REPAIR MANUAL 2012 | ammo 125 Duke EU 125 Duke DE 200 Duke EU Art. no. 3206127enINTRODUCTION 1 ‘ad this repair manual carefully and thorovarly be work 1 vehicle will only be able te meet the denands placed on it the saecitied service 1h 's performed regulerly and properly We reserve to ake changes inthe i ing this Tan We shall no prow de @ descr pt or of gereral workstop methods. likew se, safety rules that apply in @ workshop are not specif ed here Ie is assumed that :he rep work wll be perfored by 2 fully rained mechanic G sp erica reasons, :o adept ular medel without prcr netce, KTM accepts no lability for delivery misprints ard ocher erors, The models portrayed partly contain spe ape of supply Al specications are con-bind ng, KTM Spert motor tions, arices,colrs,f these fo local craitens, 25 well as to sop preduct en ofp apt ons, deviat ens from illustrations and descriptions, as wel hat does not belorg tothe ly reserves the right to med fy or delete tech 12 KTW-Sport moter All ighss reserved Rearodul owner 180 9001112 100 6062) ding to the in fen Austra tothe maximu Issued by: TOY Wt KTM-Sportotoreycle AG 30 Matlighofen, AustraTABLE OF CONTENTS 1 MEANS OF 2EPRESENTATION 6 Li Symbdls used 6 1 6 2 8 7 2.1 Repair Manual 7 22 Safety adi ce 7 23 sk and sym ? 2a 7 3. IMPORTANT NOTES 8 2.1 Guarantee, warrenty s 32 nd euxilary substances, 8 33 fe parts, accessories 5s 24 Fours 8 4 SERIAL NUMBERS: 8 al ss cumberitype 8 42 Key number 9 43 Engine rumber 8 5 MOTORCYCLE 10 Raising the motorcycle with the rear wheel 2 ereyele aff of the rear wheel cle with the front whee! Taking the metoreyce aff of tre front wheel stand) le with the work stand le from the work stand Starting. Starting the metercycle to make checks 6 FORK, TRIPLE CLAMP 6.1 Clearing the dust boos ofthe fork legs. 6.2 ReTovrg fork less 63 Installing she for Disassembling the fork legs Checking the fork les, Assembling the frk Removing the loner =r ple elemp Inscalling the lower a Check rg the steer Adjust ng the sca 7 MANOLEBAR, CONTROL TL Checking the pay in 7.2 Adjusting tre play 7.3 Checking he clute 7A Adjustiog the clutel 8 SHOCK ABSORBER, SWINGARM 82 Ie oad 8 “4 8 8 9 9.1 Removing the exraus: manifold Inscalling he exaust ~anifold Remewrg the main silencer Insualling he main silen 10 Ala FILTER 0.1 Removirg the air iter 10.2 Installing she a filter. ANK, SEAT, TRIM Opening the Fle 2 Closing tre filler cap 3. Remov ng the seat A Meurting the sea 5 Removing the 8 9 Moursing the p Removing the fuel tark cover Insvalirg te fuel t2rk Removing the fuel tank alg the fuel tark Removing the fron: spoiler Ft rg font spies Chang re the fuel fer L117. Replecirg the fuel pump WHEELS 12] Check ng the Ure alr pressure 12.2 Checking the tre congit on 123 Checking the brake discs. 24 Hon whee 12.4.1 Removing the font wheel 12.4.2 Irsalling the frort whee 2.43 Removing *he brake dsc ofthe front brake 12.44 _ Installing the brake d's of the front brake 12.5 Rear whee! 12.5.1 Removing the rear whee! 2.5.2 Iestalling the reat wheel 1253 2 he on rear brake 12.54 Installing the brake dsc of the rear brake 12.5.5 Checking the crain tersion 12.5.6 — Adjusting the chain tension 12.5.7 Check ng the che n, rear sprockel, 2nd engine sprocket 22.58 leaning th 125.9 Grecking the rar Pub rubber dampers WIRING HARNFSS, BATTERY. 18.1. Remouing the battery 18.2 _Instalirg the battery 133 Disconnecting the negat ve cable of the battery 18.4 Reconnecting the regative cable of the a 18.5. Rechargng the battery 135 Checking the charging voltage 137 1g the fuses of irividual sumers BRAKE SYSTEM 14, ching the fror: brake lin gs 14.2 Changrg the front brake linings 14.3 Checking the brake fluid level ofthe font 14.4 Adding frort brake flu 14.5 Changing the front brake fluid 14.5 Checking the rear brake ln nas 4.7 Changirg the reer brake linings 24.8 Checking the tr of foo: brake lever 14.9 Adjusting the free cravel of the foot brake fluid levelTABLE OF CONTENTS rear brake fluid 2 ing the rer brake uid 73 15. LIGHTING SYSTEM, INSTRUMENTS 75 8.1 Setting kilometers er miles 78 Ajesting the shift speed RPM L re Adjesting tne shi speed RPM 2 78 Setsing the time 76 Reselting the service interval display 76 Checkirg the headlight seting. 6 Adjusting the headliar: range " CChenging the parking light bul, 78, CChenging the Peadiigh: bulb 9 16 ENGINE 8 16.1 Removing the erg al 16.2 Installing he engine Ba 16.3. Dsessemblirg tre engine a9 163.1 Preparat ons (128 Duke) 88 16.3.2 Drainrg the engine 0! (126 Duke) ao 1633 hain securing au de (128 59 16.3.4 Removing the vale cover (126 Duke) 90 16.3.5 Removing the soark plug 90 263.6 Removing the clutch 0 16.3.7 Setting the engine to ignition top deed n 163.8 a1 16.3.9 Removing the tim ng chain tens one Duke} i the carshatt (1 the ing the pistor (126 Qube ing the water pump wheel (125, Removing the rotor (125 Duke) Removing the starter drive (128 Duke) he balancer sraf drive wheel 9a Removing the alterrator cover (126 Duke)... $5 96 ke) ing the gear posto ser (125 ing he spacer (125 Duke) Removing shee Removing the prim Removing the oil ump (2 Removing the shift staf (125 Removing the sift drum loca Duke} 200 Removing the lacking Rerevin Duke} Removing the shift als (126 Dekel Removing the shift drum (125 Duke} Removing the sift forks (125 Duke} Removing the transriss.on shatts ( Duke} Removing the balarcer shaft (125 Duke) Removing the crankshaf: (28 Duke) Preparat ors (200 Duke) re the engine o! (200 Duke) ing the chain securing guide (200, ye cover (200 Duke)... 104 3 he spark plug (200 Quke) 104 ing the vivich cover (200 Duke) ..... 104 16.3.40 Setting tre engine to ignition top deed ccerzer (200 Duke) Rerroving he starter motor (200 Duke Rerrov ng she iming chain tensioner (260 Duke} 163.43 Rerozing the camshaf: (200 Duke} 16.3.44 Removing the cylinder head (200 Duke} 16.345 Removing the pistor (200 Duke} 163.46 Removing the water pump wheel (200, Duke} 08 163.47 Removng the alleraser cover (200 Duke} 26.348. Reroving the rotor (200 Du 16.349 Reroving the slarer drve (200 Duke}... 120 163.50 Removing the balancer staf: drive wheel (200 Duke} no Rerroving the gear position sensor (200 uke} Re he epacer (200 Duke} 1 Removing the clu:ch Removing the pr rary gear ( ‘ovng the cil purnp (200 Dul Reroving he left ergire Duke} Rerraving the shift rails (200 Duke) ‘oung the shift crum (200 Duke) Rerroving the shift forks (200 Duke) Removing the ransriss.en shafts (200 Duke) 116 Removing the bslancer shaft (200 Duke)... 117 Removing the crarkshaft (200 Dukeb...... 117 k on ind dual parts ur? Work or the left section of the ergre 82 (200 uy 1642 1643 : 164e 19 645 16.4.6 ranging the 16.4.7 hanging the balancer shaft Dukel 1648 Charging re Duke} 16.49 Work or theo Checking :h Duke)... 124 oslinder (125 164.13 Gheckingimeasuring tne pistor Duke} 125 16.4.14 Crecking the 9 ston‘eyl rder re. cleararce (-25 Juke). 126 16.4.1 Grecking the oil pump (125 Duked 126TABLE OF CONTENTS Mont 2 cooeahcht bear na (204 ° 16.524 16.438 Werk onthe cylinder nead (200 Deke) 16.439. Crecking th jr head (200 Duke)... 144 164.40 Creckinglmeasuring the cylinder (200 Duke} 144 16.4.1 Checking the Duke} 148 164.42. heckingimeasuring tne pister (200 Duk 145 6.443. Checking the p stonleyl cder mourting clearance (200 Duke} 146 16.533 16.444 Checking the 01 pump (200 Duke) 146 1653 164.45 Checking the ell pressure regulator value (200 Dike} 146 16.535 164.46 Checking the clutch (200 Duke) up 6.5.36 16.441 Preassembling the clutch {200 Dy 148 l653r 16.448 Check ng the shift echanism (200 Duke} 149 16.538 164.89 senbling the shit sheft (200 Duke)... 160 165.39 Disassembling the main shaft (200 16.540 Duke} ip541 Dismantling zhe countershatt (200 Duke). recking the transmiss.on (200 Duke. Assenbl rg the "ain shaft (200 Duke) Assembling the counters 10 Duke 16.4.89 Checking she s ming essembly (260 Duke} 6645 Chang ng the ator (200 Duke) 165.46 6.4.57 Checking the electric starter deve (200 16.547 Duke} 16.548 16.4.58 Checking the reewee! (200 Duke) 165.49 lestalling tre sh ft forks (125 uke) lestalling the sh ft drum (225 Duke) lestallng tne shit ails (12 Duked ling the left 92 (125 lestalling the ail iter (128 Duke) lestalling the lacking lever (125 Duke) lestalling tre sh ft drum locating (128 Duke} lestalling the shift shaft (£25 Qube} lestalling tne oil amp (228 Duke) lestalling the primary gear (125 Duke), lestalling the clutch cage (228 Duke) (128 Duke} lestalling the gear pos “on sensor (125 Duke} Iestalling the balancer shaft deve wheel (128 Duke} Iestallig the starter dive (125 Duke) lestallng tne rotor (125 Duke) lestallng tne alternator cover (128 Duke) lstalling te water pump cover (125 Duke} ng the pston (225 Dekel lestalling the cylinder head (225 Duke) lestalling the i528 Duked lestallng tre t rng chain tens cner (125 Duke} Adjusting the val Iestalling the st lestalling the clutch cover ( lestalling the sparkplug (125 Iestalling the valve cover ( Iestalling the lestallng ire balancer shaft (200 Duke) lestalling the trarsmission Duke} lestalling tne shi forks (209 Duke} lestallng the shit: drum (200 Duked lestalling the shif: rails (200 Dul Iestalling the left engine case (200 Duke} lesta ithe ol ficer (200 Duke) the lacking lever (200 Duke) ing the shift drum locating (200 lestalling tre sh ft sraft (200 Duke} lestalling te oil pump (200 Duke lestalling the primary gear (200 Duke} lestalling the clu:ch cage (200 Duke) lestalling tne spacer (200 Duke)TABLE OF CONTENTS 5 26.5.50 Installing the gear pos ion sensor (200 23 stone 212 che a0 232 Storage 2:2 lrsaling te balancer shat deve wheal 23.2 reoarng lor vse alter storage 212 (200 bu 24 SERVICE SCHEDU: 2 trstal 24.. Servce sted 2 Irstalg the rot (200 Duke 26. WIRING DIAGRAM 2a Install g the altemator 25.1 Page Lof8 2a Irstaling he water pump 252 Pate 2018 2 Duke) ; 253 Pape 30f8 2 Urstaling the pista (200 Duke) 25.4 Page 40h 8 2 trstalrg the eylincer read (200 Duke) 285 aye 508 2 ee 2 tre 7 25.6 608 224 rs ap DBP Pate 70 2 258 Pape Bol 8 26 SUBSTANCES Crecki leararce (200 Duke)... 188 Ausra ce 200 uke) «1882 aupiLnay SUBSTANCES Irstal the clutch cover (200 Duke) 1gg 28. SPECIAL TOOLS Italo the sat lg 200 Dae ze Sianoanos ist (200 Duke ° Ital the chen searing aide 200 bute) 230 Italie i seeen 200 De). 180 Reroung the egne ror the engre sen sand 000 ule 17 SHIFT MEGHAN 17. Adising te sit er 18 WATER PUP, COOLiNe sVSTEM Draining he celert Fingeedg ie cog en is tere and alan eel» 198 Cesk te cat 5 19 Lueelention sisrew SI aie o Chek re ene pessice o Chang ng the angire ol ard il fer, clear ng the ol creer 19.5 Addog engine il 20. IGNITION SYSTEM 20.1 Alternator - checking the stator wrcing 21 TESHNICAL nr 21. 125 Duke 212 200 duke 21.3 Engine tolerance, wear | mits LBL 125 due 2132 200 duke 21.4 Engine tightening torques. DLS Capec ties 2181 Engrecil 2182 oi 218 216 21? sen, 218 sak 21.10 Shock absorber 2 tighten og tora 207 22.0) ROTEGTIVE TREATMENT 22.1 Cleaning the ratrcyele 222 Checks and mainerance steps for winter ion 21 MEANS OF REPRESENTATION 6 AA Symbols used The meaning of specific synbols 's described below, lon (eg ofa work siep or foncsony an unexpected rt ion fe.g. of 2 werk step er a furctior) Pa Ingicates a page relererce (rrore informa cn is provided on the specified page) Indicates information with mare details cr tps Incicates the result ofa testing step. wi Derotes a voltage measurement w Denotes a curent measurement The typographical formats used in this deeu'nent are expleinad below Proprietary name Teerates 3 propre nae Name® Identifies 2 protected name, Brand Identifies @ trademark2 SAFETY ADVICE 7 2A Repair Manual Read this Repair Manual cavelully and thoroveiy before begin rg work, It contairs useful infermation and tins hat wil help you reper ard ma ntain your veh cle This ‘ranval essumres thatthe necess 1y spec al KTM tools and KTM workplace are workshop equ amet ate avalable A numberof sefety instructions need to be flawed to operate the vehicle safely. Therefore, read this anual carefully. The setety instruct ors are hgrlighed vthe cext and are refered :9 atthe relevant passages. = Info The vehicle has varous formation and watrirg labels 2t prominer: locations. Do not rerneve infermaticnl they are missing, you of others may rt recogrize dangers and 7ay therefore be injred. Danger Identifies a danger that will media janine labels. It od iveriably lead to fatal or ser'ous permanent injury i Warning Identifies a danger at is kely to lead #0 fatal o serious injury if the appropriate mesures ar not Saker. ao Identifies a danger that ay lead to minor injuries if the appropriate nessures are not Note Idersiies a danger thet will ead‘ considerable machine and “aterial damage ifthe appropriate measures are nat ‘aken, Warning Iersifies a danger at wl lead to environ rental damage i he appropriate meesures are not ‘aken. ‘Special tools are necessary for certain tasks. The tools are not cor‘ained in the vehicle but can be erdered under the number in peren- theses. & 2: beerng puller (15112017000) Durirg assembly, con-reusable parts (e.g sell-locking screws and nuts, seals and sel rings, O-ings, pins, lock washers) must be faciurer instructions for use “ust be falloned. them for damage and wear, Change damaged or warn pars, ofthe ‘ter dszssembly, clear she pars tate ob ler you complete tre repair or service nork she ooeratng3 IMPORTANT NOTES 8 BL Guarantee, warranty The work prescrited inthe service schedule must be cetried out by an authorized KTM workshop orly ard confirmed in the customer's service record and nm “heKTM dealer.net ctreraise all warrarsy clams will be vows. Ne warrarty claims car be corsidered for camage result ng fron "manipulations ardor alterations to the veh cle Additional nfermation on the guarantee or watran'y ard she procedures invclued car be four inthe sere ce record Warning Environmental hazard Improper handling of fuel isa darger isthe env ronment ‘= De notallow fuel to get into the ground water, the ground, o the sewage system Use the operating and aviilary substances (suchas fuel ard lube canis} as specif ed in the manual Only use spare pars and accessories approved arclor recommended ty KTM, KTM accepts no lablity fr o:her produe's ard ary result na damage or loss The current KTM PowerParts for your vehicle can be fourd on the KTM website Incernatonal KTM Website: htpwww.ktr.com The figures cantzined in the marual may depict special equipment In the ircerest of clary, some components may be shown d sessembled ar may nat ‘semi the comporer lo perform the activly in queston, Please fallow the stu4 — SERIAL NUMBERS 8 irber @ is tayped on the right ofthe steering hes @ ison she right of the Trae behind the steering hes The Hey rumber @. | =—=—0 = Info | ANI DH You need the key rumber to order pla be found ar the KEYCODECARD. se hey. Keog the KEYCODECARD in = e075 The engine number @ is stav)ped or the left side sprocke! f the engine under the engine5 MOTORCYCLE 10 ‘5.1 Raising the motoreyele withthe rearwheel stand Note Danger of damage The parked vehicle = Always place the veticle on a firn and ev ‘Adapter Rear wheel stand (6202905 = Stand the motorcycle upright, a adapters, an It the 2505513011 p. 285) 400) (Fp. 235) he wreel star wh the link frk ane the Note Danger of damage The parked vehicle may roll anay or fall over place the veticle on a firm and even surface. = Secure tre motoreycle aga st 1 — Rerrove the rear wheel stand and lear the veh cle or the side stand @, e 4 pert of the wheel Note Danger of damage The parked vehicle may toll anay or fall over, = _Always place she vehicle on a firm and even surface Preparatory work = Rase the m Condition = le withthe rear wheel stand. (Fp. 20} ove cap ©.5 MOTORCYCLE 1" 8 gear ‘0 54 Note Danger of damage The parke = Always place the vel Taking the motorcycle off of the front wheel stand vehicle may rll anay or fll 0 en sur cnafirna = Mount ea 5.5 Raising the motorcycle with the work stand Note Danger of damage The parke vehicle may roll anay or fall oer Always place the vehicle ana firm and even surface fhe veh ele = Mourt spec al tool @ on she right s Tard Ooe2oSSOOO > p 2ET5 MOTORCYCLE 12 = Mourt s cial tool @ on the left side of the veticle Wark stara (25200500001 (% p. 236) sition the motoreycle upright, elign the specal tool ard reise the motorcycle o1ae10 Note Danger of damage The parked vehicle may roll anay or fall over - Al a firm and even surface. place the vec! = Secure the motorcycle aga rst falling over = Remove special tool @ Danger Danger of poisoning Extaust gases are nic ard irralirg them oray result n unconscieusress ardor death tres suf ve exhaust exracton system = Wren running he engine, aluays rake ventlatin, and do nat stator run the engire in an enclesed space witha are my om Danger of accidents If the vehicle's operated with a d scharged battery o without a batter, electrer'c components ard sete equipment may be demened = Never operate the vehicle with 2 discharged battery or w thout 2 battery Note Engine failure Unf lieve airhas a negative effec he sence life ofthe engre. = Never ride the vehicle without an air Fler since dust and wit can get into the engine ard resull in inoreased weer, Note Engine failure High ergire spe n cole eng a negative effect on the service life ofthe engi. = Always wer up at lw engine s5 MOTORCYCLE OQ} ® 0732-10 13 Sion thew Turn the er ‘wich tothe position ©. ‘Sw tch on the ignition by turning the ignition key 1% Alter you swtch on the ignitan, you two seconds. The furcton test ofthe combinal on instrument Shift gear te neutral 1 The green idling speed indicator lame Nig Press the elec er buiten@. 1d, and move up all the way. he position ©. fel pup working oral ural mf Info De not press the electric s nation rstrumert is fin When ster’ eg, OO NOT} slang procedure, fuel and the engire Press te starter for @ maxim of before ty 8 een the function est ofthe combi T you open the tnotle dering the d by the eng re managerert gysien nds, Wait fora least § seconds = ransmiss on is in nevital or tor seg fine sie stands ld a lease the clutch, the engine stops, Danger Danger of poisoning Extavsi eahaust usress ardor death ye ventlation, and do nt run the engive in an enclosed tater for a maximum of 8 seconds, Wal for @ OQ} ® eoo7e2.20 Turn the en he ignition by turnrg the ignition key zo the position ©. Press the electric starter button ®. = Info Do not open the title6 — FORK, TRIPLE CLAMP 4 6.1 Gleaning the dust hoots ofthe forklegs A Push dus: baot @ of both fork les cow wards, Info Bo The ous les from the fork tubes. Over Lime, dirt can penetrate behird the dust boats, If this drt is not recoved, the oil Sea's ber nd can start to leak A Waring Danger af ancidents Reduced brah brake disc = Always keep she brake discs free af ol and grees, an he cleaner niien necessary = Clean and oll the dust boots and innar fork tube of bath fork le Taw = Press the dus: boots back into tre normal os = Remove excess cil ToT spray p22) Preparatory work = Rase the otoceycle withthe work stand, (@ p. 11) = Tie the rear of th denn, = Dismount the fer: fender, (© p. 47) Main wark = Reniove seraus @ = Press back the brak Vent brake d se, Pull she retully ore side = Info fr when the brake cal er has been renow De not pull the had b 1s © ered sorew ©. = Unsoren screw @ abavt sk urns and press your hand or the sera whee! sp ndle out ofthe ade clamp, Remove screw -—@ Warning Danger of accidents. Resuced uraking ds sen by camaged brake the wheel Gown ic suet 2 way that the brake diss are the wh Take the front wheel out of ole binder and heng the wheel speed sersr to are sd,6 — FORK, TRIPLE CLAMP 18 = Loosen soraws @. Rernove the fork legs from the bottom iy ne Danger of accidents Mocificatons tothe suspens en sett ngs can seriously alter the vehicle's ride behavior = Following modifications ride slowly a Ft :o get the feel of the new ri Main wark = Push the fo the tople clamps. = Align the fork egs in the required pes ior using the fork rings = Tighter screw @, eli Sa nS TING FD J] - Fully tgnter screns @. Guideline Seren, bation ple Garp Te Position che wheel speed sersor. Mount and t ghter screws ©. ieline Fe ie ann Bee6 FORK, TRIPLE CLAMP = Mour ‘a pressure point The brake = Fullytighten screw @. deli sleigh 16 Spindle = Lift the front fork, postion tard srt the wreel spindle, deli Mont weal sp ale ne 25 Nm (8.4 tot = Position the treke cal pers ard check thatthe brake linings a weeily = Mourt screws @ bu do rot tighten ted until the brake linings are in contact wth Tron brave cal Tote 243 1 Fxation of ad the rear of 1 motoreycle fre the front brake ard com legs siaighten. = Tiahten screws @ Guideline Screw, Fak sub rr rT Te 64 Finishing wark = Intell Front fender p. 47) Disassembling the fork legs operat ors are the s Jn both fork eps Condition he fork lags have been remrved, a of the lo ak leg in the Clampre sand TOLOSH™ p24 POLED6 — FORK, TRIPLE CLAMP Empty the Devaeh the Info Unclamp ark il wth the fork tut, outer tube from the iprer tube ne inner tube, Drain the ol we the screw cap6 — FORK, TRIPLE CLAMP 18 ring ®. Info The lock ring rer can be appl 2018 = Remove seal ring @ Remove support ring @. h ust fall out af tube ona a n board Y Sire bushing ® 1 - i pois:s.20 6.5 Checking the fork legs Condition he fork lags have a 20186.6 — FORK, TRIPLE CLAMP 19 Charge the fork Measure the run-aut of the inner tube Measure the outside diameter of the inver tube in several places Exernal diameter f iver tube 975, 48.005 wm (1 69193 16981) ry + WF the measured value ig less than the specified value Ru-out of nner ube ©020 nm EOOOTI NT Cha ge the fork leg 2cKs50 op k the euter tude for damane. It Garrage ' found: Change the fork leg, = Gheck the surface of the slicing bushings. IF the dark layer @ is worn = Charge the fork Ifthe measured velue is greater tran the specif ed valve fork eg Preparatory work = Creck the fork lees. (7 p. 18) Main wark =" Clamp in the inner ‘ube with the axe clam Guideline P Use soi js Grease and slide or dust boo a Tobrean TST Info We always charge tne dust boot, ook Install the dust boot with the sean werd I rg, ard support rig. wlip ard spring exparder Fac re down6 FORK, TRIPLE CLAMP Slide on lock ring @, de or seal ring @. 20 Lobrean SLD = Info Mount w ch the sealing ip f2cirg down and the oper s de facing up. Slide on suppor: ring ©. Sand the edges of s ding bushing @ w th 600- drive (SO TPSOBOGOOI I p. 2407 = Renove wasrer ®, Remove steer ng head bearing ®. = Re ce the lower tr clamp with t lamp Main wark = Ob s, check for damage, ard - th the steering stem = Mourt washer @ with the cut-out facing dossnsard Alternative 1 Arew steering head bearing is used. = Mount and tighten the nut ®, Guideline Mat, searing Pe Nm (37 Itt) Case nul wach G01 750501 OF Altomnatve 2 The steering head bearing is used again = fount and tighten the nut ®, greet ¥ Sm GFA6 — FORK, TRIPLE CLAMP 2 Caste nul ore mop aa) = Positir the upper tr ple clamp wh the handlebar sher but do not Lighten it ye. Tie BON (38.4 bor TINn BIE = Plug r conrectors @ ard @, = Plug r conrecters ® and ®.6 — FORK, TRIPLE CLAMP 25 Fold the headligh ask up. = Mourt and sighen Guideline ‘Sereu_ hezdlaht mask We Tne A Mount expanding rivets ® on tot Testall te fork (pl Using a pleste he Tighten screw ®, er tap lightly en the upper triple elem to evo strain Guideline ‘Screw, top Seerng heed G2Nm (38.4 bor 1) Tighten sa Guideline Seren, op wiple damp cE Tele AT Finishing work =. Check thatthe wiring Ireedor of moven = Check ng head bearing lay. (* p. 25) dt pL a ine Danger of accidents Uns ile handlieg from = Adjust the steering Feed bearing play withcut del. = Remove the matoreycle from the werk Info th play 1 the steering head bearing, the bea Proparatory work = Raise the motorcycle with the werk Main wark = Move the handlebar to che sira ght hes ot ron the ciection af trax abe he steering head bear t = Adjust tre play of the steering nese bear ng. (Fp. 26) Move the hardletar to and fo over the artire ove easy over the ene Seer iceable,6 — FORK, TRIPLE CLAMP 26 click positions are naiceable = Adjust the play of the steerng nese bear ng. (Fp. 26) = Check the steering heed bearing and change if necessary Finishing work = Rerrove the motoreyele from the work stand. ¢% p. 1 Preparatory work ~ Raise the “otoreycle withthe work stand. (Fp. 11) Main wark sen serous @, = Loosen serew @ = Tighter nut © withthe special tool until there ro play inthe s ing, Ke Ser ng Fed bearing (501: OOOH p. 240) = Using plastic hammer, tap lightly er the upper triple clamp to = Tighter screw @. Guideline ‘Screw, top Seerng heed CON 8.4 tof ty = Tighter sew @. Guideline Seren, led m7 cE Finishing work = Check the steering heed bearing play. ( p. 251 e the motoreycle from the work stand. ¢® p. 12}7 HANDLEBAR, CONTROLS 2 ‘TA Checking the playinthe twatle cable = Check the throttle gr p for smeoth operation — Move the handlebar tothe ss gh-ahead pusition, Move she th wards and forwards to ascer y the thratle cable wearin Troe cable play Sn ommia02 a e throttle = Adjust the play in the throttle le play does not mee: sp ble. (p27) Danger 200392.10 Danger of poisoning Exhau in urcenseiousness andor des*h = When runring the engine, alvays make sure there is sufficient verve ton, anc do nt startorrun tre engine in an enclosed space w thout an effect ve extaus: extract on svster, — Siar he engine and let ¢run idle, Move the handlebar to ard fro over the entire steering ra The idle speed must More the handlebar to the straighter Push beck le sen tek nut @ = Agius the play she thot cable ty tring adjusting scren ©. videtine rote cable ley asa O12 027 = Tiahten lock @. = Side on sleeve the clutch lever for smooth operation, = Move the hardlebar tothe sa ght-ahe: ascertain the clutch Clutch lever play Td mm 04, O12 in) + Wthecluteh lever = Adjust the clutch cal position. Lightly pull the cluteh lever ions Note Clutch damage If there is no pley on the cl the clutch will beg ta sip = When operating the motoreyele, always check the clutch Fever play = Move the Pardlebar fo and fo over ing range The eloch lever pl ‘Ua nol charge + [the clutch lever play changes = Check the rout ng of the clut7 HANDLEBAR, CONTROLS 28 e Pust tack s nut @. Adjust the play in the cluch level @ by turning adjusting sciew ©.8 SHOCK ABSORBER, SWINGARM 29 8.1 Adjusting the spring preload of the shock absorber Warning. By sangerotaccitents ovat on he susgonson se res can serusy ae side bebavion = Following modifications ride slowly at frst :o get the feel of the new ride bet Info The spring preload defines the in Jal situation of the spring process on the shock atsorber The best spring preload seting ig ach eved when its set for tre neigh of the r der and that of ary bageage and a passenger, thus ersuring 21 Geal compromise between aneuverabil'y ard stabil y — Ture adjusting rng @ to adjust the spring preload. Guideline ‘Spring preload Slander Fall payload Bclicks Hi conch (TTO6SH p. 2417 = Info The spring preload can be set to 20 different postions Preparatory work = Raise the rotor Main nat = Re le with the work stand. (© p. 11) Info Proveet the link fork 2 Ersure thatthe chain and brake | re re na tachments from = Renove fiting @ — Lift the link fork ar sake out the shock absorber @ toward the rear Main wark = Lifs the link fork snd position sheck abseroer @ = Mourt fiting © but do rot tighter ye Guideline Fiting, bottom shock absorber TOE sw (33.2 bot ft)8 SHOCK ABSORBER, SWINGARM 30 = Lift the link fork = Mount and tighten screw . Guideline ‘Screw top shock absorber WoL 25 ONT (35.5 tet = Tighter Pting ®. Guideline iting, bolton shock a WOK 25 Wm (33.2 tot ft) Finishing work = Rerrove the motoreyele from the work stand. (& pL Condition The shock absorber has been removed = Clamp the stack aasorber in the vise usrg soft jaws for pretect en. = Note the position of tre spring preload = Looser adjusting ring @ Hook wrench (11065106 p. 241) = Clamp the stack absorber inte the special too ‘Spring cornpressor (TLAOBOS) I p 242) = Info Use the ring of she special tool with the smallest poss ble inside @ameter. IL mustbe pressed d rectly arto the spring, = Sonpresthe re = Rereve spring eta rer®, = Release te spring Reravet = Remove the spire 85 Instalingthe spring = Mout the spring shack absorber from the spec al tool A The ight col of the spring atthe bottom. Clap the shock absorber into the special tool ‘Spring compressor (ILAOSOS) (ep 2A2) = Info Use the ring of she special tool with the sna must be pressed d actly ara the sper 9. 7 The open eres oppeste the Release she spring. Remave the skack absorker fom the spee’al tel. = Clamp the stack aasarber in the vise using soft jaws for protect on, lest possible inside Gamer, It Mount sori8 SHOCK ABSORBER, SWINGARM 3 Alternative 1 ‘= Tersion tre spring ‘othe prescribed pesitior by turing the adjusting rg ieline Spring preload Sianda Full Hook wrench (TT Altemative 2 i ne Danger of a cushy alte we 29 EXHAUST 32 my ne Danger of buns The ice is driven hot components or forward slighly ‘ove the cable binder, expose the corrector @ of the lambda probe, and = Reove lambada sensor ®, = Remove te culs ©.33 ve tre exhaust man fold toward th frort sition the exhaust manifold nt nuts @ but da ot tighten hem ye Guideline Tit, exvaust Nange (128 Duke} 1 ZN (262 bor it, exhaust any 18 Onna 1 ZN (6.2 or 5 ‘Mount and tighten lamb Guideline Tair Wigs Lubre: Plug in connector @. Secure the cable with the cable pincers,9 EXHAUST a4 Nut, reciator We ERIERAEG) Proparatory work wen = Remove the front spe le Mai = Ri = Remove © Info Bde not mse coward the bottom,9 EXHAUST 35 Main ark =. Position the main slencer = Mount end vighten screw @. Guideline ‘Serou, Tain STeneer ua 2am AT eT = Mount and tighten screw @ with the ‘Séerew main slencer = Mount and tight Guideline ew © with the washers ‘Serou an Sener rg SLR Finishing wark = Fithe front spoler (p46) = Irstal the exhaust manifold. OF p. 310 AIR FILTER 36 1O.4__-Removingthe aifite Note Engine failure Unf lied intake air has @ negative effec: 0 ehicle without an air flr since dust and wit can get into the engine ard resull in inoreased weer he service life af the engi. Proparatory work riferrove the passenger seat. p. 38) = Remove the se Main wark =. Renove st = Pull the air ft tothe sde = Revove ar titer @. =. Clean the air filter box Main mark Pesivon ar flier @, Mount air fter bax tid Info Moke sure he air iter box Id seated comectly, = Moor Guideline air flte bow i tighten screws EN a Tata Finishing work = Mourt tne seat (© p, 38) = Mourt the passenger seat. p. 38)11. FUEL TANK, SEAT, TRIM 3 Danger Fire hazard Fuel s ghly flanirable es or burning cigarettes, and always snitch off tre orgie frst, Be careful that no miparenis, Clear up spilt fuel mrmeciatey scage ifthe ark severed, Si fuel s spilt, especially = Fuel nthe fuel tank Warning Danger of poisoning Fuel spo'sorevs and 2 health hazard — Avoid contact between fuel and skin, ees and clothing. 90 not inhale ately wth water and contact a doctor, Wash affected skin areas mired tacts doctor mmediztely, Change cletrirg that fas come inta carta to regulations and heep it out of tre reach of ds when warm and c he notes or refueling Warning Environmental hazard. I proper handling of fuel is und water, the ground, of the sew ger te the environment em = De not allow fuel to get ito the a = Lift she cover @ of the Tiller cap and inser the ign ian key in the Note Danger of damage Ignition key breskeze sh dow on the filler cap = To the pressure off of the igrtion key tion keys must be replaced = Turn the ignition bey 90° clockwise = Open the Filer cap, = Remove the grtion bey, Warning Fire hazard. Fuel s highly lanmadle, po soraus ard harmful te your health = When closing the filer clothing that came in came contact fuel using soap and water the filler cap. = Push down the Filer cap until the lock engages. Preparatory work = Remove the passenger seat. (7p. 28) Main wark = Reniove seraus @, = Raise the rear of the seat, pull towards the rear, and renow it uowards11. FUEL TANK, SEAT, TRIM 38 11.4 Mounting the seat Main wark =. Flech seat recesses ® 2 = Mourt ard tighten screws 2s @ and loner at the ue Nas Finishing wark = Mourt the passenger seat. 1% p, 38) 11.5 Removing the passenger seat 11.6 Mounting the passenger seat 16 @ on the subframe, ard lower it rte place Warning Danger of accidents. The p from the anchoring if tis not mounted conectly = Alter ne check that i is locked correctly ay pulling u - heck th ns 11.7 Removing the fuel tank cover Danger Fre hazard Fue = Never tes, and always snitch off the engine fist. Be careful the fuel s spil up spilt fuel mediately. = Fuel nth warm ard can escape ifthe tark overt he nates or refueling11. FUEL TANK, SEAT, TRIM 39 Warning Danger of poisoning Fuel s po'sorevs and 2 health haard = Avoid contact between fuel and skin, eyes and clothing, Do rot inhale fuel vapors. If fuel ges into youre ately with water and contact @ docter. Wash affected shin areas med ‘ely wth scap ard water, If felis swallow Cra tact with fuel. Stoe fue in 2 suitable car ster a es, rinse immed facta docior mediately. Crange clotirg that has cone to regulations and heep it out of tre reach of Warning Environmental hazard. Iproper handling of felis @darger to the eneonmert = De not allow fuel to get to the ground water, the ground, oF the sewage sytem, Preparatory work = Remove the passenger seat. (% p, 28) Remove the seat. (€ p. 37) Create the tool (special screw) Four ordinary serevs are needed = Curl sere © to length @, Tena ® a0 nm 1167 = Cute slot nto the top end of she screw, ind dually and replace therm with a spe 01d distorting the fue lark. and tighten spec e. ier another special screw @.11 FUEL TANK, SEAT, TRIM 40 = Remove screw ®. Mount and tighter anather special screw @, = Open the filler cap. p 37) = Renove filer cap ©, Fy — Remove screws © with the washers — Renove seraus ©, = Remove screws @, = Remove cap @ fram the compensating tank — Renove seraus ©,11. FUEL TANK, SEAT, TRIM a Lift the fuel zank cover. = Detach the side c oF beth sides = Push back pose clamp ® = Pulloff she ven: hose = Remove the fuel tank cover = Close the fuel tank with 2 su table plug Danger Fie hazard Fuel s ghly llavwrable fe ergire first, Be careful that no Up spilt fuel me escape ifthe tank s overt 2 he nates or refueling Warning Danger of poisoning Fuel + po sorces and @ health hacer — Avoid contact between fuel and skin, ees and clothing. 90 not inhale ately wth mater and contact a doctor, Wash al lect doctor mmediazely, Crange clo to regulstions and keep it out of tre swallowed, com riser according Warning Environmental hazard. Ieproper handling of fuel is = De net allow fuel tc get ito the ground Main wark =. Remove the slug11. FUEL TANK, SEAT, TRIM 2 Position the fuel tank cover Attach the side cover on both sides = Mourt ane sighten screws @, Guideline Reva nr Sores, Chassis We sna eT — Mourt filer cap © ce then with serene @. a serons © inciv dually and 1 Info HL stways replace the serews rd vidually, or the fuel tank wil di il the screws, be possible 9 0 Thm BTL11. FUEL TANK, SEAT, TRIM “3 = Mount plug@ = Mourt ane sighten screws @ with the washer. Guideline ‘Screw foal tk We TINn eID = Mourt ane sighten screws: Guideline ‘Sereu, fal anki Me in (8.7 AD = Mourt and sighien screws. Guideline ‘Screw, ont seat Dine NG SAT Finishing wark = Mourt tne seat, (* p, 38) = Mourt the passenger sest. IF p. 38) Danger Fire hazard Fuel 9 ghly flavwrable = Never refuel the vetile n fees spilt, csp =r flmes or bucring cigarettes, and elways sm ally on hot veh cle compocents, Clean up spill fuel rmmeiately ff tre engine first. Be = Fual rhe fuel tank expards wher ifthe ark soverfled, See she nates or refueling. Warning Danger of poisoning Fuel po soreus and 5, rinse immedi: aly wth sosp ard water I uel is swallow with fuel, Slow feel in 2 Warning Environmental hazard proper handling of fuel is a darger to the env ronmart = De not alow Fuel to get ito the ground water, the ground, or the sewepe system, Preparatory work — "Remove the passenger seat. (* p, 28) = Remove she seat. (Fp. 37) = Remeve the fuel tank co (9. 38)11. FUEL TANK, SEAT, TRIM 4 Main nark = Renove screws @, = Toke off the holder ©. = Detach eo Dezzeh the fuel line with 2 suitable tool = Push ba Pol off the and rerove the fuel tark11. FUEL TANK, SEAT, TRIM 45 Danger Fire hazard Fuel s ghly flanirable - hi g fuel s pil cle comparents, Clean up spilt fuel rrmecively. = Fuel inthe fuel tank expargs wher warm and can escape ifthe tark ‘ overfilled, See Warning TA vance cf poisoning. Fuels posorausan Sh hazard = Avoid contact between fuel ang skin, eyes and eleshing. 90 ately wth water and contact a doctor, Wash alfecied skin areas tacts doctor mmedizcely, Change cletrirg th has come inta cart to regulations and keep it out of the resch of ch laren. Warning Environmental hazard. [proper hand! = De not alow fuel to get ito th environment of fuel isa darger to und water, the ground, or the som, Main wark = Connee the fue = Pesiton hose clarp @, Remove tool ©, Plug in con ition the fuel tank on the haluer @,11. FUEL TANK, SEAT, TRIM 46 Mourt ane sighten serens @, w tighten sorens @, Guideline EFL conch ui wa Tm BAT Finishing work = Irstal he fuel tank cover. (% p. 41) = Mourt tne seat. (© p, 38) onger seat. (Fp, 38)11. FUEL TANK, SEAT, TRIM a = Mount We tighten screws Guideline Reran rg se ei, NESS i DONT TAIT = Higher screw @, Guideline Reman rg screws, chasse ne DONA aI A Remove sorews @, Remove the front fender Positios the font ferder. Maur Guideline tighten sex ‘Screw front fender Me TIN (G1 FR) Danger Fre hazard Fue mes or burning cigarettes, and always svitch ol snporens. Clear up spilt fuel mrmeciately ‘ds wher warm ard can escape ifthe tark ‘overfill, S fe ergire first, Be careul that no = Fuel in the fuel tank he notes or refueling Warning Danger of poisoning Fuel s po'sarous and = healt — Avoid contact between fuel and skin, eyes and clothing, Do rot inhale fuel v2 ately wth mater and contact 2 doctor. Wash affected shin areas mired tact doctor mmediztely, Crange cloth that has cone into carta lo regulations and keep il out of the reach of cil acer pors, I fuel gets into your eyes, rinse immedi wth scap ard water. If fel 1s swall with fue, Sto fe! i Condition The fuel ‘ank s completely full. Ersure thal the battery vllage does he gnsior sch The diagnostics tools connected drop below11. FUEL TANK, SEAT, TRIM Sout Derzeh the fi Push back Fos re with 2 suiteble tol 1p @ er pull eff the fuel ire Mourt spec al tool @, 48 Pressure testing 0 som Tp 228) Mourt spee al teal © with nozzle ea Testing fox Guideline Minima TOMe5 US eh Sw teh the ignition rol unit"Motranik Bosc Press "Continue Select "Actuator test "Please entr the passwort" Press "Continue" Solect Fuel pump relay function test Press "Contin! Te che KT dagr wth "Continue" Guideline the information page and he actuator test Mex doalion ot acum test [3mm vel pressure wah the filler ca ro hen the fuel pump ac © bar 36 >If the specification is nat rezched: nthe fille cap. (7 p. 37) = Check the tank air vert system, (Check the fuel pressure withthe filler cap open, Foal press When the fuel pump is active Ifthe spes fication snot reached = Check tat the fuel lie el = Change the fuel fe: (p43) = Replace the fuel pun. (© p. jop he "Function test of fue! pump contr" 2 ton, Dsmantle the special to test by pressing uit" but11. FUEL TANK, SEAT, TRIM 49 = Gonneet the fuel Hine and ps = Remove the to Danger Fire hazard Fuel 9 ghly flavwrable 1 oper = Never refuel the mes or burr 5, and always sv fe ergire first, Be careful that no i ‘ot ven cle conparents, Clean up spilt uel mmediately = Fuel she fuel tank expar if the tark s overfiled. See the nates or refueling, Warning Danger of poisoning Fuel spo sorvs and 2 health hazard — Avoid contact between fuel and skin, ees and clothing. Do rot inhale fuel ately with water and contact a doctor. Wash alfecie skin areas mired ately w ths lect doctor mmediately, Ci has come into cartac: with fuel, Stow (vel i lo reguletions and kes Warning Environmental hazard. Improper handing of fuel is a darger to the env ronmrt = Be net allow fuel to get ito the ground water, tre ground, or the sewage system. Preparatory work = Remove the passenger seat. (* p, 28) = Remove she seat. (7 p. 37) = Remove the fuel tank cover. (% p, 38) = Dismount the fuel tank. p. 43) = Drain the Main mark = Toke fuel fier @ out of the holder uel from the fuel k into a suitable co 3018871 Remove hese clamp @ ard pull eff the fuel hose11. FUEL TANK, SEAT, TRIM 50 sition the fue flter Connection @ faces tothe lef = Positian the fuel roses and mount nos = Position hose clans ©. co fuel filter @ ir che holder o1aa Finishing work = Irstall te fuel tark.(% p. 49) = Irstal he fuel tank cover. (& p. 42) = Move! the seat. p, 38) Mourt the passenger sest. p. 38) Danger Fire hazard Fuel sh ehly flee = Never refuel fuel s spilt, esp = Ful he fuel tank exp igarettes, and zluay miporents. Clear up spilt fuel or is wher warm ard can escape ifthe ‘ark s verflled, See the notes or refueling off tre engine fist, Be careful thet no my ee Danger of poisoning Fuel s po-sorcus and = health hazard = Avoid contact between fuel a ately wth mater and contact 2 doctor. Wi lect doctor medi lo regulations and keep it out of hing. Do rot inhale fuel vapors. If fuel ges into your eyes, rinse immed shin areas miredataly wth scap ard water. If fuel 1s svalicu nie into cartact with fuel, Store Warning Environmental hazard Improper handling of fuel is @ danger te the = De not allow fuel to get ito the aroun Preparatory work = Remove the passenger seat. (* p, 38) = Remove the seat. (® p. 37) Remove the fuel tank cover. (& p, 38) = Dismount the fuel tank. (% p.4 = Dain the fuel from the fuel rk into a suitable container. Main ark = Rens 5@, = Remeve the fuel pum with 301939.11 FUEL TANK, SEAT, TRIM 0180, pump with the ns @ ered tighten them di 51 Slat Ter Finishing work = Irstall te fuel tark.(% p. 49) = Testa he fuel tank cov seat. ( p38) = Move! th = Mourt tre p (p42) LU p38)12 WHEELS 52 4124 Cheeking the tie airpressue = Info Low tre a pressure leads to abnorral wear ard overheating of he tre Correct Ure ar pressure ersures optimal rid rg cerfor: ard trax rum tre service life eRe, Front ear Gas Bos Tre ar pressure with passennerul pay Front ps Rear (SZ esi = lie tre air o ions = Correct t Mount the dus: cap, Warning. Danger of accidents Uncontrollable vehicle Farag in the event ofa flat tie = Ie the interest of safety, replace damaged er worn tires immediately Warning Danger of crashing Por vehicle handling dve te different sire tread patterns on front and rear wheels loss of cor‘ol over the vehicle = The froot ard rear wheels must be fitted with tres with sim lar ‘read lems to p Warning Danger af accidents Uncon‘olletle handling characrarstic dus to nan approved andlor non-racem™ended *resiwheals = oniy Ihe eorrespor ding speed index should be used Info Do the type Worn tires ye @ major impact. on the riding behavior of pecially ar wet surfaces we motorcycle = Check the front ard rea ties for cu + Ifthe tres exhibit cuts, run-in obj = Change the tres = Chack the depth ofthe tread rur-in objects ard ether damage or other damage: Info Note local nat onal regulations cancer ng sonia Minimo we2d deh 22 em @ OORT) 1d depth 6 less than the eminrrum permissible depth re te bres Info The tre's date of the manufacture is usually part of the tre markings and is ingicares by the last four dgits of the DOT marking, The fist two digs refer tothe week of manvizccure and last two digits reer to the year of manufas KTM recommends thatthe atthe lates after 5 years, 3 are chenged regardless of the actual weer,12 WHEELS 33 + Mathes more tha years old = Change the tres i ine Danger of accidents Resi.ced braking eff ciancy due to worn orake vise) = Charge the worn brake disols) wthout delay. = Check the thickness ofthe fron: ard reer brake discs al s lo see if confers to messurement @. I places or the disk = Info Wear reduces the th ckness oft @ of the brake disc ake dis in ar Brake dies weer It Ze nm O12 Bem (0.192 95 ig lass than the sei ed value = Change the brake discs, hack the font and rear brake discs fa » I the brake dso shows signs of dara the brake crackirg, and deformation, cracking, or deformation = Changs cs 12.4.1 Removing the front whee! Preparatory work = Raise the metoroycle wit the rear wreel stand. (Fp. 10) = Raise the ‘otereycle with the font wheel stand. p. 10) Main wark = Loosen screw @ and serens ®. © 2bout si turns and press your hand or the serew to push the = Unseren sox ‘wheel spirale out of the axle clap, Remove screw @, Warning Danger of accidents Reduced braking ef ed by damaged brake discs = Always lay the wheel dow in such 2 way thatthe brake dses are not ores. damaged. the wheel spre. Take the font wheel eut of = Hold the fort wheel, withar the fork Info BE be not pull the hand wher the front wheel is eeneved 12.4.2 _ Installing the front whi i rine Danger of accidents Reduced traking efficiency due weil ora = Al beep the brake d ses fee of ol and grease, end clean ther wh brake cleaner wh12 WHEELS Main nark Check wheel be el bearing is dam Change the n and prea 4 ing for damage ard weet zed oF worn lean the Lift the fran The brake linings are in contact wih port sland pL herd on the fork several tres to align iS Wm Ie) Finishing work ake the 12.4.2 Removing the brake disc ofthe front brake Proparatory work bead sand, (Fp. 1 = Paso tre he rear wreel stand. (Fp Rae th fand. (% p. 10) Main wark = Remove screns @. = Rerrove the broke dise 12.4.4 _ Installing the brake disc of the front brake Main wark facing outward ie 7aNm Tectia (22.4 tbs tt) Finishing work = Irstal she front nbel. (© p. 83) = Take the motorcycle off of tre rear weal stand. (% p. 1012 WHEELS 85 12.5 Rear wheel 12.5.1 Removing the rear wheel Preparatory work — "Raise the motorcycle with the rear wreel stand. (Fp Main nark = Remove nul @end the washer. Renove chain adjuster @, = Holding the rear wheel, w hd wh = Push she ear wheel forward 2s far 8s pass spracke Warning Danger of accidents Reduced trahing elect caused by carmaged brake diss = Always lay the te damaged. ses are istemoved 12.5.2 Installing the rear wheel ay ine Danger of accidents Reed. ced brakiny = Alnays keep e brake d ses ‘ne Danger of accidents No braking effect wh = Aller vb rubber dampers. (Fp ing for damage ard wear el bearing is damaged or warn: = Change the support ang swingarm = Irstall the rubber darrper ard rear sp he rear whee! in the swings = Position the rear wheel ov she contact surfaces in = Push the rear wh sprocket12 WHEELS = Pl the rear wheel back and mourt whee Info BH sount the lef = Moun: not @ a = Push the ear wh tiah:er nut @, Guideline 86 Tr order fer the rear wheel be cowecily right chain adjusters rrust be in the save positon relat ve rnarks ®, Tut, rear wheel spindle Was ON (443 ory Finishing work = Teke the meter stand. (7 p 12.5.3 Removing the brake dise ofthe rear brake Proparatory work = Rase ihe rotorey = Remove the rer Main wark = Renove wheel and. p ser20s @, — Remove the brake disc. 1805 12.5.4 Installing the brake dise of the rear brake Main nark n the contact surface of the brake disc = Position the brake dis with the label facing cubward = Mourt and tighten screws ideline rake tise | MB 2a Nm awn Toctiie™ 243 301805. bead sand, ( pI12 WHEELS 3 42.5.5 Checking the chain tension my ee Danger of accidents Dager caused by incor =H the char ings in rar rupture othe eou sprocket or the rer sprocket and bl hain slidirg guard, press the chain upward toward the link in tension Info Hh The upper chain © rust be tau Chavo wear is not 0 yOu should renezt this measurement at different chan posit Chan sensi ba Fm, O28 Tithe chain tension ns = Adjust thea 12.5.6 Adjusting the chain tension a vine Danger of accidents. Darger cau = lithe a ings traci rupture or y powertrain (chain, engine spr ‘par from premature wea i ar and, i Foose, i or darrage the engin, hain tension an Preparatory work = Check the chair tersion. (Fp12 WHEELS 58 Main nark u Tu adjusting soreas © o7 and right maths @. Tre reer ster © are the sae posi an in lato ys even, $0 you should check the seting al diferent Tighter nuts @. ure tha chain adjusters @ are fitted corectly on anjusting sorens @, Nut, rear wheel spindle Wie ON (443 ory 12.5.7 Checking the chain, rear sprocket, and engine sprocket = Chack she rear sprocket and eng re sprocket for nea. If the rear sprocket ang eng) DE: of Se The engine sproc replaced tngere = Shift gear ton ehi®, 15g ST in Ls i o you should renest this measurement at Taaimum aban se elongest [30 ithe distare an the specified = Change t ~ 7 Info CHEK -—--COCD I ed, the ear sprocket and er 123 181920 s arose New chains wear out faster on old, worn spre12 WHEELS 59 = Reno © and © end reer Sh the chain guard aside, the chain sliin hat the chain Ifthe chain siding BOT Pe Nim OF AD BOT PT A Nm Bel Tin Soren, CHAS Sha Ga 12.5.8 Cleaning the chain i ne Danger of accidents i ore = Revo a ie Danger of accidents qi ney the orake ¢ san them wh brake leaner whey12 WHEELS 60 Warning Environmental hazard He ardous subsiarces cause env ronmental damage = Gil, rease, flees, fuel, clearer, brake flu ele., should be disposed af 2s stipulates in ap nits maintenance lean the chain regulanly = Rinse off loose drt witha soft ie ~ old grease remains with cha Char cleaner p = Aller drying, apply chain spray Ghar lube forroad ise 12.5.9 Checking the rear hub rubber dampers Info Proparatory work = Raise th wheel stand. (Fp Main ark =. Check bearing @. If the bear ng is damaged or wor = Change the bearing. Check the rubber dampers @ ofthe reer hub for da re dame hub IF the rubber dampers of the rear hub = Change all rubber dampers in the facing upwards and and tny to rorate the rear spr Info a wheel Emm ©0210 © play @ is larger chan the spec Tied valve = Change ll rubber dempers i the rear hub, Finishing wark = Install she rear whos ake the meter13 WIRING HARNESS, BATTERY 6 413.4 -Removingthe battery Warning Risk of injury Brtlery acid» ‘2p batteries ovt af the reach ofc 1 su able protecive clothing and goggles. = fvoid contact with battery acid and battery gases. 9 he baltery anay from sparks or open Tl he event of skin contact, rinse with large amou' 5 minutes and cortec: a physician i battery gases cause se only i well-vertilated areas, of water, I battery acid gets in the eyes, rinse mith water for at least Preparatory work = Remove the passenger seat. (Fp, 38) = Remove the seat. (* p. 37) Main ark the negative erminal cover @ ‘the battery = Pull beck tre pesit'vecerminal cover ©. = Disconnect the positve cable @ of the battery = Detach rubber vand ©. = Pull the battery up and out of the battery ta Info Never operate the moter Ie bth ‘neal companents and The vehicle is therefore na longer toed artery o without a battery. devices can be damaged. Main ark Position the battery inthe batter Info The battery term nals rust be atthe top rubber band @. = Reconract the pes tv = Position postive term = Connect the = Pos ion the negative terminal cover @, Finishing work = Mourt tne seat, (© p, 38) — Mourt the passenger seat. p, 38) = Set the clock. p. 78)13 WIRING HARNESS, BATTERY 8 133. Disconnecting the negative cable ofthe battery Preparatory work = Remove the passenger seat. p. 28) = Remove the seat. (Fp. 37) Main wark =" Pull back the negative erminal cover @ — Disconnect the negative cable @ of the battery. Main wark =. Connect the Finishing work = Maur! tne seat, (© p, 38) = Mourt the passenger seat. 1% p, 38) = Set the clock. (© p. 78) Warning. Risk of injury. Battery acid and be p batteries out ofthe reach of Se protective clothing and ee = Avoid contact with tattery acid ard batt 9 the battery sway from sparks or open flames. Charge only well ventilated areas Ie the evert of skin contact, rinse wth large amcunts of water. I battery acd gets in tre eyes, rin 9 minutes and contac: @ physician, with water for atleast Warning Environmental hazard The betlery conta elev’ = Be not d scard batteries w ch tre household trash, D sp xe battery in an er Give tre battery to your KTM dealer arto a recycling center that accep's used batleies thal are hanmful te the environmen compatible ma Info TW Even when there is ne load on the loses power stead ly fhe serw.ce life of the battery eile chargire with a high ch IF the charging current ct rough the safety valves, This reduces the battery capac ty. Ifthe betery is depleted fram staring the vehicle repeatedly, che battery must be charged mmediately IF the betiery is le in @ discharged state for an extended period, = will become over-dscharged and he battery. The battery is maintenance-free, which means thatthe a eed te be ehee13 WIRING HARNESS, BATTERY 63 Proparatory work = Sw:ch off all poner corsumers and = Remove the passenger seat. (Fp. 38) = Remove she seat. p. 37) switch off the eng ve. - the battery to avoid damage ta the rot electron Main ark = Correct the ba to the betvery, Sw ch on the battery cherger Bae charger (6BAZS07 40001 You can also use the batary cher bettery, and tery rest potertiel and start peteriel of he ce, you cennct cvercharge the bat Info Neve ron ge the dtxy with a ax rum of 10% of battery rousing 8 — Swich off the charger after charging, Dscannect the battery Guideline The charge ourert, charge an 3 mons Finishing wark = Mourt tne seat, (Fp. 38) = Mlourt tre passenger seet. % p. 38) = Sel the clock (© p76) Condition The batlery must be fully furetianal and complete Proparatory work = Remove the = Rene Main wark = Sart the metorcyele to make checks. (* p. 12 Vv (Charging wita charged. ssenger seat. (F p38) sure the voltage between :he specified poinss sing 90 nL Plus (4)~ Measuring po nt Ground (=) rer 135. 150¥ + IF the disolayed value is less thar the specified value = ch le from the elternator to the voltage le from che voltage reguleter to the wiring Pseness the stator winding of he alternator. p. 201) rer than the specified valve13 WIRING HARNESS, BATTERY 64 1347 Changing the fuses of individual power consumers © Info The fuse bor withthe main fuse ard the fuses ofthe ind vidual po Proparatory work = "Sw ch off ll power consumers and sw e - the passenger seat. p. 38) Main wark =" Open fuse box cover @. = Remove the Guideline Fuse 1-308 Fuse 2- 16 A combinat on instrument Foes 10m Ua mane Fusea~ 15 A grition col alarm system (OPTIONAL) Fuge 5-15 A radiator fan Fuse6- 15 A horn, brake lghi, in seal, high bear, Tow beam, Tight, taillight, Vcense plete lamp Info Ti detective fuse dicated by 2 burresd-ou: fuse wire ®, Warning Fire hazard Used. electrical syster can be cverlaaded ifshe wrorg fuses are ly fses with the prescribes amperage. Mever by-pass or repair rating ory. a a) BOI p. 206) ial he spare fuse in the fuse box so the @ pou = Close the fuse Finishing work = Mourt the is function rg propery nger seat. p. 38),14 BRAKE SYSTEM 65 “144 Cheeking the font brake nips Warning. Danger of accidents Re ficiency caused by worn brake I rings = Change wore breke Inings immediately, Note Danger of accidents Res.ced braking efficiency caused by de ged brake dises = the beake lings are ret c ir time, she steel brake lining carers grind on the brake disc. The braking effect i greatly brake gises are destroyed, Check the brake lin ras regulary Check the brake linings for minimum thickness @. TMinimor tekress @ 1am @ 008 + Ifthe minimum thickness 6 less than specified = Charge the frort brake lings. = hack the brake linings for damage and crack ng + If shere ss wear or lear rg: = Change the frort brake lings. (* p. 65) Warning. Skin tation Brake fl. & can cause skin iitation on cartec = Avoid contact with skin and ayes, and keep out ef the reach of eh laren, le = brake tid Warning Danger of accidents Reduced traking efficiency due to old brake Mui ve clothing and goggles es nto contact withthe eyes, Mus! eyes thoroughly with water and corsul: 2p = Charge the brake fluid of the font andr Warning Danger of accidents Red.ced braking effciency due tail or grea ake according o the sevice schedule, 2.0n he brake dis = Always Keep the brake d ses fre of el and gr Warning Danger ofaesons esc ak gal cen se ose af a poe se igs ase, and clean ther w :h brake cleaner when recessary ~ Bt ngs vel fm access supe tion ena cense, The Warning Environmental hazard Hazardous sub se environmental damage = Oil, grease, filters, Iuel clearer, take fluo, ete, should be disposed of as stinlated ir apo cable regulations Info DH) Avo contact between brake fluid and painted parts. Brak Use only cleen brake tut rsainer14 BRAKE SYSTEM 66 + mounted on the handlebar ‘0 a hor zortel positon Remove breke liniras @, Clean the brake caliper i position and ake sure that ro brake fluid ‘ange the brake lines pas.14 BRAKE SYSTEM 6 = Position springs ®, 7 The artow on the spring ports © = Mount bolts ®, reccior ef trevel Info vate the springs are se hy brake lever until here isa frm pressure por = Gorrecs the brake fluid lave ta level @, Guideline eae Samm (02m Bake fd bors OO SLI — Position the cover with the membrane. Mount ard tighten the sores = Info lean up overflowed lid immediately with water, my ee Danger of accidents Fe [ure of che brake system - is below the MIN nark, this indicates @ or worn-out brake liring de nat cortinue ridrg. my ve Danger of accidents Res ciency due to ad brake fuid = Charge the brake fluid of the frent and reer brake according to tre service schedule = Move the brake fluid reservar mounted on the = Check she brake fu d level in viewer @, IF the brake fluid is below the MINMmarking = Add frort brake flud p67) ay ee Danger of accidents Fs lure of she brake system = Hi the brake uid level Check the brake site below the MIN met, this indicates @ ince ridieg nthe brake sy or worn-out brake lining ay vine Skin tation Brake fl. & can cause skin initation onc = Avoid contact with skin and iaren, = Wear su able protective clothing and gos = Hf brake fluid eves thorougtly with water and aby my ee Danger of accidents Reduced braking eficiency due te old brake fluid = Charge the brake tid of the front and bake according to tre seevice schedule,14 BRAKE SYSTEM 68 Warning Environmental hazard He ardous subsiarces cause env ronmental damage = Gil, rease, flees, fuel, clearer, brake flu ele., should be disposed af 2s stipulates in ap Info parts. Brake fluid att sled con‘ainer = Move the brake fluid reservar mounted or = Renove screus @, = Remove cover @ with rem = Add brake flu d to level @. Sanam Baetea Dora sors TM pe = Pesition the cover» eribvane Mount ard tighten the Info BH ciean up or spilt brake fluid immediately with wa 14.5 Changing the front brake fluid i ere Skin imitation rake fluc can cause skin iriation = Avoid contact with skin and ayes, and keep out ofthe reach of children = Wear su able protective lething and g¢ = Hf brake fluid cores nto contact wit the flush the eves thoroughly with water and corsul: a physic‘ar Warning Environmental hazard Hazardous substarces vtonmental damage = Oil, grease, fltersMuel, clearers, brake flu ete., should bs 4 af a8 stipulated rapa) cable regulations Info Avo contact between brake Muid ard pa Use orlyclezn br parts. Brake fluid attacks pa Move the breke fluid reservar maunted on the handlebar vo a har zartal posi = Cover she painted per = Remove screws @. ver @ with membrare - id brake fluid cut of the bree fluid reserecr using a syringe and fl wh fresh broke ‘uid a BOGTOO Tp 2a) Baked OT a DOT SL Mount the corres Dleeder cover © ftor the special tool set Blee = Connees the bleed ng 201825.14 BRAKE SYSTEM 68 =. Open shutoff Info BD Folicu the operating structions ofthe bleeding dey ce. = Ersure that the filling pressure is set cn pressure gauge @, Correct the filling res: sure on the pressure regulator @ if rec Guideline Filling pressure 225 bar 29. 36 ps) ap @ ofthe bleeder rll ofthe brake caliper. Connect the hose of Blending device 1 STATO p. PBA = Open tl screw @ by approximately ore half tur = Info Drain until fresh brake flu without bubbles, erges from the hose of the bleeder bot = Tighten the = Close shutof val = Open the ble der scren Info Ths prevents cverfiling ofthe brake fluid reservo Remove the hove cf the bal Guideline Lew & Brake fd DOT 41001 = Positan cover th the seren Info BH Giean up ovettiowed or spit brake fluid immediately with we = Oreck Warning. Danger of accidents Re A = ob Note Danger of accidents iuced braking efficiency caused by den caused by worn brake lings rrr brake linings im-reditaly. 2ged brake dises brake lining carers grind on the brake . The braking =. hack the brake linings for rinimur thickness @. Minin me Elam @ 008 Ta) + Ifthe minimum thickness ‘ less than specified = Charge the rear brake linirgs. (% p. 70) = Check the brake linings for damage and ers © WFehere s weer or tearing: = Change the wear brake gs. p. 70)14 BRAKE SYSTEM 70 A Warning. Skin tation Brake fk & ca = Avoid contact with skin and ay = Wear su sable pro’ zach of chiluren, = Hf brake fluid cores nto contact withthe eves Warning flush the eves thoroughly with water and corsul: a physic‘ar Danger of accidents Reduced braking eficiency due te old brake fluid = Charge the brake fluid of the frent and reer brake according to tre service schedule Warning 1 grease ont Danger of accidents Reduced braking af ion he Always keep the brake d's free cf ol and grease, and clean them wh brake cleaner when Warning Danger of accidents Pos 1 braking eff cien = Breke linings avaiable frem accessowy suppl cl tested ard approved for use en KTM vehick tion and friction factr of the brake linings and therefore the brake power car ffer cons derably fromthe o brake linings, I brake linings nee that they corny wh nal /cense, The veh cle no longer correspands te the corciton at delivery, and sh lid Warning Environmental hazard Hazardous substarces cause ene onsnental ase, Flters fel, ce ers, brake flue, ete. s culd be disposed af 2s stipulates in apa! Info Avo contact between brake luid ard pa id fom 2 se = Push the trake caliper toward the brake @'sc wth your hand to push back the brake pistor; ensure that brake Tluid does ro: curs out ofthe brake uid reservar, remov ing tif toes breke lings @ brake cal14 BRAKE SYSTEM ” = Position brake lin ngs @, = Moun: bolts, ing clips ©, = Operate she foo: bra the brake o se and = Adjust the o ua Mount the soren Info BH Giesn up ovettiowed or spit brake fluid immediately with w mee Danger of accidents Broke eystem ‘eilre = Hite oveth is no free tr 2. dius = Dsvonnect saring @, he feat brake lever back and forth between the erd stop and she contact‘ the feat brake cylinder psten ar tice revel @. Guideline Free ravel at foot brake [ever Za ommie 02a 4 = Adjust the tee i = Recanrac spring @,14 BRAKE SYSTEM n Warning. By sangerotaccitentsexche ster ii =H there is no fee travel oth ‘overheating. Adjust the free a pressure builds up on the ear orake creult, The rear brake can fon: brake lever accercing “0 spec ficaiors, = Desvonnect saring @, = Release nut @ ard use screw © to aejust the specif ed fh Guideline Free wravel at Toot by ele 3 smn Info B the rani f adjustment isl ited, = Hold sere @ end tighten nut ©, = fectach spring @ my Ye Danger of accidents Fe [ure of che brake system — Ifthe brake fluid level fells below the MIN mark, this indicates @ leakage che brake system or worn-out brake I rings Check the brake system and cp not cartinue ridirg, Warning WS cancer ot accidents Res.ced broking efficiency de too brake ui brake according tc tre sevice schedule = Oharge the brake tld of the ent andr — Stand she vehicle varie = Check the brake flu level inthe brake tuid reserva + Ifthe flud level reaches theMINmark @: = Add rear take fluid. (% p. 73)14 BRAKE SYSTEM 3 1441 Adding rear brake fui Warning. By sangerotaccitens Fs ure of te eke sistem = lithe brake uid level (Check she brake is below the MIN mark, this indicates 2 leakage inthe brake system or worn-out brake | sings stem and de not cortinue riding. Warning By skinistsion rte fee can ease skin tation en co" = Avoid contact with skin and ayes, and keep out ef the reach Se protective clothing and = I brake tid corres nto contact wit the eyes, tush Warning Danger of accidents can mmes ately to old brake Tui. = Gharge the brake fluid of the ent nd re Aa ge ain brake according tc tre sevice schedule Environmental hazard Hazardous sub = oil, se envionment 2, fliers, fuel, leavers, brake fluo, etc, should be disposed af as stipulated appl cable ions, Info Avo contact between brake luid ard paintes parts. Brak Use arly clean brake fluid from a sealed corvaner uid ate 1 the vehicle uorig = Remove seraw cay @ with membrane @, = Adg trake flud to level @. Brake fd DOT ST OOT S.1 I p PSO) — Refit screw cap with menbrare. Info BE clean up overtioned or silt bra with water Warning. Skin tation Brake fl. & can cause skin iitation o = Avoid contact with skin and eyes, and keep out ef the reach of eh laren. Weer su able prot hing and gos = I brake fuid corres nto contact withthe ayes, flush the eves thoroughly with water and consul: a physic'an imme ately Warning Environmental hazard Hezardo.s substan se env ronmental derage = Gil, ease, filters, Muel clearers, bake flu, elc., should be disposed of as stipulated 9 apoleable ions, = Info ‘hyo.d contact between breke fluid ard pated parts, Brake fluid attacks paint! Use arly clean brake fluid from a sealed corvainer14 BRAKE SYSTEM ” he painted par Remove serew can @ with membrare Draw the old brake fluid out ofthe brake fluid fresh brake ‘uid Bleed syringe OSZONBDOOO Brake fiuid DOT 47 OOT SL voir using a syringe and [wth 1 @ thor thes Mount the corresponding tleeder cil tool set Bleeds 0250 (Connect the bleed ng Bleeding device DaSOISTOON I p 3A Open shutoff = Info Follow the operating nsiructons ofthe bleeding dey ce. Eroure thatthe fil sueon (rep Guideline Fil he Filing Pull off dust Bede Open bleeder screw © by approximately ore half turn OTSIOON ep aaa) Info until wthout bub sh brake flu erges from the hose of the bleeder bot Tighten the Bleeder seren Close shut-off val Open the bie gain unl re more brake fluid emer Info HL Ths prevents overfillng of the brake fluid a ion the bleeder screa Renove the hose ofthe bleeder battle, tach che dust bleeder Correct the tree Brake fold DOT 41 007 Relit screw cap with membrane Info lean up lid immediately with water, brake lever fora frm pressure port.15 LIGHTING SYSTEM, INSTRUMENTS 5 © Info Make the country Ug. Condition The ignitan so he motorcycle s stationary. = Press the MODE but:or briefly and repestedly until ODO 2ppeers on the display. = Press the MODE button for 8 - 20 seconds {he d'splay changes from krvh tomph or fom mph te kh Condition The gnitan son. The motorcycle is stationary = Press the MODE bu!:or tietly and = Press the MODE buttar for 8 - 20 second: The W splay RPM appears jccly unt TRIP 2 Info The ergire speed can be set at intervals of 60 RPM 1s the eng.re spoed above wich the shift warning flash = Sel the speed with che MODE and SET buttons = Info The MODE but: The SET button oF = De not activate the two buttons fo 7 The dsplay RPM 1 goes out and the se speed is stored Info Upon delivery, the speed of RPM 1 is set to 10000, Condition The ignition on The metoreycle = Press the MODE butzor briefly and repeatedly unil TRIP 2 appears on the display = Press the SET button for 5 - 10 seconds ¥ RPM 22ppcers, igre speed can be set at intervals of $0 RPM 215 1 2 fe nbieh the sh Te arn light lights up con: stant, The speedRPIA 2 rust aba bw higher than the speed RPM 1 = Sel the speed withthe MODE and SET buttons15 LIGHTING SYSTEM, INSTRUMENTS 16 Info Bh Themove but:on increases the valve The SETbutton decreases the value vate the tne buttons fe ord, prox. 15 3 pe sstore: aut ane the Condition he ignitor son, The motoreycle is stationary = Press the MODE bu!:ortriefly and repeatecly unt O00: Press the MODE 2nd SET buttons for 5~ 10 seconds, 7 The ime display bag ns to flash Sel the hours display using the MODE button, = Sei she m nutes display using the SET bution Press the MODE 2nd SET buttons for 5 10 seconds Y Thesime s se ars on the display Condition he ignitor sen. he engine s switched af The motorcycle is stationary he SET button fer more thar Position the vehicle upright on a hor zortal surface in font of leh 2 mark atthe height ofthe cer‘er of the low bean headligh = Make arother mark at 2 6 stance ® urder the fist ark Guideline Distance © inl = Position the veh he low beam Guideline 0726-1 Dista m6 A ertcally at distr ~The rder, with luggege end passenger f applicable, now mounts the moto = Chock the nezolight setting The ghi-dark boundary aust Te ead is realy io operate with therrder noun ger applicable15 LIGHTING SYSTEM, INSTRUMENTS ” Main nark =. Revove expanding Five's ©, Renove sures ®@, = ut sl ght mask slightly and sw ng forward urn eounterciock = Fold Mourt ano uidelin adlight rrask up. ren scrons @, esalaht rash We TINn BI Mount expanding rivets Finishing work =. Check the readlight setsing. (F p. 76)15 LIGHTING SYSTEM, INSTRUMENTS 7% 15.8 Changing the parking light bulb Note Damage to reflecior Recivced brightness the ell Clean she lamp ard keep an the lamp will evaporate due to the before ‘mount rg Preparatory work = Swch off all poner corsumers and switch off the ergire Main ark = Renew ing rve's @. ask sighlly ard owing fon = Renove si = Take off cover @, et with lamp © out of the bracke - bul - 2 new Ighe Bulb nthe socket Parking Wart (WSWSocKe W2. 119-60) (™ ph = Carefully positon the socket with bulb @ into tre bracke: in the headl gr15 LIGHTING SYSTEM, INSTRUMENTS 1 sition cover ©, = Mourt and tighten sa = Fold the headligh: mask up Mourt ang tighten sorens @, videlin rg 15.9 Changing the headlight bulb Note Damage to reflector - he lamp wil evap mounting feduced brightness fe due tothe heat ard b the reflector, Cle Preparatory work = "Sw ch off all power consumers and switch off the ergire exparcing screws ask sighlly ard owing forward15 LIGHTING SYSTEM, INSTRUMENTS 80 Fr fe bulb in the headlight hous, (Fp. 206) the bayonet lugs teh into the sls, Ne TI Wn (BERD ction ng propery16 ENGINE at 16.1 Removingtheengine Preparatory work = Raise the metoroycle wit the rear wreel stand. (© p. 10) = Remove the front spo ler. (Fp. 46) = Remove the passenger seat. (* p, 38) = Remove she seat. (© p. 37) = Deven alive cable ofthe battery ( p = Dre'n the coolant. (© p, 193) = Remove the exhaust manifold. ( p. 32) Main ark = Push back the whber cap. = Renove nut @ wth washers. = Heng the le ore side, Berd up the lock waster @, Devzch the clutch cable Detach com Pust back tese clap ©. Pull off she vent hose = Pull off spark plug eon16 ENGINE = Renove chain adjust 82 engine sprockel Remove sorews © and take aff the lock washer = Push the rear wheel inte the foremest positon Pll the engine sprecke: eff of the courtershaft and remove t16 ENGINE16 ENGINE a4 5 and fic using th SOOT p27 gains falling ver Preparatory work = Rase the engine onto the special tool and Fx SOOO pea Floor jack atechrvent (750290)16 ENGINE 85 Main wark =" Position she engine the frare Info ich lever @, ass tant for this step. Frame and attachments from dam = Position the ground wie ®, = Mourt fiting © but do rot tighter ye Guideline Fin Somtine bracket Io WENT (33.5 tof ft) Mourt fiting ® but do rot tighter ye Guideline Fiting, engine mounting bracket uO 7 Ie 10 — Rerrove the Moor jack with the special took Flcor jack atechrvent| no post = Mount the rad ator p pe with the O-ring = Mourt ane sighten screns ®, Guideline fora ny Serene, Chass TON TTT = Mount the radiator hose on hose clamp @,16 ENGINE 86 1 hese, carp @. Guideline Seren, eve Gear on ame 1 7 et Mount ang sghten fting @. Guideline T tng, engine wounng rachel aD 7 ibe Tighter fating ® and @. videtine F ting, engine wouning brachel 10 7 Tet) Position the throttle valve bady in the intake flange Tighten hose clarrp ®. fox it with cable binders16 ENGINE Mount and tighten nut @ withthe washer videline 87 ing rule, chassis anak the rubber cap Moun Gvidel nd tighten screw ®, We Tr Nm Biot) Totes 24a ito Pull the rea Mourt chai adjuster ®, Mount and tighten nut @ with the washer I 0 chain and slide ara right chain adjusters rus’ mats, Mut, rear wheal spindle MIS im (443 ory Position tre 1 7 Tee Position the engine sprocke Mourt and sigh:en screws ®. Guideline ne 1 7 Tee Mount and tighten screw ®, Tee)16 ENGINE 88 Mount spark plug connecter @, Mount the vent hose = Position hse clarp ®, = Plugin eon) Attach the cluten cable, Secure the le wth lock washer ®, Mount and tighten nut © with the washers, Guideline Re Fens, crass WB Sin Ie — Position the rubber cap = Position the cable ard fx it with ers, = Ren ergine with the O-ring from the the ol filler plu over and fll up wth a Engine ot THOTLOSa) | Exteel Srper ature: 0. 80°C (32129771 Fvanal emne2 tures =20.. 40°C (4. Loa) Iestall and tighten the ol filler plug with O-ring, Finishing work = Irstal te exhaust manifold. (7 p. 33) = Reconnect the le of the battery (7 p. 62) cat16 ENGINE as = Sel the clock (* p76) = Mourt tne seat. (% p, 38) — Mourt the passenger seat. 1% p, 38) = Toke the motorcycle off of the rear wheel stand, (* p. 10) = Filles the "1, © p, 193) short test re = Read out the fal: memary using the KTM diagrostes tool =. Check she engine for leakage = Check the engine ol level. (€ p. 197), (wp. 195) 16.3.1 Preparations (725 Duke) = Mount special tools @ ard @ on the Engine fring arm (G01 250020000 p. 238) Engine faxing arm (90129002050)(% p. 237) sembly = Info Have ar assistant Felp you or use 16.3.3 Removing the chain securing gui 16.3.2 Draining the engine oil (125 Duke) = Remove cil drain plug@ with the O-rrg, = Renove oll soen @ with the O-ring = Gonpletely dian the engine oll ide (125 Duke) Remove scraus @, = Toke off the chain securing guide16 ENGINE 16.3.4 Removing the valve cover (125 Duke) - 1: 16.3.5 Removing the spark plug (125 Duke) 16.3.6 Removing the clutch cover (125 Duke) = Renove 6 = Renove sere 4 seth 9016 ENGINE a 16.3.7 Setting the engine to ignition top dead center (125 Duke) Plus®, = Remove = Tun the crankshaft clockwise urtl markings @ align with ead Galle nal wrench; > drive (SO TPSOPTOOOI IT p 2357 f the cylinder 7 Wearkirgs @ and @ alu 16.3.8 Removing the starter motor (125 Duke) = Remove = Toke of the st 16.3.9 Removing the timing chain tensioner (125 Duke) cre @ with the Or = Renan 2oc010-1016 ENGINE S 16.3.10 Removing the camshaft (125 Duke) 163.11 92 Turn the timing chain tensioner sex 7 The timing chair tersioner is locked. R Reve tiring oner withthe gaske! 15 © fro the sit beer Release ser Rereve the Remove domel cde tothe inside end remove them bee Removing the cylinder head (125 Duke) Renove surews @,16 ENGINE 3 r and remove th linder head gasket ©. 6® Push the ey! rer upward Info BP Push the cv Upward only f 1 removal ofthe piston pin Remove piston ain retarer @, = Remove she piston pi. it = Push the pi Info Hac Ss f2cuited on the cylinder and the piston, you can le piston in the eyinder = Toke off cylinder base gasket ®.16 ENGINE 4 ul timing chain @, = Info the time char ‘sto be reusee, mark the direction eft timing chain tens eng ral from abo 16.3.13 Removing the water pump wheel (125 Duke) = Rene = Re mrp cover with the gasket aing ors @ = Lock al tool ©, lich hub and primary a eS SOBL TOON pO v2 nut © with west16 ENGINE 16.3.14 Removing the alternator cover (125 Duke) = Remove se te eluich hub and pr mary gear using special tool @, gent (90179081 100) tp. 2A) © witht ook Mount spacial tool @, Pres Tor orankahen (901250. = Mourt spec al tool @ or the = Info handed = Hold gh using the special Erector (901290090 Top — Remove the special tcl Pr Tor cranbahen (BOL2SDEOOOOI = Remove the spre washer.16 ENGINE 96 16.3.16 Removing the starter drive (125 Duke) = Renove st = Hens pulse generator tc ore side = Renove freenhe! HT toraue liner @, 1 tartar idler gear @ rive whee! (125 Duke) = Lock the a Jer eluich hub and primary gear using special too16 ENGINE 7 Remove nut @ wth w ren Ve a Gate nut a 2000 p. 288) Remove screw @ with th Renove balanc: Tobe oth Rerove the ne balancer shat (125 Duke) Re’ rest © end sake of she gear pos tion sersor. Remove contac: pin ard16 ENGINE 16.3.19 Removing the spacer (125 Duke) © of the covrterstal Re Gear segment (90125087 oa) = Mourt special tool ©, Holding spanver Olea Ta o00I Tp. OSE) id tre inner cluteh hut 2 nut @ w al tool Castle nu rp 2) Info I handed t = Remove the special tool Hotaing s 1290120001 1 p. 238), - inner clutch hub with the cluteh dies, ser usually sticks to che inner clutch hub, lich hub and primary gear using special tool a seamen (OO 12ON = Rerove nut © wih west Castle nut wrench 1 arve aif outer clutch hub @,16 ENGINE 16.3.21 Removing the primary gear (125 Duke) = Remeve tim ng chair sp = Take off pemary gear, il purp gear @. 9816 ENGINE Duke) = Push siding plate with the washer ing (125 Duke) 16.3.26 Removing the ol filter (125 Duke) Remove st = Remove the 0 fter co ver @ to 100 anu ©, Remove shift shaft © ay from shift drum locating @ andl cake off the shift drum her withthe washers © withthe16 ENGINE 101 we Fxing arm a tool, a for crane Mount s Pressir Bo mA Mourt spee al tool © with su able sr aparal rg (ool GOL SOEBOOON™ p. 240) Info Use the dil hole me Pull off the = Info Don16 ENGINE = Renove dowels ®, = Reniove the ergine 163.28 Removing the shift ils (125 Duke) — Reeve shi 2! © together = enove sit al @, hr upper spring and the 16.3.29 Removing the shift drum (125 Duke) = Swng shift forks @ = Remove shit crm @ side, 16.3.0 Removing the shift forks (125 Duke) Remove shift forks @, 16.3.31 Removing the transmission shafts (125 Duke) = Pull both trersmission shafts @ out ofthe bearing seats together16 ENGINE 103 16.3.32 Removing the balancer shaft (125 Duke) 16.3.33 Removing the crankshaft (125 Duke) Mount spec al tool @, P oof th = Press ov: the erarksrall ito = Mount special tools @ ard @ on Engine fang arm (9012 One 5 Zea Engine fring ae (3 oe p aa Exgine assembly Sard (122: HOTOOOH Sp. 236) = Mount th n special = Info Have ar assistant help you 16.3.35 Draining the engine oil (200 Duke) = Remove oil dain plug @ with the O-rrg,16 ENGINE 16.3.36 Removing the chain securing guide (200 Duke) = Remove se 16.3.38 Removing the spark plug (200 Duke) = Remeve the sing guide k plug using spec al tool @. 104 ‘Spark plug wrench 77 OOO pa 16.3.39 Removing the clutch cover (200 Duke) eo = Remove sera forward hth16 ENGINE 105 = Renove dowels @. = Take off clutch cover gasket © op dead center (200 Duke) plug @ = Turn she crankshaft clockwise uril rarkirgs@ align wth ead Galle nal wrench; > drive (SOTPSOP TODS p 2357 7 Markirgs @ and @ align 16.3.41 Removing the starter motor (200 Duke) = Remove se16 ENGINE 106 16.342. Removing the timing chain tensioner (200 Duke) - Rs © wity the Org 16.3.43 Imig chain tensioner sox timing chain tersi clockwi rr is looked. tiring oner withthe gaske! 15 @ from *he ou Rereve the cashaft beer Remove der de te the inside end remove ther, bee Renove intake camshaft @.16 ENGINE 107 16.3.44 Removing the cylinder head (200 Duke) = Renove sere and remove the r fF the cylinder 60 rasket ©, — Remeve tim rg chair guide ral @, — Push the ey ner upward Info Pust the upward only fe lla reraval ofthe piston pi. = Revove pistor ain retarer @, = Remove the piston pin = Info Ira other work re piston in the evinder nd the piston you can le16 ENGINE 108 iming chain tens ong rail from above 16.3.46 Removing the water pump wheel (200 Duke) = Remove se eter pump cover withthe gas at = Remove locating ors®. outer clutch hub and primary g a waren 0129081100 pA) 8 nut @ with ©.16 ENGINE 16.3.47 Removing the alteinator cover (200 Duke) = Remove se te eluich hub and pr mary gear using special tool @, 108 gent (90179081 100) tp. 2A) © witht ook Mount spacial tool @, Pres Tor orankahen (901250. = Mourt spec al tool @ or the = Info handed = Hold gh using the special Erector (901290090 Top — Remove the special tcl Pr Tor cranbahen (BOL2SDEOOOOI = Remove the spre washer.16 ENGINE 110 16.3.49_ Removing the starter drive (200 Duke) Ferg pulse generator tc ore side = Renove freenhe! 1 1 tartar idler gear @ 16.3.50 Removing the balancer shaft drive wheel (200 Duke) = Lock the a Jer eluich hub and primary gear using special too16 ENGINE = Remove nut @ wins m1 Castle nut hi Te dive (OID © with the 16.351 Removing the gear position se = Renove balancer — Take off drive wher pear @ wi @ of the baler sor (200 Duke) = Remove contact pin © ard :he con! par postion sensor16 ENGINE 16.3.52 Removing the spacer (200 Duke) © of the covrterstal 112 Re (eoi2s0aT oa) Mourt spee al tool @, Holding spanver Olea Ta o00I Tp. OSE) id tre inner cluteh hut 2 nut @ w al tool Castle nu rp 2) Info I handed t Remove the special tool Hotaing s 1290120001 1 p. 238), inner clutch hub with the cluteh dies, ser usually sticks to che inner clutch hub, lich hub and primary gear using special tool a seamen (OO 12ON Remove nut © wh west Castle nut wrench 1 arve aif outer clutch hub @,16 ENGINE 16.3.54 Removing the primary gear (200 Duke) = Re gchar sprocket @, Take off prmary gear @, Rennove sp Tek ke) = Remove lock rn = Toke off cl pur 11316 ENGINE "4 = Remove st = Tale off ol ure ®. Remove donels 16.3.56 Removing the shift shaft (200 Duke) ‘om the sh ft drum locating @, Remove shift ing (200 Duke) drum locating @ end sake off the shift drum with the 16.3.59 Removing the ol filter (200 Duke) Remove st = Rernove the 0 fer cover @ withthe O-ring,16 ENGINE = Renow screus ©. © out of th Pull al filter 115 Gireip pies reverse pay fe iting of th a wool @, we Fxing arm Mourt so Pre 2 sre for crandshat [901 2SUZOOUT Ip Mourt spee'al tool @ with su sable sere eqaralng 10a) Info Use the dil hole merved w sh 901, Pull off the section ofthe engine case by st Info Don w angire case seco The he man shaft usual16 ENGINE 116 6® = Remove the engine case gaske 16.3.61 Removing the shift rails (200 Duke) = Renove shift 12 @ to = Rernove shi ral, her with upper speieg and the lower spr 16.3.62 Removing the shift drum (200 Duke) = Swng shift ferks @ to ore side = Remove shit crm @ Remove shift forks @, 16.3.64 Removing the transmission shafts (200 Duke) = ul both trersmssion shafts @ ov16 ENGINE "7 16.3.65 Removing the balancer shaft (200 Duke) Reva 16.3.66 Removing the crankshaft (200 Duke) = Mourt 1c a too! @, = Press ov: the erarksrall 16.4 Work on individual parts 16.4.1 Work on the left section of the engine case (125 Duke) = Remove alld Renove lock ring @. = Remove shaft seal ring ® of the shift shat = Renoveol et ®. = Reeve any sealing mass remnants ard clean the er = Worn the eng, Guideline oden plate. This will Info BE try bearings that remain gine case secticn must be removed using ngs rio the bear ng seats ofthe hot engine case sec a dit to push the bearing all the way to thet i's Mus Info When pres prever' damage Only press the bearings inva the outer ring, otherwise, the bearings will be maged when shey ae pressed in ing the bearing ir, ensute shat the engine case section 1s lel 20 fer the engin ion thatthe bear ngs ar firmly seated = Info IW the bearings are rot fe ravate i the engine case renewed, aller cooling, its lke that they wil warm, In ths case, the engine case must b = Mourt t16 ENGINE 18 = Press in shaft seal ring @ of the sh ft shaft with she open side Facing in ivi flush = Press in shaft seal ring @ of the countersha withthe enen side facing irward so that iis Mus Mourt lock ring @ 7 Tectia Ga ite) eck that it's cleo i through th 16.4.2 Work on the right section of th remnants ard clean the erg 2cton in an oven, and, if necessary, use @ that i's Mus thal the engi jon isk Only press the bearings inv the outer ring maged when chey ae pressed in otherw se, the bearings will be = Aller he e ion has that sh ngs ae firmly Info Bie she bearings ate not firmly seated af rovate the ergine case when warm. In th s renewed. Maur the coal = Position all bearing leek = Mourt ane tighten screws: Guideli ‘Screw, bearngrelarer | We Tm Totes 7a 9 ith) eck thal = Blow compressed air through th 16.4.3 Changing the shaft seal ring ofthe water pump (125 Duke) ©. = Remove lock rn16 ENGINE Re 18 vove shett seal ring @, ith the open side facing ward 01st Press shat ing inward Ta nrg ae 16.4.4 Removing the main bearing (125 Duke) = Mourt se Mourt lock ring @, Pras Tig Siaave (OOIPOOTSOOO p25) = Mourt special too! @, Puller viv = Tension the ha = Pull off the man a16 ENGINE 120 = Clamp the crenkshat ai tool ®, Pressure sorea for Graken = Mourt = Mourt spec al tool @, Piller for main bearing (S0L2S01 8000) p, 238), 7 Holaing ans @ engage v he outer bearing race = Tensicn the Faldirg arms by surring nut ©. = Pull 16.4.5 Checking the radial play of the lower conrod bearing (125 Duke) = Clamp the connecting rod with sot jes sion ‘h Insert she Plastigauge cleara lothen gauge © offse: by Plastigauge Weasur re Stipe (O00250120 od be sion the deli Nut, conrad Bearing i Mount and cr Grr tet ty Info Bde not mist mpare Plastigauge clearance gous with the specficat ons on the packaging, deli Conect ng rod radial play of Ione cored bearing New cond Tint = Info The width of the Plastigauge: play16 ENGINE 16.4.6 Changing the conrod beating (125 Duke) = Clamp the con = Remove the culs @. = Revove tre Measure she deli 121 cling rod with sft jon 4 crankshaft, Remove the bearing shells ark pin diemeter Crankshaft danster crank pn (Granksha cass ical vA Grankshak: cass tieation B ia pl = Oil tre bear = Positian the corre = Mour: ideline bearing co hten nuts @, fication is indicat of the lower earnod ber rg to marking. Tt, oonred Bearing Wr Tee ft) @16 ENGINE 12 16.4.7 Changing the balancer shaft bearing (125 Duke) Mount special tools @, rib eal, bala alencer sheft wth spec al tool @ inthe press, ie 7 7azaORDOOOI I p27 he bearing, = Press on Remove the special to shaft bearing witha su able tool aft bear rib eal, bala DO he 16.4.8 Changing the camshaft bearing (125 Duke) Clamp the cemsrat: in a vise using soft = © Info 1 Pro:ect:he outer car of the camshaft agairst damage with adhesive tap = Mourt spec al tool Holding spanner = Ren On p Be) = Renove camshaft gear @,16 ENGINE 123 “0, Remeve the spacer ©, Take off beer ng @. = Oil the new bearing and s Toby cated with engine oF = Mourt the spacer Mount carshatt gear ©. F Holding lug @ engages i Mount eng tighten screw ®, he recess ofthe camshalt Guideline en a Toctive® 243 sprork = Remove the special tcl o1ste Holding se T2BOTZO0O Fp = Repeat these steps on the second 16.4.9 Work on the cylinder head (125 Duke) = Foidcam ke = Take she sh ms @ out of the valve spring retziners and ay them <0 on i ther rarmel buil-n positon Tnsert Tor vah keys rngreta rer @. vale sp ing, valve stem e the valve into 2 box according to (Cheek the eyinder head. Op. 124) Mourt valve spring seat @ and the new valve Mourt the v spring. Mount valve spring resainer ©.16 ENGINE eo B 124 pecial 100 ia Tisert for valve sprng lever {9012506000011 p. 2477 Mount valve keys, Relex the valve spring Info When mounting the check that they are erect: prefer ly, fix the ha little grease, al Place shir into the valve so Hlation postion ng retainers according tothe ins 16.4.10 Checking the cylinder head (125 Duke) Ovi the Limit plug gauge (9012902600011 p. 229), Check vaive gu a ecial too 8 valves sparkplug thread ard the valve sé for damage and IH there s weer or teznrg: = Change tne eyinder head al too dge and th Fesler gauge (09020001 lOOLI™ p. 225), Cylinder eal ng a head Oso Tithe edvalue we eyinder bead = Check seal ng seat @ of tte wal @ r VWehe seal Evans 50, 0.0433 in) scene. IF the mes "ro equal the specif ed value = Machine = Blow compressed air through all oll holes and check tha ear 16.4.1 Checking/measuring the cylinder (125 Duke) Check Jind bearing surface for damage. sing surface is damaged he cylinder and p ste, linder diameter a he @ ard © axes using 2 several places deli Gylinder = bore Gameter16 ENGINE 125 = Ghack the sealing the special co Ifthe measured value does ro: equal the specif ed valve = Change the cylinder and pis! 16.4.12 Checking the piston ring end gap (125 Duke) = Re = Pt ing ror th ce the pston ring in the cylinder and align wth the p ston. deli Under the upper edge of We oylinder eed gap © with the special ta Ting end fa 01s. Compression rng GaNZSOATIOON ep Ifthe ard gap is more tran the specified valve reck’neasure the cylinder. (© p. 124] Hinder a e the piston ring ars wihi = Mount the 9 ion nrg with che marking facing toward the piston heed. 164.13 Checking/measuring the piston (125 Duke) k he psston bearing surface for demae. he pistar bearing surface is damaged har thet t he piston ring is si n the piston ring er n ard, ihre e te pl * Tp Use ar od piston ri a clean the piston ring ston rings fo the pisten rg is dan = Chan the piston ring = Info Mount the piston ring wth the marking f =. Check the p ston pin ford IF the piston pr has strorg discoloration gns cf ner: = Change the piston pin = Insert thep en — Change the correcting rag and the p on pin into the connecting roe and 1° pin bearing has too much play16 ENGINE 126 a 16.4.14 Checking the piston/cylinder mounting clearance (125 Duke) Checkimeas he cylinder. (Fp =. The piston rmirus the piston ciamecer Guideline inder mount ng clearance isthe result of the cyl der bere darveter Pistonieyinder -maurtne ele @e Tew condition 201560 Tat 164.15 Checking the oil pump (125 Duke) = With special to o and between the external o:or eI ay between the in il pump ho = Check axial play @ of the cil pump TOTES ET . .| f= cs) = oa en 4 on o Play 0.20 mm (0.0038. rapes ff i eee = ci ay. wal play Oo, O25 mir 0.0039, 198 in) specifica = Change the ail pump eng, pring @. he length of spring @, the oil pump housrg, iT pressure pring length 2500 WHT TF the measured length is = Charge the spre, = Check control piston © for dan ean weer fan the specifieat en16 ENGINE 2 anmage or wear he onto piston bo rage or weet = Change the oil pump ho nial aston © zr ital p ste. ein the ol pump housing @ for damage ard wee = Thoroughly ail @ ers moun = Mourt washer @, 164.17 Checking the clutch (125 Duke) 900 Om no rr (Check bearing @ far damage and wea TT ehere is darage o° neat = Charge the bearing ck the length of eltch springs @, nga is less than the specified value = Change all clutch sorin = Check ier clutch hub © for deme there is damage cr wear eluteh bub) ck elute af the clutch facing dsc in the outer elute hub @ for weer ‘Contact surface, clutch facing dises in outer chuteh Mi im act surface ' very = Change the clutch facing o ch facing diss @ for dis he cuter elu:ch hub oration ard se16 ENGINE 128 oration o clutch facing i uch = Check the th ckn Cueh aone sd Balan the elu ors Charge all clutch facing dis = Check interred ate dises @ for darnage and we Ifthe intermediate dises are nat level or are p tte ye all inter ale 16.418 Preassembling the clutch (125 Duke) Lubr cate t ef ing des thoroughly ring @ a Coro Push supe ension ti irrer elute hub, Info The pretension ring must be con the supper: hat its flush withthe inner edge sion the clutch cing disc w! Cluteh hub fave com, otch for the pretersion ring onthe luch disc, positon all fur lutch facing dis nd Mount clutah pressure i 7 Marking @ ard @ ate aligned = Position the eluteh Position the reles but do rat tighten ye16 ENGINE 128 16.4.19 Checking the shift mechanism (125 Duke) ay sh “te ie — * Ohi = Check she st IT there is darrage or wes = Change the sft fork and gear wheel pa = Check shifs grooves @ of shift emu Ifthe shift groove is worn = Charge the shift rl ck the seat ofthe shill deur Ifthe shift rller is not seateo correctly Shift drom andior the for snes ane for ct move feely or are worn ck shit 121 © on there is run-a flat surface for rur-ou = Change tre shit Ital for scoring, sgrs of cowosion and stiffness I there is scaring or corosion, or the shift fork i ti = Charge the shift hits forks, = Charge tre shft sta: = Check return surface @ on the sliding lave for weer deep 0 er = Charge the shft stat = Check guide pin @ for loo i = Change the ard nes ude pin is lose an nit stat16 ENGINE 130 emble the shift shaft = Oreck the play @ 130) the sl cing plete and the shift quad: SHR shatl—play ih Side plaweerTE Das Tn quadrant 00177 in) TF the measured valve a = Charge the shift sh 2 ro: equal the specified valve 16.4.20 Preassembling the shift shaft (125 Duke) = Fix the sho Guideline ° ©6 West af J | ee o — Push spring guide ®, push return spri preg le et he shift shaft na vise fend facing upward and I the offset end over abu = Mourt washer @, 164.21 Disassembling the main shaft (125 Duke) 1589941 red and facing downatd. ide Use 50 = Remove stop disk @ and Bnd-gear Paee Remove the Sth-gear idler gear ©, = Remove lock ring @. th = Renew lock ning @, pcisk ©. = Remove collar bushing ®, = Remove 6ih gear dler gear ©, op cisk ®. = Remove 310 = Rem = Rem16 ENGINE 131 16.4.22 Dismantling the countershaft (125 Duke) nga. rg downward k @ ard the Is! ee coller bushing ®. = Remove the 6th gear sine gear ®. = Ramee lock ring @. = Remove stop disk @. = Remove the 3rd gear idler gear ©. = Revove wesher ©, = Remove the ath-gear idler gear @. = Remove stop disk ® ard look ring ®. = Remove Sth gear shi = Remove lock ring ®. = Remove collar bushing ®, = Remove the 2nd gear idler gear ©. = Remove step disk ® ard lock ring ®, 16.4.23. Checking the transmission (125 Duke) Condition he transmission has been disassembled16 ENGINE = Charge = Check the pivot poi there is darvage = Change the = Check the tooth prot i = Change the main Check the pivot points af ia there is damage or andor count los of man shaft @ ard ceuntershatt © for dam andlor countershal ‘gears @ for damage and wee par ears © and sliding gears @ for darnage ck the shift dogs of IH there is dara = Change the ees ck the tooth faces of ier there is damage or w whore he west wt = Check the tooth g there is damage or 8 weer, = Change the gezr wheel par © for sracth operation inthe profle of main shaft @. ain stat ‘operation ir the profile of countershaft ©, ove easily = Change the siding gear er the check stop d sks @ for dem = Use reu lack rings © with every reper. 164.24 Assembling the main shaft (125 Duke) 132 Info Use new leck rings in16 ENGINE 133 Preparatory work = Oilall paris carefully before assembl ng = oh mission. p. 131) (nF » Oe; “e,/ - nae Main nark = Fivthe main shaft del Use soft jas ed end far rg downs = our = Moun: 6th = Mour: callar bushing © = Mour* stop disk @ and eck rng ®, = Moun: 3a = Mount le = Mount st = Moun: th = Moun: 2 = Finally, check all ze slicing gear @ withthe srall gs gear ® ord stop cick ®. uiheels for smooth cperat on 164,25 Assembling the countershaft (125 Duke) Info Use new lock rings in avery cepair job Preparatory work = Gill parts carefully b bling. ck the transmissian. (7 p. 131)16 ENGINE 134 Main wark = Fxthe Guideline terstaft in the vse wih the ge 2 Sa as = Fsill ck ring @ and stop dk @, gear idler gear ©. Har bushing ®. ck ring® 1 Sth-gear slicing gear @ wit = Irstall lock ring @ end stop sk ©, = our I groove facing upward = Moun: 3rd = Mour = Mount si = Moun = Mourt Ist gear dler gear ®. = Mourt stop isk ®. = Replace O-ring ® of tre covntershat = Finally, check all zezr atheels for srooth eparat en16 ENGINE 16.4.26 Checking the timing assembly (125 Duke) ~ le timing crain links move easily the chain li = Change the timing e ming chain guide il © for damage ard weer. there is dara there is damage or = Change the tring an sprocket © for deme = Check time there is damage or = Change the timing cha smshaf gears @ for der dana = Charge the camshatt gears, msraft bearing @ ford is darvage or west: = Charge the carst 164.27 Changing the stator (125 Dul 13516 ENGINE 136 = Position the new starr . = Mourt ane tighten screws: Guideli Smor 1 EW Totes 24a i — Position cable gu 01586. = Positio Mount end vighten screw @. Guideli ew, flaining racke, | MB au Toctiie® 243 ator cable 1 there is darage cr weer = Change t 716 ENGINE 137 = Glare the minus power supply to th the starter = Realace th 16.4.29 Checking the freewheel (125 Duke) eonteel gear @ into jo rol wedge! eel hub by turning the freewheel che lock ng action of the freewheel gear 3 Pot turn clockwise or fi 2s no lock 16.4.30 Work on the left section of the engine case (200 Duke) e sh fl shalt 2 remnants ard cle in in an oven, Stop or sa that's flush = Info When pressing thet preven! dameze Only press the be aged wen ering ens jon isk hat the engi ese s ings inva the auterri ate passed otherw se, the bearings will be = Aller the engin ion as check that the bearings are firmly = Info Ifthe bearings are net firmly sezted after cooling, i is key that they wil rorate the e°gine case when warm, In ths case, he engine case mus: be renewed Maurt the dowel 1 shaft seal ring @ of th ini flush ft shaft with che open sd facing inward se that16 ENGINE 164.31 Work on the right section of th 138 Press ip shaft that iis Mus ourt lock ring @, eal ring ® of the countersha withthe onen side facing irward so = Mount and tighten tre all jet ®, viet OE eum Toctie2aa™ a ith) = Blo air chrough tre chancel and check that it sl compressa sigine case (200 Duke) I dowel ©, Remove the bear ng esa wooden plate, This wil cau = Info fry beatings that remain tion mus: be removed using 2 suitable ‘00 = Insert the ren cold bear rgs rio the bear ng seats ofthe hel engi and, if necessary, use @ su table press drift push the bezrig all she way tothe stop or so that i's Mus 12 r-the ergine case when warm. In thc renewed he engine case mus: be Maur the dom Pesitio all bearing lo Mourt and sigh:en screws @, Guideline ‘Screw, bearngrelarer | We T2Nm Tectia 9 ith) char eck th = Blow compressed air shrough th 16.4.32 Changing the shaft seal ring ofthe water pump (200 Duke) = Renove lock ring ®.16 ENGINE 138 Remove shett seal ring @, ith the open side facing ward 01st = Press shat ing inward Ta nrg ae 164.33 Removing the main bearing (200 Duke) = Mourt se — Mourt leek ving @. Pras Tig Siaave (OOIPOOTSOOO p25) = Mourt special too! @, Puller viv = Tension the ha = Pull off the man a16 ENGINE Camo the crarkshat = Mourt special tool ®, 140 Pressure sorea for Graken = Mourt spec al tool @, Piller for main bearing (S0L2S01 8000) p, 238), 7 Holaing ans @ engage v he outer bearing race = Tensicn the Faldirg arms by surring nut ©. = Pull 16.4.34 Checking the radial play of the lower conrod bearing (200 Duke) =. Clamp the connect sion ‘h lothen red with sft jen Insert she Plastigauge cleara gauge © offse: by Plastigauge Weasur re Stipe (O00250120 silion the conrad be Mount and 28 Nm Grr tet ty Info Pio ot twist mpare with the specficat ons on the packaging, deli Plastigauge clearance gous Conect ng rod radial play of Ione cored bearing New cond Tint = Info The width of the Plastigauge: play16 ENGINE 16.4.35 Changing the conrod bearing (200 Duke) = Clamp the con = Renove the rus @, = Remove tre oanre bearing = Measure the crank pin diameter Guideline cling rod with sot jews wat ernowe the bearing shells, Crankshaft danster crank pn rankshal. cess fication A 235 T1808, 178) Grankshak: cass tieation B 30.004, 30011 wa tL 1126. 125153 F) Info = Oil tre bear = Position the corted bearing cover ac = Mount and ‘ghten nuts @, riirg 0 marking ®. Guideline pears 20m C77 het16 ENGINE 16.4.36 Changing the balancer shaft bearing (200 Duke) = Mount special tools @, 42 rib eal, bala alencer sheft wth spec al tool @ inthe press, ie 7 7azaORDOOOI I p27 he bearing, = Press on Remove the special to a sh irq with a su table tool iby eo), balanicer shaft bear DO he 164.37 Changing the camshaft bearing (200 Duke) sing soft = Info ye with adhesive tap = Mourt spec al tool neal ina BE Pro:ect the outer car of the cash aga rst demas si Holding spanrer On ae) = Ren = Renove camshaft gear @,16 ENGINE “0, Remeve the spacer ©, Take off beer ng @. 143 = Oil the new bearing and s Toby cated with engine oF = Mourt the spacer Mount carshatt gear ©. F Holding lug @ engages i Mount eng tighten screw ®, he recess ofthe camshalt Guideline en a Toctive® 243 sprork = Remove the special tcl o1ste Holding se T2BOTZO0O Fp = Repeat these steps on the second 16.4.38 Work on the cylinder head (200 Duke) = Foidcam ke = Take she sh ms @ out of the valve spring retziners and ay them <0 on i ther rarmel buil-n positon Tnsert Tor vah keys rngreta rer @. vale sp ing, valve stem e the valve into 2 box according to (Cheek the eyinder head. Op. 144) Mourt valve spring seat @ and the r Mourt the v spring. Mount valve spring resainer ©.16 ENGINE 14 - ion the pecial too Op Insert for valve spring lever (9012906000017 p 247) Mount valve keys, Relax the valve spree Info BP when mounting the check thal they are correctly: prefer ly, Tix the valve keys to the valve with a litle grease, = Place stirs into the valve spring retainers according tothe instalation postion, 164.39 Checking the cylinder head (200 Duke) Check valve guides © with the Limit plug gauge (9012902600011 p. 229), Tike specs ser. mothe Change the valve 8 valves - e sparkplug thread ard the valve seats for damage and © |fthere s weer or tear 20182. = Change tne eyinder head ecial too dge and th al too Fesler gauge (09020001 lOOLI™ p. 225), Cylinder eal ng a head Oso IF the measured valve does rote = Change the eylinder head = Chock seal ng seat @ of the wal @ Take VWehe seal Evans 50, 0.0433 in) sozan. IF the mes "ro equal the specif ed value = Machine smpressed air hough all oil holes and check thal = Boy 16.440 Checking/measuring the cylinder (200 Duke) = Check Jind bearing surface for damage. sing surface is damaged he cylinder and p ste, inder diameter at several places the @ and @ axes using a deli Cylinder = bore Gaeter 72.027 im (28382716 ENGINE 145 = Ghack the sealing the special co Ifthe measured value does ro: equal the specif ed valve = Change the cylinder and pis! 164.41 Checking the piston ring end gap (200 Duke) = Re = Pt ing ror th ce the pston ring in the cylinder and align wth the p ston. deli Under the upper edge of We oylinder end gap ® with the sp Ting end fa 01s. Compression rng GaNZSOATIOON ep Ifthe ard gap is more tran the specified valve eck’neasure the cylinder. (© p. 144] Hinder a e the piston ring ars wihi = Mount the 9 ion nrg with che marking facing toward the piston heed. 164.42 Checking/measuring the piston (200 Duke) = Check she p sn beating surface fer demaze > Ifthe pistor bearing surface is damaged: = Change the piston ard, if rec =. Ghack thatthe pistor tn eve 8 Ifthe piston ring is si = Clean the piston ring wr * Tp 605-20 Use ar old piston ring taclear the p ston rin =. Check the piston rings fo the pisten rg is dan = Chan the piston ring = Info Mount the piston ring wth the marking f =. Check the p ston pin ford IF the piston pr has strorg discoloration gns cf ner: = Change the piston pin = Irsert the piston pin into Ifthe pistor pin besting has :oo much play — Change the correcting rag and the p connecting rod and16 ENGINE M46 Posten dieweier a 16.4.43 Checking the piston/cylinder mounting clearance (200 Duke) Checkimeas The pistorlelinder mount ng clearance i rmirus the piston ciamecer Guideline is the result of the eyinder bere d aveter Pistonieyinder -maurtne ele he cylinder. (Fp, 144) Tew condition 205995 Tat Creckimessure the piston. % p. 149) 16.4.4 Checking the oil pump (200 Duke) With special to ay bet een the interal rotor ang exteral = Check axial play @ of the cil pump c ° Sed oencen sonal or eh Ne usc STOTT . .| == abs a ao TAT See y Ta = Play 0.20 mm (0.0035. jute 3a T epic Son a eotou wal play TI, O25 mn (OOO. 198 in) cific oo (Change the oil pump and pring @. he length of spring @, the oil pump housrg, ke Changs the spre. ro] piston © for darn iT pressure valve minimum [25.00 m7 (T pring length TF the measured length is less than the specifieat on =r16 ENGINE = Thoroughly ail Maur 16.4.46 Checking the clutch (200 Duke) “7 anmage or wear he onto piston bo rage or weet Change the oil pump fo nial aston © zr ital p ste. ein the ol pump housing @ for damage a 4 wea ee washer @, 1S @ ” (Check bearing @ far damage and wea IT there is darrage or weer = Charge the bearing = Check the length af clutch springs @. nga is less than the = Change all clutch sorin (Check irrer clutch hu © for demas If shete is damage cr wear: eluteh bub) ck elute af the clutch facing & ed value sin the outer elute hu © for weer clutch Gontact surlace, ig dices m outer clue act surface ' very = Change the clutch facing o ch facing diss @ for dis hee oration ard lurch hub16 ENGINE 148 oration o clutch facing i uch = Check the th ckn Cueh aone sd the elu ors Charge all clutch facing dis = Check interred ate dises @ for darnage and we Ifthe intermediate dises are nat level or are p tte ye all inter ale 164.47 Preassembling the clutch (200 Duke) Lubr cate t ef ing des thoroughly ring @ a Coro Push supe ension ti irrer elute hub, Info The pretension ring must be con the supper: hat its flush withthe inner edge sion the clutch facing disc w : Cluteh hub fave com, luch disc, positon all fur otch for the pretersion ring onthe lutch facing dis nd Mount clutah pressure i 7 Marking @ ard @ ate aligned = Position the eluteh Position the reles but do rat tighten ye16 ENGINE 149 16.4.48 Checking the shift mechanism (200 Duke) ay sh “te ie — * Ohi = Check she st IT there is darrage or wes = Change the sft fork and gear wheel pa = Check shifs grooves @ of shift emu Ifthe shift groove is worn = Charge the shift rl ck the seat ofthe shill deur Ifthe shift rller is not seateo correctly Shift drom andior the for snes ane for ct move feely or are worn ck shit 121 © on there is run-a flat surface for rur-ou = Change tre shit Ital for scoring, sgrs of cowosion and stiffness I there is scaring or corosion, or the shift fork i ti = Charge the shift hits forks, = Charge tre shft sta: = Check return surface @ on the sliding lave for weer deep 0 er = Charge the shft stat = Check guide pin @ for loo i = Change the ard nes ude pin is lose an nit stat16 ENGINE 150 emble the shift shaft = Oreck the play @ 150) the sl cing plate and the shift quad: SHR shatl—play ih Side plaweerTE Das Tn quadrant 00177 in) TF the measured valve a = Charge the shift sh 2 ro: equal the specified valve 16.449 Preassembling the shift shaft (200 Duke) = Fix the sho Guideline ° ©6 West af J | ee o — Push spring guide ®, push return spri preg le et he shift shaft na vise fend facing upward and I the offset end over abu = Mourt washer @, 164.50. Disassembling the main shaft (200 Duke) 1589941 red and facing downatd. ide Use 50 = Remove stop disk @ and Bnd-gear Paee Remove the Sth-gear idler gear ©, = Remove lock ring @. th = Renew lock ning @, pcisk ©. = Remove collar bushing ®, = Remove 6ih gear dler gear ©, op cisk ®. = Remove 310 = Rem = Rem16 ENGINE 151 16.4.51 Dismantling the countershaft (200 Duke) nga. rg downward k @ ard the Is! ee coller bushing ®. = Remove the 6th gear sine gear ®. = Ramee lock ring @. = Remove stop disk @. = Remove the 3rd gear idler gear ©. = Revove wesher ©, = Remove the ath-gear idler gear @. = Remove stop disk ® ard look ring ®. = Remove Sth gear shi = Remove lock ring ®. = Remove collar bushing ®, = Remove the 2nd gear idler gear ©. = Remove step disk ® ard lock ring ®, 16.4.52 Checking the transmission (200 Duke) Condition he transmission has been disassembled16 ENGINE = Charge = Check the pivot poi there is darvage = Change the = Check the tooth prot i = Change the main Check the pivot points af ia there is damage or andor count los of man shaft @ ard ceuntershatt © for dam andlor countershal ‘gears @ for damage and wee par ears © and sliding gears @ for darnage ck the shift dogs of IH there is dara = Change the ees ck the tooth faces of ier there is damage or w whore he west wt = Check the tooth g there is damage or 8 weer, = Change the gezr wheel par © for sracth operation inthe profle of main shaft @. ain stat ‘operation ir the profile of countershaft ©, ove easily = Change the siding gear er the check stop d sks @ for dem = Use reu lack rings © with every reper. 164.53 Assembling the main shaft (200 Duke) 182 Info Use new leck rings in16 ENGINE 183 Preparatory work = Oilall paris carefully before assembl ng = oh mission. (% p. 181) (nF » Oe; “e,/ - nae Main nark = Fivthe main shaft del Use soft jas ed end far rg downs = our = Moun: 6th = Mour: callar bushing © = Mour* stop disk @ and eck rng ®, = Moun: 3a = Mount le = Mount st = Moun: th = Moun: 2 = Finally, check all ze slicing gear @ withthe srall gs gear ® ord stop cick ®. uiheels for smooth cperat on 16.4.54 Assembling the countershaft (200 Duke) Info Use new lock rings in avery cepair job Preparatory work = Gill parts carefully b mbling. ck the tansmissian. (7 p. 181)16 ENGINE 154 Main wark = Fxthe Guideline terstaft in the vse wih the ge 2 Sa as = Fsill ck ring @ and stop dk @, gear idler gear ©. Har bushing ®. ck ring® 1 Sth-gear slicing gear @ wit = Irstall lock ring @ end stop sk ©, = our I groove facing upward = Moun: 3rd = Mour = Mount si = Moun = Mourt Ist gear dler gear ®. = Mourt stop isk ®. = Replace O-ring ® of tre covntershat = Finally, check all zezr atheels for srooth eparat en16 ENGINE 16.455 Checking the timing assembly (200 Duke) ~ le timing crain links move easily the chain li = Change the timing e ming chain guide il © for damage ard weer. there is dara there is damage or = Change the tring an sprocket © for deme = Check time there is damage or = Change the timing cha smshaf gears @ for der dana = Charge the camshatt gears, msraft bearing @ ford is darvage or west: = Charge the carst 164.56 Changing the stator (200 Dul 18516 ENGINE 186 = Position the new starr . = Mourt ane tighten screws: Guideli Smor 1 EW Totes 24a i — Position cable gu 01586. = Positio Mount end vighten screw @. Guideli ew, flaining racke, | MB au Toctiie® 243 ator cable 1 there is darage cr weer = Change t 716 ENGINE = Glare the minus power supply to th the starter = Realace th 164.58 Checking the freewheel (200 Duke) 16.5 Assembling the engine 16.5.1 16.5.2 Installing the crankshaft (125 Duke) Installing the balancer shaft (125 Duke) 187 2 e freewheel jo rol wedge! eel hub by turning che lock ng action of the freewheel gear 3 Pot turn clockwise or fi 2s no lock Warm the eng re case sect en in ar oven, deli ouet main bearing @. Hest the mar besring Guideline 150°C (8027 beara he canis) ol ott rain bearing BOTZIO0G Mount orp 2a16 ENGINE 158 16.5.3 Mount ft © with the bear re = Info If racessary, reat the engin Position the retaring bracke! Mount eng tighten screw @, reaver | WE T2Nm Tote 24 9 ith) joaono ep 2B) Installing the transmission shafts (125 Duke) = Ol te bearing. transmission shafts @ in the bearing = Slige b % 16.54 Installing the shift forks (125 Duke) = Oi all pats carefully before assembling = Sif fork @ has a smaller inside damezer; mount i in the sh ft groove a the main shell =. Mourt shift fork @ in the laner stift groove of the countershat = Mourt shift fork @ in the upper shift growe of the councershaf 16.5.5 Installing the shift drum (125 Duke) = Side shift ry @ int Heng shit he16 ENGINE 16.5.6 Installing the shift rails (125 Duke) = Oi all parts caret = Mourt shift ral © toze = Mourt shit 1al@. assembling, with upper spring ard the lower spring, 16.5.7 Installing the left engine case (125 Duke) = Clean the sealing = Mourt dowels @. = Mount tre engine case gasket 158 Tae Mount the eng cary ap lightly with 2 rl allt while toring the tars ssion shatis Info Do net tigen the erie = Mount serens @ but da rat tighten them ye TEGO Teeth aaa™ aerissr Tea TENT eS TAT16 ENGINE 160 = Mount the fitting of the engine fxing arm 16.5.8 Installing the ol fiter (125 Duke) TNE = Tits she engin = Filoil fier @ fill the ol filler Povsing aopran, % full ith engi I Plier and insert i in = Oil the Oring ofthe ol filter cover = Install ne ol Mer cover @, = Mourt ane sighten seres @, del Wn Totes 24a 3 Wtf) Tier cower 1 16.5.9 _ Installing the locking lever (125 Duke) = Mount looking lever @ wit the sleeve, washers are sprvg, i Lighten screw @ with the washer Moun T2Nm Locking 243 G9 ith) 16.5.10_ Installing the shift drum locating (125 Duke) ing and postion the shift drum Grom leaing | WE Tosti 2aa™16 ENGINE 165.11 Installing the shift shaft (125 Duke) 161 Slide sh shaft © wit er inca the bearing seat Push siding plate @ awa drum locating ®, Insert the shift aft all the way, Lal the sliding plate engage in the shift drum locating, ‘Shift chrough :he vers ssion. Pesito al rotor in the oll pump housing, The marking @ is visble efter aunt rg Mount th v the ternal rotor withthe cl pump staf ing @ is visble after roun check tha holes are clear and fl wth a srall amount of © Mourt the dowel Positen al purp@. Mount anc tighten screws @, Guideline We T2Nm Tectia G9 th) Pesiven al aump gear ©, ckring ®. I pump Mourt renk or sine16 ENGINE 16.5.13 Installing the primary gear (125 Duke) = Position s °, = Mount spring washer @. = Mount prinary gear ©, Mount toring chain sprocket ®, 16.5.14 Installing the clutch cage (125 Duke) = Mourt collet hhh onto he b wuter elute hu 162 main shall, Turn the el ump geer unt16 ENGINE 163 = Lock the outer eluteh hub and pr mary gear using s e1 (ODL2S0B1 OO) = Mount and tighten nut @ with the washer. Guideli Tt, ria a aie Castle nu erch; 1 deve (OU 12S02 100011 p. 22ST = Position the preassembled inner eluteh h ert 1O01e: = Tighten scraus ©, del Screw, clutch s TONm Ia = Mount and tighten nut @ with the washer. Guideline Ms, ver clutch hob | NALA CONT oct 245 a3trn Gaille nut arerch; 1 drive (OOT2S0DIOOON™ p. 23ST = Moure beering @. 16.5.15 Installing the spacer (125 Duke) seal estat: before mount rg orgie grease (* p. 232) = Mourt spacer @. 16.5.16 Installing the gear position sensor (125 Duke) > Mount the contact springs ard cont vote he16 ENGINE lestall she gear pos! 164 16.5.17 Installing the balancer shaft drive wheel (125 Duke) Mourt anc sigh:en serous en Tosti 2aa™ a ith) Ne case = Info Ersure tha tly routed. Mount ane tighter Guideline Sanne m5 v7 Totes 24a a wee) Mount the spring wash Mount de Pesito Y Herkirgs @ and @. Mourt wedge ©, kt lich hub and primary gear esing al tol Gear segment (S0725081 100) p AT Mount eng tighten screw ®, chatter | WE ONT Toctiie™ 243 Gest, IMourt washer ©, 7 The outer side of the washer is contact with th faces awey ftom she drive whee!16 ENGINE Mount and tighten the nut @, videline 165 Mut, vive whee for balancer shal Wee BO Nm (443 or ty Calle nit wrerch Tie (GOISSOPPOOON™ p ASS) = Re the special ts (Gear sepmrert (90129081100) (© p. 2A 16.5.18 Installing the starter drive (125 Duke) Mount starter idler = Mourt torque li on freewas = Position the crarkshalt positon sersor = Mourt ane tighten screns @, Guideline w. igniton pulse gem") MB 7 Toctiie® 243 Gabe) =. Position the rearing bracke = Mount and vighten screw @. videl ew, freenheel gear) MG T2 NT Tectia retaining bracket Baw h16 ENGINE 165.19 Installing the rotor (125 Duke) = Lock the outer clutch hub and primary 166 165.20 Mount the spring washer Mount ar counter! rrplify assembly FEN Sib ty) Totes 24a Installing the alternator cover (125 Duke) = Mount tr = Seal the cable guide Tact 5810 = Mount th alar cover gasket ©, = Position the = Irstell he s ns © ard sighten them diagonally. we Dim BoD 165.21 Installing the water pump cover (125 Duke) sir16 ENGINE 16.5.22 Installing the piston (125 Duke) Mount the wzter pume 1s @ ard tighten them di 167 over with the seal ring, pooner rg TaN =. Shit he joint of the pstor n Push the piston carefully nto marking @ faces th ing chain tens a tighten screw @, by 120" cinder from below outed side long cil from above We T2Nm Tectia Baw h Liming chain @ in the engine c16 ENGINE ens sing retaner @, rt the spe al tool andl Fly ores it toward th 168 wr rg chain through the chair shaft. Mount p'ston pin @, Timing chain te 16.5.23 Installing the cylinder head (1 = Position timing chair gu Y Pins @ engage rece: hal the piston pin retainer is se 2, thereby pressing the p ston pin retainer ned, Push the cylinder dk eal, coreclly on both side yrand let the dow16 ENGINE 16.5.24 Installing the camshafts (125 Duke) 168 Maur Put en cylinder head gasket ©, Mourt the esi Maurt screws @ with the waster and tgnten in acr'ssoross pester del Oylnder Fed wo Sep 20Nn Bi) (25.5 tes tt) Mount an tighten sorens @. rg PGCE IAG) Turn she crankshaft clockw se until mark ngs @ and @ al gn cemstat the edge of the ey eger he16 ENGINE 16.5.25 Installing the timing chain tensioner (125 Duke) 170 - sly clean allo els ard blow through with compressed ai. = Mourt the dom — Position the cams = Mourt screws © deli bearing OU rg Tele AT =. Turn the tining chain tersiarer serew clockwi 7 The timing chair tensioner is locked. Holding it with she correct oriartat on, raunt the timing chain tens orer @ with the gasket — Mourt ane tighten screws: deli Trig chain tensioner NE TaNn BSE = Unlock the vin = Check hain tensioner iming chain tension counterclockwise = Mount and tighten screw © with the O-rrg. Guideli ow unleckng or bing chain ten] MB Tom 7a ETD16 ENGINE m 16.5.26 Checking the valve clearance (125 Duke) =. Grark the engine several times ae nut wrench Te eve Toy = Sel the engine to ignition toa dead vente. = Check the vai A Guideline Velve clearance, emhausl, Valve clearance, inlabe, old olor gauge (GS025041 100) 1% p. 22% Tale does not = Adjust the val a = Mount and tighten ser Wane Sim Te 16.5.27 Adjusting the valve clearance (125 Duke) Main nark = Remove the Ling ner (% p92) = Remove the camstaft.(% p. 92) = Swe up cam lever @, = Correct the shins @ as indicated by the results ofthe = Irstall she camstatts. (¢ p. 1 = Install he timing chain tensioner. (% p, 170) Finishing work =" Check th sarance, (© p. 171) 16.5.28. Installing the starter motor (125 Duk - he O-r ng, Position the strter motor org fe grease (7p = Mourt ane tighten screvs' videl rier omar T2Nn ESAT16 ENGINE 165.29 16.5.30 2 Installing the clutch cover (125 Duke) Info Mourt ane sighten serens @, We Installing the spark plug (125 Duke) = Mount and tighten eval tool @. del Spark plug park plug using wa Ie) Spak pug wench?16 ENGINE 13 16.5.1. Instaling the valve cover (125 Duke) pares @ and, = Position the valve cover with the gaske = Mourt ane sighten scravs @ with the ga 16.5.32 Installing the chain securing guide (125 Duke) - 16.5.33 Installing the oil screen (125 Duke) = Mourt ol screen @ with the Orne,16 ENGINE 165.35 165.26 Moun and tighten oll drain plug @ with the O-ring, Guideline m4 idea ple 20m Caster engine assembly stand (125 Duke) Remove the fit ng fo Engine Fang ann (8 Engine fang arm (90129002050) (* p. 237) are from th Have ao assistant hel you or use crane, Installing the crankshaft (200 Duke) Werm the eng in in an oven, Guideline gine assembly sand Mourt main bearing @. Hest the mar bearing. deli 150°C (802 = crankshaft @ inte the bear rg sea. Heat th Guideline the ain beating on the erankshat rain Oil the bearing ar Installing the balancer shaft (200 Duke) Mourt spec al tool @, oun SOIZS0OSO016 ENGINE 16.5.37 16.5.38 175 = Mourt ft © with the bear re = Info If racessary, reat the engin = Position the rearing bracke = Mount end vighten screw @. reaver | WE T2Nm Tote 24 9 ith) joaono ep 2B) Installing the transmission shafts (200 Duke) the bearing Installing the shift forks (200 Duke) = Oi all pats carefully before assembling =. Shif fork @ has a smaller inside diameter; ours i in the shift groove of the main shell = Mourt shit fork @ in the upper 165.29 Installing the shift drum (200 Duke) = Side shift ry @ int Heng shit he Maur shif fork @ in the lower sift groo groove of the uncersha16 ENGINE 176 16.5.40 Installing the shift rails (200 Duke) =. Oi all pats carefully be = Mout shift rail @ togesh = Mourt shit 1al@. 16.5.41 _Instaling the left engine case (200 Duke) Te necessary 9 ighlly with @ rub allt while turning the emission = Mount serens @ but da rat tighten them ye el TEGO Teeth aaa™ fens in @ crisscross pater gine cose Tea16 ENGINE = Mount the fitting of the engine fxing arm 16.5.42 Installing the ol filter (200 Duke) = Filoilf = Ollie = Festal = Tilt the engi ys ard fill tr oil ile cil and insert i in th ai Fier ith eng ting ofthe ol filter cover, 0) Mer cover @, Mourt an tighten sorens @ approx, full with engl 7 cil flier cover 1 Totes 24a coking lever @ with the sleeve, wasters ard spre. nd tighten screw @ with the washer. MG T2Nm Locking 243 G9 ith) 16.5.4 Installing the shift drum locating (200 Duke) = Mourt spacer ring @ on she shit: drun n — Press locking lever @ enay from the shift gnu locating and pes ton the © Y Pins O engaze 9 hole ®, = Release = Mount and tighten We T2Nm (6.9 INE) Tosti 2aa™16 ENGINE 178 16.5.45 Installing the shift shaft (200 Duke) = Slice shift shaft @ with the washer into the beer = Push siding plate ny the sh ft drum locating ®, Insert the shift aft all the way, = Letthe slide = Shift drcugh che vansm sion. the shift drum locating, Position the external rotor in the oil pump housing, The marking @ is visble efter aunt rg Mount the internal v the tor with she cil pump stat is vistble afer moun’ Check thatthe oll holes are Maurt the dowels Positen al purp@. Mourt anc sighsen screws ®, Guideline ‘Screw, oF PUMP WE T2 Nm Tectia G9 th) lear and fl wth a small amount of 6 Pesiven al aump gear ©, Mourt lock ring ®, Chak the oll pump gear and check for sitfness,16 ENGINE 178 16.5.47 Installing the primary gear (200 Duke) = Position spacer ring @. = Mount spring washer @. = Mourt prine Mount toring chain sprocket ®, 16.5.48 Installing the clutch cage (200 Duke) = Mourt collars Fub @ onte te er clutch hut shall. Turn the oil pump ger until16 ENGINE = Lock the outer eluteh hub and pr mary gear using s 180 e1 (ODL2S0B1 OO) = Mount and tighten nut @ with the washer. Guideli Tk, griany Gear Wie Castle nu erch; 1 deve (OU 12S02 100011 p. 22ST = Position the preassembled inner eluteh h ert 1O01e: = Tighten scraus ©, del 165.49 165.50 Installing the spacer (200 Duke) seal estat: before mount rg Screw, clutch s TONm Ia = Mount and tighten nut @ with the washer. Guideline Ms, ver clutch hob | NALA CONT oct 245 a3trn Gaille nut arerch; 1 drive (OOT2S0DIOOON™ p. 23ST = Moure beering @. orgie grease (* p. 232) = Mourt spacer @. Installing the gear position sensor (200 Duke) Mount the contact springs ard cont vote he16 ENGINE 16.551 181 = Irstell she peer pos! sa = Mourt and sighten screw en Tosti 2aa™ a ith) - ss = Info Ersure tha tly routed. = Mourt ane tighter Guideline Sanne m5 v7 Totes 24a a wee) Installing the balancer shaft drive wheel (200 Duke) = Mout the spring wesh = Mount dr = Positio Y Herkirgs @ and @. = Mourt wedge ©, = Lock lich hub and primary gear esing al tol Gear segment (S0725081 100) p AT = Mount end tighten screw, chatter | WE ONT Toctiie™ 243 Gest, = Mourt washer ©, 7 The outer side of the washer isn corta faces awey ftom she drive whee! sath th16 ENGINE 165.52 Mount ang tighten the nut @, videline 182 Mut, vive whee for balancer shal Wee BO Nm (443 or ty Calle nit wrerch Tie (GOISSOPPOOON™ p ASS) Re the special ts (Gear sepmrert (90129081100) (© p. 2A Installing the starter drive (200 Duke) Mount saner ider Mourt torque tim on freewas Position the crarksaft positon sensor Mourt ang tighten sorens ®, Guideline w. igniton pulse gem") MB 7 Toctiie® 243 Gabe) Position the retaring bracke: Mount end tighten screw @, videl ew, freenheel gear) MG T2 NT Tectia retaining bracket Baw h16 ENGINE 16.5.53 Installing the rotor (200 Duke) = Mourt 16.5.54 Installing the alternator cover (200 Dt 183 Lock the outer clutch hub and pr rary = Mount the spring washer rrplify assembly ran Totes a Sib ty) ke) Mount th Seal the cable guide Mount the alternator cover gasket @, Pesition the Iestall she screns @ ard tighten them diagonally, we Dim BoD 16.5.55 Installing the water pump cover (200 Duke) sir16 ENGINE 184 re pins @, = Mount lov = Mount the water pump cover with he seal ring, = Festal 16 @ ard tighten them diagonally Guideli Sere, waler pump cover rg TENT ISS TORT 16.5.56 Installing the piston (200 Duke) =. Shit he joint of the pstor n — Push the piston carefully nto by 120" cinder from below = Ensure tht piston marking @ faces the cutfeed side = Thee = Mou din the timing chain tens a tighten screw @, long cil from above ideline ‘Screw. timmg cham ten [Ne T2 NT Tectia soning ta Baw h = Position timing chain @ in the engine c16 ENGINE = Position pistor p 4 oplind retaner @, rt the spe al tool andl Fly ores it toward th = Thread the tig chain through the chair sha 185 Mount p ston pin @, Tisertion for ps 250 Turn al tea 16.5.57 Installing the cylinder head (200 Duke) = Position tming che Y Pins @ engage The timing Timing chain te eal, ©. 2, thereby pressing the p ston pin retainer hal the piston pin retainer is se ned, Push the cylinder dk coreclly on both side yrand let the dow186 16 ENGINE = Puten cylinder hand gasket ©, = Mourt the cylinder = Mourt screws @ with the waster and tghten iva crsserass pattern deli Oylnder Fed wo Sep Tread soiled 20Nn ad flat Gesu |ereased 40 Nn Ibe) Mount an tighten sorens @. ideline Gylnder Fe Installing the camshafts (200 Duke) I mark ngs @ and @ al gn 165.58 = Turn the eranksha clockw e u = Pull up the timing chain ard insert extaust camshaft ©. = Place the siming chain aver the camshef: gear ofthe intake camshatt sth the edge of the cyl rder head Markings @ of t16 ENGINE 165.59 Installing the ti chain tensioner (200 Duke) 187 - sly clean allo els ard blow through with compressed ai. = Mourt the dom — Position the cams = Mourt screws © deli bearing OU rg Tele AT =. Turn the timing chain tersiarer serew clockwi 7 The timing chair tensioner is locked. Holding it with she correct oriartat on, raunt the timing chain tens orer @ with the gasket — Mourt ane tighten screws: deli Trig chain tensioner NE TaNn BSE = Unlock the vin = Check hain tensioner iming chain tension counterclockwise Mount and tighten screw © with the O-rrg. Guideli ow unleckng or bing chain ten] MB Tom 7a ETD16 ENGINE 16.5.60 Checking the valve clearance (200 Duke) = Grark theerg 198 Castle na SOIZSORTOOON™ pa = Check the valve Guideline eatal Velve clearance, eahausl, co i gauge (OSOZG04T 100) Ip. deli 2 does no = Adjust the vale clean: = oun tighten sere plug & plug, ltermator cove Wm Te 16.5.61 Adjusting the valve clearance (200 Duke) Main nark =. Rene w tiring = Swe up cam le = Comets = Irstall = Irstal timing chal Finishing work 16.5.62_ Installing the starter motor (200 Duke) = Remove the canstaft. (% p. shins @ 2s indicated by the results of the amstafts. (7 p. 186) tensioner. 187)16 ENGINE 165.63 198 Installing the clutch cover (200 Duke) Info Mourt ane sighten serens @, We 16.5.64_ Installing the spark plug (200 Duke) = Mount and tighten eval tool @. del Spark plug park plug using wa Ie) Spak pug wench?16 ENGINE 190 16.5.65 Installing the valve cover (200 Duke) pares @ and, = Position the valve cover with the gaske = Mourt ane sighten scravs @ with the ga 16.5.66 Installing the chain securing guide (200 Duke) = 16.5.67 Installing the oil screen (200 Duke) = Mourt ol screen @ with the Orne,16 ENGINE Mount and tighten oil grain plug @ with the O-rrg, videline 191 ran pug 20m Caster 16.5.68 Removing the engine from the engine assembly stand (200 Duke) = Remove the fitting fro Engine Fang ann (8 Engine Png arm (9022 the engine fom the d17 SHIFT MECHANISM 192 = Info The adjustment ral ge ofthe shift lever it = Loosen nuts @, = Adjust the shift lever by turning sh ft rod ®@, Guideline Shite neat, 64 aduswent ange 100.7 Info same adustrrents ar both sides. Teast five screw threads must be sereved into the se = Check adjusting angle ® Guideline ‘Adjusiing angle © shit red, detlewsn, | 90" shift ever ~ Tighier nuts @, Info Hater she ruts rave beer tightened, she basrirgs of the shift rod mus: be centrally and identically aligned to eech ather in order te ensure freedom of ‘movement ip the bearing shel = Gheck the shift lever to ersure its funct oning progeely and can move heel,18 WATER PUMP, COOLING SYSTEM 193 18.4 Draining he coolant my ee Danger of scalding During motorcycle operation, the sets very hot ard under pressure = de ne he rao ator cap, rad ator Hoses or other cooling system cam ponents when the engine is het Allow engreal ig system te coal down, In case of scalding, rinse immed ately wth lukewarm water i rine Danger of poisoning Coclent is posoncus and e heath haze = Avoid contact beter tact 2 doctor. Wash affected ately. Charge clothes shat haw nt and skin, eyes and clothing If ges into your eyes, rinse im in ateas rrmediztely with soap end wate. If cealart is swello are into cortact wth caplants, Keep coalart aut of tre reach of Condition The engine ‘scold Proparatory work = "Remove the front spelen. p. 46) Main ark =" Stand she motorcycle uprigh = Place 2 suitable contarer under the erg'ce = Renove screw ©. = Remove thera = Gonpletely drain the coolar = Moun sre @ wth ¢ rem sel sng and tighter Guideline pump drain hole We Plog, wa Duk Warning. By sangrt sissning Covers saves and rea Pac = Avoid contact beter lack e docter. Wash affected skin areas immed ately. Charge clothes that heve come into cont nt and skin, eyes and clothing. If with soap and w with coolants, Keep into your eyes, rinse im TT eolart is swallened rt out ofthe reach = Renove blee = Tilt she ver = Pour o coolant un and tighter Alternative 1 Ue p. 2301 Alternative 2 yo ae) p. 20) = Fill the radiator completely with coolant, Mount the radiator cap = Rest the vehicle or the side stand18 WATER PUMP, COOLING SYSTEM 194 Danger Danger of poisoning. Eau in unconsciousness andor dee = When running the engine, al Von, and ge not stator run the engine in an enclosed space w thou effect ve exhaust extract on system, =. Siar he engine and let itrun warm, = Stop the engine and allow t zo cool down, = When the engire is coo! 8,2011> 6.2" ah.) Fillies she cooling 5 = Mount the rad 18.4 Checking the coolant level i vere Danger of scalding During marercycle operssion, she coolart gets very ho: ard is urder pressure rag ator cap, rad ator hoses or other cooling system camp avi rg system to cool down, In ca Warning Danger of poisoning Coolant is poisonous and a health Pavan ges into your eves, rinse immediately with water a = Avoid contact between tee th soap and w: tact @ dactor im with coolants, K Condition he engine cold night on 8 the compersting tank @, veer MINar dMAK, = Contest the Alternative 1 Altemative 2 Coolant (wre ready 1D of radistr cap @ and check th Tos be cornpletely ed level doos ro: meet spec fications olant level and fird out the cause af the loss TF the on Alternative 1 UF P Altemative 2 fant (ned ead) TOUS I yeu had to add sere >0.20115 0.2% q.) he coaling system. (* p, 193),18 WATER PUMP, COOLING SYSTEM = Mount the ra19 LUBRICATION SYSTEM 197 I (Ol drain plug ard oll screen) 2 Gil punp 3 Gin ier a Oil pressure n 5 Gite ensue z O jet for aston cooling 7 ‘Gilet for can follower lUbrcation E Orn Condition The engine is at opersting tenpercture Preparatory work = Stand the motorcycle unright on a her zor‘al surtaoe. Main ark = Check = Info After itching off the engine, wail one minute before check'rg the level The ergire ol must be between the lower and upper edge ofthe level viewer > [Fthe ange all = Add th ‘srt atthe spat ol. (* p, 200) ‘Warning Danger of scalding Ergine ol and fet very hol when the matoreycle is ridden appropriate pated safety gloves, In cas 1 immediatly with lukewarm water Warning Environmental hazard Hazzrdo.s subsiarc = Gil, grease, flees, fuel 2 ony toner nial damage learers, brake fl 6, ele, should be disposed of as stipulates v apal cable ions,19 LUBRICATION SYSTEM 198 sois34| Main nark =. Place 2 suitable contairer urder the ergie. = Renove screws ®, Ta eal filter he O-reg, = Renovecil titer ©, Grclip pliers TOOON p. 2347 - ring, Mount and Ughter the screws, We aan Totes a 69 wih) We ENT Toctiie® 24 69 Wtf) Gil pressure adaprar (ToOPaOSAOOO Ie p. PBT = Check the engine all level (Fp. 197) Danger Danger of piso in unconscious = whe on, a effect arg inaling them eray result, fake sure there is sufficient ver ne in an enclosed space wth ne ol pressure Engine o| pressure Coolant fenpe c 158 'F) Engine speed: 1,690 pm 270 bar ia Weniee Danger of urns Sore vehicle components get very net when th is arven, = Wear appropr a ive clothing ard s In case of burrs,19 LUBRICATION SYSTEM 199 = Irser tre new cl Fite. =. Oi tke Oring ofthe ot fi unt she cil filter Mount end tighten tre seren Guideline ren, a fier cover 1125 [WS ea Lockie 243 Duke} 9th) ‘Screw, oI filer over (200 | MS aN Totes 24a Duke} 69 wih Finishing work =. Check (197) ay ve Danger of scalding Ergine ol and gear il when the motereycle ridden — Wear appropriate protective cloth In case of bums, rege immediately with lukewarm water Warning Environmental hazard Hazardous substarves a) ers, brake flue, ete. s 2, filters, fuel < ofa stipulates in apa © Info Drain the engine al cy when the ergire is warm, Proparatory work = "Remove the front spelen. (* p. 46) = Stand the motorcycle en its side stand on a hes Main ark = Place 2 suitable contarrer urder the ere! Remove the oil drain plug @ with the O-ring = Reneve ail sreen @ wit ing, = Completely dram the engine ol. = Clean the oil erain plug and ol sctear shorcughly a1 screen @ and mount and tghien 0! drei Guideline Gildan pug t2s = Position plug @ with the O-reg, oka 10 Duke Tae Gildan aE = Re emove the ol ter cover @ with the Org, = Insert ol flier @. = Ol the Oring ofthe ol filter cover. Mount ci fier cover @. = Mount end tighten tre seren Guideline ‘Screa, a1 filler over 1125 | MS ay Totes 24a Duke (6.9 ith) aut Toctiie® 243 3 It) Screw, a1 Wer Gower (2 Duke} WS19 LUBRICATION SYSTEM 200 Info BE Too hale engin oil ar poorqualy theengire, ‘gre oil results in premature weer to = Remove the a filler plug @ wth the O-ring fram TSS aly Exenal omnes lures=20 — Irstall and sighten the ol filer plug wit the O-reg, Danger Danger of poisoning Exavs in unconsciousness andor dee = When running the engine, always "al ficient versie UUon, and ge net starter run the engine in an enclosed space w thou effect ve exhaust extract on syste ralieg them may result = Start the engine and cl Finishing work = F the front spaler (p46) = Check the engine ol level. (® p. 197), at tis oleh gine oll or poor-quality egine ol results ir premature wear to the ergire Main ark = Remove the ol filler plu ergine oil Ergine o1 SAE ISSO p 230) Engine oT (SAE 10720) p, 230) © wih the Oring from er and fll yp with = Info For optimal performance of the ergire oil, do nat mix d flere ergine ol Hanoropr ate ge the ergire ol 1 tighten the cil filler plug with Oring, Danger Danger of poisoning. Exravs! in urcenseiousness andor des*h = When ture ne sure there is sufficient versile ton, anc do not start cr run tre engine in an enclosed space w thout an effect ve exhaust extract on system, naling ther ray result Start the engine and cl Finishing wark = Check the engine oil level. (% p. 197),20 IGNITION SYSTEM 201 ‘Stator winding, weasurement |- check the resistance HB | - Measure the tetveen the spac fed oi OD Sister corrector HB 1 1~Stater, corrector Bpin 2 200.68) tke displayed valve does rot equal te sip value f 2 3 Change the st oom. " Stator wining measurement Il- check the resistance = Messe the esisarcebetueen the species girs Stace corrector HB p 01 = Sater, corrector HB 3 TH es noLegval the seipart vale HB 1? 8 cl fal Stator winding - check the short circuit o ground (terminal 31) - Measure the res'stance between the saecif'ed po e's Shator, connector HB p nT feasting oo nt Ground (*) Resisianee 20 IT the d splayed value do = Charge she sat ot equal the setpoint value21 TECHNICAL DATA 202 21.1 125 Duke21 TECHNICAL DATA 203 21.3 Engine tolerance, wear limits 21.3.1 125 Duke21 TECHNICAL DATA 204 21.3.2 200 Duke Tai 21.4 Engine tightening torques Loctite Lotte Losi Lost Tote atte 2A oette™ 243) oette® 243)21 TECHNICAL DATA 208 Sew on pom i a A Ta Sar Tracke, shat seal | Nin (8.1 Tat fy 2a fing. elute Soren, ht rum Tecan i a A 2a Seren, starter moon i 2A B.S FA = Sere, Urn (ens oner r at oF) = Sore, Uri iensonnr r at i) Toate 243 Seren, unlocking of tring chain ten [Mh D Nin (7A TBF = Serer wave cover oD TAIT AT = Sere, Water pu i eae = ut, conrod beeing ¢ o bry = Screw, conrad bear 7 brn = ut. TE TEA = Sore, bal aS Toate 243 Screw, cama iS Te Toate 243 Screw, run spring, Qu B31) tite 243 Stud exhaus Henge Zor = Cylinder head r ead f eased ON a0) Ten aea A Toate 243 rare en ZN (203 DFE = 2 ty = att 1 tite 243 o 7 = o T Toate 243 as a = TD = ta = 215 Capacities 215.1 Engine oil 7 Terral lenperaiure San g wag CU... 104 °F) A 21.5.2 Coolant ' ee 21.5.3 Fuel el tank CapEC r rT) ROL SSRON DSPONGII™ p 28.) eve Spb 721 TECHNICAL DATA 206 21.6 Chassis Tae tn WP Suspension WP Suspension ee DRE 21.7 Electrical system un Sera Tr Brake Te ean TED21 TECHNICAL DATA 207 21.8 Tires Front tres Rear tres TiOMOR 17 Me SAS TL TSO RTT WE EOS TL MRE reve F Re 21.9 Fork i Ne 00 F WP Suspension i wim (28.58 18) i Om ‘ow Ol ISRE SVI™ p 23. 21.11 Chassis tightening torques rast lap oN oF = 5 ain guard corre Wn a WP = eorer = z = 1 = it = r = 18 = sm Tootte 2a i = Ta 2a 2a Wu, foot brake lever du I = ut racharor r = nals r =21 TECHNICAL DATA 208 Toate 203 Toetite® 243 Toate 243 Toate Toate Toate atte petite” 243 tite 243 tite 243 pele 243 ie 2A21 TECHNICAL DATA22 CLEANING/PROTECTIVE TREATMENT 210 224 Cleaning the motoreyele Note Material damage Osi = When cleaning tre ve cables, pear rs, € Excessive aressu reelly orto electrical comporents, connecter, icf the pressure cleaner and the compare. Warning Environmental hazard Hazardous substan cause envtonmental damage, ld be disp: leavers, brake flu, ete. s = Ol, presse, flees fu < ofa stipulateg ir apal cable regulatin lean the motorcycle regularly, is value and appesrance wll be maintained ‘on the motorcycle during clezning al the exhaust syste to keep water ou = First remove coarse drt particles with @ gentle spay of water rly areas wth a coral motorcycle cleaner and ther clear with @ = Spray paibrush, cleaner 2 = Info Clean the vet le with containing normal notoreyle cleaner sia ard a sot spore th cold water, Warm salt, clean it cle 028 opersted in i enhance the corres = Aller insrg the mnotoroycle with a geetle spray of water llow i 0 dry thorcuat ly ia veniee Danger of accidents Reduced braking eff ciency due toa wet or diry brake system = Clean or dey 2 ditty or brake system by ring and braking gently Aterclezrin then aopl rms up, and © Info jons in the eng water that has = Push back :h trated to evapo = Alter the rotareycle Fas cooled off lubricate all moving parts end be: = Clean thechaw ( p. = Treat bare metal pats (exc anti-corrosion material ngs. gad preserving is for wera) rubber ara plastic (* p. 220) at all painted parts with 2. ld pains pals) High luster pelah fr pant p 220 all plastic paris and powder-coated paris with @ mild dmaie tind Paint cleaner and pol sh for high ges ae Tel and plese surfaces (® p 233), = Oil te ignitoristeering lack Universal oT spray (p23)22 CLEANING/PROTECTIVE TREATMENT at = Info IF the "notorycle is used in the winter, salt car be sion IF the vehicle was operated in road sat salt clea jons need to be taken agains: road set coro with cold water alter riding, Warm water would enrance the corosive effects of Clean the brakes, = Info , Fete ©-© pete: = Tokea24 SERVICE SCHEDULE 213 241 Service schedule KION | KSOA | KTOOR Oreck Dal Whe electra equip on To Tiemory US ne he KTM cragnase cs Ce een. (7p. 199) 7 fe ks, Perform a fark and shook absorber service Wreededend |, |. Te mp Se ~ pe 7 Day ee you 7 7 pep KION: Once after | 000 k BOA: Esery 5,000 kn (3, Ki008: 30 kar (6,214 mid or every 2 years25 WIRING DIAGRAM 25.1 Page 1 of 8 214 : a25 WIRING DIAGRAM Components:25 WIRING DIAGRAM 25.2 Page 2018 yo ; az25 WIRING DIAGRAM a7 Components: i T a Warm syorem foptonell Power eh Tey 5 Fan relay ms pin ir wah 5 7 ing lack25 WIRING DIAGRAM 218 25.3 Page 30/8 F - | ae25 WIRING DIAGRAM Components:25 WIRING DIAGRAM 220 25.4 Page 4 of 8 f 3h25 WIRING DIAGRAM Components:25 WIRING DIAGRAM 25.5 Page Sof 8 y ae25 WIRING DIAGRAM Components:25 WIRING DIAGRAM 25.6 Page 6 of 8 224 a 2825 WIRING DIAGRAM Components:25 WIRING DIAGRAM 25.7 Page 7 of 8 226 f aL25 WIRING DIAGRAM Components:25 WIRING DIAGRAM 28 25.8 Page 8 of 8 Go25 WIRING DIAGRAM Components:26 SUBSTANCES 230 ‘Brake fluid DOTA OTS. Aocording to = bor Guideline = Use only brake fluid that compl es with the spec fled standard (see spec fications on the contairer) and that possesses tre core sponding properties, ATW recommends Castrol and Motorex! preiucrs Supplier Castrol = RESPONSE BRAKE FLUID SUPER ODT 4 Motorex? = Brake Fuid 007 5.1 Guicetine = Use orly su iso in countries with igh temper ing. Kil recommends Motorex® products Midure ratio Aniilgeze protect on: = 7437) ures), Use of low-quality antilree 3 corosan inhibiovant Freeze Sh d tiled water Teter CRA) a5 CCS Supaier Motorex? = COOLANT 648 According to = NSO 1902 MA CF p, 243) = SAE (Hp. 243} (SAF 150%! Suideline = Use arly engne oils that compaly w th the specif ed standards (see spec fications or the ponding properties, ATM recommends Motore® prexucrs 50) ntainer and that possess the come Partially synthe eng ne ol Supaier Motorex = Formula 47 ‘scarding to = AS07903 MAC p, 243) = SAE (Tp. 243) (SAE LOW/I40) ieline = Use only engre sponding properie Is trat comply w 2h the specif ed standards (see spec fications or che container end that possess tre care- AIM racernmends Motores® proces Parially synthe engine ol Supplier Motorex = Formula aT26 SUBSTANCES 231 “Fork ol (SE 8) Aocording to = SHE p 243) (Sat Guideline = Use orly ols that comply mith the specified stardarcs (see specifications en the corts mer) and that possess tre corasponding properties. KTM recor ends Motarex® prods, Supplier Motorex? = Racing Fork Oi Aecorting to = _DIN EN 228 (202 95/RON 95/°0N 92) Guideline = Only use unleaded super fuel that matches or is equivalent to the specified Tvl erage = Fusl wh an etharol content of up to 20% (E10 fuel is safe to use = Info Donotuse fuel contarrng netharal fe. g M15, 5, 01100) or mote tran 10 % ethanel (e.g. F25, F25, FS, F160)27 ~~ AUXILIARY SUBSTANCES 22 [apne Se exon end Mate sts Supolier Motorex? = Chain Clean Suideline = KTM recommends Motored® products ‘Supplier Motorex? = Chainlube Road Suideline = KTM recommends Matored® produc ‘Supplier Motorex? = Protect & Shine e = KIM recomrronds SKF® prosuet, Supplier = KTM recor ends Motored® prosuc's Supaier Motorex? = Moto Polish Guideline = KTM recommends Matoreg® presiuc's Supaier Motorex = Bike Grease 2000, Suideline = KTM recommends bubeor? products, Supplier aco? = Turmsilor®6TI 300 P Suideline = KTM recommends BeHRay® produc's ‘Supplier Bel Ray? = Molylube® AntSeize27 ~~ AUXILIARY SUBSTANCES 233 ‘Motoreyele cleaner Guideline = KTM recom rends Matored® products Supolier Motorex? = Moto Clean 900, Suiceline = KTM recommends Matorey® produc Supplier Motorex? = Clean & Polish Suiceline = KTM recommends Motored® Supplier Motorex? = Joker 440 Synthetic28 SPECIAL TOOLS 8 ooo if fe Art, na.: 00029013000 ‘rt no. 00029013100 ‘rt no.» 80329060000 SS, anno. Art, no.: 61012011000 = ‘rt, no.» 89029019000 a28 SPECIAL TOOLS 235 ‘rt, no.» 89029041 100 ‘rt, no.» 60029012000 Art no. 61029055400 sovar7 ‘rt, no.» 62029085500,28 SPECIAL TOOLS —“~ 201314 ‘rl, no. 62023093000 Art, no. 62923094000 ‘rl, no, 62929985620 20030601 Art, no, 61223001000 ‘rl, no. 6252808500028 SPECIAL TOOLS 237 ‘rt, no.» 75029055000, rt no. 73029034000, ‘nt, no.: 77229032000 Art no.: 77229172000 sotsta.so ‘rt, no.» 90129002080 s014:0.2928 SPECIAL TOOLS 8 ‘rt, no.» 90129002060 ues Art. na. 90123005000 zeisiza a Aut no 90129008000 ry \ in oo > —__01s80-10] Art no.» 90129012000 sorsts.29 ‘rt, no.» 9012901800028 SPECIAL TOOLS 239 201826-20 / 205035.20 ‘rt, no.» 90129019000 ‘rt no.» 90129020000 so1s27-.0 ‘rt, no.» 90129021000 sous0..0 Art no.» 90129022000 1469.29 ‘rt, no.» 9012902600028 SPECIAL TOOLS 240 > 205036-20 ‘rt no.» 90129030000 rt, no.» 90129043000, sors. ‘tno. 90129048000 sorsro.io] Art no.» 90129056000 306037-20 “ee 201951.29 ‘rt, no.» 9012906100028 SPECIAL TOOLS 24 ‘rt, no.» 90129056000 201505.20 rt, no.» 90129060000, son0se- 10 ‘rt, no.» 90129081160 sous. Art no. T1668 301086.28 SPECIAL TOOLS 22 “Spring compressa ‘rt, no. 7140508 ‘art na.: 18288 Art no. T6128 200138-1029° STANDARDS 23 ASO 1803 MR Different technical development directions requied @ new spec fication for 4-sroke "noteroycles— the JASO T903 MA Standard, Ear- let, engire os from che aucomabile industry were used for 4 stroke mototoycles because there was na separate motorcycle spec fi cation, Whereas long service intervals are demarded for automobile engines, high performance at high engine speeds ere in the fore- ‘around for otrcycle engines, in most rrotorycles, the gearbox and the cluteh are lubricated with the samme ol as the ergre, The JASO MA Standard mee's these special require ven’ 1 classes were defined by the Society cf Automotive Engineets and ate used for class fyng os according te their costly. Ihe wsees ‘describes omly ene property of ol and sys nethirg about qualiyINDEX ocessories Air fiter fra 26 moving 26 Alternator stator winding, checking 201 Aniceaze checking 194 ‘Assembling the engine ‘alterrator cover, installing, 266, 183 balancer staft deve wheel, rstalling 164, 181 balancer staft, install rz 14 camshafts, iestall ng 163, 186 chain securing gu de, installing 173, 190, cluteh 162, 179 clutch 2 172, 189 crankshaft, installing, 57, 17a cylinder head, installing 168, 188 ‘32 pos ton Senser, installing 163, 180, locking lever, stalling 260, 177 oil fiter, stalling 360, LIF cil pum, insialing 161, 178 173, 190, pistar, insalling 167, 184 prary gear, installing 162, 179 rerrovieg the engine fiom the ergre assembly sard 174, 191 rotor, install ng 166, 183, shift drum locating, installing 260, 177, shit drum, install ng 158, 175 shift forks, installing 158, 175 shift shaft, install ng 161, 178 spacer, install eg 163, 180, spark pl, installa 172, 189 stater dive, install rg 165, 182 starter nota, rsallirg 171, 188, timing chain tensioner, insaling, 170, 187 transmission shafts, installirg 158, 175, vale cleerance, djusting 171, 188, valve clearance. checking 171. 188, Ive cover, rstalling 173, 190, water punp cover, installing 166, ‘usiliary substances 8 hs Battery correcting mirus cable © disconnecting minus 62 inctalleg él recharging 62 remonrg él Brake disc front brake, changing front brake, removing rer brake, install ng rear brake, removing Brake discs checking 53 Brake fluid front brake, add rg front brake, changing reer brake, acing rear brake, changing Broke fui level front brake, checking, rear broke, check ng Brake linings ont brake, changing. front wake, choca ng rear brake, charging Chain checking cleanrg Cain tension adjusting checking Charging voltage checking (assis number Clutch cabie play ‘dusting ‘Clutch lever play checking Coolant dering Coolant level checking Cooling sytem tilingybleed re 244 a 68 8 8 194-195 198 Disassembling the engine aherrator cover, evoure balancer shaft dr ve wheel, remov ng balancer shaft, removing camshaft, removirg chain securing guide, removing clutch cage, removing clutch cover, rerovirg crankshaft, remosing cylinder read, removing engre oll draining engine, setting to non top deed center ‘eer position serscr, removing Tcking lever, reray ng oil fiter, removing cl pump, removing piston, removing preperat ors Drirary gear, renew ng rotor, removing shift drum locating, remosing shift dum, remosing Shift forks, emovng 95, 109 96, 110 103, 117, 92, 106 89, 104 98 112 90, 104 203, 117, 90, 107 89, 103 91, 105 97,11 100, 114 100, 114 99, 113 93, Lo? 89, 103 99, 113 95, 109 100, 124 102, 116 102, 116INDEX shift shat, renevirg 100, 114 spacer, removing 98, 112 spark plug, removing 90, 104 slater drive, removing 96, 1.0 Star motor, removing 91, 105 ling chain tens oner, renexing 31, 106 transmission shafts, removing 102, 126 valve cover, remou'rg. 90, 104 water purnp wheel, remoung 94, 108 Engine ‘assembling 1s? disassembling a2 install ng a renovirg a1 werk on ind vidual par's| ur Engine - Work an individual parts balancer shaft bearing, changing 122, 142 camsheft beering, chargieg 122, 142 clutch, checking 127, 1a7 clutch, presssembl re 128, 148 cortad beer rg 121, 141 courtershaft, ssenblrg 183, 163 courtershaft,disasserrolirg 131, 161 cylinder read 123, 143 cylinder read, checking 124,144 cylinder, checking?neasur rg 124,144 electric starter drive, che 136, 166 Ireeuteel, check ra 137, 157, left engine czse see 17,137, mar bear ng, cevovng 113, 129 mai shaft, sserbl ng 132, 182 aie shafl, d'sassembling 130, 160, oil pressure regulator vale, checking 126, 146 cl pump, checking 126, 146 piston ring end gap, checking 125, 148 piston, checking 125, 148 Pistoriyl nder mouning clearance, ch 126, 146 pistors. reasuring 125, 145 racial lay of lou 120, 140 right ergire case section 118,138 shaft eel ring of water pump, eranging 118,138, shift mechanism, 129, 1a9 shift salt, preasserbling 130, 180 stator, charging 135, 168 ling assembly, checking 135, 155 trarsmiss or, checking 121, 151 Engine assembly left engine case, istalirg 189, 176 shitrals, stalling 188, 176 Engine disassembly left engine case, removing 101, 128 shftrals, removing 102, 116 Engine number 8 Engine oil adding 200 chang ng 198 Engine ol level checking 197 248 Engine oll pressure checking 197 Engine sprocket ‘checking, 58 Exhaust manifold installrg 33 reno 22 hh Figures 8 Filler cap closing 7 opering, 37 Foot brake lever free travel, adjusting 2 free travel, checking 71 Fork logs assemble 19 checking 18 dismantling 16 dust boots, cleaning ia titre ts reronre a Front fener faueg vy remonng ar Front spoiler install rg 46 rerovieg 46 font whee! installirg 83 removing 53 Fue filter charge 49 Fuel pressure checking a7 Fuel pump cherare Fuel tank futirg 48 removing 3 Fuel tank cover fing 41 renoung 28 Fuse individual power consumers, changing 64 Headlight adjustment adusting u checking 6 Headlight bulb chergieg 73 Key nunier 9 Kilometers or miles adjusting 78INDEX Lower triple clamp Tura renovrg Main silencer fire 25 renown 34 Motoreycle cleaning 20 raising with the front heel stand 10 raising wh the reer whes! stand io raising wth the work sand ul removing from wark stand 12 taking off of the fort wheel sane ul taking off of the rear heel stand io Gil circuit 19 Gi iter charge 199 Oil screen cleaning 188 ‘Operating substances Parking light oul chang og 78 Passenger seat mounting 38 removing 38 Playin trotle cable ‘dusting 2 checking a Preparing for use efter storage 212 Rear hub rubber dampers checking 60 Rea sprocket checking Rear whee! installing renoving 55 Seat mounting 38 mowing af Service interval display reinstalieg 6 Service schedule 213, Shift lever adjusting 192 Shit speed RPM 1 adjusting 6 246 Shift speed RPM 2 adjusting 6 Shack absorber Tura 29 revoure 23 spring preloed, adjust ng 23 spring, inslling 30 spring, renov'eg 30 Spare parts 8 Stating 12 lomeke checks 3 Steering head bearing play adjusting 26 checking 25 Storage 212 Technical data capacity capacity capacity chassis chassis tightening torques electrical sysier coolant engine ol fuel engi tolerance, wea mits eng re tigh:ening ‘ques fork shock absorber tires Time adjusting 16 Tire air pressure checking 52 Tire condition checking 52 Type label 8 | Warranty 8 Winter operation checks and mainte au Wiring diagram 214-229 page lof 8 24 page 2 of 8 2 page 3 of 8 218 page 4 of 8 220 page Sof 8 220 page 6 of 8 224 page 7 of 8 206 page 8 of 8 228 Work rules 7WWW.KTM.COM 2206127en oraa12 BS 27 © rowitcisaamn