2010 KTM 450SX 505SX Sevice Manual
User Manual: 2010 KTM 450SX 505SX Sevice Manual
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REPAIR MANUAL 2010 450 SX ATV 505 SX ATV P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Article no. 3206070en P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m INTRODUCTION 1 It is important that you read this owner's manual carefully and completely before the start of work. INTRODUCTION Only use ORIGINAL KTM SPARE PARTS. This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified experts. The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in the interest of technical advancement without, at the same time, updating this repair manual. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that repair work will be performed by a fully trained mechanic. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria CONTENTS CONTENTS Rear shock absorber - disassembling the piston rod .......... Rear shock absorber - disassembling the seal ring retainer ........................................................................ Changing the pilot bushing............................................. Rear shock absorber - checking the damper ..................... Rear shock absorber - removing the heim joint ................. Rear shock absorber - installing the heim joint ................. Rear shock absorber - assembling the seal ring retainer..... Rear shock absorber - assembling the piston rod .............. Rear shock absorber - assembling the damper .................. Rear shock absorber - bleeding and filling the damper ...... Rear shock absorber - filling the damper with nitrogen ...... Rear shock absorber - installing the spring ....................... 05/EXHAUST .................................................................... Removing the main silencer............................................ Installing the main silencer ............................................ Removing the manifold .................................................. Installing the manifold ................................................... 06/AIR FILTER.................................................................. Removing the air filter ................................................... Installing the air filter .................................................... Cleaning air filter........................................................... Removing the air filter box lid with the carburetor connection boot ............................................................ Installing the air filter box lid and the carburetor connection boot ............................................................ 07/FUEL TANK, SEAT, TRIM.............................................. Removing the seat ......................................................... Mounting the seat ......................................................... Removing the radiator spoiler ......................................... Installing the radiator spoiler .......................................... Removing the fuel tank .................................................. Installing the fuel tank ................................................... Fuel tap........................................................................ 08/MASK, FENDER ........................................................... Removing the heel protector ........................................... Installing the heel protector............................................ Removing the front cover................................................ Installing the front cover ................................................ Removing the front trim ................................................. Installing the front trim .................................................. Removing the rear fender ............................................... Installing the rear fender ................................................ 09/FRONT WHEEL ............................................................ Checking the tire air pressure ......................................... Checking the tire condition............................................. Removing wheel/wheels.................................................. Installing the wheel/wheels............................................. Checking brake discs ..................................................... 10/REAR WHEEL .............................................................. Checking chain dirt ....................................................... Cleaning the chain......................................................... Checking chain wear ...................................................... Checking rear sprocket / engine sprocket for wear ............. Checking the chain tension ............................................ Adjusting chain tension.................................................. Adjusting the toe width of rear axle ................................. Removing the rear axle................................................... Installing the rear axle ................................................... Changing the rear axle bearing........................................ 11/WIRING HARNESS, BATTERY ....................................... Ignition curve plug connection ........................................ P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m MEANS OF REPRESENTATION ............................................ 6 IMPORTANT NOTES ............................................................ 7 VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example) ................. 8 View of the vehicle from the right rear (example) ................ 9 LOCATION OF SERIAL NUMBERS ...................................... 10 Chassis number............................................................. 10 Type label..................................................................... 10 Key number .................................................................. 10 Engine number.............................................................. 10 Shock absorber part number, front .................................. 10 Shock absorber part number, rear ................................... 11 VEHICLE .......................................................................... 12 Jacking up the vehicle ................................................... 12 Removing the vehicle from the work stand ....................... 12 02/HANDLEBAR, INSTRUMENTS....................................... 13 Hot start lever ............................................................... 13 Adjusting handlebar position .......................................... 13 Adjusting basic position of clutch lever............................ 14 Checking the play in the throttle cable............................. 14 Adjusting play in throttle cable ....................................... 14 Removing the steering column ........................................ 14 Changing the steering column bearing ............................. 16 Installing the steering column......................................... 18 03/FRAME........................................................................ 20 Removing the engine guard ............................................ 20 Installing the engine guard ............................................. 20 04/SHOCK ABSORBER, SWINGARM................................... 21 Front shock absorber - adjusting the high-speed compression damping .................................................... 21 Front shock absorber - adjusting the low-speed compression damping .................................................... 21 Front shock absorber - adjusting the rebound damping...... 22 Front shock absorber - adjusting the spring preload .......... 23 Front shock absorber - adjusting the cross over................. 24 Removing the front shock absorber.................................. 24 Installing the front shock absorber .................................. 25 Front shock absorber - changing the oil ........................... 25 Service the front shock absorber ..................................... 27 Front shock absorber - removing the spring ...................... 28 Front shock absorber - disassembling the damper ............. 28 Front shock absorber - disassembling the piston rod ......... 29 Front shock absorber - checking the damper .................... 30 Front shock absorber - removing the heim joint ................ 31 Front shock absorber - installing the heim joint ................ 31 Front shock absorber - assembling the piston rod.............. 32 Front shock absorber - assembling the damper ................. 33 Front shock absorber - bleeding and filling the damper ..... 34 Front shock absorber - filling the damper with nitrogen ..... 37 Front shock absorber - installing the spring ...................... 38 Rear shock absorber - adjusting the high-speed compression damping .................................................... 38 Rear shock absorber - adjusting the low-speed compression damping .................................................... 39 Rear shock absorber - adjusting the rebound damping....... 40 Rear shock absorber - adjusting the spring preload ........... 40 Removing the rear shock absorber ................................... 41 Installing the rear shock absorber.................................... 42 Rear shock absorber - changing the oil ............................ 42 Servicing the rear shock absorber.................................... 44 Rear shock absorber - removing the spring ....................... 44 Rear shock absorber - disassembling the damper.............. 45 2 46 47 47 48 49 50 50 51 52 54 56 57 59 59 59 60 60 61 61 61 61 62 62 63 63 63 63 64 64 65 66 67 67 68 69 69 69 70 70 71 72 72 72 72 73 74 75 75 75 75 76 76 76 77 78 79 81 83 83 CONTENTS Removing the suction pump ......................................... Removing the shift shaft .............................................. Removing the shift drum locating unit ........................... Removing the locking lever........................................... Removing the left section of the engine case.................. Removing the shift rails ............................................... Removing the shift drum .............................................. Removing the shift forks .............................................. Removing the transmission shafts ................................. Removing the crankshaft .............................................. 30/ENGINE - WORK ON INDIVIDUAL PARTS..................... Working on the right section of the engine case .............. Working on the left section of the engine case................ Removing the water pump ............................................ Changing the shaft seal ring of the water pump .............. Installing the water pump............................................. Removing the crankshaft seal ring in the clutch cover ..... Installing the crankshaft seal ring in the clutch cover...... Removing the oil pressure regulator valve....................... Checking spring length of oil pressure regulator valve...... Installing the oil pressure regulator valve ....................... Checking the lubrication system.................................... Removing the crankshaft bearing inner race ................... Installing the crankshaft bearing inner race.................... Changing connecting rod, conrod bearing and crank pin............................................................................. Checking crankshaft run-out at bearing pin .................... Measuring the crankshaft end play ................................ Cylinder - Nikasil® coating ............................................ Checking/measuring cylinder ........................................ Checking/measuring the piston ..................................... Measuring piston/cylinder mounting clearance................ Checking the piston ring end gap .................................. Changing the camshaft bearing..................................... Checking the autodecompressor.................................... Checking camshafts..................................................... Checking the radial clearance of the camshaft bearings ..................................................................... Checking the camshaft bearing bridges.......................... Removing the valves .................................................... Checking the valves ..................................................... Checking the valve springs ........................................... Checking valve spring seat............................................ Checking the cam levers .............................................. Checking cylinder head ................................................ Installing the valves ..................................................... Removing the freewheel ............................................... Checking the freewheel ................................................ Installing the free wheel ............................................... Checking the electric starter mode ................................ Checking the timing assembly ...................................... Preparing the timing chain tensioner for installation ....... Checking clutch .......................................................... Checking shift mechanism ........................................... Preassembling the shift shaft........................................ Disassembling the main shaft ....................................... Disassembling the countershaft .................................... Checking transmission ................................................. Assembling the main shaft ........................................... Assembling the countershaft......................................... 30/ENGINE ASSEMBLY ................................................... Installing the crankshaft............................................... P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Changing the ignition curve ............................................ 83 Removing the battery ..................................................... 83 Installing the battery...................................................... 83 Recharging the battery ................................................... 84 Changing the main fuse ................................................. 85 Changing the fuses of individual power consumers............ 85 Checking the battery voltage........................................... 86 Checking the charging voltage ........................................ 86 Checking the quiescent current....................................... 86 Checking the starter relay ............................................... 87 13/BRAKE SYSTEM........................................................... 88 Hand brake lever, parking brake...................................... 88 Checking the free travel of the hand brake lever ............... 88 Adjusting basic position of hand brake lever..................... 88 Checking front brake fluid level....................................... 89 Topping up the front brake fluid...................................... 89 Changing the front brake fluid ........................................ 90 Checking the front brake linings...................................... 91 Removing front brake linings .......................................... 91 Mounting front brake linings........................................... 92 Changing the front brake linings ..................................... 92 Checking free travel of foot brake lever ............................ 93 Adjusting basic position of foot brake lever ...................... 93 Checking rear brake fluid level........................................ 94 Adding rear brake fluid .................................................. 94 Changing the rear brake fluid.......................................... 95 Checking rear brake linings ............................................ 96 Removing rear brake linings............................................ 96 Mounting rear brake linings ............................................ 97 Changing rear brake linings ............................................ 98 30/ENGINE....................................................................... 99 Removing the engine ..................................................... 99 Installing the engine .................................................... 100 30/DISASSEMBLING THE ENGINE................................... 103 Preparations................................................................ 103 Removing the shift lever............................................... 103 Draining the engine oil ................................................. 103 Removing the oil filter.................................................. 103 Removing the spark plug .............................................. 104 Removing the valve cover ............................................. 104 Removing the starter motor .......................................... 104 Removing the alternator cover....................................... 104 Removing the torque limiter ......................................... 105 Positioning the engine at ignition top dead center (TDC) ......................................................................... 105 Removing the camshaft................................................ 106 Removing the timing chain tensioner............................. 106 Removing the double wheel .......................................... 107 Removing the cylinder head.......................................... 107 Removing the water pump cover ................................... 108 Removing the clutch cover ........................................... 108 Removing the piston .................................................... 109 Removing the timing chain rails.................................... 109 Removing the timing chain........................................... 109 Removing the rotor and starter idler gear ....................... 110 Removing the ignition pulse generator ........................... 110 Removing the drive wheel of the balancer gear ............... 111 Removing the force pump ............................................ 111 Removing the spacer ................................................... 112 Removing the outer clutch hub ..................................... 112 Removing the primary gear ........................................... 113 Removing the centrifugal separator ............................... 113 3 114 114 115 115 115 116 116 116 116 117 118 118 119 120 121 122 123 123 123 123 124 124 125 125 125 126 127 127 127 128 129 129 129 130 130 130 131 131 132 133 133 133 133 134 135 135 135 136 137 137 138 139 140 141 141 142 143 144 145 145 CONTENTS 145 145 146 146 146 147 147 147 147 148 148 149 149 150 151 151 151 152 152 152 152 154 154 155 155 156 156 157 158 158 159 159 159 159 160 160 160 161 32/CLUTCH .................................................................... Checking fluid level of hydraulic clutch ......................... Changing the hydraulic clutch fluid ............................... 33/TRANSMISSION......................................................... Removing the engine sprocket ...................................... Installing the engine sprocket ....................................... 35/WATER PUMP, COOLING SYSTEM .............................. Checking antifreeze and coolant level ............................ Checking the coolant level............................................ Draining coolant .......................................................... Filling coolant/bleeding the cooling system .................... 38/LUBRICATION SYSTEM .............................................. Oil circuit ................................................................... Changing the engine oil and oil filter, cleaning the oil screen ........................................................................ Draining the engine oil ................................................. Removing the oil filter.................................................. Installing the oil filter .................................................. Filling up with engine oil.............................................. Checking the engine oil level ........................................ Adding engine oil ........................................................ 39/IGNITION SYSTEM ..................................................... Removing the stator..................................................... Installing the stator ..................................................... Checking the ignition system ........................................ Checking the ignition coil............................................. Checking the spark plug connector................................ Checking the CDI controller .......................................... Checking the ignition pulse generator ............................ Checking the alternator ................................................ 61/ATV FRONT END ........................................................ Checking the toe ......................................................... Adjusting the toe ......................................................... Checking/adjusting the camber ..................................... Adjusting the fork offset ............................................... Removing the wheel carrier .......................................... Changing the wheel bearing.......................................... Installing the wheel carrier ........................................... Removing the A-arms................................................... Installing the A-arms ................................................... A-Arm top - changing the bearing.................................. A-Arm bottom - changing the bearing ............................ TECHNICAL DATA - ENGINE ............................................ Capacity - engine oil .................................................... Capacity - coolant........................................................ TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS ........................................................................... TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ TECHNICAL DATA - CARBURETOR................................... TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES....................................................................... TECHNICAL DATA - CHASSIS .......................................... Tires .......................................................................... Capacity - fuel............................................................. TECHNICAL DATA - FRONT SHOCK ABSORBER................ TECHNICAL DATA - REAR SHOCK ABSORBER.................. TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... CLEANING...................................................................... Cleaning the vehicle .................................................... STORAGE ....................................................................... Storage....................................................................... Putting the vehicle into operation after storage ............... P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Installing the transmission shafts .................................. Installing the shift forks ............................................... Installing the shift drum............................................... Installing the shift rails ................................................ Installing the left engine case ....................................... Installing the locking lever............................................ Installing the shift drum locating unit............................ Installing the shift shaft ............................................... Installing the suction pumps ........................................ Installing the centrifugal separator ................................ Installing the force pump ............................................. Installing the primary gear............................................ Installing the outer clutch hub...................................... Installing the spacer .................................................... Installing the drive wheel of the balancer gear ................ Installing the timing chain............................................ Installing the free wheel gear........................................ Installing the ignition pulse generator............................ Installing the rotor ....................................................... Installing the timing chain rails..................................... Installing the piston..................................................... Installing the clutch cover ............................................ Installing the water pump cover .................................... Installing the cylinder head .......................................... Installing the double wheel........................................... Installing the timing chain tensioner ............................. Checking the valve timing ............................................ Adjusting the valve timing ............................................ Checking the valve clearance ........................................ Adjusting the valve clearance........................................ Installing the torque limiter .......................................... Installing the alternator cover ....................................... Installing the starter motor ........................................... Installing the valve cover .............................................. Installing the spark plug............................................... Installing the oil screen................................................ Installing the oil filter .................................................. Installing the shift lever ............................................... Removing the engine from the universal mounting rack ........................................................................... 31/CARBURETOR ........................................................... Choke......................................................................... Checking the play in the throttle cable........................... Carburetor - adjusting idle ............................................ Checking the position of the throttle position sensor ....... Draining the carburetor float chamber ........................... Removing the carburetor .............................................. Installing the carburetor ............................................... Disassembling the carburetor........................................ Checking/adjusting the carburetor components............... Checking/adjusting the accelerator pump....................... Checking the choke slide.............................................. Checking the hot start slide .......................................... Checking the throttle position sensor ............................. Checking the jet needle................................................ Checking the throttle slide............................................ Checking/adjusting the throttle slide opening ................. Checking the needle jet................................................ Checking the float needle valve..................................... Checking/adjusting the float level.................................. Adjusting the position of the throttle position sensor ....... Assembling the carburetor ............................................ 4 161 162 162 162 162 163 164 164 166 167 170 170 171 171 171 172 172 173 173 173 174 174 175 178 178 178 179 179 179 180 180 180 181 181 183 183 183 184 184 185 185 185 186 187 187 187 187 188 189 189 189 190 191 191 192 193 194 194 196 197 198 199 200 201 204 204 204 205 206 208 209 210 211 211 212 213 214 215 215 216 216 216 CONTENTS 217 217 218 218 220 220 223 225 227 240 241 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m SERVICE SCHEDULE....................................................... Important maintenance work to be carried out by an authorized KTM workshop ............................................ Important maintenance work to be carried out by an authorized KTM workshop (as an additional order) .......... Important checks and maintenance work to be carried out by the rider ........................................................... WIRING DIAGRAM .......................................................... 450/525 SX ATV ......................................................... SUBSTANCES................................................................. AUXILIARY SUBSTANCES................................................ SPECIAL TOOLS.............................................................. STANDARDS................................................................... INDEX ............................................................................ 5 MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following. 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). Identifies a page reference (more information is provided on the specified page). Formats used P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The typographical and other formats used are explained below. Proprietary name Denotes a proprietary name. Name® Denotes a protected name. Brand™ Denotes a brand available on the open market. 6 IMPORTANT NOTES 7 Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be accepted for damage resulting from manipulations and/or alterations to the vehicle. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories Use only spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com Work rules Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses. E.g.: valve spring mounter (59029019000) When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must be replaced with new parts. If a thread locker (e.g. Loctite®) is used for screw connections, follow the instructions for use from the manufacturer. Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear. Replace damaged or worn parts. After finishing the repair and maintenance work, ensure that the vehicle is roadworthy. Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. Repair instructions – It is imperative that you read this owner's manual carefully and completely before the start of work. It contains extensive information and many tips to help you repair and maintain your vehicle. – The necessary KTM special tools must be available and the workplace and workshop must be fully equipped. VIEW OF VEHICLE 8 View of the vehicle from the left front (example) 1 2 3 4 5 6 7 8 9 10 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3.1 Hand brake lever Fuse box Shock absorber compression adjustment Front shock absorber Shock absorber rebound adjustment Heel protector Shift lever Kill switch/emergency OFF switch with rip cord Clutch lever Hot start lever 301769-10 VIEW OF VEHICLE 9 View of the vehicle from the right rear (example) 1 2 3 4 5 6 7 8 9 10 11 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3.2 Filler cap Main silencer Seat release Shock absorber rebound adjustment Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Handlebar bridge Throttle lever Handlebar cushion 301770-10 LOCATION OF SERIAL NUMBERS 10 Chassis number 4.1 The chassis number is stamped on the right side of the frame in the vicinity of the upper control arm. 301771-10 Type label 4.2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The type label is located on the frame tube on the right and left in front of the radiator. 301858-10 Key number 4.3 The key number is indicated on the KEYCODECARD. Info You need the key number to order a replacement key. Keep the KEYCODECARD in a safe place. 100089-10 Engine number 4.4 The engine number is stamped on the left side of the engine under the engine sprocket. 301772-10 Shock absorber part number, front 4.5 The shock absorber part number is stamped on the upper part of the shock absorber. 301832-10 LOCATION OF SERIAL NUMBERS Shock absorber part number, rear 4.6 The shock absorber part number is stamped on the upper part of the shock absorber. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301831-10 11 VEHICLE 12 Jacking up the vehicle 5.1 Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. – Jack up the vehicle on the frame underneath the engine. The wheels must no longer touch the ground. – Secure the vehicle. 301785-10 Removing the vehicle from the work stand 5.2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Lower the vehicle. – Remove the work stand. 02/HANDLEBAR, INSTRUMENTS 13 Hot start lever 6.1 Hot start lever is fitted on the left side of the handlebar. If you pull the hot start lever to the handlebar when starting the engine, an opening is exposed in the carburetor through which the engine can draw additional air. This gives a leaner fuel-air mixture, which is needed for a hot start. Possible states • Hot start function is activated – The hot start lever has been pulled all the way out. • Hot start function is deactivated – The hot start lever has been pushed all the way in. 301775-10 Adjusting handlebar position 6.2 Remove the handlebar cushion. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Info Protect the vehicle and its attachments from damage by covering them. Do not bend the cables and lines. 301846-10 – Remove the four screws . Remove the handlebar clamps , swing the handlebar forward and set it down. – Remove the nuts and remove the handlebar support with the screws. – Remove screws and . – Remove screws . Remove the handlebar bridge . – Place the handlebar bridge onto the steering column in the desired position. Mount and tighten screw . Guideline Screw, steering bridge – M8 20 Nm (14.8 lbf ft) M20x1.5 25 Nm (18.4 lbf ft) M8 20 Nm (14.8 lbf ft) Mount and tighten screw . Guideline Screw, steering column, top – Mount and tighten screws . Guideline Screw, steering bridge 100099-10 – Mount the handlebar support in the desired position using the screws. Mount new self-locking nuts and tighten. Guideline Nut, handlebar support – M10 45 Nm (33.2 lbf ft) Position the handlebar and fix it with the handlebar clamps . Mount and tighten screws . Guideline Screw, handlebar clamp M8 Info Make sure cables and wiring are positioned correctly. – Mount the handlebar cushion. 20 Nm (14.8 lbf ft) 02/HANDLEBAR, INSTRUMENTS 14 Adjusting basic position of clutch lever 6.3 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw . Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! 301813-10 Checking the play in the throttle cable 6.4 Move the handlebar to the straight-ahead position. Move the throttle lever back and forth slightly to ascertain the play in the throttle cable . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Guideline Play in throttle cable » 3… 5 mm (0.12… 0.2 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. ( p. 14) Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. 301795-11 – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. » If the idle speed changes: – Adjust the play in the throttle cable. ( p. 14) Adjusting play in throttle cable 6.5 – Check throttle cable route. – Move the handlebar to the straight-ahead position. – Loosen the nut and use the screw to adjust the play in the throttle cable . Guideline Play in throttle cable 3… 5 mm (0.12… 0.2 in) – Tighten nut . – Remove the front cover. ( – Remove handlebar cushion . 301795-10 Removing the steering column 6.6 301859-10 p. 69) 02/HANDLEBAR, INSTRUMENTS – Loosen screw . Info The screw cannot be removed. 301860-10 Loosen screws . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301861-10 – Remove screw . – Take off the handlebar with the handlebar bridge and screw , swing it forward and set it down. Info Protect the vehicle and its attachments from damage by covering them. 301862-10 – Remove screw . – Loosen screws . – Pull the steering arm down. – Remove screws . – Swing the cable guide forward. 301519-10 301520-10 301863-10 15 02/HANDLEBAR, INSTRUMENTS 16 – Remove screws . – Pull out the steering column with bearing support from above. – Pull bearing support off from above. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301864-10 301523-10 Changing the steering column bearing 6.7 – Remove the steering column. ( – Remove spacer . – Remove shaft seal ring . – Remove lock ring . – Mount special tool . p. 14) 301528-10 301524-10 301529-10 Extractor (83019020000) ( – 301525-10 p. 235) Press out the steering column bearing by turning in the screw. 02/HANDLEBAR, INSTRUMENTS 17 – Position the steering column bearing. – Mount special tool . Extractor (83019020000) ( p. 235) – Press in the steering column bearing by turning in the screw. – Mount lock ring . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301526-10 301529-10 – Position the shaft seal ring. – Mount special tool . Extractor (83019020000) ( p. 235) – Press in the shaft seal ring by turning in the screw. – Mount spacer . – Remove shaft seal rings from the bearing support. – Press out the sleeve bearing. 301527-10 301528-10 301530-10 Extractor (83019020000) ( 301531-10 p. 235) 02/HANDLEBAR, INSTRUMENTS – 18 Press in the sleeve bearing. Extractor (83019020000) ( p. 235) 301532-10 Press in shaft seal rings from the outside to the inside with the open side facing inward. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301530-10 Installing the steering column 6.8 – Lightly grease bearing support and slide it onto the steering column. Long-life grease ( p. 225) 301523-11 – Mount the steering column with bearing support from above. – Position the bearing support. – Mount and tighten screws . Guideline Screw, bearing support, steering M8 25 Nm (18.4 lbf ft) M6 10 Nm (7.4 lbf ft) M10 25 Nm (18.4 lbf ft) 301864-11 – Position the cable guide. – Mount and tighten screws . Guideline Remaining screws, chassis 301863-11 – Position the steering arm. – Tighten screw . Guideline Screw, steering column at bottom of steering lever 301520-11 02/HANDLEBAR, INSTRUMENTS – 19 Mount and tighten screw . Guideline Screw, steering column, bottom M20x1.5 40 Nm (29.5 lbf ft) 301519-10 – Mount the handlebar with the handlebar bridge and screw . – Mount and tighten screw . Guideline M8 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Remaining screws, chassis 25 Nm (18.4 lbf ft) 301862-11 – Tighten screws . Guideline Screw, steering bridge M8 20 Nm (14.8 lbf ft) M20x1.5 25 Nm (18.4 lbf ft) 301861-11 – Tighten screw . Guideline Screw, steering column, top 301860-11 301859-11 – Mount handlebar cushion on the handlebar. – Install the front cover. ( p. 69) 03/FRAME 20 Removing the engine guard 7.1 – Remove screws and . Remove the engine guard. – Position the engine guard on the frame bearer. Mount and tighten screws and . 301823-10 Installing the engine guard P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 7.2 Guideline 301823-10 Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Remaining screws, chassis M8 25 Nm (18.4 lbf ft) 04/SHOCK ABSORBER, SWINGARM 21 Front shock absorber - adjusting the high-speed compression damping 8.1 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info The high-speed setting has an impact on the fast compression of the shock absorber. The left and right shock absorbers should have the same settings. – Turn adjusting screw all the way clockwise with a socket wrench. Info Do not loosen nut ! – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 301786-10 Comfort 1.5 turns Standard 1 turn Sport 1 turn Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Front shock absorber - adjusting the low-speed compression damping 8.2 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Info The low-speed setting has an impact on the slow to normal compression of the shock absorber. The left and right shock absorbers should have the same settings. 04/SHOCK ABSORBER, SWINGARM – 22 Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen nut ! – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed 301787-10 Comfort 20 clicks Standard 15 clicks Sport 12 clicks P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Front shock absorber - adjusting the rebound damping 8.3 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Info The rebound damping setting has an impact on the rebound of the shock absorber. The left and right shock absorbers should have the same settings. – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 301788-10 Comfort 20 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 04/SHOCK ABSORBER, SWINGARM 23 Front shock absorber - adjusting the spring preload 8.4 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling. Tip Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. – Jack up the vehicle. ( – Clean the shock absorber thoroughly. – Release counter ring . p. 12) Hook wrench (83019001000) ( p. 234) – Turn adjusting ring until the spring pack is no longer under tension. – Measure the overall spring pack when not under tension. 301790-11 – Tighten the spring pack by turning adjusting ring to measurement . Guideline Spring preload Comfort 3 mm Standard 5 mm Sport 8 mm Info Spring preload is the difference in length between the spring pack when it is unloaded and when it is installed. The spring pack should never be installed loosely (without preload). The standard setting is the lowest permissible spring preload. Therefore, you can only increase the spring preload. If you increase the spring preload, you should also slightly increase the rebound damping. The left and right shock absorbers should have the same settings. 800064-10 – Tighten the lock ring and adjusting ring. – Remove the vehicle from the work stand. ( p. 12) 04/SHOCK ABSORBER, SWINGARM 24 Front shock absorber - adjusting the cross over 8.5 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The cross over setting is used to adjust the suspension travel of the short (soft) spring. Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower. The suspension travel and the progressive part of the long (hard) spring is not fully utilized. Less cross over makes the spring action at the front harder and the front of the vehicle lies higher. – Adjust the spring preload for the front shock absorbers. ( – Jack up the vehicle. ( – Clean the shock absorber thoroughly. – Loosen adjusting rings and . p. 23) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 12) Hook wrench (83019001000) ( p. 234) 301789-10 – Measure the cross over setting between sliding bushing and the collar of adjusting ring . Guideline Cross over 19±1.5 mm (0.75±0.059 in) – Adjust the sleeve by turning adjusting ring to the specified measurement . – Lock the adjusting rings. – Remove the vehicle from the work stand. ( p. 12) 301790-10 Removing the front shock absorber 8.6 Info The operations are the same on the left and right sides. 301534-10 – Jack up the vehicle. ( – Secure the upper A-arm on the frame using tension belt . p. 12) 04/SHOCK ABSORBER, SWINGARM 25 – Remove screw . – Remove screw . Remove the shock absorber. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301535-10 301536-10 Installing the front shock absorber 8.7 Info The operations are the same on the left and right. – Position the front shock absorber. Mount and tighten screw . Guideline Screw, front shock absorber M10 45 Nm (33.2 lbf ft) 301536-11 – Position the shock absorber in the lower A-arm. Mount and tighten screw . Guideline Screw, front shock absorber – Remove the tension belt. – Remove the vehicle from the work stand. ( M10 p. 12) 301535-11 Front shock absorber - changing the oil 8.8 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. – Remove the spring from the front shock absorber. ( p. 28) 45 Nm (33.2 lbf ft) 04/SHOCK ABSORBER, SWINGARM 26 – Note down the present state of rebound damping and compression damping . – Completely open the adjusters of the rebound and compression damping. – Remove rubber cap of the reservoir. – Slowly open screw . 201133-10 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The pressurized nitrogen is bled off. 201134-10 – Remove screw . Let the oil drain out. – Bleed and fill the damper of the front shock absorber. ( – Fill the damper of the front shock absorber with nitrogen. ( – Mount rubber cap of the reservoir. p. 34) p. 37) 201218-10 201150-11 Alternative 1 – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 201133-10 Comfort 20 clicks Standard 15 clicks Sport 12 clicks – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks 04/SHOCK ABSORBER, SWINGARM 27 – Turn adjusting screw all the way clockwise with a socket wrench. – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – – – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Turn adjusting screw and to the position determined when the part was removed. Install the spring of the front shock absorber. ( p. 38) Service the front shock absorber 8.9 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. 201217-01 – Remove the spring from the front shock absorber. ( – Disassemble the damper of the front shock absorber. ( – Disassemble the piston rod of the front shock absorber. ( – Remove the heim joint from the front shock absorber. ( – Check the damper of the front shock absorber. ( – Install the heim joint of the front shock absorber. ( – Assemble the piston rod of the front shock absorber. ( – Assemble the damper of the front shock absorber. ( – Install the spring of the front shock absorber. ( p. 28) p. 28) p. 29) p. 31) p. 30) p. 31) p. 32) p. 33) p. 38) 04/SHOCK ABSORBER, SWINGARM 28 Front shock absorber - removing the spring 8.10 Condition The shock absorber has been removed. – Clamp the shock absorber in a vise using soft jaws. – Measure and note down the spring length in the preloaded state. – Release counter ring . – Turn adjusting ring all the way up. Hook wrench (83019001000) ( p. 234) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 201131-10 – Pull the spring down. Remove spring retainer . – Remove the spring. – Remove sleeve . – Remove spring . – Remove adjusting ring and retaining ring . 201132-10 Front shock absorber - disassembling the damper 8.11 – Remove the spring from the front shock absorber. ( – Note down the present state of rebound damping and compression damping . – Completely open the adjusters of the rebound and compression damping. – Remove rubber cap of the reservoir. – Slowly open screw . 201133-10 The pressurized nitrogen is bled off. 201134-10 – Remove locking cap . – Press in seal ring retainer . Remove lock ring . Info Do not scratch the inner surface. 201135-10 p. 28) 04/SHOCK ABSORBER, SWINGARM 29 – Remove the piston rod. Drain the oil. – Remove compression damping . Remove the spring and piston. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 201136-10 201137-10 Front shock absorber - disassembling the piston rod 8.12 – Disassemble the damper of the front shock absorber. ( – Clamp the piston rod with the heim joint in a bench vise. – Remove nut . – Remove supporting plate . – Remove rebound shim stack . p. 28) 201139-10 Info Thread the rebound shim stack onto a screwdriver and set them down together. – Remove piston . – Remove compression shim stack with bushing . 201140-10 Info Thread the compression shim stack onto a screwdriver and set them down together. 201141-10 200924-10 – Remove seal ring retainer . – Remove locking cap and rubber buffer . 04/SHOCK ABSORBER, SWINGARM 30 Front shock absorber - checking the damper 8.13 Condition The damper has been disassembled. – Measure the inside diameter on both ends and in the middle of the damper cartridge. Damper cartridge Minimum diameter » If the measured value is greater than the specified value: – – If there is damage or wear: – Change the damper cartridge. Measure the diameter of the piston rod. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Change the damper cartridge. Check the damper cartridge for damage and wear. » 201138-10 36.04 mm (1.4189 in) Piston rod Diameter » If the specified value is not reached: – – ≥ 13.95 mm (≥ 0.5492 in) Replace the piston rod. Measure the run-out of the piston rod. Piston rod 200946-10 Run-out » If the measured value is greater than the specified value: – – If there is damage or wear: – – Replace the piston rod. Check the heim joint for damage and wear. » If there is damage or wear: – 300460-01 Replace the piston rod. Check the piston for damage and wear. » ≤ 0.06 mm (≤ 0.0024 in) Change the heim joint. 04/SHOCK ABSORBER, SWINGARM 31 Front shock absorber - removing the heim joint 8.14 Info The operations are the same on the top and bottom heim joint. Condition The shock absorber has been removed. – Clamp the shock absorber in a vise using soft jaws. – Remove both collar bushings of the heim joint. p. 237) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Pin (T120) ( 200906-10 – Remove seal rings on both sides. – Press heim joint to the side. 200907-10 Pressing tool (T1207S) ( p. 238) The heim joint is lined up with a lock ring. – Remove the other lock ring . – Place special tool underneath and press out the heim joint using special tool . 200908-10 Pressing tool (T1207S) ( 200909-10 Front shock absorber - installing the heim joint 8.15 Info The operations are the same on the top and bottom heim joint. p. 238) 04/SHOCK ABSORBER, SWINGARM – 32 Place special tool underneath and press in the heim joint to the lock ring using special tool . Pressing tool (T1207S) ( Pressing tool (T1206) ( p. 238) p. 238) 200911-10 – Mount the second lock ring . – Mount and grease seal rings on both sides. p. 225) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Lubricant (T158) ( 200912-10 – Press in both collar bushings of the heim joint. 201142-10 Front shock absorber - assembling the piston rod 8.16 – Check the damper of the front shock absorber. ( – Clamp the piston rod with the heim joint in a bench vise. – Mount bump rubber and locking cap . – Position special tool on the piston rod. Mounting sleeve (T313) ( – p. 239) Grease the seal ring and slide seal ring retainer onto the piston rod. Lubricant (T625) ( 201144-10 p. 30) p. 225) – Remove the special tool. – Mount bushing . Info Mount the larger inside diameter of the supporting plate facing downward. – Mount compression damping shim stack with the smaller shims facing downward. – Grind the piston on both sides on a surface plate using 1200 grit sandpaper. – Clean the piston. – Mount the piston. 201145-10 Guideline 201146-10 View Top view of piston View Bottom view of piston 04/SHOCK ABSORBER, SWINGARM – 33 Mount rebound damping shim stack with the smaller shims at the top. – Mount supporting plate . – Mount and tighten nut with the collar facing upward. Guideline Nut, piston rod M10x1 30 Nm (22.1 lbf ft) 201147-10 Front shock absorber - assembling the damper 8.17 – Slide the spring and piston onto compression damping adjuster . – Lubricate the O-rings. p. 225) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Lubricant (T158) ( – Lubricate the thread. Lubricant (T159) ( – p. 226) Mount and tighten the compression damping adjuster. Guideline 201148-10 Compression damping adjuster – M31x1 Fill the damper cartridge about half full. Shock absorber oil (SAE 2,5) (50180342S1) ( – 50 Nm (36.9 lbf ft) p. 224) Grease the O-ring of the seal ring retainer. Lubricant (T158) ( p. 225) – Carefully mount the piston rod. – Mount seal ring retainer and slide it below the ring groove. – Mount lock ring . 201136-10 Info Do not scratch the inner surface. 201149-10 201150-10 – Pull out the piston rod until the seal ring retainer is in line with the lock ring. – Mount locking cap of the damper cartridge. – Bleed and fill the damper of the front shock absorber. ( – Fill the damper of the front shock absorber with nitrogen. ( – Mount rubber cap of the reservoir. p. 34) p. 37) 04/SHOCK ABSORBER, SWINGARM 34 Alternative 1 – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 201151-10 Comfort 20 clicks Standard 15 clicks Sport 12 clicks – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks – Turn adjusting screw all the way clockwise with a socket wrench. – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Turn adjusting screws , and to the position determined when the part was removed. Front shock absorber - bleeding and filling the damper 8.18 Info Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound and compression damping. – Remove the screw from the filling port. – Mount adapter on the damper. Info Hand-tighten only without using a tool. 201152-10 – Connect adapter to connector of the vacuum pump. – Clamp the damper with soft jaws or hold it as shown in the photo. 04/SHOCK ABSORBER, SWINGARM 35 Info The filling port must be located at the highest point. The piston rod moves in and out during filling; do not immobilize it by holding it with your hand. – Position the control lever as shown in the photo. Control lever External tank is set to Closed; Damper is set to Vacuum; and Oil reservoir is set to Vacuum. – Activate On/Off switch . The suction process begins. Pressure gauge drops to the required value. < 0 bar 200271-10 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Vacuum gauge drops to the required value. 4 mbar – When the vacuum gauge reaches the specified value, measure distance between the floating piston and reservoir hole using the special tool. Depth micrometer (T107S) ( p. 237) The floating piston is positioned in the lowermost position. 201153-10 – Turn control lever Oil reservoir to Equalize pressure. Guideline 4 mbar The pressure gauge increases to the required value. 0 bar 200267-10 – When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar The pressure gauge drops to the required value. 0 bar 200269-10 04/SHOCK ABSORBER, SWINGARM – 36 When the pressure gauge reaches the required value, turn control lever Oil reservoir to Vacuum. Guideline 0 bar The vacuum gauge drops to the required value. 8 mbar 200270-10 – When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize Pressure. Guideline 8 mbar P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The pressure gauge drops to the required value. 0 bar 200267-10 – When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar The pressure gauge drops to the required value. 0 bar – When the pressure gauge reaches the required value, activate the On/Off switch. Guideline 200269-10 0 bar The vacuum pump is switched off. – Stand the damper in a vertical position. Info Do not close off the adapter yet. – Slide O-ring to the end of the special tool by the specified value (distance minus specified value). Guideline 10 mm 201154-10 Depth micrometer (T107S) ( – p. 237) Push the floating piston into the reservoir to the distance described above using the special tool. Info When the piston rod is fully extended, the floating piston must be at precisely this position; otherwise, damage will occur when the shock absorber compresses and rebounds. 04/SHOCK ABSORBER, SWINGARM 37 – Remove the special tool. – Remove adapter from connector of the vacuum pump. Info Hold the damper so that the filling port is at the highest location. – Remove the adapter. – Mount and tighten screw . Guideline Screw, filling port 201155-10 M10x1 14 Nm (10.3 lbf ft) Front shock absorber - filling the damper with nitrogen 8.19 Screw in screw by approx. 2 turns but do not tighten. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Info The piston rod is fully extended. 201156-10 – Fix the special tool in the vise. Nitrogen filling tool (T170S1) ( – p. 239) Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen – Adjust the pressure regulator. Guideline 201157-10 Gas pressure – 10 bar (145 psi) Position the damper in the special tool. The hexagonal part of turning handle engages in the female hexagonal section of the filling port screw. – Open spigot . – Fill the damper for at least 15 seconds. Guideline Gas pressure 10 bar (145 psi) Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pressure. – Screw the filling port shut with turning handle . – Close the spigot and remove the damper from the special tool. – Tighten the filling port screw. Guideline Screw, filling port for reservoir M5 3 Nm (2.2 lbf ft) 04/SHOCK ABSORBER, SWINGARM 38 Front shock absorber - installing the spring 8.20 – Clamp the damper in a vise using soft jaws. – Mount retaining ring and adjusting ring . – Measure the overall spring length in an unloaded state. – Position spring . – Mount sleeve . – Position the spring and pull it down. – Mount spring retainer . The open end is opposite to the spring end. 201143-10 Alternative 1 – Tighten the spring by turning adjusting ring to the specified measurement. Guideline P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Spring preload Comfort 3 mm Standard 5 mm Sport 8 mm Hook wrench (83019001000) ( 201131-10 p. 234) Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Tighten the spring by turning the adjusting ring to the position determined when it was removed. – Hold the adjusting ring in place. Tighten retaining ring . – Loosen adjusting rings and . Hook wrench (83019001000) ( – p. 234) Measure the cross over setting between sliding bushing and the collar of adjusting ring . Guideline Cross over 302076-10 19±1.5 mm (0.75±0.059 in) – Adjust the sleeve by turning adjusting ring to the specified measurement . – Lock the adjusting rings. Rear shock absorber - adjusting the high-speed compression damping 8.21 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. 04/SHOCK ABSORBER, SWINGARM 39 Info The high-speed setting has an impact on the fast compression of the shock absorber. – Turn adjusting screw all the way clockwise with a socket wrench. Info Do not loosen nut ! – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 1.5 turns Standard 1 turn P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301791-10 Sport 1 turn Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Rear shock absorber - adjusting the low-speed compression damping 8.22 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Info The low-speed setting has an impact on the slow to normal compression of the shock absorber. – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen nut ! – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline 301791-11 Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 04/SHOCK ABSORBER, SWINGARM 40 Rear shock absorber - adjusting the rebound damping 8.23 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info The rebound damping setting has an impact on the rebound of the shock absorber. – Turn adjusting screw clockwise up to the last perceptible click. – Turn back to the left by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 301792-10 Comfort 20 clicks Standard 15 clicks Sport 15 clicks Info Turning to the right increases damping, while turning to the left lessens damping. Rear shock absorber - adjusting the spring preload 8.24 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling. Tip Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. – Remove the rear shock absorber. ( – After removing the shock absorber, clean it thoroughly. p. 41) 04/SHOCK ABSORBER, SWINGARM – 41 Release counter ring . Hold adjusting ring while doing so. Hook wrench (83019002000) ( p. 234) – Turn the adjusting ring until the spring pack is no longer under tension. – Measure the overall spring pack when not under tension. 200601-01 Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The spring preload is the difference in length between the spring pack when it is unloaded and when it is installed. – Tighten the spring pack by turning the adjusting ring to the specified measurement. Guideline Spring preload – Comfort 3 mm Standard 5 mm Sport 5 mm Tighten the lock ring and adjusting ring. Info If you increase the spring preload, you should also slightly increase the rebound damping. – Install the rear shock absorber. ( p. 42) 400540-10 Removing the rear shock absorber 8.25 – Jack up the vehicle. ( – Remove the rear fender. ( p. 12) p. 70) Note Danger of damage The chain sliding piece and frame can be damaged from incorrect handling. – When removing the rear shock absorber, secure the swingarm with a tension belt to prevent it from swinging down further. – Attach the swingarm to the subframe with a tension belt to relieve the shock absorber. – Remove the bottom screw of the shock absorber. Tip Press the screw out of the swingarm with a screw driver while moving the tension belt. – 301835-10 Remove the top screw of the shock absorber and carefully remove the shock absorber out of the vehicle toward the rear. 04/SHOCK ABSORBER, SWINGARM 42 Installing the rear shock absorber 8.26 – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw . Guideline Screw, rear top shock absorber – M12 60 Nm (44.3 lbf ft) Position the shock absorber in the swingarm. Mount and tighten the bottom screw. Guideline Screw, rear bottom shock absorber – Remove the tension belt. – Install the rear fender. ( – Remove the vehicle from the work stand. ( M12 70 Nm (51.6 lbf ft) p. 71) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 12) 301834-10 Rear shock absorber - changing the oil 8.27 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. – Remove the spring from the rear shock absorber. ( – Note down the present state of rebound damping and compression damping . – Completely open the adjusters of the rebound and compression damping. – Remove rubber cap of the reservoir. – Slowly open screw . p. 44) 201050-11 The pressurized nitrogen is bled off. 201051-10 201052-10 – Remove screw . Let the oil drain out. – Bleed and fill the damper of the rear shock absorber. ( – Fill the damper of the rear shock absorber with nitrogen. ( p. 54) p. 56) 04/SHOCK ABSORBER, SWINGARM – 43 Mount rubber cap of the reservoir. 201082-11 Alternative 1 – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline Rebound damping 201050-11 Comfort 20 clicks Standard 15 clicks Sport 15 clicks – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks – Turn adjusting screw all the way clockwise with a socket wrench. – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – – – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Turn adjusting screw and to the position determined when the part was removed. Install the spring of the rear shock absorber. ( p. 57) 04/SHOCK ABSORBER, SWINGARM 44 Servicing the rear shock absorber 8.28 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. – Remove the spring from the rear shock absorber. ( – Disassemble the damper of the rear shock absorber. ( p. 44) p. 45) – Disassemble the piston rod of the rear shock absorber. ( – Disassemble the seal ring retainer of the rear shock absorber. ( – Checking the damper of the rear shock absorber. ( – Assemble the seal ring retainer of the rear shock absorber. ( p. 46) p. 48) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Assemble the piston rod of the rear shock absorber. ( – Assemble the damper of the rear shock absorber. ( – Install the spring of the rear shock absorber. ( p. 47) p. 50) p. 51) p. 52) p. 57) 201216-01 Rear shock absorber - removing the spring 8.29 Condition The shock absorber has been removed. – Clamp the shock absorber in a vise using soft jaws. – Measure and note down the spring length in the preloaded state. – Release counter ring . – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T157S) ( p. 239) 201046-10 201047-10 – Remove ring . – Remove spring retainer and washer . – Remove spring. 04/SHOCK ABSORBER, SWINGARM – Remove sleeve . – Remove spring with washer . 45 201048-10 Rear shock absorber - disassembling the damper 8.30 – Remove the spring from the rear shock absorber. ( – Note down the present state of rebound damping and compression damping . – Completely open the adjusters of the rebound and compression damping. – Remove rubber cap of the reservoir. – Slowly open screw . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 44) 201050-11 The pressurized nitrogen is bled off. 201051-10 – Remove screw . Let the oil drain out. – Remove locking cap . – Press in seal ring retainer . – Remove lock ring . 201052-10 Info Do not scratch the inner surface. 201053-10 201054-10 – Remove the piston rod. Drain the remaining oil. – Remove adjusting ring with the intermediate washer and retaining ring . 04/SHOCK ABSORBER, SWINGARM – 46 Remove compression damping adjuster . Remove the spring and piston. 201055-10 Rear shock absorber - disassembling the piston rod 8.31 Disassemble the damper of the rear shock absorber. ( Clamp the piston rod into a vise. – Remove nut . – Remove rebound shim stack . – Remove piston . – Remove compression shim stack . p. 45) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – 201063-10 Info Thread the compression shim stack onto a screwdriver and set them down together. 201064-10 – Remove sleeve . – Remove rebound shim stack . Info Thread the rebound shim stack onto a screwdriver and set them down together. 201065-10 – Remove piston . – Remove compression shim stack . Info Thread the compression shim stack onto a screwdriver and set them down together. 201066-10 201067-10 – Remove rebound washer . – Remove seal ring retainer . 04/SHOCK ABSORBER, SWINGARM – 47 Remove locking cap and rubber buffer . 201068-10 Rear shock absorber - disassembling the seal ring retainer 8.32 Disassemble the piston rod of the rear shock absorber. ( Remove rebound rubber . – Remove centering disk . – Remove seal ring . – Remove washer from seal ring . – Remove washer . p. 46) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – 200785-10 200786-10 – Remove O-ring . – Remove dust boot . 200787-10 Changing the pilot bushing 8.33 – Disassemble the seal ring retainer of the rear shock absorber. ( – Press pilot bushing out of seal ring retainer using the special tool. Press drift (T1504) ( 200796-10 p. 238) p. 47) 04/SHOCK ABSORBER, SWINGARM – 48 Slide the new pilot bushing onto the special tool. Press drift (T1504) ( – Position the pilot bushing in the seal ring retainer using the special tool. Press drift (T1504) ( – p. 238) p. 238) Support seal ring retainer using sleeve of the special tool. Press the pilot bushing all the way in. Assembly tool (T150S) ( 200797-10 – Lubricate the special tool. Fork oil (SAE 5) ( p. 224) Calibration pin (T1205) ( p. 238) Support seal ring retainer using sleeve of the special tool. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – p. 238) Assembly tool (T150S) ( – p. 238) Press the special tool through the new pilot bushing. Calibration pin (T1205) ( 200798-10 p. 238) The pilot bushing is calibrated. – Assemble the seal ring retainer of the rear shock absorber. ( p. 50) Rear shock absorber - checking the damper 8.34 Condition The damper has been disassembled. – Measure the inside diameter on both ends and in the middle of the damper cartridge. Damper cartridge Minimum diameter » If the measured value is greater than the specified value: – – If there is damage or wear: – – Change the damper cartridge. Check the heim joint for damage and wear. » If there is damage or wear: – – Change the damper cartridge. Check the damper cartridge for damage and wear. » 201070-10 46.10 mm (1.815 in) Change the heim joint. Measure the diameter of the piston rod. Piston rod Diameter » If the specified value is not reached: – – ≥ 17.95 mm (≥ 0.7067 in) Replace the piston rod. Measure the run-out of the piston rod. Piston rod 201069-10 Run-out » If the measured value is greater than the specified value: – – Replace the piston rod. Check the piston for damage and wear. » ≤ 0.03 mm (≤ 0.0012 in) If there is damage or wear: – Replace the piston rod. 04/SHOCK ABSORBER, SWINGARM – 49 Check the piston rings for damage and wear. » If damaged or if a bronze-colored surface is visible: – Change the piston rings. 200813-10 Rear shock absorber - removing the heim joint 8.35 Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The operations are the same on the top and bottom heim joint. Condition The shock absorber has been removed. – Clamp the shock absorber in a vise using soft jaws. – Remove both collar bushings of the heim joint using a pin. – Remove seal rings on both sides. – Press the heim joint against a lock ring using the special tool. 201084-10 201085-10 Pressing tool (T1207S) ( p. 238) – Remove the second lock ring . – Place special tool underneath and press out heim joint using special tool . 201086-10 Pressing tool (T1207S) ( 201087-10 p. 238) 04/SHOCK ABSORBER, SWINGARM 50 Rear shock absorber - installing the heim joint 8.36 Info The operations are the same on the top and bottom heim joint. – Position the new heim joint and the special tool. Pressing tool (T1206) ( – p. 238) Press the heim joint all the way in. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 201088-10 – Press the heim joint against the lock ring using the special tool. Pressing tool (T1207S) ( p. 238) – Mount the second lock ring . – Mount seal rings on both sides. – Position and press in both collar bushings . 201086-11 201085-11 201089-10 Rear shock absorber - assembling the seal ring retainer 8.37 – Mount dust boot with the special tool. Mounting sleeve (T1204) ( – Lubricate the sealing lip of the dust boot. Lubricant (T625) ( 200792-10 p. 237) p. 225) 04/SHOCK ABSORBER, SWINGARM – 51 Lubricate the groove of the O-ring. Lubricant (T158) ( p. 225) – Mount O-ring . – Mount washer . – Position washer on seal ring . – Grease the seal ring and mount with the washer facing downward. 200793-10 p. 226) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Lubricant (T511) ( 200794-10 – Mount centering disk . – Mount rebound rubber . 200795-10 Rear shock absorber - assembling the piston rod 8.38 – Assemble the seal ring retainer of the rear shock absorber. ( – Clamp the piston rod into a vise. – Mount bump rubber and locking cap . – Position the special tool on the piston rod. Mounting sleeve (T1554) ( – p. 239) Grease the dust boot and slide seal ring retainer onto the piston rod. Lubricant (T625) ( 201071-10 p. 50) p. 225) – Remove the special tool. – Mount rebound damping washer . – Mount compression damping shim stack with the smaller shims facing downward. – Grind piston on both sides, using 1200 grit sandpaper on a surfacing plate. – Clean the piston. – Mount the piston. 201072-10 Guideline 201073-10 View Top view of piston View Bottom view of piston 04/SHOCK ABSORBER, SWINGARM 52 – Mount rebound damping shim stack with the smaller shims at the top. – Mount sleeve . – Mount compression damping shim stack with the smaller shims at the bottom. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 201074-10 201075-10 – Grind piston on both sides on a surface plate using 1200 grit sandpaper. – Clean the piston. – Mount the piston. Guideline View Top view of piston View Bottom view of piston 201076-10 – Mount the lower rebound washer and washer . Info The washer centers the lower rebound washer. – Mount the upper rebound washer . – Mount and tighten nut . Guideline Nut, piston rod 201077-10 M10x1 30 Nm (22.1 lbf ft) Rear shock absorber - assembling the damper 8.39 – Assemble the piston rod of the rear shock absorber. ( – Slide the spring and piston onto compression damping adjuster . – Lubricate the O-rings. Lubricant (T158) ( – 201078-10 p. 225) Lubricate the thread. Lubricant (T159) ( – p. 51) p. 226) Mount and tighten compression damping adjuster . Guideline Compression damping adjuster M31x1 50 Nm (36.9 lbf ft) 04/SHOCK ABSORBER, SWINGARM – 53 Mount adjusting ring with the intermediate washer and retaining ring . Info It is not possible to mount the rings after the piston rod has been mounted. – Mount screw but do not tighten yet. – Lubricate the O-ring of the seal ring retainer. 201079-10 Lubricant (T158) ( – p. 225) Fill the damper cartridge about half full. p. 224) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Shock absorber oil (SAE 2,5) (50180342S1) ( 201080-10 – Carefully mount the piston rod. – Mount seal ring retainer and slide it below the ring groove. – Mount lock ring . Info Do not scratch the inner surface. – Pull out the piston rod until the seal ring retainer is in line with the lock ring. – Mount locking cap of the damper cartridge. – Bleed and fill the damper of the rear shock absorber. ( – Fill the damper of the rear shock absorber with nitrogen. ( – Mount rubber cap of the reservoir. – Turn adjusting ring with the intermediate washer and retaining ring all the way down. p. 54) p. 56) 201081-10 201082-10 Alternative 1 – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 201083-10 Comfort 20 clicks Standard 15 clicks Sport 15 clicks – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. 04/SHOCK ABSORBER, SWINGARM 54 Guideline Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks – Turn adjusting screw all the way clockwise with a socket wrench. – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 1.5 turns Standard 1 turn Sport 1 turn P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Comfort Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Turn adjusting screws , and to the position determined when the part was removed. Rear shock absorber - bleeding and filling the damper 8.40 Info Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound and compression damping. – Remove the screw from the filling port. – Mount adapter on the damper. Info Hand-tighten only without using a tool. – Connect adapter to connector of the vacuum pump. – Clamp the damper with soft jaws or hold it as shown in the photo. Info 201090-10 Clamp the damper only lightly. The filling port must be located at the highest point. The piston rod moves in and out during filling; do not immobilize it by holding it with your hand. – Position the control lever as shown in the photo. Control lever External tank is set to Closed; Damper is set to Vacuum; and Oil reservoir is set to Vacuum. – Activate On/Off switch . The suction process begins. Pressure gauge drops to the required value. < 0 bar 200271-10 Vacuum gauge drops to the required value. 4 mbar 04/SHOCK ABSORBER, SWINGARM – 55 Determine distance between the floating piston and reservoir hole with the special tool. Depth micrometer (T107S) ( p. 237) The floating piston is positioned in the lowermost position. 201091-10 – When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize pressure. Guideline 4 mbar P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The pressure gauge increases to the required value. 0 bar 200267-10 – When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar The pressure gauge drops to the required value. 0 bar 200269-10 – When the pressure gauge reaches the required value, turn control lever Oil reservoir to Vacuum. Guideline 0 bar The vacuum gauge drops to the required value. 8 mbar 200270-10 – When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize Pressure. Guideline 8 mbar The pressure gauge drops to the required value. 0 bar 200267-10 04/SHOCK ABSORBER, SWINGARM – 56 When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The pressure gauge drops to the required value. 0 bar – When the pressure gauge reaches the required value, activate the On/Off switch. Guideline 200269-10 0 bar The vacuum pump is switched off. – Slide O-ring to the end of the special tool by the specified value (distance minus specified value). Guideline 10 mm Depth micrometer (T107S) ( – 201092-10 p. 237) Push the floating piston into the reservoir to the distance described above using the special tool. Info When the piston rod is fully extended, the floating piston must be at precisely this position; otherwise, damage will occur when the shock absorber compresses and rebounds. – Remove the special tool. – Remove adapter from connector of the vacuum pump. Info Hold the damper so that the filling port is at the highest location. – Remove the adapter. – Mount and tighten screw . Guideline Screw, filling port 201093-10 M10x1 Rear shock absorber - filling the damper with nitrogen 8.41 – Screw in screw by approx. 2 turns but do not tighten. Info The piston rod is fully extended. 201095-10 14 Nm (10.3 lbf ft) 04/SHOCK ABSORBER, SWINGARM – Fix the special tool in the vise. Nitrogen filling tool (T170S1) ( – 57 p. 239) Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen – Adjust the pressure regulator. Guideline 201096-10 Gas pressure – 10 bar (145 psi) Position the damper in the special tool. The hexagonal part of turning handle engages in the female hexagonal section of the filling port screw. – Open spigot . – Fill the damper for at least 15 seconds. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline Gas pressure 10 bar (145 psi) Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pressure. – Screw the filling port shut with turning handle . – Close spigot and remove the damper from the special tool. – Tighten the filling port screw. Guideline Screw, filling port for reservoir M5 3 Nm (2.2 lbf ft) Rear shock absorber - installing the spring 8.42 – Ensure that adjusting ring is screwed on with the washer and retaining ring . – Screw the adjusting ring and retaining ring all the way down. – Measure the overall spring length in an unloaded state. – Position spring . 201049-11 Guideline Spring rate, auxiliary spring – Mount washer and sleeve . – Position the spring. 100 N/mm (571 lb/in) 201048-11 Guideline Spring rate, main spring 201047-11 Weight of rider: 65… 75 kg (143… 165 lb.) 78 N/mm (445 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 82 N/mm (468 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 85 N/mm (485 lb/in) 04/SHOCK ABSORBER, SWINGARM 58 – Mount washer and spring retainer . – Mount ring . Alternative 1 – Tighten the spring by turning adjusting ring to the specified measurement. Guideline Spring preload Comfort 3 mm Standard 5 mm Sport 5 mm Hook wrench (T157S) ( 201046-11 p. 239) Alternative 2 Warning P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Only make adjustments within the recommended range. – After making adjustments, ride slowly at first to get the feel of the new ride behavior. Tighten the spring by turning adjusting ring to the position determined when it was removed. Hook wrench (T157S) ( – p. 239) Hold adjusting ring and tighten lock ring . Hook wrench (T157S) ( p. 239) 05/EXHAUST 59 Removing the main silencer 9.1 Info In order to present them more clearly, the following steps are shown with a removed fender. – Remove spring . Spring hooks (50305017000) ( p. 227) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301856-10 – Remove screws and and remove the main silencer. 301857-10 Installing the main silencer 9.2 Info In order to present them more clearly, the following steps are shown with a removed fender. – Attach the main silencer and position and tighten screws and . Guideline Remaining screws, chassis M6 301857-11 – Reconnect spring . Spring hooks (50305017000) ( 301856-11 p. 227) 10 Nm (7.4 lbf ft) 05/EXHAUST 60 Removing the manifold 9.3 Info In order to present them more clearly, the following steps are shown with a removed fender. – Remove the main silencer. ( – Remove both springs . p. 59) p. 227) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Spring hooks (50305017000) ( 301580-10 – Remove screws . – Slip out the manifold. 301865-10 Installing the manifold 9.4 Info In order to present them more clearly, the following steps are shown with a removed fender. – Position manifold and mount springs . Spring hooks (50305017000) ( p. 227) 301580-11 – Mount and tighten screw . Guideline Remaining screws, chassis – 301865-11 Install the main silencer. ( M8 p. 59) 25 Nm (18.4 lbf ft) 06/AIR FILTER 61 Removing the air filter 10.1 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Remove the seat ( – Raise the rear of the air filter box lid . At the same time, use your other hand to press on the carburetor connection boot to kink it at that location. This prevents the carburetor connection boot from disconnecting from the carburetor. – Unhook the air filter holder and swing it to the side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. – Mount the clean air filter onto the air filter support. – Grease the air filter in area . p. 63) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301824-10 Installing the air filter 10.2 Long-life grease ( p. 225) 301262-10 – Put in both parts together, position them and fix them with the air filter support . Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. – Mount the air filter box lid. Info If the air filter box lid is not correctly mounted, dust and dirt can penetrate into the engine and cause damage. 301825-10 – Mount the seat. ( p. 63) Cleaning air filter 10.3 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. – Remove the air filter. ( – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 61) p. 225) 06/AIR FILTER 62 Info Only press the air filter to dry it, never wring it out. – Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( p. 226) – Clean the air filter box. – Check carburetor connection boot for damage and tightness. – Install the air filter. ( p. 61) Removing the air filter box lid with the carburetor connection boot 10.4 – Remove the seat ( – Remove hose clip . – Raise the air filter box lid and remove with carburetor connection boot . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 63) 301854-10 Installing the air filter box lid and the carburetor connection boot 10.5 301854-10 – Attach the air filter box lid with carburetor connection boot and hose clip to the carburetor. – Position the air filter box lid. – Position hose clamp and tighten. – Mount the seat. ( p. 63) 07/FUEL TANK, SEAT, TRIM 63 Removing the seat 11.1 – Pull the release hook back. Lift up the seat at the rear, pull it back and then remove from above. – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the seat and slide tab under fuel tank . 301809-10 Mounting the seat P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 11.2 301810-10 – Push down the rear of the seat until release hook engages. – Make sure that the seat is correctly locked in. 301809-11 Removing the radiator spoiler 11.3 Info The operations are the same on the left and right. – Remove the seat ( – Remove the screws on the fuel tank. – Remove the screws on the radiator. – Detach the radiator spoiler and remove it. p. 63) 301817-10 301816-10 07/FUEL TANK, SEAT, TRIM 64 Installing the radiator spoiler 11.4 Info The operations are the same on the left and right. – Hook catch of the radiator spoiler into holder of the fuel tank and position it on the radiator. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301819-10 – Mount and tighten screws on the radiator. Guideline Remaining screws, chassis – M6 10 Nm (7.4 lbf ft) Mount and tighten screws on the fuel tank. Guideline Screw on fuel tank – Mount the seat. ( M6 6 Nm (4.4 lbf ft) p. 63) 301818-10 Removing the fuel tank 11.5 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. – Remove the front trim. ( – Remove the radiator spoiler. ( – Turn the handle of the fuel tap to OFF. – Undo hose clip . – Pull off fuel hose . p. 69) p. 63) Info Remaining fuel may run out of the fuel hose. 301533-10 07/FUEL TANK, SEAT, TRIM – 65 Remove screw and take off the fuel tank. 301855-11 Installing the fuel tank 11.6 Danger Fire hazard Fuel is highly flammable. Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. – Position the fuel tank, insert screw with the bushing and tighten. Guideline Remaining screws, chassis M6 301855-10 301533-11 – Connect fuel hose . – Position hose clip . – Install the radiator spoiler. ( – Install the front trim. ( p. 64) p. 70) 10 Nm (7.4 lbf ft) 07/FUEL TANK, SEAT, TRIM 66 Fuel tap 11.7 The fuel tap is located on the right side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Possible states • Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. • Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties completely. 301779-10 08/MASK, FENDER 67 Removing the heel protector 12.1 – Remove screws . – Remove screw . – Remove screw . – Pull the heel protector off of the cross member. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301849-11 301848-11 – Remove screws . – Remove screw . – Remove screw . – Pull the heel protector off of the cross member. – Remove screw . – Take off brace and washer . 301851-11 301850-11 301847-11 08/MASK, FENDER 68 Installing the heel protector 12.2 – Position washer and cross member . – Mount screw but do not tighten yet. Guideline Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) 301847-10 – Slide the heel protector onto the cross member and position it. – Mount screw but do not tighten yet. Guideline M6 15 Nm (11.1 lbf ft) M6 15 Nm (11.1 lbf ft) M6 15 Nm (11.1 lbf ft) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Remaining nuts, chassis 301848-10 – – Position the retaining bracket. Mount screws but do not tighten yet. Guideline Remaining nuts, chassis – Mount screws but do not tighten yet. Guideline Remaining nuts, chassis 301849-10 – Slide the heel protector onto the cross member and position it. – Mount screw but do not tighten yet. Guideline Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) M6 15 Nm (11.1 lbf ft) M6 15 Nm (11.1 lbf ft) Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) 301850-10 – Position the retaining bracket. – Mount screws but do not tighten yet. Guideline Remaining nuts, chassis – Mount screws but do not tighten yet. Guideline Remaining nuts, chassis 301851-10 – Tighten all screws. Guideline 08/MASK, FENDER 69 Removing the front cover 12.3 – Remove screw . – Slide the front cover up and remove it. 301811-10 Installing the front cover 12.4 Position the front cover in slots on both sides of the front trim. Mount and tighten the screw. – Remove the front cover. ( – Remove screws . – Raise the front trim and disconnect the plug-in connector from the emergency OFF switch with the rip cord. – Remove the front trim. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – 301812-10 Removing the front trim 12.5 301820-10 p. 69) 08/MASK, FENDER 70 Installing the front trim 12.6 – Connect the plug-in connector of the emergency OFF switch with the rip cord and position the front trim. – Mount all screws. – Fully tighten screws . Guideline Screw on fuel tank – M6 6 Nm (4.4 lbf ft) M6 10 Nm (7.4 lbf ft) Fully tighten screws . Guideline Remaining screws, chassis Install the front cover. ( p. 69) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301820-11 Removing the rear fender 12.7 – Remove the seat ( – Remove screws . – Raise the rear of the air filter box lid . At the same time, use your other hand to press on the carburetor connection boot to kink it at that location. This prevents the carburetor connection boot from disconnecting from the carburetor. – Raise fender at the rear and remove it. p. 63) 301822-10 301821-10 08/MASK, FENDER 71 Installing the rear fender 12.8 – Raise the rear of air filter box lid . At the same time, use your other hand to press on the carburetor connection boot to kink it at that location. This prevents the carburetor connection boot from disconnecting from the carburetor. – Position front fender . – Fix the air filter box lid in the fender. Info If the air filter box lid is not correctly mounted, dust and dirt can penetrate into the engine and cause damage. 301821-11 – Mount and tighten screws . Guideline M6 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Remaining screws, chassis – 301822-11 Mount the seat. ( p. 63) 10 Nm (7.4 lbf ft) 09/FRONT WHEEL 72 Checking the tire air pressure 13.1 Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. Check the tire pressure on all wheels and correct it if necessary. – Remove the dust cap. – Check the tire air pressure when the tires are cold. Tire pressure gauge (83519001000) Tire air pressure off road » 0.3 bar (4 psi) If the tire pressure does not meet specifications: Correct the tire pressure. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 100044-10 – Mount the dust cap. Checking the tire condition 13.2 Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on vehicle handling. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the vehicle. The tires mounted on the front and rear wheels must have similar profiles. Worn tires have a negative effect on vehicle handling, especially on wet surfaces. – Examine the tire for cuts, foreign bodies and other damage. – Check the tire age. Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. 400602-10 » If the tire is older than five years: – Change the tire. Removing wheel/wheels 13.3 Info Proceed in the same way on the other wheels if necessary. – Pull the hand brake lever, push the locking pawl down and release the hand brake lever. (Figure 301776-10 p. 88) 09/FRONT WHEEL 73 – Loosen the wheel nuts . – Jack up the vehicle. ( – Remove the wheel nuts. Remove the wheel. p. 12) Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Carefully remove the wheel, making sure it does not become jammed with the threads of the screws. 300278-10 Installing the wheel/wheels 13.4 Note Material damage Damage and destruction of components from incorrect positioning and mounting. – Do not swap the wheels; the tire valves must always be on the outside when the wheels are positioned and mounted. Info Proceed in the same way on the other wheels if necessary. – Position the wheel on the hub. Info Note the direction of travel of the front wheels. Carefully position the wheel on the hub, being careful not to damage the threads of the screws. – Mount wheel nuts but do not tighten. – Remove the vehicle from the work stand. ( – Pull the hand brake lever, push the locking pawl down and release the hand brake lever. (Figure 301776-10 p. 88) – Tighten the wheel nuts crosswise. p. 12) Guideline Wheel nut 300278-10 M10x1.25 45 Nm (33.2 lbf ft) 09/FRONT WHEEL 74 Checking brake discs 13.5 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement . Info Wear reduces the thickness of the brake disc around the area used by the brake linings. Brake discs - wear limit Front 3.5 mm (0.138 in) Rear 3.5 mm (0.138 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 400362-10 » If the brake disc thickness is less than the specified value: – – Change the brake disc. Check the front and rear brake discs for damage, cracking and deformation. » If the brake disc exhibits damage, cracking or deformation: – Change the brake disc. 10/REAR WHEEL 75 Checking chain dirt 14.1 – Check the chain for heavy soiling. » If the chain is very dirty: – p. 75) Clean the chain. ( 400678-01 Cleaning the chain 14.2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 225) Off-road chain spray ( p. 226) 400725-01 Checking chain wear 14.3 – Park the vehicle on a horizontal surface and shift gears to neutral. – Pull on the lower part of the chain with the specified weight . Guideline Chain-wear measuring weight – 10… 15 kg (22… 33 lb.) Measure the distance of 18 chain links in the upper chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance at the longest chain section » 272 mm (10.71 in) If the distance is greater than the specified measurement: – Replace the chain. Info When you replace the chain, you should also replace the rear sprocket and engine sprocket. New chains wear out faster on old, worn sprockets. 301796-10 10/REAR WHEEL 76 Checking rear sprocket / engine sprocket for wear 14.4 – Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Replace the rear sprocket / engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be replaced together. 400227-01 – Check that the chain guides are tight. Checking the chain tension 14.5 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel eccentric element) are under additional load. Apart from premature wear, in extreme transmission output shaft or the drive chain may snap. Conversely, if the chain is too loose it may jump off the engine and rear sprockets, causing the rear wheel to lock up or even leading to engine damage. Check for correct chain tension and adjust if necessary. – Park the vehicle on a horizontal surface and shift gears to neutral. – Push the upper chain section at the end of the chain sliding component upwards to measure the chain tension . Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension 100093-10 » 140… 145 mm (5.51… 5.71 in) If the chain tension does not meet specifications: – Adjust the chain tension. ( p. 76) Adjusting chain tension 14.6 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel eccentric element) are under additional load. Apart from premature wear, in extreme transmission output shaft or the drive chain may snap. Conversely, if the chain is too loose it may jump off the engine and rear sprockets, causing the rear wheel to lock up or even leading to engine damage. Check for correct chain tension and adjust if necessary. – Park the vehicle on a horizontal surface and shift gears to neutral. – Push the upper chain section at the end of the chain sliding component upwards to measure the chain tension . Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. 100093-10 10/REAR WHEEL 77 – Loosen the screws by four turns. Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric element. Alternative 2 – Position the special tool at the rear wheel eccentric element. Hook wrench (83019011000) ( – p. 234) To adjust the chain tension , slowly turn at the rear wheel or the special tool to rotate the rear wheel eccentric element forward or backward. Guideline Chain tension 140… 145 mm (5.51… 5.71 in) Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Rotating the rear wheel eccentric element forward increases chain tension. Rotating the rear wheel eccentric element backward reduces chain tension. The rear wheel eccentric element should always be positioned such that the grease nipple is visible. This ensures that the vehicle has the greatest ground clearance. 301797-10 – Fully tighten screws . Guideline Screw, rear wheel eccentric element – M8 20 Nm (14.8 lbf ft) Remove the tool . Adjusting the toe width of rear axle 14.7 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. – Engage 1st gear. – Loosen nuts of the wheel hubs on both sides. – Jack up the vehicle. ( – Remove the nuts on both sides and take all parts off of the rear axle. p. 12) 301538-10 2 3 00 Setting a narrow toe width: – Mount the wheel hub . 0 1 – 100103-10 2 Mount the conical ring with the cone facing outward. – Mount the spacer with the cone facing inward. – Mount the washer and the new self-locking nut. 10/REAR WHEEL 78 Setting a wide toe width: – Mount the spacer with the cone facing inward. 2 0 0 3 0 1 – Mount the conical ring with the cone facing outward. – Mount the wheel hub . – Mount the washer and the new self-locking nut. 100104-10 – – Remove the vehicle from the work stand. ( p. 12) Tighten nuts on both sides. Guideline M18x1.5 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Nut, rear wheel hub – 130 Nm (95.9 lbf ft) Shift gear to neutral. 301538-10 Removing the rear axle 14.8 – Engage 1st gear. – Loosen nuts of the wheel hubs on both sides. – Jack up the vehicle. ( – Remove nuts on both sides and take all parts off of the rear axle. – Remove chain joint . Remove the chain from the rear sprocket. – Loosen screw . – Turn clamping nut counterclockwise using the special tool until lock rings are freely accessible. Remove the lock rings. p. 12) 301538-12 600409-10 Open-end wrench attachment, 46 mm (83019010461) ( p. 234) – Turn clamping nut clockwise using the special tool and remove. – Remove screws . – Push back the brake linings by tilting brake caliper slightly to one side on the brake disc. Carefully pull the brake caliper off of the brake disc and let it hang to one side. 600410-10 Info Do not operate the foot brake when the brake caliper has been removed. 600411-10 10/REAR WHEEL 79 – Take brake disc off the rear axle with the holder. – Remove the O-ring. – Push the rear axle slightly to the left. Using a plastic hammer, lightly strike against the chain sprocket carrier to release the chain sprocket carrier from the lock rings. Remove lock rings . – Pull the rear axle out of the swingarm in the direction of the arrow. 600412-10 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info Hold the rear sprocket carrier. – Remove rear sprocket carrier with the O-ring. 600414-10 Installing the rear axle 14.9 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Slide on the rear axle from the left to the right all the way. Info The machined surfaces must be to the right of bearing seat . 600422-10 – Position O-ring . Attach chain sprocket carrier with the nuts facing outward. – Carefully insert sealing area on the chain sprocket carrier into the shaft seal ring of the rear wheel eccentric by lightly turning and tilting the rear axle. Info Do not damage the sealing lip of the shaft seal ring. 600423-10 600424-10 – Position lock ring with the high collar facing to the left. Slide the main shaft all the way in in the direction of the arrow. – Check that the lock rings are seated properly. 10/REAR WHEEL 80 – Position O-ring . Attach brake disc holder with the thread facing outward. – Carefully insert sealing area on the brake disc carrier into the shaft seal ring of the rear wheel eccentric by lightly turning and tilting the rear axle. Info Do not damage the sealing lip of the shaft seal ring. 600425-10 – Lightly grease the thread of the clamping nut. Long-life grease ( p. 224) Ensure that the rear axle and the brake disc holder have been correctly installed. – Turn clamping nut all the way onto the brake disc holder. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Info LH thread! 600426-10 – Position lock rings . – Tighten the clamping nut in the direction of the arrow using the special tool. 600427-10 Guideline Clamping nut, rear axle 600428-10 2"-10UNS2B-LH 25 Nm (18.4 lbf ft) Open-end wrench attachment, 46 mm (83019010461) ( – Only applies when using: Open-end wrench attachment, 46 mm (83019010461) ( p. 234) p. 234) Tighten screw . Guideline Screw, clamping nut, rear axle – M6 10 Nm (7.4 lbf ft) Position the brake caliper. Mount and tighten screws . Guideline Screw, rear brake caliper 600429-10 M6 10 Nm (7.4 lbf ft) Loctite® 243™ – Clean the brake disc and brake disc holder. – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point. – Fill the rear wheel eccentric with grease via grease nipple . Long-life grease ( p. 224) 10/REAR WHEEL 81 – Place the chain on the sprocket. Mount chain joint . Info When installing the chain joint, always make sure that the closed side of the joint is facing forward (direction of travel). 600409-11 bp 0 b0q Setting a narrow toe width: – Mount wheel hub . – Mount conical ring with the cone facing outward. – Mount spacing sleeve with the cone facing inward. – Mount the washer and the new self-locking nut. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 0 bo 100103-11 Setting a wide toe width: – Mount spacing sleeve with the cone facing inward. b0p b0q bp 0 bq 0 bo bo 0 – Mount conical ring with the cone facing outward. – Mount wheel hub . – Mount the washer and the new self-locking nut. 100104-11 – – Remove the vehicle from the work stand. ( p. 12) Tighten nuts on both sides. Guideline Nut, rear wheel hub – bp bq 0 M18x1.5 Check the chain tension. ( 130 Nm (95.9 lbf ft) p. 76) 301538-11 Changing the rear axle bearing 14.10 0 bo – Remove the rear axle. ( – Remove lock ring . – Remove brake caliper support . – Mark the position of the rear wheel eccentric in the swingarm. – Loosen screw . Remove the rear wheel eccentric in the direction of the arrow. p. 78) 600415-10 600416-10 10/REAR WHEEL 82 – Take out shaft seal rings on both sides and remove inner bearing races . – Remove old grease and clean the rear wheel eccentric. – Heat the rear wheel eccentric. 600417-10 Guideline 100 °C (212 °F) Remove outer bearing races on both sides. Mount the new outer bearing races using the special tool. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – Press mandrel (83019012000) ( 600418-10 p. 234) – After the rear wheel eccentric has cooled, check that the bearing races are firmly seated. – Insert the inner bearing race in rear wheel eccentric on the left side . – Mount shaft seal ring with the blue marking on the left side . Use the special tool. Press mandrel (83019012000) ( p. 234) – Insert the inner bearing race in rear wheel eccentric on the right side . – Mount shaft seal ring with the green marking on the right side . Use the special tool. Press mandrel (83019012000) ( p. 234) Info Do not swap the shaft seal rings, as otherwise grease may get onto the brake disc from the rear wheel eccentric. – Lightly grease the sealing lips of the shaft seal rings. Long-life grease ( p. 224) 600420-10 – Insert the rear wheel eccentric into the swingarm and align it with the marking made when it was dismantled. – Tighten screws . Guideline Screw, rear wheel eccentric element M8 20 Nm (14.8 lbf ft) Info The rear wheel eccentric element should always be positioned such that the grease nipple is visible. This ensures that the vehicle has the greatest ground clearance. 600416-11 600415-11 – Position brake caliper support . – Mount lock ring . – Install the rear axle. ( p. 79) 11/WIRING HARNESS, BATTERY 83 Ignition curve plug connection 15.1 Plug-in connector is located under the trim at the front on the frame tube. Possible states • Performance – The plug-in connector is connected to achieve better performance. • Soft – The plug-in connector is disconnected for better driveability. 301829-10 Changing the ignition curve 15.2 – Remove the front trim. ( p. 69) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Changing the ignition curve from Performance to Soft. – Disconnect plug-in connector . (Figure 301829-10 p. 83) Soft – The plug-in connector is disconnected for better driveability. ( Changing the ignition curve from Soft to Performance. – Connect the plug-in connector . (Figure 301829-10 p. 83) p. 83) Performance – The plug-in connector is connected to achieve better performance. ( – Install the front trim. ( p. 83) p. 70) Removing the battery 15.3 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. – In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor. – Switch off all power consumers and switch off the engine. – Remove the rear fender. ( – Disconnect the negative (minus) cable of the battery. – Pull back the plus pole cover and disconnect the positive (plus) cable of the battery. – Loosen the rubber band . – Remove the battery. – Place the battery in the battery holder. p. 70) 300279-10 Installing the battery 15.4 Battery (YTX5L-BS) ( – 300279-11 p. 210) Reconnect rubber band . – Attach the positive (plus) cable and replace the plus pole cover . – Connect the negative (minus) cable of the battery. – Install the rear fender. ( p. 71) 11/WIRING HARNESS, BATTERY 84 Recharging the battery 15.5 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. – In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor. Warning Environmental hazard Battery parts and acid are harmful to the environment. Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even if there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid charging with a high charging current has a negative impact on the service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes via the safety valves. This reduces the battery capacity. If the vehicle is started repeatedly until the battery is depleted, the battery must be charged immediately. If the battery is left in a discharged state for an extended period, it will drain completely and sulfate, destroying the battery. The battery is maintenance-free, which means that the acid level does not need to be checked. – Switch off all power consumers and switch off the engine. – Remove the rear fender. ( – Disconnect the minus (negative) cable of the battery to avoid damage to the vehicle's electronics. – Connect the battery charger to the battery. Switch on the battery charger. p. 70) Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove the lid . Charge the battery to a maximum of 10% of the capacity specified on the battery housing . – Switch off the charger after charging. Disconnect the battery. Guideline The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the vehicle is not in use – 301540-10 Install the rear fender. ( p. 71) 3 months 11/WIRING HARNESS, BATTERY 85 Changing the main fuse 15.6 – Switch off all power consumers and switch off the engine. – The main fuse is located in the starter relay in front of the battery. – Remove protection covers . – Remove the faulty main fuse. Info You can recognize a blown fuse by its broken filament . Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. Use only fuses with the prescribed amperage. Never by-pass or repair fuses. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – Insert the new fuse. Fuse (58011109120) Tip Replacement fuse should always be present in the starter relay to make sure it is available when needed. 301833-10 – Replace the protection covers. Changing the fuses of individual power consumers 15.7 – Remove the front cover. ( – Switch off all power consumers and switch off the engine. – Open the cover of the fuse box . p. 69) Info The designation of the fuses is located on the inside cover of the fuse box . – Remove the faulty fuse. Guideline Fuse 1 - 10A - CDI controller Fuse 2 - 10A - radiator fan Fuse 3 - not used Fuse 4 - not used Fuse 5 - power supply for auxiliary equipment Fuse res. - 10A - spare fuses Info You can recognize a blown fuse by its broken filament . Warning 301815-10 Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Insert a new fuse of the appropriate strength. Fuse (58011109110) Tip The replacement fuses should always be present in the fuse box to make sure they are available when needed. 11/WIRING HARNESS, BATTERY 86 – Close the cover of the fuse box. – Install the front cover. ( – Turn the key in the ignition switch to the position – Remove the rear fender. ( – Connect the measuring leads of the multimeter to the battery terminals. – Measure the voltage while unloaded (no electrical consumer is switched on). p. 69) Checking the battery voltage 15.8 . p. 70) Battery voltage unloaded: » 12.4… 12.8 V If the displayed value does not meet specifications: Recharge the battery. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 600405-01 Checking the charging voltage 15.9 Condition All plug-in contacts must be free of corrosion and firmly connected. The battery must be ready to start but should not be fully charged. If the battery is fully charged, start a number of times. – Remove the rear fender. ( – Connect the multimeter. The black measuring lead is connected to the negative terminal (ground) of the battery. Connect the red measuring lead to the positive terminal. – Measurement while loaded (light switched on, brakes activated) p. 70) Charging voltage under load at: 5,000 rpm » If the value displayed does not meet specifications: » If the alternator is working properly: – 600405-01 13.5… 15 V – Check the alternator. ( p. 190) Change the voltage regulator. Checking the quiescent current 15.10 – Switch off all power consumers and switch off the engine. – Remove the rear fender. ( – Disconnect the negative (minus) cable of the battery. – Connect the multimeter between the negative cable and negative terminal of the battery. Check the quiescent current. p. 70) Maximum quiescent current » 600404-01 < 1 mA If the measured value exceeds the specified value: – Check the plug-in connections and wiring harness. – To identify the power consumer, disconnect and reconnect the power consumers from the wiring harness one by one while observing the quiescent current. Info The power consumers in question may be a faulty voltage regulator/rectifier or creepage current in the plug-in connectors. 11/WIRING HARNESS, BATTERY 87 Checking the starter relay 15.11 – Remove the rear fender. ( – Disconnect the negative (minus) cable of the battery. – Remove the starter relay from holder next to the battery. p. 70) – Disconnect connector from the starter relay. – Disconnect cables and from the starter relay. – Connect the starter relay to a 12 V power supply as shown in the figure. Use a multimeter to check the route between the terminals. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 600406-10 Info When the starter relay is switched, a clicking sound can also be heard. Resistance with the starter relay pulled » 700089-01 0Ω When the display does not equal the setpoint: – Change the starter relay. 13/BRAKE SYSTEM 88 Hand brake lever, parking brake 16.1 The hand brake lever is located on the right side of the handlebar and operates the front brakes. The hand brake lever is combined with the parking brake, which blocks the front wheels to prevent the vehicle from rolling away. To activate the parking brake, pull the hand brake lever, push the locking pawl down and release the hand brake lever. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Possible states • Hand brake lever in basic position – Front wheels are not locked. • Hand brake lever pulled and locked in position – Front wheels are locked. 301776-10 Checking the free travel of the hand brake lever 16.2 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications. – Push the hand brake lever forward and check free travel . Free travel of hand brake lever » ≥ 3 mm (≥ 0.12 in) If the free travel does not meet specifications: – Adjust the basic position of hand brake lever. ( p. 88) 301799-10 Adjusting basic position of hand brake lever 16.3 – Check the free travel of the hand brake lever. ( – Adjust the basic setting of the hand brake lever to your hand size by turning adjusting screw . p. 88) Info 301800-10 Pull the brake lever forward and turn the adjusting screw. Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! 13/BRAKE SYSTEM 89 Checking front brake fluid level 16.4 Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and not continue riding. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in the viewer . When the brake fluid level has dropped below the bottom of the viewer: P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m » – Add front brake fluid. ( p. 89) 301801-10 Topping up the front brake fluid 16.5 Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never user DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and may damage painted surfaces! Use only clean brake fluid from a sealed container! 13/BRAKE SYSTEM 90 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws . – Remove cover with membrane . – Add brake fluid to level . Guideline Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( – 5 mm (0.2 in) p. 223) Position the cover with the membrane. Mount and tighten screws. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Clean up overflowed or spilt brake fluid immediately with water. 301802-10 Changing the front brake fluid 16.6 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! – Remove the wheel/wheels. ( – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws . p. 72) – Remove cover with membrane . – Extract the old brake fluid from the brake fluid reservoir with a syringe and add fresh brake fluid. Bleed syringe (50329050000) ( Brake fluid DOT 4 / DOT 5.1 ( p. 227) p. 223) 302054-10 – Pull off dust cap and connect a commercially available suction device (workshop equipment). – Remove the bleeder screw and suck out the old brake fluid. Info During suction, ensure that the brake fluid reservoir is always sufficiently filled with fresh brake fluid. – 302058-10 Tighten the bleeder screw. Remove the suction device and attach the dust cap. 13/BRAKE SYSTEM 91 – Pull off dust cap and connect a commercially available suction device (workshop equipment). – Remove the bleeder screw and suck out the old brake fluid. Info During suction, ensure that the brake fluid reservoir is always sufficiently filled with fresh brake fluid. – Tighten the bleeder screw. Remove the suction device and attach the dust cap. – Add brake fluid to level . 302059-10 Guideline Measurement of 5 mm (0.2 in) p. 223) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Brake fluid DOT 4 / DOT 5.1 ( – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 302055-10 – Install the wheel/wheels. ( p. 73) Checking the front brake linings 16.7 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. – Remove the wheel/wheels. ( – Check the brake linings of both front brake calipers for minimum thickness . p. 72) ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – – If damage or cracking is visible: – – p. 92) Check the brake linings for damage and cracking. » 100074-10 Change the front brake linings. ( Change the front brake linings. ( Install the wheel/wheels. ( p. 92) p. 73) Removing front brake linings 16.8 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. Info The operations are the same on the left and right. – Remove the wheel/wheels. ( – Pull the hand brake lever and release it again. p. 72) Locking pawl moves into its basic position, parking brake is deactivated. 13/BRAKE SYSTEM 92 – Push the brake piston back to release pressure on the brake linings. – Remove the locking split pins , withdraw the bolt, and take out the brake linings. – Clean the brake caliper and bolts. 100071-10 Mounting front brake linings 16.9 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. Info The operations are the same on the left and right. – Check the brake discs. ( p. 74) – Insert the inside brake lining into the brake caliper and fix with bolt . – Insert the external brake lining into the brake caliper and slide the bolts in all the way. 100072-10 – Mount the locking split pins . – Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point. – Install the wheel/wheels. ( p. 73) 100073-10 Changing the front brake linings 16.10 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. 13/BRAKE SYSTEM 93 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and may damage painted surfaces! Use only clean brake fluid from a sealed container! – Remove the front brake linings. ( – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws . – Remove cover with membrane . – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. – Mount the front brake linings. ( – Correct brake fluid level to . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 91) p. 92) Guideline Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( – 5 mm (0.2 in) p. 223) Position the cover with the membrane. Mount and tighten screws. Info Clean up overflowed or spilt brake fluid immediately with water. 301802-10 Checking free travel of foot brake lever 16.11 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications. – Disconnect spring . – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel . Guideline Free travel at foot brake lever » If the free travel does not meet specifications: – 301803-10 – 3… 5 mm (0.12… 0.2 in) Adjust the basic position of the foot brake lever. ( p. 93) Reconnect spring . Adjusting basic position of foot brake lever 16.12 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications. 13/BRAKE SYSTEM 94 – Disconnect spring . – Loosen nut and with push rod , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever individually, loosen nut and turn screw accordingly. Info The range of adjustment is limited. – Turn push rod accordingly until you have free travel . 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 and tighten nut . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline Remaining nuts, chassis – M8 30 Nm (22.1 lbf ft) M6 15 Nm (11.1 lbf ft) Hold push rod and tighten nut . Guideline 301804-10 Remaining nuts, chassis – Reconnect spring . Checking rear brake fluid level 16.13 Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and not continue riding. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. – Park the vehicle on a horizontal surface. – Check the brake fluid level in the viewer . » When the brake fluid level has dropped to the bottom of the viewer : – Add rear brake fluid. ( p. 94) 301805-10 Adding rear brake fluid 16.14 Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. 13/BRAKE SYSTEM 95 Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and may damage painted surfaces! Use only clean brake fluid from a sealed container! – Remove screw with membrane . – Add brake fluid to level . 301806-10 Brake fluid DOT 4 / DOT 5.1 ( – p. 223) Refit screw with membrane . Info Clean up overflowed or spilt brake fluid immediately with water. 301807-10 Changing the rear brake fluid 16.15 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! 13/BRAKE SYSTEM 96 – Remove screw cap with membrane . – Extract the old brake fluid from the brake fluid reservoir with a syringe and add fresh brake fluid. Bleed syringe (50329050000) ( Brake fluid DOT 4 / DOT 5.1 ( p. 227) p. 223) 302056-10 – Pull off dust cap and connect a commercially available suction device (workshop equipment). – Remove the bleeder screw and suck out the old brake fluid. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m During suction, ensure that the brake fluid reservoir is always sufficiently filled with fresh brake fluid. – Tighten the bleeder screw. Remove the suction device and attach the dust cap. – Add brake fluid to level . 302060-10 Brake fluid DOT 4 / DOT 5.1 ( – p. 223) Mount the screw cap with the membrane. Info Clean up overflowed or spilt brake fluid immediately with water. – Repeatedly activate the foot brake lever until a firm pressure point is reached. 302057-10 Checking rear brake linings 16.16 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. – Check the brake linings for minimum thickness . Minimum thickness » If the minimum thickness is less than specified: – – Change the rear brake linings. ( p. 98) Check the brake linings for damage and cracking. » If damage or cracking is visible: – Change the rear brake linings. ( 100038-10 Removing rear brake linings 16.17 Warning Danger of accident Brake system failure. – ≥ 1 mm (≥ 0.04 in) Maintenance work and repairs must be carried out professionally. p. 98) 13/BRAKE SYSTEM 97 – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. – Loosen the screw while holding the hexagonal head of the bearing bolt. Unscrew the screw by approx. 10 turns and use the screw to press the bearing bolt out of the brake caliper. Remove screw. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301830-10 100064-10 Note Danger of damage Kinking of brake line. – 100066-10 Position and handle the brake line without straining it. The brake line must be replaced if it is kinked. – Swing the brake caliper up, unhook it from the brake caliper support and set it down. – Remove the brake linings . – Clean brake caliper and brake caliper support. Mounting rear brake linings 16.18 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. – Check the brake discs. ( – Check that the sliding plate is seated correctly in the brake caliper support and insert the brake linings. p. 74) Info Make sure that the decoupling plate is mounted on the piston side of the brake lining. 300265-10 13/BRAKE SYSTEM 98 – Grease the bearing bolt and insert the brake caliper with the bearing bolt into the brake caliper support . Lubricant (T625) ( p. 225) 100068-10 – Swing the brake caliper downward. Mount and tighten the screw. Guideline Screw, rear brake caliper 10 Nm (7.4 lbf ft) Loctite® 243™ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – M6 100069-10 Changing rear brake linings 16.19 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and may damage painted surfaces! Use only clean brake fluid from a sealed container! – Remove the rear brake linings. ( – Remove screw with membrane . – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. – Mount the rear brake linings. ( – Add brake fluid to level . p. 96) p. 97) Brake fluid DOT 4 / DOT 5.1 ( 301808-10 – p. 223) Refit screw with membrane . Info Clean up overflowed or spilt brake fluid immediately with water. 30/ENGINE 99 Removing the engine 17.1 – Remove the engine guard. ( p. 20) – Remove the heel protector. ( – Drain the coolant. ( p. 67) p. 181) – Remove the rear fender. ( – Remove the manifold. ( – Remove the carburetor. ( – Remove the engine sprocket. ( – Disconnect the negative cable from the battery. – Remove screws and take off clutch slave cylinder . p. 70) p. 60) p. 164) p. 179) Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Do not activate the clutch lever if the clutch slave cylinder has been removed. 301583-10 – Remove cable binder . 301584-10 – Disconnect plug of the alternator. – Disconnect plug of the ignition pulse generator. – Detach spark plug connector . – Remove screw . Hang the ground wire to the side. – Slide back the cover. Remove nut from the electrical connection on the starter motor and detach the cable. – Loosen hose clips and remove the radiator hoses and hose clips. 301585-10 301586-10 301587-10 30/ENGINE 100 – Disconnect spring . Spring hooks (50305017000) ( p. 227) 301588-10 – Remove nut . – Pull out the swingarm pivot. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Pull the swingarm pivot to the point where it is still being held. – Secure the swingarm with a suitable pin . – Remove screw . – Remove screws and take off both engine bearers. – Remove screw . – Lift the engine out of the frame. 301853-10 301590-10 301591-10 Info It is recommended to have assistance for performing this step. 301852-10 Installing the engine 17.2 – Position the engine in the frame. Info It is recommended to have assistance for performing this step. 301852-10 30/ENGINE 101 – Mount screw but do not tighten yet. Guideline Engine mounting bolt M10 60 Nm (44.3 lbf ft) 301591-11 – Position both engine bearers on the frame. Mount screws but do not tighten yet. Guideline Engine bracket screw 60 Nm (44.3 lbf ft) Mount screw but do not tighten yet. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – M10 Guideline Engine mounting bolt M10 60 Nm (44.3 lbf ft) M16x1.5 100 Nm (73.8 lbf ft) M10 60 Nm (44.3 lbf ft) M10 60 Nm (44.3 lbf ft) M10 60 Nm (44.3 lbf ft) 301590-11 – Remove pin . – Mount the swingarm pivot. – Mount and tighten nut . Guideline Nut, swingarm pivot – Tighten screw . Guideline 301853-11 Engine mounting bolt – Tighten screw . Guideline Engine bracket screw – Tighten screw . Guideline Engine mounting bolt – Reconnect spring . Spring hooks (50305017000) ( p. 227) 301588-11 – 301587-11 Attach the radiator hoses. Position and tighten hose clamps . 30/ENGINE 102 – Position the electrical connection on the starter motor. Mount and tighten nut . Slide on the cover. Guideline Remaining nuts, chassis – M6 15 Nm (11.1 lbf ft) Position the ground wire. Mount and tighten screw . Guideline Screw, starter motor M6 10 Nm (7.4 lbf ft) 301586-11 Mount spark plug connector . – Plug in connector of the ignition pulse generator. – Connector plug of the alternator. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301585-11 – Secure the cable with cable binder . – Position clutch slave cylinder . Mount and tighten screws . 301584-11 Guideline Screw, clutch slave cylinder 301583-11 10 Nm (7.4 lbf ft) – Connect the negative cable of the battery. – Install the engine sprocket. ( – Install the carburetor. ( – Install the manifold. ( – Install the rear fender. ( – Remove the filler cap on the clutch cover and fill up with engine oil. Engine oil – 302071-10 M6 p. 179) p. 166) p. 60) p. 71) 2.00 l (2.11 qt.) External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 223) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 223) Mount and tighten screw cap . – Fill coolant/bleed the cooling system. ( – Install the heel protector. ( – Install the engine guard. ( – Take a short test ride. – Check the engine for leakage. – Check the engine oil level. ( – Check the cooling system for leakage. – Check the coolant level. ( p. 68) p. 20) p. 185) p. 180) p. 181) 30/DISASSEMBLING THE ENGINE 103 Preparations 18.1 – Mount the special tool on the engine work stand. Engine fixing arm (83529002000) ( Engine work stand (61229001000) ( – p. 237) p. 230) Mount the engine on the special tool. Info Use a helper or motorized hoist. 301596-10 Removing the shift lever 18.2 Remove screw . Take off the shift lever. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301597-10 Draining the engine oil 18.3 – Remove oil drain plug with magnet . – Loosen screw plug by striking it lightly with a hammer a few times. 301598-10 – Remove screw plug with the oil screen and the O-rings. – Completely drain the engine oil. – Remove screws . Remove oil filter cover with the O-ring. 301599-10 Removing the oil filter 18.4 301600-10 30/DISASSEMBLING THE ENGINE – 104 Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 228) 301601-10 Removing the spark plug 18.5 – Remove the spark plug using special tool . p. 232) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Spark plug wrench (77329072000) ( 301602-10 Removing the valve cover 18.6 – Remove screws . Remove the valve cover with the valve cover seal. – Remove screws and the starter motor. – Remove screws . Take off the alternator cover. 301603-10 Removing the starter motor 18.7 301604-10 Removing the alternator cover 18.8 301605-10 30/DISASSEMBLING THE ENGINE – Remove centering pins . Take off the alternator cover gasket . – Remove torque limiter . 301606-10 Removing the torque limiter P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18.9 301607-10 Positioning the engine at ignition top dead center (TDC) 18.10 – Remove screw . – Turn the crankshaft counterclockwise until holes of the camshafts are flush above sealing area . – Mark the double wheel and the cylinder head in one line. 301608-10 301609-10 Info The markings will be of assistant when the camshafts are assembled. 301610-10 105 30/DISASSEMBLING THE ENGINE – 106 Mount special tool . Engine blocking screw (77329010000) ( p. 231) 301611-10 Removing the camshaft 18.11 – Remove screws . – Take off the camshaft bearing bridge. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info Ensure that the needle rollers and the O-ring remain in place. 301612-10 – Remove camshafts . – Loosen screw . – Remove screw with the seal ring. – Pull out timing chain tensioner . Remove O-ring . 301613-10 Removing the timing chain tensioner 18.12 301614-10 301615-10 30/DISASSEMBLING THE ENGINE Removing the double wheel 18.13 – Remove screws . – Take off the retaining bracket. – Screw a fitting screw into spindle . – Hold the double wheel and remove spindle . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301616-10 301617-10 – Take the timing chain off the double wheel. – Remove the double wheel with both needle bearings. – Remove the screw from the spindle. – Remove nut . 301618-10 Removing the cylinder head 18.14 301619-10 301620-10 – Unscrew nuts in a crisscross pattern and remove them with the washers. – Take off the cylinder head. 107 30/DISASSEMBLING THE ENGINE 108 – Remove centering pins and cylinder head gasket . – Remove screws . Take off the water pump cover. – Remove the gasket. 301621-10 Removing the water pump cover P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18.15 301622-10 Removing the clutch cover 18.16 – Remove screw . Info If work is to be performed on the water pump, unscrew the nut of the water pump impeller. 301623-10 – Mount special tool . Assembly pin (77329012100) ( – Remove screws and take off the clutch cover. – Remove the locating pins. – Remove quad ring . – Take off O-ring . 301624-10 301625-10 p. 231) 30/DISASSEMBLING THE ENGINE 109 Removing the piston 18.17 – Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out. 301626-10 – Remove the piston pin retainer . – Remove the piston pin. – Take off the cylinder and piston. – Push the piston upward out of the cylinder. Info If no further work is to be performed on the cylinder and piston, the piston can remain in the cylinder. Take off locating pins and cylinder base gasket . – Remove O-rings . – Remove spindle . – Remove the timing chain guide rail from above. – Remove spindle . – Remove the timing chain tensioning rail from above. – Remove screws . – Take off the retaining bracket. – Screw a fitting screw into spindle . – Hold the timing chain and remove spindle . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301627-10 Removing the timing chain rails 18.18 301628-10 Removing the timing chain 18.19 301629-10 301630-10 30/DISASSEMBLING THE ENGINE – 110 Take off the timing chain and balancer gear with the needle bearings. Info Identify the direction of travel. 301631-10 Removing the rotor and starter idler gear 18.20 Remove screw . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301632-10 – Insert special tool into the crankshaft. Protection cover (75029090000) ( – p. 230) Attach special tool to the rotor. Counteracting with the special tool, pull off the rotor by screwing in the screw. Extractor (58012009000) ( p. 228) Info Ensure that the spring washer remains in place. 301633-10 – Remove starter idler gear . – Remove screws . – Take off the retaining bracket. – Pull the cable support sleeve from the engine case. – Remove screws . – Take off the ignition pulse generator with the holder. 301634-10 Removing the ignition pulse generator 18.21 301635-10 30/DISASSEMBLING THE ENGINE 111 Removing the drive wheel of the balancer gear 18.22 – Remove freewheel gear with the needle bearing. – Remove nut with the special tool. 301636-10 Special socket, 36 mm; ½" drive (77329021000) ( Take off drive wheel of the balancer gear. – Remove screws . – Take off oil pump housing . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301648-10 Removing the force pump 18.23 p. 231) Info Ensure that the dowel pins remain in place. 301649-10 – Take off force pump . – Remove needle roller . – Remove oil pump housing with the gasket. 301650-10 301651-10 30/DISASSEMBLING THE ENGINE 112 Removing the spacer 18.24 – Remove spacer from the countershaft. – Remove the O-ring. – Unscrew screws and remove them with the washers and springs. – Remove pressure cap . 301652-10 Removing the outer clutch hub P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18.25 301683-10 – Remove pressure piece with the push rod. – Completely remove clutch discs . – Remove the special tool. 301684-10 Engine blocking screw (77329010000) ( p. 231) – Bend open lock washer . – Hold the inner clutch hub with special tool and remove nut with the lock washer. Clutch holder (77329003000) ( p. 231) – Take off the inner clutch hub. – Lock the outer clutch hub and primary gear using the special tool. 301685-10 Gear quadrant (80029004000) ( – p. 233) Loosen nut with the special tool. Special socket, 36 mm; ½" drive (77329021000) ( 301686-10 p. 231) 30/DISASSEMBLING THE ENGINE – Take off washer . – Take off the outer clutch hub. – Remove needle bearing and collar sleeve . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301688-10 301689-10 Removing the primary gear 18.26 – Remove nut . – Take off primary gear . – Remove the drive wheel of balancer shaft . – Take off centrifugal separator . 301653-10 301654-10 Removing the centrifugal separator 18.27 301655-10 113 30/DISASSEMBLING THE ENGINE Removing the suction pump 18.28 – Remove the shaft locking device . – Take off washers . – Remove oil pump gear and oil pump idler gear with the bearing. – Remove pin . 301656-10 Remove screws . Take off the oil pump cover. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – 301657-10 – Remove suction pump . – Remove pin . – Remove suction pump with the needle roller and oil pump shaft . – Push sliding plate away from the shift drum locating unit. – Remove shift shaft with the washer. 301658-10 301659-10 Removing the shift shaft 18.29 301660-10 114 30/DISASSEMBLING THE ENGINE 115 Removing the shift drum locating unit 18.30 – Remove screw . – Push away locking lever from shift drum locating unit and remove the shift drum locating unit. – Relieve tension from the locking lever. – Unscrew and remove together with locking lever , washer, sleeve and spring. 301661-10 Removing the locking lever P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18.31 301662-10 Removing the left section of the engine case 18.32 – Remove screws . – Remove screws . – Tilt the left section of the engine case upward and remove the threaded fasteners of the engine fixing arm. – Insert the special tool into the crankshaft. 301663-10 Protection cover (75029090000) ( – p. 230) Mount special tool with the appropriate screws. Extractor (83529048000) ( p. 237) Info Use the drill hole marked with 835. 301690-10 – Take off the section of the engine case. Info Do not subject the section of the engine case to any stress. The washer of the main shaft usually adheres to the bearing. – Take off the left section of the engine case. – Remove the special tool. 30/DISASSEMBLING THE ENGINE Removing the shift rails 18.33 – Remove shift rails together with upper springs and the lower springs. – Tilt shift forks to the side. 301691-10 Removing the shift drum P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18.34 Info Do not misplace the shift rollers. – Remove shift drum . – Remove shift forks . 301692-10 Removing the shift forks 18.35 Info Do not misplace shift rollers . 301693-10 Removing the transmission shafts 18.36 – Secure the engine in an upright position. – Remove lock ring . – Pull out both transmission shafts together from the bearing seats. 301695-10 Info Do not misplace the washers. 301696-10 116 30/DISASSEMBLING THE ENGINE Removing the crankshaft 18.37 – Take out crankshaft . – Take off the right section of the engine case. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301697-10 117 30/ENGINE - WORK ON INDIVIDUAL PARTS 118 Working on the right section of the engine case 19.1 – Remove all dowels. – Remove shaft seal ring of the crankshaft. – Remove the screws of bearing bolt . – Take off bearing bolt with the lock washer. – Remove jet . – Remove oil jet for conrod bearing lubrication. – Remove oil jet for piston cooling. – Remove screws . Remove the bearing retainers. – Remove the rest of the sealing compound and thoroughly clean the section of the engine case. – Warm the section of the engine case in an oven. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline 150 °C (302 °F) – Place the section of the engine case on a flat sheet of wood and knock on the case; the bearings will then fall out of the bearing seats. Info Any bearings still remaining in the section of the engine case must be removed with a suitable tool. 301699-10 – Insert the new cold bearings in the bearing seats of the heated section of the engine case; if necessary, use a suitable press drift to push them all the way in and make them flush. Info When pressing in, ensure that the section of the engine case lies flat in order to prevent damage. Only press in the bearings by way of the outer ring, as otherwise the bearings will be damaged when they are pressed in. – After the section of the engine case has cooled down, check to ensure that the bearings are firmly seated. Info If the bearings are not firmly seated once cooled down, it can be assumed that the bearing races will turn in the engine case at higher temperatures. In this case, the engine case needs to be replaced. – Mount the dowels. – Press in shaft seal ring of the crankshaft with the open side facing out so it is flush. – Position bearing bolt with the lock washer. – Mount and tighten the screws of bearing bolt . Guideline Screw, bearing bolt of oil pump idler shaft – M5 6 Nm (4.4 lbf ft) Loctite® 243™ M4 On block Loctite® 243™ Mount and tighten jet . Guideline Jet, engine case breather – Mount and tighten oil jet for conrod lubrication. Guideline Oil jet for conrod lubrication – M4 4 Nm (3 lbf ft) Loctite® 243™ 4 Nm (3 lbf ft) Loctite® 243™ Mount and tighten oil jet for piston cooling. Guideline Oil jet, piston cooling M4 30/ENGINE - WORK ON INDIVIDUAL PARTS – Position all bearing retainers. – Mount and tighten screws . 119 Guideline Locking screw for bearing – M5 6 Nm (4.4 lbf ft) Loctite® 243™ Blow out the oil channel with compressed air and check that it is clear. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301757-10 Working on the left section of the engine case 19.2 – Remove all dowels. – Remove shaft seal ring of the crankshaft, shift shaft and countershaft . – Remove bearing bolt . – Remove oil jet in the oil channel. – Remove oil jet for piston cooling. – Remove screws . Remove the bearing retainers. – Remove oil suction pipe . – Remove the rest of the sealing compound and thoroughly clean the section of the engine case. – Warm the section of the engine case in an oven. Guideline 150 °C (302 °F) – Place the section of the engine case on a flat sheet of wood and knock on the case; the bearings will then fall out of the bearing seats. Info Any bearings still remaining in the section of the engine case must be removed with a suitable tool. 301698-10 – Insert the new cold bearings in the bearing seats of the heated section of the engine case; if necessary, use a suitable press drift to push them all the way in and make them flush. Info When pressing in, ensure that the section of the engine case lies flat in order prevent damage. Only press in the bearings by way of the outer ring, as otherwise the bearings will be damaged when they are pressed in. – Insert bearing bolt . – After the section of the engine case has cooled down, check to ensure that the bearings are firmly seated. Info If the bearings are not firmly seated once cooled down, it can be assumed that the bearing races will turn in the engine case at higher temperatures. In this case, the engine case needs to be replaced. – Mount the dowels. – Press in shaft seal ring of the crankshaft so it is flush with the open side facing out. – Press in shaft seal ring of the shift shaft so it is flush with the open side facing in. 30/ENGINE - WORK ON INDIVIDUAL PARTS 120 – Press in shaft seal ring of the countershaft so it is flush with the open side facing in. – Mount and tighten oil jet in the oil channel. Guideline Oil jet, clutch oil supply – 6 Nm (4.4 lbf ft) Loctite® 243™ M4 4 Nm (3 lbf ft) Loctite® 243™ M5 6 Nm (4.4 lbf ft) Loctite® 243™ 15 Nm (11.1 lbf ft) Loctite® 243™ M5x1 Mount and tighten oil jet for piston cooling. Guideline Oil jet, piston cooling – Position all bearing retainers. – Mount and tighten screws . Guideline P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Locking screw for bearing – Mount and tighten oil suction pipe . Guideline Oil suction pipe M14x1 – Blow out the oil channel with compressed air and check that it is clear. – Remove nut . – Take off the water pump impeller . – Remove screws . – Press out balancer shaft gear with the bearing. 301756-10 Removing the water pump 19.3 301673-10 301674-10 30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove nut . – Pull off bearing . Extractor (59029033000) ( – 121 p. 229) Remove retaining bracket . 301209-10 Changing the shaft seal ring of the water pump 19.4 Remove shaft seal ring . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301675-10 – Remove shaft seal ring . – Press in shaft seal ring all the way, with the open side facing inward. 301676-10 Distance pieces face outward. 301676-11 – 301675-10 Press shaft seal ring , with the open side facing inward, all the way in toward distance pieces . 30/ENGINE - WORK ON INDIVIDUAL PARTS 122 Installing the water pump 19.5 – Position retaining bracket . – Press bearing in place. – Mount and tighten nut . Guideline Nut, compensating sprocket M14x1 20 Nm (14.8 lbf ft) Loctite® 243™ 301209-11 – Mount special tool . p. 228) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Mounting sleeve (58529005000) ( 301210-10 – Press balancer gear into the clutch cover. – Position the retaining bracket. – Mount and tighten screws . Guideline Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™ 6 Nm (4.4 lbf ft) Loctite® 243™ 301674-11 – Align marking with special tool . Assembly pin (77329012100) ( p. 231) 301681-10 – Mount and tighten nut . Guideline Nut, water-pump wheel 301677-10 M6 30/ENGINE - WORK ON INDIVIDUAL PARTS 123 Removing the crankshaft seal ring in the clutch cover 19.6 – Remove shaft seal ring of the crankshaft. 301678-10 Installing the crankshaft seal ring in the clutch cover 19.7 Press in shaft seal ring all the way, with the open side facing inward. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Info Support the clutch cover properly when pressing in. – Grease the sealing lip. Long-life grease ( p. 225) 301678-10 – Blow out the oil channel with compressed air and check that it is clear. 301755-10 Removing the oil pressure regulator valve 19.8 – Remove screw plug with sealing washer . – Remove pressure spring and ball . 301672-10 Checking spring length of oil pressure regulator valve 19.9 – Remove the oil pressure regulator valve. ( – Measure the spring length of the oil pressure regulator valve. p. 123) Oil pressure regulator valve Minimum length of pressure spring » If the measured value does not meet specifications: – – 200155-10 38.5 mm (1.516 in) Change the spring. Install the oil pressure regulator valve. ( p. 124) 30/ENGINE - WORK ON INDIVIDUAL PARTS 124 Installing the oil pressure regulator valve 19.10 – – Install ball and pressure spring . Mount and tighten screw plug with sealing washer . Guideline Oil pressure regulator valve plug M14x1.5 18 Nm (13.3 lbf ft) 301672-11 Checking the lubrication system P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 19.11 0 1 2 0 0 1 4 0 3 0 1 – Check the internal rotor and external rotor of oil pumps for damage and wear. » If there is damage or wear: – – If there is damage or wear: – Change the oil pump shaft. Check oil pump housing and oil pressure regulator valve for damage and wear. » If there is damage or wear: – – Change the oil pumps. Check oil pump shaft for damage and wear. » – 0 3 Change the oil pump housing, oil pressure regulator valve and, if necessary, the engine case. Check the oil pump cover for damage and wear. » If there is damage or wear: – Change the oil pump cover. 301740-01 30/ENGINE - WORK ON INDIVIDUAL PARTS 125 Removing the crankshaft bearing inner race 19.12 – Fix the crankshaft in the vise. Info Use soft jaws. – Warm up special tool . Guideline 150 °C (302 °F) Tool for inner bearing race (58429037037) ( 301247-10 p. 228) Push the warmed up special tool onto the crankshaft bearing inner race, press firmly together and pull jointly from the crankshaft. – Take off the compensating disk. – Repeat these steps on the opposite side. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Installing the crankshaft bearing inner race 19.13 – Fix the crankshaft in the vise. Info Use soft jaws. – Slide on the compensating disk. – Heat the crankshaft bearing inner race in special tool and mount together. Guideline 301247-10 120 °C (248 °F) – Repeat these steps on the opposite side. – Ensure that the new crankshaft bearing inner race is flush. Info After replacing the crankshaft bearings, the crankshaft end play must be measured. Changing connecting rod, conrod bearing and crank pin 19.14 – Position the crankshaft in the press with the special tool . Extrude plate, base (77629009001) ( – Position the special tool between the crank webs. Extrude plate, top (77629009002) ( – p. 233) p. 233) Press the crank pin with the special tool out of the upper crank web. Pressing device for crankshaft, complete (75029047000) ( 301286-10 Info Hold the lower crank web. 301279-10 – Remove the connecting rod and bearing. – Press the crank pin out of the lower crank web. p. 230) 30/ENGINE - WORK ON INDIVIDUAL PARTS – 126 Press in the new crank pin as far as possible. Oil hole is aligned with oil hole . If the oil holes are not correctly aligned, the conrod bearing will not be supplied with oil. – Use compressed air to check that the oil hole is clear. – Mount the new bearing and connecting rod . 301706-10 Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Thoroughly oil the bearing. 301284-10 – Position the special tool on the press. Pressing device for crankshaft, complete (75029047000) ( Pressing tool, crankshaft (77629008000) ( p. 230) p. 233) – Insert the crank web with connecting rod and bearing. Position the second crank web. – Position the special tool with the heel pointing down. 301280-10 Pressing tool, crankshaft (77629008000) ( – p. 233) Press in the upper crank web as far as possible. Info The press mandrel must be positioned over the crank pin. – Take the crankshaft out of the special tool and check that the connecting rod can move freely. – Measure the end play between the connecting rod and the crank webs with the special tool . 301281-10 Feeler gauge (59029041100) ( p. 229) Connecting rod - end play of lower conrod bearing » If the measured value is less than the specification: – 301704-10 – 0.40… 0.60 mm (0.0157… 0.0236 in) Correct it so the dimension is equal to the specified value. Check the crankshaft run-out at the bearing pin. ( p. 126) Checking crankshaft run-out at bearing pin 19.15 – Position the crankshaft on a roller block. – Turn the crankshaft slowly. – Check the crankshaft run-out on both bearing pins. Crankshaft - run-out at bearing pin » If the crankshaft run-out at the bearing pin is larger than the specification: – 301705-10 ≤ 0.10 mm (≤ 0.0039 in) Align the crankshaft. 30/ENGINE - WORK ON INDIVIDUAL PARTS 127 Measuring the crankshaft end play 19.16 – Insert the crankshaft in the right section of the engine case. Info Do not forget the fitted bushings. – Mount the left section of the engine case. – Mount and tighten the screws. Guideline 301214-10 M6 10 Nm (7.4 lbf ft) Screw, engine case M7x1 14 Nm (10.3 lbf ft) Mount the dial gauge support on the engine case, and measure and note the crankshaft end play. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Screw, engine case Guideline Crankshaft - end play » 0.25… 0.35 mm (0.0098… 0.0138 in) If the measured value does not meet specifications: – Remove the crankshaft. – Remove the crankshaft bearing inner race. ( – Determine the thickness of the compensating disks by calculating. – Add or subtract compensating disks equally on both sides. p. 125) Info If the end play is too small, compensating disks must be removed. If the end play is too large, compensating disks must be added. – Install the crankshaft bearing inner race. ( p. 125) Cylinder - Nikasil® coating 19.17 Nikasil® is a surface protection layer for a coating procedure developed by Mahle. The name is derived from the two materials used in this procedure - a layer of nickel into which is embedded the particularly hard silicone carbide. The most important advantages of the Nikasil® coating are very good heat conductivity, resulting in much improved performance, low wear, and a lightweight cylinder. 301248-10 Checking/measuring cylinder 19.18 – Check the cylinder bearing surface for damage. » If the cylinder bearing surface is damaged: – – Change the cylinder and piston. Measure the cylinder diameter at several locations on the ‑ and ‑axes using a micrometer to identify oval wear. Guideline Cylinder - drill hole diameter (450 SX ATV) Size I 97.000… 97.012 mm (3.81889… 3.81936 in) Size II 97.013… 97.025 mm (3.8194… 3.81987 in) 301215-10 Cylinder - drill hole diameter (505 SX ATV) Size I 100.000… 100.012 mm (3.937… 3.93747 in) Size II 100.013… 100.025 mm (3.93751… 3.93798 in) 30/ENGINE - WORK ON INDIVIDUAL PARTS 128 – The cylinder size is marked on the cylinder collar. – Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. 301249-10 Feeler gauge (59029041100) ( p. 229) ≤ 0.10 mm (≤ 0.0039 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Cylinder/cylinder head - distortion of sealing area » If the measured value does not meet specifications: – Change the cylinder. 400376-10 Checking/measuring the piston 19.19 – Check the piston sliding surface for damage. » If the piston sliding surface is damaged: – – Replace the piston and, if necessary, the cylinder. Check that the piston rings move easily in the piston ring grooves. » If a piston ring exhibits excessive resistance: – Clean the piston ring groove. Tip An old piston ring can be used to clean the piston ring groove. 301217-10 – Check the piston rings for damage. » If the piston ring is damaged: – Replace the piston ring. 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: – – Place the piston pin in the connecting rod and check the seating for play. » If the piston pin seating has excessive play: – – Replace the piston pin. Replace the connecting rod and piston pin. Measure the pistons at the piston skirt, perpendicular to the piston pin. Guideline Piston - diameter (450 SX ATV) Size I 96.960… 96.970 mm (3.81732… 3.81771 in) Size II 96.971… 96.980 mm (3.81775… 3.8181 in) Piston - diameter (505 SX ATV) 301216-10 Size I 99.960… 99.970 mm (3.93543… 3.93582 in) Size II 99.971… 99.980 mm (3.93586… 3.93621 in) Info Piston dimensions are marked on the piston head. 30/ENGINE - WORK ON INDIVIDUAL PARTS 129 Measuring piston/cylinder mounting clearance 19.20 – Check/measure the cylinder. ( – Check/measure the piston. ( – The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mounting clearance equals the largest cylinder bore diameter minus the smallest piston diameter. p. 127) p. 128) Guideline Piston/cylinder - mounting clearance Size I 0.030… 0.052 mm (0.00118… 0.00205 in) Size II 0.032… 0.054 mm (0.00126… 0.00213 in) Wear limit 0.070 mm (0.00276 in) Checking the piston ring end gap 19.21 Remove the piston ring from the piston. – Place the piston ring in the cylinder and align with the piston. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Guideline Below the upper edge of the cylinder – 10 mm (0.39 in) Measure the end gap with feeler gauge . Guideline Piston ring - end gap 301218-10 » ≤ 0.80 mm (≤ 0.0315 in) Oil scraper ring ≤ 1.00 mm (≤ 0.0394 in) If the end gap is greater than the specified measurement: – » Compression ring Check/measure the cylinder. ( p. 127) If cylinder wear lies within the specified tolerance: – Replace the piston ring. – Mount the piston ring with the marking facing toward the piston head. – Clamp camshaft into a vise. Changing the camshaft bearing 19.22 Info Protect the outer cam of the camshaft against damage with an adhesive tape. Use soft jaws. – Remove screw . – Force camshaft gear off the camshaft. – Take off roller bearing . – Degrease the cone of the camshaft and camshaft gear. – Oil roller bearing and slide it on the camshaft. 301219-10 lubricated with engine oil – 301220-10 Mount camshaft gear . 30/ENGINE - WORK ON INDIVIDUAL PARTS – 130 Mount screw but do not tighten yet. Guideline Screw, camshaft gear M10x1 50 Nm (36.9 lbf ft) – Repeat these steps for the second camshaft. – Check the autodecompressor for damage. lubricated with engine oil 301219-11 Checking the autodecompressor 19.23 » If there is damage or wear: Change the exhaust camshaft. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – Slide the camshaft bearing to the camshaft gear. – Pull lever away from camshaft and release it. » If the lever does not return to its original position: – Change the exhaust camshaft. 301221-10 Checking camshafts 19.24 – Check the camshaft for damage and wear. » – If there is damage or wear: – Change the camshaft. – If the surface of the cams is damaged, check the oil supply to the camshaft and cam lever. Measure the cams of the camshaft. Camshaft - cam height Exhaust 301250-10 33.10… 33.30 mm (1.3031… 1.311 in) Camshaft - cam height (450 SX ATV) Intake 33.90… 34.10 mm (1.3346… 1.3425 in) Camshaft - cam height (505 SX ATV) Intake » 34.20… 34.40 mm (1.3465… 1.3543 in) If the measured value does not meet specifications: – Change the camshaft. Checking the radial clearance of the camshaft bearings 19.25 – Position the camshafts. – Insert the Plastigauge clearance gauge in area . The valves are not activated. Plastigauge measuring strips (60029012000) ( 301222-10 p. 230) 30/ENGINE - WORK ON INDIVIDUAL PARTS – 131 Position camshaft bearing bridge and . Mount and tighten the screws. Guideline Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) lubricated with engine oil Info Do not forget the O-ring and needle rollers. Do not turn the camshaft. 301223-10 – Remove camshaft bearing bridge again. Compare the Plastigauge clearance gauge with the specifications on the packaging. Guideline Camshaft bearing - radial clearance 0.029… 0.053 mm (0.00114… 0.00209 in) Wear limit 0.055 mm (0.00217 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Radial clearance Info 301224-10 The width of the Plastigauge clearance gauge is a measure of the bearing play. – Remove camshaft bearing bridge . – Take off the camshafts and clean the parts. – Check the camshaft bearing bridges for damage. Checking the camshaft bearing bridges 19.26 » If there is damage or wear: – Change the cylinder head with the camshaft bearing bridge. 301225-10 Removing the valves 19.27 – Fold up the cam levers. – Take shims out of the valve spring retainers and set them aside in the arrangement corresponding to their installation positions. – Remove the screw plugs of the cam lever shaft with the O-ring. – Turn screw into the cam lever shaft. – Hold cam levers and remove the cam lever shafts. 301228-10 Info If the cam levers will continue to be used, note down their installation position. 301229-10 30/ENGINE - WORK ON INDIVIDUAL PARTS – 132 Pre-tension the valve springs using the special tool. Valve spring compressor (59029019000) ( Insert for valve spring lever (77329060000) ( p. 229) p. 232) – Remove the valve keys and unload the valve springs. – Remove the valve spring retainer and valve springs. – Pull the valve out of the valve guide from below and remove valve stem seal and valve spring seat . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301230-10 301679-10 – Mark the valves corresponding to their installation position. Info Place the valves in a carton corresponding to their installation position and label them. 300117-10 Checking the valves 19.28 – Check the valve plate for run-out. Valve - run-out At the valve plate » ≤ 0.05 mm (≤ 0.002 in) If the measured value does not meet specifications: – Change the valve. 200193-10 – Check sealing seat on the valve. Valve - sealing seat width Intake 0 A 1.50 mm (0.0591 in) Valve - sealing seat width Exhaust » 400373-10 1.50 mm (0.0591 in) If the sealing seat is not centered on the valve seat or deviates from the specification: – Machine the valve seat. 30/ENGINE - WORK ON INDIVIDUAL PARTS 133 Checking the valve springs 19.29 – Check the valve springs for breakage and wear (visual check). » If the valve spring is broken or worn: – – Change the valve spring. Measure the length of the valve springs. Valve spring Minimum length » If the measured value does not meet specifications: – 301680-10 42.8 mm (1.685 in) Change the valve springs. Checking valve spring seat 19.30 – Check the valve spring seat for breakage and wear (visual check). If the valve spring seat is broken or worn: P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m » – – Change the valve spring seat. Measure the thickness of the valve spring seat. Valve spring seat - thickness » 1.4… 1.5 mm (0.055… 0.059 in) If the measured value does not meet specifications: – Change the valve spring seat. 500173-01 Checking the cam levers 19.31 – Check the cam levers and cam lever shafts for damage and wear. » If there is damage or wear: – Change the cam levers and/or cam lever shafts. 301227-10 Checking cylinder head 19.32 – Check the valve guides with the special tool . Limit plug gauge (59029026006) ( » If the special tool is easy to insert into the valve guide: – – Change the valve guide and valve. Check the sealing area of the spark plug thread and the valve seats from damage and cracking. » If there is damage or cracking: – 301252-10 – Change the cylinder head. Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. Feeler gauge (59029041100) ( p. 229) Cylinder/cylinder head - distortion of sealing area » ≤ 0.10 mm (≤ 0.0039 in) If the measured value does not meet specifications: – 400375-10 p. 229) Change the cylinder head. 30/ENGINE - WORK ON INDIVIDUAL PARTS – 134 Check sealing seat of the valves. Valve - sealing seat width Intake 0 A 1.50 mm (0.0591 in) Valve - sealing seat width Exhaust » 400373-10 1.50 mm (0.0591 in) If the measured value does not meet specifications: – Machine the valve seat. – Blow out all oil holes with compressed air and check that they are clear. – Position valve spring seat . Mount valve stem seal . – Mount the valves corresponding to their installation position. – Mount the valve springs with the tighter coil at the bottom. – Mount the valve spring retainers. – Pre-tension the valve springs using the special tool. Installing the valves P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 19.33 301679-11 Valve spring compressor (59029019000) ( p. 229) Insert for valve spring lever (77329060000) ( p. 232) 301230-10 – Mount valve keys . Info When mounting the valve keys, ensure that they are seated properly; it is recommended to adhere the valve keys to the valves with a small amount of grease. 301233-10 – Position cam levers in the positions they had before they were removed. Info Note the wider cam lever for autodecompressors. – Mount the cam lever shafts. – Remove screw . – Mount and tighten the screw plugs. Guideline 301229-11 Screw plug, cam lever shafts – 301228-11 M10x1 10 Nm (7.4 lbf ft) Place the shims in the valve spring retainers in the positions they had before they were removed. 30/ENGINE - WORK ON INDIVIDUAL PARTS 135 Removing the freewheel 19.34 – Press expansion ring together using suitable pliers. – Take freewheel out of the freewheel hub. – Insert freewheel gear into the freewheel hub, turning the freewheel gear clockwise; do not wedge. 301234-10 Checking the freewheel P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 19.35 – Check the locking action of starter gear . » If the freewheel gear does not turn clockwise or if it does not lock counterclockwise: – Remove the freewheel. ( – Turn the freewheel 180°. – Install the free wheel. ( p. 135) p. 135) 301236-10 Installing the free wheel 19.36 – Thoroughly oil all parts. – Pull the ends of expansion ring together. – Slide freewheel into the freewheel hub. Info Note the direction of rotation. 301234-10 – Ensure that all of the tabs of the expansion ring pass through the slots of the freewheel. Info If necessary, apply pressure using a screwdriver. 301235-10 30/ENGINE - WORK ON INDIVIDUAL PARTS 136 Checking the electric starter mode 19.37 5 6 2 4 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1 3 301211-01 – Check the gear mesh and bearing of starter idler gear for damage and wear. » If there is damage or wear: – – Check the gear mesh and bearing of torque limiter for damage and wear. » If there is damage or wear: – – If there is damage or wear: – Change the freewheel gear or bearing. Check free wheel for damage and wear when it is disassembled. » If there is damage or wear: – – Change the torque limiter. Check the gear mesh and bearing of freewheel gear for damage and wear. » – Change the starter idler gear. Change the free wheel. Checking the gear mesh of starter motor for damage and wear » If there is damage or wear: – Change the starter motor. – Change O-ring of the starter motor. – Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Briefly connect the positive cable of the power supply with the connector of the starter motor. » If the starter motor does not turn when the circuit is closed: – Change the starter motor. 30/ENGINE - WORK ON INDIVIDUAL PARTS 137 Checking the timing assembly 19.38 4 0 0 1 4 0 0 5 0 3 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 2 0 1 0 301245-01 – Clean all parts well. – Check the balancer gear/double wheel for damage and wear. » If there is damage or wear: – – » If there is damage or wear: – – If there is damage or wear: – If there is damage or wear: – Change the camshaft gears. Check timing chain for damage and wear. » If there is damage or wear: – – Replace the timing chain guide rail. Check camshaft gears for damage and wear. » – Replace the timing chain tensioning rail. Check the timing chain guide rail for damage and wear. » – Change the balancer gear/double wheel. Check the timing chain tensioning rail for damage and wear. Replace the timing chain. Check the timing chain links for smooth operation. Let the timing chain hang down freely. » The chain links no longer align in a straight line: – Replace the timing chain. Preparing the timing chain tensioner for installation 19.39 – Press the timing chain tensioner together completely. Info This requires some force, as the oil must be pressed out. Without pressure, the timing chain tensioner extends again completely. 200171-10 30/ENGINE - WORK ON INDIVIDUAL PARTS – 138 Place two spacing washers or similar aids next to the timing chain tensioner piston. This ensures that, when pressed in, the piston cannot go in all the way. Guideline Thickness of the spacing washers – 2… 2.5 mm (0.08… 0.098 in) Release the timing chain tensioner. The detent mechanism engages and the piston remains in place. Final position of the piston after engagement 200172-10 3 mm (0.12 in) Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m This position is necessary for installation. If the timing chain tensioner is now pressed again and is only extended a maximum of half way (it is prevented from extending completely), this locks the detent mechanism and the timing chain tensioner can no longer be squeezed together. This function is necessary in order to ensure sufficient timing chain tension even at low oil pressures. Checking clutch 19.40 0 9 4 0 bbm 0m 0 5 0k bbk 0 2 bbl 0l 0 7 0 1 0 3 – If there is damage or wear: – If there is damage or wear: – Change the axial bearing. Place push rod on a level surface and check for run-out. » If there is run-out: – – Change the pressure piece. Check axial bearing for damage and wear. » – Change the push rod. Check the length of clutch springs . Clutch spring - length » Change all clutch springs. Check the thrust face of pressure cap for damage and wear. » If there is damage or wear: – – 39.0… 40.0 mm (1.535… 1.575 in) If the clutch spring length is less than the specified value: – – 301246-01 Check the pressure piece for damage and wear. » – 0 6 8 0 Change the pressure cap. Check the thrust surfaces of the clutch lining discs in the outer clutch hub for wear. Contact surface of clutch facing discs in outer clutch hub ≤ 0.5 mm (≤ 0.02 in) 30/ENGINE - WORK ON INDIVIDUAL PARTS » If the contact surface exhibits significant wear: – – If there is damage or wear: – If the intermediate discs are not flat or have punctiform outbreaks: – Change all intermediate discs. Check clutch facing discs for discoloration and scoring. » If there is discoloration or scoring: – – Change the needle bearing and collar sleeve. Check the intermediate disc for damage and wear. » – Change the clutch lining discs and the outer clutch hub. Check needle bearing and collar sleeve for damage and wear. » – Change all clutch lining discs. Check the thickness of clutch facing discs . ≥ 2.6 mm (≥ 0.102 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Clutch facing disk - thickness » If the clutch lining disc does not meet specifications: – – Change all clutch lining discs. Check the disc for damage and wear. » If there is damage or wear: – – 139 Change the disc. Check the inner clutch hub for damage and wear. » If there is damage or wear: – Change the inner clutch hub. Checking shift mechanism 19.41 0 3 D 0 C 0 0 B 0 A 0 1 0 A 2 0 0 5 0 E 0 3 0 4 A 0 1 0 0 1 0 4 – Check the shift forks on disc for damage and wear (visual check). » If there is damage or wear: – – » If the shift groove is worn: – – Change the shift drum. Check the seating of the shift drum in the grooved ball bearings . » If the shift drum is not correctly seated: – – Change the shift fork and idler/fixed wheel pair. Check shift grooves of shift drum for wear. Change the shift drum and/or the grooved ball bearing. Check grooved ball bearing for smooth operation and wear. » If the grooved ball bearings are stiff or worn: 301263-01 30/ENGINE - WORK ON INDIVIDUAL PARTS – – If there is damage or wear: – If the spring is damaged or worn: – If there is run-out: – If scoring or wear is present or of the shift fork is stiff: – P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m If the sliding plate is worn: – If there is severe grooving: – Change the sliding plate. Check guide bolts for firm seating and wear. » If the guide bolts are loose or worn: – – Change the sliding plate. Check return surface on the sliding plate for wear. » – Change the shift rail. Check sliding plate for wear on contact areas . » – Change the shift rail. Check the shift rails for scoring, wear and smooth operation in the shift forks. » – Change the spring of the shift rail. Check the shift rails for run-out on a flat surface. » – Change the shift rollers. Check the springs of the shift rails for damage and wear. » – Change the grooved ball bearing. Check the shift rollers for damage and wear. » – 140 Change the sliding plate. p. 140) Preassemble the shift shaft. ( – Preassemble the shift shaft. ( – Check clearance between the sliding plate and the shift quadrant. p. 140) Shift shaft - sliding plate/shift quadrant clearance F 0 » If the measured value does not meet specifications: – 0 0.40… 0.80 mm (0.0157… 0.0315 in) Change the sliding plate. 300122-01 Preassembling the shift shaft 19.42 – 5 2 Guideline Use soft jaws. 13 0 46 300154-01 F Secure the short end of the shift shaft in the bench vise. – Mount sliding plate with the guide pin facing downward and put the guide pin on the shift quadrant. – Mount pressure spring . – Slide on spring guide , push return spring , with the offset end facing upward, over the spring guide and lift the offset end over abutment bolt . – Mount stop disk . 30/ENGINE - WORK ON INDIVIDUAL PARTS 141 Disassembling the main shaft 19.43 b0k bk 8 0 b0l bl 6 0 9 0 2 0 5 0 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 7 0 4 0 3 0 1 0 301259-01 – Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws. – Remove stop disk and 2nd-gear fixed gear . – Remove 5th-gear idler gear and needle bearing . – Remove stop disk . – Remove lock ring . – Remove 4th-gear sliding gear . – Remove lock ring . – Remove stop disk . – Remove 3rd-gear idler gear . – Remove needle bearing . Disassembling the countershaft 19.44 2 0 4 0 1 0 b0n bn b0o bo b0p bq bp b0q 7 0 3 0 5 0 0 6 8 0 9 0 b0k bk b0l bl b0m bm 301261-01 – Secure the countershaft with the toothed end facing downward in the vise. Guideline Use soft jaws 30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove stop disk and 1st-gear idler gear . – Remove needle bearing and stop disk . – Remove 3rd-gear sliding gear . – Remove lock ring . – Remove stop disk . – Remove the 4th-gear idler gear and needle bearing . – Remove stop disk . – Remove lock ring . – Remove 5th-gear sliding gear . – Remove lock ring . – Remove stop disk . – Remove 2nd-gear idler gear and needle bearing . 142 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Checking transmission 19.45 6 0 4 0 0 6 0 5 7 0 0 2 0 1 0 7 0 1 0 4 0 1 4 0 0 6 0 7 0 7 0 5 4 0 0 6 0 1 0 7 0 5 0 6 3 0 0 5 6 0 0 1 4 0 5 0 6 0 301258-01 – Check the needle bearings for damage and wear. » If there is damage or wear: – – » If there is damage or wear: – – If there is damage or wear: – If there is damage or wear: – If there is damage or wear: – Change the idler/solid gear pair. Check the tooth faces of idler gears and solid gears for damage and wear. » If there is damage or wear: – – Change the idler/solid gear pair. Check the shift dogs of idler gears and solid gears for damage and wear. » – Change the main shaft and/or countershaft. Check the pivot points of idler gears for damage and wear. » – Change the main shaft and/or countershaft. Check the tooth profile of main shaft and countershaft for damage and wear. » – Change the needle bearing. Check the pivot points of main shaft and countershaft for damage and wear. Change the idler/solid gear pair. Check the tooth profiles of solid gears for damage and wear. » If there is damage or wear: – Change the idler/solid gear pair. 30/ENGINE - WORK ON INDIVIDUAL PARTS – Check solid gears for smooth operation in the profile of main shaft . » If the solid gear does not move freely: – – If the solid gear does not move freely: – Change the solid gear or the countershaft. Check stop disks for damage and wear. » If there is damage or wear: – – Change the solid gear or the main shaft. Check solid gears for smooth operation in the profile of countershaft . » – 143 Change the stop disks. Use new lock rings with every repair. Assembling the main shaft 19.46 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info Use new lock rings with every repair. – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 142) 2 0 4 0 1 0 6 0 3 0 5 0 8 0 b0k 7 0 9 0 b0l 301260-01 – Mount needle bearing . – Mount 3rd-gear idler gear . – Mount stop disk and lock ring . – Mount 4th-gear sliding gear . – Mount lock ring and stop disk . – Mount needle bearing . – Mount 5th-gear idler gear . – Mount 2nd-gear fixed gear and stop disk . – In conclusion, check all gear wheels for smooth operation. 2 4 1 6 3 5 8 bk 7 9 bl 30/ENGINE - WORK ON INDIVIDUAL PARTS 144 Assembling the countershaft 19.47 Info Use new lock rings with every repair. – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 142) b0p b0n b0q P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 4 0 3 0 – b0k b0o b0m b0l 9 0 8 0 7 0 2 0 0 1 6 0 5 0 bp Secure the countershaft with the toothed end facing downward in the vise. Guideline Use soft jaws 301262-01 bn bq bk – Mount needle bearing and 2nd-gear idler gear onto the countershaft with the protruding collar facing downward. – Mount stop disk and lock ring . – Mount the 5th-gear sliding gear with the shift groove facing up. – Mount lock ring and stop disk . – Mount needle bearing and 4th-gear idler gear with the shift dogs facing upward. – Mount stop disk and lock ring . – Mount the 3rd-gear sliding gear with the shift groove facing downward. – Mount stop disk . – Mount needle bearing and 1st-gear idler gear . – Mount stop disk . – In conclusion, check all gear wheels for smooth operation. 4 3 bo bm bl 9 2 1 7 8 5 6 30/ENGINE ASSEMBLY 145 Installing the crankshaft 20.1 – Position the right section of the engine case in the engine work stand. – Push crankshaft into the bearing seat. – Slide both transmission shafts into the bearing seats. 301697-10 Installing the transmission shafts P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 20.2 Info Do not misplace the washers. 301696-10 – Mount lock ring . – Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. – Mount shift fork in the lower shift groove of the countershaft. – Mount shift fork in the upper shift groove of the countershaft. – Slide on shift rollers . 301695-10 Installing the shift forks 20.3 Tip Fix the shift rollers to the shift forks with grease. Markings In of shift forks and face each other 301694-10 30/ENGINE ASSEMBLY 146 Installing the shift drum 20.4 – Push shift drum into the bearing seat. – Put shift forks in the shift drum. Info Do not misplace the shift rollers. 301692-11 Installing the shift rails 20.5 Install shift rails together with upper springs and lower springs. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301691-10 Installing the left engine case 20.6 – Mount the dowels. – Degrease the sealing area. Apply the sealing compound to the left section of the engine case. Loctite® 5910 301193-10 – Mount the left section of the engine case. If necessary, strike it lightly with a rubber mallet and turn the transmission shafts. Info Do not use the screws to pull the two sections of the engine case together. – Mount screws and, once all screws of the left section of the engine case have been mounted, tighten them. Guideline Screw, engine case 301663-10 – M6 10 Nm (7.4 lbf ft) Mount screws and tighten all screws in a crisscross pattern. Guideline Screw, engine case M7x1 14 Nm (10.3 lbf ft) 30/ENGINE ASSEMBLY 147 Installing the locking lever 20.7 – Mount locking lever with the sleeve and spring. – Mount and tighten screw with the washer. Guideline Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™ 301662-11 Installing the shift drum locating unit 20.8 Push away locking lever from the shift drum locating unit and position the shift drum locating unit . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Info The flat areas of the shift drum locating unit are not symmetric. – Relieve tension from the locking lever. – Mount and tighten screw . Guideline 301661-11 Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™ Installing the shift shaft 20.9 – Slide shift shaft with the washer into the bearing seat. – Push sliding plate away from the shift drum locating unit. Insert the shift shaft all the way. – Let sliding plate engage in the shift drum locating unit. – Shift through the transmission. – Oil the oil pump shaft, internal rotor and external rotor before assembly. 301660-11 Installing the suction pumps 20.10 Engine oil (SAE 10W/50) ( – p. 223) Mount suction pump with the pin and oil pump shaft . Info The rounded side of the suction pump faces the engine case. 301664-10 – Position the oil pump cover. Mount and tighten screws . Guideline Screw, oil pump cover Marking faces upward. – 301657-11 Insert pin . M5 6 Nm (4.4 lbf ft) Loctite® 243™ 30/ENGINE ASSEMBLY 148 – Position oil pump gear and oil pump idler gear with the bearing. – Position washers . – Mount shaft locking devices . – Crank the oil pump gear and ensure that it can move easily. – Mount the needle roller. – Insert suction pump . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301656-11 301659-11 Installing the centrifugal separator 20.11 – Mount centrifugal separator . – Mount oil pump housing with the gasket. 301655-10 Installing the force pump 20.12 Info Ensure that the dowel pins are seated properly. – Insert needle roller . – Position force pump . 301651-11 Info Ensure that the dowel pins are seated properly. 301659-12 30/ENGINE ASSEMBLY 149 – – Position oil pump housing . Mount and tighten screws . Guideline Screw, oil pump casing M6 10 Nm (7.4 lbf ft) – Crank the oil pump gear and ensure that it can move easily. – Position the drive wheel of balancer shaft . Loctite® 243™ 301649-11 Installing the primary gear P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 20.13 301654-11 – Position primary gear . – Mount nut but do not tighten yet. Guideline Nut, primary gear M27x1 80 Nm (59 lbf ft) Loctite® 243™ 301653-11 Installing the outer clutch hub 20.14 – Mount collar sleeve and needle bearing . – Mount the outer clutch hub. 301689-11 Info Turn the outer clutch hub and oil pump gears back and forth slightly to help them engage. – 301688-11 Mount washer . 30/ENGINE ASSEMBLY 150 – Lock the outer clutch hub and primary gear with the special tool and tighten nut . Guideline Nut, primary gear M27x1 Gear quadrant (80029004000) ( 80 Nm (59 lbf ft) Loctite® 243™ p. 233) Info 301687-10 Ensure that the crankshaft is not locked. – Mount the inner clutch hub. – Position the new lock washer and mount nut . Hold the inner clutch hub using special tool and tighten the nut. Guideline M18x1.5 80 Nm (59 lbf ft) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Nut, inner clutch hub Clutch holder (77329003000) ( 301685-11 p. 231) – Secure the nut with the lock washer. – Thoroughly oil the clutch facing discs. Engine oil (SAE 10W/50) ( Loctite® 243™ p. 223) – Beginning with an intermediate disc, alternately insert all other clutch facing discs and intermediate discs into the outer clutch hub. – Insert pressure piece with the push rod into the gearbox main shaft. – Position the crankshaft at TDC and lock it with the special tool. 301684-11 Engine blocking screw (77329010000) ( – p. 231) Position pressure cap . Mount screws with the washers and springs. Tighten the screws in a crisscross pattern. Guideline Screw, clutch spring M6 10 Nm (7.4 lbf ft) 301683-11 Installing the spacer 20.15 301652-10 – Grease the shaft seal ring before mounting. – Position the O-ring. Mount spacer with the bevel facing inward. 30/ENGINE ASSEMBLY 151 Installing the drive wheel of the balancer gear 20.16 – – Position drive wheel of the balancer gear. Mount and tighten nut with the special tool. Guideline Nut, freewheel hub M27x1 80 Nm (59 lbf ft) Special socket, 36 mm; ½" drive (77329021000) ( Loctite® 243™ p. 231) 301648-11 Installing the timing chain 20.17 Insert the needle bearings in the balancer gear and oil. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – lubricated with engine oil – Place the timing chain on the balancer gear. Info If the timing chain was used before, ensure it is running in the correct direction. – Mount the stop disks with the collar facing the balancer gear. – Insert the timing chain, balancer gear with stop disk and needle bearings into the chain shaft. – Align markings and to each other. – Mount spindle with the O-ring. – Position the retaining bracket. – Mount and tighten screws . 301665-10 Guideline Screw, timing train axle retaining bracket M5 6 Nm (4.4 lbf ft) 301666-10 Installing the free wheel gear 20.18 301636-10 – Oil the starter freewheel and needle bearing. – Mount freewheel gear with the needle bearing. Loctite® 243™ 30/ENGINE ASSEMBLY 152 Installing the ignition pulse generator 20.19 – – Position the ignition pulse generator. Mount screws but do not tighten yet. Guideline Screw, ignition pulse generator adapter 301669-10 M5 6 Nm (4.4 lbf ft) Loctite® 243™ – Position the cable and insert the cable support sleeve into the engine case. – Position the retaining bracket. – Mount and tighten screws . Guideline Screw, ignition pulse generator cable holder M6 10 Nm (7.4 lbf ft) Loctite® 243™ P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Installing the rotor 20.20 – Mount starter idler gear . – Ensure that the spring washers are seated properly. Mount the rotor. – Mount and tighten screw . 301668-10 Guideline Screw, rotor M10x1 80 Nm (59 lbf ft) lubricated with engine oil 301667-10 Installing the timing chain rails 20.21 – Slip in the timing chain guide rail from above. Mount and tighten spindle . Guideline Axle guide rail for timing chain – M14x1 15 Nm (11.1 lbf ft) Slip in the timing chain tensioning rail from above. Mount and tighten spindle . Guideline Axle tension rail for timing chain M14x1 301628-11 15 Nm (11.1 lbf ft) Installing the piston 20.22 – Move the joints of the compression ring and oil scraper ring so they are offset by 180°. – Place the oiled piston on the cylinder. Compress the piston rings using the special tool. Piston ring mounting tool (60029015000) ( p. 230) The special tool must press the piston rings together properly and lie flush with the cylinder. 301155-10 – Carefully tap the piston into the cylinder using the handle of the hammer. The piston rings should not catch or they will be damaged. 30/ENGINE ASSEMBLY 153 – Mount O-rings . – Mount locating pins and position cylinder base gasket . – Ensure that piston mark faces the exhaust side. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301627-11 301156-10 – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. Info In order to present them more clearly, the following steps will be shown with a removed piston. – Position the piston pin retainer. – Insert the special tool and press it forcefully to the piston. – Turn the special tool counterclockwise, thereby pushing the piston pin retainer into the groove. 400366-10 (450 SX ATV) Insert for piston pin retainer (77329030100) ( p. 232) (505 SX ATV) Insertion for piston ring lock (77629030000) ( – 200084-10 p. 233) Ensure that the piston pin retainer is seated properly on both sides. 30/ENGINE ASSEMBLY 154 – Remove the cloth. Keep the timing chain taut. – Carefully push the cylinder downward, letting the locating pins engage. 301647-10 Installing the clutch cover 20.23 Insert quad ring . Mount O-ring . – Position the dowel pins. – Ensure that the crankshaft has been locked in the TDC position. – Degrease the sealing area and thinly apply sealant to it. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – 301625-11 Loctite® 5910 – Mount the clutch cover. – Mount screws and tighten once all of the clutch cover screws have been mounted. Guideline Screw, clutch cover 301624-11 – M7x1 14 Nm (10.3 lbf ft) Mount screws and tighten all screws in a crisscross pattern. Guideline Screw, clutch cover – 10 Nm (7.4 lbf ft) Remove the special tool. Assembly pin (77329012100) ( – M6 p. 231) Mount and tighten screw with the O-ring. Guideline Screw plug, clutch cover M10x1 10 Nm (7.4 lbf ft) 301623-11 Installing the water pump cover 20.24 – Position the gasket. – Put the water pump cover on. Mount screw and tighten once all of the water pump cover screws have been mounted. Guideline Screw, water pump cover – M7x1 14 Nm (10.3 lbf ft) Mount screw and tighten all screws in a crisscross pattern. Guideline 301622-11 Screw, water pump cover M6 10 Nm (7.4 lbf ft) 30/ENGINE ASSEMBLY 155 Installing the cylinder head 20.25 – Mount centering pins . – Position cylinder head gasket . – Put the cylinder head in place. – Mount nut with the washers and tighten in a crisscross pattern. 301621-11 Guideline M10x1.25 Tightening sequence: Tighten in diagonal sequence. Tightening stage 1 10 Nm (7.4 lbf ft) Tightening stage 2 30 Nm (22.1 lbf ft) Tightening stage 3 50° lubricated with engine oil 10 Nm (7.4 lbf ft) lubricated with engine oil P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Nut, cylinder head 301620-11 – Mount and tighten nut . Guideline Nut, cylinder head M6 301619-11 Installing the double wheel 20.26 – Oil the needle bearings and insert them in the double wheel. lubricated with engine oil – Place the timing chain on the double wheel. – Align markings and to each other. – Mount spindle with the O-ring. – Align the spindle for the retaining bracket. – Position the retaining bracket. – Mount and tighten screws . 301646-10 Guideline Screw, camshaft bearing retaining bracket 301616-11 M5 6 Nm (4.4 lbf ft) Loctite® 243™ 30/ENGINE ASSEMBLY 156 Installing the timing chain tensioner 20.27 – Position timing chain tensioner and insert it with new O-ring . – Mount and tighten screw plug with the seal ring. 301615-11 Guideline M24x1.5 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Plug, timing chain tensioner 25 Nm (18.4 lbf ft) – Remove screw . – Press the timing chain tensioner toward the timing chain using special tool . 301614-11 Release device for timing chain tensioner (77329051000) ( p. 232) The timing chain tensioner unlocks. – Mount and tighten screw . Guideline Screw, unlocking of timing chain tensioner M10x1 10 Nm (7.4 lbf ft) 301645-10 Checking the valve timing 20.28 Condition The camshaft has not been disassembled. – Oil the camshafts and bearing positions. lubricated with engine oil – Position the camshafts and turn them so the flat surfaces face upward. – Position special tool . 301642-10 Adjustment bush bridge (77329050000) ( – p. 232) Check the valve timing. The special tool must be full contact with the cylinder head and flat surfaces. » 301640-10 If the special tool is not in full contact: – Take off the special tool. – Remove the camshafts. – Force the camshaft gears off the camshafts. – Adjust the valve timing. ( p. 157) 30/ENGINE ASSEMBLY 157 – Position the camshaft bearing bridges. Info Ensure that the needle rollers and the O-ring are correctly seated. – Mount screws and tighten from the inside to the outside. Guideline Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) lubricated with engine oil 301612-11 Adjusting the valve timing 20.29 – Position the camshafts and turn them so the flat surfaces face upward. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The valves are not activated. 301642-10 – Mount the special tool. Adjustment bush bridge (77329050000) ( – p. 232) Mount and tighten screws . Guideline Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) lubricated with engine oil 301641-10 – Position camshaft bearing bridge . Info Ensure that the locating pins are seated properly. – Mount and tighten the screws. Guideline Screw, camshaft bearing bridge 301643-10 – M7x1 14 Nm (10.3 lbf ft) lubricated with engine oil M10x1 50 Nm (36.9 lbf ft) lubricated with engine oil Tighten screw . Guideline Screw, camshaft gear – Remove the special tool. Adjustment bush bridge (77329050000) ( – p. 232) Position camshaft bearing bridge . Info Ensure that the needle rollers and the O-ring are correctly seated. – 301644-10 Mount and tighten the screws. Guideline Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) lubricated with engine oil 30/ENGINE ASSEMBLY 158 Checking the valve clearance 20.30 – Remove special tool . Engine blocking screw (77329010000) ( p. 231) – Crank over the engine repeatedly. – Position the engine at ignition top dead center (TDC). ( – Check the valve clearance at all valves between the camshaft and cam levers. p. 105) 301611-11 Guideline 0.12… 0.18 mm (0.0047… 0.0071 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Valve clearance, cold, exhaust Valve clearance, cold, intake 0.07… 0.13 mm (0.0028… 0.0051 in) Feeler gauge (59029041100) ( » 301637-10 p. 229) If the valve clearance does not meet specifications: – Adjust the valve clearance. ( – Remove special tool . – Mount and tighten screw . p. 158) Guideline Plug, crankshaft location M8 20 Nm (14.8 lbf ft) 301638-10 Adjusting the valve clearance 20.31 – Remove the camshaft. ( – Raise cam levers . – Remove shims and set down in the position in which they were installed. – Correct the shims according to the findings from checking the valve play. – Insert the fitting shims. – Position the camshaft bearing bridges. p. 106) 301639-10 Info Ensure that the needle rollers and the O-ring are correctly seated. – Mount screws and tighten from the inside to the outside. Guideline Screw, camshaft bearing bridge 301612-12 – Check the valve clearance. ( M7x1 p. 158) 14 Nm (10.3 lbf ft) lubricated with engine oil 30/ENGINE ASSEMBLY 159 Installing the torque limiter 20.32 – Mount torque limiter . – Mount centering pins . Position alternator cover gasket . 301607-10 Installing the alternator cover P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 20.33 301606-11 – Position the alternator cover. Mount screws and tighten in a crisscross pattern. Guideline Screw, alternator cover M6 10 Nm (7.4 lbf ft) 301605-11 Installing the starter motor 20.34 – Grease the O-ring. Position the starter motor. Long-life grease ( – p. 225) Mount and tighten screws . Guideline Screw, starter motor M6 10 Nm (7.4 lbf ft) 301604-10 Installing the valve cover 20.35 – Position the valve cover with the gasket. Mount and tighten screws . Guideline Screw, valve cover 301603-10 M6 8 Nm (5.9 lbf ft) 30/ENGINE ASSEMBLY 160 Installing the spark plug 20.36 – Mount and tighten the spark plug with special tool . Guideline Spark plug Spark plug wrench (77329072000) ( M10 10… 12 Nm (7.4… 8.9 lbf ft) p. 232) 301602-10 Installing the oil screen 20.37 – Mount and tighten the oil drain plug with magnet and the new sealing ring. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 301598-10 – Mount and tighten screw plug with the oil screen and the O-rings. Guideline Plug, oil screen M32x1.5 30 Nm (22.1 lbf ft) 301599-10 Installing the oil filter 20.38 – Tilt the engine on one side and fill the oil filter housing to about ⅓ full with engine oil. – Fill the oil filter with engine oil and place it in the oil filter container. – Oil the O-ring of the oil filter cover. – Mount oil filter cover . – Mount and tighten screws . 301601-11 Guideline Screw, oil filter cover 301600-11 M5 6 Nm (4.4 lbf ft) 30/ENGINE ASSEMBLY 161 Installing the shift lever 20.39 – Position the shift lever. Mount and tighten screw with the collar sleeve. Guideline Screw, shift lever M6 10 Nm (7.4 lbf ft) 301597-10 Removing the engine from the universal mounting rack 20.40 Remove the screw connection from the special tool. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Engine fixing arm (83529002000) ( – Remove the engine from the universal mounting rack. Engine work stand (61229001000) ( 301596-10 p. 237) p. 230) Loctite® 243™ 31/CARBURETOR 162 Choke 21.1 The choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated. 301780-10 Possible states • Choke function activated – The choke lever is pulled out to the stop. • Choke function deactivated – The choke lever is pushed in to the stop. Checking the play in the throttle cable 21.2 Move the handlebar to the straight-ahead position. Move the throttle lever back and forth slightly to ascertain the play in the throttle cable . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – Guideline Play in throttle cable » 3… 5 mm (0.12… 0.2 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. ( p. 14) Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. 301795-11 – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. » If the idle speed changes: – Adjust the play in the throttle cable. ( p. 14) Carburetor - adjusting idle 21.3 – Screw in the idle adjusting screw until it stops and then to the prescribed basic setting. Guideline Idle mixture adjusting screw Open 1.5 turns Adjustment tool for mixture control screw (59029034000) ( – p. 229) Run the engine until warm. Guideline 301826-10 Warm-up time – ≥ 5 min Adjust the idle speed with the adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 162) Idle speed 1,500… 1,600 rpm Info If the idle speed is set significantly higher, the engine does not start. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark. – Turn the idle adjusting screw slowly clockwise until the idle speed begins to fall. 31/CARBURETOR 163 – Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls. – Adjust to the point between these two positions with the highest idle speed. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m If there is a large increase in the engine speed, reduce the idle speed to a normal level and repeat the above steps. The extremely sporty rider will set the mixture about 1/4 of a turn back from this ideal value (leaner, clockwise) since the engine has a higher operating temperature in sporting use. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle adjusting screw to the end without any change of engine speed, you have to fit a smaller idling jet. The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet. After changing the idling jet, start from the beginning with the adjusting steps. – Adjust the idle speed with the adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 162) Idle speed 1,500… 1,600 rpm Info Following extreme air temperature or altitude changes, adjust the idle speed again. Checking the position of the throttle position sensor 21.4 – Remove the fuel tank. ( – Remove the front cover. ( – Remove the relay. – Mount a cable jumper between the green and red-white cables on connector . – Disconnect plug-in connector of the throttle position sensor. – Connect the special tool to both connectors. p. 64) p. 69) 302075-10 302073-10 Adapter cable (83029043000) ( – p. 236) Connect the positive cable of the multimeter to the yellow cable and the ground wire to the black cable of the special tool. Measure the throttle position sensor voltage. Variable throttle position sensor voltage Vvar (throttle slide closed) 302074-10 0.505… 0.855 V 31/CARBURETOR 164 » » If the specified value is not reached: – Carburetor - adjust the idle speed. ( – Adjust the position of the throttle position sensor. ( p. 162) p. 174) If the specified value is reached: – Remove the cable jumper. – Connect the relay and mount it. – Remove the special tool. Adapter cable (83029043000) ( – p. 236) Connect the plug-in connector of the throttle position sensor. – Install the fuel tank. ( – Install the front cover. ( p. 65) p. 69) Draining the carburetor float chamber P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 21.5 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. Info Carry out this work with a cold engine. – Turn handle of the fuel tap to the OFF position. (Figure 301779-10 – Guide the hose coming down behind the engine into a suitable container. p. 66) No more fuel flows from the tank to the carburetor. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber. – Tighten screw . 301826-11 Removing the carburetor 21.6 – Remove the fuel tank. ( – Remove the air filter box lid with the carburetor connection boot. ( p. 64) p. 62) 31/CARBURETOR 165 – Unplug connector of the throttle position sensor. – Remove cable binder . – Detach engine breather hose from the carburetor. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301544-10 301545-10 – Loosen hose clip . – Take carburetor out of the frame from the rear and set it down on the frame. – Remove screws . Remove carburetor cover . – Loosen nut . Detach the throttle cable and hang it to the side. 301546-10 301547-10 301548-10 301549-10 31/CARBURETOR 166 – Unscrew the hot start activation . – Remove the carburetor. – Mount the hot start activation . 301550-10 Installing the carburetor 21.7 Guideline M12 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Hot start activation 2.5 Nm (1.84 lbf ft) 301550-11 – Attach the throttle cable. Info Ensure that the throttle cable is routed correctly. – Adjust the play in the throttle cable and tighten nut . Guideline Play in throttle cable 3… 5 mm (0.12… 0.2 in) 301549-11 – Position carburetor cover . Mount and tighten screws . Guideline Other screws, carburetor M5 301548-11 – Insert carburetor into the rubber sleeve. Info Ensure that the carburetor hoses are routed correctly. 301547-11 – 301546-11 Position and tighten hose clamp . 5 Nm (3.7 lbf ft) 31/CARBURETOR 167 – Attach engine breather hose to the carburetor. Info Ensure that the engine breather hose is routed properly. 301545-11 – Connect plug of the throttle position sensor. – Secure the cables with cable binders . – Install the air filter box lid and the carburetor connection boot. ( – Install the fuel tank. ( – Check the play in the throttle cable. ( p. 65) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 162) 301544-11 Disassembling the carburetor 21.8 Condition The carburetor has been removed. – Remove screws and detach all vent hoses from the carburetor. – Remove screws . Take off the throttle slide cover and seal. 301561-10 301560-10 301562-10 – Remove screw with the spring and washer. – Pull the jet needle out of the throttle slide. – Remove screw . p. 62) 31/CARBURETOR 168 – Pull up throttle slide arm . Take throttle slide out of the carburetor along with throttle slide roller and the throttle slide plate. – Remove screws . Take off the accelerator pump cover with the seal ring. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301563-10 301551-10 – Remove seal rings , spring and membrane . – Remove screws and take off the float chamber body. – Remove fulcrum pin . Take off the float and float needle valve. – Remove main jet . – Remove idling jet , cold start jet , needle jet and buffer plate . – Screw in mixture control screw all the way, counting and noting down the number of rotations. – Remove the mixture control screw with the spring, washer and O-ring. – Screws should not be removed. 301552-10 301554-10 301555-10 301556-10 31/CARBURETOR 169 – Remove screw . Pull the hose connector out of the carburetor. – Remove screw . Take off throttle position sensor . 301557-10 Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Only remove the throttle position sensor if necessary. If screw is loosened, the throttle position sensor must be readjusted. – Unscrew choke slide . – Remove idle air jet . – Clean all jets and other parts thoroughly and blow out with compressed air. 301558-10 Carburetor cleaner ( – Clean the carburetor housing and blow out all channels in the carburetor with compressed air. Carburetor cleaner ( 301559-10 p. 225) p. 225) Info Do not use nitro thinner to clean the carburetor. 31/CARBURETOR 170 Checking/adjusting the carburetor components – P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 21.9 Disassemble the carburetor. ( p. 167) – Check/adjust the accelerator pump. ( – Check the choke slide. ( – Check the jet needle. ( – Check the throttle slide. ( – Check the needle jet. ( – Check the float needle valve. ( – Check/adjust the float level. ( – Check/adjust the throttle slide opening. ( – Check the throttle position sensor. ( – Assemble the carburetor. ( p. 170) p. 171) p. 172) p. 172) p. 173) p. 173) p. 174) p. 173) p. 171) p. 175) Checking/adjusting the accelerator pump 21.10 Condition The carburetor and accelerator pump have been removed. – Check the membrane of damage or brittleness. » If the membrane is damaged or brittle: – – Change the membrane. Check holes to ensure that they are free. » If the holes are not free: – Clean the holes. Carburetor cleaner ( 700051-10 p. 225) 301703-01 31/CARBURETOR 171 – Check/adjust the throttle slide opening. ( p. 173) Info Adjustment of the play of the accelerator pump affects the starting point of injection and has no influence on the injection rate or the intensity of the accelerator pump. – Check piston rod overhang . Guideline Piston rod overhang 700065-10 » 0.9… 1.0 mm (0.035… 0.039 in) If piston rod overhang does not meet specifications: – Correct the piston rod overhang by turning adjusting screw . Checking the choke slide 21.11 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Condition The choke slide has been removed. – Check the choke slide for smooth operation. » If the choke slide cannot be moved easily or is soiled: – Clean the choke slide. Carburetor cleaner ( – Check the plunger of the choke slide for damage and wear. » If the plunger of the choke slide is damaged or worn: – 301722-10 – p. 225) Change the choke slide. Check the rubber sleeve and lock. » If the rubber sleeve is damaged or brittle, or if the lock does not function: – Change the choke slide. Checking the hot start slide 21.12 Condition The hot start slide has been removed. – Check the hot start slide for smooth operation. » If the hot start slide cannot be moved easily or is soiled: – Clean the hot start slide. Carburetor cleaner ( – Check the plunger of the hot start slide for damage and wear. » If the plunger of the hot start slide is damaged or worn: – 302065-10 – p. 225) Change the hot start slide. Check the rubber collar. » If the rubber collar is damaged or brittle: – Change the hot start slide. Checking the throttle position sensor 21.13 Info The value in the figure is an example only. Condition The carburetor has been removed. Component temperature: 20 °C (68 °F) – Check/adjust the throttle slide opening. ( p. 173) 31/CARBURETOR 172 – Connect the plus cable of the multimeter to the blue (bu) cable and the ground cable to the black (bl) cable of the throttle position sensor connector. Measure the total throttle position sensor resistance Rtot. Guideline Throttle position sensor, total resistance Rtot 4… 6 kΩ 700063-10 – Connect the plus cable of the multimeter to the yellow (ye) cable and the ground cable to the black (bl) cable of the throttle position sensor connector. – Slowly open the throttle slide and measure the variable throttle position sensor resistance Rvar. 3… 4.5 kΩ P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Variable throttle position sensor, resistance Rvar (throttle slide fully open) » If the value does not increase at a uniform rate: » If the value is outside of specifications: – 700064-10 – Change the throttle position sensor. Adjust the position of the throttle position sensor. ( p. 174) Checking the jet needle 21.14 Condition The jet needle has been removed. – Check the jet needle for bending and wear of the coating. » If the jet needle is bent, or the coating is damaged or worn: – – Change the jet needle. Check that the needle clip is firmly seated. » If the needle clip is not firmly seated: – Change the needle clip or jet needle. 700052-10 Checking the throttle slide 21.15 Condition The throttle slide has been removed. – Check the throttle slide rollers for damage and wear. » If the throttle slide rollers do not turn smoothly, are worn or have flattened surfaces: – – » If the throttle slide rollers are loose: – 700055-10 – If the coating is damaged or worn: – If the membrane is damaged or brittle: – Change the membrane. Check that membrane is correctly seated. » If the membrane is not correctly seated: – 700056-10 Change the throttle slide. Check the membrane of the throttle slide plate for damage, brittleness and correct seating. » – Change the throttle slide. Check the coating of the throttle slide and throttle slide plate for damage and wear. » – Change the throttle slide. Except for the throttle slide valve (removable), all rollers must be firmly seated on the throttle slide. Position the membrane correctly. 31/CARBURETOR 173 Checking/adjusting the throttle slide opening 21.16 Info The basic setting of the throttle slide is used to check the beginning of injection of the accelerator pump and the basic setting of the throttle position sensor. Condition The carburetor has been removed. – Check the throttle slide opening using a wire or a drill shank. Throttle slide opening » 1 mm (0.04 in) If the throttle slide opening does not meet specifications: Adjust the throttle slide opening with adjusting screw . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301567-10 Checking the needle jet 21.17 Condition The needle jet has been removed. – Use a new jet needle as a gauge. On the jet needle, make a mark above the level at a distance . Guideline Distance 3 mm (0.12 in) Info The marking must be completely removable. 700053-10 – Insert the marked jet needle into the needle jet to be tested. Push the two parts together carefully. – Check the needle jet. » If marking is not visible on the jet needle at the upper edge of the needle jet: – Change the needle jet. 700054-10 Checking the float needle valve 21.18 Condition The float needle valve has been removed. – Check the float needle valve and the valve seat for deposits. » If deposits are present: – Clean the valve seat. Clean or change the float needle valve. Carburetor cleaner ( – Check the float needle valve for wear and check the sealing areas for notches. » If the sealing area is damaged or worn: – 700057-10 p. 225) Change the float needle valve. 31/CARBURETOR 174 Checking/adjusting the float level 21.19 Condition The carburetor and float chamber have been removed. – Tilt the carburetor to one side, preventing the pin of the float from falling out. – Tilt the carburetor until the float rests against the float needle valve but the float needle valve is not pushed together. » If the edge of the float is not parallel to the sealing area of the float housing in this position: – Adjust the float level by bending float lever . 700061-10 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Adjusting the position of the throttle position sensor 21.20 Info The value in the figure is an example only. Condition The carburetor has been removed. Component temperature: 20 °C (68 °F) – Check/adjust the throttle slide opening. ( – Connect the plus cable of the multimeter to the blue (bu) cable and the ground cable to the black (bl) cable of the throttle position sensor connector. Measure the total throttle position sensor resistance Rtot. p. 173) Guideline Throttle position sensor, total resistance Rtot 4… 6 kΩ 700063-10 – Multiply the total throttle position sensor resistance Rtot by 0.17. The product is the variable throttle position sensor resistance Rvar for the setting. – Rtot x 0.17 = Rvar (tolerance ± 0.05 kΩ) – Connect the plus cable of the multimeter to the yellow (ye) cable and the ground cable to the black (bl) cable of the throttle position sensor connector. – Measure the variable throttle position sensor resistance Rvar. 700064-10 Info The throttle slide must be in the basic position. 700066-10 – Loosen screw . Adjust the throttle position sensor by turning to the calculated value. – Tighten screw . Guideline Screw, throttle position sensor – M5 Check the variable throttle position sensor resistance Rvar again. » If the measured value is outside of the calculated value: – Repeat the adjustment procedure. 3.5 Nm (2.58 lbf ft) 31/CARBURETOR 175 Assembling the carburetor 21.21 – Mount and tighten idle air jet . Guideline Idle air jet M4.5x0.75 2 Nm (1.5 lbf ft) M12 2.5 Nm (1.84 lbf ft) 301559-11 – Mount and tighten choke slide . Guideline P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Choke slide – Position throttle position sensor . Mount screw with the spring ring and washer but do not tighten yet. Info When installing the throttle position sensor, ensure that the flat area of the inner clutch hub engages in the recess of the throttle position sensor. 301558-11 – Position the hose connection. Mount and tighten screw . Guideline Screw, hose connection M4 2 Nm (1.5 lbf ft) Loctite® 243™ Info The hose connection must be easy to turn when it is mounted. 301557-11 – Screw in the mixture control screw with the spring, washer, and O-ring all the way. Guideline Mixture control screw – M6x0.5 1 Nm (0.7 lbf ft) Screw in the mixture control screw by the number of turns that were required to disassemble it, or adjust it to the specified basic setting. Guideline Idle mixture adjusting screw 301555-11 Open 1.5 turns Info The mixture control screw may be open a maximum of 2 turns. If more than two turns are necessary (rich mixture), use a larger idling jet. – Position buffer plate . Mount and tighten needle jet , cold start jet and idling jet . Guideline Needle jet M7x0.75 3.5 Nm (2.58 lbf ft) Cold start jet M5x0.75 2 Nm (1.5 lbf ft) Idling jet M6x0.75 2 Nm (1.5 lbf ft) 31/CARBURETOR 176 – Mount and tighten main jet . Guideline Main jet M5x0.75 2 Nm (1.5 lbf ft) – Position the float together with the float needle valve, and mount fulcrum pin . – Check/adjust the float level. ( – Mount and tighten spill jet . p. 174) 301554-11 Guideline M4x0.7 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Spill jet 2 Nm (1.5 lbf ft) 700058-11 – Position the float chamber and adjusting screw. – Mount screws but do not tighten yet. – Insert throttle slide with throttle slide roller and the throttle slide plate into throttle slide arm and position it in the carburetor. – Position the needle clip on the jet needle. 301564-10 Guideline Needle position 3rd position from top – Insert the jet needle. – Mount and tighten screw with the spring and washer. 301563-11 Guideline Needle screw – M8 3.5 Nm (2.58 lbf ft) Mount and tighten screw . Guideline Screw, throttle slide arm M4 2 Nm (1.5 lbf ft) Loctite® 243™ 301562-11 – Position the throttle slide cover with the gasket. Mount and tighten screws . Guideline Other screws, carburetor – 301560-11 Check/adjust the throttle slide opening. ( M4 p. 173) 2 Nm (1.5 lbf ft) 31/CARBURETOR 177 – Check/adjust the accelerator pump. ( – Position seal ring , membrane and spring . p. 170) Info The label on the membrane must be visible when the membrane is mounted. 301566-10 Position seal ring in the accelerator pump cover with the rounded side facing out. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301565-10 – Position the accelerator pump cover. Mount and tighten screws . Guideline Other screws, carburetor M4 2 Nm (1.5 lbf ft) 301551-11 – Position and mount the bleeder hoses. – Position the hose holder. Mount screws and tighten all screws in a crisscross pattern. Guideline Other screws, carburetor – 301561-01 M4 Adjust the position of the throttle position sensor. ( p. 174) 2 Nm (1.5 lbf ft) 32/CLUTCH 178 Checking fluid level of hydraulic clutch 22.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws . – Remove cover with membrane . – Check the fluid level. Fluid level under top level of container » 4 mm (0.16 in) If the coolant level does not meet specifications: Correct the fluid level of the hydraulic clutch. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301814-10 Hydraulic fluid (15) ( – p. 224) Position the cover with the membrane. Mount and tighten screws. Changing the hydraulic clutch fluid 22.2 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws . – Remove cover with membrane . – Fill bleeding syringe with the appropriate hydraulic fluid. 302061-10 Bleed syringe (50329050000) ( Hydraulic oil (15) ( p. 227) p. 224) – Remove the bleeder screw on the clutch slave cylinder and mount the bleeding syringe. – Inject the liquid into the system until it escapes from hole of the clutch master cylinder without bubbles. – To prevent overflow, interrupt this process to drain fluid from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. – Correct the fluid level of the hydraulic clutch. 302062-10 Guideline Fluid level below container rim 302063-10 4 mm (0.16 in) – Position the cover with the membrane. Mount and tighten the screws. – Check that the clutch is functioning properly. 33/TRANSMISSION 179 Removing the engine sprocket 23.1 – Disconnect plug of the brake light switch. – Remove screws and . Take off the engine sprocket cover. – Activate the rear brake and remove screw with spring washer . – Pull engine sprocket off the countershaft with chain . Remove the engine sprocket. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 301543-10 301542-10 Installing the engine sprocket 23.2 – Insert engine sprocket into chain with the collar facing the engine and slide onto the countershaft together. – Activate the rear brake. Mount and tighten screw with spring washer . Guideline Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite® 243™ 301542-11 – Position the engine sprocket cover. Mount and tighten screws . Guideline – 301543-11 Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) Remaining screws, chassis M8 25 Nm (18.4 lbf ft) Connect plug of the brake light switch. 35/WATER PUMP, COOLING SYSTEM 180 Checking antifreeze and coolant level 24.1 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under lukewarm water immediately. Warning Danger of poisoning Coolant is poisonous and a health hazard. Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. – Remove the front trim. ( – Remove the radiator cap. – Check antifreeze of coolant. p. 69) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – – Correct the coolant antifreeze. Check the coolant level in the radiator. Coolant level above the radiator fins. 400243-10 » 10 mm (0.39 in) If the coolant level does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 223) Alternative 2 Coolant (mixed ready to use) ( – p. 223) Mount the radiator cap. Checking the coolant level 24.2 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under lukewarm water immediately. Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. – Remove the front trim. ( – Remove the radiator cap. – Check the coolant level in the radiator. p. 69) Coolant level above the radiator fins. » 10 mm (0.39 in) If the coolant level does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( 400243-10 p. 223) Alternative 2 Coolant (mixed ready to use) ( p. 223) 35/WATER PUMP, COOLING SYSTEM – 181 Mount the radiator cap. Draining coolant 24.3 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under lukewarm water immediately. Warning Danger of poisoning Coolant is poisonous and a health hazard. Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – Remove the front trim. ( – Place a suitable container under the vehicle. – Remove screw . – Remove screw . – Remove the radiator cap . Completely drain the coolant. p. 69) 301837-10 – Mount screw with a new seal and tighten it. Guideline Screw, water pump cover – M6 10 Nm (7.4 lbf ft) Mount screw with a new seal and tighten it. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 301838-10 Filling coolant/bleeding the cooling system 24.4 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. – Remove the front trim. ( – Remove the radiator spoiler. ( – Remove the radiator cap . – Fill the coolant into the radiator. Coolant p. 69) p. 63) 1.50 l (1.59 qt.) Coolant ( p. 223) Coolant (mixed ready to use) ( p. 223) 301838-11 35/WATER PUMP, COOLING SYSTEM – 182 Open screw to bleed the radiator. Tighten the screw when coolant emerges from the opening. Guideline Remaining screws, chassis M6 301840-10 – Add coolant to level above the radiator fins. Guideline 10 mm (0.39 in) Mount the radiator cap. – Install the front trim. ( – Make a short test ride. – Check the coolant level. ( p. 70) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301839-10 p. 180) 10 Nm (7.4 lbf ft) 38/LUBRICATION SYSTEM 183 Oil circuit 25.1 b0k bk bk b0k bbl 0l bbl 0l 9 90 0 0 6 0 6 0 5 7 0 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 0 8 bbn 0n bbm 0m 2 0 0 1 bbm 0m 0 3 0 4 Oil circuit, force pump 1 2 3 4 5 6 7 8 9 10 11 Oil screen Force pump Oil pressure regulator valve Oil filter Oil jet, timing chain tensioner Oil jet, piston cooling Oil jet, conrod lubrication Oil jet for oil supply, clutch Oil channel, cam lever bearing Oil jet for cam lever lubrication Oil channel, camshaft bearing Oil circuit, suction pump 12 13 Suction pump for evacuating the crank chamber Oil channel, transmission lubrication Changing the engine oil and oil filter, cleaning the oil screen 25.2 301702-10 – Drain the engine oil. ( – Remove the oil filter. ( – Install the oil filter. ( – Fill up with engine oil. ( p. 184) p. 184) p. 185) p. 185) 301300-01 38/LUBRICATION SYSTEM 184 Draining the engine oil 25.3 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under lukewarm water immediately. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Drain the engine oil only when the engine is warm. – Park the vehicle on a horizontal surface. – Remove the engine guard. ( – Place a suitable container under the engine. p. 20) – Remove oil drain plug with the seal ring. – Completely drain the engine oil. – Thoroughly clean the oil drain plug with the magnet. – Clean the sealing area on the engine. – Fit oil drain plug with seal ring and tighten it. Guideline Oil drain plug with magnet 301841-10 – M12x1.5 20 Nm (14.8 lbf ft) Clean the oil screen. Removing the oil filter 25.4 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under lukewarm water immediately. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Place a suitable container under the engine. – Remove screws . Take off the oil filter cover with the O-ring. – Pull oil filter element out of the oil filter case. 301843-10 Circlip pliers reverse (51012011000) ( 301844-11 – Completely drain the engine oil. – Thoroughly clean parts and sealing area. p. 228) 38/LUBRICATION SYSTEM 185 Installing the oil filter 25.5 – Fill oil filter with engine oil and place it in the oil filter housing. – Oil the O-ring of the oil filter cover and install it with the oil filter cover. – Mount and tighten screws . 301844-10 Guideline M5 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Screw, oil filter cover 6 Nm (4.4 lbf ft) 301843-11 Filling up with engine oil 25.6 Info A lack of engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the filler cap on the clutch cover and fill up with engine oil. Engine oil – 2.00 l (2.11 qt.) External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 223) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 223) Mount and tighten filler cap . 301845-10 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. – Start the engine and check that it is oil-tight. – Check the engine oil level. ( p. 185) Checking the engine oil level 25.7 Info The engine oil level can be checked on a cold or hot engine. – Park the vehicle on a horizontal surface. Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil reaches the middle of the viewer . 800061-10 38/LUBRICATION SYSTEM 186 » When the engine oil does not reach the middle of the viewer : – Add engine oil. ( p. 186) Condition The engine is cold. – Check the engine oil level. The engine oil reaches the bottom of the viewer . » When the engine oil does not reach the bottom of the viewer : – Add engine oil. ( p. 186) 800061-11 Adding engine oil 25.8 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info A lack of engine oil or poor-quality engine oil results in premature wear to the engine. – – Check the engine for leakage. Remove the filler cap on the clutch cover and fill up with engine oil. Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 223) Condition External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( 301845-10 p. 223) Info To ensure optimal engine oil performance, it is advisable to not use different engine oils. We recommend making an oil change in this case. – Mount and tighten filler cap . 39/IGNITION SYSTEM 187 Removing the stator 26.1 Condition The alternator cover has been removed. – Remove screw and the retaining bracket. – Remove cable support sleeve from the alternator case. – Remove screws . – Take the stator out of the alternator cover. 301682-10 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Installing the stator 26.2 – Position the stator in the alternator cover. – Mount screws . Guideline Screw, stator bracket M5 6 Nm (4.4 lbf ft) – Position cable support sleeve in the alternator case. – Position the retaining bracket. Mount and tighten screw . Loctite® 243™ Guideline 301682-11 Screw, stator cable holder M5 6 Nm (4.4 lbf ft) Loctite® 243™ Checking the ignition system 26.3 Warning Risk of injury The ignition system is under high voltage. – To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and immediately after measuring. Condition The battery must be charged. The fuse in the starter relay must be functional. – Shift gear to neutral. – Pull off the spark plug connector and remove the spark plug connector from the ignition wire. Hold the free end of the ignition wire a distance from ground. Guideline Distance – 5 mm (0.2 in) Press the electric starter button. Info Do not open the throttle. 301568-10 – Check the ignition spark. » If an ignition spark is not visible: – Check the ground connection of the CDI controller and ignition coil. – Check the cable from the CDI controller to the ignition coil. Info The CDI controller cannot be tested by simple means but must be placed on an ignition test bench. – Check the ignition coil. ( – Check the ignition pulse generator. ( p. 188) p. 189) 39/IGNITION SYSTEM 188 – Check the alternator. ( p. 190) – Check the spark plug connector. ( – Change the spark plug. p. 189) – Connect the spark plug connector with the ignition wire again. Unscrew the spark plug and insert it into the spark plug connector. Touch the spark plug to ground. – Press the electric starter button. Info Do not open the throttle. – Check the ignition spark. » If an ignition spark is not visible: – 301569-10 Change the spark plug. Checking the ignition coil P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 26.4 Condition All plug contacts must be free of corrosion and the plug-in connectors must be firmly seated. The battery must be charged. – Remove the fuel tank. ( – Remove the spark plug connector. – Measure the primary winding with a multimeter. p. 64) Ignition coil - primary winding Ground - ignition coil input at: 20 °C (68 °F) » 0.25… 0.35 Ω If the measured value differs from the set value: – Change the ignition coil. 301572-10 – Measure the secondary winding with a multimeter. Ignition coil - secondary winding Ignition wire - ignition coil input at: 20 °C (68 °F) » 5… 7.5 kΩ If the measured value differs from the set value: – Change the ignition coil. 301573-10 – Connect the special tool to the multimeter. Peak voltage adapter (58429042000) ( p. 228) Info When using the peak voltage adapter, the measurement range of the multimeter should be set to DCV. 301574-10 – Follow the instructions on starting the engine. – Touch the red measuring lead of the special tool to ground. Touch the black measuring lead to the ignition coil input. Ignition coil Ground - ignition coil input » 190… 210 V If the displayed value does not meet specifications: – Change the ignition coil. 39/IGNITION SYSTEM 189 Checking the spark plug connector 26.5 – Measure the dismantled spark plug connector with a multimeter. Spark plug connector Resistance at: 20 °C (68 °F) » 3.75… 6.25 kΩ If the value displayed does not meet specifications: – Change the spark plug connector. 301473-10 Checking the CDI controller 26.6 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Info Never check the CDI controller with a conventional measuring instrument. This may result in the destruction of highly sensitive electronic components. – Check the cables and plug-in connections of the CDI controller. A functional check of the CDI controller is only possible on an ignition test bench. 301570-10 Checking the ignition pulse generator 26.7 Condition All plug contacts must be free of corrosion and the plug-in connectors must be firmly seated. The battery must be charged. – Remove the fuel tank. ( – Disconnect the electrical plug-in connector connecting the ignition pulse generator to the CDI controller. – Measure the resistance of the ignition pulse generator using a multimeter. p. 64) Ignition pulse generator - resistance » – 80… 120 Ω Red - ground at: 20 °C (68 °F) ∞ If the measured value differs from the set value: – 301577-10 Red - green at: 20 °C (68 °F) Change the ignition pulse generator. Connect the special tool to the multimeter. Peak voltage adapter (58429042000) ( p. 228) Info When using the peak voltage adapter, the measurement range of the multimeter should be set to DCV. – Connect the red measuring lead of the special tool to the green wire. Connect the black measuring lead to the red wire. – Press the electric starter button. Ignition pulse generator - output voltage - connector disconnected Red - green at: 20 °C (68 °F) » If the displayed value does not meet specifications: – 301571-10 1.5… 3 V Change the ignition pulse generator. 39/IGNITION SYSTEM 190 – Connect the CDI controller. Connect the red measuring lead of the special tool to the green wire. Connect the black measuring lead to the red wire. – Remove the spark plug connector. – Press the electric starter button. Ignition pulse generator - output voltage - connector connected Red - green at: 20 °C (68 °F) » 1… 2 V If the displayed value does not meet specifications: – Change the ignition pulse generator. Checking the alternator 26.8 Condition All plug-in contacts must be free of corrosion and firmly connected. The battery must be charged. – Remove the fuel tank. ( – Disconnect the electrical plug-in connector of the stator coil. – Measure the stator coil with a multimeter. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m p. 64) Stator coil - resistance » ≤1Ω Alternator outputs against ground ∞ If the value displayed does not meet specifications: – 301576-10 Alternator outputs against each other Change the stator. – Check the alternator output for voltage between the individual wires. – Connect the special tool to the multimeter. Peak voltage adapter (58429042000) ( p. 228) Info When using the peak voltage adapter, the measurement range of the multimeter should be set to DCV. 301575-10 – Pull off the spark plug connector. – Measure the charging coil with the peak voltage adapter. – Press the electric starter button. Alternator output/plug disconnected Alternator outputs against each other » 9… 13 V If the value displayed does not meet specifications: – Change the stator. 61/ATV FRONT END 191 Checking the toe 27.1 – Park the vehicle on a horizontal surface. – Check the tire condition. ( – Check the tire air pressure. ( p. 72) p. 72) – Check the chassis parts for damage, play and wear. – Load the vehicle with the specified weight. Guideline Average rider weight – 70… 80 kg (154… 176 lb.) Move the handlebar into the straight-ahead position and fix it. Handlebar fixation for straight-ahead position (83019015100) ( p. 235) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 300272-10 400333-10 – Measure distances and . » If distances and are not equal: – – Adjust the toe. ( p. 192) Measure distances and . Guideline Toe Front 0 mm (0 in) Info The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. » If the toe does not meet specifications: – Adjust the toe. ( p. 192) 61/ATV FRONT END 192 Adjusting the toe 27.2 – Park the vehicle on a horizontal surface. – Check the tire condition. ( – Check the tire air pressure. ( – Check the chassis parts for damage, play and wear. Replace damaged or worn parts. – Load the vehicle with the specified weight. p. 72) p. 72) Guideline Average rider weight – 70… 80 kg (154… 176 lb.) Move the handlebar into the straight-ahead position and fix it. p. 235) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Handlebar fixation for straight-ahead position (83019015100) ( 300272-10 400333-11 – Loosen nuts and . – Adjust the distances and to the same value by rotating the tie rods . – Adjust the distances and to the specified value by evenly rotating the tie rods . Guideline Toe Front 0 mm (0 in) Info The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. – Tighten nuts and . Guideline Lock nut, tie rod, outside M12x1.25 20 Nm (14.8 lbf ft) Lock nut, tie rod, inside M12LHx1.25 20 Nm (14.8 lbf ft) Info The tie rods must still be freely movable. 61/ATV FRONT END 193 Checking/adjusting the camber 27.3 Info The left and right camber should have the same settings. The operations are the same on the left and right. Jack up the vehicle. ( – Loosen nuts . p. 12) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 300273-10 – Remove screws with bushings . – Insert tool in the heim joint and clip onto the A-arm. 300274-10 Camber gauge (83019014000) ( – p. 235) Check the camber on both heim joints. » If marking is not aligned with the top edge of the A-arm: – Turn tool with the heim joint in steps of 180° until the marking is in line with the top edge of the A-arm. – Remove tool . – Position the A-arm with bushings . Mount and tighten screws . 300277-10 Guideline Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) 300274-10 – Align the heim joint at right angles to screws and tighten nut . Guideline Nut, A-arm top M12x1.25 30 Nm (22.1 lbf ft) Info All four heim joints must be checked and adjusted if necessary. 300273-10 – Remove the vehicle from the work stand. ( p. 12) 61/ATV FRONT END 194 Adjusting the fork offset 27.4 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( – Remove screws with bushings . – Place the A-arm with bushings in the desired position. Mount and tighten screws . p. 12) Guideline Screw, A-arm top Remove the vehicle from the work stand. ( 45 Nm (33.2 lbf ft) p. 12) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – M10x52 300274-11 Removing the wheel carrier 27.5 Info The operations are the same on the left and right. – Remove the wheel/wheels. ( – Remove brake disc guard . – Remove cable clamp and take off brake line guide . – Pull the hand brake lever and release it again. p. 72) 301500-10 Locking pawl moves into its basic position, parking brake is deactivated. – Remove screws . Press the brake caliper onto the brake disc by hand in order to push back the brake piston. – Remove the brake caliper. Info 301501-10 Do not operate the hand brake lever when the brake caliper has been removed. 61/ATV FRONT END 195 Unthread the brake caliper. – Hang the brake caliper and the brake line loosely to one side. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 400691-10 – Remove nut and take the tie rod out of the wheel carrier. – Remove nuts . – Position special tool . Press the lower ball head out of the wheel carrier. 301502-10 301503-10 Push-out tool (83019021000) ( p. 236) 301504-10 301505-10 – Turn and position special tool . Press the upper ball head out of the wheel carrier. – Remove the wheel carrier. 61/ATV FRONT END 196 Changing the wheel bearing 27.6 Info The operations are the same on the left and right. – Remove the wheel carrier. ( – Fix the wheel carrier in the vise. p. 194) Info Use soft jaws. Remove nut . Remove the wheel hub. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – – 301509-10 – Remove spacers . – Pry out shaft seal rings . – Secure the wheel bearing with a suitable tool. – Remove the bearing spacer. – Press the wheel bearing all the way in. 301510-10 301511-10 301512-10 Press mandrel (83019013000) ( – 301514-10 Mount the bearing spacer. p. 235) 61/ATV FRONT END 197 – Press the wheel bearing all the way in. Press mandrel (83019013000) ( p. 235) 301513-10 Press in shaft seal rings so they are flush. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301511-10 – Mount spacers . – Slide the wheel hub onto the wheel carrier. – Mount and tighten nut . 301510-10 Guideline Nut, front wheel hub – Install the wheel carrier. ( M12 70 Nm (51.6 lbf ft) p. 197) 301509-10 Installing the wheel carrier 27.7 Info The operations are the same on the left and right sides. – Insert the wheel carrier between the A-arms. Mount and tighten nuts . Guideline 301503-11 Nut, ball head, A-arm bottom M12x1.5 40 Nm (29.5 lbf ft) Nut, ball head, A-arm top M10x1.25 35 Nm (25.8 lbf ft) 61/ATV FRONT END 198 – Insert the tie rod in the wheel carrier. Mount and tighten nut . Guideline Nut, tie rod end M10x1.25 45 Nm (33.2 lbf ft) 301502-11 Thread the brake caliper and position it. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 400691-11 – Mount and tighten screws . Guideline Screw, front brake caliper M8 20 Nm (14.8 lbf ft) Loctite® 243™ – When both Brake calipers have been mounted, activate the hand brake lever several times until the brake linings are in contact with brake disc and there is a pressure point. – Position brake line guide and secure it with cable clamp . 301501-11 Info Note the holding lug of the brake line guide. – Mount brake disc guard . – Install the wheel/wheels. ( – Check the toe. ( p. 73) p. 191) 301500-11 Removing the A-arms 27.8 Info The operations are the same on the left and right sides. – Remove the wheel carrier. ( p. 194) 61/ATV FRONT END 199 – Remove screws and take off upper A-arm . Info When removing screws , make sure that bushings remain in place. 301506-10 Remove screw and the shock absorber out of the guide. – Remove screws and take off lower A-arm . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m – 301507-10 Installing the A-arms 27.9 Info The operations are the same on the left and right sides. – Position lower A-arm . Mount and tighten screws . Guideline Screw, A-arm bottom – M10x70 45 Nm (33.2 lbf ft) Position the shock absorber in the lower A-arm. Mount and tighten screw . Guideline Screw, front shock absorber M10 45 Nm (33.2 lbf ft) 301507-11 – Insert tool in the heim joint and clip onto the A-arm. Camber gauge (83019014000) ( – Check the camber on both heim joints. » 300277-10 p. 235) If the marking is not flush with the top edge of the A-arm: – Remove the nuts on the heim joint. – Turn tool with the heim joint in steps of 180° until the marking is in line with the top edge of the A-arm. – Remove tool . – Position upper A-arm with bushings . Mount and tighten screws . Guideline Screw, A-arm top M10x52 Info The fork offset is set using the bushings . 301506-11 45 Nm (33.2 lbf ft) 61/ATV FRONT END 200 – When the nuts on the heim joint have been released, align the heim joint at right angles to the screws and tighten nut . Guideline Nut, A-arm top – M12x1.25 Install the wheel carrier. ( 30 Nm (22.1 lbf ft) p. 197) 301508-10 A-Arm top - changing the bearing 27.10 Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The operations are the same on the left and right sides. – Remove the A-arms. ( – Remove lock ring . p. 198) Circlip pliers reverse (51012011000) ( p. 228) 600467-10 – Press out ball head using special tool . Disassembly/assembly holder (83019020150) ( p. 236) 600468-10 – Press in the ball head using the special tool. Press mandrel (83019020130) ( Mounting sleeve (83019020100) ( p. 236) p. 235) 600469-01 – Mount lock ring . Circlip pliers reverse (51012011000) ( p. 228) Info When mounting the lock ring, do not damage the rubber boot. 600467-10 61/ATV FRONT END 201 – Loosen nuts . Remove heim joint . Screw the nuts off of the heim joints. – Screw the nuts on the new heim joints. Mount the heim joints . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 600470-10 600471-10 – Insert the tool in the heim joint and clip onto the A-arm. Camber gauge (83019014000) ( – p. 235) Align marking with the upper edge of the A-arm by rotating the heim joint. Info Nuts are tightened when the A-arm is installed. – Install the A-arms. ( 600472-10 A-Arm bottom - changing the bearing 27.11 Info The operations are the same on the left and right sides. – Remove the A-arms. ( p. 198) p. 199) 61/ATV FRONT END 202 5 1 2 3 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1 4 2 3 3 5 5 3 1 5 4 A 1 – Remove flange adapters and bearing sleeves . – Remove shaft seal rings . – Remove spacing washers . 6 7 600457-01 Info The spacing washers are only installed at the front pivot point. – Press out needle bearing using the thin long side of the special tool. Press mandrel (83019020170) ( p. 236) Press mandrel (83019020130) ( p. 236) – Clean the pivot point. – Press in a new needle bearing on all pivot points using the thick end of the special tool. 600458-01 Press mandrel (83019020170) ( p. 236) Info The needle bearing cannot be pushed through from one side. 600459-01 – Grease the needle bearing. – On the front pivot point, insert the two spacing washers. – Install the new shaft seal rings. Lightly grease the sealing lips of the shaft seal rings. – Mount the bearing sleeves and flange adapters. 61/ATV FRONT END 203 – Remove lock ring . Circlip pliers reverse (51012011000) ( p. 228) 600464-10 – Press out ball head using the special tool. p. 236) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Disassembly/assembly holder (83019020150) ( 600465-10 – Press in the ball head using the special tool. Press mandrel (83019020130) ( p. 236) Disassembly/assembly holder (83019020150) ( p. 236) 600466-01 – Mount lock ring . Circlip pliers reverse (51012011000) ( p. 228) Info When mounting the lock ring, do not damage the rubber boot. – 600464-10 Install the A-arms. ( p. 199) TECHNICAL DATA - ENGINE 204 1-cylinder 4-stroke engine, water-cooled Displacement (450 SX ATV) 449.3 cm³ (27.418 cu in) Displacement (505 SX ATV) 477.5 cm³ (29.139 cu in) Stroke 60.8 mm (2.394 in) Bore (450 SX ATV) 97 mm (3.82 in) Bore (505 SX ATV) 100 mm (3.94 in) Compression ratio 12.5:1 Control DOHC, four valves controlled via cam lever, drive via helical gear pair and tooth-wheel chain Valve diameter, intake 40.4 mm (1.591 in) Valve diameter, exhaust 31.7 mm (1.248 in) Valve clearance, cold, intake 0.07… 0.13 mm (0.0028… 0.0051 in) Valve clearance, cold, exhaust 0.12… 0.18 mm (0.0047… 0.0071 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Design Crankshaft bearing 2 cylinder roller bearing Conrod bearing Needle bearing Piston pin bearing (450 SX ATV) Bronze bush Piston pin bearing (505 SX ATV) not a bearing bush - DLC-plated piston pins Pistons Forged light alloy Piston rings 1 compression ring, 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmission 29:74 Clutch Multidisc clutch in oil bath/hydraulically activated Transmission ratio 1st gear 16:34 2nd gear 19:31 3rd gear 20:26 4th gear 23:25 5th gear 26:24 Alternator 12 V, 42 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK CR 9 EKB Spark plug electrode gap 0.7 mm (0.028 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter Capacity - engine oil 28.1 Engine oil 2.00 l (2.11 qt.) External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 223) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 223) Capacity - coolant 28.2 Coolant 1.50 l (1.59 qt.) Coolant ( p. 223) Coolant (mixed ready to use) ( p. 223) TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS Camshaft - cam height Exhaust 33.10… 33.30 mm (1.3031… 1.311 in) Camshaft - cam height (450 SX ATV) Intake 33.90… 34.10 mm (1.3346… 1.3425 in) Camshaft - cam height (505 SX ATV) Intake 34.20… 34.40 mm (1.3465… 1.3543 in) Camshaft bearing - radial clearance Radial clearance 0.029… 0.053 mm (0.00114… 0.00209 in) Wear limit 0.055 mm (0.00217 in) Valve spring Minimum length 42.8 mm (1.685 in) Valve - sealing seat width 1.50 mm (0.0591 in) Exhaust 1.50 mm (0.0591 in) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Intake Valve - run-out At the valve plate ≤ 0.05 mm (≤ 0.002 in) At the valve stem ≤ 0.05 mm (≤ 0.002 in) Valve spring seat - thickness 1.4… 1.5 mm (0.055… 0.059 in) Cylinder/cylinder head - distortion of sealing area ≤ 0.10 mm (≤ 0.0039 in) Piston - diameter (450 SX ATV) Size I 96.960… 96.970 mm (3.81732… 3.81771 in) Size II 96.971… 96.980 mm (3.81775… 3.8181 in) Piston - diameter (505 SX ATV) Size I 99.960… 99.970 mm (3.93543… 3.93582 in) Size II 99.971… 99.980 mm (3.93586… 3.93621 in) Cylinder - drill hole diameter (450 SX ATV) Size I 97.000… 97.012 mm (3.81889… 3.81936 in) Size II 97.013… 97.025 mm (3.8194… 3.81987 in) Cylinder - drill hole diameter (505 SX ATV) Size I 100.000… 100.012 mm (3.937… 3.93747 in) Size II 100.013… 100.025 mm (3.93751… 3.93798 in) Piston/cylinder - mounting clearance Size I 0.030… 0.052 mm (0.00118… 0.00205 in) Size II 0.032… 0.054 mm (0.00126… 0.00213 in) Wear limit 0.070 mm (0.00276 in) Piston ring - end gap Compression ring ≤ 0.80 mm (≤ 0.0315 in) Oil scraper ring ≤ 1.00 mm (≤ 0.0394 in) Connecting rod - end play of lower conrod bearing 0.40… 0.60 mm (0.0157… 0.0236 in) Crankshaft - run-out at bearing pin ≤ 0.10 mm (≤ 0.0039 in) Crankshaft - end play 0.25… 0.35 mm (0.0098… 0.0138 in) Clutch facing disk - thickness ≥ 2.6 mm (≥ 0.102 in) Clutch spring - length 39.0… 40.0 mm (1.535… 1.575 in) Contact surface of clutch facing discs in outer clutch hub ≤ 0.5 mm (≤ 0.02 in) Oil pressure regulator valve Minimum length of pressure spring Shift shaft - sliding plate/shift quadrant clearance 38.5 mm (1.516 in) 0.40… 0.80 mm (0.0157… 0.0315 in) 205 TECHNICAL DATA - ENGINE TIGHTENING TORQUES 206 Jet, engine case breather M4 On block Loctite® 243™ Oil jet for conrod lubrication M4 4 Nm (3 lbf ft) Loctite® 243™ Oil jet, cam lever lubrication M4 6 Nm (4.4 lbf ft) Loctite® 243™ Oil jet, piston cooling M4 4 Nm (3 lbf ft) Loctite® 243™ Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, bearing bolt of oil pump idler shaft M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, camshaft bearing retaining bracket M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, ignition pulse generator adapter M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™ M5 6 Nm (4.4 lbf ft) – Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, stator bracket M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, stator cable holder M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, timing train axle retaining bracket M5 6 Nm (4.4 lbf ft) Loctite® 243™ Oil jet, clutch oil supply M5x1 6 Nm (4.4 lbf ft) Loctite® 243™ Nut, cylinder head M6 10 Nm (7.4 lbf ft) lubricated with engine oil Nut, water-pump wheel M6 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, alternator cover M6 10 Nm (7.4 lbf ft) – Screw, clutch cover M6 10 Nm (7.4 lbf ft) – Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) – Screw, clutch spring M6 10 Nm (7.4 lbf ft) – Screw, engine case M6 10 Nm (7.4 lbf ft) – Screw, exhaust flange M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, ignition pulse generator cable holder M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, oil pump casing M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, starter motor M6 10 Nm (7.4 lbf ft) – Screw, valve cover M6 8 Nm (5.9 lbf ft) – Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Stud, cylinder head M6 10 Nm (7.4 lbf ft) – Oil jet, timing chain tensioner M6x0.6 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) lubricated with engine oil Screw, clutch cover M7x1 14 Nm (10.3 lbf ft) – Screw, engine case M7x1 14 Nm (10.3 lbf ft) – Screw, water pump cover M7x1 14 Nm (10.3 lbf ft) – Plug, crankshaft location M8 20 Nm (14.8 lbf ft) – Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite® 243™ Spark plug M10 10… 12 Nm (7.4… 8.9 lbf ft) – Plug, cam lever axle M10x1 10 Nm (7.4 lbf ft) – Screw, camshaft gear M10x1 50 Nm (36.9 lbf ft) lubricated with engine oil Screw, rotor M10x1 80 Nm (59 lbf ft) lubricated with engine oil Screw, unlocking of timing chain tensioner M10x1 10 Nm (7.4 lbf ft) – P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Screw, oil filter cover TECHNICAL DATA - ENGINE TIGHTENING TORQUES 207 M10x1.25 Tightening sequence: Tighten in diagonal sequence. Tightening stage 1 10 Nm (7.4 lbf ft) Tightening stage 2 30 Nm (22.1 lbf ft) Tightening stage 3 50° lubricated with engine oil Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Screw-in fitting, engine case M12x1.5 20 Nm (14.8 lbf ft) – Axle guide rail for timing chain M14x1 15 Nm (11.1 lbf ft) – Axle tension rail for timing chain M14x1 15 Nm (11.1 lbf ft) – Nut, compensating sprocket M14x1 20 Nm (14.8 lbf ft) Loctite® 243™ Oil suction pipe M14x1 15 Nm (11.1 lbf ft) Loctite® 243™ Oil pressure regulator valve plug M14x1.5 18 Nm (13.3 lbf ft) – Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) Loctite® 243™ Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) – Nut, freewheel hub M27x1 80 Nm (59 lbf ft) Loctite® 243™ Nut, primary gear M27x1 80 Nm (59 lbf ft) Loctite® 243™ Plug, oil screen M32x1.5 30 Nm (22.1 lbf ft) – P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Nut, cylinder head TECHNICAL DATA - CARBURETOR 208 Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4125L Needle position 3 th position from top Idle mixture adjusting screw Open Pump membrane stop 1.5 turns 2.15 mm (0.0846 in) Hot start button Diameter of bore in carburetor body 2.5 mm (0.098 in) 175 Jet needle OBEKR Idling jet 42 Idle air jet 100 Cold start jet 85 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Main jet TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES 209 M4 2 Nm (1.5 lbf ft) – Screw, hose connection M4 2 Nm (1.5 lbf ft) Loctite® 243™ Screw, throttle slide arm M4 2 Nm (1.5 lbf ft) Loctite® 243™ Spill jet M4x0.7 2 Nm (1.5 lbf ft) – Idle air jet M4.5x0.75 2 Nm (1.5 lbf ft) – Screw, carburetor cover M5 2.5 Nm (1.84 lbf ft) – Screw, throttle position sensor M5 3.5 Nm (2.58 lbf ft) – Cold start jet M5x0.75 2 Nm (1.5 lbf ft) – Main jet M5x0.75 2 Nm (1.5 lbf ft) – Mixture control screw M6x0.5 1 Nm (0.7 lbf ft) – Idling jet M6x0.75 2 Nm (1.5 lbf ft) – Needle jet M7x0.75 3.5 Nm (2.58 lbf ft) – Needle screw M8 3.5 Nm (2.58 lbf ft) – Choke slide M12 2.5 Nm (1.84 lbf ft) – Hot start activation M12 2.5 Nm (1.84 lbf ft) – P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Other screws, carburetor TECHNICAL DATA - CHASSIS Frame 210 Double cradle of chromium molybdenum steel tubes, powdercoated Wheel suspension Front Single wheel suspension with double transverse control arm Rear Rigid axle Suspension travel Front 244 mm (9.61 in) Rear 258 mm (10.16 in) Fork offset Front 50 mm (1.97 in) Front 0 mm (0 in) Toe P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Camber Front 0° Toe width Front 1,265 mm (49.8 in) Rear, narrow 1,265 mm (49.8 in) Rear, wide 1,341 mm (52.8 in) Wheelbase 1,280±10 mm (50.39±0.39 in) Turning radius 5,685 mm (223.82 in) Fording depth 305 mm (12.01 in) Seat height unloaded 795 mm (31.3 in) Ground clearance unloaded 265 mm (10.43 in) Weight Fuel tank empty 165 kg (364 lb.) Fuel tank full 173 kg (381 lb.) Maximum allowable axle load Front 144 kg (317 lb.) Rear 149 kg (328 lb.) Maximum permissible overall weight 293 kg (646 lb.) Vehicle length 1,810 mm (71.26 in) Vehicle width 1,265 mm (49.8 in) Vehicle height 1,100 mm (43.31 in) Brake system Front Disc brakes, brake calipers fixed, 4 brake pistons per brake caliper Rear Disc brake, brake caliper floating, 1 brake piston Brake discs - diameter Front 180 mm (7.09 in) Rear 200 mm (7.87 in) Brake discs - wear limit Front 3.5 mm (0.138 in) Rear 3.5 mm (0.138 in) Tire air pressure off road 0.3 bar (4 psi) Rim Front 5x10" DWT Al 6061 Rear 8x8" DWT Al 6061 Rear wheel gearing 14:38 Chain 5/8 x 1/4" Rear sprockets available 37, 38, 39 Battery YTX5L-BS Battery voltage: 12 V Nominal capacity: 4 Ah Maintenance-free TECHNICAL DATA - CHASSIS 211 Tires 33.1 Front tire Rear tire 21 x 7.00 - 10 MAXXIS Razr M‑931 20 x 11.00 - 9 MAXXIS Razr M‑932 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 33.2 Total fuel tank capacity approx. Super unleaded (ROZ 95 / RON 95 / PON 91) ( 3 l (3 qt.) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Fuel reserve approx. 10.3 l (2.72 US gal) p. 224) TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber part number 03.18.7J.16 Shock absorber WP Suspension 3612 BAVP DCC 212 Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks Rebound damping 20 clicks Standard 15 clicks Sport 12 clicks P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Comfort Cross over 19±1.5 mm (0.75±0.059 in) Spring preload Comfort 3 mm Standard 5 mm Sport 8 mm Spring rate, main spring Weight of rider: 64… 75 kg (141… 165 lb.) 21… 26 N/mm (120… 148 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 24… 29 N/mm (137… 166 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 27… 32 N/mm (154… 183 lb/in) Spring rate, auxiliary spring 40 N/mm (228 lb/in) Spring length, main spring 275 mm (10.83 in) Spring length, auxiliary spring 60 mm (2.36 in) Fitted length 463 mm (18.23 in) Gas pressure 10 bar (145 psi) Shock absorber oil Shock absorber oil (SAE 2,5) (50180342S1) ( p. 224) TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber part number 15.18.7J.16 Shock absorber WP Suspension PDS 4618 BAVP DCC 213 Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks Rebound damping 20 clicks Standard 15 clicks Sport 15 clicks P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Comfort Cross over 19±1.5 mm (0.75±0.059 in) Spring preload Comfort 3 mm Standard 5 mm Sport 5 mm Spring rate, main spring Weight of rider: 65… 75 kg (143… 165 lb.) 78 N/mm (445 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 82 N/mm (468 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 85 N/mm (485 lb/in) Spring rate, auxiliary spring 100 N/mm (571 lb/in) Spring length, main spring 200 mm (7.87 in) Spring length, auxiliary spring 55 mm (2.17 in) Fitted length 440.5 mm (17.342 in) Gas pressure 10 bar (145 psi) Shock absorber oil Shock absorber oil (SAE 2,5) (50180342S1) ( p. 224) TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 214 M6 15 Nm (11.1 lbf ft) – Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Screw on fuel tank M6 6 Nm (4.4 lbf ft) – Screw, clamping nut, rear axle M6 10 Nm (7.4 lbf ft) – Screw, foot brake cylinder M6 7 Nm (5.2 lbf ft) Loctite® 243™ Screw, rear brake caliper M6 10 Nm (7.4 lbf ft) Loctite® 243™ Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) – Remaining screws, chassis M8 25 Nm (18.4 lbf ft) – Screw, bearing support, steering M8 25 Nm (18.4 lbf ft) – Screw, front brake caliper M8 20 Nm (14.8 lbf ft) Loctite® 243™ Screw, front brake disc M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) – Screw, rear brake caliper M8 20 Nm (14.8 lbf ft) Loctite® 243™ Screw, rear brake disc M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, rear wheel eccentric element M8 20 Nm (14.8 lbf ft) – Screw, steering bridge M8 20 Nm (14.8 lbf ft) – Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite® 243™ Engine bracket screw M10 60 Nm (44.3 lbf ft) – Engine mounting bolt M10 60 Nm (44.3 lbf ft) – Nut, handlebar support M10 45 Nm (33.2 lbf ft) – Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) – Remaining screws, chassis M10 45 Nm (33.2 lbf ft) – Screw, A-arm bottom M10x70 45 Nm (33.2 lbf ft) – Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) – Screw, footrest M10 45 Nm (33.2 lbf ft) – Screw, front shock absorber M10 45 Nm (33.2 lbf ft) – Screw, steering column at bottom of steering lever M10 25 Nm (18.4 lbf ft) – Nut, ball head, A-arm top M10x1.25 35 Nm (25.8 lbf ft) – Nut, rear sprocket screw M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™ Nut, tie rod end M10x1.25 45 Nm (33.2 lbf ft) – Wheel nut M10x1.25 45 Nm (33.2 lbf ft) – Nut, front wheel hub M12 70 Nm (51.6 lbf ft) – Screw, rear bottom shock absorber M12 70 Nm (51.6 lbf ft) – Screw, rear top shock absorber M12 60 Nm (44.3 lbf ft) – Lock nut, tie rod, inside M12LHx1.25 20 Nm (14.8 lbf ft) – Lock nut, tie rod, outside M12x1.25 20 Nm (14.8 lbf ft) – Nut, A-arm top M12x1.25 30 Nm (22.1 lbf ft) – Nut, ball head, A-arm bottom M12x1.5 40 Nm (29.5 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Nut, rear wheel hub M18x1.5 130 Nm (95.9 lbf ft) – Screw, steering column, bottom M20x1.5 40 Nm (29.5 lbf ft) – Screw, steering column, top M20x1.5 25 Nm (18.4 lbf ft) – Clamping nut, rear axle 2"-10UNS-2B-LH 25 Nm (18.4 lbf ft) Only applies when using: Open-end wrench attachment, 46 mm (83019010461) ( p. 234) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Remaining nuts, chassis CLEANING 215 Cleaning the vehicle 37.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m If you clean the vehicle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the vehicle during cleaning. Info Do not rest the vehicle on its rear frame bracket to clean it as it could fall over. Never lift the vehicle by yourself, even if a gear is engaged. Fuel can emerge from the fuel tank. – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p. 226) Info Use warm water containing normal motorcycle cleaner and a soft sponge. – After rinsing the vehicle with a gentle spray of water, allow it to dry thoroughly. – Clean and dry the air filter box. – Drain the carburetor float chamber. ( p. 164) Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – – Clean or dry dirty or wet brakes by riding and braking gently. After cleaning, ride a short distance until the engine reaches operating temperature. Info The heat produced causes water at inaccessible locations in the engine and the brakes to evaporate. – Push back the protection covers of the handlebar grips to allow any water that has penetrated to evaporate. – After the vehicle has cooled off, oil or grease all moving parts and bearings. – Clean the chain. ( – Treat bare metal parts (except for brake discs and exhaust system) with corrosion's materials. p. 75) Cleaning and preserving materials for metal, rubber and plastic ( – p. 225) Treat all plastic parts and undercoated parts with a mild cleaning and care product. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( – To prevent electrical problems, treat electric contacts and switches with contact spray. Contact spray ( p. 225) p. 226) STORAGE 216 Storage 38.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. Info If you want to store the vehicle for a longer period, take the following actions. Info P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Before storing the vehicle, 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 vehicle. ( – Change the engine oil and oil filter, clean the oil screen. ( – Check the antifreeze and coolant level. ( – Drain the fuel from the tank into a suitable container. – Drain the carburetor float chamber. ( – Check the tire air pressure. ( p. 215) – Remove the battery. ( – Recharge the battery. ( p. 183) p. 180) p. 164) p. 72) p. 83) p. 84) Guideline Storage temperature of battery without direct sunshine 0… 35 °C (32… 95 °F) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. – Cover the vehicle with a tarp or cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine of a vehicle in storage for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust. Putting the vehicle into operation after storage 38.2 – Install the battery. ( – Fill up with fuel. – Checks before putting into operation – Make a cautious test ride. p. 83) SERVICE SCHEDULE 217 Important maintenance work to be carried out by an authorized KTM workshop 39.1 Engine Change the engine oil and oil filter, clean the oil screen. ( S1N S3N S10A S30A • • • • p. 183) Replace spark plug. carburetor Attachments • Check the valve clearance and adjust if necessary. • • • Check engine mounting screws for tightness. • • • Clean spark plug connectors and check for tightness. • • • Check shift lever screw for tightness. • • • • • Check carburetor connection boots for cracks and leakage. Check vent hoses for damage and routing without sharp bends. • • • Check idle. • • • Check the cooling system for leaks. • • • • • • • • p. 180) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Check the antifreeze and coolant level. ( Check the exhaust system for leakage and faulty attachment. Check control cables for damage, smooth operation and routing without sharp bends. • • • Check the fluid level of the hydraulic clutch. ( • • • • • • • • Clean the air filter. ( p. 178) p. 61) Check cables for damage and kink-free routing. Brakes Check the functioning of the electrical equipment. • • • Check the front brake linings. ( • • • • • • • • • • • • p. 91) Check the rear brake linings. ( Check the brake discs. ( p. 96) p. 74) Check the front brake fluid level. ( Check the rear brake fluid level. ( p. 89) • • • Check that brake lines are undamaged and free of leaks. p. 94) • • • Check the free travel of the hand brake lever. ( • • • Check the free travel of the foot brake lever. ( Chassis p. 88) • • • Check the brake system. p. 93) • • • Check screws and guide pins of the brake system for tightness. • • • Check shock absorbers for cracks and proper functioning. • • • Check the steering column bearing for wear and smooth operation. • • • Clean and grease bearing and sealing elements of steering column. • • • Check the handlebar for smooth operation and play. • • • Check the handlebar bridge bearing for excessive play. • • • Check tie rods and tie rod ends for damage and play. • • • Check front wheel suspension for wear and tightness. • • • Check that front and rear wheel hubs are tight. • • • • • • • • • Check the swingarm bearing. Check the bearing of the rear axle for play. • Grease the rear wheel eccentric element. Wheels Check all screws to make sure they are tight. • • • Check rim run-out. • • • • • • • • • • • • • • • • • • • • • Check the tire condition. ( p. 72) Check the tire air pressure. ( Check the chain wear. ( Check the chain tension. ( Clean the chain. ( p. 72) p. 75) p. 76) p. 75) Check front wheel bearing for play. S1N: Once after 1 service hour - corresponds to about 7 liters of fuel (1.8 US gal) S3N: Once after 3 service hours - corresponds to about 21 liters of fuel (5.5 US gal) S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal) SERVICE SCHEDULE 218 Important maintenance work to be carried out by an authorized KTM workshop (as an additional order) 39.2 S10A Change the oil in the front shock absorber. ( Service the front shock absorber. ( p. 25) S40A S80A • • p. 27) J1A • Change the oil in the rear shock absorber. ( Service the rear shock absorber. ( S20A p. 42) • p. 44) • • • • J2A • • Treat electric contacts with contact spray. • • Change the hydraulic clutch fluid. ( • • • • • • • • Change the front brake fluid. ( Change the rear brake fluid. ( Check the clutch. ( p. 178) p. 90) p. 95) p. 138) • • • • • • • • • • • • • Change the valves. • • Change the valve springs. • • Check the timing-chain tensioner function. • • • • • • Check the seating of the piston pin. • • Change the crankshaft main bearing. • • Check the transmission. ( • • • • • • • • • • • • • • Check/measure the cylinder. ( p. 127) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Replace piston. Check the camshafts. ( p. 130) Check the valve spring seat. ( Check the cylinder head. ( p. 133) p. 133) Check the crankshaft run-out at the bearing pin. ( p. 126) Change the connecting rod, conrod bearing and crank pin. ( p. 125) p. 142) Check the shift mechanism. ( p. 139) Check the spring length of the oil pressure regulator valve. ( p. 123) Change glass fiber yarn filling of main silencer. • Replace foot brake cylinder seals. Check/adjust the carburetor components. ( S10A: Every 10 service S20A: Every 20 service S40A: Every 40 service S80A: Every 80 service J1A: Annually J2A: Every two years hours hours hours hours - corresponds corresponds corresponds corresponds p. 170) to to to to about about about about 70 liters of fuel (18.5 US gal) 140 liters of fuel (37 US gal) 280 liters of fuel (74 US gal) 560 liters of fuel (148 US gal) Important checks and maintenance work to be carried out by the rider 39.3 Check the engine oil level. ( p. 185) Check the front brake fluid level. ( Check the rear brake fluid level. ( Check the front brake linings. ( p. 89) p. 94) p. 91) Check the rear brake linings. ( NB1A • • • • p. 96) • Check and adjust control cables. • Clean the chain. ( • p. 75) Check the chain tension. ( Check the chain wear. ( p. 76) Check rear sprocket / engine sprocket for wear. ( Clean the air filter. ( • p. 75) p. 61) Check the tire air pressure. ( • p. 76) • • p. 72) • SERVICE SCHEDULE 219 NB1A Check the tire condition. ( p. 72) • Check the coolant level. ( p. 180) • Check that all controls for smooth operation. • Check braking force (incl. parking brake). • Check all screws, nuts and hose clamps regularly for tightness. • P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m NB1A: Depending on conditions of use according to requirements. -K2 1 -X24 4 CR/1 16 1 18 -M2 -S4 4 -S3 BA/1 1 -S5 1 AL/2 AT/2 2 6 -M1 M 39,41,33 -K1 3 2 15 A 4 AF/4 31 41 39 5 -X5 21,22 -X2 -B1 32 M t AK/2 2 43,17 AU/2 2 1 19 AH/2 13 BI/2 1 2 14 3 CR/1 2 12 -X1 1 10A -F1 -F2 10A 2 -F5 10A 2 2 EJ/2 EK/2 1 -S1 -X201 EI/1 EH/1 1 1 -L1 15 1 BU/18 3 4 -X200 -X102 2 5 2.1 2.2 2.3 2.4 2 8 3 9 10 11 12 13 14 15 16 17 18 4 1 7 AN/4 CU/4 6 -A1 9 11 5 9 10 2 450/505 SX ATV 4 31 30 -X101 -X3 1 AR/3 2 AM/3 3 6 32,34 1 AT/2 AL/2 2 11 17 3 8 2 -X23 7 3 10 29 7 8 -L2 1 -G1 33 34 35 7 1 2 1 42,29,30 43 AV/2 38 3 3 FB/4 7 4 4 16 -X4 42 2 2.1 37 37 1 EB/4 1 26 18 3 35 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 4 25 40 3 20,21 1 -S2 2 24 28 A 27 1 23 BK/4 22 BR/4 1 40 5 B 1 38 1 28 6 6 C 20 2 12 36 14 13 D E F 1 4 5 220 WIRING DIAGRAM 40.1 450/525 SX ATV 19 27 FA/4 3 EY/3 EZ/3 G U -N1 -G2 8 8 F E D C B A 302012-01 WIRING DIAGRAM Components CDI controller B1 Throttle position sensor G1 Battery G2 Alternator K1 Starter relay with fuse K2 Power relay L1 Ignition coil L2 Ignition pulse generator M1 Starter motor M2 Radiator fan N1 Voltage regulator/rectifier S1 Switch for throttle lever S2 S3 S4 S5 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m A1 Electric starter button Emergency OFF switch with rip cord Temperature switch for radiator fan Clutch switch Cable colors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 White-blue brown white Blue-red Grey white-red White-black Yellow-green Black-yellow Red Green Blue Yellow Black White-brown Brown Black-yellow Black-red Yellow White-red White-red White-red 23 Green 24 Green 25 Green 26 Green 27 Red 28 Orange 29 Brown 30 Brown 31 Blue-red 32 Brown 33 White-red 34 Brown 221 WIRING DIAGRAM White-black 36 Brown 37 Brown 38 Black 39 White-red 40 White-black 41 White-red 42 Brown 43 Black-yellow P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 35 222 SUBSTANCES 223 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline – Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends Motorex® products. Mixture ratio Antifreeze protection: −25… −45 °C (−13… −49 °F) 50 % corrosion inhibitor/antifreeze 50 % distilled water Coolant (mixed ready to use) −40 °C (−40 °F) Antifreeze Supplier Motorex® – Anti Freeze Engine oil (SAE 10W/50) According to – JASO T903 MA ( – SAE ( p. 240) p. 240) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Cross Power 4T Engine oil (SAE 5W/40) According to – JASO T903 MA ( – SAE ( p. 240) p. 240) (SAE 5W/40) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Power Synt 4T SUBSTANCES 224 Fork oil (SAE 5) According to – SAE ( p. 240) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Racing Fork Oil Hydraulic fluid (15) According to – ISO VG (15) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Hydraulic Fluid 75 Hydraulic oil (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. HUSABERG recommends Motorex® products. Supplier Motorex® – Hydraulic Fluid 75 Long-life grease According to – NLGI Guideline – Use only grease that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Fett 2000 Shock absorber oil (SAE 2,5) (50180342S1) According to – SAE ( p. 240) (SAE 2,5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91) AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Twin Air Dirt Bio Remover Carburetor cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Carburetor P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Chain cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chain Clean 611 Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex® products. Supplier Motorex® – Protect & Shine 645 Contact spray Guideline – KTM recommends Motorex® products. Supplier Motorex® – Accu Contact Long-life grease Guideline – KTM recommends Motorex® products. Supplier Motorex® – Fett 2000 Lubricant (T158) Guideline – KTM recommends Lubcon® products. Supplier Lubcon® – Turmogrease® PP 300 Lubricant (T625) Guideline – KTM recommends Molykote® products. Supplier Molykote® – 33 Medium 225 AUXILIARY SUBSTANCES Lubricant (T159) Guideline – KTM recommends Bel‑Ray® products. Supplier Bel‑Ray® – MC‑11® Lubricant (T511) Guideline – KTM recommends Lubcon® products. Supplier Lubcon® – Turmsilon® GTI 300 P P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Motorcycle cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900 Off-road chain spray Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chain Lube 622 Oil for foam air filter Guideline – KTM recommends Motorex® products. Supplier Motorex® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex® products. Supplier Motorex® – Clean & Polish 226 SPECIAL TOOLS 227 Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018000 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Feature 12… 16 mm (0.47… 0.63 in) 400038-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400125-01 Spring hooks Art. no.: 50305017000 400363-01 Bleed syringe Art. no.: 50329050000 400058-01 SPECIAL TOOLS 228 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 58012009000 400073-01 Tool for inner bearing race Art. no.: 58429037037 400082-01 Peak voltage adapter Art. no.: 58429042000 400083-01 Mounting sleeve Art. no.: 58529005000 400095-01 SPECIAL TOOLS 229 Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01 Adjustment tool for mixture control screw Art. no.: 59029034000 400106-01 Feeler gauge Art. no.: 59029041100 35 30 25 20 15 12 5 10 400110-01 SPECIAL TOOLS 230 Plastigauge measuring strips Art. no.: 60029012000 400122-01 Piston ring mounting tool P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 60029015000 400123-01 Engine work stand Art. no.: 61229001000 200306-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01 Protection cover Art. no.: 75029090000 400167-01 SPECIAL TOOLS 231 Clutch holder Art. no.: 77329003000 301488-10 Engine blocking screw P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 77329010000 400177-01 Assembly pin Art. no.: 77329012100 400178-01 Internal bearing puller Art. no.: 77329020000 Feature 8… 12 mm (0.31… 0.47 in) 400038-01 Special socket, 36 mm; ½" drive Art. no.: 77329021000 301703-01 SPECIAL TOOLS 232 Insert for piston pin retainer Art. no.: 77329030100 400160-01 Adjustment bush bridge P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 77329050000 301381-10 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Insert for valve spring lever Art. no.: 77329060000 400129-01 Spark plug wrench Art. no.: 77329072000 400170-01 SPECIAL TOOLS 233 Pressing tool, crankshaft Art. no.: 77629008000 400185-01 Extrude plate, base P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 77629009001 400187-01 Extrude plate, top Art. no.: 77629009002 400186-01 Insertion for piston ring lock Art. no.: 77629030000 400160-01 Gear quadrant Art. no.: 80029004000 500164-01 SPECIAL TOOLS 234 Hook wrench Art. no.: 83019001000 200224-10 Hook wrench P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 83019002000 200225-10 Open-end wrench attachment, 46 mm Art. no.: 83019010461 500172-01 Hook wrench Art. no.: 83019011000 600430-01 Press mandrel Art. no.: 83019012000 600421-01 SPECIAL TOOLS 235 Press mandrel Art. no.: 83019013000 600476-01 Camber gauge P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 83019014000 500229-01 Handlebar fixation for straight-ahead position Art. no.: 83019015100 200424-10 Extractor Art. no.: 83019020000 600477-01 Mounting sleeve Art. no.: 83019020100 600461-01 SPECIAL TOOLS 236 Press mandrel Art. no.: 83019020130 600462-01 Disassembly/assembly holder P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 83019020150 600463-01 Press mandrel Art. no.: 83019020170 600460-01 Push-out tool Art. no.: 83019021000 600452-01 Adapter cable Art. no.: 83029043000 600402-01 SPECIAL TOOLS 237 Engine fixing arm Art. no.: 83529002000 301487-10 Extractor P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: 83529048000 301700-10 Depth micrometer Art. no.: T107S 300577-10 Pin Art. no.: T120 201235-10 Mounting sleeve Art. no.: T1204 200788-10 SPECIAL TOOLS 238 Calibration pin Art. no.: T1205 200790-10 Pressing tool P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Press drift Art. no.: T1504 200789-10 Assembly tool Art. no.: T150S 200791-10 SPECIAL TOOLS 239 Mounting sleeve Art. no.: T1554 300578-10 Hook wrench P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Art. no.: T157S 200899-10 Nitrogen filling tool Art. no.: T170S1 300574-10 Mounting sleeve Art. no.: T313 300578-10 STANDARDS 240 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements. SAE P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 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. INDEX 241 valve timing, checking . . . . . . . . . . . . . . . . . . . . . . . 156 water pump cover, installing . . . . . . . . . . . . . . . . . . 154 INDEX A A-Arm bottom changing the bearing . . . . . . . . . . . . . . . . . . . . . . . . 201 A-arm top changing the bearing . . . . . . . . . . . . . . . . . . . . . . . . 200 A-arms installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Battery installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Battery voltage checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Brake discs checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Brake fluid front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 90 rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 95 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 B Air filter box lid with carburetor connection boot installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Brake fluid level of front brake checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Alternator checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Brake fluid of front brake topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Brake fluid of rear brake checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Assembling the engine alternator cover, installing . . . . . . . . . . . . . . centrifugal separator, installing . . . . . . . . . . . clutch cover, installing . . . . . . . . . . . . . . . . crankshaft, installing . . . . . . . . . . . . . . . . . . cylinder head, installing . . . . . . . . . . . . . . . double wheel, installing . . . . . . . . . . . . . . . . drive wheel of balancer gear, installing . . . . . engine, removing from universal mounting rack force pump, installing . . . . . . . . . . . . . . . . . freewheel gear, installing . . . . . . . . . . . . . . . ignition pulse generator, installing . . . . . . . . left engine case, installing . . . . . . . . . . . . . . locking lever, installing . . . . . . . . . . . . . . . . oil filter, installing . . . . . . . . . . . . . . . . . . . oil screen, installing . . . . . . . . . . . . . . . . . . outer clutch hub, installing . . . . . . . . . . . . . piston, installing . . . . . . . . . . . . . . . . . . . . primary gear, installing . . . . . . . . . . . . . . . . rotor, installing . . . . . . . . . . . . . . . . . . . . . . shift drum locating unit, installing . . . . . . . . shift drum, installing . . . . . . . . . . . . . . . . . . shift forks, installing . . . . . . . . . . . . . . . . . . shift lever, installing . . . . . . . . . . . . . . . . . . shift rails, installing . . . . . . . . . . . . . . . . . . shift shaft, installing . . . . . . . . . . . . . . . . . . spacer, installing . . . . . . . . . . . . . . . . . . . . spark plug, installing . . . . . . . . . . . . . . . . . . starter motor, installing . . . . . . . . . . . . . . . . suction pump, installing . . . . . . . . . . . . . . . timing chain guide rail, installing . . . . . . . . . timing chain tensioner, installing . . . . . . . . . timing chain, installing . . . . . . . . . . . . . . . . torque limiter, installing . . . . . . . . . . . . . . . transmission shafts, installing . . . . . . . . . . . valve clearance, adjusting . . . . . . . . . . . . . . valve clearance, checking . . . . . . . . . . . . . . valve cover, installing . . . . . . . . . . . . . . . . . valve timing, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 148 154 145 155 155 151 161 148 151 152 146 147 160 160 149 152 149 152 147 146 145 161 146 147 150 160 159 147 152 156 151 159 145 158 158 159 157 Brake linings of front brake changing . . . . . . . . . checking . . . . . . . . . installing . . . . . . . . . removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 91 92 91 Brake linings of rear brake changing . . . . . . . . . checking . . . . . . . . . installing . . . . . . . . . removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 96 97 96 C Camber adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Carburetor adjusting idle . . . . . . . . assembling . . . . . . . . . disassembling . . . . . . . float chamber, emptying installing . . . . . . . . . . . removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 175 167 164 166 164 Carburetor - Work on individual parts accelerator pump, checking/adjusting choke slide, checking . . . . . . . . . . . float level, checking/adjusting . . . . . float needle valve, checking . . . . . . . hot start slide, checking . . . . . . . . . jet needle, checking . . . . . . . . . . . . needle jet, checking . . . . . . . . . . . . throttle slide, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 171 174 173 171 172 173 172 Carburetor components checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 170 CDI controller checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Chain cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 INDEX 242 Chain tension adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Chain wear checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Charging voltage checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Clutch fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . 178 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Coolant level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Cooling system bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . . . 127 D E Engine installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 positioning at ignition top dead center . . . . . . . . . . . . 105 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Engine - Work on individual parts autodecompressor, checking . . . . . . . . . . . . . . . . . . cam levers, checking . . . . . . . . . . . . . . . . . . . . . . . . camshaft bearing bridges, checking . . . . . . . . . . . . . camshaft, changing . . . . . . . . . . . . . . . . . . . . . . . . camshafts, checking . . . . . . . . . . . . . . . . . . . . . . . . clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod, conrod bearing and crank pin, changing countershaft, assembling . . . . . . . . . . . . . . . . . . . . . countershaft, disassembling . . . . . . . . . . . . . . . . . . . crankshaft bearing inner race, installing . . . . . . . . . . . crankshaft bearing inner race, removing . . . . . . . . . . . crankshaft end play, measuring . . . . . . . . . . . . . . . . crankshaft run-out at the bearing pin, checking . . . . . crankshaft seal ring in clutch cover, removing . . . . . . . crankshaft seal ring, installing in clutch cover . . . . . . . cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . cylinder, checking/measuring . . . . . . . . . . . . . . . . . . electric starter mode, checking . . . . . . . . . . . . . . . . . freewheel, checking . . . . . . . . . . . . . . . . . . . . . . . . freewheel, installing . . . . . . . . . . . . . . . . . . . . . . . . freewheel, removing . . . . . . . . . . . . . . . . . . . . . . . . left section of the engine case, working on . . . . . . . . . lubrication system, checking . . . . . . . . . . . . . . . . . . main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . main shaft, disassembling . . . . . . . . . . . . . . . . . . . . piston ring end gap, checking . . . . . . . . . . . . . . . . . . piston, checking/measuring . . . . . . . . . . . . . . . . . . . piston/cylinder, determining the mounting clearance . . radial clearance of camshaft bearings, checking . . . . . right section of the engine case . . . . . . . . . . . . . . . . shaft seal ring of water pump, changing . . . . . . . . . . . shift mechanism, checking . . . . . . . . . . . . . . . . . . . shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . spring length of oil pressure regulator valve, checking . timing assembly, checking . . . . . . . . . . . . . . . . . . . . timing chain tensioner, preparing for installation . . . . . transmission, checking . . . . . . . . . . . . . . . . . . . . . . valve spring seat, checking . . . . . . . . . . . . . . . . . . . valve springs, checking . . . . . . . . . . . . . . . . . . . . . . valves, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . valves, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . valves, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . water pump, installing . . . . . . . . . . . . . . . . . . . . . . . water pump, removing . . . . . . . . . . . . . . . . . . . . . . . P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Clutch lever basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 14 valve cover, removing . . . . . . . . . . . . . . . . . . . . . . . 104 water pump cover, removing . . . . . . . . . . . . . . . . . . . 108 Disassembling the engine alternator cover, removing . . . . . . . . camshaft, removing . . . . . . . . . . . . centrifugal separator, removing . . . . . clutch cover, removing . . . . . . . . . . crankshaft, removing . . . . . . . . . . . . cylinder head, removing . . . . . . . . . . double wheel, removing . . . . . . . . . . drive wheel of balancer gear, removing engine case, removing left section . . . engine oil, draining . . . . . . . . . . . . . force pump, removing . . . . . . . . . . . ignition pulse generator, removing . . . locking lever, removing . . . . . . . . . . oil filter, removing . . . . . . . . . . . . . outer clutch hub, removing . . . . . . . piston, removing . . . . . . . . . . . . . . . preparations . . . . . . . . . . . . . . . . . primary gear, removing . . . . . . . . . . rotor and starter idler gear, removing . shift drum locating unit, removing . . shift drum, removing . . . . . . . . . . . . shift forks, removing . . . . . . . . . . . . shift lever, removing . . . . . . . . . . . . shift rails, removing . . . . . . . . . . . . shift shaft, removing . . . . . . . . . . . . spacer, removing . . . . . . . . . . . . . . spark plug, removing . . . . . . . . . . . . starter motor, removing . . . . . . . . . . suction pump, removing . . . . . . . . . timing chain rails, removing . . . . . . . timing chain tensioner, removing . . . timing chain, removing . . . . . . . . . . torque limiter, removing . . . . . . . . . transmission shafts, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 106 113 108 117 107 107 111 115 103 111 110 115 103 112 109 103 113 110 115 116 116 103 116 114 112 104 104 114 109 106 109 105 116 130 133 131 129 130 138 125 144 141 125 125 127 126 123 123 127 133 127 136 135 135 135 119 124 143 141 129 128 129 130 118 121 139 140 123 137 137 142 133 133 132 134 131 122 120 Engine guard installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 INDEX 243 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Engine oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Engine sprocket installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Handlebar position adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Heel protector installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Hot start lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I Ignition coil checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Fender, rear installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Ignition curve changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Foot brake lever basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 93 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 93 Ignition pulse generator checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m F Fork offset adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Front cover installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Front shock absorber bleeding and filling . . . . . . . . . . . . . . . . . . . compression damping, high-speed adjustment compression damping, low-speed adjustment . cross over, adjusting . . . . . . . . . . . . . . . . . . damper, assembling . . . . . . . . . . . . . . . . . . damper, checking . . . . . . . . . . . . . . . . . . . . damper, disassembling . . . . . . . . . . . . . . . . damper, filling with nitrogen . . . . . . . . . . . . heim joint, installing . . . . . . . . . . . . . . . . . . heim joint, removing . . . . . . . . . . . . . . . . . . installing . . . . . . . . . . . . . . . . . . . . . . . . . . oil change . . . . . . . . . . . . . . . . . . . . . . . . . piston rod, assembling . . . . . . . . . . . . . . . . piston rod, disassembling . . . . . . . . . . . . . . rebound damping, adjusting . . . . . . . . . . . . . removing . . . . . . . . . . . . . . . . . . . . . . . . . . shock absorber, servicing . . . . . . . . . . . . . . . spring preload, adjusting . . . . . . . . . . . . . . . spring, installing . . . . . . . . . . . . . . . . . . . . spring, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 21 21 24 33 30 28 37 31 31 25 25 32 29 22 24 27 23 38 28 Front trim installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Ignition system checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 K Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 M Main fuse changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Main silencer installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Manifold installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 O Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Oil filter changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Oil pressure regulator valve installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 spring length, checking . . . . . . . . . . . . . . . . . . . . . . 123 Oil screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 P Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Fuel tank installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Play in throttle cable adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 162 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Putting into operation after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Fuse changing fuses of individual power consumers . . . . . . . 85 changing the main fuse . . . . . . . . . . . . . . . . . . . . . . . 85 Q H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 88 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 88 Quiescent current checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 R Radiator spoiler installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 INDEX 244 carburetor tightening torques . chassis . . . . . . . . . . . . . . . . chassis tightening torques . . . engine . . . . . . . . . . . . . . . . engine - tolerance, wear limits engine tightening torques . . . front shock absorber . . . . . . . rear shock absorber . . . . . . . . Rear axle installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Rear axle bearing changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 38 39 52 48 45 56 50 49 42 42 51 46 40 41 50 47 44 40 57 44 Rear sprocket / engine sprocket checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 210-211 . . . 214 . . . 204 . . . 205 206-207 . . . 212 . . . 213 Throttle slide opening checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 173 Tire air pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Toe adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 rear toe width, adjusting . . . . . . . . . . . . . . . . . . . . . . 77 Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 V Vehicle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 removing from work stand . . . . . . . . . . . . . . . . . . . . . 12 W Seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 217-219 Servicing the front shock absorber . . . . . . . . . . . . . . . . . . . 27 Servicing the rear shock absorber . . . . . . . . . . . . . . . . . . . 44 Shock absorber pilot bushing, changing . . . . . . . . . . . . . . . . . . . . . . . 47 shock absorber part number, front . . . . . . . . . . . . . . . . 10 shock absorber part number, rear . . . . . . . . . . . . . . . . 11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Spark plug connector checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Starter relay checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Stator installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Steering column installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering column bearing changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Storage . . . . . . . . Throttle position sensor checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 174 position, checking . . . . . . . . . . . . . . . . . . . . . . . . . 163 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Rear shock absorber bleeding and filling . . . . . . . . . . . . . . . . . . . compression damping, high-speed adjustment compression damping, low-speed adjustment . damper, assembling . . . . . . . . . . . . . . . . . . damper, checking . . . . . . . . . . . . . . . . . . . . damper, disassembling . . . . . . . . . . . . . . . . damper, filling with nitrogen . . . . . . . . . . . . heim joint, installing . . . . . . . . . . . . . . . . . . heim joint, removing . . . . . . . . . . . . . . . . . . installing . . . . . . . . . . . . . . . . . . . . . . . . . . oil change . . . . . . . . . . . . . . . . . . . . . . . . . piston rod, assembling . . . . . . . . . . . . . . . . piston rod, disassembling . . . . . . . . . . . . . . rebound damping, adjusting . . . . . . . . . . . . . removing . . . . . . . . . . . . . . . . . . . . . . . . . . seal ring retainer, assembling . . . . . . . . . . . . seal ring retainer, disassembling . . . . . . . . . . shock absorber, servicing . . . . . . . . . . . . . . . spring preload, adjusting . . . . . . . . . . . . . . . spring, installing . . . . . . . . . . . . . . . . . . . . spring, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 T Technical data carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wheel bearing changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Wheel carrier installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Wheel/wheels installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 *3206070en* P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3206070en 08/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.6 Linearized : Yes Encryption : Standard V4.4 (128-bit) User Access : Print, Copy, Extract, Print high-res Author : www.PartShark.com Create Date : 2009:09:01 08:46:42+02:00 Modify Date : 2010:01:04 14:07:40-05:00 Has XFA : No XMP Toolkit : Adobe XMP Core 4.2.1-c041 52.342996, 2008/05/07-20:48:00 Producer : GView Metadata Date : 2010:01:04 14:07:40-05:00 Document ID : uuid:7608e8b0-63d5-3da6-8226-47f2661ef512 Instance ID : uuid:d70de4ba-3d29-42a1-b364-70f0031a7de7 Format : application/pdf Creator : www.PartShark.com Title : Page Layout : SinglePage Page Mode : UseOutlines Page Count : 247EXIF Metadata provided by EXIF.tools