2010 KTM 450SX 505SX Sevice Manual

User Manual: 2010 KTM 450SX 505SX Sevice Manual

Open the PDF directly: View PDF PDF.
Page Count: 247 [warning: Documents this large are best viewed by clicking the View PDF Link!]

REPAIR MANUAL 2010
450 SX ATV
505 SX ATV
Article no. 3206070en
PartShark.com
877-999-5686
PartShark.com
877-999-5686
INTRODUCTION 1
INTRODUCTION
It is important that you read this owner's manual carefully and completely before the start of work.
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.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial 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
PartShark.com
877-999-5686
CONTENTS 2
CONTENTS
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
Rear shock absorber - disassembling the piston rod .......... 46
Rear shock absorber - disassembling the seal ring
retainer ........................................................................ 47
Changing the pilot bushing............................................. 47
Rear shock absorber - checking the damper ..................... 48
Rear shock absorber - removing the heim joint ................. 49
Rear shock absorber - installing the heim joint ................. 50
Rear shock absorber - assembling the seal ring retainer..... 50
Rear shock absorber - assembling the piston rod .............. 51
Rear shock absorber - assembling the damper.................. 52
Rear shock absorber - bleeding and filling the damper ...... 54
Rear shock absorber - filling the damper with nitrogen ...... 56
Rear shock absorber - installing the spring....................... 57
05/EXHAUST .................................................................... 59
Removing the main silencer............................................ 59
Installing the main silencer ............................................ 59
Removing the manifold .................................................. 60
Installing the manifold ................................................... 60
06/AIR FILTER.................................................................. 61
Removing the air filter ................................................... 61
Installing the air filter .................................................... 61
Cleaning air filter........................................................... 61
Removing the air filter box lid with the carburetor
connection boot ............................................................ 62
Installing the air filter box lid and the carburetor
connection boot ............................................................ 62
07/FUEL TANK, SEAT, TRIM.............................................. 63
Removing the seat......................................................... 63
Mounting the seat ......................................................... 63
Removing the radiator spoiler ......................................... 63
Installing the radiator spoiler .......................................... 64
Removing the fuel tank .................................................. 64
Installing the fuel tank................................................... 65
Fuel tap........................................................................ 66
08/MASK, FENDER ........................................................... 67
Removing the heel protector ........................................... 67
Installing the heel protector............................................ 68
Removing the front cover................................................ 69
Installing the front cover ................................................ 69
Removing the front trim ................................................. 69
Installing the front trim.................................................. 70
Removing the rear fender ............................................... 70
Installing the rear fender ................................................ 71
09/FRONT WHEEL ............................................................ 72
Checking the tire air pressure ......................................... 72
Checking the tire condition............................................. 72
Removing wheel/wheels.................................................. 72
Installing the wheel/wheels............................................. 73
Checking brake discs ..................................................... 74
10/REAR WHEEL .............................................................. 75
Checking chain dirt ....................................................... 75
Cleaning the chain......................................................... 75
Checking chain wear...................................................... 75
Checking rear sprocket / engine sprocket for wear ............. 76
Checking the chain tension ............................................ 76
Adjusting chain tension.................................................. 76
Adjusting the toe width of rear axle ................................. 77
Removing the rear axle................................................... 78
Installing the rear axle ................................................... 79
Changing the rear axle bearing........................................ 81
11/WIRING HARNESS, BATTERY ....................................... 83
Ignition curve plug connection........................................ 83
PartShark.com
877-999-5686
CONTENTS 3
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
Removing the suction pump ......................................... 114
Removing the shift shaft .............................................. 114
Removing the shift drum locating unit........................... 115
Removing the locking lever........................................... 115
Removing the left section of the engine case.................. 115
Removing the shift rails ............................................... 116
Removing the shift drum.............................................. 116
Removing the shift forks .............................................. 116
Removing the transmission shafts ................................. 116
Removing the crankshaft.............................................. 117
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 118
Working on the right section of the engine case.............. 118
Working on the left section of the engine case................ 119
Removing the water pump............................................ 120
Changing the shaft seal ring of the water pump .............. 121
Installing the water pump............................................. 122
Removing the crankshaft seal ring in the clutch cover ..... 123
Installing the crankshaft seal ring in the clutch cover...... 123
Removing the oil pressure regulator valve....................... 123
Checking spring length of oil pressure regulator valve...... 123
Installing the oil pressure regulator valve ....................... 124
Checking the lubrication system.................................... 124
Removing the crankshaft bearing inner race................... 125
Installing the crankshaft bearing inner race.................... 125
Changing connecting rod, conrod bearing and crank
pin............................................................................. 125
Checking crankshaft run-out at bearing pin .................... 126
Measuring the crankshaft end play ................................ 127
Cylinder - Nikasil®coating............................................ 127
Checking/measuring cylinder ........................................ 127
Checking/measuring the piston ..................................... 128
Measuring piston/cylinder mounting clearance................ 129
Checking the piston ring end gap .................................. 129
Changing the camshaft bearing..................................... 129
Checking the autodecompressor.................................... 130
Checking camshafts..................................................... 130
Checking the radial clearance of the camshaft
bearings ..................................................................... 130
Checking the camshaft bearing bridges.......................... 131
Removing the valves .................................................... 131
Checking the valves ..................................................... 132
Checking the valve springs ........................................... 133
Checking valve spring seat............................................ 133
Checking the cam levers .............................................. 133
Checking cylinder head ................................................ 133
Installing the valves..................................................... 134
Removing the freewheel ............................................... 135
Checking the freewheel ................................................ 135
Installing the free wheel............................................... 135
Checking the electric starter mode ................................ 136
Checking the timing assembly ...................................... 137
Preparing the timing chain tensioner for installation ....... 137
Checking clutch .......................................................... 138
Checking shift mechanism ........................................... 139
Preassembling the shift shaft........................................ 140
Disassembling the main shaft ....................................... 141
Disassembling the countershaft .................................... 141
Checking transmission ................................................. 142
Assembling the main shaft ........................................... 143
Assembling the countershaft......................................... 144
30/ENGINE ASSEMBLY ................................................... 145
Installing the crankshaft............................................... 145
PartShark.com
877-999-5686
CONTENTS 4
Installing the transmission shafts.................................. 145
Installing the shift forks ............................................... 145
Installing the shift drum............................................... 146
Installing the shift rails ................................................ 146
Installing the left engine case....................................... 146
Installing the locking lever............................................ 147
Installing the shift drum locating unit............................ 147
Installing the shift shaft ............................................... 147
Installing the suction pumps ........................................ 147
Installing the centrifugal separator ................................ 148
Installing the force pump ............................................. 148
Installing the primary gear............................................ 149
Installing the outer clutch hub...................................... 149
Installing the spacer .................................................... 150
Installing the drive wheel of the balancer gear................ 151
Installing the timing chain............................................ 151
Installing the free wheel gear........................................ 151
Installing the ignition pulse generator............................ 152
Installing the rotor....................................................... 152
Installing the timing chain rails..................................... 152
Installing the piston..................................................... 152
Installing the clutch cover ............................................ 154
Installing the water pump cover .................................... 154
Installing the cylinder head .......................................... 155
Installing the double wheel........................................... 155
Installing the timing chain tensioner ............................. 156
Checking the valve timing ............................................ 156
Adjusting the valve timing ............................................ 157
Checking the valve clearance........................................ 158
Adjusting the valve clearance........................................ 158
Installing the torque limiter .......................................... 159
Installing the alternator cover ....................................... 159
Installing the starter motor ........................................... 159
Installing the valve cover .............................................. 159
Installing the spark plug............................................... 160
Installing the oil screen................................................ 160
Installing the oil filter .................................................. 160
Installing the shift lever ............................................... 161
Removing the engine from the universal mounting
rack ........................................................................... 161
31/CARBURETOR ........................................................... 162
Choke......................................................................... 162
Checking the play in the throttle cable........................... 162
Carburetor - adjusting idle............................................ 162
Checking the position of the throttle position sensor ....... 163
Draining the carburetor float chamber ........................... 164
Removing the carburetor .............................................. 164
Installing the carburetor............................................... 166
Disassembling the carburetor........................................ 167
Checking/adjusting the carburetor components............... 170
Checking/adjusting the accelerator pump....................... 170
Checking the choke slide.............................................. 171
Checking the hot start slide .......................................... 171
Checking the throttle position sensor............................. 171
Checking the jet needle................................................ 172
Checking the throttle slide............................................ 172
Checking/adjusting the throttle slide opening ................. 173
Checking the needle jet................................................ 173
Checking the float needle valve..................................... 173
Checking/adjusting the float level.................................. 174
Adjusting the position of the throttle position sensor ....... 174
Assembling the carburetor............................................ 175
32/CLUTCH .................................................................... 178
Checking fluid level of hydraulic clutch ......................... 178
Changing the hydraulic clutch fluid............................... 178
33/TRANSMISSION......................................................... 179
Removing the engine sprocket ...................................... 179
Installing the engine sprocket ....................................... 179
35/WATER PUMP, COOLING SYSTEM .............................. 180
Checking antifreeze and coolant level............................ 180
Checking the coolant level............................................ 180
Draining coolant .......................................................... 181
Filling coolant/bleeding the cooling system .................... 181
38/LUBRICATION SYSTEM .............................................. 183
Oil circuit ................................................................... 183
Changing the engine oil and oil filter, cleaning the oil
screen ........................................................................ 183
Draining the engine oil................................................. 184
Removing the oil filter.................................................. 184
Installing the oil filter .................................................. 185
Filling up with engine oil.............................................. 185
Checking the engine oil level ........................................ 185
Adding engine oil ........................................................ 186
39/IGNITION SYSTEM ..................................................... 187
Removing the stator..................................................... 187
Installing the stator ..................................................... 187
Checking the ignition system ........................................ 187
Checking the ignition coil............................................. 188
Checking the spark plug connector................................ 189
Checking the CDI controller.......................................... 189
Checking the ignition pulse generator............................ 189
Checking the alternator ................................................ 190
61/ATV FRONT END........................................................ 191
Checking the toe ......................................................... 191
Adjusting the toe......................................................... 192
Checking/adjusting the camber ..................................... 193
Adjusting the fork offset............................................... 194
Removing the wheel carrier .......................................... 194
Changing the wheel bearing.......................................... 196
Installing the wheel carrier ........................................... 197
Removing the A-arms................................................... 198
Installing the A-arms ................................................... 199
A-Arm top - changing the bearing.................................. 200
A-Arm bottom - changing the bearing ............................ 201
TECHNICAL DATA - ENGINE............................................ 204
Capacity - engine oil .................................................... 204
Capacity - coolant........................................................ 204
TECHNICAL DATA - ENGINE TOLERANCES, WEAR
LIMITS........................................................................... 205
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 206
TECHNICAL DATA - CARBURETOR................................... 208
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES....................................................................... 209
TECHNICAL DATA - CHASSIS .......................................... 210
Tires .......................................................................... 211
Capacity - fuel............................................................. 211
TECHNICAL DATA - FRONT SHOCK ABSORBER................ 212
TECHNICAL DATA - REAR SHOCK ABSORBER.................. 213
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 214
CLEANING...................................................................... 215
Cleaning the vehicle .................................................... 215
STORAGE ....................................................................... 216
Storage....................................................................... 216
Putting the vehicle into operation after storage............... 216
PartShark.com
877-999-5686
CONTENTS 5
SERVICE SCHEDULE....................................................... 217
Important maintenance work to be carried out by an
authorized KTM workshop ............................................ 217
Important maintenance work to be carried out by an
authorized KTM workshop (as an additional order) .......... 218
Important checks and maintenance work to be carried
out by the rider ........................................................... 218
WIRING DIAGRAM .......................................................... 220
450/525 SX ATV......................................................... 220
SUBSTANCES................................................................. 223
AUXILIARY SUBSTANCES................................................ 225
SPECIAL TOOLS.............................................................. 227
STANDARDS................................................................... 240
INDEX ............................................................................ 241
PartShark.com
877-999-5686
MEANS OF REPRESENTATION 6
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
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.
PartShark.com
877-999-5686
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.
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 parenthe-
ses. 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 miss-
ing, 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 informa-
tion 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.
PartShark.com
877-999-5686
VIEW OF VEHICLE 8
3.1View of the vehicle from the left front (example)
301769-10
1 Hand brake lever
2 Fuse box
3 Shock absorber compression adjustment
4 Front shock absorber
5 Shock absorber rebound adjustment
6 Heel protector
7 Shift lever
8 Kill switch/emergency OFF switch with rip cord
9 Clutch lever
10 Hot start lever
PartShark.com
877-999-5686
VIEW OF VEHICLE 9
3.2View of the vehicle from the right rear (example)
301770-10
1 Filler cap
2 Main silencer
3 Seat release
4 Shock absorber rebound adjustment
5 Rear sprocket with chain
6 Rear wheel eccentric element
7 Rear brake
8 Foot brake pedal
9 Handlebar bridge
10 Throttle lever
11 Handlebar cushion
PartShark.com
877-999-5686
LOCATION OF SERIAL NUMBERS 10
4.1Chassis number
301771-10
The chassis number is stamped on the right side of the frame in the vicinity of the
upper control arm.
4.2Type label
301858-10
The type label is located on the frame tube on the right and left in front of the radia-
tor.
4.3Key number
100089-10
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.
4.4Engine number
301772-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.5Shock absorber part number, front
301832-10
The shock absorber part number is stamped on the upper part of the shock
absorber.
PartShark.com
877-999-5686
LOCATION OF SERIAL NUMBERS 11
4.6Shock absorber part number, rear
301831-10
The shock absorber part number is stamped on the upper part of the shock
absorber.
PartShark.com
877-999-5686
VEHICLE 12
5.1Jacking up the vehicle
301785-10
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.
5.2Removing the vehicle from the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Lower the vehicle.
–Remove the work stand.
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 13
6.1Hot start lever
301775-10
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.
6.2Adjusting handlebar position
301846-10
–Remove the handlebar cushion.
Info
Protect the vehicle and its attachments from damage by covering them.
Do not bend the cables and lines.
100099-10
–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)
–Mount and tighten screw .
Guideline
Screw, steering column, top M20x1.5 25 Nm
(18.4 lbf ft)
–Mount and tighten screws .
Guideline
Screw, steering bridge M8 20 Nm
(14.8 lbf ft)
–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 20 Nm
(14.8 lbf ft)
Info
Make sure cables and wiring are positioned correctly.
–Mount the handlebar cushion.
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 14
6.3Adjusting basic position of clutch lever
301813-10
–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!
6.4Checking the play in the throttle cable
301795-11
–Move the handlebar to the straight-ahead position. Move the throttle lever back and
forth slightly to ascertain the play in the throttle cable .
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.
–When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–Start the engine and 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)
6.5Adjusting play in throttle cable
–Check throttle cable route.
301795-10
–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 .
6.6Removing the steering column
–Remove the front cover. ( p. 69)
301859-10
–Remove handlebar cushion .
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 15
301860-10
–Loosen screw .
Info
The screw cannot be removed.
301861-10
–Loosen screws .
301862-10
–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.
301519-10
–Remove screw .
301520-10
–Loosen screws .
–Pull the steering arm down.
301863-10
–Remove screws .
–Swing the cable guide forward.
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 16
301864-10
–Remove screws .
–Pull out the steering column with bearing support from above.
301523-10
–Pull bearing support off from above.
6.7Changing the steering column bearing
–Remove the steering column. ( p. 14)
301528-10
–Remove spacer .
301524-10
–Remove shaft seal ring .
301529-10
–Remove lock ring .
301525-10
–Mount special tool .
Extractor (83019020000) ( p. 235)
–Press out the steering column bearing by turning in the screw.
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 17
301526-10
–Position the steering column bearing.
–Mount special tool .
Extractor (83019020000) ( p. 235)
–Press in the steering column bearing by turning in the screw.
301529-10
–Mount lock ring .
301527-10
–Position the shaft seal ring.
–Mount special tool .
Extractor (83019020000) ( p. 235)
–Press in the shaft seal ring by turning in the screw.
301528-10
–Mount spacer .
301530-10
–Remove shaft seal rings from the bearing support.
301531-10
–Press out the sleeve bearing.
Extractor (83019020000) ( p. 235)
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 18
301532-10
–Press in the sleeve bearing.
Extractor (83019020000) ( p. 235)
301530-10
–Press in shaft seal rings from the outside to the inside with the open side facing
inward.
6.8Installing the steering column
301523-11
–Lightly grease bearing support and slide it onto the steering column.
Long-life grease ( p. 225)
301864-11
–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)
301863-11
–Position the cable guide.
–Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
301520-11
–Position the steering arm.
–Tighten screw .
Guideline
Screw, steering column at bottom of
steering lever
M10 25 Nm
(18.4 lbf ft)
PartShark.com
877-999-5686
02/HANDLEBAR, INSTRUMENTS 19
301519-10
–Mount and tighten screw .
Guideline
Screw, steering column, bottom M20x1.5 40 Nm
(29.5 lbf ft)
301862-11
–Mount the handlebar with the handlebar bridge and screw .
–Mount and tighten screw .
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
301861-11
–Tighten screws .
Guideline
Screw, steering bridge M8 20 Nm
(14.8 lbf ft)
301860-11
–Tighten screw .
Guideline
Screw, steering column, top M20x1.5 25 Nm
(18.4 lbf ft)
301859-11
–Mount handlebar cushion on the handlebar.
–Install the front cover. ( p. 69)
PartShark.com
877-999-5686
03/FRAME 20
7.1Removing the engine guard
301823-10
–Remove screws and . Remove the engine guard.
7.2Installing the engine guard
301823-10
–Position the engine guard on the frame bearer. Mount and tighten screws
and .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 21
8.1Front shock absorber - adjusting the high-speed compression damping
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 charac-
teristics 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 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.
301786-10
–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
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
8.2Front shock absorber - adjusting the low-speed compression damping
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 charac-
teristics 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.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 22
301787-10
–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
Comfort 20 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
8.3Front shock absorber - adjusting the rebound damping
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 charac-
teristics 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.
301788-10
–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
Comfort 20 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 23
8.4Front shock absorber - adjusting the spring preload
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 charac-
teristics 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.
–Jack up the vehicle. ( p. 12)
–Clean the shock absorber thoroughly.
301790-11
–Release counter ring .
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.
800064-10
–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.
–Tighten the lock ring and adjusting ring.
–Remove the vehicle from the work stand. ( p. 12)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 24
8.5Front shock absorber - adjusting the cross over
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. ( p. 23)
–Jack up the vehicle. ( p. 12)
–Clean the shock absorber thoroughly.
301789-10
–Loosen adjusting rings and .
Hook wrench (83019001000) ( p. 234)
301790-10
–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)
8.6Removing the front shock absorber
Info
The operations are the same on the left and right sides.
–Jack up the vehicle. ( p. 12)
301534-10
–Secure the upper A-arm on the frame using tension belt .
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 25
301535-10
–Remove screw .
301536-10
–Remove screw . Remove the shock absorber.
8.7Installing the front shock absorber
Info
The operations are the same on the left and right.
301536-11
–Position the front shock absorber. Mount and tighten screw .
Guideline
Screw, front shock absorber M10 45 Nm
(33.2 lbf ft)
301535-11
–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)
–Remove the tension belt.
–Remove the vehicle from the work stand. ( p. 12)
8.8Front shock absorber - changing the oil
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)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 26
201133-10
–Note down the present state of rebound damping and compression damping .
–Completely open the adjusters of the rebound and compression damping.
201134-10
–Remove rubber cap of the reservoir.
–Slowly open screw .
The pressurized nitrogen is bled off.
201218-10
–Remove screw . Let the oil drain out.
–Bleed and fill the damper of the front shock absorber. ( p. 34)
–Fill the damper of the front shock absorber with nitrogen. ( p. 37)
201150-11
–Mount rubber cap of the reservoir.
201133-10
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
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
PartShark.com
877-999-5686
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 seri-
ously alter the vehicle's ride behavior.
–Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
–Only make adjustments 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)
8.9Service the front shock absorber
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. ( p. 28)
–Disassemble the damper of the front shock absorber. ( p. 28)
–Disassemble the piston rod of the front shock absorber. ( p. 29)
–Remove the heim joint from the front shock absorber. ( p. 31)
–Check the damper of the front shock absorber. ( p. 30)
–Install the heim joint of the front shock absorber. ( p. 31)
–Assemble the piston rod of the front shock absorber. ( p. 32)
–Assemble the damper of the front shock absorber. ( p. 33)
–Install the spring of the front shock absorber. ( p. 38)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 28
8.10Front shock absorber - removing the spring
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.
201131-10
–Release counter ring .
–Turn adjusting ring all the way up.
Hook wrench (83019001000) ( p. 234)
201132-10
–Pull the spring down. Remove spring retainer .
–Remove the spring.
–Remove sleeve .
–Remove spring .
–Remove adjusting ring and retaining ring .
8.11Front shock absorber - disassembling the damper
–Remove the spring from the front shock absorber. ( p. 28)
201133-10
–Note down the present state of rebound damping and compression damping .
–Completely open the adjusters of the rebound and compression damping.
201134-10
–Remove rubber cap of the reservoir.
–Slowly open screw .
The pressurized nitrogen is bled off.
201135-10
–Remove locking cap .
–Press in seal ring retainer . Remove lock ring .
Info
Do not scratch the inner surface.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 29
201136-10
–Remove the piston rod. Drain the oil.
201137-10
–Remove compression damping . Remove the spring and piston.
8.12Front shock absorber - disassembling the piston rod
–Disassemble the damper of the front shock absorber. ( p. 28)
201139-10
–Clamp the piston rod with the heim joint in a bench vise.
–Remove nut .
–Remove supporting plate .
201140-10
–Remove rebound shim stack .
Info
Thread the rebound shim stack onto a screwdriver and set them down
together.
–Remove piston .
201141-10
–Remove compression shim stack with bushing .
Info
Thread the compression shim stack onto a screwdriver and set them down
together.
200924-10
–Remove seal ring retainer .
–Remove locking cap and rubber buffer .
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 30
8.13Front shock absorber - checking the damper
Condition
The damper has been disassembled.
201138-10
–Measure the inside diameter on both ends and in the middle of the damper car-
tridge.
Damper cartridge
Minimum diameter 36.04 mm (1.4189 in)
» If the measured value is greater than the specified value:
–Change the damper cartridge.
–Check the damper cartridge for damage and wear.
» If there is damage or wear:
–Change the damper cartridge.
200946-10
–Measure the diameter of the piston rod.
Piston rod
Diameter ≥13.95 mm (≥0.5492 in)
» If the specified value is not reached:
–Replace the piston rod.
–Measure the run-out of the piston rod.
Piston rod
Run-out ≤0.06 mm (≤0.0024 in)
» If the measured value is greater than the specified value:
–Replace the piston rod.
–Check the piston for damage and wear.
» If there is damage or wear:
–Replace the piston rod.
300460-01
–Check the heim joint for damage and wear.
» If there is damage or wear:
–Change the heim joint.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 31
8.14Front shock absorber - removing the heim joint
Info
The operations are the same on the top and bottom heim joint.
Condition
The shock absorber has been removed.
200906-10
–Clamp the shock absorber in a vise using soft jaws.
–Remove both collar bushings of the heim joint.
Pin (T120) ( p. 237)
200907-10
–Remove seal rings on both sides.
200908-10
–Press heim joint to the side.
Pressing tool (T1207S) ( p. 238)
The heim joint is lined up with a lock ring.
–Remove the other lock ring .
200909-10
–Place special tool underneath and press out the heim joint using special tool .
Pressing tool (T1207S) ( p. 238)
8.15Front shock absorber - installing the heim joint
Info
The operations are the same on the top and bottom heim joint.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 32
200911-10
–Place special tool underneath and press in the heim joint to the lock ring using
special tool .
Pressing tool (T1207S) ( p. 238)
Pressing tool (T1206) ( p. 238)
200912-10
–Mount the second lock ring .
–Mount and grease seal rings on both sides.
Lubricant (T158) ( p. 225)
201142-10
–Press in both collar bushings of the heim joint.
8.16Front shock absorber - assembling the piston rod
–Check the damper of the front shock absorber. ( p. 30)
201144-10
–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) ( p. 225)
–Remove the special tool.
201145-10
–Mount bushing .
Info
Mount the larger inside diameter of the supporting plate facing downward.
–Mount compression damping shim stack with the smaller shims facing down-
ward.
201146-10
–Grind the 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
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 33
201147-10
–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)
8.17Front shock absorber - assembling the damper
201148-10
–Slide the spring and piston onto compression damping adjuster .
–Lubricate the O-rings.
Lubricant (T158) ( p. 225)
–Lubricate the thread.
Lubricant (T159) ( p. 226)
–Mount and tighten the compression damping adjuster.
Guideline
Compression damping adjuster M31x1 50 Nm
(36.9 lbf ft)
201136-10
–Fill the damper cartridge about half full.
Shock absorber oil (SAE 2,5) (50180342S1) ( p. 224)
–Grease the O-ring of the seal ring retainer.
Lubricant (T158) ( p. 225)
–Carefully mount the piston rod.
201149-10
–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 front shock absorber. ( p. 34)
–Fill the damper of the front shock absorber with nitrogen. ( p. 37)
201150-10
–Mount rubber cap of the reservoir.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 34
201151-10
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
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
–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 seri-
ously alter the vehicle's ride behavior.
–Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
–Only make adjustments 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.
8.18Front shock absorber - bleeding and filling the damper
Info
Before working with the vacuum pump, carefully read the vacuum pump operating manual.
Completely open the adjusters of the rebound and compression damping.
201152-10
–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.
PartShark.com
877-999-5686
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 hold-
ing it with your hand.
200271-10
–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
Vacuum gauge drops to the required value.
4 mbar
201153-10
–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.
200267-10
–Turn control lever Oil reservoir to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.
0 bar
200268-10
–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
200269-10
–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
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 36
200270-10
–When the pressure gauge reaches the required value, turn control lever Oil reser-
voir to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.
8 mbar
200267-10
–When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir to Equalize Pressure.
Guideline
8 mbar
The pressure gauge drops to the required value.
0 bar
200268-10
–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
200269-10
–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
0 bar
The vacuum pump is switched off.
201154-10
–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
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 pre-
cisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 37
–Remove the special tool.
201155-10
–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 M10x1 14 Nm
(10.3 lbf ft)
8.19Front shock absorber - filling the damper with nitrogen
201156-10
–Screw in screw by approx. 2 turns but do not tighten.
Info
The piston rod is fully extended.
201157-10
–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
Gas pressure 10 bar (145 psi)
–Position the damper in the special tool.
The hexagonal part of turning handle engages in the female hexagonal sec-
tion 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)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 38
8.20Front shock absorber - installing the spring
201143-10
–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.
201131-10
Alternative 1
–Tighten the spring by turning adjusting ring to the specified measurement.
Guideline
Spring preload
Comfort 3 mm
Standard 5 mm
Sport 8 mm
Hook wrench (83019001000) ( p. 234)
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
–Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
–Only make adjustments 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 .
302076-10
–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 19±1.5 mm (0.75±0.059 in)
–Adjust the sleeve by turning adjusting ring to the specified measurement .
–Lock the adjusting rings.
8.21Rear shock absorber - adjusting the high-speed compression damping
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 charac-
teristics 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.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 39
Info
The high-speed setting has an impact on the fast compression of the shock absorber.
301791-10
–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
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
8.22Rear shock absorber - adjusting the low-speed compression damping
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 charac-
teristics 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.
301791-11
–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
Comfort 20 clicks
Standard 15 clicks
Sport 15 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 40
8.23Rear shock absorber - adjusting the rebound damping
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 charac-
teristics 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.
301792-10
–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
Comfort 20 clicks
Standard 15 clicks
Sport 15 clicks
Info
Turning to the right increases damping, while turning to the left lessens
damping.
8.24Rear shock absorber - adjusting the spring preload
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 charac-
teristics 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. ( p. 41)
–After removing the shock absorber, clean it thoroughly.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 41
200601-01
–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.
400540-10
–Measure the overall spring pack when not under tension.
Info
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)
8.25Removing the rear shock absorber
–Jack up the vehicle. ( p. 12)
–Remove the rear fender. ( p. 70)
301835-10
Note
Danger of damage The chain sliding piece and frame can be damaged from incor-
rect 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.
–Remove the top screw of the shock absorber and carefully remove the shock
absorber out of the vehicle toward the rear.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 42
8.26Installing the rear shock absorber
301834-10
–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 M12 70 Nm
(51.6 lbf ft)
–Remove the tension belt.
–Install the rear fender. ( p. 71)
–Remove the vehicle from the work stand. ( p. 12)
8.27Rear shock absorber - changing the oil
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. ( p. 44)
201050-11
–Note down the present state of rebound damping and compression damping .
–Completely open the adjusters of the rebound and compression damping.
201051-10
–Remove rubber cap of the reservoir.
–Slowly open screw .
The pressurized nitrogen is bled off.
201052-10
–Remove screw . Let the oil drain out.
–Bleed and fill the damper of the rear shock absorber. ( p. 54)
–Fill the damper of the rear shock absorber with nitrogen. ( p. 56)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 43
201082-11
–Mount rubber cap of the reservoir.
201050-11
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
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 seri-
ously alter the vehicle's ride behavior.
–Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
–Only make adjustments 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)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 44
8.28Servicing the rear shock absorber
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.
201216-01
–Remove the spring from the rear shock absorber. ( p. 44)
–Disassemble the damper of the rear shock absorber. ( p. 45)
–Disassemble the piston rod of the rear shock absorber. ( p. 46)
–Disassemble the seal ring retainer of the rear shock absorber. ( p. 47)
–Checking the damper of the rear shock absorber. ( p. 48)
–Assemble the seal ring retainer of the rear shock absorber. ( p. 50)
–Assemble the piston rod of the rear shock absorber. ( p. 51)
–Assemble the damper of the rear shock absorber. ( p. 52)
–Install the spring of the rear shock absorber. ( p. 57)
8.29Rear shock absorber - removing the spring
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.
201046-10
–Release counter ring .
–Turn adjusting ring until the spring is no longer under tension.
Hook wrench (T157S) ( p. 239)
201047-10
–Remove ring .
–Remove spring retainer and washer .
–Remove spring.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 45
201048-10
–Remove sleeve .
–Remove spring with washer .
8.30Rear shock absorber - disassembling the damper
–Remove the spring from the rear shock absorber. ( p. 44)
201050-11
–Note down the present state of rebound damping and compression damping .
–Completely open the adjusters of the rebound and compression damping.
201051-10
–Remove rubber cap of the reservoir.
–Slowly open screw .
The pressurized nitrogen is bled off.
201052-10
–Remove screw . Let the oil drain out.
201053-10
–Remove locking cap .
–Press in seal ring retainer .
–Remove lock ring .
Info
Do not scratch the inner surface.
201054-10
–Remove the piston rod. Drain the remaining oil.
–Remove adjusting ring with the intermediate washer and retaining ring .
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 46
201055-10
–Remove compression damping adjuster -. Remove the spring and piston.
8.31Rear shock absorber - disassembling the piston rod
–Disassemble the damper of the rear shock absorber. ( p. 45)
201063-10
–Clamp the piston rod into a vise.
–Remove nut .
–Remove rebound shim stack .
201064-10
–Remove piston .
–Remove compression shim stack .
Info
Thread the compression shim stack onto a screwdriver and set them down
together.
201065-10
–Remove sleeve .
–Remove rebound shim stack .
Info
Thread the rebound shim stack onto a screwdriver and set them down
together.
201066-10
–Remove piston .
–Remove compression shim stack .
Info
Thread the compression shim stack onto a screwdriver and set them down
together.
201067-10
–Remove rebound washer .
–Remove seal ring retainer .
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 47
201068-10
–Remove locking cap - and rubber buffer .
8.32Rear shock absorber - disassembling the seal ring retainer
–Disassemble the piston rod of the rear shock absorber. ( p. 46)
200785-10
–Remove rebound rubber .
–Remove centering disk .
200786-10
–Remove seal ring .
–Remove washer from seal ring .
200787-10
–Remove washer .
–Remove O-ring .
–Remove dust boot .
8.33Changing the pilot bushing
–Disassemble the seal ring retainer of the rear shock absorber. ( p. 47)
200796-10
–Press pilot bushing out of seal ring retainer using the special tool.
Press drift (T1504) ( p. 238)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 48
200797-10
–Slide the new pilot bushing onto the special tool.
Press drift (T1504) ( p. 238)
–Position the pilot bushing in the seal ring retainer using the special tool.
Press drift (T1504) ( p. 238)
–Support seal ring retainer using sleeve of the special tool. Press the pilot
bushing all the way in.
Assembly tool (T150S) ( p. 238)
200798-10
–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.
Assembly tool (T150S) ( p. 238)
–Press the special tool through the new pilot bushing.
Calibration pin (T1205) ( p. 238)
The pilot bushing is calibrated.
–Assemble the seal ring retainer of the rear shock absorber. ( p. 50)
8.34Rear shock absorber - checking the damper
Condition
The damper has been disassembled.
201070-10
–Measure the inside diameter on both ends and in the middle of the damper car-
tridge.
Damper cartridge
Minimum diameter 46.10 mm (1.815 in)
» If the measured value is greater than the specified value:
–Change the damper cartridge.
–Check the damper cartridge for damage and wear.
» 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 heim joint.
201069-10
–Measure the diameter of the piston rod.
Piston rod
Diameter ≥17.95 mm (≥0.7067 in)
» If the specified value is not reached:
–Replace the piston rod.
–Measure the run-out of the piston rod.
Piston rod
Run-out ≤0.03 mm (≤0.0012 in)
» If the measured value is greater than the specified value:
–Replace the piston rod.
–Check the piston for damage and wear.
» If there is damage or wear:
–Replace the piston rod.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 49
200813-10
–Check the piston rings for damage and wear.
» If damaged or if a bronze-colored surface is visible:
–Change the piston rings.
8.35Rear shock absorber - removing the heim joint
Info
The operations are the same on the top and bottom heim joint.
Condition
The shock absorber has been removed.
201084-10
–Clamp the shock absorber in a vise using soft jaws.
–Remove both collar bushings of the heim joint using a pin.
201085-10
–Remove seal rings on both sides.
201086-10
–Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) ( p. 238)
–Remove the second lock ring .
201087-10
–Place special tool underneath and press out heim joint using special tool .
Pressing tool (T1207S) ( p. 238)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 50
8.36Rear shock absorber - installing the heim joint
Info
The operations are the same on the top and bottom heim joint.
201088-10
–Position the new heim joint and the special tool.
Pressing tool (T1206) ( p. 238)
–Press the heim joint all the way in.
201086-11
–Press the heim joint against the lock ring using the special tool.
Pressing tool (T1207S) ( p. 238)
–Mount the second lock ring .
201085-11
–Mount seal rings on both sides.
201089-10
–Position and press in both collar bushings .
8.37Rear shock absorber - assembling the seal ring retainer
200792-10
–Mount dust boot with the special tool.
Mounting sleeve (T1204) ( p. 237)
–Lubricate the sealing lip of the dust boot.
Lubricant (T625) ( p. 225)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 51
200793-10
–Lubricate the groove of the O-ring.
Lubricant (T158) ( p. 225)
–Mount O-ring .
–Mount washer .
200794-10
–Position washer on seal ring .
–Grease the seal ring and mount with the washer facing downward.
Lubricant (T511) ( p. 226)
200795-10
–Mount centering disk .
–Mount rebound rubber .
8.38Rear shock absorber - assembling the piston rod
–Assemble the seal ring retainer of the rear shock absorber. ( p. 50)
201071-10
–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) ( p. 225)
–Remove the special tool.
201072-10
–Mount rebound damping washer .
–Mount compression damping shim stack with the smaller shims facing down-
ward.
201073-10
–Grind piston on both sides, using 1200 grit sandpaper on a surfacing plate.
–Clean the piston.
–Mount the piston.
Guideline
View Top view of piston
View Bottom view of piston
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 52
201074-10
–Mount rebound damping shim stack with the smaller shims at the top.
–Mount sleeve .
201075-10
–Mount compression damping shim stack with the smaller shims at the bottom.
201076-10
–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
201077-10
–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 M10x1 30 Nm
(22.1 lbf ft)
8.39Rear shock absorber - assembling the damper
–Assemble the piston rod of the rear shock absorber. ( p. 51)
201078-10
–Slide the spring and piston onto compression damping adjuster .
–Lubricate the O-rings.
Lubricant (T158) ( p. 225)
–Lubricate the thread.
Lubricant (T159) ( p. 226)
–Mount and tighten compression damping adjuster .
Guideline
Compression damping adjuster M31x1 50 Nm
(36.9 lbf ft)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 53
201079-10
–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.
201080-10
–Lubricate the O-ring of the seal ring retainer.
Lubricant (T158) ( p. 225)
–Fill the damper cartridge about half full.
Shock absorber oil (SAE 2,5) (50180342S1) ( p. 224)
–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.
201081-10
–Mount locking cap of the damper cartridge.
–Bleed and fill the damper of the rear shock absorber. ( p. 54)
–Fill the damper of the rear shock absorber with nitrogen. ( p. 56)
201082-10
–Mount rubber cap of the reservoir.
–Turn adjusting ring with the intermediate washer and retaining ring all the
way down.
201083-10
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
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.
PartShark.com
877-999-5686
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
Comfort 1.5 turns
Standard 1 turn
Sport 1 turn
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
–Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
–Only make adjustments 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.
8.40Rear shock absorber - bleeding and filling the damper
Info
Before working with the vacuum pump, carefully read the vacuum pump operating manual.
Completely open the adjusters of the rebound and compression damping.
201090-10
–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
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 hold-
ing it with your hand.
200271-10
–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
Vacuum gauge drops to the required value.
4 mbar
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 55
201091-10
–Determine distance between the floating piston and reservoir hole with the spe-
cial tool.
Depth micrometer (T107S) ( p. 237)
The floating piston is positioned in the lowermost position.
200267-10
–When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.
0 bar
200268-10
–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
200269-10
–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
200270-10
–When the pressure gauge reaches the required value, turn control lever Oil reser-
voir to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.
8 mbar
200267-10
–When the vacuum gauge reaches the required value, turn control lever Oil reser-
voir to Equalize Pressure.
Guideline
8 mbar
The pressure gauge drops to the required value.
0 bar
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 56
200268-10
–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
200269-10
–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
0 bar
The vacuum pump is switched off.
201092-10
–Slide O-ring to the end of the special tool by the specified value (distance
minus specified value).
Guideline
10 mm
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 pre-
cisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.
–Remove the special tool.
201093-10
–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 M10x1 14 Nm
(10.3 lbf ft)
8.41Rear shock absorber - filling the damper with nitrogen
201095-10
–Screw in screw by approx. 2 turns but do not tighten.
Info
The piston rod is fully extended.
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 57
201096-10
–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
Gas pressure 10 bar (145 psi)
–Position the damper in the special tool.
The hexagonal part of turning handle engages in the female hexagonal sec-
tion 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 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)
8.42Rear shock absorber - installing the spring
201049-11
–Ensure that adjusting ring is screwed on with the washer and retaining ring .
–Screw the adjusting ring and retaining ring all the way down.
201048-11
–Measure the overall spring length in an unloaded state.
–Position spring .
Guideline
Spring rate, auxiliary spring 100 N/mm (571 lb/in)
–Mount washer and sleeve .
201047-11
–Position the spring.
Guideline
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)
PartShark.com
877-999-5686
04/SHOCK ABSORBER, SWINGARM 58
–Mount washer and spring retainer .
–Mount ring .
201046-11
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) ( p. 239)
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
–Extreme modifications to the adjustment of the spring elements can
cause a serious deterioration in the handling characteristics and
overload some components.
–Only make adjustments 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)
PartShark.com
877-999-5686
05/EXHAUST 59
9.1Removing the main silencer
Info
In order to present them more clearly, the following steps are shown with a removed fender.
301856-10
–Remove spring .
Spring hooks (50305017000) ( p. 227)
301857-10
–Remove screws and and remove the main silencer.
9.2Installing the main silencer
Info
In order to present them more clearly, the following steps are shown with a removed fender.
301857-11
–Attach the main silencer and position and tighten screws and .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
301856-11
–Reconnect spring .
Spring hooks (50305017000) ( p. 227)
PartShark.com
877-999-5686
05/EXHAUST 60
9.3Removing the manifold
Info
In order to present them more clearly, the following steps are shown with a removed fender.
–Remove the main silencer. ( p. 59)
301580-10
–Remove both springs .
Spring hooks (50305017000) ( p. 227)
301865-10
–Remove screws .
–Slip out the manifold.
9.4Installing the manifold
Info
In order to present them more clearly, the following steps are shown with a removed fender.
301580-11
–Position manifold and mount springs .
Spring hooks (50305017000) ( p. 227)
301865-11
–Mount and tighten screw .
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
–Install the main silencer. ( p. 59)
PartShark.com
877-999-5686
06/AIR FILTER 61
10.1Removing the air filter
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 ( p. 63)
301824-10
–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.
10.2Installing the air filter
301262-10
–Mount the clean air filter onto the air filter support.
–Grease the air filter in area .
Long-life grease ( p. 225)
301825-10
–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.
–Mount the seat. ( p. 63)
10.3Cleaning air filter
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. ( p. 61)
–Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner ( p. 225)
PartShark.com
877-999-5686
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)
10.4Removing the air filter box lid with the carburetor connection boot
–Remove the seat ( p. 63)
301854-10
–Remove hose clip .
–Raise the air filter box lid and remove with carburetor connection boot .
10.5Installing the air filter box lid and the carburetor connection boot
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)
PartShark.com
877-999-5686
07/FUEL TANK, SEAT, TRIM 63
11.1Removing the seat
301809-10
–Pull the release hook back. Lift up the seat at the rear, pull it back and then
remove from above.
11.2Mounting the seat
301810-10
–Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the
seat and slide tab under fuel tank .
301809-11
–Push down the rear of the seat until release hook engages.
–Make sure that the seat is correctly locked in.
11.3Removing the radiator spoiler
Info
The operations are the same on the left and right.
–Remove the seat ( p. 63)
301817-10
–Remove the screws on the fuel tank.
301816-10
–Remove the screws on the radiator.
–Detach the radiator spoiler and remove it.
PartShark.com
877-999-5686
07/FUEL TANK, SEAT, TRIM 64
11.4Installing the radiator spoiler
Info
The operations are the same on the left and right.
301819-10
–Hook catch of the radiator spoiler into holder of the fuel tank and position it
on the radiator.
301818-10
–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 M6 6 Nm (4.4 lbf ft)
–Mount the seat. ( p. 63)
11.5Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–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 immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
–Remove the front trim. ( p. 69)
–Remove the radiator spoiler. ( p. 63)
–Turn the handle of the fuel tap to OFF.
301533-10
–Undo hose clip .
–Pull off fuel hose .
Info
Remaining fuel may run out of the fuel hose.
PartShark.com
877-999-5686
07/FUEL TANK, SEAT, TRIM 65
301855-11
–Remove screw and take off the fuel tank.
11.6Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–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 immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
301855-10
–Position the fuel tank, insert screw with the bushing and tighten.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
301533-11
–Connect fuel hose .
–Position hose clip .
–Install the radiator spoiler. ( p. 64)
–Install the front trim. ( p. 70)
PartShark.com
877-999-5686
07/FUEL TANK, SEAT, TRIM 66
11.7Fuel tap
301779-10
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 car-
buretor.
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.
PartShark.com
877-999-5686
08/MASK, FENDER 67
12.1Removing the heel protector
301849-11
–Remove screws .
–Remove screw .
301848-11
–Remove screw .
–Pull the heel protector off of the cross member.
301851-11
–Remove screws .
–Remove screw .
301850-11
–Remove screw .
–Pull the heel protector off of the cross member.
301847-11
–Remove screw .
–Take off brace and washer .
PartShark.com
877-999-5686
08/MASK, FENDER 68
12.2Installing the heel protector
301847-10
–Position washer and cross member .
–Mount screw but do not tighten yet.
Guideline
Remaining nuts, chassis M8 30 Nm
(22.1 lbf ft)
301848-10
–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)
301849-10
–Position the retaining bracket.
–Mount screws but do not tighten yet.
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
–Mount screws but do not tighten yet.
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
301850-10
–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)
301851-10
–Position the retaining bracket.
–Mount screws but do not tighten yet.
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
–Mount screws but do not tighten yet.
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
–Tighten all screws.
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
Remaining nuts, chassis M8 30 Nm
(22.1 lbf ft)
PartShark.com
877-999-5686
08/MASK, FENDER 69
12.3Removing the front cover
301811-10
–Remove screw .
–Slide the front cover up and remove it.
12.4Installing the front cover
301812-10
–Position the front cover in slots on both sides of the front trim.
–Mount and tighten the screw.
12.5Removing the front trim
–Remove the front cover. ( p. 69)
301820-10
–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.
PartShark.com
877-999-5686
08/MASK, FENDER 70
12.6Installing the front trim
301820-11
–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)
–Fully tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Install the front cover. ( p. 69)
12.7Removing the rear fender
–Remove the seat ( p. 63)
301822-10
–Remove screws .
301821-10
–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.
PartShark.com
877-999-5686
08/MASK, FENDER 71
12.8Installing the rear fender
301821-11
–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 car-
buretor 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.
301822-11
–Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Mount the seat. ( p. 63)
PartShark.com
877-999-5686
09/FRONT WHEEL 72
13.1Checking the tire air pressure
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.
100044-10
–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.
–Mount the dust cap.
13.2Checking the tire condition
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.
400602-10
–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 indi-
cate the week of manufacture and the last two digits the year of manufac-
ture.
KTM recommends that the tires be changed after 5 years at the latest,
regardless of the actual state of wear.
» If the tire is older than five years:
–Change the tire.
13.3Removing wheel/wheels
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)
PartShark.com
877-999-5686
09/FRONT WHEEL 73
300278-10
–Loosen the wheel nuts .
–Jack up the vehicle. ( p. 12)
–Remove the wheel nuts. Remove the wheel.
Info
Carefully remove the wheel, making sure it does not become jammed with
the threads of the screws.
13.4Installing the wheel/wheels
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.
300278-10
–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. ( p. 12)
–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.
Guideline
Wheel nut M10x1.25 45 Nm
(33.2 lbf ft)
PartShark.com
877-999-5686
09/FRONT WHEEL 74
13.5Checking brake discs
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
–Change the worn brake disc(s) without delay.
400362-10
–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)
» 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.
PartShark.com
877-999-5686
10/REAR WHEEL 75
14.1Checking chain dirt
400678-01
–Check the chain for heavy soiling.
» If the chain is very dirty:
–Clean the chain. ( p. 75)
14.2Cleaning the chain
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.
400725-01
–Clean the chain regularly and then treat with chain spray.
Chain cleaner ( p. 225)
Off-road chain spray ( p. 226)
14.3Checking chain wear
–Park the vehicle on a horizontal surface and shift gears to neutral.
301796-10
–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.
PartShark.com
877-999-5686
10/REAR WHEEL 76
14.4Checking rear sprocket / engine sprocket for wear
400227-01
–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.
–Check that the chain guides are tight.
14.5Checking the chain tension
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, bear-
ings 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.
100093-10
–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 140… 145 mm (5.51… 5.71 in)
» If the chain tension does not meet specifications:
–Adjust the chain tension. ( p. 76)
14.6Adjusting chain tension
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, bear-
ings 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.
100093-10
–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.
PartShark.com
877-999-5686
10/REAR WHEEL 77
301797-10
–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
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.
–Fully tighten screws .
Guideline
Screw, rear wheel eccentric element M8 20 Nm
(14.8 lbf ft)
–Remove the tool .
14.7Adjusting the toe width of rear axle
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.
301538-10
–Loosen nuts of the wheel hubs on both sides.
–Jack up the vehicle. ( p. 12)
–Remove the nuts on both sides and take all parts off of the rear axle.
0
0
3
30
0
1
1
0
0
2
2
100103-10
Setting a narrow toe width:
–Mount the wheel hub .
–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.
PartShark.com
877-999-5686
10/REAR WHEEL 78
0
0
22
0
0
11
0
0
33
100104-10
Setting a wide toe width:
–Mount the spacer with the cone facing inward.
–Mount the conical ring with the cone facing outward.
–Mount the wheel hub .
–Mount the washer and the new self-locking nut.
301538-10
–Remove the vehicle from the work stand. ( p. 12)
–Tighten nuts on both sides.
Guideline
Nut, rear wheel hub M18x1.5 130 Nm
(95.9 lbf ft)
–Shift gear to neutral.
14.8Removing the rear axle
–Engage 1st gear.
301538-12
–Loosen nuts of the wheel hubs on both sides.
–Jack up the vehicle. ( p. 12)
–Remove nuts on both sides and take all parts off of the rear axle.
600409-10
–Remove chain joint . Remove the chain from the rear sprocket.
600410-10
–Loosen screw .
–Turn clamping nut counterclockwise using the special tool until lock rings are
freely accessible. Remove the lock rings.
Open-end wrench attachment, 46 mm (83019010461) ( p. 234)
–Turn clamping nut clockwise using the special tool and remove.
600411-10
–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.
Info
Do not operate the foot brake when the brake caliper has been removed.
PartShark.com
877-999-5686
10/REAR WHEEL 79
600412-10
–Take brake disc off the rear axle with the holder.
–Remove the O-ring.
600414-10
–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.
Info
Hold the rear sprocket carrier.
–Remove rear sprocket carrier with the O-ring.
14.9Installing the rear axle
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.
600422-10
–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 .
600423-10
–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.
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.
PartShark.com
877-999-5686
10/REAR WHEEL 80
600425-10
–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.
600426-10
–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.
Info
LH thread!
600427-10
–Position lock rings .
600428-10
–Tighten the clamping nut in the direction of the arrow using the special tool.
Guideline
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)
Open-end wrench attachment, 46 mm (83019010461) ( p. 234)
–Tighten screw .
Guideline
Screw, clamping nut, rear axle M6 10 Nm (7.4 lbf ft)
600429-10
–Position the brake caliper. Mount and tighten screws -.
Guideline
Screw, rear brake caliper 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)
PartShark.com
877-999-5686
10/REAR WHEEL 81
600409-11
–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).
0
0
bq
bq 0
0
bo
bo
0
0
bp
bp
100103-11
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.
0
0
bp
bp
0
0
bo
bo
0
0
bq
bq
100104-11
Setting a wide toe width:
–Mount spacing sleeve  with the cone facing inward.
–Mount conical ring with the cone facing outward.
–Mount wheel hub .
–Mount the washer and the new self-locking nut.
301538-11
–Remove the vehicle from the work stand. ( p. 12)
–Tighten nuts  on both sides.
Guideline
Nut, rear wheel hub M18x1.5 130 Nm
(95.9 lbf ft)
–Check the chain tension. ( p. 76)
14.10Changing the rear axle bearing
–Remove the rear axle. ( p. 78)
600415-10
–Remove lock ring .
–Remove brake caliper support .
600416-10
–Mark the position of the rear wheel eccentric in the swingarm.
–Loosen screw . Remove the rear wheel eccentric in the direction of the arrow.
PartShark.com
877-999-5686
10/REAR WHEEL 82
600417-10
–Take out shaft seal rings on both sides and remove inner bearing races .
600418-10
–Remove old grease and clean the rear wheel eccentric.
–Heat the rear wheel eccentric.
Guideline
100 °C (212 °F)
–Remove outer bearing races on both sides.
–Mount the new outer bearing races using the special tool.
Press mandrel (83019012000) ( p. 234)
–After the rear wheel eccentric has cooled, check that the bearing races are firmly
seated.
600420-10
–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 spe-
cial 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)
600416-11
–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.
600415-11
–Position brake caliper support .
–Mount lock ring .
–Install the rear axle. ( p. 79)
PartShark.com
877-999-5686
11/WIRING HARNESS, BATTERY 83
15.1Ignition curve plug connection
301829-10
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.
15.2Changing the ignition curve
–Remove the front trim. ( p. 69)
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. ( p. 83)
Changing the ignition curve from Soft to Performance.
–Connect the plug-in connector . (Figure 301829-10 p. 83)
Performance –The plug-in connector is connected to achieve better performance. ( p. 83)
–Install the front trim. ( p. 70)
15.3Removing the battery
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. ( p. 70)
300279-10
–Disconnect the negative (minus) cable of the battery.
–Pull back the plus pole cover and disconnect the positive (plus) cable of the bat-
tery.
–Loosen the rubber band .
–Remove the battery.
15.4Installing the battery
300279-11
–Place the battery in the battery holder.
Battery (YTX5L-BS) ( 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)
PartShark.com
877-999-5686
11/WIRING HARNESS, BATTERY 84
15.5Recharging the battery
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.
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. ( p. 70)
–Disconnect the minus (negative) cable of the battery to avoid damage to the vehi-
cle's electronics.
301540-10
–Connect the battery charger to the battery. Switch on the battery charger.
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 bat-
tery.
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
3 months
–Install the rear fender. ( p. 71)
PartShark.com
877-999-5686
11/WIRING HARNESS, BATTERY 85
15.6Changing the main fuse
–Switch off all power consumers and switch off the engine.
301833-10
–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.
–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.
–Replace the protection covers.
15.7Changing the fuses of individual power consumers
–Remove the front cover. ( p. 69)
–Switch off all power consumers and switch off the engine.
301815-10
–Open the cover of the fuse box .
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
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.
PartShark.com
877-999-5686
11/WIRING HARNESS, BATTERY 86
–Close the cover of the fuse box.
–Install the front cover. ( p. 69)
15.8Checking the battery voltage
–Turn the key in the ignition switch to the position .
–Remove the rear fender. ( p. 70)
600405-01
–Connect the measuring leads of the multimeter to the battery terminals.
–Measure the voltage while unloaded (no electrical consumer is switched on).
Battery voltage
unloaded: 12.4… 12.8 V
» If the displayed value does not meet specifications:
–Recharge the battery.
15.9Checking the charging voltage
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. ( p. 70)
600405-01
–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)
Charging voltage
under load at: 5,000 rpm 13.5… 15 V
» If the value displayed does not meet specifications:
–Check the alternator. ( p. 190)
» If the alternator is working properly:
–Change the voltage regulator.
15.10Checking the quiescent current
–Switch off all power consumers and switch off the engine.
–Remove the rear fender. ( p. 70)
600404-01
–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.
Maximum quiescent current < 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 con-
sumers from the wiring harness one by one while observing the quiescent
current.
Info
The power consumers in question may be a faulty voltage regula-
tor/rectifier or creepage current in the plug-in connectors.
PartShark.com
877-999-5686
11/WIRING HARNESS, BATTERY 87
15.11Checking the starter relay
–Remove the rear fender. ( p. 70)
600406-10
–Disconnect the negative (minus) cable of the battery.
–Remove the starter relay from holder next to the battery.
–Disconnect connector from the starter relay.
–Disconnect cables and from the starter relay.
700089-01
–Connect the starter relay to a 12 V power supply as shown in the figure. Use a mul-
timeter to check the route between the terminals.
Info
When the starter relay is switched, a clicking sound can also be heard.
Resistance with the starter relay pulled 0 Ω
» When the display does not equal the setpoint:
–Change the starter relay.
PartShark.com
877-999-5686
13/BRAKE SYSTEM 88
16.1Hand brake lever, parking brake
301776-10
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.
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.
16.2Checking the free travel of the hand brake lever
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.
301799-10
–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)
16.3Adjusting basic position of hand brake lever
301800-10
–Check the free travel of the hand brake lever. ( p. 88)
–Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing screw .
Info
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!
PartShark.com
877-999-5686
13/BRAKE SYSTEM 89
16.4Checking front brake fluid level
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.
301801-10
–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:
–Add front brake fluid. ( p. 89)
16.5Topping up the front brake fluid
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!
PartShark.com
877-999-5686
13/BRAKE SYSTEM 90
301802-10
–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)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
–Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
16.6Changing the front brake fluid
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid 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. ( p. 72)
302054-10
–Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screws .
–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) ( p. 227)
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
302058-10
–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.
–Tighten the bleeder screw. Remove the suction device and attach the dust cap.
PartShark.com
877-999-5686
13/BRAKE SYSTEM 91
302059-10
–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.
–Tighten the bleeder screw. Remove the suction device and attach the dust cap.
302055-10
–Add brake fluid to level .
Guideline
Measurement of 5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
–Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
–Install the wheel/wheels. ( p. 73)
16.7Checking the front brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–Change worn brake linings immediately.
–Remove the wheel/wheels. ( p. 72)
100074-10
–Check the brake linings of both front brake calipers for minimum thickness .
Minimum thickness ≥1 mm (≥0.04 in)
» If the minimum thickness is less than specified:
–Change the front brake linings. ( p. 92)
–Check the brake linings for damage and cracking.
» If damage or cracking is visible:
–Change the front brake linings. ( p. 92)
–Install the wheel/wheels. ( p. 73)
16.8Removing front brake linings
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. ( p. 72)
–Pull the hand brake lever and release it again.
Locking pawl moves into its basic position, parking brake is deactivated.
PartShark.com
877-999-5686
13/BRAKE SYSTEM 92
100071-10
–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.
16.9Mounting front brake linings
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 construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Info
The operations are the same on the left and right.
–Check the brake discs. ( p. 74)
100072-10
–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.
100073-10
–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)
16.10Changing the front brake linings
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.
PartShark.com
877-999-5686
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!
301802-10
–Remove the front brake linings. ( p. 91)
–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. ( p. 92)
–Correct brake fluid level to .
Guideline
Dimension (brake fluid level below
top edge of container)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
–Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
16.11Checking free travel of foot brake lever
Warning
Danger of accidents Brake system failure.
–If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
301803-10
–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 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
–Adjust the basic position of the foot brake lever. ( p. 93)
–Reconnect spring .
16.12Adjusting basic position of foot brake lever
Warning
Danger of accidents Brake system failure.
–If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
PartShark.com
877-999-5686
13/BRAKE SYSTEM 94
301804-10
–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 .
Guideline
Remaining nuts, chassis M8 30 Nm
(22.1 lbf ft)
–Hold push rod and tighten nut .
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
–Reconnect spring .
16.13Checking rear brake fluid level
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.
301805-10
–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)
16.14Adding rear brake fluid
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.
PartShark.com
877-999-5686
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
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!
301806-10
–Remove screw with membrane .
301807-10
–Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
–Refit screw with membrane .
Info
Clean up overflowed or spilt brake fluid immediately with water.
16.15Changing the rear brake fluid
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid 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!
PartShark.com
877-999-5686
13/BRAKE SYSTEM 96
302056-10
–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) ( p. 227)
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
302060-10
–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.
–Tighten the bleeder screw. Remove the suction device and attach the dust cap.
302057-10
–Add brake fluid to level .
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.
16.16Checking rear brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–Change worn brake linings immediately.
100038-10
–Check the brake linings for minimum thickness .
Minimum thickness ≥1 mm (≥0.04 in)
» 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. ( p. 98)
16.17Removing rear brake linings
Warning
Danger of accident Brake system failure.
–Maintenance work and repairs must be carried out professionally.
PartShark.com
877-999-5686
13/BRAKE SYSTEM 97
301830-10
–Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
100064-10
–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.
100066-10
Note
Danger of damage Kinking of brake line.
–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.
16.18Mounting rear brake linings
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 construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
–Check the brake discs. ( p. 74)
300265-10
–Check that the sliding plate is seated correctly in the brake caliper support and
insert the brake linings.
Info
Make sure that the decoupling plate is mounted on the piston side of the
brake lining.
PartShark.com
877-999-5686
13/BRAKE SYSTEM 98
100068-10
–Grease the bearing bolt and insert the brake caliper with the bearing bolt into
the brake caliper support .
Lubricant (T625) ( p. 225)
100069-10
–Swing the brake caliper downward. Mount and tighten the screw.
Guideline
Screw, rear brake caliper M6 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.
16.19Changing rear brake linings
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!
301808-10
–Remove the rear brake linings. ( p. 96)
–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. ( p. 97)
–Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 223)
–Refit screw with membrane .
Info
Clean up overflowed or spilt brake fluid immediately with water.
PartShark.com
877-999-5686
30/ENGINE 99
17.1Removing the engine
–Remove the engine guard. ( p. 20)
–Remove the heel protector. ( p. 67)
–Drain the coolant. ( p. 181)
–Remove the rear fender. ( p. 70)
–Remove the manifold. ( p. 60)
–Remove the carburetor. ( p. 164)
–Remove the engine sprocket. ( p. 179)
301583-10
–Disconnect the negative cable from the battery.
–Remove screws and take off clutch slave cylinder .
Info
Do not activate the clutch lever if the clutch slave cylinder has been
removed.
301584-10
–Remove cable binder .
301585-10
–Disconnect plug of the alternator.
–Disconnect plug of the ignition pulse generator.
–Detach spark plug connector .
301586-10
–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.
301587-10
–Loosen hose clips and remove the radiator hoses and hose clips.
PartShark.com
877-999-5686
30/ENGINE 100
301588-10
–Disconnect spring .
Spring hooks (50305017000) ( p. 227)
301853-10
–Remove nut -.
–Pull out the swingarm pivot.
Info
Pull the swingarm pivot to the point where it is still being held.
–Secure the swingarm with a suitable pin .
301590-10
–Remove screw .
–Remove screws  and take off both engine bearers.
301591-10
–Remove screw .
301852-10
–Lift the engine out of the frame.
Info
It is recommended to have assistance for performing this step.
17.2Installing the engine
301852-10
–Position the engine in the frame.
Info
It is recommended to have assistance for performing this step.
PartShark.com
877-999-5686
30/ENGINE 101
301591-11
–Mount screw but do not tighten yet.
Guideline
Engine mounting bolt M10 60 Nm
(44.3 lbf ft)
301590-11
–Position both engine bearers on the frame. Mount screws but do not tighten yet.
Guideline
Engine bracket screw M10 60 Nm
(44.3 lbf ft)
–Mount screw but do not tighten yet.
Guideline
Engine mounting bolt M10 60 Nm
(44.3 lbf ft)
301853-11
–Remove pin .
–Mount the swingarm pivot.
–Mount and tighten nut .
Guideline
Nut, swingarm pivot M16x1.5 100 Nm
(73.8 lbf ft)
–Tighten screw .
Guideline
Engine mounting bolt M10 60 Nm
(44.3 lbf ft)
–Tighten screw .
Guideline
Engine bracket screw M10 60 Nm
(44.3 lbf ft)
–Tighten screw .
Guideline
Engine mounting bolt M10 60 Nm
(44.3 lbf ft)
301588-11
–Reconnect spring .
Spring hooks (50305017000) ( p. 227)
301587-11
–Attach the radiator hoses. Position and tighten hose clamps .
PartShark.com
877-999-5686
30/ENGINE 102
301586-11
–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)
301585-11
–Mount spark plug connector .
–Plug in connector - of the ignition pulse generator.
–Connector plug  of the alternator.
301584-11
–Secure the cable with cable binder .
301583-11
–Position clutch slave cylinder . Mount and tighten screws .
Guideline
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
–Connect the negative cable of the battery.
–Install the engine sprocket. ( p. 179)
–Install the carburetor. ( p. 166)
–Install the manifold. ( p. 60)
–Install the rear fender. ( p. 71)
302071-10
–Remove the filler cap  on the clutch cover and fill up with engine oil.
Engine oil 2.00 l (2.11 qt.) External tem-
perature: ≥0 °C
(≥32 °F)
Engine oil
(SAE 10W/50)
( p. 223)
External tem-
perature: < 0 °C
(< 32 °F)
Engine oil
(SAE 5W/40)
( p. 223)
–Mount and tighten screw cap .
–Fill coolant/bleed the cooling system. ( p. 181)
–Install the heel protector. ( p. 68)
–Install the engine guard. ( p. 20)
–Take a short test ride.
–Check the engine for leakage.
–Check the engine oil level. ( p. 185)
–Check the cooling system for leakage.
–Check the coolant level. ( p. 180)
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 103
18.1Preparations
301596-10
–Mount the special tool on the engine work stand.
Engine fixing arm (83529002000) ( p. 237)
Engine work stand (61229001000) ( p. 230)
–Mount the engine on the special tool.
Info
Use a helper or motorized hoist.
18.2Removing the shift lever
301597-10
–Remove screw . Take off the shift lever.
18.3Draining the engine oil
301598-10
–Remove oil drain plug with magnet .
301599-10
–Loosen screw plug by striking it lightly with a hammer a few times.
–Remove screw plug with the oil screen and the O-rings.
–Completely drain the engine oil.
18.4Removing the oil filter
301600-10
–Remove screws . Remove oil filter cover with the O-ring.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 104
301601-10
–Pull oil filter out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 228)
18.5Removing the spark plug
301602-10
–Remove the spark plug using special tool .
Spark plug wrench (77329072000) ( p. 232)
18.6Removing the valve cover
301603-10
–Remove screws . Remove the valve cover with the valve cover seal.
18.7Removing the starter motor
301604-10
–Remove screws and the starter motor.
18.8Removing the alternator cover
301605-10
–Remove screws . Take off the alternator cover.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 105
301606-10
–Remove centering pins . Take off the alternator cover gasket .
18.9Removing the torque limiter
301607-10
–Remove torque limiter .
18.10Positioning the engine at ignition top dead center (TDC)
301608-10
–Remove screw .
301609-10
–Turn the crankshaft counterclockwise until holes of the camshafts are flush
above sealing area .
301610-10
–Mark the double wheel and the cylinder head in one line.
Info
The markings will be of assistant when the camshafts are assembled.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 106
301611-10
–Mount special tool .
Engine blocking screw (77329010000) ( p. 231)
18.11Removing the camshaft
301612-10
–Remove screws .
–Take off the camshaft bearing bridge.
Info
Ensure that the needle rollers and the O-ring remain in place.
301613-10
–Remove camshafts .
18.12Removing the timing chain tensioner
301614-10
–Loosen screw .
–Remove screw with the seal ring.
301615-10
–Pull out timing chain tensioner . Remove O-ring .
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 107
18.13Removing the double wheel
301616-10
–Remove screws .
–Take off the retaining bracket.
301617-10
–Screw a fitting screw into spindle .
–Hold the double wheel and remove spindle .
301618-10
–Take the timing chain off the double wheel.
–Remove the double wheel with both needle bearings.
–Remove the screw from the spindle.
18.14Removing the cylinder head
301619-10
–Remove nut .
301620-10
–Unscrew nuts in a crisscross pattern and remove them with the washers.
–Take off the cylinder head.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 108
301621-10
–Remove centering pins and cylinder head gasket .
18.15Removing the water pump cover
301622-10
–Remove screws . Take off the water pump cover.
–Remove the gasket.
18.16Removing the clutch cover
301623-10
–Remove screw .
Info
If work is to be performed on the water pump, unscrew the nut of the water
pump impeller.
301624-10
–Mount special tool .
Assembly pin (77329012100) ( p. 231)
–Remove screws and take off the clutch cover.
301625-10
–Remove the locating pins.
–Remove quad ring .
–Take off O-ring .
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 109
18.17Removing the piston
301626-10
–Push the cylinder upward.
Info
Only push the cylinder as far up as necessary to take the piston pin out.
–Remove the piston pin retainer .
–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.
301627-10
–Take off locating pins and cylinder base gasket .
–Remove O-rings .
18.18Removing the timing chain rails
301628-10
–Remove spindle .
–Remove the timing chain guide rail from above.
–Remove spindle .
–Remove the timing chain tensioning rail from above.
18.19Removing the timing chain
301629-10
–Remove screws .
–Take off the retaining bracket.
301630-10
–Screw a fitting screw into spindle .
–Hold the timing chain and remove spindle .
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 110
301631-10
–Take off the timing chain and balancer gear with the needle bearings.
Info
Identify the direction of travel.
18.20Removing the rotor and starter idler gear
301632-10
–Remove screw .
301633-10
–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.
301634-10
–Remove starter idler gear .
18.21Removing the ignition pulse generator
301635-10
–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.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 111
18.22Removing the drive wheel of the balancer gear
301636-10
–Remove freewheel gear with the needle bearing.
301648-10
–Remove nut with the special tool.
Special socket, 36 mm; ½" drive (77329021000) ( p. 231)
–Take off drive wheel of the balancer gear.
18.23Removing the force pump
301649-10
–Remove screws .
–Take off oil pump housing .
Info
Ensure that the dowel pins remain in place.
301650-10
–Take off force pump .
301651-10
–Remove needle roller .
–Remove oil pump housing with the gasket.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 112
18.24Removing the spacer
301652-10
–Remove spacer from the countershaft.
–Remove the O-ring.
18.25Removing the outer clutch hub
301683-10
–Unscrew screws and remove them with the washers and springs.
–Remove pressure cap .
301684-10
–Remove pressure piece with the push rod.
–Completely remove clutch discs .
301685-10
–Remove the special tool.
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.
301686-10
–Lock the outer clutch hub and primary gear using the special tool.
Gear quadrant (80029004000) ( p. 233)
–Loosen nut with the special tool.
Special socket, 36 mm; ½" drive (77329021000) ( p. 231)
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 113
301688-10
–Take off washer .
–Take off the outer clutch hub.
301689-10
–Remove needle bearing  and collar sleeve -.
18.26Removing the primary gear
301653-10
–Remove nut .
–Take off primary gear .
301654-10
–Remove the drive wheel of balancer shaft .
18.27Removing the centrifugal separator
301655-10
–Take off centrifugal separator .
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 114
18.28Removing the suction pump
301656-10
–Remove the shaft locking device .
–Take off washers .
–Remove oil pump gear and oil pump idler gear with the bearing.
301657-10
–Remove pin .
–Remove screws .
–Take off the oil pump cover.
301658-10
–Remove suction pump .
–Remove pin .
301659-10
–Remove suction pump with the needle roller and oil pump shaft .
18.29Removing the shift shaft
301660-10
–Push sliding plate away from the shift drum locating unit.
–Remove shift shaft with the washer.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 115
18.30Removing the shift drum locating unit
301661-10
–Remove screw .
–Push away locking lever from shift drum locating unit and remove the shift
drum locating unit.
–Relieve tension from the locking lever.
18.31Removing the locking lever
301662-10
–Unscrew and remove together with locking lever , washer, sleeve and spring.
18.32Removing the left section of the engine case
301663-10
–Remove screws .
–Remove screws .
–Tilt the left section of the engine case upward and remove the threaded fasteners
of the engine fixing arm.
301690-10
–Insert the special tool into the crankshaft.
Protection cover (75029090000) ( p. 230)
–Mount special tool with the appropriate screws.
Extractor (83529048000) ( p. 237)
Info
Use the drill hole marked with 835.
–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.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 116
18.33Removing the shift rails
301691-10
–Remove shift rails together with upper springs and the lower springs.
18.34Removing the shift drum
301692-10
–Tilt shift forks to the side.
Info
Do not misplace the shift rollers.
–Remove shift drum .
18.35Removing the shift forks
301693-10
–Remove shift forks .
Info
Do not misplace shift rollers .
18.36Removing the transmission shafts
301695-10
–Secure the engine in an upright position.
–Remove lock ring .
301696-10
–Pull out both transmission shafts together from the bearing seats.
Info
Do not misplace the washers.
PartShark.com
877-999-5686
30/DISASSEMBLING THE ENGINE 117
18.37Removing the crankshaft
301697-10
–Take out crankshaft .
–Take off the right section of the engine case.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 118
19.1Working on the right section of the engine case
301699-10
–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.
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.
–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 bear-
ings 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™
–Mount and tighten jet .
Guideline
Jet, engine case breather M4 On block Loctite®243™
–Mount and tighten oil jet for conrod lubrication.
Guideline
Oil jet for conrod lubrica-
tion
M4 4 Nm
(3 lbf ft)
Loctite®243™
–Mount and tighten oil jet for piston cooling.
Guideline
Oil jet, piston cooling M4 4 Nm
(3 lbf ft)
Loctite®243™
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 119
–Position all bearing retainers.
–Mount and tighten screws .
Guideline
Locking screw for bearing M5 6 Nm
(4.4 lbf ft)
Loctite®243™
301757-10
–Blow out the oil channel with compressed air and check that it is clear.
19.2Working on the left section of the engine case
301698-10
–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.
–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 bear-
ings 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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 120
–Press in shaft seal ring of the countershaft so it is flush with the open side fac-
ing in.
–Mount and tighten oil jet in the oil channel.
Guideline
Oil jet, clutch oil supply M5x1 6 Nm
(4.4 lbf ft)
Loctite®243™
–Mount and tighten oil jet for piston cooling.
Guideline
Oil jet, piston cooling M4 4 Nm
(3 lbf ft)
Loctite®243™
–Position all bearing retainers.
–Mount and tighten screws .
Guideline
Locking screw for bearing M5 6 Nm
(4.4 lbf ft)
Loctite®243™
–Mount and tighten oil suction pipe .
Guideline
Oil suction pipe M14x1 15 Nm
(11.1 lbf ft)
Loctite®243™
301756-10
–Blow out the oil channel with compressed air and check that it is clear.
19.3Removing the water pump
301673-10
–Remove nut .
–Take off the water pump impeller .
301674-10
–Remove screws .
–Press out balancer shaft gear with the bearing.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 121
301209-10
–Remove nut .
–Pull off bearing .
Extractor (59029033000) ( p. 229)
–Remove retaining bracket .
19.4Changing the shaft seal ring of the water pump
301675-10
–Remove shaft seal ring .
301676-10
–Remove shaft seal ring .
301676-11
–Press in shaft seal ring all the way, with the open side facing inward.
Distance pieces face outward.
301675-10
–Press shaft seal ring , with the open side facing inward, all the way in toward dis-
tance pieces .
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 122
19.5Installing the water pump
301209-11
–Position retaining bracket .
–Press bearing in place.
–Mount and tighten nut .
Guideline
Nut, compensating
sprocket
M14x1 20 Nm
(14.8 lbf ft)
Loctite®243™
301210-10
–Mount special tool .
Mounting sleeve (58529005000) ( p. 228)
301674-11
–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™
301681-10
–Align marking with special tool .
Assembly pin (77329012100) ( p. 231)
301677-10
–Mount and tighten nut .
Guideline
Nut, water-pump wheel M6 6 Nm
(4.4 lbf ft)
Loctite®243™
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 123
19.6Removing the crankshaft seal ring in the clutch cover
301678-10
–Remove shaft seal ring of the crankshaft.
19.7Installing the crankshaft seal ring in the clutch cover
301678-10
–Press in shaft seal ring all the way, with the open side facing inward.
Info
Support the clutch cover properly when pressing in.
–Grease the sealing lip.
Long-life grease ( p. 225)
301755-10
–Blow out the oil channel with compressed air and check that it is clear.
19.8Removing the oil pressure regulator valve
301672-10
–Remove screw plug with sealing washer .
–Remove pressure spring and ball .
19.9Checking spring length of oil pressure regulator valve
–Remove the oil pressure regulator valve. ( p. 123)
200155-10
–Measure the spring length of the oil pressure regulator valve.
Oil pressure regulator valve
Minimum length of pressure spring 38.5 mm (1.516 in)
» If the measured value does not meet specifications:
–Change the spring.
–Install the oil pressure regulator valve. ( p. 124)
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 124
19.10Installing the oil pressure regulator valve
301672-11
–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)
19.11Checking the lubrication system
0
0
11
0
0
22
0
0
11
0
0
33
0
0
33
0
0
11
44
301740-01
–Check the internal rotor and external rotor of oil pumps for damage and wear.
» If there is damage or wear:
–Change the oil pumps.
–Check oil pump shaft for damage and 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 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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 125
19.12Removing the crankshaft bearing inner race
301247-10
–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) ( 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.
19.13Installing the crankshaft bearing inner race
301247-10
–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
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.
19.14Changing connecting rod, conrod bearing and crank pin
301286-10
–Position the crankshaft in the press with the special tool .
Extrude plate, base (77629009001) ( p. 233)
–Position the special tool between the crank webs.
Extrude plate, top (77629009002) ( p. 233)
–Press the crank pin with the special tool out of the upper crank web.
Pressing device for crankshaft, complete (75029047000) ( p. 230)
Info
Hold the lower crank web.
–Remove the connecting rod and bearing.
301279-10
–Press the crank pin out of the lower crank web.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 126
301706-10
–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 sup-
plied with oil.
–Use compressed air to check that the oil hole is clear.
301284-10
–Mount the new bearing and connecting rod .
Info
Thoroughly oil the bearing.
301280-10
–Position the special tool on the press.
Pressing device for crankshaft, complete (75029047000) ( p. 230)
Pressing tool, crankshaft (77629008000) ( p. 233)
–Insert the crank web with connecting rod and bearing. Position the second crank
web.
301281-10
–Position the special tool with the heel pointing down.
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.
301704-10
–Measure the end play between the connecting rod and the crank webs with the spe-
cial tool .
Feeler gauge (59029041100) ( p. 229)
Connecting rod - end play of lower con-
rod bearing
0.40… 0.60 mm (0.0157…
0.0236 in)
» If the measured value is less than the specification:
–Correct it so the dimension is equal to the specified value.
–Check the crankshaft run-out at the bearing pin. ( p. 126)
19.15Checking crankshaft run-out at bearing pin
301705-10
–Position the crankshaft on a roller block.
–Turn the crankshaft slowly.
–Check the crankshaft run-out on both bearing pins.
Crankshaft - run-out at bearing pin ≤0.10 mm (≤0.0039 in)
» If the crankshaft run-out at the bearing pin is larger than the specification:
–Align the crankshaft.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 127
19.16Measuring the crankshaft end play
301214-10
–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
Screw, engine case 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.
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. ( p. 125)
–Determine the thickness of the compensating disks by calculating.
–Add or subtract compensating disks equally on both sides.
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)
19.17Cylinder - Nikasil®coating
301248-10
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.
19.18Checking/measuring cylinder
301215-10
–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)
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)
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 128
301249-10
–The cylinder size is marked on the cylinder collar.
400376-10
–Using a straightedge and the special tool, check the sealing area of the cylinder
head 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:
–Change the cylinder.
19.19Checking/measuring the piston
301217-10
–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.
–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:
–Replace the piston pin.
–Place the piston pin in the connecting rod and check the seating for play.
» If the piston pin seating has excessive play:
–Replace the connecting rod and piston pin.
301216-10
–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)
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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 129
19.20Measuring piston/cylinder mounting clearance
–Check/measure the cylinder. ( p. 127)
–Check/measure the piston. ( p. 128)
–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.
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)
19.21Checking the piston ring end gap
301218-10
–Remove the piston ring from the piston.
–Place the piston ring in the cylinder and align with the piston.
Guideline
Below the upper edge of the cylinder 10 mm (0.39 in)
–Measure the end gap with feeler gauge .
Guideline
Piston ring - end gap
Compression ring ≤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:
–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.
19.22Changing the camshaft bearing
301219-10
–Clamp camshaft into a vise.
Info
Protect the outer cam of the camshaft against damage with an adhesive
tape.
Use soft jaws.
–Remove screw .
301220-10
–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.
lubricated with engine oil
–Mount camshaft gear .
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 130
301219-11
–Mount screw but do not tighten yet.
Guideline
Screw, camshaft gear M10x1 50 Nm
(36.9 lbf ft)
lubricated with
engine oil
–Repeat these steps for the second camshaft.
19.23Checking the autodecompressor
301221-10
–Check the autodecompressor for damage.
» If there is damage or wear:
–Change the exhaust camshaft.
–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.
19.24Checking camshafts
301250-10
–Check the camshaft for damage and wear.
» If there is damage or wear:
–Change the camshaft.
–If the surface of the cams is damaged, check the oil supply to the camshaft
and cam lever.
–Measure the cams of the camshaft.
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)
» If the measured value does not meet specifications:
–Change the camshaft.
19.25Checking the radial clearance of the camshaft bearings
301222-10
–Position the camshafts.
The valves are not activated.
–Insert the Plastigauge clearance gauge in area .
Plastigauge measuring strips (60029012000) ( p. 230)
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 131
301223-10
–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.
301224-10
–Remove camshaft bearing bridge again. Compare the Plastigauge clearance
gauge with the specifications on the packaging.
Guideline
Camshaft bearing - radial clearance
Radial clearance 0.029… 0.053 mm (0.00114…
0.00209 in)
Wear limit 0.055 mm (0.00217 in)
Info
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.
19.26Checking the camshaft bearing bridges
301225-10
–Check the camshaft bearing bridges for damage.
» If there is damage or wear:
–Change the cylinder head with the camshaft bearing bridge.
19.27Removing the valves
301228-10
–Fold up the cam levers.
–Take shims out of the valve spring retainers and set them aside in the arrange-
ment corresponding to their installation positions.
301229-10
–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.
Info
If the cam levers will continue to be used, note down their installation posi-
tion.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 132
301230-10
–Pre-tension the valve springs using the special tool.
Valve spring compressor (59029019000) ( p. 229)
Insert for valve spring lever (77329060000) ( p. 232)
–Remove the valve keys and unload the valve springs.
301679-10
–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 .
300117-10
–Mark the valves corresponding to their installation position.
Info
Place the valves in a carton corresponding to their installation position and
label them.
19.28Checking the valves
200193-10
–Check the valve plate for run-out.
Valve - run-out
At the valve plate ≤0.05 mm (≤0.002 in)
» If the measured value does not meet specifications:
–Change the valve.
0
0
AA
400373-10
–Check sealing seat on the valve.
Valve - sealing seat width
Intake 1.50 mm (0.0591 in)
Valve - sealing seat width
Exhaust 1.50 mm (0.0591 in)
» If the sealing seat is not centered on the valve seat or deviates from the specifi-
cation:
–Machine the valve seat.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 133
19.29Checking the valve springs
301680-10
–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 42.8 mm (1.685 in)
» If the measured value does not meet specifications:
–Change the valve springs.
19.30Checking valve spring seat
500173-01
–Check the valve spring seat for breakage and wear (visual check).
» If the valve spring seat is broken or worn:
–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.
19.31Checking the cam levers
301227-10
–Check the cam levers and cam lever shafts for damage and wear.
» If there is damage or wear:
–Change the cam levers and/or cam lever shafts.
19.32Checking cylinder head
301252-10
–Check the valve guides with the special tool .
Limit plug gauge (59029026006) ( p. 229)
» 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:
–Change the cylinder head.
400375-10
–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:
–Change the cylinder head.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 134
0
0
AA
400373-10
–Check sealing seat of the valves.
Valve - sealing seat width
Intake 1.50 mm (0.0591 in)
Valve - sealing seat width
Exhaust 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.
19.33Installing the valves
301679-11
–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.
301230-10
–Pre-tension the valve springs using the special tool.
Valve spring compressor (59029019000) ( p. 229)
Insert for valve spring lever (77329060000) ( p. 232)
301233-10
–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.
301229-11
–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
Screw plug, cam lever shafts M10x1 10 Nm (7.4 lbf ft)
301228-11
–Place the shims in the valve spring retainers in the positions they had before
they were removed.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 135
19.34Removing the freewheel
301234-10
–Press expansion ring together using suitable pliers.
–Take freewheel out of the freewheel hub.
19.35Checking the freewheel
301236-10
–Insert freewheel gear into the freewheel hub, turning the freewheel gear clock-
wise; do not wedge.
–Check the locking action of starter gear .
» If the freewheel gear does not turn clockwise or if it does not lock counterclock-
wise:
–Remove the freewheel. ( p. 135)
–Turn the freewheel 180°.
–Install the free wheel. ( p. 135)
19.36Installing the free wheel
301234-10
–Thoroughly oil all parts.
–Pull the ends of expansion ring together.
–Slide freewheel into the freewheel hub.
Info
Note the direction of rotation.
301235-10
–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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 136
19.37Checking the electric starter mode
55
66
22
11
33
44
301211-01
–Check the gear mesh and bearing of starter idler gear for damage and wear.
» If there is damage or wear:
–Change the starter idler gear.
–Check the gear mesh and bearing of torque limiter for damage and wear.
» If there is damage or wear:
–Change the torque limiter.
–Check the gear mesh and bearing of freewheel gear for damage and 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 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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 137
19.38Checking the timing assembly
0
0
44
0
0
44
0
0
11
0
0
55
0
0
33
0
0
22
0
0
11
301245-01
–Clean all parts well.
–Check the balancer gear/double wheel for damage and wear.
» If there is damage or wear:
–Change the balancer gear/double wheel.
–Check the timing chain tensioning rail for damage and wear.
» If there is damage or wear:
–Replace the timing chain tensioning rail.
–Check the timing chain guide rail for damage and wear.
» If there is damage or wear:
–Replace the timing chain guide rail.
–Check camshaft gears for damage and 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.
–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.
19.39Preparing the timing chain tensioner for installation
200171-10
–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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 138
200172-10
–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
3 mm (0.12 in)
Info
This position is necessary for installation.
If the timing chain tensioner is now pressed again and is only extended a
maximum of half way (it is prevented from extending completely), this locks
the detent mechanism and the timing chain tensioner can no longer be
squeezed together. This function is necessary in order to ensure sufficient
timing chain tension even at low oil pressures.
19.40Checking clutch
0
0
44
0
0
55
0
0
22
0
0
11
0
0
33
0
0
blbl
0
0
66
0
0
88
0
0
77
0
0
bmbm
0
0
bkbk
0
0
99
301246-01
–Check the pressure piece for damage and wear.
» If there is damage or wear:
–Change the pressure piece.
–Check axial bearing for damage and 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 push rod.
–Check the length of clutch springs .
Clutch spring - length 39.0… 40.0 mm (1.535… 1.575 in)
» If the clutch spring length is less than the specified value:
–Change all clutch springs.
–Check the thrust face of pressure cap for damage and wear.
» If there is damage or wear:
–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)
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 139
» If the contact surface exhibits significant wear:
–Change the clutch lining discs and the outer clutch hub.
–Check needle bearing and collar sleeve for damage and wear.
» If there is damage or wear:
–Change the needle bearing and collar sleeve.
–Check the intermediate disc for damage and 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 all clutch lining discs.
–Check the thickness of clutch facing discs .
Clutch facing disk - thickness ≥2.6 mm (≥0.102 in)
» 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:
–Change the disc.
–Check the inner clutch hub  for damage and wear.
» If there is damage or wear:
–Change the inner clutch hub.
19.41Checking shift mechanism
0
0
DD
0
0
CC0
0
EE
0
0
55
0
0
33
0
0
BB
0
0
33
0
0
AA
0
0
110
0
22
0
0
AA
0
0
11
0
0
44
0
0
11
0
0
AA0
0
44
301263-01
–Check the shift forks on disc for damage and wear (visual check).
» If there is damage or wear:
–Change the shift fork and idler/fixed wheel pair.
–Check shift grooves of shift drum for 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 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:
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 140
–Change the grooved ball bearing.
–Check the shift rollers for damage and wear.
» If there is damage or wear:
–Change the shift rollers.
–Check the springs of the shift rails for damage and wear.
» If the spring is damaged or worn:
–Change the spring of the shift rail.
–Check the shift rails for run-out on a flat surface.
» If there is run-out:
–Change the shift rail.
–Check the shift rails for scoring, wear and smooth operation in the shift forks.
» If scoring or wear is present or of the shift fork is stiff:
–Change the shift rail.
–Check sliding plate for wear on contact areas .
» If the sliding plate is worn:
–Change the sliding plate.
–Check return surface on the sliding plate for wear.
» 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.
–Preassemble the shift shaft. ( p. 140)
00
0
0
0
F
F
300122-01
–Preassemble the shift shaft. ( p. 140)
–Check clearance between the sliding plate and the shift quadrant.
Shift shaft - sliding plate/shift quad-
rant clearance
0.40… 0.80 mm (0.0157…
0.0315 in)
» If the measured value does not meet specifications:
–Change the sliding plate.
19.42Preassembling the shift shaft
0
0
1133
66
22
55
44
300154-01
–Secure the short end of the shift shaft in the bench vise.
Guideline
Use soft jaws.
–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 .
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 141
19.43Disassembling the main shaft
0
0
11
0
0
33
0
0
55
0
0
77
0
0
99
0
0
blbl 0
0
88
0
0
22
0
0
44
0
0
66
0
0
bkbk
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 -.
19.44Disassembling the countershaft
0
0
bpbp
0
0
55
0
0
33
0
0
11
0
0
66
0
0
88
0
0
bkbk
0
0
bmbm
0
0
bqbq
0
0
bobo
0
0
bnbn
0
0
22
0
0
44
0
0
77
0
0
99
0
0
blbl
301261-01
–Secure the countershaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 142
–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 .
19.45Checking transmission
0
0
440
0
110
0
55
0
0
66
0
0
110
0
77
0
0
55
0
0
66
0
0
44
0
0
77
0
0
66
0
0
55
0
0
11
0
0
33
0
0
77
0
0
44
0
0
660
0
55
0
0
660
0
440
0
55
0
0
11
0
0
77
0
0
77
0
0
44
0
0
11
0
0
22
0
0
66
0
0
66
301258-01
–Check the needle bearings for damage and wear.
» If there is damage or wear:
–Change the needle bearing.
–Check the pivot points of main shaft and countershaft for damage and wear.
» If there is damage or wear:
–Change the main shaft and/or countershaft.
–Check the tooth profile of main shaft and countershaft for damage and wear.
» If there is damage or wear:
–Change the main shaft and/or countershaft.
–Check the pivot points of idler 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.
» 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 tooth profiles of solid gears for damage and wear.
» If there is damage or wear:
–Change the idler/solid gear pair.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 143
–Check solid gears for smooth operation in the profile of main shaft .
» If the solid gear does not move freely:
–Change the solid gear or the main shaft.
–Check solid gears for smooth operation in the profile of countershaft .
» 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 stop disks.
–Use new lock rings with every repair.
19.46Assembling the main shaft
Info
Use new lock rings with every repair.
–Carefully lubricate all parts before assembling.
–Check the transmission. ( p. 142)
0
0
bl
bl
0
0
9
9
0
0
7
7
0
0
5
5
0
0
3
3
0
0
1
1
0
0
4
4
0
0
bk
bk
0
0
8
8
0
0
6
6
0
0
2
2
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.
PartShark.com
877-999-5686
30/ENGINE - WORK ON INDIVIDUAL PARTS 144
19.47Assembling the countershaft
Info
Use new lock rings with every repair.
–Carefully lubricate all parts before assembling.
–Check the transmission. ( p. 142)
0
0
2
2
0
0
bm
bm
0
0
bo
bo
0
0
bq
bq
0
0
bl
bl
0
0
9
9
0
0
7
7
0
0
5
5
0
0
1
1
0
0
3
3
0
0
4
4
0
0
bp
bp
0
0
bn
bn
0
0
bk
bk
0
0
8
8
0
0
6
6
301262-01
–Secure the countershaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws
–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.
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 145
20.1Installing the crankshaft
301697-10
–Position the right section of the engine case in the engine work stand.
–Push crankshaft into the bearing seat.
20.2Installing the transmission shafts
301696-10
–Slide both transmission shafts into the bearing seats.
Info
Do not misplace the washers.
301695-10
–Mount lock ring .
20.3Installing the shift forks
301694-10
–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 .
Tip
Fix the shift rollers to the shift forks with grease.
Markings In of shift forks and face each other
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 146
20.4Installing the shift drum
301692-11
–Push shift drum into the bearing seat.
–Put shift forks in the shift drum.
Info
Do not misplace the shift rollers.
20.5Installing the shift rails
301691-10
–Install shift rails together with upper springs and lower springs.
20.6Installing the left engine case
301193-10
–Mount the dowels.
–Degrease the sealing area. Apply the sealing compound to the left section of the
engine case.
Loctite®5910
301663-10
–Mount the left section of the engine case. If necessary, strike it lightly with a rub-
ber mallet and turn the transmission shafts.
Info
Do not use the screws to pull the two sections of the engine case together.
–Mount screws and, once all screws of the left section of the engine case have
been mounted, tighten them.
Guideline
Screw, engine case 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)
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 147
20.7Installing the locking lever
301662-11
–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™
20.8Installing the shift drum locating unit
301661-11
–Push away locking lever from the shift drum locating unit and position the shift
drum locating unit .
Info
The flat areas of the shift drum locating unit are not symmetric.
–Relieve tension from the locking lever.
–Mount and tighten screw .
Guideline
Screw, shift drum locating M6 10 Nm
(7.4 lbf ft)
Loctite®243™
20.9Installing the shift shaft
301660-11
–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.
20.10Installing the suction pumps
301664-10
–Oil the oil pump shaft, internal rotor and external rotor before assembly.
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.
301657-11
–Position the oil pump cover. Mount and tighten screws .
Guideline
Screw, oil pump cover M5 6 Nm
(4.4 lbf ft)
Loctite®243™
Marking faces upward.
–Insert pin .
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 148
301656-11
–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.
301659-11
–Mount the needle roller.
–Insert suction pump .
20.11Installing the centrifugal separator
301655-10
–Mount centrifugal separator .
20.12Installing the force pump
301651-11
–Mount oil pump housing with the gasket.
Info
Ensure that the dowel pins are seated properly.
–Insert needle roller .
301659-12
–Position force pump .
Info
Ensure that the dowel pins are seated properly.
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 149
301649-11
–Position oil pump housing .
–Mount and tighten screws .
Guideline
Screw, oil pump casing M6 10 Nm
(7.4 lbf ft)
Loctite®243™
–Crank the oil pump gear and ensure that it can move easily.
20.13Installing the primary gear
301654-11
–Position the drive wheel of balancer shaft .
301653-11
–Position primary gear .
–Mount nut but do not tighten yet.
Guideline
Nut, primary gear M27x1 80 Nm
(59 lbf ft)
Loctite®243™
20.14Installing the outer clutch hub
301689-11
–Mount collar sleeve and needle bearing .
301688-11
–Mount the outer clutch hub.
Info
Turn the outer clutch hub and oil pump gears back and forth slightly to help
them engage.
–Mount washer .
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 150
301687-10
–Lock the outer clutch hub and primary gear with the special tool and tighten
nut .
Guideline
Nut, primary gear M27x1 80 Nm
(59 lbf ft)
Loctite®243™
Gear quadrant (80029004000) ( p. 233)
Info
Ensure that the crankshaft is not locked.
301685-11
–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
Nut, inner clutch hub M18x1.5 80 Nm
(59 lbf ft)
Loctite®243™
Clutch holder (77329003000) ( p. 231)
–Secure the nut with the lock washer.
301684-11
–Thoroughly oil the clutch facing discs.
Engine oil (SAE 10W/50) ( 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.
301683-11
–Position the crankshaft at TDC and lock it with the special tool.
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)
20.15Installing the spacer
301652-10
–Grease the shaft seal ring before mounting.
–Position the O-ring. Mount spacer with the bevel facing inward.
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 151
20.16Installing the drive wheel of the balancer gear
301648-11
–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)
Loctite®243™
Special socket, 36 mm; ½" drive (77329021000) ( p. 231)
20.17Installing the timing chain
301665-10
–Insert the needle bearings in the balancer gear and oil.
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.
301666-10
–Position the retaining bracket.
–Mount and tighten screws .
Guideline
Screw, timing train axle
retaining bracket
M5 6 Nm
(4.4 lbf ft)
Loctite®243™
20.18Installing the free wheel gear
301636-10
–Oil the starter freewheel and needle bearing.
–Mount freewheel gear with the needle bearing.
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 152
20.19Installing the ignition pulse generator
301669-10
–Position the ignition pulse generator.
–Mount screws but do not tighten yet.
Guideline
Screw, ignition pulse gen-
erator adapter
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 gen-
erator cable holder
M6 10 Nm
(7.4 lbf ft)
Loctite®243™
20.20Installing the rotor
301668-10
–Mount starter idler gear .
301667-10
–Ensure that the spring washers are seated properly. Mount the rotor.
–Mount and tighten screw .
Guideline
Screw, rotor M10x1 80 Nm
(59 lbf ft)
lubricated with
engine oil
20.21Installing the timing chain rails
301628-11
–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 spin-
dle .
Guideline
Axle tension rail for timing chain M14x1 15 Nm
(11.1 lbf ft)
20.22Installing the piston
301155-10
–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.
–Carefully tap the piston into the cylinder using the handle of the hammer.
The piston rings should not catch or they will be damaged.
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 153
301627-11
–Mount O-rings .
–Mount locating pins and position cylinder base gasket .
301156-10
–Ensure that piston mark faces the exhaust side.
400366-10
–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.
200084-10
–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.
(450 SX ATV)
Insert for piston pin retainer (77329030100) ( p. 232)
(505 SX ATV)
Insertion for piston ring lock (77629030000) ( p. 233)
–Ensure that the piston pin retainer is seated properly on both sides.
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 154
301647-10
–Remove the cloth. Keep the timing chain taut.
–Carefully push the cylinder downward, letting the locating pins engage.
20.23Installing the clutch cover
301625-11
–Insert quad ring .
–Mount O-ring .
–Position the dowel pins.
301624-11
–Ensure that the crankshaft has been locked in the TDC position.
–Degrease the sealing area and thinly apply sealant to it.
Loctite®5910
–Mount the clutch cover.
–Mount screws and tighten once all of the clutch cover screws have been
mounted.
Guideline
Screw, clutch cover M7x1 14 Nm
(10.3 lbf ft)
–Mount screws and tighten all screws in a crisscross pattern.
Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
301623-11
–Remove the special tool.
Assembly pin (77329012100) ( p. 231)
–Mount and tighten screw with the O-ring.
Guideline
Screw plug, clutch cover M10x1 10 Nm (7.4 lbf ft)
20.24Installing the water pump cover
301622-11
–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
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 155
20.25Installing the cylinder head
301621-11
–Mount centering pins .
–Position cylinder head gasket .
–Put the cylinder head in place.
301620-11
–Mount nut with the washers and tighten in a crisscross pattern.
Guideline
Nut, cylinder head 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
301619-11
–Mount and tighten nut .
Guideline
Nut, cylinder head M6 10 Nm
(7.4 lbf ft)
lubricated with
engine oil
20.26Installing the double wheel
301646-10
–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.
301616-11
–Align the spindle for the retaining bracket.
–Position the retaining bracket.
–Mount and tighten screws .
Guideline
Screw, camshaft bearing
retaining bracket
M5 6 Nm
(4.4 lbf ft)
Loctite®243™
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 156
20.27Installing the timing chain tensioner
301615-11
–Position timing chain tensioner and insert it with new O-ring .
301614-11
–Mount and tighten screw plug with the seal ring.
Guideline
Plug, timing chain tensioner M24x1.5 25 Nm
(18.4 lbf ft)
–Remove screw .
301645-10
–Press the timing chain tensioner toward the timing chain using special tool .
Release device for timing chain tensioner (77329051000) ( p. 232)
The timing chain tensioner unlocks.
–Mount and tighten screw .
Guideline
Screw, unlocking of timing chain ten-
sioner
M10x1 10 Nm (7.4 lbf ft)
20.28Checking the valve timing
Condition
The camshaft has not been disassembled.
301642-10
–Oil the camshafts and bearing positions.
lubricated with engine oil
–Position the camshafts and turn them so the flat surfaces face upward.
301640-10
–Position special tool .
Adjustment bush bridge (77329050000) ( p. 232)
–Check the valve timing.
The special tool must be full contact with the cylinder head and flat surfaces.
» 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)
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 157
301612-11
–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
20.29Adjusting the valve timing
301642-10
–Position the camshafts and turn them so the flat surfaces face upward.
The valves are not activated.
301641-10
–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
301643-10
–Position camshaft bearing bridge .
Info
Ensure that the locating pins are seated properly.
–Mount and tighten the screws.
Guideline
Screw, camshaft bearing
bridge
M7x1 14 Nm
(10.3 lbf ft)
lubricated with
engine oil
–Tighten screw .
Guideline
Screw, camshaft gear M10x1 50 Nm
(36.9 lbf ft)
lubricated with
engine oil
301644-10
–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.
–Mount and tighten the screws.
Guideline
Screw, camshaft bearing
bridge
M7x1 14 Nm
(10.3 lbf ft)
lubricated with
engine oil
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 158
20.30Checking the valve clearance
301611-11
–Remove special tool .
Engine blocking screw (77329010000) ( p. 231)
–Crank over the engine repeatedly.
–Position the engine at ignition top dead center (TDC). ( p. 105)
301637-10
–Check the valve clearance at all valves between the camshaft and cam levers.
Guideline
Valve clearance, cold, exhaust 0.12… 0.18 mm (0.0047…
0.0071 in)
Valve clearance, cold, intake 0.07… 0.13 mm (0.0028…
0.0051 in)
Feeler gauge (59029041100) ( p. 229)
» If the valve clearance does not meet specifications:
–Adjust the valve clearance. ( p. 158)
301638-10
–Remove special tool .
–Mount and tighten screw .
Guideline
Plug, crankshaft location M8 20 Nm
(14.8 lbf ft)
20.31Adjusting the valve clearance
–Remove the camshaft. ( p. 106)
301639-10
–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.
301612-12
–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
–Check the valve clearance. ( p. 158)
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 159
20.32Installing the torque limiter
301607-10
–Mount torque limiter .
20.33Installing the alternator cover
301606-11
–Mount centering pins . Position alternator cover gasket .
301605-11
–Position the alternator cover. Mount screws and tighten in a crisscross pattern.
Guideline
Screw, alternator cover M6 10 Nm (7.4 lbf ft)
20.34Installing the starter motor
301604-10
–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)
20.35Installing the valve cover
301603-10
–Position the valve cover with the gasket. Mount and tighten screws .
Guideline
Screw, valve cover M6 8 Nm (5.9 lbf ft)
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 160
20.36Installing the spark plug
301602-10
–Mount and tighten the spark plug with special tool .
Guideline
Spark plug M10 10… 12 Nm
(7.4… 8.9 lbf ft)
Spark plug wrench (77329072000) ( p. 232)
20.37Installing the oil screen
301598-10
–Mount and tighten the oil drain plug with magnet and the new sealing ring.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
301599-10
–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)
20.38Installing the oil filter
301601-11
–Tilt the engine on one side and fill the oil filter housing to about ⅓full with engine
oil.
–Fill the oil filter with engine oil and place it in the oil filter container.
301600-11
–Oil the O-ring of the oil filter cover.
–Mount oil filter cover .
–Mount and tighten screws .
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)
PartShark.com
877-999-5686
30/ENGINE ASSEMBLY 161
20.39Installing the shift lever
301597-10
–Position the shift lever. Mount and tighten screw with the collar sleeve.
Guideline
Screw, shift lever M6 10 Nm
(7.4 lbf ft)
Loctite®243™
20.40Removing the engine from the universal mounting rack
301596-10
–Remove the screw connection from the special tool.
Engine fixing arm (83529002000) ( p. 237)
–Remove the engine from the universal mounting rack.
Engine work stand (61229001000) ( p. 230)
PartShark.com
877-999-5686
31/CARBURETOR 162
21.1Choke
301780-10
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.
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.
21.2Checking the play in the throttle cable
301795-11
–Move the handlebar to the straight-ahead position. Move the throttle lever back and
forth slightly to ascertain the play in the throttle cable .
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.
–When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–Start the engine and 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)
21.3Carburetor - adjusting idle
301826-10
–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
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.
PartShark.com
877-999-5686
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
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.
21.4Checking the position of the throttle position sensor
–Remove the fuel tank. ( p. 64)
–Remove the front cover. ( p. 69)
302075-10
–Remove the relay.
–Mount a cable jumper between the green and red-white cables on connector .
302073-10
–Disconnect plug-in connector of the throttle position sensor.
302074-10
–Connect the special tool to both connectors.
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 volt-
age.
Variable throttle position sensor volt-
age Vvar (throttle slide closed)
0.505… 0.855 V
PartShark.com
877-999-5686
31/CARBURETOR 164
» If the specified value is not reached:
–Carburetor - adjust the idle speed. ( p. 162)
–Adjust the position of the throttle position sensor. ( 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. ( p. 65)
–Install the front cover. ( p. 69)
21.5Draining the carburetor float chamber
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 immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
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 p. 66)
No more fuel flows from the tank to the carburetor.
301826-11
–Guide the hose coming down behind the engine into a suitable container.
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 .
21.6Removing the carburetor
–Remove the fuel tank. ( p. 64)
–Remove the air filter box lid with the carburetor connection boot. ( p. 62)
PartShark.com
877-999-5686
31/CARBURETOR 165
301544-10
–Unplug connector of the throttle position sensor.
–Remove cable binder .
301545-10
–Detach engine breather hose from the carburetor.
301546-10
–Loosen hose clip .
301547-10
–Take carburetor out of the frame from the rear and set it down on the frame.
301548-10
–Remove screws . Remove carburetor cover .
301549-10
–Loosen nut . Detach the throttle cable and hang it to the side.
PartShark.com
877-999-5686
31/CARBURETOR 166
301550-10
–Unscrew the hot start activation .
–Remove the carburetor.
21.7Installing the carburetor
301550-11
–Mount the hot start activation .
Guideline
Hot start activation M12 2.5 Nm
(1.84 lbf ft)
301549-11
–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)
301548-11
–Position carburetor cover . Mount and tighten screws .
Guideline
Other screws, carburetor M5 5 Nm (3.7 lbf ft)
301547-11
–Insert carburetor into the rubber sleeve.
Info
Ensure that the carburetor hoses are routed correctly.
301546-11
–Position and tighten hose clamp .
PartShark.com
877-999-5686
31/CARBURETOR 167
301545-11
–Attach engine breather hose to the carburetor.
Info
Ensure that the engine breather hose is routed properly.
301544-11
–Connect plug of the throttle position sensor.
–Secure the cables with cable binders .
–Install the air filter box lid and the carburetor connection boot. ( p. 62)
–Install the fuel tank. ( p. 65)
–Check the play in the throttle cable. ( p. 162)
21.8Disassembling the carburetor
Condition
The carburetor has been removed.
301561-10
–Remove screws and detach all vent hoses from the carburetor.
301560-10
–Remove screws . Take off the throttle slide cover and seal.
301562-10
–Remove screw with the spring and washer.
–Pull the jet needle out of the throttle slide.
–Remove screw .
PartShark.com
877-999-5686
31/CARBURETOR 168
301563-10
–Pull up throttle slide arm . Take throttle slide out of the carburetor along with
throttle slide roller and the throttle slide plate.
301551-10
–Remove screws . Take off the accelerator pump cover with the seal ring.
301552-10
–Remove seal rings , spring  and membrane -.
–Remove screws  and take off the float chamber body.
301554-10
–Remove fulcrum pin . Take off the float and float needle valve.
–Remove main jet .
301555-10
–Remove idling jet , cold start jet , needle jet  and buffer plate .
–Screw in mixture control screw  all the way, counting and noting down the num-
ber of rotations.
–Remove the mixture control screw with the spring, washer and O-ring.
301556-10
–Screws  should not be removed.
PartShark.com
877-999-5686
31/CARBURETOR 169
301557-10
–Remove screw -. Pull the hose connector out of the carburetor.
301558-10
–Remove screw . Take off throttle position sensor .
Info
Only remove the throttle position sensor if necessary. If screw  is loos-
ened, the throttle position sensor must be readjusted.
–Unscrew choke slide .
301559-10
–Remove idle air jet .
–Clean all jets and other parts thoroughly and blow out with compressed air.
Carburetor cleaner ( p. 225)
–Clean the carburetor housing and blow out all channels in the carburetor with com-
pressed air.
Carburetor cleaner ( p. 225)
Info
Do not use nitro thinner to clean the carburetor.
PartShark.com
877-999-5686
31/CARBURETOR 170
21.9Checking/adjusting the carburetor components
301703-01
–Disassemble the carburetor. ( p. 167)
–Check/adjust the accelerator pump. ( p. 170)
–Check the choke slide. ( p. 171)
–Check the jet needle. ( p. 172)
–Check the throttle slide. ( p. 172)
–Check the needle jet. ( p. 173)
–Check the float needle valve. ( p. 173)
–Check/adjust the float level. ( p. 174)
–Check/adjust the throttle slide opening. ( p. 173)
–Check the throttle position sensor. ( p. 171)
–Assemble the carburetor. ( p. 175)
21.10Checking/adjusting the accelerator pump
Condition
The carburetor and accelerator pump have been removed.
700051-10
–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 ( p. 225)
PartShark.com
877-999-5686
31/CARBURETOR 171
700065-10
–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 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 .
21.11Checking the choke slide
Condition
The choke slide has been removed.
301722-10
–Check the choke slide for smooth operation.
» If the choke slide cannot be moved easily or is soiled:
–Clean the choke slide.
Carburetor cleaner ( p. 225)
–Check the plunger of the choke slide for damage and wear.
» If the plunger of the choke slide is damaged or worn:
–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.
21.12Checking the hot start slide
Condition
The hot start slide has been removed.
302065-10
–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 ( p. 225)
–Check the plunger of the hot start slide for damage and wear.
» If the plunger of the hot start slide is damaged or worn:
–Change the hot start slide.
–Check the rubber collar.
» If the rubber collar is damaged or brittle:
–Change the hot start slide.
21.13Checking the throttle position sensor
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)
PartShark.com
877-999-5686
31/CARBURETOR 172
700063-10
–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 resis-
tance Rtot
4… 6 kΩ
700064-10
–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.
Variable throttle position sensor, resis-
tance Rvar (throttle slide fully open)
3… 4.5 kΩ
» If the value does not increase at a uniform rate:
–Change the throttle position sensor.
» If the value is outside of specifications:
–Adjust the position of the throttle position sensor. ( p. 174)
21.14Checking the jet needle
Condition
The jet needle has been removed.
700052-10
–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.
21.15Checking the throttle slide
Condition
The throttle slide has been removed.
700055-10
–Check the throttle slide rollers for damage and wear.
» If the throttle slide rollers do not turn smoothly, are worn or have flattened sur-
faces:
–Change the throttle slide.
–Except for the throttle slide valve (removable), all rollers must be firmly seated
on the throttle slide.
» If the throttle slide rollers are loose:
–Change the throttle slide.
–Check the coating of the throttle slide and throttle slide plate for damage and
wear.
» If the coating is damaged or worn:
–Change the throttle slide.
700056-10
–Check the membrane of the throttle slide plate for damage, brittleness and cor-
rect seating.
» If the membrane is damaged or brittle:
–Change the membrane.
–Check that membrane is correctly seated.
» If the membrane is not correctly seated:
–Position the membrane correctly.
PartShark.com
877-999-5686
31/CARBURETOR 173
21.16Checking/adjusting the throttle slide opening
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.
301567-10
–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 .
21.17Checking the needle jet
Condition
The needle jet has been removed.
700053-10
–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.
700054-10
–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.
21.18Checking the float needle valve
Condition
The float needle valve has been removed.
700057-10
–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 ( p. 225)
–Check the float needle valve for wear and check the sealing areas for notches.
» If the sealing area is damaged or worn:
–Change the float needle valve.
PartShark.com
877-999-5686
31/CARBURETOR 174
21.19Checking/adjusting the float level
Condition
The carburetor and float chamber have been removed.
700061-10
–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 .
21.20Adjusting the position of the throttle position sensor
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)
700063-10
–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 resis-
tance Rtot
4… 6 kΩ
700064-10
–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)
700066-10
–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.
–Measure the variable throttle position sensor resistance Rvar.
Info
The throttle slide must be in the basic position.
–Loosen screw . Adjust the throttle position sensor by turning to the calculated
value.
–Tighten screw .
Guideline
Screw, throttle position sensor M5 3.5 Nm
(2.58 lbf ft)
–Check the variable throttle position sensor resistance Rvar again.
» If the measured value is outside of the calculated value:
–Repeat the adjustment procedure.
PartShark.com
877-999-5686
31/CARBURETOR 175
21.21Assembling the carburetor
301559-11
–Mount and tighten idle air jet .
Guideline
Idle air jet M4.5x0.75 2 Nm (1.5 lbf ft)
301558-11
–Mount and tighten choke slide .
Guideline
Choke slide M12 2.5 Nm
(1.84 lbf ft)
–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.
301557-11
–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.
301555-11
–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
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)
PartShark.com
877-999-5686
31/CARBURETOR 176
301554-11
–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. ( p. 174)
700058-11
–Mount and tighten spill jet .
Guideline
Spill jet M4x0.7 2 Nm (1.5 lbf ft)
301564-10
–Position the float chamber and adjusting screw.
–Mount screws  but do not tighten yet.
301563-11
–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.
Guideline
Needle position 3rd position from top
–Insert the jet needle.
301562-11
–Mount and tighten screw  with the spring and washer.
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™
301560-11
–Position the throttle slide cover with the gasket. Mount and tighten screws .
Guideline
Other screws, carburetor M4 2 Nm (1.5 lbf ft)
–Check/adjust the throttle slide opening. ( p. 173)
PartShark.com
877-999-5686
31/CARBURETOR 177
301566-10
–Check/adjust the accelerator pump. ( p. 170)
–Position seal ring -, membrane  and spring .
Info
The label on the membrane must be visible when the membrane is
mounted.
301565-10
–Position seal ring  in the accelerator pump cover with the rounded side facing
out.
301551-11
–Position the accelerator pump cover. Mount and tighten screws .
Guideline
Other screws, carburetor M4 2 Nm (1.5 lbf ft)
301561-01
–Position and mount the bleeder hoses.
–Position the hose holder. Mount screws  and tighten all screws in a crisscross
pattern.
Guideline
Other screws, carburetor M4 2 Nm (1.5 lbf ft)
–Adjust the position of the throttle position sensor. ( p. 174)
PartShark.com
877-999-5686
32/CLUTCH 178
22.1Checking fluid level of hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
301814-10
–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.
Hydraulic fluid (15) ( p. 224)
–Position the cover with the membrane. Mount and tighten screws.
22.2Changing the hydraulic clutch fluid
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.
302061-10
–Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screws .
–Remove cover with membrane .
302062-10
–Fill bleeding syringe with the appropriate hydraulic fluid.
Bleed syringe (50329050000) ( p. 227)
Hydraulic oil (15) ( p. 224)
–Remove the bleeder screw on the clutch slave cylinder and mount the bleeding
syringe.
302063-10
–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.
Guideline
Fluid level below container rim 4 mm (0.16 in)
–Position the cover with the membrane. Mount and tighten the screws.
–Check that the clutch is functioning properly.
PartShark.com
877-999-5686
33/TRANSMISSION 179
23.1Removing the engine sprocket
301543-10
–Disconnect plug of the brake light switch.
–Remove screws and . Take off the engine sprocket cover.
301542-10
–Activate the rear brake and remove screw with spring washer .
–Pull engine sprocket off the countershaft with chain . Remove the engine
sprocket.
23.2Installing the engine sprocket
301542-11
–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™
301543-11
–Position the engine sprocket cover. Mount and tighten screws .
Guideline
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.
PartShark.com
877-999-5686
35/WATER PUMP, COOLING SYSTEM 180
24.1Checking antifreeze and coolant level
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 immedi-
ately.
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
–Remove the front trim. ( p. 69)
400243-10
–Remove the radiator cap.
–Check antifreeze of coolant.
−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. 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.
24.2Checking the coolant level
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 immedi-
ately.
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
–Remove the front trim. ( p. 69)
400243-10
–Remove the radiator cap.
–Check the coolant level in the radiator.
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 ( p. 223)
Alternative 2
Coolant (mixed ready to use) ( p. 223)
PartShark.com
877-999-5686
35/WATER PUMP, COOLING SYSTEM 181
–Mount the radiator cap.
24.3Draining coolant
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 immedi-
ately.
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
–Remove the front trim. ( p. 69)
301837-10
–Place a suitable container under the vehicle.
–Remove screw .
–Remove screw .
301838-10
–Remove the radiator cap . Completely drain the coolant.
–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)
24.4Filling coolant/bleeding the cooling system
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
–Remove the front trim. ( p. 69)
–Remove the radiator spoiler. ( p. 63)
301838-11
–Remove the radiator cap .
–Fill the coolant into the radiator.
Coolant 1.50 l (1.59 qt.) Coolant ( p. 223)
Coolant (mixed ready to use)
( p. 223)
PartShark.com
877-999-5686
35/WATER PUMP, COOLING SYSTEM 182
301840-10
–Open screw to bleed the radiator. Tighten the screw when coolant emerges from
the opening.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
301839-10
–Add coolant to level above the radiator fins.
Guideline
10 mm (0.39 in)
–Mount the radiator cap.
–Install the front trim. ( p. 70)
–Make a short test ride.
–Check the coolant level. ( p. 180)
PartShark.com
877-999-5686
38/LUBRICATION SYSTEM 183
25.1Oil circuit
00
0
bkbk 0
0
bkbk
0
0
990
0
99
0
0
blbl 0
0
blbl
0
0
88
0
0
bnbn
0
0
110
0
22
0
0
bmbm 0
0
bmbm
0
0
330
0
44
0
0
55
0
0
77
0
0
66
0
0
66
301300-01
Oil circuit, force pump
1 Oil screen
2 Force pump
3 Oil pressure regulator valve
4 Oil filter
5 Oil jet, timing chain tensioner
6 Oil jet, piston cooling
7 Oil jet, conrod lubrication
8 Oil jet for oil supply, clutch
9 Oil channel, cam lever bearing
10 Oil jet for cam lever lubrication
11 Oil channel, camshaft bearing
Oil circuit, suction pump
12 Suction pump for evacuating the crank chamber
13 Oil channel, transmission lubrication
25.2Changing the engine oil and oil filter, cleaning the oil screen
301702-10
–Drain the engine oil. ( p. 184)
–Remove the oil filter. ( p. 184)
–Install the oil filter. ( p. 185)
–Fill up with engine oil. ( p. 185)
PartShark.com
877-999-5686
38/LUBRICATION SYSTEM 184
25.3Draining the engine oil
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 immedi-
ately.
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
Drain the engine oil only when the engine is warm.
–Park the vehicle on a horizontal surface.
–Remove the engine guard. ( p. 20)
301841-10
–Place a suitable container under the engine.
–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 M12x1.5 20 Nm
(14.8 lbf ft)
–Clean the oil screen.
25.4Removing the oil filter
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 immedi-
ately.
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.
301843-10
–Remove screws . Take off the oil filter cover with the O-ring.
301844-11
–Pull oil filter element out of the oil filter case.
Circlip pliers reverse (51012011000) ( p. 228)
–Completely drain the engine oil.
–Thoroughly clean parts and sealing area.
PartShark.com
877-999-5686
38/LUBRICATION SYSTEM 185
25.5Installing the oil filter
301844-10
–Fill oil filter with engine oil and place it in the oil filter housing.
301843-11
–Oil the O-ring of the oil filter cover and install it with the oil filter cover.
–Mount and tighten screws .
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)
25.6Filling up with engine oil
Info
A lack of engine oil or poor-quality engine oil results in premature wear to the engine.
301845-10
–Remove the filler cap on the clutch cover and fill up with engine oil.
Engine oil 2.00 l (2.11 qt.) External tem-
perature: ≥0 °C
(≥32 °F)
Engine oil
(SAE 10W/50)
( p. 223)
External tem-
perature: < 0 °C
(< 32 °F)
Engine oil
(SAE 5W/40)
( p. 223)
–Mount and tighten filler cap .
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 ventila-
tion, 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)
25.7Checking the engine oil level
Info
The engine oil level can be checked on a cold or hot engine.
–Park the vehicle on a horizontal surface.
800061-10
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 .
PartShark.com
877-999-5686
38/LUBRICATION SYSTEM 186
» When the engine oil does not reach the middle of the viewer :
–Add engine oil. ( p. 186)
800061-11
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)
25.8Adding engine oil
Info
A lack of engine oil or poor-quality engine oil results in premature wear to the engine.
301845-10
–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) ( 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 .
PartShark.com
877-999-5686
39/IGNITION SYSTEM 187
26.1Removing the stator
Condition
The alternator cover has been removed.
301682-10
–Remove screw and the retaining bracket.
–Remove cable support sleeve from the alternator case.
–Remove screws .
–Take the stator out of the alternator cover.
26.2Installing the stator
301682-11
–Position the stator in the alternator cover.
–Mount screws .
Guideline
Screw, stator bracket M5 6 Nm
(4.4 lbf ft)
Loctite®243™
–Position cable support sleeve in the alternator case.
–Position the retaining bracket. Mount and tighten screw .
Guideline
Screw, stator cable holder M5 6 Nm
(4.4 lbf ft)
Loctite®243™
26.3Checking the ignition system
Warning
Risk of injury The ignition system is under high voltage.
–To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme-
diately after measuring.
Condition
The battery must be charged.
The fuse in the starter relay must be functional.
–Shift gear to neutral.
301568-10
–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.
–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. ( p. 188)
–Check the ignition pulse generator. ( p. 189)
PartShark.com
877-999-5686
39/IGNITION SYSTEM 188
–Check the alternator. ( p. 190)
–Check the spark plug connector. ( p. 189)
–Change the spark plug.
301569-10
–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:
–Change the spark plug.
26.4Checking the ignition coil
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. ( p. 64)
–Remove the spark plug connector.
301572-10
–Measure the primary winding with a multimeter.
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.
301573-10
–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.
301574-10
–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 multi-
meter should be set to DCV.
–Follow the instructions on starting the engine.
–Touch the red measuring lead of the special tool to ground. Touch the black mea-
suring 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.
PartShark.com
877-999-5686
39/IGNITION SYSTEM 189
26.5Checking the spark plug connector
301473-10
–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.
26.6Checking the CDI controller
Info
Never check the CDI controller with a conventional measuring instrument. This may result in the destruction of highly sensitive
electronic components.
301570-10
–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.
26.7Checking the ignition pulse generator
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. ( p. 64)
301577-10
–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.
Ignition pulse generator - resistance
Red - green at: 20 °C (68 °F) 80… 120 Ω
Red - ground at: 20 °C (68 °F) ∞
» If the measured value differs from the set value:
–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 multi-
meter should be set to DCV.
301571-10
–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) 1.5… 3 V
» If the displayed value does not meet specifications:
–Change the ignition pulse generator.
PartShark.com
877-999-5686
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.
26.8Checking the alternator
Condition
All plug-in contacts must be free of corrosion and firmly connected.
The battery must be charged.
–Remove the fuel tank. ( p. 64)
301576-10
–Disconnect the electrical plug-in connector of the stator coil.
–Measure the stator coil with a multimeter.
Stator coil - resistance
Alternator outputs against each
other
≤1Ω
Alternator outputs against ground ∞
» If the value displayed does not meet specifications:
–Change the stator.
301575-10
–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 multi-
meter should be set to DCV.
–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.
PartShark.com
877-999-5686
61/ATV FRONT END 191
27.1Checking the toe
–Park the vehicle on a horizontal surface.
–Check the tire condition. ( p. 72)
–Check the tire air pressure. ( p. 72)
–Check the chassis parts for damage, play and wear.
300272-10
–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)
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)
PartShark.com
877-999-5686
61/ATV FRONT END 192
27.2Adjusting the toe
–Park the vehicle on a horizontal surface.
–Check the tire condition. ( p. 72)
–Check the tire air pressure. ( p. 72)
–Check the chassis parts for damage, play and wear. Replace damaged or worn
parts.
300272-10
–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)
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.
PartShark.com
877-999-5686
61/ATV FRONT END 193
27.3Checking/adjusting the camber
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. ( p. 12)
300273-10
–Loosen nuts .
300274-10
–Remove screws with bushings .
300277-10
–Insert tool in the heim joint and clip onto the A-arm.
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 .
300274-10
–Position the A-arm with bushings . Mount and tighten screws .
Guideline
Screw, A-arm top M10x52 45 Nm
(33.2 lbf ft)
300273-10
–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.
–Remove the vehicle from the work stand. ( p. 12)
PartShark.com
877-999-5686
61/ATV FRONT END 194
27.4Adjusting the fork offset
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. ( p. 12)
300274-11
–Remove screws with bushings .
–Place the A-arm with bushings in the desired position. Mount and tighten
screws .
Guideline
Screw, A-arm top M10x52 45 Nm
(33.2 lbf ft)
–Remove the vehicle from the work stand. ( p. 12)
27.5Removing the wheel carrier
Info
The operations are the same on the left and right.
–Remove the wheel/wheels. ( p. 72)
301500-10
–Remove brake disc guard .
–Remove cable clamp and take off brake line guide .
301501-10
–Pull the hand brake lever and release it again.
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
Do not operate the hand brake lever when the brake caliper has been
removed.
PartShark.com
877-999-5686
61/ATV FRONT END 195
400691-10
–Unthread the brake caliper.
–Hang the brake caliper and the brake line loosely to one side.
301502-10
–Remove nut and take the tie rod out of the wheel carrier.
301503-10
–Remove nuts .
301504-10
–Position special tool . Press the lower ball head out of the wheel carrier.
Push-out tool (83019021000) ( p. 236)
301505-10
–Turn and position special tool . Press the upper ball head out of the wheel car-
rier.
–Remove the wheel carrier.
PartShark.com
877-999-5686
61/ATV FRONT END 196
27.6Changing the wheel bearing
Info
The operations are the same on the left and right.
–Remove the wheel carrier. ( p. 194)
301509-10
–Fix the wheel carrier in the vise.
Info
Use soft jaws.
–Remove nut .
–Remove the wheel hub.
301510-10
–Remove spacers .
301511-10
–Pry out shaft seal rings .
301512-10
–Secure the wheel bearing with a suitable tool.
–Remove the bearing spacer.
301514-10
–Press the wheel bearing all the way in.
Press mandrel (83019013000) ( p. 235)
–Mount the bearing spacer.
PartShark.com
877-999-5686
61/ATV FRONT END 197
301513-10
–Press the wheel bearing all the way in.
Press mandrel (83019013000) ( p. 235)
301511-10
–Press in shaft seal rings so they are flush.
301510-10
–Mount spacers .
301509-10
–Slide the wheel hub onto the wheel carrier.
–Mount and tighten nut .
Guideline
Nut, front wheel hub M12 70 Nm
(51.6 lbf ft)
–Install the wheel carrier. ( p. 197)
27.7Installing the wheel carrier
Info
The operations are the same on the left and right sides.
301503-11
–Insert the wheel carrier between the A-arms. Mount and tighten nuts .
Guideline
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)
PartShark.com
877-999-5686
61/ATV FRONT END 198
301502-11
–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)
400691-11
–Thread the brake caliper and position it.
301501-11
–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.
301500-11
–Position brake line guide and secure it with cable clamp .
Info
Note the holding lug of the brake line guide.
–Mount brake disc guard .
–Install the wheel/wheels. ( p. 73)
–Check the toe. ( p. 191)
27.8Removing the A-arms
Info
The operations are the same on the left and right sides.
–Remove the wheel carrier. ( p. 194)
PartShark.com
877-999-5686
61/ATV FRONT END 199
301506-10
–Remove screws and take off upper A-arm .
Info
When removing screws , make sure that bushings remain in place.
301507-10
–Remove screw and the shock absorber out of the guide.
–Remove screws and take off lower A-arm .
27.9Installing the A-arms
Info
The operations are the same on the left and right sides.
301507-11
–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)
300277-10
–Insert tool in the heim joint and clip onto the A-arm.
Camber gauge (83019014000) ( p. 235)
–Check the camber on both heim joints.
» 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 .
301506-11
–Position upper A-arm with bushings . Mount and tighten screws .
Guideline
Screw, A-arm top M10x52 45 Nm
(33.2 lbf ft)
Info
The fork offset is set using the bushings .
PartShark.com
877-999-5686
61/ATV FRONT END 200
301508-10
–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 30 Nm
(22.1 lbf ft)
–Install the wheel carrier. ( p. 197)
27.10A-Arm top - changing the bearing
Info
The operations are the same on the left and right sides.
–Remove the A-arms. ( p. 198)
600467-10
–Remove lock ring .
Circlip pliers reverse (51012011000) ( p. 228)
600468-10
–Press out ball head using special tool .
Disassembly/assembly holder (83019020150) ( p. 236)
600469-01
–Press in the ball head using the special tool.
Press mandrel (83019020130) ( p. 236)
Mounting sleeve (83019020100) ( p. 235)
600467-10
–Mount lock ring .
Circlip pliers reverse (51012011000) ( p. 228)
Info
When mounting the lock ring, do not damage the rubber boot.
PartShark.com
877-999-5686
61/ATV FRONT END 201
600470-10
–Loosen nuts . Remove heim joint . Screw the nuts off of the heim joints.
600471-10
–Screw the nuts on the new heim joints. Mount the heim joints .
600472-10
–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. ( p. 199)
27.11A-Arm bottom - changing the bearing
Info
The operations are the same on the left and right sides.
–Remove the A-arms. ( p. 198)
PartShark.com
877-999-5686
61/ATV FRONT END 202
3
3
4
3
1
5
1
1
5
6
A
7
1
3
4
5
2
5
2
600457-01
–Remove flange adapters and bearing sleeves .
–Remove shaft seal rings .
–Remove spacing washers .
Info
The spacing washers are only installed at the front pivot point.
600458-01
–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.
600459-01
–Press in a new needle bearing on all pivot points using the thick end of the special
tool.
Press mandrel (83019020170) ( p. 236)
Info
The needle bearing cannot be pushed through from one side.
–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.
PartShark.com
877-999-5686
61/ATV FRONT END 203
600464-10
–Remove lock ring .
Circlip pliers reverse (51012011000) ( p. 228)
600465-10
–Press out ball head using the special tool.
Disassembly/assembly holder (83019020150) ( p. 236)
600466-01
–Press in the ball head using the special tool.
Press mandrel (83019020130) ( p. 236)
Disassembly/assembly holder (83019020150) ( p. 236)
600464-10
–Mount lock ring .
Circlip pliers reverse (51012011000) ( p. 228)
Info
When mounting the lock ring, do not damage the rubber boot.
–Install the A-arms. ( p. 199)
PartShark.com
877-999-5686
TECHNICAL DATA - ENGINE 204
Design 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)
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 igni-
tion 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
28.1Capacity - 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)
28.2Capacity - coolant
Coolant 1.50 l (1.59 qt.) Coolant ( p. 223)
Coolant (mixed ready to use) ( p. 223)
PartShark.com
877-999-5686
TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS 205
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
Intake 1.50 mm (0.0591 in)
Exhaust 1.50 mm (0.0591 in)
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 38.5 mm (1.516 in)
Shift shaft - sliding plate/shift quadrant clearance 0.40… 0.80 mm (0.0157… 0.0315 in)
PartShark.com
877-999-5686
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™
Screw, oil filter cover 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 ten-
sioner
M10x1 10 Nm (7.4 lbf ft) –
PartShark.com
877-999-5686
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 207
Nut, cylinder head 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) –
PartShark.com
877-999-5686
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 1.5 turns
Pump membrane stop 2.15 mm (0.0846 in)
Hot start button
Diameter of bore in carburetor body 2.5 mm (0.098 in)
Main jet 175
Jet needle OBEKR
Idling jet 42
Idle air jet 100
Cold start jet 85
PartShark.com
877-999-5686
TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES 209
Other screws, carburetor 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) –
PartShark.com
877-999-5686
TECHNICAL DATA - CHASSIS 210
Frame Double cradle of chromium molybdenum steel tubes, powder-
coated
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)
Toe
Front 0 mm (0 in)
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
PartShark.com
877-999-5686
TECHNICAL DATA - CHASSIS 211
33.1Tires
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
33.2Capacity - fuel
Total fuel tank capacity
approx.
10.3 l (2.72 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 224)
Fuel reserve approx. 3 l (3 qt.)
PartShark.com
877-999-5686
TECHNICAL DATA - FRONT SHOCK ABSORBER 212
Shock absorber part number 03.18.7J.16
Shock absorber WP Suspension 3612 BAVP DCC
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
Comfort 20 clicks
Standard 15 clicks
Sport 12 clicks
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)
PartShark.com
877-999-5686
TECHNICAL DATA - REAR SHOCK ABSORBER 213
Shock absorber part number 15.18.7J.16
Shock absorber WP Suspension PDS 4618 BAVP DCC
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
Comfort 20 clicks
Standard 15 clicks
Sport 15 clicks
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)
PartShark.com
877-999-5686
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 214
Remaining nuts, chassis 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)
PartShark.com
877-999-5686
CLEANING 215
37.1Cleaning the vehicle
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 electri-
cal 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
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. ( p. 75)
–Treat bare metal parts (except for brake discs and exhaust system) with corrosion's materials.
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 ( p. 226)
–To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray ( p. 225)
PartShark.com
877-999-5686
STORAGE 216
38.1Storage
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 immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
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
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. ( p. 215)
–Change the engine oil and oil filter, clean the oil screen. ( p. 183)
–Check the antifreeze and coolant level. ( p. 180)
–Drain the fuel from the tank into a suitable container.
–Drain the carburetor float chamber. ( p. 164)
–Check the tire air pressure. ( p. 72)
–Remove the battery. ( p. 83)
–Recharge the battery. ( 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.
38.2Putting the vehicle into operation after storage
–Install the battery. ( p. 83)
–Fill up with fuel.
–Checks before putting into operation
–Make a cautious test ride.
PartShark.com
877-999-5686
SERVICE SCHEDULE 217
39.1Important maintenance work to be carried out by an authorized KTM workshop
S1N S3N S10A S30A
Engine Change the engine oil and oil filter, clean the oil screen. ( p. 183) • • • •
Replace spark plug. •
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. • • •
carburetor Check carburetor connection boots for cracks and leakage. • •
Check vent hoses for damage and routing without sharp bends. • • •
Check idle. • • •
Attachments Check the cooling system for leaks. • • •
Check the antifreeze and coolant level. ( p. 180) • • •
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. ( p. 178) • • •
Clean the air filter. ( p. 61) • • •
Check cables for damage and kink-free routing. • •
Check the functioning of the electrical equipment. • • •
Brakes Check the front brake linings. ( p. 91) • • •
Check the rear brake linings. ( p. 96) • • •
Check the brake discs. ( p. 74) • • •
Check the front brake fluid level. ( p. 89) • • •
Check the rear brake fluid level. ( p. 94) • • •
Check that brake lines are undamaged and free of leaks. • • •
Check the free travel of the hand brake lever. ( p. 88) • • •
Check the free travel of the foot brake lever. ( p. 93) • • •
Check the brake system. • • •
Check screws and guide pins of the brake system for tightness. • • •
Chassis 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. • •
Check all screws to make sure they are tight. • • •
Wheels Check rim run-out. • • •
Check the tire condition. ( p. 72) • • •
Check the tire air pressure. ( p. 72) • • •
Check the chain wear. ( p. 75) • • •
Check the chain tension. ( p. 76) • • •
Clean the chain. ( 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)
PartShark.com
877-999-5686
SERVICE SCHEDULE 218
39.2Important maintenance work to be carried out by an authorized KTM workshop (as an additional order)
S10A S20A S40A S80A J1A J2A
Change the oil in the front shock absorber. ( p. 25) • •
Service the front shock absorber. ( p. 27) • •
Change the oil in the rear shock absorber. ( p. 42) • • •
Service the rear shock absorber. ( p. 44) • • •
Treat electric contacts with contact spray. • •
Change the hydraulic clutch fluid. ( p. 178) • •
Change the front brake fluid. ( p. 90) • •
Change the rear brake fluid. ( p. 95) • •
Check the clutch. ( p. 138) • • •
Check/measure the cylinder. ( p. 127) • •
Replace piston. • •
Check the camshafts. ( p. 130) • •
Check the valve spring seat. ( p. 133) • •
Check the cylinder head. ( p. 133) • •
Change the valves. • •
Change the valve springs. • •
Check the timing-chain tensioner function. • •
Check the crankshaft run-out at the bearing pin. ( p. 126) • •
Change the connecting rod, conrod bearing and crank pin. ( p. 125) • •
Check the seating of the piston pin. • •
Change the crankshaft main bearing. • •
Check the transmission. ( 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. ( p. 170) • • • •
S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal)
S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)
S80A: Every 80 service hours - corresponds to about 560 liters of fuel (148 US gal)
J1A: Annually
J2A: Every two years
39.3Important checks and maintenance work to be carried out by the rider
NB1A
Check the engine oil level. ( p. 185) •
Check the front brake fluid level. ( p. 89) •
Check the rear brake fluid level. ( p. 94) •
Check the front brake linings. ( p. 91) •
Check the rear brake linings. ( p. 96) •
Check and adjust control cables. •
Clean the chain. ( p. 75) •
Check the chain tension. ( p. 76) •
Check the chain wear. ( p. 75) •
Check rear sprocket / engine sprocket for wear. ( p. 76) •
Clean the air filter. ( p. 61) •
Check the tire air pressure. ( p. 72) •
PartShark.com
877-999-5686
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. •
NB1A: Depending on conditions of use according to requirements.
PartShark.com
877-999-5686
WIRING DIAGRAM 220
40.1450/525 SX ATV
302012-01
PartShark.com
877-999-5686
WIRING DIAGRAM 221
Components
A1 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 Electric starter button
S3 Emergency OFF switch with rip cord
S4 Temperature switch for radiator fan
S5 Clutch switch
Cable colors
1 White-blue
2 brown
3 white
4 Blue-red
5 Grey
6 white-red
7 White-black
8 Yellow-green
9 Black-yellow
10 Red
11 Green
12 Blue
13 Yellow
14 Black
15 White-brown
16 Brown
17 Black-yellow
18 Black-red
19 Yellow
20 White-red
21 White-red
22 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
PartShark.com
877-999-5686
WIRING DIAGRAM 222
35 White-black
36 Brown
37 Brown
38 Black
39 White-red
40 White-black
41 White-red
42 Brown
43 Black-yellow
PartShark.com
877-999-5686
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 corre-
sponding properties. KTM recommends Castrol and Motorex®products.
Supplier
Castrol
–RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
–Brake Fluid DOT 5.1
Coolant
Guideline
–Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. 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)
Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
–Anti Freeze
Engine oil (SAE 10W/50)
According to
–JASO T903 MA ( p. 240)
–SAE ( 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 corre-
sponding properties. KTM recommends Motorex®products.
Synthetic engine oil
Supplier
Motorex®
–Cross Power 4T
Engine oil (SAE 5W/40)
According to
–JASO T903 MA ( p. 240)
–SAE ( 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 corre-
sponding properties. KTM recommends Motorex®products.
Synthetic engine oil
Supplier
Motorex®
–Power Synt 4T
PartShark.com
877-999-5686
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)
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 cor-
responding 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 corre-
sponding 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)
PartShark.com
877-999-5686
AUXILIARY SUBSTANCES 225
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
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
PartShark.com
877-999-5686
AUXILIARY SUBSTANCES 226
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
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
PartShark.com
877-999-5686
SPECIAL TOOLS 227
Bearing puller
400037-01
Art. no.: 15112017000
Insert for bearing puller
400038-01
Art. no.: 15112018000
Feature
12… 16 mm (0.47… 0.63 in)
Insert for bearing puller
400125-01
Art. no.: 15112018100
Feature
18… 23 mm (0.71… 0.91 in)
Spring hooks
400363-01
Art. no.: 50305017000
Bleed syringe
400058-01
Art. no.: 50329050000
PartShark.com
877-999-5686
SPECIAL TOOLS 228
Circlip pliers reverse
400059-01
Art. no.: 51012011000
Extractor
400073-01
Art. no.: 58012009000
Tool for inner bearing race
400082-01
Art. no.: 58429037037
Peak voltage adapter
400083-01
Art. no.: 58429042000
Mounting sleeve
400095-01
Art. no.: 58529005000
PartShark.com
877-999-5686
SPECIAL TOOLS 229
Valve spring compressor
400101-01
Art. no.: 59029019000
Limit plug gauge
400104-01
Art. no.: 59029026006
Extractor
400105-01
Art. no.: 59029033000
Adjustment tool for mixture control screw
400106-01
Art. no.: 59029034000
Feeler gauge
25
20
30
15
10
12
5
35
400110-01
Art. no.: 59029041100
PartShark.com
877-999-5686
SPECIAL TOOLS 230
Plastigauge measuring strips
400122-01
Art. no.: 60029012000
Piston ring mounting tool
400123-01
Art. no.: 60029015000
Engine work stand
200306-01
Art. no.: 61229001000
Pressing device for crankshaft, complete
400185-01
Art. no.: 75029047000
Protection cover
400167-01
Art. no.: 75029090000
PartShark.com
877-999-5686
SPECIAL TOOLS 231
Clutch holder
301488-10
Art. no.: 77329003000
Engine blocking screw
400177-01
Art. no.: 77329010000
Assembly pin
400178-01
Art. no.: 77329012100
Internal bearing puller
400038-01
Art. no.: 77329020000
Feature
8… 12 mm (0.31… 0.47 in)
Special socket, 36 mm; ½" drive
301703-01
Art. no.: 77329021000
PartShark.com
877-999-5686
SPECIAL TOOLS 232
Insert for piston pin retainer
400160-01
Art. no.: 77329030100
Adjustment bush bridge
301381-10
Art. no.: 77329050000
Release device for timing chain tensioner
400181-01
Art. no.: 77329051000
Insert for valve spring lever
400129-01
Art. no.: 77329060000
Spark plug wrench
400170-01
Art. no.: 77329072000
PartShark.com
877-999-5686
SPECIAL TOOLS 233
Pressing tool, crankshaft
400185-01
Art. no.: 77629008000
Extrude plate, base
400187-01
Art. no.: 77629009001
Extrude plate, top
400186-01
Art. no.: 77629009002
Insertion for piston ring lock
400160-01
Art. no.: 77629030000
Gear quadrant
500164-01
Art. no.: 80029004000
PartShark.com
877-999-5686
SPECIAL TOOLS 234
Hook wrench
200224-10
Art. no.: 83019001000
Hook wrench
200225-10
Art. no.: 83019002000
Open-end wrench attachment, 46 mm
500172-01
Art. no.: 83019010461
Hook wrench
600430-01
Art. no.: 83019011000
Press mandrel
600421-01
Art. no.: 83019012000
PartShark.com
877-999-5686
SPECIAL TOOLS 235
Press mandrel
600476-01
Art. no.: 83019013000
Camber gauge
500229-01
Art. no.: 83019014000
Handlebar fixation for straight-ahead position
200424-10
Art. no.: 83019015100
Extractor
600477-01
Art. no.: 83019020000
Mounting sleeve
600461-01
Art. no.: 83019020100
PartShark.com
877-999-5686
SPECIAL TOOLS 236
Press mandrel
600462-01
Art. no.: 83019020130
Disassembly/assembly holder
600463-01
Art. no.: 83019020150
Press mandrel
600460-01
Art. no.: 83019020170
Push-out tool
600452-01
Art. no.: 83019021000
Adapter cable
600402-01
Art. no.: 83029043000
PartShark.com
877-999-5686
SPECIAL TOOLS 237
Engine fixing arm
301487-10
Art. no.: 83529002000
Extractor
301700-10
Art. no.: 83529048000
Depth micrometer
300577-10
Art. no.: T107S
Pin
201235-10
Art. no.: T120
Mounting sleeve
200788-10
Art. no.: T1204
PartShark.com
877-999-5686
SPECIAL TOOLS 238
Calibration pin
200790-10
Art. no.: T1205
Pressing tool
200583-10
Art. no.: T1206
Pressing tool
200585-01
Art. no.: T1207S
Press drift
200789-10
Art. no.: T1504
Assembly tool
200791-10
Art. no.: T150S
PartShark.com
877-999-5686
SPECIAL TOOLS 239
Mounting sleeve
300578-10
Art. no.: T1554
Hook wrench
200899-10
Art. no.: T157S
Nitrogen filling tool
300574-10
Art. no.: T170S1
Mounting sleeve
300578-10
Art. no.: T313
PartShark.com
877-999-5686
STANDARDS 240
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles –the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
PartShark.com
877-999-5686
INDEX 241
INDEX
A
A-Arm bottom
changingthebearing ........................ 201
A-arm top
changingthebearing ........................ 200
A-arms
installing ................................ 199
removing ................................ 198
Accessories ................................... 7
Air filter
cleaning ................................. 61
installing ................................. 61
removing ................................. 61
Air filter box lid with carburetor connection boot
installing ................................. 62
removing ................................. 62
Alternator
checking ................................ 190
Antifreeze
checking ................................ 180
Assembling the engine
alternator cover, installing . . . . . . . . . . . . . . . . . . . . 159
centrifugal separator, installing . . . . . . . . . . . . . . . . . 148
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 154
crankshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 145
cylinder head, installing . . . . . . . . . . . . . . . . . . . . . 155
double wheel, installing . . . . . . . . . . . . . . . . . . . . . . 155
drive wheel of balancer gear, installing . . . . . . . . . . . 151
engine, removing from universal mounting rack . . . . . . 161
force pump, installing . . . . . . . . . . . . . . . . . . . . . . . 148
freewheel gear, installing . . . . . . . . . . . . . . . . . . . . . 151
ignition pulse generator, installing . . . . . . . . . . . . . . 152
left engine case, installing . . . . . . . . . . . . . . . . . . . . 146
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 147
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 160
oil screen, installing . . . . . . . . . . . . . . . . . . . . . . . . 160
outer clutch hub, installing . . . . . . . . . . . . . . . . . . . 149
piston,installing .......................... 152
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 149
rotor,installing ............................ 152
shift drum locating unit, installing . . . . . . . . . . . . . . 147
shift drum, installing . . . . . . . . . . . . . . . . . . . . . . . . 146
shift forks, installing . . . . . . . . . . . . . . . . . . . . . . . . 145
shift lever, installing . . . . . . . . . . . . . . . . . . . . . . . . 161
shift rails, installing . . . . . . . . . . . . . . . . . . . . . . . . 146
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 147
spacer,installing .......................... 150
spark plug, installing . . . . . . . . . . . . . . . . . . . . . . . . 160
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 159
suction pump, installing . . . . . . . . . . . . . . . . . . . . . 147
timing chain guide rail, installing . . . . . . . . . . . . . . . 152
timing chain tensioner, installing . . . . . . . . . . . . . . . 156
timing chain, installing . . . . . . . . . . . . . . . . . . . . . . 151
torque limiter, installing . . . . . . . . . . . . . . . . . . . . . 159
transmission shafts, installing . . . . . . . . . . . . . . . . . 145
valve clearance, adjusting . . . . . . . . . . . . . . . . . . . . 158
valve clearance, checking . . . . . . . . . . . . . . . . . . . . 158
valve cover, installing . . . . . . . . . . . . . . . . . . . . . . . 159
valve timing, adjusting . . . . . . . . . . . . . . . . . . . . . . 157
valve timing, checking . . . . . . . . . . . . . . . . . . . . . . . 156
water pump cover, installing . . . . . . . . . . . . . . . . . . 154
B
Battery
installing ................................. 83
recharging ................................ 84
removing ................................. 83
Battery voltage
checking ................................. 86
Brake discs
checking ................................. 74
Brake fluid
frontbrake,changing ........................ 90
rearbrake,changing ......................... 95
Brake fluid level of front brake
checking ................................. 89
Brake fluid of front brake
toppingup ................................ 89
Brake fluid of rear brake
checking ................................. 94
toppingup ................................ 94
Brake linings of front brake
changing ................................. 92
checking ................................. 91
installing ................................. 92
removing ................................. 91
Brake linings of rear brake
changing ................................. 98
checking ................................. 96
installing ................................. 97
removing ................................. 96
C
Camber
adjusting ................................ 193
checking ................................ 193
Carburetor
adjustingidle ............................. 162
assembling .............................. 175
disassembling ............................ 167
float chamber, emptying . . . . . . . . . . . . . . . . . . . . . 164
installing ................................ 166
removing ................................ 164
Carburetor - Work on individual parts
accelerator pump, checking/adjusting . . . . . . . . . . . . 170
choke slide, checking . . . . . . . . . . . . . . . . . . . . . . . 171
float level, checking/adjusting . . . . . . . . . . . . . . . . . 174
float needle valve, checking . . . . . . . . . . . . . . . . . . . 173
hot start slide, checking . . . . . . . . . . . . . . . . . . . . . 171
jetneedle,checking ........................ 172
needlejet,checking ........................ 173
throttle slide, checking . . . . . . . . . . . . . . . . . . . . . . 172
Carburetor components
checking/adjusting ......................... 170
CDI controller
checking ................................ 189
Chain
cleaning ................................. 75
PartShark.com
877-999-5686
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
Clutch lever
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 14
Coolant
draining ................................ 181
refilling ................................. 181
Coolant level
checking ................................ 180
Cooling system
bleeding ................................ 181
Cylinder - Nikasil®coating ....................... 127
D
Disassembling the engine
alternator cover, removing . . . . . . . . . . . . . . . . . . . . 104
camshaft,removing ........................ 106
centrifugal separator, removing . . . . . . . . . . . . . . . . . 113
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 108
crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 117
cylinder head, removing . . . . . . . . . . . . . . . . . . . . . . 107
double wheel, removing . . . . . . . . . . . . . . . . . . . . . . 107
drive wheel of balancer gear, removing . . . . . . . . . . . 111
engine case, removing left section . . . . . . . . . . . . . . . 115
engineoil,draining ......................... 103
force pump, removing . . . . . . . . . . . . . . . . . . . . . . . 111
ignition pulse generator, removing . . . . . . . . . . . . . . . 110
locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 115
oilfilter,removing ......................... 103
outer clutch hub, removing . . . . . . . . . . . . . . . . . . . 112
piston,removing ........................... 109
preparations ............................. 103
primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 113
rotor and starter idler gear, removing . . . . . . . . . . . . . 110
shift drum locating unit, removing . . . . . . . . . . . . . . 115
shiftdrum,removing ........................ 116
shift forks, removing . . . . . . . . . . . . . . . . . . . . . . . . 116
shift lever, removing . . . . . . . . . . . . . . . . . . . . . . . . 103
shift rails, removing . . . . . . . . . . . . . . . . . . . . . . . . 116
shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 114
spacer,removing .......................... 112
sparkplug,removing ........................ 104
starter motor, removing . . . . . . . . . . . . . . . . . . . . . . 104
suction pump, removing . . . . . . . . . . . . . . . . . . . . . 114
timing chain rails, removing . . . . . . . . . . . . . . . . . . . 109
timing chain tensioner, removing . . . . . . . . . . . . . . . 106
timing chain, removing . . . . . . . . . . . . . . . . . . . . . . 109
torque limiter, removing . . . . . . . . . . . . . . . . . . . . . 105
transmission shafts, removing . . . . . . . . . . . . . . . . . 116
valve cover, removing . . . . . . . . . . . . . . . . . . . . . . . 104
water pump cover, removing . . . . . . . . . . . . . . . . . . . 108
E
Engine
installing ................................ 100
positioning at ignition top dead center . . . . . . . . . . . . 105
removing ................................. 99
Engine - Work on individual parts
autodecompressor, checking . . . . . . . . . . . . . . . . . . 130
camlevers,checking ........................ 133
camshaft bearing bridges, checking . . . . . . . . . . . . . 131
camshaft,changing ........................ 129
camshafts,checking ........................ 130
clutch,checking ........................... 138
connecting rod, conrod bearing and crank pin, changing 125
countershaft, assembling . . . . . . . . . . . . . . . . . . . . . 144
countershaft, disassembling . . . . . . . . . . . . . . . . . . . 141
crankshaft bearing inner race, installing . . . . . . . . . . . 125
crankshaft bearing inner race, removing . . . . . . . . . . . 125
crankshaft end play, measuring . . . . . . . . . . . . . . . . 127
crankshaft run-out at the bearing pin, checking . . . . . 126
crankshaft seal ring in clutch cover, removing . . . . . . . 123
crankshaft seal ring, installing in clutch cover . . . . . . . 123
cylinder - Nikasil®coating .................... 127
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . 133
cylinder, checking/measuring . . . . . . . . . . . . . . . . . . 127
electric starter mode, checking . . . . . . . . . . . . . . . . . 136
freewheel,checking ........................ 135
freewheel, installing . . . . . . . . . . . . . . . . . . . . . . . . 135
freewheel,removing ........................ 135
left section of the engine case, working on . . . . . . . . . 119
lubrication system, checking . . . . . . . . . . . . . . . . . . 124
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 143
main shaft, disassembling . . . . . . . . . . . . . . . . . . . . 141
piston ring end gap, checking . . . . . . . . . . . . . . . . . . 129
piston, checking/measuring . . . . . . . . . . . . . . . . . . . 128
piston/cylinder, determining the mounting clearance . . 129
radial clearance of camshaft bearings, checking . . . . . 130
right section of the engine case . . . . . . . . . . . . . . . . 118
shaft seal ring of water pump, changing . . . . . . . . . . . 121
shift mechanism, checking . . . . . . . . . . . . . . . . . . . 139
shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . 140
spring length of oil pressure regulator valve, checking . 123
timing assembly, checking . . . . . . . . . . . . . . . . . . . . 137
timing chain tensioner, preparing for installation . . . . . 137
transmission, checking . . . . . . . . . . . . . . . . . . . . . . 142
valve spring seat, checking . . . . . . . . . . . . . . . . . . . 133
valve springs, checking . . . . . . . . . . . . . . . . . . . . . . 133
valves,checking ........................... 132
valves,installing ........................... 134
valves,removing ........................... 131
water pump, installing . . . . . . . . . . . . . . . . . . . . . . . 122
water pump, removing . . . . . . . . . . . . . . . . . . . . . . . 120
Engine guard
installing ................................. 20
removing ................................. 20
Engine number ................................ 10
Engine oil
adding ................................. 186
PartShark.com
877-999-5686
INDEX 243
changing ................................ 183
draining ................................ 184
refilling ................................. 185
Engine oil level
checking ................................ 185
Engine sprocket
installing ................................ 179
removing ................................ 179
F
Fender, rear
installing ................................. 71
removing ................................. 70
Foot brake lever
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 93
freetravel,checking ......................... 93
Fork offset
adjusting ................................ 194
Front cover
installing ................................. 69
removing ................................. 69
Front shock absorber
bleedingandfilling .......................... 34
compression damping, high-speed adjustment . . . . . . . 21
compression damping, low-speed adjustment . . . . . . . . 21
crossover,adjusting ......................... 24
damper,assembling ......................... 33
damper,checking ........................... 30
damper, disassembling . . . . . . . . . . . . . . . . . . . . . . . 28
damper, filling with nitrogen . . . . . . . . . . . . . . . . . . . 37
heimjoint,installing ......................... 31
heimjoint,removing ......................... 31
installing ................................. 25
oilchange ................................ 25
piston rod, assembling . . . . . . . . . . . . . . . . . . . . . . . 32
piston rod, disassembling . . . . . . . . . . . . . . . . . . . . . 29
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 22
removing ................................. 24
shock absorber, servicing . . . . . . . . . . . . . . . . . . . . . . 27
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 23
spring,installing ........................... 38
spring,removing ............................ 28
Front trim
installing ................................. 70
removing ................................. 69
Fuel tank
installing ................................. 65
removing ................................. 64
Fuel tap .................................... 66
Fuel, oils, etc. ................................. 7
Fuse
changing fuses of individual power consumers . . . . . . . 85
changing the main fuse . . . . . . . . . . . . . . . . . . . . . . . 85
H
Hand brake lever .............................. 88
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 88
freetravel,checking ......................... 88
Handlebar position
adjusting ................................. 13
Heel protector
installing ................................. 68
removing ................................. 67
Hot start lever ................................ 13
I
Ignition coil
checking ................................ 188
Ignition curve
changing ................................. 83
plugconnection ............................ 83
Ignition pulse generator
checking ................................ 189
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
Play in throttle cable
adjusting ................................. 14
checking ............................. 14,162
Putting into operation
afterstorage ............................. 216
Q
Quiescent current
checking ................................. 86
R
Radiator spoiler
installing ................................. 64
removing ................................. 63
PartShark.com
877-999-5686
INDEX 244
Rear axle
installing ................................. 79
removing ................................. 78
Rear axle bearing
changing ................................. 81
Rear shock absorber
bleedingandfilling .......................... 54
compression damping, high-speed adjustment . . . . . . . 38
compression damping, low-speed adjustment . . . . . . . . 39
damper,assembling ......................... 52
damper,checking ........................... 48
damper, disassembling . . . . . . . . . . . . . . . . . . . . . . . 45
damper, filling with nitrogen . . . . . . . . . . . . . . . . . . . 56
heimjoint,installing ......................... 50
heimjoint,removing ......................... 49
installing ................................. 42
oilchange ................................ 42
piston rod, assembling . . . . . . . . . . . . . . . . . . . . . . . 51
piston rod, disassembling . . . . . . . . . . . . . . . . . . . . . 46
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 40
removing ................................. 41
seal ring retainer, assembling . . . . . . . . . . . . . . . . . . . 50
seal ring retainer, disassembling . . . . . . . . . . . . . . . . . 47
shock absorber, servicing . . . . . . . . . . . . . . . . . . . . . . 44
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 40
spring,installing ........................... 57
spring,removing ............................ 44
Rear sprocket / engine sprocket
checkingforwear ........................... 76
S
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 ................................... 216
T
Technical data
carburetor ............................... 208
carburetor tightening torques . . . . . . . . . . . . . . . . . . 209
chassis ..............................210-211
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 214
engine ................................. 204
engine - tolerance, wear limits . . . . . . . . . . . . . . . . . 205
engine tightening torques . . . . . . . . . . . . . . . . . 206-207
frontshockabsorber ........................ 212
rearshockabsorber ......................... 213
Throttle position sensor
checking ................................ 171
position,adjusting ......................... 174
position,checking ......................... 163
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
jackingup ................................ 12
removing from work stand . . . . . . . . . . . . . . . . . . . . . 12
W
Warranty ..................................... 7
Wheel bearing
changing ................................ 196
Wheel carrier
installing ................................ 197
removing ................................ 194
Wheel/wheels
installing ................................. 73
removing ................................. 72
Wiring diagram .............................. 220
Work rules ................................... 7
PartShark.com
877-999-5686
*3206070en*
3206070en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
08/2009 Photo: Mitterbauer
PartShark.com
877-999-5686

Navigation menu