining the gear oil................... 177 cylinder head ............................ 222
18.3.4 Disassembling the alternator 18.5.6 Gear oil drain plug, installing ...... 227
side .......................................... 177 18.5.7 Removing the engine from the
18.3.5 Dismantling the clutch side ........ 178 engine work stand...................... 227
18.3.6 Preparing the engine for housing 19 CLUTCH ................................................... 228
disassembly .............................. 181
18.3.7 Dismantling the engine case ....... 183 19.1 Checking/correcting the fluid level
18.4 Working on individual parts............. 185 of hydraulic clutch ......................... 228
18.4.1 Working on the right section of 19.2 Changing the hydraulic clutch
the engine case ......................... 185 fluid ............................................. 229
18.4.2 Working on the left section of 19.3 Checking the clutch ....................... 230
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the engine case ......................... 186
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INDEX
20 WATER PUMP, COOLING SYSTEM ............. 238 24.5 Checking the crankshaft speed
sensor........................................... 275
20.1 Cooling system .............................. 238
24.6 Changing the spark plug ................. 276
20.2 Checking the antifreeze and
24.7 Changing the spark plug and spark
coolant level .................................. 238
plug connector............................... 276
20.3 Checking the coolant level .............. 239
24.8 Removing the stator ....................... 278
20.4 Draining the coolant ....................... 239
24.9 Installing the stator ........................ 278
20.5 Refilling with coolant ..................... 240
20.6 Changing the coolant...................... 242 25 ELECTRIC STARTER SYSTEM .................... 279
20.7 Changing the coolant pipe .............. 243 25.1 Checking the starter motor .............. 279
21 THROTTLE VALVE BODY ........................... 248 26 TECHNICAL SPECIFICATIONS ................... 280
21.1 Programming ambient air 26.1 Engine .......................................... 280
pressure........................................ 248
26.2 Tolerance, engine wear limits .......... 280
21.2 Changing the throttle valve body...... 248
26.3 Engine tightening torques ............... 281
21.3 Checking the basic throttle valve
26.4 Capacities ..................................... 282
position sensor setting.................... 254
26.4.1 Gear oil..................................... 282
21.4 Adjusting the basic throttle
position sensor setting.................... 255 26.4.2 Engine oil ................................. 282
21.5 Performing the basic setting of the 26.4.3 Coolant ..................................... 282
throttle valve with the KTM 26.4.4 Fuel ......................................... 282
diagnostics tool.............................. 256 26.5 Chassis ......................................... 283
21.6 Adjusting the idle speed ................. 256 26.6 Electrical system............................ 284
21.7 Setting the cold start rev speed 26.7 Tires ............................................. 284
increase ........................................ 257 26.8 Fork.............................................. 284
21.8 Cold start button............................ 258 26.9 Shock absorber .............................. 285
26.10 Chassis tightening torques .............. 285
22 EXHAUST CONTROL ................................. 259
27 CLEANING, CARE ..................................... 289
22.1 Programming the end positions of
the exhaust control......................... 259 27.1 Cleaning the motorcycle ................. 289
22.2 Programming the end positions of 27.2 Checks and maintenance steps for
the exhaust control with a winter operation............................. 290
diagnostics tool.............................. 260
28 STORAGE ................................................. 291
23 LUBRICATION SYSTEM............................. 261
28.1 Storage ......................................... 291
23.1 Changing the gear oil...................... 261 28.2 Preparing for use after storage......... 292
23.2 Checking the gear oil level .............. 262
23.3 Adding the gear oil......................... 262 29 SERVICE SCHEDULE ................................ 293
23.4 Checking 2-stroke oil level .............. 263 29.1 Additional information .................... 293
23.5 Opening 2-stroke oil tank cap.......... 263 29.2 Service schedule............................ 293
23.6 Adding 2-stroke oil......................... 264
23.7 Closing 2-stroke oil tank cap ........... 264 30 WIRING DIAGRAM .................................... 296
23.8 Priming oil pump ........................... 264 30.1 Page 1 of 5 (All EXC models) .......... 296
23.9 Cleaning the oil screen in the oil 30.2 Page 2 of 5 (All EXC models) .......... 298
tank.............................................. 266 30.3 Page 3 of 5 (All EXC models) .......... 300
23.10 Changing the oil pump, cleaning 30.4 Page 4 of 5 (All EXC models) .......... 302
the oil screen................................. 268
30.5 Page 5 of 5 (All EXC models) .......... 304
24 IGNITION SYSTEM.................................... 272 30.6 Page 1 of 4 (All XC‑W models) ........ 306
30.7 Page 2 of 4 (All XC‑W models) ........ 308
24.1 Checking the ignition system........... 272
30.8 Page 3 of 4 (All XC‑W models) ........ 310
24.2 Ignition coil - checking the primary
winding......................................... 273 30.9 Page 4 of 4 (All XC‑W models) ........ 312
24.3 Checking the spark plug 31 SUBSTANCES .......................................... 314
connector...................................... 273
24.4 Alternator – checking the stator 32 AUXILIARY SUBSTANCES ......................... 316
winding......................................... 274 33 SPECIAL TOOLS ....................................... 318
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INDEX
34 STANDARDS ............................................ 335

35 LIST OF ABBREVIATIONS.......................... 336
INDEX ............................................................. 337
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6
MEANS OF REPRESENTATION 1
1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name® Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
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2 SAFETY ADVICE
2.1 Repair Manual

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

A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
with transponder key) or the motor must be at a standstill (models without ignition lock or transponder key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
Unless otherwise noted, normal conditions apply to all tasks and descriptions.
Ambient temperature 20 °C (68 °F)
Ambient air pressure 1,013 mbar (14.69 psi)
Relative air humidity 60 ± 5 %
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instruc-
tions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
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8
SAFETY ADVICE 2
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
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3 IMPORTANT NOTES
3.1 Manufacturer warranty, implied warranty

The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con-
firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3 Spare parts, technical accessories

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 latest news KTM PowerParts on your vehicle can be found on the KTM website.
International KTM Website: KTM.COM
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
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SERIAL NUMBERS 4
4.1 Vehicle identification number

The vehicle identification number 1 is stamped on the right side
of the steering head.
401945-10
4.2 Type label

Type label 1 is fixed to the front of the steering head.
401946-10
4.3 Engine number

The engine number 1 is located on the left side of the engine
over the engine sprocket.
H01047-10
4.4 Fork part number

The fork part number 1 is stamped on the inside of the axle
clamp.
401947-10
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4 SERIAL NUMBERS
4.5 Shock absorber article number

Shock absorber article number 1 is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.
401948-10
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12
MOTORCYCLE 5
5.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall
over.
– Park the vehicle on a firm and level surface.
– Raise the motorcycle at the frame underneath the engine.

Lift stand (78129955100) ( p. 324)
401942-01 Neither wheel is in contact with the ground.

– Secure the motorcycle against falling over.
5.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Remove the motorcycle from the lift stand.

– Remove the lift stand.
– To park the motorcycle, press side stand 1
to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with the rubber strap.
401943-10
5.3 Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
– Take the motorcycle off side stand 1 and secure the side
stand with rubber strap 2.
– Shift the transmission to neutral position.
Condition
Ambient temperature: < 10 °C (< 50 °F)
– Push the cold start button in all the way.
Info
401944-10 If the engine is warm, the cold start button must be
deactivated.
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5 MOTORCYCLE
– Press the start button.
Info
Do not open the throttle.
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at start-
ing.
At temperatures below 6 °C (45 °F), several attempts at
starting may be necessary to warm-up the lithium-ion
400733-01 battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
5.4 Starting the motorcycle to check the function
Danger

Info
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at start-
ing.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
400733-01 During the starting process, the malfunction indicator
lamp lights up.
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14
FORK, TRIPLE CLAMP 6
6.1 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Turn white adjuster 1 clockwise as far as it will go.

Info
Adjusters 1 COMP are located at the top end of the
fork legs.
– Turn counterclockwise by the number of clicks corresponding

to the fork type.
Guideline
W00297-10
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 7 clicks
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping during compression.
6.2 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
– Turn red adjuster 1 clockwise as far as it will go.

Info
Adjusters 1 REB are located at the bottom end of the
fork legs.

to the fork type.
Guideline
W00298-10
Rebound damping
Comfort 19 clicks
Standard 17 clicks
Sport 9 clicks
Info
Turn clockwise to increase the damping; turn counter-
clockwise to reduce damping when the shock absorber
rebounds.
15
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6 FORK, TRIPLE CLAMP
6.3 Bleeding the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 13)
Main work
– Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
W00297-11
Finishing work
– Remove the motorcycle from the lift stand. ( p. 13)
6.4 Cleaning the dust boots of the fork legs

Preparatory work
– Remove the fork protector. ( p. 18)
Main work
– Push dust boots 1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles
from the inside fork tubes. Over time, dirt can accumu-
late behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
K00070-10
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when nec-
essary.
– Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray ( p. 317)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 18)
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16
6.5 Removing the fork legs

Preparatory work
– Remove the front wheel. ( p. 115)
Main work
– Remove screws 1 and take off the clamp.
– Remove the cable tie.
– Remove screws 2 and take off the brake caliper.
– Allow the brake caliper and the brake line to hang loosely to
the side.
Info
E00375-10 Do not actuate the hand brake lever when the front
wheel is removed.
– Loosen screws 3. Remove the left fork leg.

– Loosen screws 4. Remove the right fork leg.
W00341-10
6.6 Installing the fork legs

Main work
– Position the fork legs.
Bleeder screws 1 are positioned toward the front.
Info
The rebound damping is located on the bottom of fork
leg REB (red adjuster). The compression damping is
located at the top of fork leg COMP (white adjuster).
Grooves are milled into the side of the upper end of the
W00297-11 fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
(All standard models)

– Tighten screws 2.
Guideline
Screw, top triple M8 20 Nm
clamp (14.8 lbf ft)
Guideline
Screw, bottom M8 15 Nm
W00341-11
triple clamp (11.1 lbf ft)
(All special models)
17
,
Guideline
clamp (12.5 lbf ft)
Guideline
Screw, bottom M8 12 Nm (8.9 lbf ft)
triple clamp
– Position the brake caliper, and mount and tighten screws 4.

Guideline
Screw, front M8 25 Nm (18.4 lbf ft)
brake caliper Loctite®243™
– Mount the cable ties.
– Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws 5 .
E00375-11
Finishing work
– Install the front wheel. ( p. 116)
6.7 Removing the fork protector

– Remove screws 1 and take off the clamp.
– Remove screws 2 and take off the left fork protector.
– Remove screws 3 and take off the right fork protector.
V00332-10
6.8 Installing the fork protector

– Position the fork protector on the left fork leg. Mount and
tighten screws .1
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Position the brake line, wiring harness, and clamp. Mount and
tighten screws . 2
– Position the fork protector on the right fork leg. Mount and
V00332-11 tighten screws .3
Guideline
chassis
,
18
6.9 Servicing the fork
Info
The operations are the same on both fork legs.
Condition
The fork legs have been removed.
– Disassemble the fork legs. ( p. 19)
– Disassemble the cartridge. ( p. 22)
– Disassemble the piston rod. ( p. 24)
– Disassemble the pressure stage unit. ( p. 26)
– Disassemble the gasket support. ( p. 27)
– Check the fork legs. ( p. 28)
– Assemble the gasket support. ( p. 30)
– Assemble the pressure stage unit. ( p. 31)
– Assemble the piston rod. ( p. 32)
– Assemble the cartridge. ( p. 34)
– Assemble the fork legs. ( p. 36)
D07907-10
6.10 Disassembling the fork legs
Info
Condition
The fork legs have been removed.
– Make a note of the present state of rebound 1 and compres-
sion damping 2 .
– Open the adjusters of the rebound and compression damping
completely.
D07924-10
19
,
– Clamp the fork leg in the area of the lower triple clamp with
the special tool.
Clamping stand (T1403S) ( p. 332)
– Remove screw 3. Remove the adjuster on the compression
damping.
D07926-10
– Undo cartridge 4.
Ring wrench (T14017) ( p. 332)
Info
The cartridge cannot be taken off yet.
D07927-10
– Unclamp the fork leg.

– Drain the fork oil.
Info
Place a suitable container underneath.
D07931-10
– Clamp the fork leg on the fork shoe.

Guideline
Use soft jaws.
– Remove screw 5. Remove the adjuster of the rebound damp-
ing.
– Remove rebound adjuster 6.
D07932-10
– Remove the cartridge.
D07934-10
,
20
– Push dust boot 7 downwards.

– Remove fork protection ring 8.
D07935-10
– Remove lock ring 9.

Info
The lock ring has a beveled end where a screwdriver
can be applied.
D07936-10
– Warm up the outside fork tube in area A of the lower sliding

bushing.
Guideline
50 °C (122 °F)
– Pull the outside fork tube off the inside fork tube with a jerk.
Info
Lower sliding bushing bk must be drawn from its bear-
D07937-10 ing seat.
– Remove upper sliding bushing bl.

Info
Without using a tool, pull the stack slightly apart by
hand.
– Take off lower sliding bushing bk.

– Take off support ring bm .
– Take off seal ring bn .
D07940-10
– Take off lock ring 9.
– Take off dust boot 7.
– Take off lift indicator bo.
– Unclamp the fork leg.
21
,
6.11 Disassembling the cartridge
Info
The steps are the same for both cartridges.
Preparatory work
Main work
– Allow oil to drain from breathing hole 1.
Info
D07943-10
– Degrease the cartridge, turn it round, and clamp it in the area

of the pressure vessel using the special tool.
– Pull the spring down and then pull the piston rod up slightly to
relieve the spring seat.
– Remove spring seat 2.
D07948-10
– Remove spring 3 with the preload spacer(s).
D07949-10
– Remove spring seat 4 and washer 5.
D07950-10
,
22
– Remove spacing tube 6.
D07951-10
– Unclamp the cartridge, turn it round, and clamp it on the flat

surface of the pressure vessel.
Guideline
Use soft jaws.
– Loosen pressure stage unit 7 using the special tool.
Special socket (T14084) ( p. 333)
– Push the piston rod upwards and remove the pressure stage
D07990-10 unit.
– Release the cartridge.

– Drain the remaining fork oil.
Info
D07947-10

of the inner tube using the special tool.
Info
When clamping, make sure that the cartridge is not
clamped in the area of the thread of the gasket support.
– Heat up thread area A of the tube.

D07952-10
Guideline
50 °C (122 °F)
– Loosen gasket support 8.
– Remove the piston rod.
D07953-10
23
,
6.12 Disassembling the piston rod
Info
The steps are the same for both piston rods.
Preparatory work
Main work
– Clamp the piston rod using the special tool.
– Remove nut 1.
Info
In order to protect it, the end of the tap rebound is
pressed in for delivery. Therefore, the end of the thread
D07961-10 must be carefully filed off.
Cover components to prevent dirt from getting in.
– Remove rebound shim stack 2.

Info
Guide the rebound shim stack onto a screwdriver and
put them to one side together.
– Remove piston 3.
– Remove compression shim stack 4.
Info
Guide the compression shim stack onto a screwdriver
and put them to one side together.
D07963-10
,
24
– Remove spring 5.
– Warm up the piston rod in area A.
Guideline
50 °C (122 °F)
– Remove tap rebound 6.
– Remove O-ring 7.
D07966-10
– Remove needle 8 with the spring and the O-ring.

– Remove spring bk.
D07970-10
– Remove spring bl with the bushing.
D07972-10
– Remove adjusting tube bm.
D07969-10
25
,
– Remove gasket support bn.

Info
If the gasket support is below the clamping tool,
unclamp the piston rod and remove the gasket support.
D07973-10
6.13 Disassembling the pressure stage unit
Info
The steps are the same for both pressure stage units.
Preparatory work
Main work
– Clamp special tool 1 into the bench vise.
– Mount pressure stage unit on special tool.
– Remove nut 2.
Info
In order to protect it, the end of the tap compression is
D07976-10
pressed when it is prepared for delivery. Therefore, the
end of the thread must be carefully filed off.
Cover components to prevent dirt from getting in.
– Remove washer 3.
Info
The shims can stick to the washer.
– Remove rebound shim stack 4.

Info
D07979-10 put them to one side together.
Info
and put them to one side together.
D07981-10
,
26
– Remove tap compression 8.
D07984-10
– Remove spring seats bk with spring bl.
D07986-10
– Remove X-ring bm.

– Remove O-ring bn.
D07978-10
6.14 Disassembling the gasket support
Info
The steps are the same for both gasket supports.
Preparatory work
Main work
– Remove ring 2.
D07956-10
27
,
– Remove seal ring 4.
D07958-10
– Press out the pilot bushing using special tool 5.

Guideline
Use soft jaws.
Pressing tool (T14076) ( p. 333)
D07959-10
6.15 Checking the fork legs
Info
Condition
The fork legs have been disassembled.
– Check the inside fork tube for damage.
» If damage is found:
– Change the inside fork tube.
D07918-10
– Measure the outside diameter of the inside fork tube at several

places.
Outside diameter of the 47.84 … 48.14 mm
inside fork tube (1.8835 … 1.8953 in)
» If the measured value is less than the specified value:
D07917-10
,
28
– Measure the run-out of the inside fork tube.

Run-out of the inside fork ≤ 0.20 mm (≤ 0.0079 in)
tube
» If the measured value is greater than the specified value:
D07917-11
– Measure the inside diameter at several places of the outside

fork tube.
Inside diameter of the out- 49.07 … 49.14 mm
side fork tube (1.9319 … 1.9346 in)
– Change the outside fork tube.
– Check the outside fork tube for damage.
D07919-10
– Change the outside fork tube.
– Check the surface of the sliding bushings.
» If a bronze-colored layer Aunder sliding layer B is visi-
ble or the surface is rough:
– Change the sliding bushings.
D07920-10
– Check the piston ring for damage and wear.

» If there is damage or wear:
– Change the piston ring.
D07921-10
– Check the piston rod for damage.

– Replace the piston rod.
– Measure the outside diameter of the piston rod at several loca-
tions.
Outside diameter of the pis- ≥ 11.965 mm
ton rod (≥ 0.47106 in)
D07922-10
– Measure the run-out of the piston rod.
Run-out of the piston rod ≤ 0.40 mm (≤ 0.0157 in)
29
,

– Check the spring length.
Guideline
Spring length with preload 476 mm (18.74 in)
spacer(s)
– Reduce the thickness of the preload spacer(s).
– Increase the thickness of the preload spacer(s).
D07923-10
6.16 Assembling the gasket support
Info
The steps are the same for both gasket supports.
– Press new pilot bushing 1 in with special tool 2.

Guideline
Use soft jaws.

– Position the gasket support with a suitable tool.
– Grease and press through special tool 3.
Fork oil (SAE 4) (48601166S1) ( p. 315)
Calibrating unit (T14021) ( p. 332)
The pilot bushing is to be calibrated.
D07960-10
– Lightly grease and mount seal ring 4.

Lubricant (T14034) ( p. 316)
– Lightly grease and mount O-ring 5.
Lubricant (T159) ( p. 316)
D07958-11
,
30
– Mount ring 6.
The label faces upward.
– Mount lock ring 7.
D07957-10
6.17 Assembling the pressure stage unit
Info
The steps are the same for both pressure stage units.
– Mount O-ring 1.
– Mount X-ring 2.
D07978-11
– Clamp special tool into the bench vise.

– Mount pressure stage unit on special tool.
– Mount spring 3 with spring seats 4.
The ridge of the spring seats faces the spring.
Info
The spring seats are the same on both sides.
D07987-10
– Lightly grease the inner O-ring of the piston.

Fork oil (SAE 4) (48601166S1) ( p. 315)
– Mount piston 5 with the shorter inner cut-out facing upward.
– Mount and tighten tap compression 6.
Guideline
Tap compres- M8x1 8 Nm (5.9 lbf ft)
sion on piston Loctite®243™
rod
– Mount washer 7 with the groove facing downward.
D07985-10
31
,
– Mount compression shim stack 8.

Info
Note the setting list.
D07983-10
– Mount piston 9 with seal ring.

Guideline
View A of piston from above
View B of piston from below
D07982-10
– Mount rebound shim stack bk.

Info
– Mount washer bl with the groove facing upward.
D07980-10
– Mount and tighten nut bm.

Guideline
Nut on pressure M6x1 5.5 Nm (4.06 lbf ft)
stage unit Loctite®243™
Do not reuse the nut, always mount a new nut.
D07977-10
6.18 Assembling the piston rod
Info
The steps are the same for both piston rods.
,
32
– Lightly grease the seal ring of the gasket support.

Lubricant (T14034) ( p. 316)
– Lightly grease the O-ring of the gasket support.
– Mount gasket support 1 on the piston rod with the thread
facing upward.
D07975-10 Info
Incorrect assembly can damage the sealing lip of the
seal ring and this could mean that the cartridge can no
longer be assembled.
– Clamp the piston rod using the special tool.

– Mount spring 2 with the bushing facing downward.
D07972-11
– Mount adjusting tube 3.

The side with the smaller outside diameter at the end of
the adjusting tube points downwards.
D07968-10
– Mount spring 4.
Special grease (00062010053) ( p. 317)
– Mount needle 6 with the spring and O-ring.
The needle tip faces upward.
D07971-10

Special grease (00062010053) ( p. 317)
– Mount and tighten tap rebound 8 with the spring seat and
the O-ring.
Guideline
Tap rebound on M9x1 20 Nm (14.8 lbf ft)
the piston rod Loctite®243™
D07967-10
33
,
– Mount spring 9.
– Mount compression shim stack bk.
Info
– Press the shim stack down against the spring force and over
the collar of the tap rebound.
D07965-10
– Mount piston bl with the piston ring.

Guideline
D07974-10
– Mount rebound shim stack bm.

Info
– Mount and tighten nut bn with the collar facing downward.

Guideline
Nut, tap M6x0.5 5 Nm (3.7 lbf ft)
rebound Loctite®243™
D07962-10
Do not reuse the nut, always mount a new nut.

The lower shim stack is free to move against the spring
force.
6.19 Assembling the cartridge
Info
The steps are the same for both cartridges.

of the inner tube using the special tool.
Info
When clamping, make sure that the cartridge is not
clamped in the area of the thread of the gasket support.
– Lubricate piston ring 1.

D07953-11
Fork oil (SAE 4) (48601166S1) ( p. 315)
– Mount the piston rod.
,
34
– Mount and tighten gasket support 2.

Guideline
Gasket support M24.5x1 46 Nm (33.9 lbf ft)
on cartridge Loctite®243™
D07952-11
– Unclamp the cartridge, turn it round, and clamp it on the flat

surface of the pressure vessel.
Guideline
Use soft jaws.
– Add the fork oil while pulling out and pushing in the piston rod
numerous times.
Oil capacity, car- 175 ml Fork oil (SAE 4)
tridge (5.92 fl. oz.) (48601166S1)
D07988-10 ( p. 315)
– Lubricate O-rings 3 and seal ring 4 of pressure stage

unit5 .
Fork oil (SAE 4) (48601166S1) ( p. 315)
– Push the piston rod upward and mount and tighten pressure
stage unit 5 using the special tool.
Guideline
Pressure stage unit M44x1 30 Nm (22.1 lbf ft)
on the cartridge
D07989-10
– Unclamp the cartridge and clamp it in the area of the pressure

vessel using the special tool.
– Mount spacing tube 6.
D07951-10
– Mount washer 7 and spring seat 8.

The side of the spring seat with the smaller inside diame-
ter faces upward.
D07950-11
35
,
– Position spring 9 with the preload spacer(s).
D07949-11
– Pull the spring down and then pull the piston rod up slightly so
that the the spring seat can be mounted.
Info
The piston rod may slip down during this step and must
be pulled up again.
– Mount spring seat bk.

D07948-11
6.20 Assembling the fork legs
Info
Preparatory work
– Check the fork legs. ( p. 28)
Main work
– Clamp inside fork tube on fork shoe.
Guideline
Use soft jaws.
– Mount the special tool.
Protecting sleeve (T1401) ( p. 331)
– Position lift indicator 1.
D07942-10 – Grease and push on dust boot 2.
Fork oil (SAE 4) (48601166S1) ( p. 315)
The sealing lip with the spring expander points downward.
Info
Always change the dust boot, seal ring, lock ring, and
support ring.
– Push on lock ring 3.

– Grease and push on seal ring 4.
Fork oil (SAE 4) (48601166S1) ( p. 315)
The sealing lip points downward, the open side upward.
– Remove the special tool.
,
36
– Push on support ring 5.

– Sand edges of the sliding bushings with 600 grit sandpaper;
then clean and grease the bushings.
Fork oil (SAE 4) (48601166S1) ( p. 315)
– 6.
Push on lower sliding bushing
– Mount upper sliding bushing 7.
D07941-10
Info
Without using a tool, pull the stack slightly apart by
hand.
– Warm up the outside fork tube in area A of the lower sliding

bushing.
Guideline
50 °C (122 °F)
– Hold the lower sliding bushing with the longer side of the spe-
cial tool.
Mounting tool (T14040S) ( p. 332)
D07939-10 – Slide on the outside fork tube.

– Press the sliding bushing all the way into the outside fork
tube.
– Position the support ring.
– Hold the seal ring with shorter side of the special tool.
Mounting tool (T14040S) ( p. 332)
– Press the seal ring and support ring all the way into the out-
side fork tube.
D07938-10

The lock ring engages audibly.
D07936-11
– Mount dust boot 2.

– Mount fork protection ring 8.
D07935-11
37
,
– Slide the cartridge into the inside fork tube.
D07934-10
– Lightly lubricate O-ring 9 on the rebound adjuster.

– Mount and tighten the rebound adjuster.
Guideline
Rebound adjuster on M20x1 40 Nm (29.5 lbf ft)
the axle clamp
– Mount the adjuster of the rebound damping. Mount screw bk.
D07933-10 Guideline
Screw, rebound M4x0.5 1.5 Nm
damping adjustment (1.11 lbf ft)
– Unclamp the fork leg and clamp it vertically on the axle clamp.
Guideline
Use soft jaws.
– Fill with fork oil.
Oil capacity, external 390 ml Fork oil (SAE 4)
mechanism (13.19 fl. oz.) (48601166S1)
( p. 315)
D07930-10
– Lubricate O-ring bl of the cartridge.

– Push the outside fork tube upwards and screw in the cartridge.
– Clamp the outside fork tube in the area of the lower triple
clamp with the special tool.
D07929-10
– Tighten cartridge bm.

Guideline
Screw cap on outside M51x1 50 Nm (36.9 lbf ft)
fork tube
Ring wrench (T14017) ( p. 332)

– Mount the adjuster on the compression damping.
– Mount and tighten screw bn.
D07928-10
,
38
Guideline
Screw, compression M4x0.5 2 Nm (1.5 lbf ft)
adjuster
Condition
Value not determined on removal:
– Turn compression adjuster bo and rebound adjuster bp
clockwise all the way.
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline
Compression damping
D07925-10 Comfort 17 clicks
Standard 15 clicks
Sport 7 clicks
Rebound damping
Comfort 19 clicks
Standard 17 clicks
Sport 9 clicks
Condition
Value determined on removal:
– Turn compression adjuster bo and rebound adjuster bp
clockwise all the way.
– Set the adjusters to the positions determined upon
removal.
6.21 Lubricating the steering head bearing

– Remove the lower triple clamp. ( p. 39)
– Install the lower triple clamp. ( p. 40)
Info
The steering head bearing is cleaned and lubricated in
the course of removal and installation of the lower triple
clamp.
H02387-01
6.22 Removing the lower triple clamp

Preparatory work
– Remove the fork legs. ( p. 17)
– Remove the headlight mask with the headlight. ( p. 109)
– Remove front fender. ( p. 108)
– Remove the seat. ( p. 95)
– Remove the fuel tank. ( p. 96)
– Take off the handlebar cushion.
39
,
Main work
– Loosen screw 1.
– Remove screw 2.
– Take off the upper triple clamp with the handlebar and hang
them to the side.
Info
Cover the components to protect them against damage.
W00353-10
Do not kink the cables or lines.
– Remove protective ring 3.

– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
W00354-10
6.23 Installing the lower triple clamp

Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 316)
– Insert the lower triple clamp with the steering stem. Mount
upper steering head bearing.
– Push on protective ring 1.
W00319-11
– Position the upper triple clamp and handlebar.

– Mount screw 2, but do not tighten it yet.
W00353-11
,
40
– Position the fork legs.

Bleeder screws 3 are positioned toward the front.
Info
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
The pressure and rebound damping is located in the
left and right fork leg.
W00297-13

Guideline
Screw, bottom M8 15 Nm
triple clamp (11.1 lbf ft)
Guideline
W00341-13
Screw, bottom M8 12 Nm (8.9 lbf ft)
triple clamp
– Tighten screw 2.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head
Guideline
Screw, top steering M8 20 Nm (14.8 lbf ft)
stem (All standard
W00339-12
models)

Guideline
clamp (14.8 lbf ft)
Guideline
W00341-12
clamp (12.5 lbf ft)
– Position the brake caliper, and mount and tighten screws 7.

Guideline
brake caliper Loctite®243™
– Position the brake line, the wiring harness, and the clamp.
W00355-10
41
,
Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 108)
– Install the headlight mask with the headlight. ( p. 109)
– Check the wiring harness, cables, and brake and clutch lines
for freedom of movement and correct routing.
– Check the steering head bearing for play. ( p. 43)
– Check the headlight setting. ( p. 156)
– Install the fuel tank. ( p. 97)
– Mount the seat. ( p. 95)
6.24 Changing the steering head bearing

Preparatory work
– Remove the fork legs. ( p. 17)
– Remove front fender. ( p. 108)
– Take off the handlebar cushion.
– Remove the lower triple clamp. ( p. 39)
Main work
– Remove lower bearing ring 1 with special tool 2.
Tool bracket (58429089000) ( p. 321)
Pressing tool (58429092000) ( p. 322)
R02802-10
– Press the new bearing ring up to the stop with special tool 3.
Tool bracket (58429089000) ( p. 321)
Pressing tool (58429091000) ( p. 322)
R02803-10
,
42
– Remove upper bearing ring 4 with special tool 2.

Tool bracket (58429089000) ( p. 321)
Pressing tool (58429092000) ( p. 322)
R02804-10
– Remove lower steering head bearing 5.

– Remove the seal ring.
– Grease and mount the new seal ring.
– Press on the new bearing with a suitable tube as far as it will
go.
Info
Only press the bearing in via the inner ring.
D08171-10
Finishing work
– Install the lower triple clamp. ( p. 40)
– Mount the handlebar cushion.
– Install front fender. ( p. 108)
– Check the wiring harness, cables, and brake and clutch lines
for freedom of movement and correct routing.
6.25 Checking the steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ages components.
– Correct incorrect steering head bearing play immediately.
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
43
,
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play. ( p. 44)
– Move the handlebar to and fro over the entire steering range.
H01167-01 It must be possible to move the handlebar easily over the

entire steering range. There should be no detectable detent
positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 44)
– Check the steering head bearing and change if neces-
sary.
– Check the steering stop bolts for correct adjustment and lock-
ing.
Finishing work
6.26 Adjusting the steering head bearing play

Preparatory work
Main work
– Loosen screws 1 and 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head
– Using a plastic hammer, tap lightly on the upper triple clamp
to avoid stresses.
W00339-10
Guideline
clamp (14.8 lbf ft)
Guideline
clamp (12.5 lbf ft)
Guideline
Screw, top steering M8 20 Nm (14.8 lbf ft)
stem (All standard
models)
Finishing work
,
44
45
,
7 HANDLEBAR, CONTROLS
7.1 Handlebar position

The holes on the handlebar support are placed at a distance
A
of from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar support can be mounted in two different posi-

tions.
W00321-10

The holes on the handlebar support are placed at a distance
A
of from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar support can be mounted in two different posi-

tions.
W00322-10
7.2 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
– Change the handlebar if the handlebar is damaged or bent.
,
46
HANDLEBAR, CONTROLS 7

– Remove screws 1 . Take off the handlebar clamp. Take
off the handlebar and lay it to one side.
Info
Cover the components to protect them against dam-
age.
– Remove screws 2. Take off the handlebar support.

– Place the handlebar support in the required position.
Guideline
Screw, handle- M10 40 Nm (29.5 lbf ft)
bar support Loctite®243™
Info
Position the handlebar support so that it is even.
W00324-10 – Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
– Position the handlebar clamp. Mount screws 1 and

tighten evenly.
Guideline
Screw, handlebar M8 20 Nm
clamp (14.8 lbf ft)
Info
Make sure the installed gaps are even.

– Remove screws 1 . Take off the handlebar clamp. Take
off the handlebar and lay it to one side.
Info
Cover the components to protect them against dam-
age.
– Remove screws 2. Take off the handlebar support.

– Place the handlebar support in the required position.
Guideline
Screw, handle- M10 40 Nm (29.5 lbf ft)
bar support Loctite®243™
Info
Position the handlebar support so that it is even.
W00323-10 – Position the handlebar.
47
,
Info
Make sure the cables and wiring are positioned cor-
rectly.
– Position the handlebar clamp. Mount screws 1 and

tighten evenly.
Guideline
Screw, handlebar M8 20 Nm
clamp (14.8 lbf ft)
Info
Make sure the installed gaps are even.
7.3 Adjusting the basic position of the clutch lever

– Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw 1.
Info
Turn the adjusting screw counterclockwise to decrease
the distance between the clutch lever and the handle-
bar.
Turn the adjusting screw clockwise to increase the
distance between the clutch lever and the handlebar.
W00307-10 The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
7.4 Checking the rubber grip

– Check the rubber grips on the handlebar for damage, wear,
and looseness.
Info
The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
401197-01
» If a rubber grip is damaged or worn:
– Change the rubber grip.
,
48
– Check that screw 1 is firmly seated.

Guideline
Screw, fixed M4 5 Nm (3.7 lbf ft)
grip Loctite®243™
Diamond A must be positioned visibly as shown in the fig-

ure.
W00325-10
7.5 Checking the throttle cable routing
Warning
Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor-
rectly.
If the throttle cable is kinked, trapped or blocked, the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-
tion.
Preparatory work
Main work
– Check the throttle cable routing.
Both throttle cables must be routed, side by side, on the
back of the handlebars, above the fuel tank roller on the
right of the frame to the throttle valve body. Both throttle
cables must be secured behind the rubber strap of the fuel
tank support.
» If the throttle cable routing is not as specified:
– Correct the throttle cable routing.
I00443-02
Finishing work
49
,
7.6 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Turn handlebar as far as possible to the right. Turn the throttle
grip back and forth slightly and determine the play in throttle
cable .A
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
– Adjust the play in the throttle cable. ( p. 50)
400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
– Start the engine and let it run at idle speed. Move the handle-
bar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. ( p. 50)
7.7 Adjusting the play in the throttle cable
Info
If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be
removed.
Preparatory work
– Check the throttle cable routing. ( p. 49)
,
50
Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1.
– Loosen nut 2.
– Turn adjusting screw 3 in as far as possible.
– Loosen nut 4.
– 6 all the way to the stop.
Push cold start button
– Turn adjusting screw 5 so that the cold start button moves to
the basic position when the throttle grip is turned to the front.
– Tighten nut 4.
– Turn adjusting screw 3 so that there is play in the throttle
cable at the throttle grip.
Guideline
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
– Tighten nut 2.
– Slide on sleeve1.
S05548-10
– Check the throttle grip for smooth operation.
Finishing work
– Check the play in the throttle cable. ( p. 50)
7.8 Setting the characteristic map of the throttle response
Info
On the throttle grip, the characteristic map of the throttle response is changed by changing the guide
plate.
A guide plate with a different characteristic map is supplied.
Main work
– Push back sleeve 1.
– Remove screws 2 and half-shells 3.
– Detach the throttle cables and take off the grip tube.
B06139-10
51
,
– Remove guide plate 4 from handle tube 5.

– Position the required guide plate on the grip tube.
Guideline
The label OUTSIDE must be visible. Marking A must be
positioned at marking .B
Grey guide plate (79002014000)
Alternative 1
Black guide plate (79002014100)
Info
The gray guide plate opens the throttle valve more
slowly.
The black guide plate opens the throttle valve more
quickly.
The gray guide plate is mounted upon delivery.
102246-10
– Clean the outside of the handlebar and the inside of the grip
tube. Mount the grip tube on the handlebar.
– Attach the throttle cables to the guide plate and route cor-
rectly.
– Position half-shells 3, mount and tighten screws 2.
Guideline
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
– Slide on sleeve 1 and check the throttle grip for ease of
movement.
B06140-10
Finishing work
,
52
FRAME 8
8.1 Checking the frame

– Check the frame for damage, cracks, and deformation.
» If the frame shows signs of damage, cracks, or deforma-
tion:
– Change the frame.
Guideline
Repairs on the frame are not permitted.
W00308-10
8.2 Changing the footrests

Preparatory work
– Remove the frame protector. ( p. 55)
Main work
– Remove pin 1 and take off the washer.
B06182-10
– Apply pressure to the spring with your thumb.

– Remove pin 2.
– Take off the footrest.
B06183-10
– Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
B06184-10
53
8 FRAME
– Position spring as shown.

The spring engages in area A and B.
D08172-10
– Apply pressure to the spring with your thumb.

– Mount pin 2.
B06183-10
– Mount the washer and splint 1.

– Repeat these steps on the opposite side.
B06182-10
Finishing work
– Install the frame protector. ( p. 55)
,
54
FRAME 8
8.3 Removing the frame protector

– Remove the cable ties.
– Remove screws 1 with the bushings.
– Take off the left frame protector.
– Push the right frame protector to the front and take off at the
bottom.
S05536-11
8.4 Installing the frame protector

– Position the left frame protector.
– Insert the right frame protector from below and push it to the
rear.
– Mount screws 1 with the bushings and tighten.
Guideline
Screw, frame protec- M5 3 Nm (2.2 lbf ft)
tor
– Secure the frame protector with cable ties.
S05492-11
8.5 Removing the engine guard (All XC-W and special models)
– Remove screws 1 and engine guard.
H01638-10
8.6 Installing the engine guard (All XC-W and special models)
– Attach the engine guard on the frame at the rear and swing up
at the front.
– Mount and tighten screws 1.
Guideline
chassis
H01638-10
55
,
9 SHOCK ABSORBER, LINK FORK
9.1 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided.
Info
The effect of the high speed compression adjuster can be seen in the fast compression of the shock
absorber.
– Turn adjusting screw 1 clockwise all the way.

– Turn counterclockwise by the number of turns corresponding
to the shock absorber type.
Guideline
Highspeed compression damping
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
W00316-11
Info
wise to reduce damping.
9.2 Adjusting the low-speed compression damping of the shock absorber
Caution
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
– Turn adjusting screw 1 clockwise up to the last perceptible

click.
Guideline
Lowspeed compression damping
Comfort 18 clicks
Standard 15 clicks
W00316-10
Sport 12 clicks
,
56
SHOCK ABSORBER, LINK FORK 9
Info
wise to reduce damping.
9.3 Adjusting the rebound damping of the shock absorber
Caution
– Turn adjusting screw 1 clockwise up to the last perceptible

click.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
W00317-10
Sport 12 clicks
Info
Turn clockwise to increase the damping; turn counter-
clockwise to reduce damping when the shock absorber
rebounds.
9.4 Measuring the dimension of the rear wheel unloaded

Preparatory work
57
,
Main work
– Position the sag gage in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090100)
Pin, sag scale (00029990010)
– Note the value as dimension A.
402415-10
Finishing work
9.5 Checking the static sag of the shock absorber

– Measure dimension A of rear wheel unloaded. ( p. 57)
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance again between the rear axle and mark-
ing SAG on the rear fender using the sag gage.
– Note the value as dimension B.
Info
The static sag is the difference between
measurements A and B .
– Check the static sag.

Static sag 38 mm (1.5 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
( p. 59)
402416-10
,
58
9.6 Checking the rider sag of the shock absorber

– Measure dimension A of rear wheel unloaded. ( p. 57)
– With another person holding the motorcycle, the rider, wear-
ing full protective clothing, sits on the seat in a normal sitting
position (feet on footrests) and bounces up and down a few
times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear
axle and marking SAG on the rear fender using the sag gage.
– Note the value as dimension C.
Info
The rider sag is the difference between
measurements A and C .
– Check the rider sag.

Riding sag 110 mm (4.33 in)
» If the rider sag differs from the specified measurement:
– Adjust the rider sag. ( p. 60)
402417-10
9.7 Adjusting the spring preload of the shock absorber
Caution
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring
length.
Preparatory work
– Remove main silencer. ( p. 86)
– Remove the shock absorber. ( p. 61)
– After removing the shock absorber, clean it thoroughly.
59
,
Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under ten-
sion.
Hook wrench (90129051000) ( p. 325)
Info
If the spring cannot be fully released, the spring must
be removed to accurately measure the spring length.
– Measure the total spring length while the spring is not under
tension.
– Tension the spring by turning adjusting ring 2 to specified
dimension A .
Guideline
Spring preload 7 mm (0.28 in)
Info
402405-10 Depending on the static sag and/or the rider sag, it may
be necessary to increase or decrease the spring preload.
Guideline
Screw, shock M5 5 Nm (3.7 lbf ft)
absorber adjusting
ring
Finishing work
– Install the shock absorber. ( p. 62)
– Install the main silencer. ( p. 86)
9.8 Adjusting the rider sag

Preparatory work
– Remove the shock absorber. ( p. 61)
– After removing the shock absorber, clean it thoroughly.
,
60
Main work
– Select and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65 … 66 N/mm (377 lb/in)
75 kg (143 … 165 lb.)
85 kg (165 … 187 lb.)
B00292-10 Weight of rider: 85 … 72 N/mm (411 lb/in)
95 kg (187 … 209 lb.)
Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber. ( p. 62)
– Check the static sag of the shock absorber. ( p. 58)
– Check the rider sag of the shock absorber. ( p. 59)
– Adjust the rebound damping of the shock absorber. ( p. 57)
9.9 Removing the shock absorber

Preparatory work
Main work
– Loosen and remove screws 1
. Disconnect the tail light and
turn signal plug-in connections.
– Loosen screws 2 and screws 3 and remove them.
– Take off the license plate holder with tail light toward the rear.
W00327-10
– Loosen and remove screw 4.

– Loosen and remove screw 5.
– Carefully take off the right side cover to the side.
The right side cover also engages behind the spoiler.
I00439-10
61
,
– Remove screw 6 and lower the rear wheel with the link fork
as far as possible without blocking the rear wheel. Secure the
rear wheel in this position.
– Remove screw 7 , push splash protector 8 to the side, and
remove the shock absorber.
I00441-10
9.10 Installing the shock absorber

Main work
– Push splash protector 1
to the side and position the shock
absorber. Mount and tighten screw .2
Guideline
Screw, top M12 80 Nm (59 lbf ft)
shock absorber Loctite®2701™
– Mount and tighten screw 3.
Guideline
I00441-11
Screw, bottom M12 80 Nm (59 lbf ft)
Info
The heim joint for the shock absorber on the link fork
is Teflon coated. It must not be lubricated with grease,
nor with any other lubricants. Lubricants dissolve the
Teflon coating, thereby drastically reducing the service
life.
– Position the right side cover on the tail section.

Position the right side cover correctly behind the spoiler.
Ensure that it is correctly seated on the tail section.
Tighten screw hand-tight.
Guideline
I00439-11
Screw, sub- M8 35 Nm (25.8 lbf ft)
frame, top Loctite®243™
– Slide the license plate holder with tail light carefully onto the
tail section.
Pay attention to cable routing.
– Fit and tighten screws 6.
Guideline
chassis
– Connect the plug-in connections for the tail light and turn sig-
I00442-10 nals and secure and stow them well.
,
62
Guideline
chassis
– Fit and tighten screws 8.
Guideline
Remaining screws, EJOT PT® 2 Nm (1.5 lbf ft)
chassis K60x25‑Z
Finishing work
9.11 Servicing the shock absorber
Caution
Condition
The shock absorber has been removed.
– Remove the spring. ( p. 64)
– Disassemble the damper. ( p. 65)
– Check the damper. ( p. 67)
– Change the heim joint. ( p. 68)
– Assemble the damper. ( p. 71)
– Install the spring. ( p. 77)
Z03231-10
63
,
9.12 Removing the spring

Condition
– Clamp the shock absorber into the vise.
Guideline
Use soft jaws.
– Measure and note the spring length while the spring is under
tension.
– Loosen screw 1.
– Turn the adjusting ring until the spring is completely without
tension.
Z03160-10
Hook wrench (90129051000) ( p. 325)
– Remove lock ring2.

– Remove spring seat 3.
Z03161-10
– Remove spring 5.
Z03162-10
Z03163-10
,
64
9.13 Disassembling the damper

Preparatory work
Main work
– Make a note of the present state of compression damping 1
and rebound damping .2
– Open the adjusters of the compression and rebound damping
completely.
Z03166-10
– Slowly open screw 3.

The nitrogen pressure dissipates.
– Remove screw 3 with the O-ring.
Z03167-10
– Remove locking cap 4.
Z03168-10
– Push in seal ring retainer 5.
Z03169-10

Info
Check inner surface; do not scratch. If necessary,
remove any burrs with sandpaper.
Z03170-10
65
,
– Remove the piston rod.
Z03171-10
– Remove adjusting ring 7 with the clamping ring.

– Drain the oil.
Info
Place a collecting container underneath.
Z03180-10
– Remove compression adjuster 8 using the special tool.

Remove the spring and piston.
Socket (T18004) ( p. 334)
Info
Place a collecting container underneath.
Z03172-10
9.14 Disassembling the piston rod

Preparatory work
– Disassemble the damper. ( p. 65)
Main work
– Clamp the piston rod with the fork in a bench vise.
Guideline
Use soft jaws.
– Remove nut 1.
Z03173-10
,
66

Info
and put them aside together.
– Heat up support 4 in area A.

Guideline
50 °C (122 °F)
Z03174-10
– Remove holder.
– Remove rebound shim stack 5 and washer.
Info
put them aside together.
Z03175-10

Info
and put them aside together.
– Remove rebound washer 8.
Z03176-10
– Remove seal ring retainer 9.

– Remove locking cap bk and rubber buffer bl.
Z03177-10
9.15 Checking the damper

Condition
The damper has been disassembled.
67
,
– Measure the inside diameter on both ends and in the middle of

the damper cartridge.
Damper cartridge
Diameter ≤ 46.08 mm (≤ 1.8142 in)
– Change the damper cartridge.
– Check the damper cartridge for damage and wear.
Z03235-10
– Change the damper cartridge.
– Check the heim joint for damage and wear.
– Change the heim joint.
– Measure the diameter of the piston rod.
Piston rod
Diameter ≥ 17.95 mm (≥ 0.7067 in)
– Change the piston rod.
– Measure the run-out of the piston rod.
Piston rod
Z03234-10
Run-out ≤ 0.02 mm (≤ 0.0008 in)
– Check the piston rod for damage and wear.
– Check the piston rings for damage and wear.
» If damage or a bronze-colored surface is visible:
– Change the piston.
Z03233-10
9.16 heim joint, changing

Condition
,
68
– Clamp the shock absorber into the vise.

Guideline
Use soft jaws.
– Remove both collar bushings 1 of the heim joint with a spe-
cial tool.
Drift (T120) ( p. 330)
Z03196-10
– Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) ( p. 330)
– Remove second lock ring 2.
Z03198-10
– Place special tool A underneath and press out heim joint 3

using special tool B.
Z03199-10
– Position new heim joint 3 and the special tool.

Guideline
Use soft jaws.

– Press the heim joint all the way in.
Z03200-10
– Press the heim joint against the lock ring using the special
tool.
– Mount second lock ring 2.
Z03198-10
69
,
– Position both collar bushings 1 and press in.

Info
Always use new collar bushings.
Z03201-10
9.17 Assembling the piston rod

– Clamp the piston rod with the fork in a bench vise.
Guideline
Use soft jaws.
– Mount rubber buffer 1 and protection cap 2.
– Position special tool on the piston rod.
Mounting sleeve (T1554) ( p. 333)
– Grease the dust boot and slide the seal ring retainer 3 onto
Z03190-10 the piston rod.
– Mount rebound washer 4 with cut-out facing down.
– Mount compression shim stack 5 with the smaller washers
facing downward.
Z03187-10
– Mount piston 6.
Guideline
Z03188-10
,
70
– Mount rebound shim stack 7 with the smaller washers facing

upward.
– Mount and tighten support 8.
Guideline
Piston rod M12x1 40 Nm (29.5 lbf ft)
holder Loctite®2701™
Z03189-10
– Mount compression shim stack 9 with the smaller washers

facing downward.
– Mount piston bk.
Z03191-10
– Mount and tighten nut bl.

Guideline
Piston rod nut M10x1 25 Nm (18.4 lbf ft)
Z03192-10
9.18 Assembling the damper

Preparatory work
Main work
– Grease the O-rings of the compression adjuster.
– Lubricate the thread.
– Mount the piston with the spring.
– Mount and tighten compression adjuster 1.
Z03181-10
Guideline
Compression damp- M31x1 35 Nm (25.8 lbf ft)
ing adjuster
71
,
– Clamp the damper in a bench vise.

Guideline
Use soft jaws.
– Mount adjusting ring 2 with the clamping ring.
Info
The adjusting ring cannot be mounted after the piston
rod has been mounted.
Z03195-10
– Fill the damper cartridge about half full.

Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 315)
– Lubricate O-ring 3 of the seal ring retainer.
– Mount the piston rod carefully.
Z03182-10
– Mount seal ring retainer 4 and slide it under the ring groove.
Info
Do not scratch the inside surface.
– Pull out the piston rod until the seal ring retainer is flush with
the lock ring.
Z03183-10
– Mount locking cap 6 of the damper cartridge.

– Bleed and fill the damper. ( p. 73)
– Fill the damper with nitrogen. ( p. 76)
Z03184-10
Alternative 1
– Turn adjusting screw 7 clockwise up to the last percepti-
ble click.
ing to the shock absorber type.
Guideline
Comfort 18 clicks
Z03166-11 Standard 15 clicks
Sport 12 clicks
– Turn adjusting screw 8 clockwise all the way.
,
72
– Turn counterclockwise by the number of turns correspond-

Guideline
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
– Turn adjusting screw 9 clockwise up to the last percepti-
ble click.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Alternative 2
Warning
Danger of accidents Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Modifications which are not coordinated with oth-
ers to the suspension setting may cause a serious
deterioration in the handling characteristic and
overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.
– Position adjusting screws , 78

, and 9 in the location
determined during disassembly.
9.19 Bleeding and filling the damper
Info
Before working with the vacuum pump, carefully read the operating manual included with the vacuum
pump.
Open the adjusters of the rebound and compression damping completely.
73
,
– Clamp the damper as shown.

Guideline
Use soft jaws.
Info
The filling port must be located at the highest position.
The piston rod moves in and out during filling; do not
immobilize it by holding it with your hand.
Z02334-10
– Remove the screw from the filling port.
– Mount adapter 1 on the damper.
Info
Hand-tighten only without using a tool.
– Connect adapter 1 to connector 2 of the vacuum pump.

Vacuum pump (T1240S) ( p. 331)
– Adjust the control lever as shown.

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

voir hole with the special tool.
Depth micrometer (T107S) ( p. 330)
The floating piston is located in the lowermost position.
Z02335-10
– When the vacuum gauge reaches the required value, turn con-
trol lever Oil reservoir 5
to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.
0 bar
200267-10
,
74
– When the pressure gauge reaches the specified value, turn

control lever Damper4 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
3 bar
200268-10

control lever Damper4 to Vacuum.
Guideline
3 bar
The pressure gauge drops to the required value.
0 bar
200269-10

5
control lever Oil reservoir to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.
4 mbar
200270-10
– When the vacuum gauge reaches the required value, turn con-
5
trol lever Oil reservoir to Equalize Pressure.
Guideline
4 mbar
0 bar
200267-10

control lever Damper4 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
3 bar
200268-10
75
,

control lever Damper 4
to Vacuum.
Guideline
3 bar
0 bar
– When the pressure gauge reaches the required value, activate
200269-10 the On/Off switch.
Guideline
0 bar
The vacuum pump is switched off.
– Slide O-ring B
to the end of the special tool by the specified
value (distance A minus specified value).
Guideline
5 mm
Depth micrometer (T107S) ( p. 330)

– Slide the floating piston into the reservoir to the shortened
position using the special tool.
Z02336-10
Info
The floating piston must be positioned at exactly this
point when the rod is fully extended; otherwise, damage
will occur during compression of the shock absorber.

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

Guideline
Z02337-10
Filling port screw 1/8" 14 Nm (10.3 lbf ft)
9.20 Filling the damper with nitrogen

– Mount screw 1 with the O-ring and screw in approx. 2 full
turns, but do not tighten it fully.
Info
The piston rod is fully extended.
Z02298-11
,
76
– Secure the special tool in the vise.

Filling tool (T170S1) ( p. 333)
Filling adapter (T18001) ( p. 334)
– Connect the special tool to the pressure regulator of the filling
cylinder.
Filling gas - nitrogen
– Adjust the pressure regulator.
Z02338-10
Guideline
Gas pressure 10 bar (145 psi)
– Position the damper in the special tool.
The hexagonal part of tap handle A engages in the
hexagon socket of the filling port screw.
– Open filler tap B.
– Fill the damper for at least 15 seconds.
Guideline
Info
Watch the pressure regulator dial.
Ensure that the damper is filled to the specified pres-
sure.
– Screw the filling port shut with tap handle A.

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

– Mount washer 1.
Z03163-11
77
,
– Measure the total spring length while the spring is not under
tension.
– Position spring 2.
Guideline
Spring rate
75 kg (143 … 165 lb.)
Z03164-10 85 kg (165 … 187 lb.)
95 kg (187 … 209 lb.)
– Mount washer 3.
– Mount spring seat 4.
Alternative 1
– Tension the spring by turning the adjusting ring to the pre-
scribed value.
Guideline
Z03165-10 Hook wrench (90129051000) ( p. 325)

Alternative 2
Warning
Danger of accidents Modifications to the suspen-
sion setting may seriously alter the handling char-
acteristic.
Modifications which are not coordinated with oth-
ers to the suspension setting may cause a serious
deterioration in the handling characteristic and
overload components.
– Only make adjustments within the
recommended range.
– Ride slowly to start with after making adjust-
ments to get the feel of the new handling char-
acteristic.
– Tension the spring to the length measured during disas-

sembly by turning the adjusting ring.
Hook wrench (90129051000) ( p. 325)
Guideline
Screw, shock M5 5 Nm (3.7 lbf ft)
absorber adjusting
ring
Z03160-11
,
78
9.22 Checking the link fork

– Check the link fork for damage, cracks, and deformation.
» If the link fork shows signs of damage, cracks, or deforma-
tion:
– Change the link fork.
Guideline
Repairs on the link fork are not permitted.
W00309-10
9.23 Checking the shock absorber heim joint for play

Preparatory work
– Place a load on the front of the vehicle.
The rear wheel is not in contact with the ground.
Main work
– Check the top and bottom heim joints.
– Move the link fork up and down.
– Change the heim joint. ( p. 68)
H01897-01
Finishing work
– Remove the load from the front of the vehicle.
9.24 Checking the fork bearing for play

Preparatory work
Main work
– Move the link fork up and down.
– Change the link fork bearing. ( p. 82)
– Move the link fork from one side to the other.
– Change the link fork bearing. ( p. 82)
H01898-01
Finishing work
79
,
9.25 Removing the link fork

Preparatory work
– Remove the rear wheel. ( p. 119)
Main work
– Take the brake line out of the guide.
B06185-10
– Push the brake caliper forward, slip it out, and hang it to the
side.
Info
D08187-10
– Remove connecting link 1 of the chain.

Info
– Take off the chain.
D08183-12
– Remove screw 2.
– Push the link fork down and away from the shock absorber.
D08188-10
,
80
– Remove nut 3.
– Remove the swingarm pivot.
– Take off the link fork.
B06186-10
9.26 Installing the link fork

Main work
– Position the link fork. Mount the swingarm pivot.
– Mount and tighten nut 1.
Guideline
Nut, fork pivot M16x1.5 100 Nm
(73.8 lbf ft)
B06186-11
– Lift the link fork and position the shock absorber.

Guideline
Screw, bottom M12 80 Nm (59 lbf ft)
D08188-10
– Mount the chain.

– Connect the chain with connecting link 3.
Guideline
The closed side of the chain joint lock must face in the
direction of travel.
D08183-13
– Position the brake caliper.
D08187-11
81
,
– Position the brake line in the guide.
B06185-10
Finishing work
– Install the rear wheel. ( p. 120)
– Check the chain tension. ( p. 125)
9.27 Changing the link fork bearing

Preparatory work
– Remove the link fork. ( p. 80)
Left fork bearing
– Remove collar bushings 1.
R02757-10
,
82
– Remove bushing 2.
R02758-10
– Remove radial shaft seal rings 3 using a suitable tool.

– Remove stop disks 4.
– Press out bearing 5 using a suitable tool.
– Using a suitable tool, press in new bearing 5.
– Position the stop disks 4.
– Press in radial shaft seal rings 3.
R02759-10
– Mount bushing 2.
R02758-10
– Grease the radial shaft seal rings.

Long-life grease ( p. 316)
– Position the collar bushings 1 with the shoulder facing
inward.
R02763-10
83
,
Right fork bearing

– Remove collar bushings 6.
R02760-10
– Remove bushing 7.
R02761-10
– Remove radial shaft seal rings 8 using a suitable tool.

– Using a suitable tool, press in new bearing 9.
– Press in radial shaft seal rings 8.
R02762-10
– Mount bushing 7.
R02761-10
,
84
– Grease the radial shaft seal rings.

– Position the collar bushings 6 with the shoulder facing
inward.
R02764-10
Finishing work
– Install the link fork. ( p. 81)
85
,
10 EXHAUST SYSTEM
10.1 Removing the main silencer
Warning
Danger of burns The exhaust system gets hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
– Remove screws 1.
– Pull off the main silencer with exhaust sleeve 2 and the
spring ring from the manifold.
S05505-10
10.2 Installing the main silencer

– Mount the main silencer with rubber sleeve 1 and the spring
rings.
Guideline
chassis
S05506-10
10.3 Removing the manifold
Warning
Preparatory work
Main work
(All EU models)
– Remove the cable tie(s) and expose the cable.
B06174-10
,
86
EXHAUST SYSTEM 10
– Disconnect plug-in connector 1 of the lambda sensor.

– Expose the cable.
B06175-10
– Remove springs 2.
Spring hook (50305017000C1) ( p. 329)
B06176-10
– Remove screw 3.
– Take off the manifold in a forward direction.
B06177-10
(All EU models apart from EU)

– Remove springs 1 .
Spring hook (50305017000C1) ( p. 329)
B06171-10
– Remove screw 2.
B06172-10
87
,
10 EXHAUST SYSTEM
– Remove screw 3.
– Take off the manifold in a forward direction.
B06173-10
10.4 Installing the manifold

Main work
(All EU models)
– Position the manifold and mount springs 1.
Spring hook (50305017000C1) ( p. 329)
B06178-10

Guideline
chassis
B06177-11
– Join plug-in connector 3 of the lambda sensor.
B06175-11
– Route the cable without tension and secure it with a cable

tie.
B06174-10
,
88
EXHAUST SYSTEM 10
(All EU models apart from EU)

– Position the manifold and mount springs 1.
Spring hook (50305017000C1) ( p. 329)
B06171-10
– Mount screw 2, but do not tighten it yet.

Guideline
chassis
B06173-11

Guideline
chassis
Guideline
chassis
B06172-11
Finishing work
10.5 Changing the glass fiber yarn filling of the main silencer
Warning
Info
Over time, the fibers of the glass fiber yarn filling escape and the damper "burns" out.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
89
,
10 EXHAUST SYSTEM
Main work
– Remove screws 1. Pull out inner tube 2 with O-ring 3.
– Pull glass fiber yarn filling 4 from the inner tube.
– Clean the parts that need to be reinstalled and check for dam-
age.
– Mount new glass fiber yarn filling 4 on the inner tube.
– Push outer tube 5 over the inner tube with the new glass
fiber yarn filling and the O-ring.
– Mount and tighten all screws 1.
Guideline
Screws on main M5 7 Nm (5.2 lbf ft)
silencer
V01636-10
Finishing work
,
90
AIR FILTER 11
11.1 Removing the air filter box cover

Condition
The air filter box cover is secured.
– Remove screw 1.
S05540-10
– Pull off the air filter box cover in area Aand push it sideways
and forward. Take off the air filter box cover.
S05541-10
11.2 Installing the air filter box cover

– Insert the air filter box cover in area A and clip it into
area B .
I00438-10
Condition
The air filter box cover is secured.
Guideline
Screw, air filter box EJOT PT® 3 Nm (2.2 lbf ft)
cover K60x20-Z
S05540-10
91
,
11 AIR FILTER
11.3 Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Only operate the vehicle if it is equipped with an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
– Remove the air filter box cover. ( p. 91)
Main work
– Detach retaining tab 1. Remove air filter with air filter sup-
port.
– Remove air filter from air filter support.
S05498-10
11.4 Installing the air filter

Main work
– Mount the clean air filter on the air filter support.
– Grease the air filter in area A.
H02459-01
– Insert air filter and position retaining pin 1 in bushing B.

The air filter is correctly positioned.
– Insert retaining tab2.
Retaining pin 3 is secured with retaining tab 2.
Info
If the air filter is not mounted correctly, dust and dirt
may enter the engine and result in damage.
S05544-10
Finishing work
– Install the air filter box cover. ( p. 91)
,
92
AIR FILTER 11
11.5 Cleaning the air filter and air filter box
Note
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
– Remove the air filter. ( p. 92)
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner ( p. 316)
Info
Only press the air filter to dry it, never wring it out.
W00299-10
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 317)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Finishing work
– Install the air filter. ( p. 92)
11.6 Preparing air filter box cover for securing

Preparatory work
Main work
– Drill a hole at marking A.
Guideline
Diameter 6 mm (0.24 in)
W00334-10
Finishing work
93
,
12 FUEL TANK, SEAT, TRIM
12.1 Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing if fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
– Press release button 1 , turn the fuel tank filler cap counter-
clockwise, and lift it off.
E00929-10
12.2 Closing the fuel tank filler cap

– Mount the fuel tank filler cap and turn it clockwise until
release button 1 engages.
Info
Route fuel tank breather hose 2 without kinks.
E00930-10
,
94
FUEL TANK, SEAT, TRIM 12
12.3 Removing the seat

– Remove screw 1.
W00301-10
– Pull seat toward the fuel tank and lift it off.
W00311-10
12.4 Mounting the seat

– Mount the front of the seat on the collar bushings of the fuel
tank, lower the seat at the rear, and push the seat to the rear.
The holding lugs engage in the recesses at the back.
– Make sure the seat is latched in place correctly.
W00314-10

Guideline
Screw, seat fixing M6 8 Nm (5.9 lbf ft)
W00301-10
95
,
12.5 Removing the fuel tank
Danger
Warning
Preparatory work
Main work
– Unplug fuel pump connector 1.
– Remove hose 2 from the fuel tank breather.
I00435-10
– Clean the quick release coupling thoroughly with compressed

air.
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
– Disconnect the quick release coupling.
S05530-10
Info
Remaining fuel may flow out of the fuel hose.
– Mount wash cap set 3.

Wash cap set (81212016100)
,
96
– Remove screw 4 with the rubber bushing.
S05377-10
– Remove screws 5 with the collar bushings.

(All EXC models)
– Hang the horn and horn bracket to one side.
S05360-10
– Pull both spoilers off laterally from the radiator bracket and lift
off the fuel tank.
S05361-10
12.6 Installing the fuel tank
Danger
Warning
97
,
Main work
– Position the fuel tank and fit the two spoilers to the sides in
front of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or dam-
aged.
(All EXC models)
– Position the horn with the horn bracket.
I00434-10
– Mount and tighten screw 1 with the collar bushing.

Guideline
chassis
S05360-11
– Mount and tighten screws 2 with the collar bushings.

Guideline
chassis
– Remove the wash cap set.
– Clean the quick release coupling thoroughly with compressed
air.
I00436-10 Info
– Spray silicone spray onto a lint-free cleaning cloth and lightly

lubricate the O-ring of the quick-release coupling.
Silicone spray ( p. 317)
– Join quick release coupling 3.
Info
Route the cable and fuel line at a safe distance from
the exhaust system.
– 4.
Attach fuel tank breather hose
– Plug in fuel pump connector 5.
I00437-10
,
98
Finishing work
12.7 Changing the fuel screen
Danger
Warning
Note
– Clean quick release coupling 1 thoroughly with compressed

air.
Info
Info
– Pull fuel screen 2 out of the connecting piece.

– Insert the new fuel screen all the way into the connecting
piece.
– Spray silicone spray onto a lint-free cleaning cloth and lightly
lubricate the O-ring of the quick-release coupling.
– Join the quick release coupling.
S05528-10
99
,
Danger
– Start the engine and check the response.
12.8 Changing the fuel filter
Danger
Warning
Note
Preparatory work
Main work
(All EU/ASEAN models)
– Clean quick release coupling 1 thoroughly with com-
pressed air.
Info
Under no circumstances should dirt enter into the
fuel line. Dirt in the fuel line clogs the injection
valve!
D08176-10
,
100
Info
– Mount wash cap set A.

Wash cap set (81212016100)
(All BR/CN/XC-W models)

pressed air.
Info
valve!
D08177-10
Info

Wash cap set (81212016100)

– Pull out the fuel pump.
E03125-10
– Carefully disassemble locks 4.

– Take off the fuel filter 5 with the O-ring.
– Mount new O-ring 6.
– Mount a new fuel filter.
The wide side of the fuel filter faces the fuel line.
The fuel filter engages in the fuel pump with an audible
click.
E03127-10
101
,
– Position the fuel pump.

The connector and the fuel line face the rear.
– Thread the fuel line downwards.
Guideline
Screw, fuel pump EJOT PT® 2.5 Nm
K60x30 Z (1.84 lbf ft)
E03125-10

– Remove the wash cap set and thoroughly clean the quick
release coupling using compressed air.
Info
valve!
– Spray silicone spray onto a lint-free cleaning cloth and

D08173-10
lightly lubricate the O-ring of the quick-release coupling.
– Join the quick-release coupling 1 of the fuel line.
Info
Route the cable and fuel line at a safe distance
from the exhaust system.

Info
valve!

D08174-10
Info
Finishing work
,
102
12.9 Changing the fuel pump
Danger
Warning
Note
Preparatory work
Main work
pressed air.
Info
valve!
D08176-10
Info

Wash cap set (81212016100)
103
,

pressed air.
Info
valve!
D08177-10
Info

Wash cap set (81212016100)

E03125-10
– Pull out the fuel pump.

– Position the new fuel pump.
The connector and the fuel line face the rear.
– Thread the fuel line downwards.
E03126-01

Guideline
Screw, fuel pump EJOT PT® 2.5 Nm
K60x30 Z (1.84 lbf ft)
E03125-10
,
104

Info
valve!

D08173-10
Info

Info
valve!

D08174-10
Info
Finishing work
12.10 Checking the fuel pressure
Danger
105
,
Warning
Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The diagnostics tool is disconnected.
– Clean the quick release coupling thoroughly with com-
pressed air.
Info
valve!
– Press on the small metal plate and disconnect quick

D08173-10
release coupling 1 .
Info

– Clean the quick release coupling thoroughly with com-
pressed air.
Info
valve!
– Press on the small metal plate and disconnect quick

D08174-10
release coupling 1 .
Info
– Mount special tool 2.

Pressure testing tool (61029094000) ( p. 323)
– Mount special tool 3 with nozzle code 0,60.
Testing hose (61029093000) ( p. 323)
– Position the hose end in a fuel can.
Guideline
Minimum size, fuel can 10 l (2.6 US gal)
400926-10
,
– Connect the diagnostics tool and start it.
106
– Select "Actuator test" > "Fuel pump".

Guideline
Maximum duration of the 3 min
actuator test
– Check the fuel pressure with the fuel tank filler cap closed.
Fuel pressure
When the fuel pump is 3.3 … 3.7 bar (48 …
active 54 psi)
» If the specification is not reached:
– Open the fuel tank filler cap. ( p. 94)
– Check the fuel tank breather.
400927-01
– Check the fuel pressure with the fuel tank filler cap open.
Fuel pressure
When the fuel pump is 3.3 … 3.7 bar (48 …
active 54 psi)
– Check that the fuel line is clear.
– Change the fuel filter. ( p. 100)
400928-01
– Change the fuel pump. ( p. 103)
– Stop the "Actuator test" > "Fuel pump" by pressing the "Quit" but-
ton.
– Remove the special tools.
– Join the quick release coupling.
107
,
13 MASK, FENDER
13.1 Removing front fender

Preparatory work
Main work
V00340-10
– Remove screws 2. Take off front fender.
V00341-10
13.2 Installing front fender

Main work
– Position front fender. Mount and tighten screws 1.
Guideline
chassis
V00341-11

Guideline
chassis
V00340-11
Finishing work
,
108
MASK, FENDER 13
13.3 Removing the headlight mask with the headlight

– Release screws 1.
– Slide the headlight mask up and swing it forward.
– Disconnect the brake line at the headlight mask.
W00349-10
(All EXC models)

– Detach plug-in connectors 2 and take off the headlight
mask with the headlight.
W00350-10
(All XC‑W models)

– Disconnect plug-in connector 2 and take off the head-
light mask together with the headlight.
W00351-10
13.4 Installing the headlight mask with the headlight

Main work
(All EXC models)
– Join plug-in connectors 1.
W00350-11
(All XC‑W models)

– Join plug-in connector 1.
W00351-11
109
,
13 MASK, FENDER
– Position the brake line in the brake line guide.

– Position the headlight mask.
The holding lugs engage in the fender.
Guideline
chassis
W00349-11
Finishing work
,
110
WHEELS 14
14.1 Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
– Remove protection cap.

– Check tire pressure when the tires are cold.
Street tire pressure (All EXC models)
front 2.0 bar (29 psi)
rear 2.0 bar (29 psi)
Offroad tire pressure

400695-01
» If the tire pressure does not meet specifications:
– Correct tire pressure.
– Mount the protection cap.
14.2 Checking the tire condition
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the
motorcycle.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
– Check the front and rear tires for cuts, embedded objects, and
other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check the tread depth.
Info
Adhere to the legally required minimum tread depth.
400602-10
Minimum tread depth ≥ 2 mm (≥ 0.08 in)
» If the tread depth is less than the minimum tread depth:
– Check the tire age.
H01144-01
111
,
14 WHEELS
Info
The tire date of manufacture is usually contained in the
tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of
manufacture and the last two digits the year of manu-
facture.
KTM recommends that the tires be changed after 5
years at the latest, regardless of the actual state of
wear.
» If the tires are more than 5 years old:

14.3 Checking the wheel bearing for play

Preparatory work
– Place a load on the rear of the vehicle.
The front wheel is not in contact with the ground.
Main work
– Move the front wheel from side to side.
Info
Hold fork leg to check it.

– Change front wheel bearing. ( p. 118)
H01899-01

– Move the rear wheel from side to side.
Info
Hold the link fork to check it.

– Change the rear wheel bearing. ( p. 122)
H01896-01
Finishing work
14.4 Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately.
,
112
WHEELS 14
– Check the front and rear brake disc thickness at multiple

points for the dimension .A
Info
Wear reduces the thickness of the brake disc around
the contact surface of the brake linings.
Brake discs - wear limit (All standard models)

front 2.5 mm (0.098 in)
400257-10
rear 3.5 mm (0.138 in)
Brake discs - wear limit (All special models)
front 2.5 mm (0.098 in)
rear 3.7 mm (0.146 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc. ( p. 117)
– Change the rear brake disc. ( p. 121)
– Check the front and rear brake discs for damage, cracking, and
deformation.
» If the brake disc exhibits damage, cracking, or deforma-
tion:
– Change the front brake disc. ( p. 117)
– Change the rear brake disc. ( p. 121)
14.5 Checking the rim run-out
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec-
ondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
– Check spoke tension regularly, and in particular on a new vehicle.
Info
A loose spoke can unbalance the wheel and other spokes may loosen within a short period.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
113
,
14 WHEELS
– Check for lateral and radial run-out of the rims.

Lateral runout
Outside the rim joint < 1.8 mm (< 0.071 in)
Radial runout
Outside the rim joint < 1.8 mm (< 0.071 in)
– Center the rim.
Info
Center the rim by pulling the spoke nipple on
the other side of the rim run-out. If there is sig-
nificant deformation, change the rim.
– Correct the spoke tension.
400998-01
14.6 Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec-
ondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
– Check spoke tension regularly, and in particular on a new vehicle.
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke
length and spoke diameter.
If you hear different tone frequencies from different
spokes of equal length and diameter, this is an indica-
tion of different spoke tensions.
400694-01 You should hear a high note.

» If the spoke tension differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple, front M4.5 6 Nm (4.4 lbf ft)
wheel
Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft)
wheel
Torque wrench kit (58429094000) ( p. 322)

,
114
WHEELS 14
14.7 Front wheel
14.7.1 Removing the front wheel

Preparatory work
Main work
– Manually press the brake caliper toward the brake disc to push
back the brake pistons.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
V00363-10
– Loosen screw 1 by several rotations.

– Loosen screws 2.
– Press on screw 1 to push the wheel spindle out of the axle
clamp.
– Remove screw 1.
V00364-10
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.
– Hold the front wheel and remove the wheel spindle. Take the
V00365-10
front wheel out of the fork.
Info
Do not actuate the hand brake lever when the front
wheel is removed.
(All models apart from HARDENDURO)

– Remove spacers 3 .
H00934-10
115
,
14 WHEELS
(All HARDENDURO models)

– Remove spacer 3 and brake disc guard 4.
H01890-10
14.7.2 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Clean the brake discs with brake cleaner when necessary.
(All models apart from HARDENDURO)

– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Clean and grease shaft seal rings 1 and contact sur-
faces A
of the spacers.
H00935-10
– Insert the spacers.
– Clean and grease the wheel spindle.
– Jack up the front wheel into the fork, position it, and insert
the wheel spindle.
The brake linings are correctly positioned.
(All HARDENDURO models)
– Clean and grease shaft seal rings 1 and contact sur-
faces A
of the spacers.
S01631-10
– Insert the spacer and brake disc guard.
– Position the front wheel and insert the wheel spindle.
,
116
WHEELS 14
– Align the brake disc guard so that distance B and C are

equal in size.
S01633-10

Guideline
Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft)
spindle
– Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
– Operate the front brake and compress the fork a few times
V00364-11 firmly.
The fork legs straighten.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
14.7.3 Changing the front brake disc
Info
If the brake discs are changed, the brake linings must also be changed.
Preparatory work
Main work
– Remove screws 1. Take off the brake disc.
– Clean the contact surface of the brake disc.
– Position the brake disc with the label facing outward.
Guideline
D00187-10 brake disc Loctite®243™
117
,
14 WHEELS

Guideline
brake disc Loctite®243™
D02131-10
Finishing work
14.7.4 Changing the front wheel bearing

Preparatory work
Main work
– Remove radial shaft seal rings 1 and 2.
D00195-10

Info
Spacing tube4 can be pushed aside.
D00197-10

– Press in new bearing 5 all the way using a suitable tool.
Info
Only press the bearing in via the outer bearing race,
otherwise the bearing will be damaged when it is
pressed in.
D00199-10
,
118
WHEELS 14
– Clean, grease, and mount spacing tube 4.

– Press in new bearing 3 all the way using a suitable tool.
Info
pressed in.
D00198-10
– Grease new radial shaft seal rings 2 and 1 and press in

until they are flush.
D00196-10
Finishing work
14.8 Rear wheel
14.8.1 Removing the rear wheel

Preparatory work
Main work
back the brake piston.
Info
against the spokes when pushing back the brake piston.
– Remove nut 1.
– Take off chain adjuster 2 . Pull out wheel spindle 3 far
enough to allow the rear wheel to be pushed forward.
– Push the rear wheel forward as far as possible. Remove the
chain from the rear sprocket.
Info
Warning
Danger of accidents Damaged brake discs reduce the
V00366-10
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.
119
,
14 WHEELS
– Hold the rear wheel and remove the wheel spindle. Take the
rear wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel
is removed.
– Remove spacers 4.
H03002-10
14.8.2 Installing the rear wheel
Warning
Main work
– Change the rear wheel bearing. ( p. 122)
– Clean and grease shaft seal rings 1 and contact surfaces A
of the spacers.
– Insert the spacers.
H03001-10
– Position rear wheel and insert wheel spindle 2.

V00367-10
,
120
WHEELS 14
– Position chain adjuster 3. Mount nut 4, but do not tighten

it yet.
– Make sure that chain adjusters 3 are fitted correctly on
adjusting screws .5
– Tighten nut 4.
Guideline
Nut, wheel spindle, M22x1.5 80 Nm (59 lbf ft)
rear
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters 3 can be turned by 180°.
– Operate the foot brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
V00368-10
Finishing work
14.8.3 Changing the rear brake disc
Info
If the brake discs are changed, the brake linings must also be changed.
Preparatory work
Main work
Guideline
Screw, rear M6 14 Nm (10.3 lbf ft)
D00220-10 brake disc Loctite®243™

Guideline
Screw, rear M6 14 Nm (10.3 lbf ft)
brake disc Loctite®243™
D02133-10
121
,
14 WHEELS
Finishing work
14.8.4 Changing the rear wheel bearing

Preparatory work
Main work
– Remove radial shaft seal ring 1.
– Remove lock ring 2 .
R00607-10
D00211-10
– Using a suitable tool, press bearing 4 out from the inside to

the outside.
R00609-10
– Using a suitable tool, press bearing 6 out from the inside to

the outside.
– Check spacer washer 7 for damage and wear.
» If the spacer washer is damaged or worn:
– Replace the spacer washer.
D00214-10
,
122
WHEELS 14
– Press new bearing 4 all the way in from the outside to the
inside.
Info
pressed in.
Z00155-10

The lock ring engages audibly.
– Grease new radial shaft seal ring 1 and press it in until it is
flush.
Z00156-10
– Clean, grease, and mount spacing tube 5.

– Position spacer washer 7.
– Press new bearing 6 all the way in from the outside to the
inside.
Info
Z00157-10
pressed in.
– Grease new radial shaft seal ring 3 and press it in until it is

flush.
D00211-10
Finishing work
123
,
14 WHEELS
14.8.5 Checking the chain for dirt

– Check the chain for heavy soiling.
» If the chain is very dirty:
– Clean the chain. ( p. 124)
400678-01
14.8.6 Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.
Warning
Note
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 316)
– After drying, apply chain spray.
Off-road chain spray ( p. 317)
400725-01
Finishing work
,
124
WHEELS 14
14.8.7 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
Main work
– Pull the chain at the end of the chain sliding piece upward to
measure chain tension .A
Info
Lower chain section 1 must be taut.
When the chain guard is mounted, it must be possible
to pull up the chain at least to the point where it makes
contact with chain guard B .
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
Chain tension 55 … 58 mm (2.17 …

2.28 in)
» If the chain tension does not meet the specification:
– Adjust the chain tension. ( p. 128)
E00885-10
Finishing work
14.8.8 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
Main work
– Shift the transmission into neutral.
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
– Change the drivetrain kit. ( p. 128)
Info
The engine sprocket, rear sprocket, and chain
should always be replaced together.
400227-01
125
,
14 WHEELS
– Pull on the top section of the chain with the specified

weight A.
Guideline
Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.)
ment
– Measure distance B of 18 chain rollers in the lower chain
section.
Info
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
Maximum distance Bfrom 272 mm (10.71 in)

18 chain rollers at the
longest chain section
» If distance B is greater than the specified measurement:
– Change the drivetrain kit. ( p. 128)
400987-10 Info
When a new chain is mounted, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on old, worn sprock-
ets.
– Check the chain sliding guard for wear.

» If the lower edge of the chain pins 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 screws on the chain sliding guard.
Guideline
Screw, chain M6 6 Nm (4.4 lbf ft)
sliding guard Loctite®243™
W00303-10
,
126
WHEELS 14
– Check chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below
the chain sliding piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten screw on the chain sliding piece.
Guideline
Screw, chain slid- M8 15 Nm
ing piece (11.1 lbf ft)
W00304-10
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:

– Change the chain guide.
400985-01
– Check that the chain guide is firmly seated.

» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws, M6 10 Nm
chassis (7.4 lbf ft)
W00305-10
Finishing work
127
,
14 WHEELS
14.8.9 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 left
and right.
Guideline
Chain tension 55 … 58 mm (2.17 …
2.28 in)
Turn adjusting screws 3 on the left and right so that the
markings on the left and right chain adjusters are in the
same position relative to reference marks A
. The rear
wheel is then correctly aligned.
– Tighten nuts 2.
– Make sure that chain adjusters 4 are fitted correctly on
adjusting screws 3
.
– Tighten nut 1.
Guideline
E00330-10
Nut, wheel spindle, M22x1.5 80 Nm (59 lbf ft)
rear
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters 4 can be turned by 180°.
Finishing work
14.8.10 Changing the drivetrain kit

Preparatory work
,
128
WHEELS 14
Main work
– Remove screw 1.
– Remove screw 2.
– Take the engine sprocket cover off to the front.
B06187-10
– Have an assistant operate the rear brake.

– Remove screw 3 with washer.
B06188-10
– Remove connecting link 4 of the chain.

Info

B06189-10
– Remove engine sprocket 5.
B06190-10

– Remove fittings 6. Take off the rear sprocket.
– Position the new rear sprocket. Mount and tighten the fit-
tings.
Guideline
Nut, rear M8 35 Nm (25.8 lbf ft)
sprocket screw Loctite®2701™
D08241-10
129
,
14 WHEELS

– Remove fittings 6. Take off the rear sprocket.
– Position the new rear sprocket. Mount and tighten the fit-
tings.
Guideline
Nut, rear M8 35 Nm (25.8 lbf ft)
sprocket screw Loctite®2701™
D08242-10
– Slide new engine sprocket 5 onto the countershaft.

B06190-10
– Mount the new chain.

– Connect the chain with connecting link 4.
Guideline
B06189-11
– Have an assistant operate the rear brake.

– Mount and tighten screw 3 with washer.
Guideline
Screw, drive M10 60 Nm (44.3 lbf ft)
chain engine Loctite®2701™
sprocket
B06188-10
– Position the engine sprocket cover.

Guideline
chassis
Guideline
B06187-10
Screw, engine M8 15 Nm (11.1 lbf ft)
sprocket cover
Finishing work
–
,
Check the chain tension. ( p. 125)
130
WHEELS 14
131
,
15 WIRING HARNESS, BATTERY
15.1 Changing the main fuse
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Info
The main fuse protects all electrical power consumers of the vehicle.
Preparatory work
Main work
– Take off protection caps 1.
– Remove faulty main fuse 2.
Info
A faulty fuse has a burned-out fuse wire A .
A spare fuse 3 is located in the starter relay.
– Insert a new main fuse.

Fuse (58011109120) ( p. 284)
– Check that the electrical system is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
– Mount the protection caps.

– Mount the starter relay onto the holder and route the cable.
W00372-10
Finishing work
15.2 Disconnecting the negative cable of the 12-V battery

Preparatory work
Main work
– Disconnect negative cable 1 of the 12-V battery.
D08168-10
,
132
WIRING HARNESS, BATTERY 15
15.3 Connecting the negative cable of the 12-V battery

Main work
– Connect negative cable 1 of the 12-V battery.
Guideline
Screw, battery termi- M5 2.5 Nm
nal (1.84 lbf ft)
D08168-10
Finishing work
15.4 Removing the 12-V battery
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
Note
Preparatory work
Main work
Warning
Risk of injury 12 V batteries contain harmful sub-
stances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V bat-
teries.
W00356-10 – Only charge 12 V batteries in well-ventilated
rooms.
– Maintain a minimum clearance from inflammable
materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if
the charge is already below the minimum voltage.
Minimum voltage before 9 V
the start of the charge
– Dispose of 12 V batteries correctly if they have less
than the minimum voltage.
– Disconnect negative cable 1 from the 12-V battery.
133
,
– Pull back positive terminal cover 2 and disconnect positive

cable 3 from the 12-V battery.
– Remove screw 4.
W00357-10
– Pull up battery holding bracket 5 and remove the 12-V bat-

tery to the rear.
Info
Pay attention to the wiring harness.
W00358-10
15.5 Installing the 12-V battery

Main work
– Pull up battery holding bracket 1
, insert the 12-V battery
into the battery compartment with the terminals facing upward
and secure with battery holding bracket 1 .
12-V battery (HJTZ5S-FP-C) ( p. 284)
Info
Ensure that the cable is routed correctly.
W00358-11

Guideline
Screw, battery sup- M6 6 Nm (4.4 lbf ft)
port bracket
W00357-11
,
134
– Connect positive cable 3 to the 12-V battery.

Guideline
nal (1.84 lbf ft)
– Connect negative cable 4 to the 12 V battery.
Guideline
nal (1.84 lbf ft)
Contact disks A must be mounted under screws 5 and

cable sockets 6 with the claws toward the battery termi-
nal.
– Slide positive terminal cover 7 over the positive terminal.
W00359-10
Finishing work
15.6 Charging the 12-V battery
Warning
Risk of injury 12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V batteries.
– Only charge 12 V batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
– Dispose of 12 V batteries correctly if they have less than the minimum voltage.
Note
Danger of damage An incorrectly selected charging mode will damage the 12-V battery.
– Always select a charging mode that is compatible with the type of battery.
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
Note
135
,
Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, the 12-V battery will be destroyed.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and suffer a loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.
Preparatory work
– Disconnect the negative cable of the 12-V battery. ( p. 132)
Main work
– Connect a battery charger to the 12-V battery. Adjust the bat-
tery charger.
EU battery charger XCharge‑professional (00029095050)
( p. 319)
Alternative 1
US battery charger XCharge‑professional
(00029095051) ( p. 319)
311910-10
Alternative 2
UK battery charger XCharge‑professional
(00029095052) ( p. 319)
Info
Follow the instructions of the charger and the manual.
– Disconnect the battery charger after charging the 12-V battery.

Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery 3 months
regularly when the motorcy-
cle is not being used
Finishing work
– Connect the negative cable of the 12-V battery. ( p. 133)
15.7 Checking the charging voltage

Condition
The 12-V battery must be fully functional and completely charged.
Preparatory work
,
136
Main work
– Carry out start procedure. ( p. 13)
– Measure the voltage between the specified points.
Measuring point plus (+) – Measuring point Ground (−)
Charging voltage
5,000 rpm 13.5 … 15.0 V
» If the displayed value is less than the specified value:
D08169-10 – Check the plug-in connections from the alternator to
the voltage regulator.
– Check the plug-in connections from the voltage regula-
tor to the wiring harness.
– Check the stator winding of the alternator. ( p. 274)
» If the displayed value is greater than the specified value:
– Change voltage regulator.
Finishing work
15.8 Checking the open-circuit current

Preparatory work
Main work
– Measure the current between the 12-V battery ground (−) and
the negative cable.
Info
The value of the open-circuit current only applies to
vehicles in their original state without additional electri-
cal power consumers.
D08170-10 Maximum open-circuit cur- < 1.0 mA

rent
– Disconnect the voltage regulator from the wiring har-
ness and perform the measurement again.
Finishing work
137
,
15.9 Checking the starter relay

Preparatory work
Main work
– Pull starter relay 1 from the holder.
D08203-10
– Unplug connector 2.
– Disconnect cable 3 from the starter relay.
– Disconnect cable 4 from the starter relay.
E03232-10
– Connect the starter relay to a 12-V power supply as shown in

the figure.
– Measure the resistance between the specified points.
Resistance of open circuit 0Ω
» If the value displayed does not meet specifications:
– Change the starter relay.
601201-10
– Clamp cable 4 on the starter relay.

– Clamp cable 3 on the starter relay.
– Plug in connector 2.
– Mount the starter relay onto the holder and route the cable.
E03232-10
Finishing work
,
138
15.10 Checking the wiring harness

– Check that the wiring harness has been routed without kinks.
» If the wiring harness is kinked or trapped/pinched:
– Correct the routing of the wiring harness.
– Check the wiring harness for damage.
» If the wiring harness is damaged:
– Change the wiring harness.
Info
H05465-10 Repair of the wiring harness is not
recommended by KTM.
15.11 Diagnostics connector

Diagnostics connector 1 is located under the seat below the
engine control unit.
H00933-12
15.12 OCU
OCU 1
is located under the seat.
The OCU replaces the electronic fuses and relays.
All outputs are switched depending on the signals of the voltage
regulator and ECU.
The outputs are deactivated individually in the event of overcur-
rent.
This enables easy error detection because the status of each out-
put is indicated via LED lights.
The OCU monitors the electronics system completely indepen-
W00331-10 dently.
As soon as an indicated error is rectified, the status light of the
OCU changes from red to green.
Overview
A Ignition
B Light
C Brake light + horn
D Fuel pump
E Radiator fan
139
,
16 BRAKE SYSTEM
16.1 Checking that the brake linings of the front brake are secured
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately.
– Check the brake linings for lining thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If it is less than the minimum thickness:

– Change the brake linings of the front brake.
( p. 140)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
E00342-10 – Change the brake linings of the front brake.
( p. 140)
– Check that the brake linings are secured.
» If the brake linings are not secured correctly:
– Secure brake linings, replace with new parts if neces-
sary.
16.2 Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally.
Warning
Skin irritation Brake fluid is a harmful substance.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake
system.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
– Make sure that only clean, approved brake fluid from a tightly sealed container is used.
Warning
,
140
BRAKE SYSTEM 16
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
– Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
– Take off cover 2 with membrane 3.
back the brake pistons. Ensure that brake fluid does not flow
out of the brake fluid reservoir, extract some if necessary.
E01226-10
Info
against the spokes when pushing back the brake
pistons.
– Remove cotter pin 4, pull out pin 5, and remove the brake
linings.
– Clean the brake caliper and the brake caliper bracket.
E00344-10
– Check that spring plate 6 in the brake caliper and brake pad
sliding plate 7 in the brake caliper bracket are seated cor-
rectly.
100397-01
141
,
16 BRAKE SYSTEM
– Insert the new brake linings, insert the pin, and mount the cot-
ter pins.
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake lin-
point.
E00345-10
– Correct the brake fluid level to level A.

Guideline
Level A(brake fluid level 5 mm (0.2 in)
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 314)

– Position the cover with the membrane. Mount and tighten the
screws.
E01226-11
Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.
16.3 Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
(All EXC models)

– Push the hand brake lever to the handlebar and check free
travel .A
Free travel of hand brake ≥ 3 mm (≥ 0.12 in)
lever
» If the free travel does not match the specification:
– Adjust the free travel of the handbrake lever.
( p. 143)
S04873-12
(All XC‑W models)

– Push the hand brake lever forward and check free
travel .A
Free travel of hand brake ≥ 3 mm (≥ 0.12 in)
lever
» If the free travel does not match the specification:
– Adjust the basic position of the hand brake lever.
S04873-11
,
142
BRAKE SYSTEM 16
16.4 Adjusting the free travel of the handbrake lever

– Check the free travel of the hand brake lever. ( p. 142)
– Adjust the free travel of the hand brake lever with adjusting
screw 1.
Info
Turn the adjusting screw clockwise to reduce free
travel. The pressure point moves away from the
handlebar.
Turn the adjusting screw counterclockwise to increase
W00306-10 free travel. The pressure point moves towards the han-
dlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
16.5 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated.
Warning
system.
schedule.

– Check the brake fluid level in level viewer 1.
» If the brake fluid level has dropped below marking A in
the level viewer:
– Add front brake fluid. ( p. 144)
S03517-10
143
,
16 BRAKE SYSTEM
16.6 Adding front brake fluid
Warning
Warning
with the eyes.
Warning
system.
schedule.
Note
Info
Preparatory work
– Check that the brake linings of the front brake are secured.
( p. 140)
,
144
BRAKE SYSTEM 16
Main work
– Add brake fluid to level A.
Guideline
Level A (brake fluid level 5 mm (0.2 in)

screws.
Info
E01225-10
16.7 Changing the front brake fluid
Warning
Warning
with the eyes.
Warning
system.
schedule.
Note
145
,
16 BRAKE SYSTEM
Info

– Cover the painted parts.
– Take off cover 2 with membrane.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 320)
H04373-10
– Pull off protection cap 3 of the brake caliper bleeder screw.

Connect the bleeder bottle hose.
– Pull the hand brake lever and hold it in place.
– Open bleeder screw 4 by approx. one half turn.
Brake fluid runs into the bleeder bottle hose.
– Tighten bleeder screw 4.
– Release the hand brake lever.
– Repeat the procedure until fresh brake fluid emerges from the
H04380-10
hose of the bleeder bottle without bubbles.
Info
Ensure that the brake fluid reservoir is always filled
with a sufficient amount of fresh brake fluid.
– Remove the bleeder bottle hose. Mount protection cap 3.

– Add brake fluid to level A.
Guideline
Level A (brake fluid level 5 mm (0.2 in)

– Position cover 2 with the membrane. Mount and tighten
screws 1 .
Info
– Check the hand brake lever for a firm pressure point.
H04372-10
,
146
BRAKE SYSTEM 16
16.8 Checking that the brake linings of the rear brake are secured
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately.
– Check the brake linings for lining thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If it is less than the minimum thickness:

– Change the rear brake linings. ( p. 147)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
– Change the rear brake linings. ( p. 147)
E00349-10 – Check that the brake linings are secured.
» If the brake linings are not secured correctly:
– Secure brake linings, replace with new parts if neces-
sary.
16.9 Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally.
Warning
with the eyes.
Warning
system.
schedule.
147
,
16 BRAKE SYSTEM
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Info
– Stand the vehicle upright.

– Remove screw cap 1 with membrane 2 and the O-ring.
– Press the brake piston back into the basic position and ensure
that brake fluid does not flow out of the brake fluid reservoir;
extract some if necessary.
Info
against the spokes when pushing back the brake piston.
W00089-10
– Remove cotter pin 3, pull out pin 4, and remove the brake
linings.
– Clean the brake caliper and the brake caliper bracket.
E00351-10
– Check that spring plate 5 in the brake caliper and brake pad
sliding plate 6 in the brake caliper bracket are seated cor-
rectly.
E00352-10
,
148
BRAKE SYSTEM 16
– Insert the new brake linings, insert the pin, and mount the cot-
ter pins.
Info
Always change the brake linings in pairs.
– Operate the foot brake lever repeatedly until the brake lin-
point.
E00353-01
– Correct brake fluid level to marking A.

– Mount screw cap 1 with membrane 2 and O-ring.
Info
W00090-11
16.10 Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Ensure that the adjustment steps are performed properly.
– 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.
402026-10
( p. 150)
– Reconnect spring 1.
149
,
16 BRAKE SYSTEM
16.11 Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Ensure that the adjustment steps are performed properly.
– Detach spring 1.
402026-10
– Loosen nut 2
and, with push rod 3, turn it back until you
have maximum free travel.
– To adjust the basic position of the foot brake lever to individ-
ual requirements, loosen nut 4 and turn screw 5 accord-
ingly.
Info
The range of adjustment is limited.
E00346-10 – Turn push rod 3 accordingly until you have free travel A . If
necessary, adjust the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
– Hold screw 5 and tighten nut 4.
Guideline
Rear brake lever stop M8 20 Nm (14.8 lbf ft)
nut
– Hold push rod 3 and tighten nut 2.
Guideline
Remaining nuts, M6 10 Nm (7.4 lbf ft)
chassis
– Attach spring 1.
,
150
BRAKE SYSTEM 16
16.12 Checking the rear brake fluid level
Warning
Warning
system.
schedule.

– Check the brake fluid level in the viewer1.
» If the fluid has dropped below marking A in the level
viewer:
– Add rear brake fluid. ( p. 151)
S03518-10
16.13 Adding rear brake fluid
Warning
Warning
with the eyes.
Warning
system.
schedule.
151
,
16 BRAKE SYSTEM
Note
Info
Preparatory work
– Check that the brake linings of the rear brake are secured.
( p. 147)
Main work
– Remove screw cap 1 with membrane 2 and the O-ring.
– Add brake fluid up to the marking A.
– Mount and tighten the screw cap with the membrane and O-
ring.
W00090-11
Info
Finishing work
16.14 Changing the rear brake fluid
Warning
Warning
with the eyes.
,
152
BRAKE SYSTEM 16
Warning
system.
schedule.
Note
Info
– Remove the cable ties from the frame protector in the area of
the brake fluid reservoir.
– Remove screw cap 1 with the membrane and the O-ring.
– Extract the old brake fluid from the brake fluid reservoir using
a syringe and fill with fresh brake fluid.
Syringe (50329050000) ( p. 320)
D07369-10
– Pull off protection cap 2 of the brake caliper bleeder screw.

Connect the bleeder bottle hose.
– Actuate the foot brake lever and hold it in place.
– Open bleeder screw 3 by approx. one half turn.
Brake fluid runs into the bleeder bottle hose.
– Tighten bleeder screw 3.
– Release foot brake lever.
– Repeat the procedure until fresh brake fluid emerges from the
D07370-10
hose of the bleeder bottle without bubbles.
Info
Ensure that the brake fluid reservoir is always filled
with a sufficient amount of fresh brake fluid.
– Remove the bleeder bottle hose. Mount protection cap 2.
153
,
16 BRAKE SYSTEM

– Correct the brake fluid to marking A.
– Mount and tighten screw cap 1with the membrane and O-
ring.
Info
– Check the foot brake lever for a firm pressure point.

– Mount the new cable ties on the frame protector in the area of
the brake fluid reservoir.
D07371-10
,
154
LIGHTING SYSTEM, INSTRUMENTS 17
17.1 Changing the headlight bulb
Note
Impairments to reflectors and lamps Grease on the reflector reduces the emitted light.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service
life.
– Clean and degrease the bulbs before mounting.
– Do not touch the bulbs with your bare hands.
Preparatory work
Main work
– Turn LED unit 1 counterclockwise all the way and take it out
of the reflector.
Guideline
Only touch the LED unit on the cooling element.
I00431-10
– Insert the LED unit into the reflector and turn it clockwise all
the way.
Headlight (LED)
Info
Ensure that O-ring 2 is seated properly.
I00432-10
Finishing work
17.2 Changing the turn signal bulb (All EXC models)
Note
Impairments to reflectors and lamps Grease on the reflector reduces the emitted light.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service
life.
– Clean and degrease the bulbs before mounting.
– Do not touch the bulbs with your bare hands.
155
,
17 LIGHTING SYSTEM, INSTRUMENTS
Main work
– Remove the screw on the rear of the turn signal housing.
– Carefully remove turn signal glass 1.
– Lightly squeeze orange cap 2 in the area of the holding lugs
and take it off.
– Press the turn signal bulb lightly into the socket, turn it coun-
terclockwise by about 30°, and take it out of the socket.
Info
Do not touch the reflector with your fingers and keep it
free from grease.
– Press the new turn signal bulb carefully into the socket and
turn it clockwise until it stops.
Turn signal (R10W / socket BA15s) ( p. 284)
– Mount the orange cap.
– Position the turn signal glass.
– Insert the screw and first turn counterclockwise until it
E00360-10 engages in the thread with a small jerk. Tighten the screw
lightly.
Finishing work
– Check that the turn signal system is functioning properly.
17.3 Checking the headlight setting

– Park the vehicle on a horizontal surface in front of a light-
colored wall and make a mark at the height of the center of
the low beam headlight.
– Make another mark at a distance B under the first marking.
Guideline
Distance B 5 cm (2 in)
– Position the vehicle vertically at a distance A away from the

wall.
400726-10
Guideline
Distance A 5 m (16 ft)
– The rider now sits down on the motorcycle.

– Switch on the low beam.
– Check the headlight setting.
The boundary between light and dark must be exactly on the
lower mark for a motorcycle with rider.
» If the boundary between light and dark does not meet
specifications:
– Adjust the headlight range. ( p. 157)
,
156
17.4 Adjusting the headlight range

Preparatory work
Main work
– Loosen screw 1.
– Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on the
lower mark for a motorcycle with rider (instructions on how
to apply the mark: Checking the headlight setting).
V00369-10 Info
If you have a payload, you may have to correct the
headlight range.
17.5 Changing the combination instrument battery

Preparatory work
Main work
– Pull the combination instrument upward out of the holder.
E00901-10
– Using a coin, turn protection cap 2 all the way counterclock-

wise and take it off.
– Remove combination instrument battery 3.
– Insert the combination instrument battery with the label facing
outward.
Combination instrument battery (CR 2430) ( p. 284)
– Check the O-ring of the protection cap for correct seating.
V00371-10
– Position protection cap 2 and turn all the way clockwise

using a coin.
– Press any button on the combination instrument.
The combination instrument is activated.
– Position the combination instrument in the holder.
– Mount and tighten the screws with washers.
V00372-10
157
,
Finishing work
– Set kilometers or miles. ( p. 158)
– Adjust combination instrument function. ( p. 159)
– Set the clock. ( p. 160)
17.6 Combination instrument overview

– The button is used to select menus and make settings.
– The button is used to select menus and make settings.
Info
When the vehicle is delivered, only the SPEED/H and
SPEED/ODO display modes are activated.
V00799-01
17.7 Activation and test

Activating combination instrument
The combination instrument is activated when one of the buttons
is pressed or an impulse comes from the wheel speed sensor.
Display test
To enable you to check that the display is functioning properly, all
display segments light up briefly.
400313-01
WS (wheel size)
After the display function check, the wheel circumference WS is
displayed briefly.
Info
The number 2205 equals the circumference of the 21"
front wheel with standard tires.
The display then changes to the last selected mode.
400314-01
17.8 Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
,
158
– Repeatedly press the button briefly until H appears at the

bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
– Repeatedly press the button briefly until Km/h/Mph flashes.
Adjusting the Km/h
– Press the button .
400329-01 Adjusting the Mph
– Wait 3 - 5 seconds.
The settings are stored.
Info
If no button is pressed for 10–12 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
17.9 Adjusting combination instrument function
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The Setup menu is displayed and the active functions are
shown.
Info
If no button is pressed for 10–12 seconds, the settings
are automatically saved.
400318-01 If no button is pressed for 20 seconds, or if an impulse
comes from the wheel speed sensor, the settings are
automatically saved and the setup menu is closed.
– Repeatedly press the button briefly until the desired func-

tion flashes.
The selected function flashes.
Activating the function
The symbol continues to appear in the display and the
next function appears.
Deactivating a function
The symbol disappears in the display and the next
function appears.
159
,
17.10 Setting the clock

Condition
– Repeatedly press the button briefly until CLK appears at the
The hour display flashes.
– Adjust hour display with the button and/or button .
– Wait 3 - 5 seconds.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the
400330-01 hours by pressing the button and the button .
Info
The seconds can only be set to zero.
If no button is pressed for 15–20 seconds, or if an
settings are automatically saved and the setup menu is
closed.
17.11 Adjusting the wheel circumference
Note
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for oper-
ation on public roads in the homologated version.
– After the conversions, only use the vehicle on closed circuits that are not open to public road traffic.
– Inform the rider and owner that the public road approval and insurance coverage are no longer valid.
– If you are requested to carry out these conversions, insist on a shop order signed by your customer, in which
you also inform the customer that these conversions will be carried out at the customer’s own risk and that
the vehicle will thereafter no longer be approved for use on public roads.
Condition
Preparatory work
– Unplug combination instrument connector.
Main work
– Repeatedly press the button until the WS indicator flashes.
– Press the button briefly.
Info
The wheel circumference is displayed in millimeters.
400315-01
Enlarging the wheel circumference

Reducing the wheel circumference
,
160
Info
If no button is pressed for 20 seconds, or if no
settings are automatically saved and the Setup
menu is closed.
Finishing work
– Plug in combination instrument connector.
17.12 Viewing the lap time
Info
This function can only be opened if lap times have actually been timed.
Condition
– Repeatedly press the button briefly until LAP appears at the
– Briefly press the button .
LAP 1 appears on the left side of the display.
– The laps 1 - 10 can be viewed with the button .
– Press and hold the button for 3 - 5 seconds.
The lap times are deleted.
– Briefly press the button .
400321-01
Next display mode
Info
When an impulse is received from the wheel speed sen-
sor, the left side of the display changes back to the
SPEED mode.
161
,
18 ENGINE
18.1 Removing the engine

Preparatory work
(All XC-W and special models)
– Remove the engine guard. ( p. 55)
– Drain the coolant. ( p. 239)
– Remove the manifold. ( p. 86)
Main work
– Unplug hose piece 1.
B06221-10
B06222-10
,
162
ENGINE 18
– Push hose clip 3 back and pull the hose off the engine.
– Pull the fuel vapor valve off of the holder and remove it.
B06202-10
– Unplug connector 4 on the brake light switch.
B06200-10
– Push back hose clamp 5.

– Pull the hose off the reed valve housing.
Info
Residual oil may escape from the hose.
B06201-10
– Loosen screws6.
B06203-10
163
,
18 ENGINE
– Loosen hose clip 8.

– Lift up the subframe slightly.
– Take off hose clip 8.
B06204-10
– Pivot the subframe up and secure it.
Z01417-10
– Remove screw 9.
– Remove screw bk.
– Take off the engine sprocket cover.
B06205-10
– Remove screws bl.

– Take off the slave cylinder of the clutch and hang to the side.
Info
Do not kink the clutch line.
Do not activate the clutch lever while the slave cylinder
of the clutch is removed.
B06206-10
– Actuate the foot brake lever.

– Loosen screw bm.
Info
The help of an assistant is useful in this step.
B06207-10
,
164
ENGINE 18
– Remove connecting link bn of the chain.

Info
B06208-10
– Remove screw bm with washer.

– Take off the engine sprocket.
B06207-10
– Disconnect spark plug connector bo.
B06209-10
– Pull off vent hose bp.
B06210-10
– Remove cover bq.

– Disconnect plug br of the exhaust control.
B06211-10
165
,
18 ENGINE
– Remove the cable ties and expose the cable.
B06212-10
– Unplug connector bs.

– Disconnect plug-in connector bt.
– Disconnect plug-in connector ck.
– Expose the cable.
B06213-10
– Remove spring cl.

– Push back protection cap cm and remove the nut.
– Hang the positive cable to the side.
B06214-10

– Remove screws cn.
– Remove screws co.
– Take the engine brace off with the bracket.
B06215-10
,
166
ENGINE 18

– Remove screws cn.
– Remove screws co.
– Take off the engine braces.
B06216-10
– Loosen hose clip cp.

– Pull the throttle valve body out of the intake flange toward the
rear and hang it to one side.
B06217-10
– Loosen hose clip cq.

– Push back protection cap cr and remove the connector.
– Release hose clips cs.
– Pull off the radiator hoses.
B06218-10
– Remove nut ct.

– Remove the swingarm pivot.
– Pull the link fork back slightly.
B06219-10
– Remove screws dk.

– Lift out the engine sideways.
Info
Make sure that the motorcycle is sufficiently secured
against falling over.
B06220-10
167
,
18 ENGINE
18.2 Installing the engine

Main work
– Position the engine in the frame.
Info
Make sure that the motorcycle is sufficiently secured
against falling over.
B06220-11 – Mount screws 1, but do not tighten yet.

Guideline
Engine bracket screw M10 60 Nm (44.3 lbf ft)
– Position the link fork.

– Mount the swingarm pivot.
– Mount nut 2, but do not tighten yet.
Guideline
(73.8 lbf ft)
B06219-11
– Mount the radiator hoses.

– Position and tighten hose clips 3 and 4.
– Plug in connector and position protection cap 5.
B06218-11
– Position the throttle valve body in the intake flange.

– Position and tighten hose clip 6.
B06217-11

– Position the engine brace with the bracket.
Guideline
Screw, engine M8x15 25 Nm (18.4 lbf ft)
brace Loctite®2701™
,
B06215-11
168
ENGINE 18
Guideline
– Tighten screws 1 and nut 2.
Guideline
Engine bracket M10 60 Nm
screw (44.3 lbf ft)
(73.8 lbf ft)

– Position the engine braces.
Guideline
Guideline
B06216-11
– Tighten screws 1 and nut 2.
Guideline
Engine bracket M10 60 Nm
screw (44.3 lbf ft)
(73.8 lbf ft)
– Mount spring 9.
– Position the positive cable and mount and tighten the nut.
Guideline
Nut, cable on starter M6 4 Nm (3 lbf ft)
motor
– Mount protection cap bk.
B06214-11
169
,
18 ENGINE
– Plug in connector bl.

– Route the cable without tension and join plug-in
connector bm .
– Route the cable without tension and join plug-in
connector bn .
B06213-11
– Route the cables without tension and secure with the cable
ties.
B06212-10
– Plug in connector bo of the exhaust control.

– Position cover bp .
B06211-11
– Mount vent hose bq.
B06210-11
,
170
ENGINE 18
– Plug in spark plug connector br.
B06209-11
– Slide on the engine sprocket with the collar facing the engine.
– Mount screw bs with washer, but do not tighten yet.
Guideline
sprocket
B06207-11

– Connect the chain with connecting link bt.
Guideline
B06208-11
– Actuate the foot brake lever.

– Tighten bolt bs.
Guideline
sprocket
Info
B06207-11 The help of an assistant is useful in this step.
– Position the clutch slave cylinder with the O-ring.

– Mount and tighten screws ck.
Guideline
Screw, clutch slave M6 10 Nm (7.4 lbf ft)
cylinder
B06206-11
171
,
18 ENGINE
– Position the engine sprocket cover.

– Mount and tighten screw cl.
Guideline
Screw, clutch slave M6 10 Nm (7.4 lbf ft)
cylinder
– Mount and tighten screw cm.
Guideline
B06205-11
Screw, engine M8 15 Nm (11.1 lbf ft)
sprocket cover
– Remove the locking piece and position the subframe.
Info
Watch out for the intake flange.
– Position the inlet sleeve on the throttle valve body.

– Position and tighten hose clip cn.
B06204-11
– Mount and tighten screws co.

Guideline
– Remove screws cp.
– Mount and tighten screws cp.
Guideline
B06203-11 Screw, sub- M8 30 Nm (22.1 lbf ft)
frame bottom Loctite®2701™
– Mount hose on the reed valve housing.

– Position hose clamp cq.
B06201-11

– Plug in connector cr of the brake light switch.
B06200-11
,
172
ENGINE 18
– Mount fuel vapor valve on the holder.
Info
Make sure the cables and wiring are routed cor-
rectly.
– Plug the hose into the engine and position hose clip cs.
B06202-11
– Plug in connector ct.
B06222-11
– Plug in hose piece dk.
B06221-11
– Remove filler plug dl with the O-ring, and fill up with gear
oil.
Gear oil 0.80 l Engine oil
(0.85 qt.) (15W/50)
( p. 314)
– Mount and tighten filler plug dl with the O-ring.
B06111-10
Finishing work
– Install the manifold. ( p. 88)
173
,
18 ENGINE

– Refill with coolant. ( p. 240)
– Install the engine guard. ( p. 55)
Condition
Work on the exhaust control has been carried out.
– Program the end positions of the exhaust control.
( p. 259)
– Clear the fault memory using the KTM diagnostics tool.
– Go for a short test ride.
– Read out the fault memory using the KTM diagnostics tool.
– Check the engine for leaks.
– Check the gear oil level. ( p. 262)
– Check 2-stroke oil level. ( p. 263)
– Check the coolant level. ( p. 239)
18.3 Engine disassembly
18.3.1 Clamping engine into the engine work stand

– Mount special tool 1 on motor work stand 2.
Engine work stand (61229001000) ( p. 323)
Holder and fitting for work stand (55429002000)
( p. 321)
– Mount the motor on special tool 1.
E03284-10
18.3.2 Removing the cylinder head and the cylinder

Preparatory work
– Clamp the engine into the engine work stand. ( p. 174)
Removing the cylinder head
– Remove spark plug 1.
E03466-10
,
174
ENGINE 18
– Loosen screws 2 in a crisscross pattern and remove

them.
– Take off the cylinder head.
Info
The cylinder head consists of two parts; the com-
bustion chamber liner and the cylinder head cover.
E03373-10
– Remove O-rings 3 and 4.
E03268-10
Removing the cylinder

– Remove screw 5.
– Take off cover 6.
E03269-10
– Take off actuator 8.
Info
If the actuator of the exhaust control has been
removed, the end positions of the exhaust control
must be reprogrammed.
E03270-10
175
,
18 ENGINE
– Take off both covers of the exhaust control with the gas-
kets.
E03271-10
– Remove nuts bk.

Info
Raise the cylinder slightly to be able to remove the
front nuts.
– Carefully slide the cylinder up and take it off.
E03272-10
– Take off cylinder base gasket bl.

– Uncover the crankcase.
E03273-10
Removing the piston

– Remove piston ring lock bm.
– Remove the piston pin.
– Take off the piston.
E03274-10
– Remove upper conrod bearing bn.
E03275-10
,
176
ENGINE 18
18.3.3 Draining the gear oil

– Remove gear oil drain plug 1 with the magnet and seal ring.
– Let the gear oil drain fully.
E03283-10
18.3.4 Disassembling the alternator side

Preparatory work
Removing the alternator cover
– Remove screws 1 . Take off alternator cover 2 with the
gasket.
Info
Ensure that the cylindrical pins remain in place.
E03276-10
Removing the rotor

– Mount special tool 3.
Holding wrench (A44029012000) ( p. 329)
– Remove nut 4 with washer.
E03278-10
– Mount special tool 5 , hold, and pull off the rotor by

screwing in the screw.
Puller (79229032044) ( p. 324)
Info
Ensure that the woodruff key remains in place.
E03279-10
177
,
18 ENGINE
– Take off Bendix 6.
E03280-10
– Pull the rubber grommet out of the engine case.

– Take off the crankshaft speed sensor.
E03281-10
18.3.5 Dismantling the clutch side

Preparatory work
– Drain the gear oil. ( p. 177)
Main work
– Remove clutch push rod 1.
– Remove screw 2 with washers. Take off the shift lever.
E03282-10
Removing the water pump and clutch cover

– Remove screws . 3
– Take off the water pump cover with the gasket.
E03285-10
,
178
ENGINE 18
– Take off the clutch cover with the gasket.
Info
Ensure that the cylindrical pins remain in place.
E03286-10
Removing the clutch discs

– Loosen screws 5 in an incremental crisscross pattern and
remove them.
– 6.
Take off spring retainer
– Take off spring washer 7.
E03287-10
– Take off pretension ring 8.

– Take off clutch pressure cap 9.
E03288-10
– Remove clutch disc pack bk completely.

– Remove clutch throw-out bl.
E03289-10
Removing the clutch basket

– Hold the primary gear wheel using special tool bm.
Gear segment (80029004000) ( p. 325)
– Remove nut bn.
Info
LH thread!
E03290-10
179
,
18 ENGINE
– Hold the inner clutch hub with special tool bo. Loosen
nut bp .
Holding wrench (59029003100) ( p. 322)
Alternative 1
Holding wrench (51129003000) ( p. 320)
– Remove the nut with the wedge lock washer.
E03291-10
– Take off inner clutch hub bq and washer br.

Info
The washer usually sticks to the inner clutch hub.
– Take off clutch basket bs.
E03292-10
– Take off needle bearing bt and collar bushing ck.
E03293-10
Removing the balancer shaft drive wheel and primary gear

– Hold the balancer shaft in place using the special tool bm.
Gear segment (80029004000) ( p. 325)
– Remove screw cl with washer.
E03294-10
– Mount special tool cm and pull off the primary gear wheel
by screwing in the screw.
Puller (46129021000) ( p. 319)
– Take off primary gear wheel cn.
Info
Ensure that the woodruff key remains in place.
E03295-10
,
180
ENGINE 18
– Remove balancer shaft drive wheel co.
E03296-10
– Remove woodruff key cp.
E03297-10
Removing the shift shaft, shift drum locating unit and locking lever
– Remove screw cq with washer.
– Take off locking lever cr with the sleeve and spring.
E03298-10
– Remove screw cs.

– Push shift shaft sliding plate ct away from shift drum
locating unit dk and take off the shift drum locating unit.
E03299-10
– Remove shift shaft dl with the washer.
E03300-10
18.3.6 Preparing the engine for housing disassembly

Preparatory work
– Remove the cylinder head and the cylinder. ( p. 174)
181
,
18 ENGINE
– Disassemble the alternator side. ( p. 177)

– Dismantle the clutch side. ( p. 178)
Removing the spacer, balancer shaft and lock ring
– Remove spacer . 1
E03301-10
– Take off O-ring 2.
E03302-10
– Remove balancer shaft 3 toward the left.
E03303-10
E03304-10
Removing the reed valve housing

– Remove screws .5
– Take off intake flange and gasket.
E03305-10
,
182
ENGINE 18
– Remove reed valve housing 6.

– Take off the gasket.
E03306-10
Removing the starter motor

– Remove screw 7 .
– Take off cover 8.
E03307-10
– Take off the starter motor.
E03308-10
18.3.7 Dismantling the engine case

Preparatory work
– Remove the cylinder head and the cylinder. ( p. 174)
– Disassemble the alternator side. ( p. 177)
– Dismantle the clutch side. ( p. 178)
– Prepare the engine for housing disassembly. ( p. 181)
Removing the left engine case
– Remove screws .1
– Tilt the left section of the engine case upward and remove
the fitting of the engine fixing arm.
– Loosen the left section of the engine case by striking it
lightly with a plastic hammer and remove it.
Info
Do not pry it apart with screwdrivers, since the seal-
E03309-10
ing areas are easily damaged.
183
,
18 ENGINE
Removing shift rails, shift drum and shift forks

– Remove shift rail 2 with the springs.
– Remove shift rail 3 with the springs.
E03310-10
– 4 to the side.
Tilt shift forks
– Remove shift drum 5.
E03311-10
– Remove shift forks 4.

Info
Do not misplace the shift rollers.
E03312-10
Removing the transmission shafts and crankshaft

– Pull both transmission shafts 6 out of the bearing seats
together.
Info
The stop disks of the transmission shafts usually
stick to the bearings.
E03313-10
– Remove crankshaft 7.
E03314-10
,
184
ENGINE 18
E03316-10
– Remove distance sleeve 9.
E03315-10
18.4 Working on individual parts
18.4.1 Working on the right section of the engine case

– Remove all dowels.
– Remove radial shaft seal ring 1 of the crankshaft.
– 2.
Remove lock ring
– Remove screws 3. Remove the bearing retainers.
– Clean the section of the engine case thoroughly.
– Warm the section of the engine case in an oven.
Guideline
180 °C (356 °F)
– Knock the section of the engine case against a level wooden
board. This will cause the bearings to drop out of the bearing
seats.
Info
Any bearings that remain in the section of the engine
case must be removed using a suitable tool.
E03318-10
– Blow out lubrication bore 4 with compressed air and check

that it is clear.
– Insert the new cold bearings in the bearing seats of the heated
section of the engine case; if necessary, use a suitable press-
ing tool to push them all the way in and make them flush.
E03319-10
185
,
18 ENGINE
Info
When pressing in, ensure that the section of the engine
case lies flat in order to prevent damage.
Only press the bearings in using the outer bearing race;
otherwise, the bearings will be damaged when they are
pressed in.
– After the section of the engine case has cooled, check that the
bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.
– Press in radial shaft seal ring 1 of the crankshaft with the

open side facing in so that it is flush.
– Mount and tighten screws 3 with the bearing retainers.
Guideline
Screw, bearing M5 6 Nm (4.4 lbf ft)
retainer Loctite®243™
– Mount the dowels.
18.4.2 Working on the left section of the engine case

– Remove all dowels.
– Press out radial shaft seal ring 1 of the crankshaft from the
outside toward the inside.
– Remove radial shaft seal ring 2 from the shift shaft and 3
from the countershaft.
– Remove radial shaft seal ring 4 of the balancer shaft.
– Clean the section of the engine case thoroughly.
– Warm the section of the engine case in an oven.
Guideline
180 °C (356 °F)
– Knock the section of the engine case against a level wooden
board. This will cause the bearings to drop out of the bearing
seats.
Info
Any bearings that remain in the section of the engine
case must be removed using a suitable tool.
E03321-10
,
186
ENGINE 18
– Blow out lubrication bore 6 with compressed air and check

that it is clear.
E03320-10
– Insert the new cold bearings in the bearing seats of the heated
section of the engine case; if necessary, use a suitable man-
drel to push them all the way in and make them flush.
Info
When pressing in, ensure that the section of the engine
case lies flat in order to prevent damage.
Only press the bearings in using the outer bearing race;
otherwise, the bearings will be damaged when they are
pressed in.
– After the section of the engine case has cooled, check that the
bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be replaced.
– Press in radial shaft seal ring1 of the crankshaft with the

open side facing inward so that it is flush.
E03321-10
– Press in radial shaft seal ring2 of the shift shaft so it is
flush with the open side facing inward.
– Press in radial shaft seal ring3 of the countershaft so it is
flush with the open side facing in.
– Press in radial shaft seal ring4 of the balancer shaft so it is
flush with the open side facing in.
18.4.3 Removing the crankshaft bearing inner race

– Fixate the crankshaft in the vice with special tool 1.
Guideline
Use soft jaws.
Separator plate (54829009000) ( p. 320)

– Warm up special tool 2.
Guideline
180 °C (356 °F)
312224-10
Puller (58429037043) ( p. 321)

– Push the warmed up special tool 2 onto the crankshaft bear-
ing inner race, press firmly together, and pull jointly from the
crankshaft.
187
,
18 ENGINE
18.4.4 Installing the crankshaft bearing inner race

– Fixate the crankshaft in the vice with special tool 1.
Guideline
Use soft jaws.

– Heat the crankshaft bearing inner race in special tool 2 and
mount together.
Guideline
312224-10
120 °C (248 °F)
Puller (58429037043) ( p. 321)

– Ensure that the new crankshaft bearing inner race is flush.
18.4.5 Changing the connecting rod, conrod bearing and crank pin
Main work
– Position crankshaft 1 in the press using special tool 2.
– Press the crank pin out of the upper crankweb with a suitable
tool.
Info
Hold the lower crankweb.
312225-10
– Take off the connecting rod and bearing.
– Press the crank pin out of the lower crankweb.
312226-10
– Lubricate the new crank pin 3 and push in up to the stop.
312219-10
,
188
ENGINE 18
– Mount new bearing 4 with washers 5 and connecting

rod 6
.
Info
Thoroughly oil the bearing.
312220-10
– Position special tool 7 on the press.

Crankshaft pressing tool (75029047000) ( p. 324)
Insert for crankshaft pressing tool (54829108000)
( p. 321)
– Insert the crankweb with the connecting rod and bearing. Posi-
tion the second crankweb.
312227-10
– Position special tool 8 with the heel pointing down.

Insert for crankshaft pressing tool (54829108000)
( p. 321)
– Press in the upper crankweb as far as possible.
Info
The press mandrel must be positioned over the crank
pin.
312228-10
– Take the crankshaft out of the special tool and check that the
connecting rod can move freely.
– Measure axial play A
between the connecting rod and the
crankwebs using the special tool.
Feeler gauge (79129941000) ( p. 324)
Connecting rod - axial play of 0.60 … 0.70 mm (0.0236

lower conrod bearing … 0.0276 in)
– Correct it so the dimension is equal to the specified
312221-10 value.
Finishing work
– Check the crankshaft run-out at the bearing pin. ( p. 190)
189
,
18 ENGINE
18.4.6 Checking the crankshaft run-out at the bearing pin

– Position the crankshaft on a roller block.
– Turn the crankshaft slowly.
– Check the crankshaft run-out on both bearing pins.
Crankshaft - run-out at bear- ≤ 0.03 mm (≤ 0.0012 in)
ing pin
» If the crankshaft run-out at the bearing pin is larger than
the specification:
– Align the crankshaft.
D05016-10
18.4.7 Checking/measuring the cylinder

– Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
– Change the cylinder and piston.
– Measure the bore diameter at several locations on
the ‑ and
X ‑axes using a micrometer to identify oval wear.
Y
Guideline
Cylinder - drill hole diameter (All 250 models)
Size I 66.400 … 66.412 mm
(2.61417 … 2.61464 in)
Size II 66.412 … 66.425 mm
(2.61464 … 2.61515 in)
Size I 72.000 … 72.012 mm
(2.83464 … 2.83511 in)
Size II 72.012 … 72.025 mm
(2.83511 … 2.83562 in)
Info
E03341-10
The cylinder size 1 is labeled on the right side of the
cylinder.
– Using a straightedge and the special tool, check the sealing

surface of the cylinder head for distortion.
Feeler gauge (79129941000) ( p. 324)
Cylinder/cylinder head - dis- ≤ 0.10 mm (≤ 0.0039 in)

tortion of sealing surface
» If the measured value does not meet specifications:
– Change the cylinder.
E03342-01
18.4.8 Removing the exhaust control
Info
If work has been carried out on the exhaust control, the end positions must be reprogrammed.
,
190
ENGINE 18
– Position special tool 1.

Retaining bracket (A44029065000) ( p. 329)
– Remove screw 2 with washer.
– Remove screw 3.
– Take off the special tool.
– Take off control flap lever 4.
E03360-10
– Take off right control gate 5.
E03361-10
– Remove screw 6.
Info
The screw point of the retaining bracket may be in a
different position.
– Take off the retaining bracket.

– Remove right control shaft 7.
E03362-10
– Remove left control gate 8 with the idler shaft of the exhaust
control.
E03363-10
– Remove screw 9.
Info
different position.
– Take off the retaining bracket.

– Remove left control shaft bk.
E03364-10
191
,
18 ENGINE
– Remove screws bl.

– Take off the exhaust flange.
E03365-10
– Remove control flap bm evenly from the grooves on both sides.

Info
If the control flap is tilted, the cylinder may be dam-
aged.
E03366-10
18.4.9 Checking the exhaust control

Condition
Exhaust control removed.
E03329-10
– Check control shafts 1 for damage and wear.

– Change the control shaft.
– Check control gates 2 for damage and wear.
– Change the control gates.
– Check bearing sleeves 3 for damage and wear.
,
– Change the bearing sleeves.
192
ENGINE 18
– Check control flap 4 for damage and wear.

– Change the control flap.
– Check idler shaft 5 of the exhaust control for damage and wear.
– Change the idler shaft of the exhaust control.
– Check inner clutch hub 6 of the actuator for damage and wear.
– Change the actuator.
18.4.10 Installing the exhaust control
Info
– Mount and grease O-rings 1.

– Mount and grease bearing sleeves 2.
E03367-10
– Set control flap 3 to the open position in the grooves.
E03366-11
– Degrease the sealing surface and apply a thin coat of sealing

compound.
Loctite® 5910
– Position the exhaust flange.
The control flap is still in the open position.
Guideline
E03365-11 Screw, exhaust M6 8 Nm (5.9 lbf ft)
flange
Info
Do not forget the spring hangers.
193
,
18 ENGINE
– Mount and grease O-rings 5.

E03368-10
– Mount left control shaft 6.

The control shaft with marking L is installed on the left.
– Mount the retaining bracket.
Guideline
Screw, retain- M5 6 Nm (4.4 lbf ft)
ing bracket of Loctite®2701™
exhaust control
E03364-11
Info
different position.
– Mount left control gate 8 with the idler shaft of the exhaust
control.
Pin A of the control shaft engages in guide B of the
left control gate when the control flap is closed.
E03369-10
– Mount right control shaft 9.

The control shaft with marking R is installed on the right.
– Mount the retaining bracket.
– Mount and tighten screw bk.
Guideline
Screw, retain- M5 6 Nm (4.4 lbf ft)
ing bracket of Loctite®2701™
exhaust control
E03362-11
,
194
ENGINE 18
Info
different position.
– Mount right control gate bl.

The inner clutch hub of the idler shaft engages correctly
in the control gate.
Pin C of the control shaft engages in guide D of the
right control gate when the control flap is closed.
– Mount screw bm but do not tighten yet.
Guideline
Screw, idler M5 8 Nm (5.9 lbf ft)
shaft, exhaust Loctite®243™
control
E03370-10
– Mount control flap lever bn.

The inner clutch hub of the control flap engages correctly
in the control flap lever.
Pin E of the control flap lever engages in guide F of
the right control gate.
– Mount screw bo with washer but do not tighten yet.
Guideline
Screw, control M5 8 Nm (5.9 lbf ft)
E03371-10 flap, exhaust Loctite®243™
control
– Position special tool bp.

Retaining bracket (A44029065000) ( p. 329)
– Tighten screw bm.
Guideline
Screw, idler M5 8 Nm (5.9 lbf ft)
shaft, exhaust Loctite®243™
control
E03360-11 – Tighten screw bo.
Guideline
Screw, control M5 8 Nm (5.9 lbf ft)
flap, exhaust Loctite®243™
control
– Take off the special tool.
195
,
18 ENGINE
18.4.11 Checking/measuring the piston

– Check the piston bearing surface for damage.
» If the piston bearing surface is damaged:
– Replace the piston and, if necessary, the cylinder.
– Check that the piston rings move easily in the piston ring
grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.
E03326-01 Tip
An old piston ring can be used to clean the pis-
ton ring groove.
– Check the piston rings for damage.

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

» If the piston pin shows severe discoloration/signs of wear:
– Change the piston pin.
– Place the upper conrod bearing and piston pin in the connect-
ing rod and check the seating for play.
» If the piston pin seating has excessive play:
– Change the connecting rod, conrod bearing, and crank
pin.
– Measure the piston at the piston skirt, at right angles to the
piston pin, at a distance . A
Guideline
Distance A 50 mm (1.97 in)
Piston - diameter (All 250 models)
Size I 66.340 … 66.350 mm
(2.61181 … 2.6122 in)
Size II 66.351 … 66.360 mm
E03327-10 (2.61224 … 2.61259 in)
Size I 71.925 … 71.934 mm
(2.83169 … 2.83204 in)
Size II 71.935 … 71.944 mm
(2.83208 … 2.83244 in)
Info
Piston dimensions 1 are marked on the piston head.
,
196
ENGINE 18
18.4.12 Checking the piston ring end gap

– Remove the piston ring from the piston.
– Place the piston ring in the cylinder and align with the piston.
Guideline
Below the upper edge of the 20 mm (0.79 in)
cylinder
– Measure end gap A with a feeler gauge.
Guideline
Piston ring end gap (All 250 models)
E03328-10
Ring 1 ≤ 0.60 mm (≤ 0.0236 in)
Ring 2 ≤ 0.60 mm (≤ 0.0236 in)
Ring 1 ≤ 0.40 mm (≤ 0.0157 in)
Ring 2 ≤ 0.40 mm (≤ 0.0157 in)
» If the end gap is greater than the specified value:
– Check/measure the cylinder. ( p. 190)
» If cylinder wear lies within the specified tolerance:
– Mount the piston ring with the marking facing toward the pis-
ton head.
18.4.13 Measuring the piston/cylinder mounting clearance

– Check/measure the cylinder. ( p. 190)
– Check/measure the piston. ( p. 196)
– The smallest piston/cylinder mounting clearance equals the
smallest cylinder bore diameter minus the largest piston diam-
eter. The largest piston/cylinder mounting clearance equals the
largest cylinder bore diameter minus the smallest piston diam-
eter.
Guideline
Piston/cylinder - mounting clearance (All 250 models)
E03326-01
New condition 0.050 … 0.074 mm
(0.00197 … 0.00291 in)
Wear limit 0.10 mm (0.0039 in)
New condition 0.066 … 0.088 mm
(0.0026 … 0.00346 in)
197
,
18 ENGINE
18.4.14 Disassemble the reed valve housing

311407-10
– Remove the reed valve housing 2 from the back plate.
E03322-10
– Remove screws 3 on both sides.

– 4 on both sides.
Take off stop plate
– Remove the outer reed valve 5 on both sides.
E03324-10
– Separate the reed valve holders. Remove holding strip 7.
D06260-10
– Take off the inner reed valve 8 from both reed valve holders.
D06261-10
,
198
ENGINE 18
18.4.15 Checking the reed valve housing, reed valve and intake flange
Condition
Reed valve housing has been removed.
– Check intake flange 1 for damage and wear.
– Change the intake flange.
– Check reed valve 2 for damage and wear.
– Change the reed valve.
– Check the reed valve housing for damage and wear.
– Change the reed valve housing.
E03330-10
18.4.16 Assemble the reed valve housing

– Position the inner reed valve 1 on both reed valve holders.
The recesses are located on the right side.
D06262-10
199
,
18 ENGINE
– Position holding strip 2.

The holding lugs engage in the drilled holes.
D06263-10
– Position the reed valve holders.
D06264-10
– Mount screws 3 and screw in all the way.

Info
Mount the screws at right angles to prevent damage.
– Loosen screws 3 and tighten again.

Guideline
Screw, inner reed EJOT DELTA PT 1 Nm (0.7 lbf ft)
paddles ® 3.5x25
G01324-10
Distance A is equal on both sides.

– Position the outer reed valve 4 on both sides.
The recesses are located on the right side.
G01328-10
,
200
ENGINE 18
– Position the stop plates on both sides.

– Mount screws 5 on both sides and screw in all the way.
– Loosen screws 5 and tighten again.
Guideline
Screw, outer reed EJOT DELTA PT 1 Nm (0.7 lbf ft)
paddles ® 3x6
E03325-10
– Position gasket 6.
D07836-10
– Position the reed valve housing in the support plate.

The outer recess is located on the right in the direction of
travel when installed.
Guideline
Screw, membrane EJOT DELTA PT 1 Nm (0.7 lbf ft)
support plate ® 3x12
311407-11
18.4.17 Working on the clutch cover
Info
Remove the outer clutch cover to avoid damage.
– Remove nut 1.
– Take off the water pump impeller.
E03332-10
201
,
18 ENGINE
– Remove form washer 2.
E03333-10
– Remove water pump gear wheel 3.
E03334-10
E03335-10
– Press out bearing 5 toward the inside.
E03336-10

– Press the new radial shaft seal ring all the way in to the stop.
E03337-10
,
202
ENGINE 18
– Press bearing 5 all the way in to the stop from the inside.
E03336-10
– Press in radial shaft seal ring 4 flush.

– Ensure that the bearing can turn freely and does not touch the
radial shaft seal ring.
E03335-10
– Mount water pump gear wheel 3.
E03334-10
– Position form washer 2.
E03333-10
– Mount the water pump impeller.

– Mount and tighten nut 1.
Guideline
Nut, water M6 5 Nm (3.7 lbf ft)
pump impeller Loctite®243™
E03332-10
203
,
18 ENGINE
18.4.18 Checking the clutch
304690-10
– Check clutch throw-out 1 for damage and wear.

– Change the clutch push rod.
– Place the clutch push rod 2 on a flat surface and check for run-out.
» If there is run-out:
– Check spring retainer 3 for damage and wear.
– Change the spring retainer.
– Check pretension ring 4 for damage and wear.
– Change the pretension ring.
– Check spring washer 5 for damage and wear.
– Change the spring washer.
– Check the contact surface of clutch pressure cap 6 for damage and wear.
– Change the clutch pressure cap.
– Check clutch center 7 for damage and wear.
– Change the clutch center.
– Check damping rubber pieces 8 for damage and wear.
– Change the damping rubber pieces.
– Check inner clutch hub 9 for damage and wear.
– Change the inner clutch hub.
,
– Check the thrust surfaces of the clutch facing discs in clutch basket bk for damage and wear.
204
ENGINE 18

– Change the clutch facing discs and the clutch basket.
– Check needle bearing bl and collar bushing bm for damage and wear.
– Change the needle bearing and collar bushing.
– Check intermediate discs bn for damage and wear.
» If the intermediate discs are not flat or have punctiform outbreaks:
– Change all intermediate discs.
– Check clutch facing discs bo for discoloration and scoring.
» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs bo.
Clutch facing disc - thickness ≥ 1.9 mm (≥ 0.075 in)
» If the clutch facing disc does not meet specifications:
18.4.19 Preassembling shift shaft

– Secure the short end of the shift shaft in the bench vise.
Guideline
Use soft jaws.
– Mount shift shaft sliding plate1 with the guide pin facing
downwards and attach the guide pin on the shift quadrant.
– Mount pressure spring 2.
– Slide on spring guide 3, push return spring 4, with the off-
set end facing upward, over the spring guide and lift the offset
E02939-10
end over abutment bolt 5 .
– Mount stop disk 6.
205
,
18 ENGINE
18.4.20 Checking the shift mechanism
E03343-10
– Check shift forks 1 on plate A for damage and wear (visual check).
– Change the shift fork.
– Check shift grooves B of shift drum 2 for wear.
» If the shift groove is worn:
– Change the shift drum.
– Check the seat of the shift drum in bearings 3.
» If the shift drum is not seated correctly:
– Change the shift drum and/or the bearing.
– Check bearing 3 for stiffness and wear.
» If the bearings are stiff or are worn:
– Change the bearings.
– Check the shift rollers for damage and wear.
– Change the shift rollers.
– Check shift rail 4 for run-out on a flat surface.
– Change the shift rail.
– Check the shift rails for scoring, wear and smooth operation in the shift forks.
» If there is scoring or corrosion, or if the shift rail in the shift forks is stiff:
– Change the shift rail.
– Check shift shaft sliding plate 5 in contact areas C for wear.
» If the shift shaft sliding plate is worn:
– Change the shift shaft sliding plate.
– Check return surface D on the shift shaft sliding plate for wear.
» If deep notches are present:
,
– Check guide pin E for looseness and wear.
206
ENGINE 18
» If the guide pin is loose and/or worn:

– Preassemble the shift shaft. ( p. 205)

– Check clearance F between the shift shaft sliding plate and
the shift quadrant.
Shift shaft - sliding 0.40 … 0.80 mm (0.0157
plate/shift quadrant play … 0.0315 in)
» If the measured value does not meet specifications:
E02940-10
18.4.21 Disassembling the main shaft

– Secure the main shaft in the vise with the gear teeth facing downward.
Guideline
Use soft jaws.
E03462-10
– Remove second-gear fixed gear 1.

– Remove sixth-gear idler gear 2.
– Remove needle bearing 3 and stop disk 4.
– Remove third/fourth-gear sliding gear 6.
– Remove stop disk 8 and fifth-gear idler gear 9.
– Remove needle bearing bk.
18.4.22 Disassembling the countershaft

– Secure the countershaft in the bench vise with the toothed end facing downward.
207
,
18 ENGINE
Guideline
Use soft jaws.
E03461-10
– Remove stop disk 1 and first-gear idler gear 2.

– Remove needle bearing 3 and stop disk 4.
– Remove fifth-gear sliding gear 5.
– Remove stop disk 7.
– Remove third-gear idler gear 8 and needle bearing 9.
– Remove fourth-gear idler gear bk.
– Remove needle bearing bl.
– Remove stop disk bm.
– Remove lock ring bn.
– Remove sixth-gear sliding gear bo.
– Remove lock ring bp.
– Remove stop disk bq.
– Remove second-gear idler gear br and needle bearing bs.
18.4.23 Checking the transmission

Condition
The transmission has been disassembled.
,
208
ENGINE 18
E03463-10
– Check needle bearings 1 for damage and wear.

– Change the needle bearings.
– Check the pivot points of main shaft 2 and countershaft 3 for damage and wear.
– Change the main shaft and/or countershaft.
– Check the tooth profiles of main shaft 2 and countershaft 3 for damage and wear.
– Change the main shaft and/or countershaft.
– Check the pivot points of idler gears 4 for damage and wear.
– Change the gear wheel pair.
– Check the shift dogs of idler gears 4 and sliding gears 5 for damage and wear.
– Check the tooth faces of idler gears 4, sliding gears 5, and fixed gear 6 for damage and wear.
– Check the tooth profiles of sliding gears 5 for damage and wear.
– Check sliding gears 5 for smooth operation in the profile of main shaft 3.
» If the sliding gear does not move freely:
– Change the sliding gear or the main shaft.
– Check sliding gears 5 for smooth operation in the profile of countershaft 3.
» If the sliding gear does not move freely:
– Change the sliding gear or the countershaft.
– Check stop disks 7 for damage and wear.
– Change the stop disks.
209
,
18 ENGINE
– Use new lock rings 8 in every repair.
18.4.24 Assembling the main shaft
Info
Use new lock rings with every repair.
Preparatory work
– Check the transmission. ( p. 208)
– Carefully lubricate all parts before assembling.
Main work
– Secure the main shaft in the vise with the gear teeth facing downward.
Guideline
Use soft jaws.
E03462-11
– Mount needle bearing 1.

– Mount fifth-gear idler gear 2 with the shift dogs facing up.
– Mount stop disk 3 and lock ring 4.
– Attach third/fourth-gear sliding gear 5 with the small gear wheel facing downward and mount lock ring 6.
– Mount stop disk 7 and needle bearing 8.
– Mount sixth-gear idler gear 9 with the shift dogs facing downward.
– Mount the second-gear fixed gear bk with the collar facing downward.
– Finally, check all the gear wheels for smooth operation.
18.4.25 Assembling the countershaft
Info
Use new lock rings with every repair.
,
210
ENGINE 18
Preparatory work
– Check the transmission. ( p. 208)
– Carefully lubricate all parts before assembling.
Main work
– Secure the countershaft in the bench vise with the toothed end facing downward.
Guideline
Use soft jaws.
E03461-11
– Mount needle bearing 1 and second-gear idler gear 2 onto the countershaft with the protruding collar fac-
ing downward.
– Mount stop disk 3 and lock ring 4.
– Mount the fifth-gear sliding gear 5 with the shift groove facing upward.
– Mount lock ring 6 and stop disk 7.
– Mount needle bearing 8 and the fourth-gear idler gear 9 with the collar facing up.
– Mount needle bearing bk and the third-gear idler gear bl with the collar facing down.
– Mount stop disk bm and lock ring bn.
– Mount sixth-gear sliding gear bo with the shift groove facing downward and stop disk bp.
– Mount needle bearing bq, first-gear idler gear br with the recess facing downward, and stop disk bs.
– Finally, check all the gear wheels for smooth operation.
211
,
18 ENGINE
18.4.26 Checking the electric starter drive

– Check the gear teeth of rotor 1 for damage and wear.
– Change the rotor.
– Check the gear teeth and bearing of the Bendix 2 for smooth
operation, damage, and wear.
» If damaged or worn, or if the Bendix does not move easily:
– Change the Bendix.
– Check gear teeth of starter motor 3 for damage and wear.
E03331-10
– Change starter motor.
– Connect negative cable of a 12-V power supply to the housing
of the starter motor. Connect positive cable of the power sup-
ply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is
closed:
18.5 Engine assembly
18.5.1 Assembling the engine case

Installing the crankshaft and the transmission shaft
– Mount O-ring 1 .
E03316-11
– Position the right section of the engine case in the engine

work stand.
Engine work stand (61229001000) ( p. 323)
( p. 321)
– Warm up the crankshaft bearing.
Guideline
100 °C (212 °F)
E03314-11
– Slide crankshaft 2 all the way into the bearing seat of
the right section of the engine case.
,
212
ENGINE 18
– Oil all bearings.

Engine oil (15W/50) ( p. 314)
– Assemble the two transmission shafts 3 and slide them
into the bearing seats together.
E03313-11
Installing the shift fork, shift drum and shift rails

– Shift fork 4 has a smaller inside diameter; mount this in
the shift groove of the main shaft.
– Mount shift fork 5 in the lower shift groove of the coun-
tershaft.
The side of shift fork 5 with marking out faces the
clutch side.
– Mount shift fork 6 in the upper shift groove of the coun-
tershaft.
The side of shift fork 6 with marking out faces to the
alternator side.
E03465-10
– Push shift drum 7 into the bearing seat.

– Position shift forks 8 in the shift grooves.
Info
Do not misplace the shift rollers.
E03311-11
– Mount shift rails 9 with the springs.
E03310-11
213
,
18 ENGINE
left engine case, assembling

– Clean and degrease the sealing surface.
– Thinly coat the sealing surface A
of the right section of
the engine case with sealing compound.
Loctite® 5910
– Check that dowels bk are seated correctly.
E03345-10
– Mount the left section of the engine case.
Info
Do not use the screws to pull the two sections of
the engine case together.
– Mount screw bl and, once all screws of the left section of

the engine case have been mounted, tighten.
Guideline
E03309-11 Screw, engine case M6x45 10 Nm (7.4 lbf ft)
– Mount screws bm and, once all screws of the left section
of the engine case have been mounted, tighten.
Guideline
Screw, engine case M6x60 10 Nm (7.4 lbf ft)
– Secure the engine in the engine work stand.
– Remove the excess lengths of the engine case gasket in
the area of the cylinder support and the reed valve hous-
ing.
– Grease the radial shaft seal ring and mount distance
sleeve bn .
E03346-10
18.5.2 Preparing the engine for assembly

Preparatory work
– Assemble the engine case. ( p. 212)
Installing the starter motor
– Position the starter motor.
Guideline
Screw, starter motor M6 10 Nm (7.4 lbf ft)
E03308-11
,
214
ENGINE 18
– Position cover 2.
Guideline
Screw, cover, M6 8 Nm (5.9 lbf ft)
starter motor
E03307-11
Installing the reed valve housing

– Position the gasket.
– Position reed valve housing 4 in the engine case open-
ing.
E03306-11
– Position the intake flange with the gasket.

– Mount screws 5 and tighten in a crisscross pattern.
Guideline
Screw, intake M6 6 Nm (4.4 lbf ft)
flange/reed valve
housing
E03305-10
Installing the lock ring, balancer shaft and spacer

– Mount lock ring 6 .
E03304-11
– Mount balancer shaft 7.
E03303-11
215
,
18 ENGINE
– Before mounting, grease spacer 8 in area A and O-

ring9 .
– Position the O-ring in the cut-out of the spacer.
E03347-10
– Grease the radial shaft seal ring.

– Push spacer 8 with the O-ring onto the countershaft with
a twisting motion.
The cut-out with the O-ring must face inward.
The radial shaft seal ring rests against the spacer
along its entire circumference.
E03301-11
18.5.3 Assembling the alternator side

Preparatory work
– Prepare the engine for assembly. ( p. 214)
Installing the rotor
– Position the crankshaft speed sensor.
Guideline
Screw, M5 6 Nm (4.4 lbf ft)
crankshaft Loctite®243™
speed sensor
– Position the rubber grommet in the engine case.
E03281-11
– Mount Bendix 2.
E03280-11
,
216
ENGINE 18
– Ensure that the woodruff key is seated correctly.

– Degrease the cone.
– Mount the rotor and hold it with special tool 3.
Holding wrench (A44029012000) ( p. 329)
– Mount and tighten nut 4 with washer.
Guideline
Nut, rotor M12x1 60 Nm
E03278-10 (44.3 lbf ft)
Installing the alternator cover

– Position alternator cover 5 with the gasket.
Info
Make sure the cylindrical pins are set correctly.

Guideline
E03276-11
Screw, alternator M6 8 Nm (5.9 lbf ft)
cover
18.5.4 Assembling the clutch side

Preparatory work
– Prepare the engine for assembly. ( p. 214)
Installing the shift shaft, shift drum locating unit and locking lever
– Slide shift shaft 1 with the washer into the bearing seat.
Guideline
Ensure that the spring in area A engages correctly
E03300-11
– Position shift drum locating unit 2, pushing shift shaft

sliding plate 3 away from the shift drum locating unit.
Info
Flat surfaces B of the shift drum locating unit are
not symmetric.
– Let the shift shaft sliding plate engage in the shift drum
locating unit.
E03348-10 – Mount and tighten screw 4.
Guideline
Screw, shift M6 10 Nm (7.4 lbf ft)
drum locating Loctite®243™
217
,
18 ENGINE
– Position locking lever 5 with sleeve and spring.

Guideline
Ensure that the spring of the locking lever engages cor-
rectly in the cut-out of the housing.
– Mount screw 6 with the washer and screw in approx. 2
full turns, but do not tighten it fully.
Guideline
Screw, locking M5 6 Nm (4.4 lbf ft)
E03298-11
lever Loctite®243™
– Tension the locking lever and allow it to engage in the shift
drum locating unit.
Guideline
Screw, locking M5 6 Nm (4.4 lbf ft)
– Shift through the transmission.
Mounting the balancer shaft drive wheel and primary gear
– Mount primary gear wheel 7 .
Info
Ensure that the woodruff key is seated properly.
E03352-10
– Mount woodruff key 8.
E03297-11
– Mount balancer shaft drive wheel 9.

– Hold the balancer shaft in place using the special tool bk.
Gear segment (80029004000) ( p. 325)
Info
The marking of the balancer shaft and the marking of
the primary gear must align.
G05822-10
– Mount and tighten screw bl with washer.
Guideline
Screw, bal- M8 30 Nm (22.1 lbf ft)
ancer shaft Loctite®243™
,
218
ENGINE 18
Installing the clutch basket

– Mount collar bushing bm.
– Oil and mount needle bearings bn.
Engine oil (15W/50) ( p. 314)
E03293-11
– bo onto the gearbox main shaft.

Slide clutch basket
– Slide on washer bp and inner clutch hub bq.
Guideline
TeethC of the washer must be aligned with drill
hole D of the shaft.
E03349-10
– Mount nut br with wedge lock washer. Hold the inner

clutch hub using special tool bs
and tighten the nut.
Guideline
Nut, inner clutch M18x1.5 100 Nm
hub (73.8 lbf ft)
Check the cams and gear teeth of the wedge lock washer
for wear and tear before assembly and replace if neces-
sary.
E03291-11
Holding wrench (59029003100) ( p. 322)
Alternative 1
Holding wrench (51129003000) ( p. 320)
– Hold the primary gear wheel using special tool bk.

Gear segment (80029004000) ( p. 325)
– Mount and tighten nut bt.
Guideline
Nut, primary M18LHx1.5 150 Nm (110.6 lbf ft)
gear wheel Loctite®243™
E03354-10
219
,
18 ENGINE
Info
LH thread!
– Crank the engine and check for smooth operation.

Installing the clutch discs
– Thoroughly oil the clutch facing discs.
– Mount intermediate clutch disc E with marking S.
Guideline
Thickness of intermediate 1.0 mm (0.039 in)
clutch disc E
– Alternately place the clutch facing and 7 intermediate
discs into the clutch basket.
E03350-10
Guideline
clutch discs
– Place intermediate clutch disc F into the clutch basket.
Guideline
clutch disc F
– Mount clutch throw-out ck.
E03289-11
– Position clutch pressure cap cl.

– Mount pretension ring cm with marking Top facing up.
E03288-11
– Position spring washer cn.

– Position spring retainer co with marking 1.
– Mount screws cp and tighten incrementally in a crisscross
pattern.
Guideline
Screw, clutch M5 6 Nm (4.4 lbf ft)
spring retainer
E03287-11
,
220
ENGINE 18
– Using a straightedge and the special tool, check the spring

washer for distortion.
Feeler gauge (79129941000) ( p. 324)
Spring washer distortion 0 … 0.10 mm (0 …

0.0039 in)
» If the specified value is not reached:
– Remove screws cp and mount the spring retainer
with marking 2.
Feeler gauge (79129941000) ( p. 324)

0.0039 in)
– Remove screws cp and mount the spring retainer
with marking 3.
E03351-10
Feeler gauge (79129941000) ( p. 324)

0.0039 in)
– Change the clutch facing discs.
clutch and water pump cover, installing
– Mount clutch cover gasket cq
.
Info
Make sure the cylindrical pins are set correctly.
E03355-10
– Position the clutch cover.

– Mount screws cr, but do not tighten yet.
Guideline
Screw, clutch cover M6x25 10 Nm (7.4 lbf ft)
– Mount screws cs and tighten all screws in a crisscross
pattern.
Guideline
E03286-11
221
,
18 ENGINE
– Position the water pump cover with the gasket.

– Mount and tighten screws ct.
Guideline
Bleeder screw, M6x25 8 Nm (5.9 lbf ft)
water pump cover
– Mount and tighten screws dk.
Guideline
E03285-11
Screw, water pump M6x60 10 Nm (7.4 lbf ft)
cover, long
– Mount and tighten screw dl with the seal ring.
Guideline
Bleeder screw, M6x25 8 Nm (5.9 lbf ft)
water pump cover
– Position the shift lever. Mount and tighten screw dm with

washers.
Guideline
Screw, shift M6 14 Nm (10.3 lbf ft)
– Mount clutch push rod dn.
The rounded side faces inwards.
E03282-11
18.5.5 Installing the cylinder and cylinder head

Installing the piston
– Oil the upper conrod bearing and position it in the con-
necting rod.
– Position the piston.
Piston marking 1 must face the exhaust side.
312207-10
– Cover the engine case opening with a cloth.

– Slide piston pin 2 into the connecting rod by hand.
E03274-11
,
222
ENGINE 18
– Position the piston ring locks in the 6 o'clock or 12 o'clock

position.
– Ensure that the piston ring lock is in the correct position
on both sides.
– Remove the cloth.
302973-10
Installing the cylinder

– Place new cylinder base gasket 3 in position.
Info
If neither the piston, cylinder, crankshaft, or engine
case need to be changed, the same gasket thick-
ness can be used as before.
– Oil the cylinder and piston.

E03273-11
– Position the piston ring.

The anti-rotation lock engages in piston ring end 4.
E03358-10
– Slide the cylinder over the piston.

– Push the cylinder down carefully.
– Mount nuts 5 on both sides and tighten in a crisscross
pattern.
Guideline
Nut, cylinder base M10 38 Nm (28 lbf ft)
Info
E03272-11 Raise the cylinder slightly to be able to install the
front nuts.
Checking the X-distance
Info
The X-distance is the distance defined for the piston
protrusion, when the cylinder is clamped down and the
piston is at top dead center position.
The X-distance must be checked very carefully. If the
X-distance is too large, the compression ratio decreases
and the engine loses power. If the X-distance is too
small, the engine knocks and overheats.
The X-distance is adjusted by inserting cylinder base
gaskets of various thicknesses.
223
,
18 ENGINE
(All 250 models)

– Apply special tool 6 to the cylinder.
Setting gauge (54829001100) ( p. 320)
The cut-out faces downward.
– Position the piston at top dead center.
– Check the X-distance using the special tool.
Feeler gauge (79129941000) ( p. 324)
E03357-10
X-distance (upper edge 0 … 0.10 mm (0 …
of piston to special tool) 0.0039 in)
– Replace the cylinder base gasket with a cylin-
der base gasket of the required X-distance.
Info
Multiple cylinder base gaskets can be
combined.
(All 300 models)

– Apply special tool 6 to the cylinder.
Setting gauge (54829001100) ( p. 320)
The cut-out faces upward.
– Position the piston at top dead center.
– Check the X-distance using the special tool.
Feeler gauge (79129941000) ( p. 324)
E03449-10
X-distance (upper edge 0 … 0.10 mm (0 …
of piston to special tool) 0.0039 in)
– Replace the cylinder base gasket with a cylin-
der base gasket of the required X-distance.
Info
Multiple cylinder base gaskets can be
combined.
Setting the Z-distance
Info
The Z-distance is the distance from the lower edge of
the control flap to the upper edge of the cylinder, mea-
sured in the middle of the exhaust port.
,
224
ENGINE 18
– Counterhold screw 7 and loosen nut 8.
E03359-10
– Adjust the Z-distance using the depth micrometer.

Guideline
Z distance (height of con- 50.0 mm (1.969 in)
trol flap) (All 250 models)
– Position the depth micrometer and swivel control flap 9
downwards.
E03356-10
– Adjust the Z-distance by turning screw 7.

The Z-distance is set correctly, the control flap is flush
with the depth micrometer and screw 7 is in contact
with the idler shaft.
– Hold screw 7 and tighten nut 8.
Guideline
Nut, axle for control M5 5 Nm (3.7 lbf ft)
flap
E03359-10
– Check the Z dimension.
Guideline
– Position both covers of the exhaust control with the gas-

kets.
– Mount and tighten screws bk.
Guideline
Screw, exhaust con- M5 6 Nm (4.4 lbf ft)
trol cover
E03271-11
225
,
18 ENGINE
– Position actuator bl.

– Mount and tighten screws bm.
Guideline
Screw, actu- M5 5 Nm (3.7 lbf ft)
ator, exhaust Loctite®243™
control
E03270-11
– Position cover bn.

– Mount and tighten screw bo.
Guideline
Screw, cover, M5 5 Nm (3.7 lbf ft)
actuator, Loctite®243™
exhaust control
Info
E03269-11 If the actuator of the exhaust control has been
removed, the end positions of the exhaust control
must be reprogrammed.
Installing the cylinder head

– Position O-ring bp and bq.
E03268-11
– Mount O-ring br on combustion chamber liner bs.

Guideline
Use the new O-ring.
– Mount combustion chamber liner bs in cylinder head
cover bt.
– Put the cylinder head in place.
Guideline
Ensure that the combustion chamber liner is correctly
seated in the cylinder head cover.
– Mount screws ckwith washers and tighten them in a
crisscross pattern.
Guideline
Screw, cylinder M8 27 Nm
head (19.9 lbf ft)
Info
Use new washers.
E03374-10
,
226
ENGINE 18
– Mount and tighten spark plug cl.

Guideline
Spark plug M14x1.25 25 Nm
(18.4 lbf ft)
E03466-11
18.5.6 Gear oil drain plug, installing

– Mount and tighten gear oil drain plug 1 with the magnet and
a new seal ring.
Guideline
Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft)
with magnet
E03283-10
18.5.7 Removing the engine from the engine work stand

– Remove the fitting from the special tool.
( p. 321)
– Remove the engine from the engine work stand.
E03284-01
227
,
19 CLUTCH
19.1 Checking/correcting the fluid level of hydraulic clutch
Warning
with the eyes.
Note
Info
The fluid level rises with increasing wear of the clutch facing discs.
– Move the hydraulic clutch fluid reservoir mounted on the han-

dlebar into a horizontal position.
– Check the fluid level.
Fluid level below container 4 mm (0.16 in)
rim
E01223-10
» If the level of the fluid does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
screws.
Info
,
228
CLUTCH 19
19.2 Changing the hydraulic clutch fluid
Warning
with the eyes.
Note
Info
– Move the hydraulic clutch fluid reservoir mounted on the han-

dlebar into a horizontal position.
E01223-10
– Fill bleeding syringe 4 with the appropriate hydraulic fluid.

Syringe (50329050000) ( p. 320)
– On the clutch slave cylinder, remove bleeder protection cap,
release the bleeder screw 5and mount bleeding syringe .4
H04934-10
– Now press the fluid into the system until it emerges from
hole 6 of the master cylinder without bubbles.
– Occasionally extract the fluid from the master cylinder reser-
voir to prevent overflowing.
– Remove the bleeding syringe. Tighten the bleeder screw.
Mount the protection cap.
– Correct the fluid level of the hydraulic clutch.
Guideline
E01224-10 Fluid level below container 4 mm (0.16 in)
rim
229
,
19 CLUTCH
screws.
Info
19.3 Checking the clutch

Main work
– Drain the fuel from the fuel tank into a suitable container.
– Lay the vehicle on its side on the work stand.
Info
Remaining fuel may flow out of the fuel tank.
H02264-01
– Detach spring 1.
G05898-10
– Take off the clutch cover with the gasket.
G05899-10
– Loosen screws 3 in a crisscross pattern and remove them.

– 4.
Take off spring retainer
G05831-10
,
230
CLUTCH 19
– Take off spring washer 5.
G05832-10
– Take off pretension ring 6.
G05833-10
– Take off clutch pressure cap 7.
G05834-10
– Take off clutch throw-out 8 with clutch push rod 9.
G05835-10
– Remove sleeves bk.
G05836-10
231
,
19 CLUTCH
– Remove clutch discs bl completely.
G05837-10
– Hold the inner clutch hub with the special tool. Loosen
nut bm .
Holding wrench (51129003000) ( p. 320)
– Remove the nut with the wedge lock washers.
G05838-10
– Take off inner clutch hub bn and washer bo.

Info
The washer usually sticks to the inner clutch hub.
– Take off clutch basket bp.
G05839-10
– Take off needle bearing bq and collar bushing br.

Info
The needle bearing and collar bushing may be in the
clutch basket.
G05840-10
,
232
CLUTCH 19
D02006-11
– Check clutch throw-out 8 for damage and wear.

– Change the clutch throw-out.
– Place the clutch push rod 9 on a flat surface and check for run-out.
– Check spring retainer 4 for damage and wear.
– Change the spring retainer.
– Check pretension ring 6 for damage and wear.
– Change the pretension ring.
– Check spring washer 5 for damage and wear.
– Change the spring washer.
– Check the contact surface of clutch pressure cap 7 for damage and wear.
– Change the clutch pressure cap.
– Check clutch center bs for damage and wear.
– Change the clutch center.
– Check damping rubber pieces bt for damage and wear.
– Change the damping rubber pieces.
– Check inner clutch hub bn for damage and wear.
– Change the inner clutch hub.
– Check the thrust surfaces of the clutch facing discs in clutch basket bp for damage and wear.
– Change the clutch facing discs and the clutch basket.
233
,
19 CLUTCH
– Check needle bearings bq and collar bushing br for damage and wear.
– Change the needle bearings and collar bushing.
– Check intermediate clutch discs ck for damage and wear.
» If the intermediate clutch discs are not level and are pitted:
– Change all intermediate clutch discs.
– Check clutch facing discs cl for discoloration and scoring.
» If there is discoloration or scoring:
– Check the thickness of clutch facing discs cl.
» If the clutch facing disc does not meet specifications:
– Mount collar bushing br and needle bearings bq.
G05840-10
– Mount clutch basket bp.

Turn the clutch basket until the gear teeth of the kick
starter intermediate gear mesh.
– Mount washer bo and inner clutch hub bn.
G05839-10
– Mount nut bm with wedge lock washer. Hold the inner clutch
hub with the special tool and tighten the nut.
Guideline
Nut, inner clutch hub M18x1.5 100 Nm
(73.8 lbf ft)
Check the cams and gear teeth of the wedge lock washer for
wear and tear before assembly and replace if necessary.
G05838-10 Holding wrench (51129003000) ( p. 320)

,
234
CLUTCH 19
– Mount sleeves bk.
D08245-10
– Thoroughly oil the clutch facing discs.

– Mount intermediate clutch disc A with marking S.
Guideline
clutch disc A
– Alternately place the clutch facing and 7 intermediate discs
into the clutch basket.
Guideline
311602-10
clutch discs
– Place intermediate clutch disc B into the clutch basket.
Guideline
clutch disc B
– Mount clutch throw-out 8 with clutch push rod 9.
G05835-10
– Position clutch pressure cap 7.
G05834-10
235
,
19 CLUTCH
– Mount pretension ring 6 with marking Top facing up.
G05833-10
– Position spring washer 5.
G05832-10
– Position spring retainer 4 with marking 1.

– Mount screws 3 and tighten in a crisscross pattern.
Guideline
Screw, clutch spring M5 6 Nm (4.4 lbf ft)
retainer
G05841-10

Feeler gauge (79129941000) ( p. 324)

0.0039 in)
– Remove screws 3 and mount the spring retainer with
marking 2.
Feeler gauge (79129941000) ( p. 324)

0.0039 in)
– Remove screws 3 and mount the spring retainer with
marking 3.
G05842-10
Feeler gauge (79129941000) ( p. 324)
,
236
CLUTCH 19

0.0039 in)
– Change the clutch facing discs.
– Position the clutch cover with the gasket.
Guideline
Screw, outer clutch M6 8 Nm (5.9 lbf ft)
cover
G05899-10
– Attach spring 1.
G05898-10
– Place vehicle in upright position and lean on the side stand.
G05137-10
Finishing work
237
,
20 WATER PUMP, COOLING SYSTEM
20.1 Cooling system

Water pump 1in the engine ensures forced circulation of the
coolant.
The pressure resulting from the warming of the cooling system is
regulated by a valve in radiator cap 2
. This ensures that operat-
ing the vehicle at the specified coolant temperature will not result
in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
S05545-10 The lower the speed, the less the cooling effect. Dirty cooling fins
also reduce the cooling effect.
20.2 Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant antifreeze.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the speci-
fied value:
– Correct the coolant antifreeze.
400243-10
– Check the coolant level in the radiator.
Coolant level A above the 10 mm (0.39 in)

radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 314)
– Mount the radiator cap.
,
238
WATER PUMP, COOLING SYSTEM 20
20.3 Checking the coolant level
Warning
Warning
Condition
The engine is cold.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level A above the 10 mm (0.39 in)

radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
400243-10 Coolant ( p. 314)
– Mount the radiator cap.
20.4 Draining the coolant
Warning
239
,
Warning
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Bleeder screw, water M6x25 8 Nm (5.9 lbf ft)
pump cover
S05545-11
20.5 Refilling with coolant
Warning
Main work
– Make sure that screw 1 is tightened.
S05546-10
,
240
– Pour coolant in up to level A above the radiator fins.

Guideline
10 mm (0.39 in)
Coolant 1.2 l (1.3 qt.) Coolant ( p. 314)
400243-10
– Remove screw 2 and wait until coolant emerges without bub-

bles.
Guideline
Bleeder screw, cylin- M6 10.5 Nm
der head (7.74 lbf ft)
W00102-10

Guideline
10 mm (0.39 in)
Coolant ( p. 314)
400243-10
– Mount radiator cap 3.

Danger
S05547-10
– Allow the engine to warm up and cool down again.

Finishing work
241
,
20.6 Changing the coolant
Warning
Warning
Condition
The engine is cold.
– Remove screw 1. Take off radiator cap 2.
– Place an appropriate container under the water pump cover.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Bleeder screw, water M6x25 8 Nm (5.9 lbf ft)
pump cover
S05545-11

Guideline
10 mm (0.39 in)
Coolant ( p. 314)
400243-10
– Remove screw 3 and wait until coolant emerges without bub-

bles.
Guideline
Bleeder screw, cylin- M6 10.5 Nm
der head (7.74 lbf ft)
W00102-11
,
242

Guideline
10 mm (0.39 in)
Coolant ( p. 314)
400243-10
– Mount radiator cap 2.

Danger
S05547-11
– Allow the engine to warm up and cool down again.

– Check the cooling system for leaks.
20.7 Changing the coolant pipe

Preparatory work
– Drain the coolant. ( p. 239)
Main work
B06161-10
– Slip overflow hose 2 out of the hose guide.
B06162-10
243
,
– Remove radiator shield on both sides.
B06163-10
– Release hose clips 4.

– Pull off the radiator hoses.
B06164-10
– Remove hose clips5.

– Detach radiator 6 and remove to the side.
B06165-10
– Push back protection cap 7 and remove the connector.

– Release hose clips 8.
– Pull off the radiator hose.
B06166-10
,
244
– Remove coolant pipe 9.
B06167-10
– Pull off connecting piece bk to the side and remove.
B06168-10
– Mount new connecting piece bk in the frame.
B06168-11
– Mount and new coolant pipe 9 with new O-ring bl and

tighten.
Guideline
Screw-in fitting, M24x1.5 7.5 Nm (5.53 lbf ft)
cooling system Loctite®243™
Info
Ensure that the O-ring is seated properly.
B06169-10
245
,
– Mount the radiator hose.

– Position and tighten hose clips 8.
– Plug in connector 7 and mount the protection cap.
B06166-10
– Detach the radiator6 and position.

– Ensure that the cable guides in area A are correctly hooked
into the radiator.
B06170-10
– Mount the radiator hoses.

B06164-10
– Position the radiator shield on both sides.

Guideline
chassis
B06163-10
,
246
– Slip overflow hose 2 into the hose guide.
B06162-10

B06161-10
Finishing work
– Refill with coolant. ( p. 240)
247
,
21 THROTTLE VALVE BODY
21.1 Programming ambient air pressure
Danger
Info
If the vehicle is ridden with the engine running at various heights above sea level, the ambient pressure is
programmed on an ongoing basis.
If the vehicle is transported over great differences in height, the ambient pressure must be reprogrammed.
– Start the vehicle at the new height above sea level and switch
off the engine again.
– Wait for at least five seconds.
– Start the vehicle again and check the response of the vehicle.
» If the response has not improved:
– Repeat the procedure.
H02349-01
21.2 Changing the throttle valve body
Note
Preparatory work
Main work
– Remove screw 1.
– Push the frame protector to the front and take off at the bot-
tom.
B06191-10
,
248
THROTTLE VALVE BODY 21

– Unplug hose piece 2.
B06192-10
– Pull fuel vapor valve off the holder and hang it to the side.
B06193-10
– Loosen hose clip 4.
B06194-10
– Loosen screw5.
– Remove screw 6.
B06195-10
– Pivot the subframe up and secure it.
Z01417-10
249
,
– 7.
Push back sleeve
– Remove screws 8 and half-shells 9.
– Detach the throttle cables and take off the grip tube.
B06103-10
– Remove screws bk.

– Take off the cover.
B06196-10
– Unplug connector bl.
B06197-10
– Loosen hose clip bm.

– Pull off the throttle valve body.
B06198-10
– Push back the cover.

– Unplug connectors bn and bo.
– Slip out the throttle valve body with the throttle cable to the
side.
B06199-10
,
250
– Remove screw bp.

– Remove the cover.
B06108-10
– Push back sleeves bq.

– Loosen nuts.
– Detach and remove throttle cables A and B.
– Attach throttle cables A
and B to the new throttle valve
body and route them correctly.
Throttle cable A of the opening cable is hooked in on
the left.
B06109-10
Throttle cable B of the closing cable is hooked in on the
right.
– Mount the cover.
– Mount and tighten screw bp.
Guideline
Screw, throttle valve M5 2.6 Nm
body cover (1.92 lbf ft)
B06108-10
– Plug in connectors bo and bn.

– Slide on the cover.
B06199-10
– Position the throttle valve body in the intake flange.

– Position and tighten hose clip bm.
B06198-10
251
,
– Plug in connector bl.
B06197-10
– Position the cover.

– Mount and tighten screws bk.
Guideline
B06196-10
– Clean the outside of the handlebar and the inside of the grip
tube. Mount the grip tube on the handlebar.
– Attach the throttle cables to the guide plate and route cor-
rectly.
– Position half-shells 9, mount and tighten screws 8.
Guideline
– Slide on sleeve 7 and check the throttle grip for ease of
movement.
B06110-10
Info
Watch out for the intake flange.
– Position the inlet sleeve on the throttle valve body.

Guideline
B06195-10
– Remove screw 5.
,
252
Guideline
– Position and tighten hose clip 4.
B06194-10

– Mount fuel vapor valve on the holder.
Info
Make sure the cables and wiring are routed cor-
rectly.
B06193-11
– Plug in hose piece 2.
B06192-10
– Insert the frame protector from below and push it to the rear.
– Mount and tighten screw 1 with washer.
Guideline
Screw, frame protec- M5 3 Nm (2.2 lbf ft)
tor
B06191-11
Finishing work
253
,
– Check the basic throttle valve position sensor setting.

( p. 254)
21.3 Checking the basic throttle valve position sensor setting

Condition
The diagnostics tool is connected and running.
Preparatory work
Main work
– Remove screw 1 and take off cover 2.
– Turn idle speed adjusting screw 3 counterclockwise all the
way out.
– Pull cold start button 4 and turn it counterclockwise all the
way out.
Neither the idle speed adjusting screw nor the cold start
button touch the cable disk.
E03467-10 – Open the throttle grip 2 times all the way and release.
– Select "Engine control unit" > "Measured values" >
Angepasste vollständig geschlossene Drosselklappenstellung,
Drosselklappensensor Spannung and "Throttle valve position".
Throttle valve position sensor circuit A
0.32 … 0.42 V
"Adapted fully closed throt-
tle valve position"

Throttle valve position 0°
» If the displayed value of Drosselklappensensor Spannung
does not match the value of Angepasste voll-
ständig geschlossene Drosselklappenstellung:
– Perform the basic setting of the throttle valve with the
KTM diagnostics tool. ( p. 256)
– Adjust the idle speed. ( p. 256)
– Set the cold start rev speed increase. ( p. 257)
– Mount cover 2 , mount and tighten screw 1.
Guideline
,
254
21.4 Adjusting the basic throttle position sensor setting

Condition
Preparatory work
Main work
– Remove screw 1 and take off cover 2.
– Turn idle speed adjusting screw 3 counterclockwise all the
way out.
– Pull cold start button 4 and turn it counterclockwise all the
way out.
Neither the idle speed adjusting screw nor the cold start
button touch the cable disk.
E03467-10
– Select "Engine control unit" > "Measured value"

> "Adapted fully closed throttle valve position",
"Throttle position sensor voltage" and "Throttle valve position".
– Remove screws 5 and cover 6.
E03468-10
– Set the "throttle position sensor voltage" by carefully turning
throttle valve position sensor 8
to the setpoint value. Tighten
screws 7
.
Guideline
position sensor (2.58 lbf ft)

E03469-10
"Throttle position sen- 0.40 V
sor voltage"
» If the displayed value is equal to the setpoint value:
– Unplug the VCI and wait until you hear a click from the
power relay.
– Plug in the VCI, open the throttle grip 3 times all the
way and release.
The set value is saved under
"Adjusted fully closed throttle valve position".
Info
The teaching procedure only works for up to
25 seconds after the VCI has been plugged in.
The newly saved value is only displayed after
the measured value block has been restarted.
255
,
– Check measured values of "throttle position sensor volt-

age" and "adjusted fully closed throttle valve position"
again and adjust if necessary.
– Position cover 6.
Guideline
position sensor cover (1.55 lbf ft)
– Adjust the idle speed. ( p. 256)
– Set the cold start rev speed increase. ( p. 257)
E03468-10
– Mount cover 2, mount and tighten screw 1.

Guideline
E03467-10
21.5 Performing the basic setting of the throttle valve with the KTM diagnostics tool
Condition
– Perform "Engine control unit" > "Control unit functions" >
Basic adjustment throttle body.
Info
The instructions must be followed precisely.
» If the specified value is reached:

– Take a test ride.
H02627-01
– Read out the fault memory using the KTM diagnostics
tool.
21.6 Adjusting the idle speed
Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
– Set the idle speed to the specified value.
Condition
,
256

"Throttle valve position".
– Adjust the opening angle of the throttle valve by turning idle
speed adjusting screw . 1
Info
Turning counterclockwise decreases the opening angle
of the throttle valve.
Turning clockwise increases the opening angle of the
S05514-10 throttle valve.
Make the setting in small steps.
(All 250 models)

Opening angle throttle 2.5 … 3.5°
valve position idle
(All 300 models)
Opening angle throttle 3.0 … 4.0°
valve position idle
– Open the throttle grip all the way and close it.
– Check the measured value from "throttle valve position"
Info
Fine adjustments to the idle speed can be made
in the speed range when the engine is at operat-
ing temperature.
21.7 Setting the cold start rev speed increase

Condition
"Throttle valve position".
– Press cold start button 1
, turn it clockwise and set the rev
speed increase until "throttle valve position" attains the speci-
fied value.
Info
Turning counterclockwise decreases the opening angle
of the throttle valve.
E03467-12 Turning clockwise increases the opening angle of the
throttle valve.

Cold start opening angle 4 … 8°
throttle valve position
– Open the throttle grip all the way and close it.
257
,
– Check the measured value from "throttle valve position"

– Pull out the cold start button.
21.8 Cold start button

The cold start button 1 is fitted to the bottom of the throttle
valve body.
The electronic fuel injection system extends the injection time if
the engine is cold and the ambient temperature is low. To help the
engine burn the increased fuel quantity, it must be supplied with
additional oxygen by pushing the cold start button.
Info
Check whether the cold start button has returned to its
S05535-10 basic position.
Possible states
• The cold start button is activated – The cold start button is
pushed in all the way.
• The cold start button is deactivated – The cold start button is
in its basic position.
,
258
EXHAUST CONTROL 22
22.1 Programming the end positions of the exhaust control
Info
Condition
The engine is off.
Preparatory work
Main work
– Pull diagnostics connector 1 off the holder.
D08200-10
– Move throttle grip 2 to where it is half open and hold in posi-

tion.
D08201-10
– Plug wake-up connector A into diagnostics connector 1.

Info
Wake-up connector A is in the motorcycle's separate
enclosure.

The end positions of the exhaust control are read. The pro-
cedure is clearly audible.
D08202-10
The combination instrument lighting is activated, the
combination switch lights up green.
– Release the fixing from the throttle grip.
The end positions of the exhaust control are programmed.
– Wait until you can no longer hear the exhaust control engine
operating.
– Disconnect wake-up connector A from diagnostics connec-
tor 1 .
259
,
22 EXHAUST CONTROL
– Mount diagnostics connector 1 on the holder.
D08200-10
Finishing work
22.2 Programming the end positions of the exhaust control with a diagnostics tool
Info
Condition
Ensure that the battery voltage does not drop below 12.5 V.
– Execute "Engine control unit" > "Control unit functions" >
"Teach in exhaust control actuator".
Info
The instructions must be followed precisely.
» If the specified value is reached:

– Take a test ride.
H02627-01
– Read out the fault memory using the KTM diagnostics
tool.
,
260
LUBRICATION SYSTEM 23
23.1 Changing the gear oil
Warning
Danger of scalding Engine and gear oil get hot when the motorcycle is operated.
– Wear suitable protective clothing and safety gloves.
Note
Info
Drain the gear oil while the engine is at operating temperature.
Preparatory work
– Remove the engine guard. ( p. 55)
– Park the motorcycle on a level surface.
– Position an appropriate container under the engine.
Main work
– Remove gear oil drain plug 1 with magnet.
– Let the gear oil drain fully.
– Thoroughly clean the gear oil drain plug with magnet.
– Clean the sealing surface on the engine.
– Mount and tighten gear oil drain plug 1 with the magnet and
a new seal ring.
Guideline
E00913-10
Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft)
with magnet
– Remove filler plug 2 with the O-ring, and fill up with gear oil.
Gear oil 0.80 l Engine oil
(0.85 qt.) (15W/50)
( p. 314)
– Mount and tighten the filler plug together with the O-ring.
Danger
401955-11 ing them may result in unconsciousness and death.
– Start the engine and check it for leaks.

Finishing work
– Install the engine guard. ( p. 55)
261
,
23 LUBRICATION SYSTEM
23.2 Checking the gear oil level
Info
The gear oil level must be checked when the engine is cold.
Preparatory work
Main work
– Remove gear oil level monitoring screw 1.
– Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add the gear oil. ( p. 262)
– Mount and tighten the gear oil level monitoring screw.
S05549-10 Guideline
Screw, gear oil level M6 8 Nm (5.9 lbf ft)
monitoring
23.3 Adding the gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Gear oil must only be topped up when the engine is cold.
Preparatory work
– Park the motorcycle on a level surface.
Main work
– Detach the foot brake lever spring.
– Remove gear oil level monitoring screw 1.
S05549-10
– Remove filler plug 2 with the O-ring.

– Add gear oil until it emerges from the drill hole of the gear oil
level monitoring screw.
Engine oil (15W/50) ( p. 314)
– Mount and tighten the gear oil level monitoring screw.
Guideline
Screw, gear oil level M6 8 Nm (5.9 lbf ft)
monitoring
401955-11
– Mount and tighten filler plug 2 with the O-ring.

– Attach the foot brake lever spring.
,
262
Danger
– Start the engine and check it for leaks.

Finishing work
23.4 Checking 2-stroke oil level
Warning
Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank.
If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
– As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the
tank is depleted.
– At the next opportunity add 2-stroke oil before you refuel.
– Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully
depleted in error.
Preparatory work
Main work
– Check the 2-stroke oil level in the oil tank.
Info
For a full tank of fuel, the 2-stroke oil tank must be
filled up to at least the upper abutting edge A .
The 2-stroke oil tank must be completely filled if possible.

» If the 2-stroke oil level is too low:
I00444-10
– Add 2-stroke oil. ( p. 264)
23.5 Opening 2-stroke oil tank cap

– Fold loop 1upward.
– Turn the 2-stroke oil tank cap counterclockwise and pull it up.
E00861-10
263
,
23.6 Adding 2-stroke oil
Warning
tank is depleted.
depleted in error.
– Open 2-stroke oil tank cap. ( p. 263)

– Fill the 2-stroke oil tank up to the lower edge A of the filler
neck.
Guideline
Only use 2-stroke oil which is appropriate for separate lubri-
cation.
2-stroke oil tank con- 0.8 l (0.8 qt.) Engine oil, 2-stroke
tent approx. ( p. 314)
– Close 2-stroke oil tank cap. ( p. 264)
M01516-10
23.7 Closing 2-stroke oil tank cap

– Put the 2-stroke oil tank cap on and turn it clockwise.
– Fold loop 1down.
The 2-stroke oil tank cap engages.
E00861-11
23.8 Priming oil pump
Warning
tank is depleted.
depleted in error.
Condition
The engine is off.
Preparatory work
– Remove the seat. (
,
p. 95)
264
– Check 2-stroke oil level. ( p. 263)

Main work
– Pull diagnostics connector 1 off the holder.
I00451-10
– Put throttle grip 2 into full throttle position and secure.
I00452-10
– Plug in wake-up connector 3 for priming the oil pump to the

diagnostics connector .4
The combination instrument lighting is activated.
Info
The connector is included as part of the motorcycle's
separate enclosure.

– Release the fixing from the throttle grip.
The oil pump is timed.
Info
The oil pump is actuated at various speeds.
The procedure is clearly audible.
– Wait until you can no longer hear the oil pump operating.
– Disconnect the wake-up connector from the diagnostics con-
nector.
I00453-10
– Check whether air bubbles are visible in the hose 5.

» If air bubbles are visible:
– Repeat the entire procedure until air bubbles are no
longer visible.
– Mount the diagnostics connector on the holder.
I00454-10
Finishing work
265
,
23.9 Cleaning the oil screen in the oil tank
Note
Preparatory work
Main work
I00456-10
– Remove fuel vapor valve 3 from the bracket and hang it to

the side.
I00457-10
– Loosen clamps 4 of the throttle valve body.

(All EXC models)
– Disconnect plug-in connector 5 of the rear brake light
switch.
I00458-10
– Lift the subframe slightly and secure it.
Info
Pay attention to intake flange 6.
– Pull throttle valve body 7 towards the rear, out of the intake
flange, and hang it to the side.
,
I00459-10
266
– Open hose clamp 8 using a screwdriver.

– Pull off the angle piece and collect the 2-stroke oil in a suit-
able container.
I00460-10
– Remove oil screen 9 and clean it.

– Check the oil screen for damage.
» If the oil screen is damaged:
– Change the oil screen.
S03505-10
– Insert the oil screen and mount the angle piece with a new
hose clamp.
Hose clamp pliers (60029057000) ( p. 323)
I00460-01
– Mount throttle valve body 7.

Info
Pay attention to intake flange 6.
I00459-10
(All EXC models)

– Join plug-in connector 5 of the rear brake light switch.
– Position and tighten clamps 4 of the throttle valve body.
Guideline
Screw, intake M6 6 Nm (4.4 lbf ft)
flange/reed valve
housing
I00458-10
267
,
– Mount fuel vapor valve 3.
I00457-10

Guideline
Guideline
I00456-10 Screw, sub- M8 35 Nm (25.8 lbf ft)
Finishing work
– Prime the oil pump. ( p. 264)
23.10 Changing the oil pump, cleaning the oil screen
Note
Condition
Oil tank is empty.
Preparatory work
,
268
Main work
B06089-10

– Pull the hose off the reed valve housing.
Info
Residual oil may escape from the hose.
B06096-10
B06091-10
B06092-10
– Swivel the oil tank slightly to the side and hold it there.
– Remove screw 5.
– Pull off the hose from the oil tank.
Info
Residual oil may escape from the oil tank.
– Remove the oil pump with the hose.

B06093-10
269
,
– Open hose clamp 6 using a screwdriver and pull off the

angle piece.
B06094-10
– Remove oil screen 7 and clean it.

– Check the oil screen for damage.
» If the oil screen is damaged:
– Change the oil screen.
B06097-10
– Insert the oil screen and mount the angle piece with a new
hose clamp.
Hose clamp pliers (60029057000) ( p. 323)
B06095-10
– Position the new oil pump with the hose.

– Mount the hose from the oil tank.
– Swivel the oil tank slightly to the side and hold it there.
Guideline
Screw, oil pump M6 6 Nm (4.4 lbf ft)
B06093-10
– Position hose clamp 4.
B06092-10
,
270
B06091-10
– Mount hose on the reed valve housing.

– Position hose clamp 2.
B06096-10
– Position the oil tank.

Guideline
Screw, oil tank on M6 5 Nm (3.7 lbf ft)
frame
B06089-10
Finishing work
– Prime the oil pump. ( p. 264)
271
,
24 IGNITION SYSTEM
24.1 Checking the ignition system
Warning
Risk of injury The ignition system is under high voltage.
– Do not touch any affected metal parts or the ends of the connection cables during and immediately
after the measurement.
Preparatory work
Main work
– Unplug the spark plug connector and remove it from the igni-
tion wire.
– Remove the spark plug.
Guideline
Close the spark plug thread in the cylinder head, e.g., with a
suitable spare spark plug.
– Hold the free end of the ignition wire at distance A from
ground.
D08243-10 Guideline
Distance A 5 mm (0.2 in)
Info
– Check the ignition spark.

» If no ignition spark is visible:
– Check the emergency OFF switch.
– Check the wiring harness to the emergency OFF switch.
– Check the stop button.
– Check the ground connection of the engine control unit
and ignition coil.
– Check the cable from the engine control unit to the
ignition coil.
Info
The engine control unit cannot be tested using
simple methods; only using an ignition test
bench.
– Ignition coil - check the primary winding. ( p. 273)

– Check the crankshaft speed sensor. ( p. 275)
– Check the stator winding of the alternator. ( p. 274)
,
272
IGNITION SYSTEM 24
– Mount the spark plug connector on the ignition wire again.

Mount the spark plug in the spark plug connector. Hold the
spark plug to ground.
Info
– Check the ignition spark.

D08246-10 » If no ignition spark is visible:
– Check the spark plug connector. ( p. 273)
– Change the spark plug. ( p. 276)
Finishing work
24.2 Ignition coil - checking the primary winding
Warning
Risk of injury The ignition system is under high voltage.
– Do not touch any affected metal parts or the ends of the connection cables during and immediately
after the measurement.
Condition
Ignition coil cylinder 1 is disconnected.
Ignition coil, cylinder 1 - check the primary winding resistance.
– Measure the resistance between the specified
points.
Ignition coil pin 1 (-) – Ignition coil pin 2 (+)
Ignition coil
Primary winding resis- 0.337 … 0.412 Ω
R02908-10 tance at: 20 °C (68 °F)
» If the displayed value does not correspond to the nomi-
nal value:
– Change the ignition coil.
24.3 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.
Measuring point 1 – Measuring point 2
Spark plug connector

Resistance at: 20 °C 4.3 … 5.7 kΩ
(68 °F)
– Change the spark plug connector.
R02857-10
273
,
24 IGNITION SYSTEM
24.4 Alternator – checking the stator winding

Condition
The stator is disconnected.
Preparatory work
Main work
Stator winding measurement I - check the resistance.
Stator, connector EZ pin 1 – Stator, connector EZ pin 2
Alternator
Stator winding resistance 0.368 … 0.552 Ω
at: 20 °C (68 °F)
» If the indicated value does not correspond to the setpoint
601211-10
value:
– Change the stator.
Stator winding measurement II - check the resistance.
Stator, connector EZ pin 1 – Stator, connector EZ pin 3
Alternator
Stator winding resistance 0.368 … 0.552 Ω
at: 20 °C (68 °F)
» If the indicated value does not correspond to the setpoint
value:
601211-10 D08169-10
Stator winding - checking the short circuit to ground (terminal 31).

Stator, connector EZ pin 1 – Measuring point Ground (−)
Resistance ∞Ω
» If the indicated value does not correspond to the setpoint value:
Finishing work
,
274
IGNITION SYSTEM 24
24.5 Checking the crankshaft speed sensor

Condition
Crankshaft speed sensor is disconnected.
Crankshaft speed sensor, connector AT pin 1 –
Crankshaft speed sensor, connector AT pin 2
Crankshaft speed sensor
Resistance at: 20 °C 80 … 120 Ω
(68 °F)
– Change the crankshaft speed sensor.
400585-10
400585-10 D08169-10

Crankshaft speed sensor, connector AT pin 1 – Measuring point Ground (−)
Resistance ∞Ω
– Connect the multimeter.
– Start the motorcycle to check the function. ( p. 14)
Check the crankshaft speed sensor voltage.
– Measure the voltage between the specified points.
Crankshaft speed sensor, connector AT pin 1 –
Crankshaft speed sensor, connector AT pin 2
Voltage at starting engine 2…4V
speed
400585-10
275
,
24 IGNITION SYSTEM
24.6 Changing the spark plug

Preparatory work
Main work
– Disconnect spark plug connector 1.
B06179-10
– Remove spark plug 2 using a suitable tool.

– Mount and tighten the new spark plug using a suitable tool.
Guideline
Spark plug M14x1.25 25 Nm (18.4 lbf ft)
B06180-10
– Plug in spark plug connector 1.
B06179-10
Finishing work
24.7 Changing the spark plug and spark plug connector

Preparatory work
,
276
IGNITION SYSTEM 24
Main work
– Disconnect spark plug connector 1.
B06179-10
– Remove spark plug 2 using a suitable tool.

– Mount and tighten the new spark plug using a suitable tool.
Guideline
B06180-10
– Remove spark plug connector1.

– Mount new spark plug connector 1.
B06181-10
– Plug in spark plug connector 1.
B06179-10
Finishing work
277
,
24 IGNITION SYSTEM
24.8 Removing the stator

Condition
The alternator cover has been removed.
– Remove cable retainer plate 2 from the alternator cover.
– Remove the stator together with the rubber grommet from the
alternator cover.
E03372-10
24.9 Installing the stator

– Position the stator in the alternator cover.
Guideline
Screw, stator M5 6 Nm (4.4 lbf ft)
Loctite®243™
– Position the rubber grommet in the alternator cover.
– Mount cable retainer plate 2 in the alternator cover.
E03372-10
,
278
ELECTRIC STARTER SYSTEM 25
25.1 Checking the starter motor

Condition
The starter motor has been removed.
– Connect negative cable of a 12-V power supply to the housing
of the starter motor. Connect positive cable of the power sup-
ply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is
closed:
R02772-10
279
,
26 TECHNICAL SPECIFICATIONS
26.1 Engine
Design 1-cylinder 2-stroke engine, water-cooled, with reed
intake and exhaust control
Displacement (All 250 models) 249 cm³ (15.19 cu in)
Displacement (All 300 models) 293.15 cm³ (17.8892 cu in)
Stroke 72 mm (2.83 in)
Hole (All 250 models) 66.4 mm (2.614 in)
Hole (All 300 models) 72 mm (2.83 in)
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Piston Cast aluminum
Piston rings (All 250 models) 2 half keystone rings
Piston rings (All 300 models) 2 rectangular rings
X-distance (upper edge of piston to special tool) 0 … 0.10 mm (0 … 0.0039 in)
Z distance (height of control flap) (All 250 models) 50.0 mm (1.969 in)
Z distance (height of control flap) (All 300 models) 50.0 mm (1.969 in)
Primary transmission 26:72
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission 6-gear transmission, claw shifted
Transmission ratio
first-gear 13:33
second-gear 16:30
third-gear 18:26
fourth-gear 22:26
fifth-gear 23:23
sixth-gear 26:22
Ignition system Electronic ignition
Spark plug NGK BR 7 ES
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Electric starter system
26.2 Tolerance, engine wear limits

Size I 66.340 … 66.350 mm (2.61181 … 2.6122 in)
Size II 66.351 … 66.360 mm (2.61224 … 2.61259 in)
Size I 71.925 … 71.934 mm (2.83169 … 2.83204 in)
Size II 71.935 … 71.944 mm (2.83208 … 2.83244 in)
Size I 66.400 … 66.412 mm (2.61417 … 2.61464 in)
Size II 66.412 … 66.425 mm (2.61464 … 2.61515 in)
Size I 72.000 … 72.012 mm (2.83464 … 2.83511 in)
,
Size II 72.012 … 72.025 mm (2.83511 … 2.83562 in)
280
TECHNICAL SPECIFICATIONS 26

New condition 0.050 … 0.074 mm (0.00197 … 0.00291 in)
New condition 0.066 … 0.088 mm (0.0026 … 0.00346 in)
Ring 1 ≤ 0.60 mm (≤ 0.0236 in)
Ring 2 ≤ 0.60 mm (≤ 0.0236 in)
Ring 1 ≤ 0.40 mm (≤ 0.0157 in)
Ring 2 ≤ 0.40 mm (≤ 0.0157 in)
Cylinder/cylinder head - distortion of sealing surface ≤ 0.10 mm (≤ 0.0039 in)
Connecting rod - axial play of lower conrod bearing 0.60 … 0.70 mm (0.0236 … 0.0276 in)
Crankshaft - run-out at bearing pin ≤ 0.03 mm (≤ 0.0012 in)
Shift shaft - sliding plate/shift quadrant play 0.40 … 0.80 mm (0.0157 … 0.0315 in)
26.3 Engine tightening torques

Screw, inner reed paddles EJOT DELTA PT® 3.5x25 1 Nm (0.7 lbf ft)
Screw, membrane support plate EJOT DELTA PT® 3x12 1 Nm (0.7 lbf ft)
Screw, outer reed paddles EJOT DELTA PT® 3x6 1 Nm (0.7 lbf ft)
Nut, axle for control flap M5 5 Nm (3.7 lbf ft)
Screw, actuator, exhaust control M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, bearing retainer M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, clutch spring retainer M5 6 Nm (4.4 lbf ft)
Screw, control flap, exhaust con- M5 8 Nm (5.9 lbf ft)
trol Loctite®243™
Screw, cover, actuator, exhaust M5 5 Nm (3.7 lbf ft)
control Loctite®243™
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft)
Screw, idler shaft, exhaust control M5 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, retaining bracket of exhaust M5 6 Nm (4.4 lbf ft)
control Loctite®2701™
Screw, stator M5 6 Nm (4.4 lbf ft)
Loctite®243™
Bleeder screw, cylinder head M6 10.5 Nm (7.74 lbf ft)
Bleeder screw, water pump cover M6x25 8 Nm (5.9 lbf ft)
Nut, water pump impeller M6 5 Nm (3.7 lbf ft)
Loctite®243™
281
,
Screw, alternator cover M6 8 Nm (5.9 lbf ft)

Screw, clutch cover M6 10 Nm (7.4 lbf ft)
Screw, cover, starter motor M6 8 Nm (5.9 lbf ft)
Screw, gear oil level monitoring M6 8 Nm (5.9 lbf ft)
Screw, intake flange/reed valve M6 6 Nm (4.4 lbf ft)
housing
Screw, intermediate flange M6 8 Nm (5.9 lbf ft)
Screw, outer clutch cover M6 8 Nm (5.9 lbf ft)
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor M6 10 Nm (7.4 lbf ft)
Screw, water pump cover, long M6x60 10 Nm (7.4 lbf ft)
Screw, balancer shaft M8 30 Nm (22.1 lbf ft)
Loctite®243™
Screw, cylinder head M8 27 Nm (19.9 lbf ft)
Nut, cylinder base M10 38 Nm (28 lbf ft)
Screw, drive chain engine sprocket M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Stud, cylinder base M10 12 Nm (8.9 lbf ft)
Nut, rotor M12x1 60 Nm (44.3 lbf ft)
Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)
Nut, primary gear wheel M18LHx1.5 150 Nm (110.6 lbf ft)
Loctite®243™
26.4 Capacities
26.4.1 Gear oil

Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 314)
26.4.2 Engine oil

2-stroke oil tank content approx. 0.8 l (0.8 qt.) Engine oil, 2-stroke ( p. 314)
26.4.3 Coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 314)
26.4.4 Fuel
Total fuel tank capacity, approx. 9 l (2.4 US gal) Super unleaded (ROZ 95)
( p. 315)
,
282
Fuel reserve, approx. 1.5 l (1.6 qt.)
26.5 Chassis
Frame Central tube frame made of chrome molybdenum steel
tubing
Fork WP XPLOR CC
Shock absorber WP PDS
Suspension travel
front 300 mm (11.81 in)
Suspension travel
rear 310 mm (12.2 in)
Fork offset 22 mm (0.87 in)
Brake system Disc brakes, floating brake calipers
Brake discs - diameter
front 260 mm (10.24 in)
rear 220 mm (8.66 in)
Brake discs - wear limit (All standard models)
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
Brake discs - wear limit (All special models)
front 2.5 mm (0.098 in)
rear 3.7 mm (0.146 in)
Street tire pressure (All EXC models)
Offroad tire pressure
Secondary ratio 14:45 (13:45)
Chain 5/8 x 1/4"
Rear sprockets available 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase 1,890 ± 10 mm (74.41 ± 0.39 in)
Seat height unloaded 963 mm (37.91 in)
Ground clearance unloaded 347 mm (13.66 in)
Weight without fuel, approx. (All standard models) 104.6 kg (230.6 lb.)
Weight without fuel, approx. (All SIX DAYS models) 104.9 kg (231.3 lb.)
Weight without fuel, approx. (All HARDENDURO mod- 106.1 kg (233.9 lb.)
els)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)
283
,
26.6 Electrical system

12-V battery HJTZ5S-FP-C Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
Combination instrument battery CR 2430 Battery voltage: 3 V
Fuse 58011109120 20 A
Headlight LED
Parking light LED
Indicator lamps (All EU/ASEAN W2.3W / socket W2x4.6d 12 V
models, All XC-W and special mod- 2.3 W
els)
Turn signal (All EXC models) R10W / socket BA15s 12 V
10 W
Brake/tail light LED
License plate lamp (All EXC mod- LED
els)
26.7 Tires
Validity Front tire Rear tire
(All standard EXC models) 90/90 - 21 M/C 54R M+S TT 140/80 - 18 M/C 70R M+S TT
MAXXIS Maxx Enduro MAXXIS Maxx Enduro
(All special models) 90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT
Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME
(All XC‑W models) 80/100 - 21 51M TT 110/100 - 18 64M TT
Dunlop GEOMAX MX 33 F Dunlop GEOMAX MX 33
The tires specified represent one of the possible series production tires. For alternative manufacturers, if any,
contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the
respective technical specifications must be observed. Additional information is available in the Service section
under:
KTM.COM
26.8 Fork
Fork article number A490C163X402000
Fork WP XPLOR CC
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 7 clicks
Rebound damping
Comfort 19 clicks
Standard 17 clicks
Sport 9 clicks
Spring length with preload spacer(s) 476 mm (18.74 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.2 N/mm (24 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.4 N/mm (25.1 lb/in)
,
284
Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.6 N/mm (26.3 lb/in)

Fork length 940 mm (37.01 in)
Oil capacity, cartridge 175 ml (5.92 fl. oz.) Fork oil (SAE 4) (48601166S1)
( p. 315)
Oil capacity, external mechanism 390 ml (13.19 fl. oz.) Fork oil (SAE 4) (48601166S1)
( p. 315)
26.9 Shock absorber

Shock absorber article number A490C463X305000
Shock absorber WP PDS
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 66 N/mm (377 lb/in)
Spring length 225 mm (8.86 in)
Static sag 38 mm (1.5 in)
Riding sag 110 mm (4.33 in)
Fitted length 402.7 mm (15.854 in)
Shock absorber fluid ( p. 315) SAE 2.5
26.10 Chassis tightening torques

Hose connector, active carbon fil- - 3.8 Nm (2.8 lbf ft)
ter
Mushroom head screw for spoiler 2.5 Nm (1.84 lbf ft)
and seat
Remaining screws, chassis EJOT PT® K60x25‑Z 2 Nm (1.5 lbf ft)
Screw, emergency OFF switch (All EJOT PT® K50x18 T20 2 Nm (1.5 lbf ft)
EXC models)
Screw, fuel pump EJOT PT® K60x30 Z 2.5 Nm (1.84 lbf ft)
Screw, hose clip, inlet sleeve 2.8 Nm (2.07 lbf ft)
Screw, intake air temperature sen- EJOT DELTA PT® K50x18 T20 0.7 Nm (0.52 lbf ft)
sor
285
,
Screw, oil fill level sensor EJOT PT® 50x18 T25 7 Nm (5.2 lbf ft)
Screw, oil pump holder on oil tank EJOTDELTA PT 45x12-Z 0.7 Nm (0.52 lbf ft)
Screw, pressure regulator EJOT PT® K60x25‑Z 2.3 Nm (1.7 lbf ft)
Screw, radiator hoses clip 2.4 Nm (1.77 lbf ft)
Screw, subframe with filter box EJOT PT® K60x20AL 5 Nm (3.7 lbf ft)
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft)
Screw, frame protector M5 3 Nm (2.2 lbf ft)
Screw, light switch (All EXC mod- M5 1 Nm (0.7 lbf ft)
els)
Screw, shock absorber adjusting M5 5 Nm (3.7 lbf ft)
ring
Screw, throttle valve body cover M5 2.6 Nm (1.92 lbf ft)
Screw, turn signal switch (All M5 1 Nm (0.7 lbf ft)
EXC models)
Nut, cable on starter motor M6 4 Nm (3 lbf ft)
Nut, throttle cable wire on throttle M6 3 Nm (2.2 lbf ft)
valve body
Screw, battery support bracket M6 6 Nm (4.4 lbf ft)
Screw, brake lever M6 5 Nm (3.7 lbf ft)
Screw, brake line guide for link M6 4.5 Nm (3.32 lbf ft)
fork
Screw, cable on starter relay M6 6 Nm (4.4 lbf ft)
Screw, chain guide M6 10 Nm (7.4 lbf ft)
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, clutch lever M6 5 Nm (3.7 lbf ft)
Screw, connector board incl. com- M6 5 Nm (3.7 lbf ft)
bination instrument
Screw, fender to triple clamp M6 12 Nm (8.9 lbf ft)
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, fuel tank spoiler on radiator M6 6 Nm (4.4 lbf ft)
Screw, ground wire in tail section M6 10 Nm (7.4 lbf ft)
Screw, manifold on silent block M6 6 Nm (4.4 lbf ft)
Screw, oil pump M6 6 Nm (4.4 lbf ft)
Screw, oil tank cap M6 6 Nm (4.4 lbf ft)
Screw, oil tank on frame M6 5 Nm (3.7 lbf ft)
Screw, push rod ball joint on the M6 10 Nm (7.4 lbf ft)
rear brake cylinder Loctite®243™
,
286
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)

Loctite®243™
Screw, seat fixing M6 8 Nm (5.9 lbf ft)
Screw, silent block on frame M6 6 Nm (4.4 lbf ft)
Fuel connection on fuel pump M8 15 Nm (11.1 lbf ft)
Nut, foot brake lever M8 20 Nm (14.8 lbf ft)
Nut, pull switch (All XC‑W models) M8 0.8 Nm (0.59 lbf ft)
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft)
Rear brake lever stop nut M8 20 Nm (14.8 lbf ft)
Screw, bottom triple clamp (All M8 15 Nm (11.1 lbf ft)
standard models)
Screw, bottom triple clamp (All M8 12 Nm (8.9 lbf ft)
special models)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft)
Screw, engine brace M8x15 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, engine brace M8x20 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, engine sprocket cover M8 15 Nm (11.1 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, manifold M8 15 Nm (11.1 lbf ft)
Screw, side stand fixing M8x26 33 Nm (24.3 lbf ft)
Loctite®2701™
Screw, subframe bottom M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, subframe, top M8 35 Nm (25.8 lbf ft)
Loctite®243™
Screw, top steering stem (All stan- M8 20 Nm (14.8 lbf ft)
dard models)
Screw, top steering stem (All spe- M8 17 Nm (12.5 lbf ft)
cial models) Loctite®243™
Screw, top triple clamp (All stan- M8 20 Nm (14.8 lbf ft)
dard models)
Screw, top triple clamp (All special M8 17 Nm (12.5 lbf ft)
models)
Screw, wheel speed sensor on axle M8 4.5 Nm (3.32 lbf ft)
clamp
Engine bracket screw M10 60 Nm (44.3 lbf ft)
287
,
Screw, brake caliper on brake M10 45 Nm (33.2 lbf ft)

caliper bracket Loctite®243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Loctite®243™
Temperature sensor water to t- M10 10 Nm (7.4 lbf ft)
plate
Nut, fuel pump M12 15 Nm (11.1 lbf ft)
Screw, bottom shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Screw, top shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft)
Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft)
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
Nut, wheel spindle, rear M22x1.5 80 Nm (59 lbf ft)
Screw-in fitting, cooling system M24x1.5 7.5 Nm (5.53 lbf ft)
Loctite®243™
,
288
CLEANING, CARE 27
27.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
– Close off exhaust system to keep water from entering.

– Remove the coarse dirt particles with a gentle water jet.
– Spray the heavily soiled parts with a normal commercial motor-
cycle cleaner and clean using a brush.
Motorcycle cleaner ( p. 317)
Info
Use warm water containing normal motorcycle cleaner
401061-01 and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always
rinse the vehicle with water first.
– 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 Moisture and dirt impair the
brake system.
– Brake carefully several times to dry out and remove
dirt from the brake linings and the brake discs.
– After cleaning, ride the vehicle a short distance until the

engine warms up.
Info
The heat produced causes water at inaccessible loca-
tions in the engine and on the brake system to evapo-
rate.
– After the motorcycle has cooled down, lubricate all moving

parts and pivot points.
289
,
27 CLEANING, CARE
– Treat bare metal (except for brake discs and the exhaust sys-
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 317)
– Treat all plastic parts and powder-coated parts with a mild
cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 317)
(All EXC models)
– Oil the steering lock.
Universal oil spray ( p. 317)
27.2 Checks and maintenance steps for winter operation
Info
If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precau-
tions against aggressive road salt.
If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water
enhances the corrosive effects of salt.
– Clean the motorcycle. ( p. 289)

– Clean the brakes.
Info
After EVERY trip on salted roads, thoroughly clean the
brake calipers and brake linings, after they have cooled
down and without removing them, with cold water and
dry them carefully.
After riding on salted roads, thoroughly clean the vehi-
401060-01 cle with cold water and dry it well.
– Treat engine, link fork, and all other bare or zinc-plated parts
(except the brake discs) with a wax-based corrosion inhibitor.
Info
Corrosion inhibitor must not come in contact with the
brake discs as this would greatly reduce the braking
force.

,
290
STORAGE 28
28.1 Storage
Warning
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them per-
formed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements
are necessary, you should do this during the storage period (less workshop overload). In this way, you can
avoid long workshop waiting times at the start of the new season.
– Clean the motorcycle. ( p. 289)

– Change the gear oil. ( p. 261)
– Check the antifreeze and coolant level. ( p. 238)
– When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Fuel additive ( p. 316)
– Refuel.
401058-01
Tip
Fill the fuel tank completely as specified, using fuel
with the lowest possible ethanol content.

– Check tire pressure. ( p. 111)
– Remove the 12-V battery. ( p. 133)
– Charge the 12-V battery.
Guideline
Ideal charging and storage 10 … 20 °C (50 … 68 °F)
temperature of the lithium-
ion battery
– Store the vehicle in a dry location that is not subject to large
fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.

– Cover the vehicle with a tarp or a similar cover that is perme-
able to air.
291
,
28 STORAGE
Info
Do not use non-porous materials since they prevent
humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Because
the engine will not warm up sufficiently, the water
vapor produced during combustion will condense, caus-
ing engine parts and the exhaust system to rust.
28.2 Preparing for use after storage

– Install the 12-V battery. ( p. 134)
– Perform checks and maintenance measures when preparing for
use.
– Make a test ride.
401059-01
,
292
SERVICE SCHEDULE 29
29.1 Additional information

Any further work that results from the service work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.
29.2 Service schedule

every 24 months
Every 90 operating hours
After 15 operating hours / Every 15 operating hours
After 1 operating hour
Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ●
Check that the electrical system is functioning properly. ○ ● ● ●
Check and charge the 12-V battery. ○ ● ● ● ●
Check that the brake linings of the front brake are secured. ( p. 140) ● ● ● ●
Check that the brake linings of the rear brake are secured. ( p. 147) ● ● ● ●
Check the brake discs. ( p. 112) ● ● ● ●
Check the brake lines for damage and tightness. ● ● ● ●
Check the front brake fluid level. ( p. 143) ● ●
Change the front brake fluid. ( p. 145) ● ●
Check the rear brake fluid level. ( p. 151) ● ●
Change the rear brake fluid. ( p. 152) ● ●
Check/correct the fluid level of hydraulic clutch. ( p. 228) ●
Change the hydraulic clutch fluid. ( p. 229) ● ●
Check the free travel of the hand brake lever. ( p. 142) ○ ● ● ● ●
Check the free travel of the foot brake lever. ( p. 149) ● ● ● ●
Check the idle speed. ○ ● ● ● ●
Change the gear oil. ( p. 261) ○ ● ● ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for crack- ○ ● ● ● ●
ing, tightness, and correct routing.
Check the cables for damage and that there are no kinks in the routing. ● ● ● ●
Check that the throttle cables are undamaged, routed without kinks, and set correctly. ● ● ● ●
Check the frame. ( p. 53) ● ● ●
Check the link fork. ( p. 79) ● ● ●
Check the fork bearing for play. ( p. 79) ● ●
Check the shock absorber heim joint for play. ( p. 79) ● ●
Check the tire condition. ( p. 111) ● ● ● ●
Check tire pressure. ( p. 111) ● ● ● ●
Check the wheel bearing for play. ( p. 112) ● ● ●
Check the wheel hubs. ● ● ●
Check the rim run-out. ( p. 113) ○ ● ● ●
Check the spoke tension. ( p. 114) ○ ● ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 125) ○ ● ● ●
Check the chain tension. ( p. 125) ○ ● ● ● ●
293
,
29 SERVICE SCHEDULE
every 24 months
After 15 operating hours / Every 15 operating hours
After 1 operating hour
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth ○ ● ● ● ●
operation.
Check the basic throttle valve position sensor setting. ( p. 254) ○ ● ● ●
Change the spark plug and spark plug connector. ( p. 276) ● ●
Change the fuel filter. ( p. 100) ● ●
Check the clutch. ( p. 230) ● ●
Clean the air filter and air filter box. ( p. 93) ● ● ● ●
Change the glass fiber yarn filling of the main silencer. ( p. 89) ●
Service the fork. ( p. 19) ● ●
Perform the shock absorber service. ( p. 63) ● ●
Check all screws, nuts, and hose clips for a tight fit. ○ ● ● ● ●
Change the fuel screen. ( p. 99) ○ ● ● ● ●
Check the fuel pressure. ( p. 105) ○ ● ● ● ●
Check the antifreeze and coolant level. ( p. 238) ● ●
Check the coolant level. ( p. 239) ○ ●
Change the coolant. ( p. 242) ●
Check that the radiator fan is functioning properly. (All special models) ○ ● ● ●
Check the headlight setting. ( p. 156) ○ ● ● ●
Check the steering head bearing for play. ( p. 43) ○ ●
Lubricate the steering head bearing. ( p. 39) ● ● ●
Check the reed valve housing, reed valve and intake flange. ( p. 199) ● ●
Check the electric starter drive. ( p. 212) ● ● ●
Change the oil pump; clean the oil screen. ( p. 268) ●
Clean the oil screen in the oil tank. ( p. 266) ●
Perform minor engine service. (Change the piston. Check the cylinder head. Change ● ●
the O-rings of the manifold and the cylinder head. Check the cylinder and Z dimension.
Check the exhaust control for function and smooth operation. Check and clean the crank
chamber pressure sensor hose and clean.)
Perform major engine service including removing and installing the engine. (Change the ●
connecting rod, conrod bearing, and crank pin. Check the transmission and the shift
mechanism. Change all the engine bearings, the radial shaft seal rings and the seals.)
Final check: Check the vehicle for operating safety and take for a test ride. ○ ● ● ● ●
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ●
Make a service entry in KTM Dealer.net. ○ ● ● ● ●
○ One-time interval
● Periodic interval
,
294
SERVICE SCHEDULE 29
295
,
30 WIRING DIAGRAM
30.1 Page 1 of 5 (All EXC models)
Y02965-01
,
296
WIRING DIAGRAM 30
Components:
A10 Vehicle system control unit
A11 Engine control unit
G10 12-V battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
M13 Fuel pump
M14 Radiator fan (if installed)
S34 Combination switch, right
T20 Voltage regulator
297
,
30 WIRING DIAGRAM
Y02966-01
,
298
WIRING DIAGRAM 30
Components:
B46 Oil level sensor
B76 Front brake light switch
B77 Rear brake light switch
E75 Headlight unit
M35 Oil pump
P15 Horn
P27 Oil level warning lamp
P36 Brake/tail light
S33 Combination switch, left
299
,
30 WIRING DIAGRAM
Y02967-01
,
300
WIRING DIAGRAM 30
Components:
E60 License plate lamp
P21 Turn signal indicator lamp
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S33 Combination switch, left
301
,
30 WIRING DIAGRAM
Y02968-01
,
302
WIRING DIAGRAM 30
Components:
A41 Connectivity Unit (if installed)
B32 Fuel level sensor
B70 Front wheel speed sensor
M51/1 Injection valve 1, cylinder 1
P10 Combination instrument
P36 Brake/tail light
R30 Terminating resistor (if installed)
S53 Map Select switch (if installed)
X295 Diagnostics connector
303
,
30 WIRING DIAGRAM
Y02969-01
,
304
WIRING DIAGRAM 30
Components:
B12 Intake air temperature sensor
B13 Ambient air pressure sensor
B21 Coolant temperature sensor
B26 Tilt sensor
B37 Crankshaft speed sensor
B41 Induction manifold pressure sensor
B43 Throttle valve position sensor
B51 Lambda sensor (if installed)
M20 Fuel vapor valve
R51 Ignition coil
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
305
,
30 WIRING DIAGRAM
30.6 Page 1 of 4 (All XC‑W models)
Y03001-01
,
306
WIRING DIAGRAM 30
Components:
G10 12-V battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
M13 Fuel pump
S34 Combination switch, right
T20 Voltage regulator
307
,
30 WIRING DIAGRAM
Y03002-01
,
308
WIRING DIAGRAM 30
Components:
B46 Oil level sensor
E75 Headlight unit
M14 Radiator fan (if installed)
M35 Oil pump
P27 Oil level warning lamp
P37 Tail light
S30 Light switch
309
,
30 WIRING DIAGRAM
Y03003-01
,
310
WIRING DIAGRAM 30
Components:
A41 Connectivity Unit (if installed)
B32 Fuel level sensor
B70 Front wheel speed sensor
M22 Exhaust control actuator
P10 Combination instrument
R30 Terminating resistor (if installed)
S53 Map Select switch (if installed)
X295 Diagnostics connector
311
,
30 WIRING DIAGRAM
Y03004-01
,
312
WIRING DIAGRAM 30
Components:
B12 Intake air temperature sensor
B13 Ambient air pressure sensor
B21 Coolant temperature
B26 Tilt sensor
B37 Crankshaft speed sensor
B41 Induction manifold pressure sensor
B43 Throttle valve position sensor
R51 Ignition coil
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
313
,
31 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade
and unsuitable antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec-
tion and lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that
has the relevant properties.
Antifreeze protection to at least −25 °C (−13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs
to be diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.
MOTOREX®
– COOLANT M3.0
Engine oil (15W/50)

– JASO T903 MA2 ( p. 335)
– SAE ( p. 335) (15W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
MOTOREX®
– Top Speed 4T
Engine oil, 2-stroke

– JASO FD ( p. 335)
Guideline
– Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
,
314
SUBSTANCES 31
MOTOREX®
– Cross Power 2T
Fork oil (SAE 4) (48601166S1)

– SAE ( p. 335) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Shock absorber fluid (SAE 2.5) (50180751S1)

– SAE ( p. 335) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Super unleaded (ROZ 95)

– DIN EN 228 (ROZ 95)
Guideline
– Only use super unleaded fuel that matches or is equivalent to the specified standard.
– Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15,
E25, E85, E100).
315
,
32 AUXILIARY SUBSTANCES
Air filter cleaner

MOTOREX®
– Racing Bio Dirt Remover
Chain cleaner
MOTOREX®
– Chain Clean
Fuel additive
MOTOREX®
– Fuel Stabilizer
High viscosity grease

SKF®
– LGHB 2
Long-life grease
MOTOREX®
– Bike Grease 2000
Lubricant (T14034)
WP Performance Systems
– WP Racing Grease IPR 2
Lubricant (T159)
Bel‑Ray®
– MC‑11®
Lubricant (T625)
Molykote®
– 33 Medium
Lubricant (T158)
Lubcon®
– Turmogrease® PP 300
,
316
AUXILIARY SUBSTANCES 32
Motorcycle cleaner
MOTOREX®
– Moto Clean
Off-road chain spray

MOTOREX®
– Chainlube Offroad
Oil for foam air filter

MOTOREX®
– Racing Bio Liquid Power
Preserving materials for paints, metal and rubber

MOTOREX®
– Moto Protect
Silicone spray
MOTOREX®
– Silicone Spray
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
MOTOREX®
– Quick Cleaner
Special grease (00062010053)

Klüber Lubrication®
– Klüberfood NH1 34‑401
Universal oil spray

MOTOREX®
– Joker 440 Synthetic
317
,
33 SPECIAL TOOLS
Cable connector unlocking kit

Art. no.: 00029014000
H02257-01
Diagnostics adapter cable

Art. no.: 00029094033
Feature
Length approx. 25.8 cm (10.16 in)
501448-01
Break out box

Art. no.: 00029095001
H01895-01
Adapter and template M3C

Art. no.: 00029095013
H02568-01
,
318
SPECIAL TOOLS 33
EU battery charger XCharge‑professional

Art. no.: 00029095050
Feature
EU safety plug
Nominal voltage 230 V
Mains fuse 16 A
Power cable length 5 m (16 ft)
approx.
Charger cable length 5 m (16 ft)
H01065-01
approx.
US battery charger XCharge‑professional

Art. no.: 00029095051
Feature
US plug
Mains fuse 32 A
approx.
H01065-01
approx.
UK battery charger XCharge‑professional

Art. no.: 00029095052
Feature
UK safety plug
Mains fuse 16 A
approx.
H01065-01
approx.
Puller
Art. no.: 46129021000
H01519-01
319
,
33 SPECIAL TOOLS
Syringe
Art. no.: 50329050000
500689-01
Holding wrench
Art. no.: 51129003000
H00575-01
Setting gauge
Art. no.: 54829001100
H00583-01
Separator plate
Art. no.: 54829009000
H00584-01
,
320
SPECIAL TOOLS 33
Insert for crankshaft pressing tool

Art. no.: 54829108000
H00994-01
Holder and fitting for work stand

Art. no.: 55429002000
H01175-01
Puller
Art. no.: 58429037043
Feature
Inside diameter 43.9 mm (1.728 in)
H00598-01
Tool bracket
Art. no.: 58429089000
H00603-01
321
,
33 SPECIAL TOOLS
Pressing tool
Art. no.: 58429091000
H00604-01
Pressing tool
Art. no.: 58429092000
H00605-01
Torque wrench kit

Art. no.: 58429094000
Feature
Torque 3 … 15 Nm (2.2 … 11.1 lbf ft)
Open ended bit 3.9 mm (0.154 in)
H00606-01
Bit diameter 5.9 mm (0.232 in)
Holding wrench
Art. no.: 59029003100
H00609-01
,
322
SPECIAL TOOLS 33
Hose clamp pliers

Art. no.: 60029057000
H00650-01
Testing hose
Art. no.: 61029093000
H00659-01
Pressure testing tool

Art. no.: 61029094000
H00660-01
Engine work stand

Art. no.: 61229001000
H00662-01
323
,
33 SPECIAL TOOLS
Crankshaft pressing tool

Art. no.: 75029047000
H00714-01
Lift stand
Art. no.: 78129955100
Feature
Height 315 … 425 mm (12.4 … 16.73 in)
Load ≤ 150 kg (≤ 331 lb.)
H00980-01
Feeler gauge
Art. no.: 79129941000
Feature
20 pieces 0.05 … 1.00 mm (0.002 … 0.0394 in)
502993-01
Puller
Art. no.: 79229032044
H00808-01
,
324
SPECIAL TOOLS 33
Gear segment
Art. no.: 80029004000
H00813-01
Hook wrench
Art. no.: 90129051000
H00831-01
Diagnostics tablet
Art. no.: 00029XC2001
H02645-01
Hand strap
Art. no.: 00029XC2002
H02883-01
325
,
33 SPECIAL TOOLS
Battery charger
Art. no.: 00029XC2003
H02882-01
VCI
Art. no.: 00029XC2004
H02646-01
VCI attachment
Art. no.: 00029XC2005
H03078-01
Protective film
Art. no.: 00029XC2006
500361-01
,
326
SPECIAL TOOLS 33
Diagnostics cable extension

Art. no.: 00029XC2007
Feature
Length approx. 1.15 m (3.77 ft)
H02880-01
USB cable
Art. no.: 00029XC2008
Feature
Length approx. 5 m (16 ft)
H02879-01
12-V power supply cable

Art. no.: 00029XC2009
H02881-01
RideRecorder trigger
Art. no.: 00029XC2010
H02648-01
327
,
33 SPECIAL TOOLS
Case
Art. no.: 00029XC2011
H03082-01
Docking station
Art. no.: 00029XC2012
H03077-01
Wall attachment
Art. no.: 00029XC2013
H03080-01
Battery
Art. no.: 00029XC2014
H03079-01
,
328
SPECIAL TOOLS 33
Input stylus
Art. no.: 00029XC2015
H03083-01
Spring hook
Art. no.: 50305017000C1
500454-01
Holding wrench
Art. no.: A44029012000
502386-01
Retaining bracket
Art. no.: A44029065000
502587-01
329
,
33 SPECIAL TOOLS
Depth micrometer
Art. no.: T107S
H00842-01
Drift
Art. no.: T120
Feature
H00844-01
Pressing tool
Art. no.: T1206
Feature
Diameter 15 … 30 mm (0.59 … 1.18 in)
H00880-01
Pressing tool
Art. no.: T1207S
H00881-01
,
330
SPECIAL TOOLS 33
Vacuum pump
Art. no.: T1240S
H00890-01
Protecting sleeve
Art. no.: T1401
Feature
H00894-01
Clamping stand
Art. no.: T14015S
Feature
H01035-01
Clamping stand
Art. no.: T14016S
Feature
H01036-01
331
,
33 SPECIAL TOOLS
Ring wrench
Art. no.: T14017
Feature
Hexagonal part 50 mm (1.97 in)
H00904-01
Calibrating unit
Art. no.: T14021
Feature
H00908-01
Clamping stand
Art. no.: T1403S
Feature
H00896-01
Mounting tool
Art. no.: T14040S
Feature
H00922-01
,
332
SPECIAL TOOLS 33
Pressing tool
Art. no.: T14076
Feature
Diameter 11.95 … 14 mm (0.4705 … 0.55 in)
T04207-10
Special socket
Art. no.: T14084
Feature
Drive 1/2 in
H01518-01
Mounting sleeve
Art. no.: T1554
Feature
H00903-01
Filling tool
Art. no.: T170S1
H00855-01
333
,
33 SPECIAL TOOLS
Filling adapter
Art. no.: T18001
Z02292-10
Socket
Art. no.: T18004
Feature
Drive 1/2 in
Z02290-10
Clamping stand
Art. no.: T531S
Feature
H02439-01
,
334
STANDARDS 34
JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2
standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor-
cycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high
performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils
according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of
racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even
under extreme operating conditions.
335
,
35 LIST OF ABBREVIATIONS
Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly
,
336
INDEX
Brake lining retainers

INDEX
1 of front brake, checking . . . . . . . . . . . . . . . 140

12-V battery of rear brake, checking . . . . . . . . . . . . . . . 147
charging . . . . . . . . . . . . . . . . . . . . . . . . . 135 Brake linings
negative cable, connecting . . . . . . . . . . . . . 133 of front brake, changing . .... . . . . . . . . . 140
12-V battery of front brake, checking . . .... . . . . . . . . . 140
installing . . . . . . . . . . . . . . . . . . . . . . . . . 134 of rear brake, checking . . .... . . . . . . . . . 147
negative cable, disconnecting . . . . . . . . . . . 132 of the rear brake, changing ... . . . . . . . . . 147
removing . . . . . . . . . . . . . . . . . . . . . . . . . 133 C
2 Capacity
2-stroke oil level coolant . . . . . . . . . . . . . . . . . . . . . . 241, 282
checking . . . . . . . . . . . . . . . . . . . . . . . . . 263 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Gear oil . . . . . . . . . . . . . . . . . . 173, 261, 282
2-stroke oil tank cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Cartridge
opening . . . . . . . . . . . . . . . . . . . . . . . . . . 263 assembling . . . . . . . . . . . . . . . . . . . . . . . . 34
disassembling . . . . . . . . . . . . . . . . . . . . . . 22
A
Chain
Air filter checking . . . . . . . . . . . . . . . . . . . . . . . . . 125
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 93 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 124
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Chain guide
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 92
checking . . . . . . . . . . . . . . . . . . . . . . . . . 125
Air filter box
Chain tension
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 93
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 128
Air filter box cover checking . . . . . . . . . . . . . . . . . . . . . . . . . 125
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Characteristic map of the throttle response
preparing for securing . . . . . . . . . . . . . . . . . 93
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Charging voltage
Alternator
checking . . . . . . . . . . . . . . . . . . . . . . . . . 136
stator winding, checking . . . . . . . . . . . . . . 274
Clutch
Ambient pressure
fluid level, checking/correcting . . . . . . . . . . 228
programming . . . . . . . . . . . . . . . . . . . . . . 248
fluid, changing . . . . . . . . . . . . . . . . . . . . . 229
Antifreeze
Clutch lever
checking . . . . . . . . . . . . . . . . . . . . . . . . . 238
basic position, adjusting . . . . . . . . . . . . . . . 48
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . 10
Cold start button . . . . . . . . . . . . . . . . . . . . . . . 258
B
Cold start rev speed increase
Brake disc diagnostics tool, adjusting . . . . . . . . . . . . . 257
of rear brake, changing . . . . . . . . . . . . . . . 121 Combination instrument
of the front brake, changing . . . . . . . . . . . . 117 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 159
Brake discs clock, setting . . . . . . . . . . . . . . . . . . . . . . 160
checking . . . . . . . . . . . . . . . . . . . . . . . . . 112 combination instrument battery, changing . . 157
Brake fluid kilometers or miles, setting . . . . . . . . . . . . 158
front brake, adding . . . . . ... . . . . . . . . . . 144 overview . . . . . . . . . . . . . . . . . . . . . . . . . 158
of front brake, changing . ... . . . . . . . . . . 145 Compression damping
of the rear brake, changing .. . . . . . . . . . . 152 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 15
rear brake, adding . . . . . ... . . . . . . . . . . 151 Coolant
Brake fluid level changing . . . . . . . . . . . . . . . . . . . . . . . . . 242
of front brake, checking . . . . . . . . . . . . . . . 143 draining . . . . . . . . . . . . . . . . . . . . . . . . . 239
rear brake, checking . . . . . . . . . . . . . . . . . 151 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 240
337
,
INDEX
Coolant level intake flange, checking . . . . . . . . . . . . . . . 199

checking . . . . . . . . . . . . . . . . . . . . . . 238-239 reed valve housing, checking . . . . . . . . . . . 199
Coolant pipe reed valve, checking . . . . . . . . . . . . . . . . . 199
changing . . . . . . . . . . . . . . . . . . . . . . . . . 243 section of the engine case, right . . . . . . . . . 185
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 238 Engine assembly

alternator cover, installing . . . . . . . . . . . . . 216
alternator side, assembling . . . . . . . . . . . . 216
checking . . . . . . . . . . . . . . . . . . . . . . . . . 275
balancer shaft drive wheel, installing . . . . . . 217
D clutch and water pump cover, installing . . . . 217
Diagnostics connector . . . . . . . . . . . . . . . . . . . 139 clutch basket, installing . . . . . . . . . . . . . . 217
Drivetrain kit clutch discs, installing . . . . . . . . . . . . . . . 217
changing . . . . . . . . . . . . . . . . . . . . . . . . . 128 clutch side, assembling . . . . . . . . . . . . . . . 217
crankshaft, installing . . . . . . . . . . . . . . . . . 212
E cylinder and cylinder head, installing . . . . . 222
Engine cylinder head, installing . . . . . . . . . . . . . . 222
assembling . . . . . . . . . . . . . . .. . . . . . . . 212 cylinder, installing . . . . . . . . . . . . . . . . . . 222
disassembling . . . . . . . . . . . . .. . . . . . . . 174 engine case, assembling . . . . . . . . . . . . . . 212
installing . . . . . . . . . . . . . . . . .. . . . . . . . 168 engine, preparing for assembly . . . . . . . . . . 214
removing . . . . . . . . . . . . . . . . .. . . . . . . . 162 engine, removing from the engine work stand 227
technical specifications – engine . . . . . . . . 280 gear oil drain plug, installing . . . . . . . . . . . 227
working on individual parts . . . .. . . . . . . . 185 installing the piston . . . . . . . . . . . . . . . . . 222
Engine – work on the individual parts installing the rotor . . . . . . . . . . . . . . . . . . 216
changing the connecting rod, conrod bearing left engine case, assembling . . . . . . . . . . . 212
and crank pin . . . . . . . . . . . . . . . . . . . . . . 188 lock ring, balancer shaft and spacer, installing 214
clutch cover . . . . . . . . . . . . . . . . . . . . . . . 201 reed valve housing, installing . . . . . . . . . . . 214
countershaft, assembling . . . . . . . . . . . . . . 210 shift shaft, shift drum locating unit and locking
countershaft, disassembling . . . . . . . . . . . . 207 lever, installing . . . . . . . . . . . . . . . . . . . . 217
crankshaft run-out at the bearing pin, checking 190 starter motor, installing . . . . . . . . . . . . . . . 214
cylinder, checking/measuring . . . . . . . . . . . 190 transmission shafts, installing . . . . . . . . . . 212
electric starter drive, checking . . . . . . . . . . 212 X-distance, checking . . . . . . . . . . . . . . . . . 222
exhaust control, checking . . . . . . . . . . . . . 192 Z-distance, setting . . . . . . . . . . . . . . . . . . 222
exhaust control, installing . . . . . . . . . . . . . 193 Engine disassembly
exhaust control, removing . . . . . . . . . . . . . 190 alternator cover, removing . . . . . . . . . . . . . 177
main shaft, assembling . . . . . . . . . . . . . . . 210 balancer shaft drive wheel and primary gear,
main shaft, disassembling . . . . . . . . . . . . . 207 removing . . . . . . . . . . . . . . . . . . . . . . . . . 178
piston ring end gap, checking . . . . . . . . . . . 197 clutch basket, removing . . . . . . . . . . . . . . . 178
piston/cylinder, measuring the mounting clutch discs, removing . . . . . . . . . . . . . . . 178
clearance . . . . . . . . . . . . . . . . . . . . . . . . 197 clutch side, dismantling . . . . . . . . . . . . . . 178
reed valve housing, assembling . . . . . . . . . . 199 cylinder head and cylinder, removing . . . . . . 174
reed valve housing, disassembling . . . . . . . . 198 cylinder head, removing . . . . . . . . . . . . . . . 174
section of the engine case, left . . . . . . . . . . 186 disassembling the alternator side . . . . . . . . 177
shift mechanism, checking . . . . . . . . . . . . 206 engine case, dismantling . . . . . . . . . . . . . . 183
shift shaft, preassembling . . . . . . . . . . . . . 205 engine, clamping into the engine work stand 174
stator, installing . . . . . . . . . . . . . . . . . . . . 278 engine, preparing for housing disassembly . . 181
stator, removing . . . . . . . . . . . . . . . . . . . . 278 gear oil, draining . . . . . . . . . . . . . . . . . . . 177
transmission, checking . . . . . . . . . . . . . . . 208 left engine case, removing . . . . . . . . . . . . . 183
Engine - working on the individual parts piston and cylinder, removing . . . . . . . . . . . 174
piston, checking . . . . . . . . . . . . . . . . . . . . 196 reed valve housing, removing . . . . . . . . . . . 181
piston, measuring . . . . . . . . . . . . . . . . . . . 196 removing the starter motor . . . . . . . . . . . . . 181
removing the transmission shafts and
Engine – working on the individual parts
crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 183
clutch, checking . . . . . . . . . . . . . . . . . . . . 204
rotor, removing . . . . . . . . . . . . . . . . . . . . . 177
crankshaft bearing inner race, installing . . . . 188
shift rail, shift drum and shift fork, removing 183
,
crankshaft bearing inner race, removing . . . . 187
338
INDEX
shift shaft, shift drum locating unit and locking Fuel pressure
lever, removing . . . . . . . . . . . . . . . . . . . . . 178 checking . . . . . . . . . . . . . . . . . . . . . . . . . 105
spacer and balancer shaft, removing . . . . . . 181
Fuel pump
water pump and clutch cover, removing . . . . 178
changing . . . . . . . . . . . . . . . . . . . . . . . . . 103
Engine guard
Fuel screen
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 55
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 99
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel tank
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 11
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Engine sprocket removing . . . . . . . . . . . . . . . . . . . . . . . . . . 96
checking . . . . . . . . . . . . . . . . . . . . . . . . . 125
Fuel tank filler cap
Exhaust control closing . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
end positions with diagnostics tool, program- opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . 10
end positions, programming . . . . . . . . . . . . 259
Fuse
F
main fuse, changing . . . . . . . . . . . . . . . . . 132
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
G
Foot brake lever
basic position, adjusting . . . . . . . . . . . . . . 150 Gasket support
free travel, checking . . . . . . . . . . . . . . . . . 149 assembling . . . . . . . . . . . . . . . . . . . . . . . . 30
disassembling . . . . . . . . . . . . . . . . . . . . . . 27
Footrests
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Gear oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Fork
changing . . . . . . . . . . . . . . . . . . . . . . . . . 261
article number . . . . . . . . . . . . . . . . . . . . . . 11
Gear oil level
Fork bearing
checking . . . . . . . . . . . . . . . . . . . . . . . . . 262
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 79
H
Fork legs
assembling . . . . . . . . . . . . . . . . . . . . . . . . 36 Hand brake lever
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 16 free travel, adjusting . . . . . . . . . . . . . . . . . 143
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 28 free travel, checking . . . . . . . . . . . . . . . . . 142
disassembling . . . . . . . . . . . . . . . . . . . . . . 19 Handlebar position . . . . . . . . . . . . . . . . . . . . . . 46
dust boots, cleaning . . . . . . . . . . . . . . . . . . 16 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 46
fork, servicing . . . . . . . . . . . . . . . . . . . . . . 19
Headlight
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 17
range, adjusting . . . . . . . . . . . . . . . . . . . . 157
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Headlight bulb
Fork protector
changing . . . . . . . . . . . . . . . . . . . . . . . . . 155
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 18
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Headlight mask with headlight
installing . . . . . . . . . . . . . . . . . . . . . . . . . 109
Frame
removing . . . . . . . . . . . . . . . . . . . . . . . . . 109
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Headlight setting
Frame protector
checking . . . . . . . . . . . . . . . . . . . . . . . . . 156
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 55
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 55 High-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 56
Front fender
installing . . . . . . . . . . . . . . . . . . . . . . . . . 108 I
removing . . . . . . . . . . . . . . . . . . . . . . . . . 108 Idle speed
Front wheel diagnostics tool, adjusting . . . . . . . . . . . . . 256
installing . . . . . . . . . . . . . . . . . . . . . . . . . 116 Ignition coil
removing . . . . . . . . . . . . . . . . . . . . . . . . . 115 primary winding, checking . . . . . . . . . . . . . 273
Fuel filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . 100
339
,
INDEX
Ignition system Pressure stage unit

checking . . . . . . . . . . . . . . . . . . . . . . . . . 272 assembling . . . . . . . . . . . . . . . . . . . . . . . . 31
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . 10 disassembling . . . . . . . . . . . . . . . . . . . . . . 26
L R
Link fork Rear sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 79 checking . . . . . . . . . . . . . . . . . . . . . . . . . 125
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Rear wheel
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 80 installing . . . . . . . . . . . . . . . . . . . . . . . . . 120
Link fork bearing removing . . . . . . . . . . . . . . . . . . . . . . . . . 119
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Rebound damping
Lower triple clamp fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 15
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 40 shock absorber, adjusting . . . . . . . . . . . . . . 57
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Refueling
Low-speed compression damping 2-stroke oil . . . . . . . . . . . . . . . . . . . . . . . 264
shock absorber, adjusting . . . . . . . . . . . . . . 56 Rider sag
M adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rim run-out
Main fuse
checking . . . . . . . . . . . . . . . . . . . . . . . . . 113
changing . . . . . . . . . . . . . . . . . . . . . . . . . 132
Rubber grip
Main silencer
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 48
glass fiber yarn filling, changing . . . . . . . . . . 89
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 86 S
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Seat
Manifold mounting . . . . . . . . . . . . . . . . . . . . . . . . . 95
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 88 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 95
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Service schedule . . . . . . . . . . . . . . . . . . . 293-295
Manufacturer warranty . . . . . . . . . . . . . . . . . . . . 10 Servicing the fork . . . . . . . . . . . . . . . . . . . . . . . 19
Motorcycle Servicing the shock absorber . . . . . . . . . . . . . . . 63
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 289 Shock absorber
from lift stand, removing . . . . . . . . . . . . . . . 13 article number . . . . . . . . . . . . . . . . . . . . . . 12
raising with lift stand . . . . . . . . . . . . . . . . . 13 assembling the damper . . . . . . . . . . . . . . . . 71
O checking the rider sag . . . . . . . . . . . . . . . . . 59
damper, bleeding and filling . . . . . . . . . . . . 73
OCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
damper, checking . . . . . . . . . . . . . . . . . . . . 67
Oil pump damper, disassembling . . . . . . . . . . . . . . . . 65
changing . . . . . . . . . . . . . . . . . . . . . . . . . 268 damper, filling with nitrogen . . . . . . . . . . . . 76
priming . . . . . . . . . . . . . . . . . . . . . . . . . . 264 disassembling the piston rod . . . . . . . . . . . . 66
Oil screen heim joint, changing . . . . . . . . . . . . . . . . . . 68
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 268 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Open-circuit current installing the spring . . . . . . . . . . . . . . . . . . 77
checking . . . . . . . . . . . . . . . . . . . . . . . . . 137 piston rod, assembling . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 61
P
servicing shock absorber . . . . . . . . . . . . . . . 63
Piston rod spring preload, adjusting . . . . . . . . . . . . . . . 59
assembling . . . . . . . . . . . . . . . . . . . . . . . . 32 spring, removing . . . . . . . . . . . . . . . . . . . . . 64
disassembling . . . . . . . . . . . . . . . . . . . . . . 24 static sag, checking . . . . . . . . . . . . . . . . . . 58
Play in throttle cable Shock absorber heim joint
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 50 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 79
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing for use
,
after storage . . . . . . . . . . . . . . . . . . . . . . 292
340
INDEX
Spark plug V
changing . . . . . . . . . . . . . . . . . . . . . . . . . 276 Vehicle identification number . . . . . . . . . . . . . . . 11
Spark plug and spark plug connector W
changing . . . . . . . . . . . . . . . . . . . . . . . . . 276
Wheel bearing
Spark plug connector
checking . . . . . . . . . . . . . . . . . . . . . . . . . 112
checking . . . . . . . . . . . . . . . . . . . . . . . . . 273
of the front wheel, changing . . . . . . . . . . . . 118
Speedometer of the rear wheel, changing . . . . . . . . . . . . 122
wheel circumference, adjusting . . . . . . . . . 160
Winter operation
Spoke tension checks and maintenance steps . . . . . . . . . . 290
checking . . . . . . . . . . . . . . . . . . . . . . . . . 114
Wiring diagram ................... 296-313
Starter motor page 1 of 4 ................... . . . . 306
checking . . . . . . . . . . . . . . . . . . . . . . . . . 279 page 1 of 5 ................... . . . . 296
Starter relay page 2 of 4 ................... . . . . 308
checking . . . . . . . . . . . . . . . . . . . . . . . . . 138 page 2 of 5 ................... . . . . 298
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 page 3 of 4 ................... . . . . 310
page 3 of 5 ................... . . . . 300
Steering head bearing
page 4 of 4 ................... . . . . 312
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 42
page 4 of 5 ................... . . . . 302
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 39
page 5 of 5 ................... . . . . 304
Steering head bearing play
Wiring harness
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 44
checking . . . . . . . . . . . . . . . . . . . . . . . . . 139
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Work rules ............................ 8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
T
Technical accessories . . . . . . . . . . . . . . . . . . . . 10
Technical specifications
capacities . . . . . . . . . . . . . . . . . . . . . . . . 282
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 283
chassis tightening torques . . . . . . . . . . . . . 285
electrical system . . . . . . . . . . . . . . . . . . . 284
engine – tolerance, wear limits . . . . . . . . . . 280
engine tightening torques . . . . . . . . . . . . . 281
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
shock absorber . . . . . . . . . . . . . . . . . . . . . 285
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Throttle valve body
changing . . . . . . . . . . . . . . . . . . . . . . . . . 248
Throttle valve position sensor
basic setting, adjusting . . . . . . . . . . . . . . . 255
basic setting, checking . . . . . . . . . . . . . . . 254
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . 111
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . 111
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . 155
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
341
,
,

2024 KTM 250-300 EXC TBI Repair Manual

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250 EXC

250 EXC SIX DAYS

6.18 Assembling the piston rod................. 32

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

6.17 Assembling the pressure stage unit.... 31

the engine case ......................... 186

34 STANDARDS ............................................ 335

1.1 Symbols used

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

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

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

Name® Indicates a protected name.

Brand™ Indicates a brand available on the open market.

2.1 Repair Manual

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Work rules

3.1 Manufacturer warranty, implied warranty

3.2 Fuel, auxiliary substances

3.3 Spare parts, technical accessories

4.1 Vehicle identification number

4.2 Type label

4.3 Engine number

4.4 Fork part number

4.5 Shock absorber article number

5.1 Raising the motorcycle with a lift stand

– Raise the motorcycle at the frame underneath the engine.

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

5.2 Removing the motorcycle from the lift stand

– Remove the motorcycle from the lift stand.

5.3 Starting the vehicle

– Press the start button.

5.4 Starting the motorcycle to check the function

– Shift the transmission to neutral position.

6.1 Adjusting the compression damping of the fork

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

– Turn counterclockwise by the number of clicks corresponding

6.2 Adjusting the rebound damping of the fork

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

– Turn counterclockwise by the number of clicks corresponding

6.3 Bleeding the fork legs

6.4 Cleaning the dust boots of the fork legs

6.5 Removing the fork legs

– Loosen screws 3. Remove the left fork leg.

6.6 Installing the fork legs

(All standard models)

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

6.7 Removing the fork protector

6.8 Installing the fork protector

6.9 Servicing the fork

6.10 Disassembling the fork legs

– Unclamp the fork leg.

– Clamp the fork leg on the fork shoe.

– Remove the cartridge.