REPAIR MANUAL 2015 | Maa MORHO 1290 Super Adventure Art. no. 3206220enINTRODUCTION 1 Read this repair manual carefully and thoroughly before beginning work ‘The vehicle will only be able to meet the demands placed on it ifthe specified service work is performed regularly and properly. ‘This repair manual was written to correspond to the latest state of this model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time. ‘We shall nat provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic. Al specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc, without prior notice and without specifying reasons, to adapt these to local Conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors, The models portrayed partly contain special equipment that does not belong to the regular scape of supply. © 2017 KTM Sportmotorcycle GmbH, Mattighofen Austria Al rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner, Iso 9001(12 100 6061) According to the international quality management standard [SO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TUY Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen, Austria ‘This document is valid for the following models: 1290 Super Adventure EU (F99030A) 1290 Super Adventure FR (F99230A) 1290 Super Adventure AU (F99600A) 1290 Super Adventure JP (F99860A) 1290 Super Adventure US (F99750A) 1290 Super Adventure CN (F99870A) 3206220en 01/2017TABLE OF CONTENTS 1 MEANS OF REPRESENTATION... on 6 11 Symbols used 6 1.2 Formats used... 6 2 SAFETY ADVICE. 7 2.1 Repair Manual 7 2.2 Salety advice 7 2.3 Degrees of risk and symbols.. 7 2.4 Work rules. ? 3. IMPORTANT NOTES. 8 3.1 Warranty 8 3.2 Operating and auxiliary substances 8 3.3 Spare parts, accessories 8 3.4 Figures . 8 4 SERIAL NUMBERS vss 9 4.1 Chassis number... 9 4.2 Type label 8 4.3 Key number... 9 4.4 Engine number... 10 4.5 Fork part number. 10 4.6 Shock absorber article number 10 4.7 Steering damper item number... 10 5 MOTORCYCLE .. u 5a 5.2 83 5a 55 56 57 58 6 FORK, 6a 62 63 6a 65 66 67 68 69 6.10 ell 6.12 6.13 1d 6.15 6.16 7 HANDLEBAR, CONTROLS. 7a 72 73 78 78 76 8 FRAME. Ba B2 83 Lifting the motorcycle with the front lifting g5ar.. Taking the motoreycle from the front co gear. i Raising the motoreycle with the rea iting seer. - aL Removing the rear of motorcyle fom the liting gear 12 Raising the vehicle withthe center stand... 12 Removing the vehicle from the center stand... 12 Stating. 13 Starting the motorcycle to check the function .. 13 TRIPLE CLAMP Cleaning the dust boots ofthe fork legs Removing the fork legs, Installing the fork legs. Performing a fork service . Disassembling the fork legs. Removing the spring. Installing the spring. 4 7 Checking the fork legs. 20 ‘Assembling the fork legs al Checking the steering head bearing play... 24 ‘Adjusting the steering head bearing play aes. 24 Lubricating the steering head bearing 25 Removing the lower triple clamp. 26 Installing the lower triple clamp... . 26 Changing the steering head bearing 28 Changing the steering damper ‘Adjusting basic position of clutch lever. ‘Adjusting the handlebar position Remaving the crash bar. Installing the crash bar.. Changing the throttle grip Replacing the heated grips Rider footrest. Adjusting the footrests, Remaving the engine guard... 10 u 12 13 “4 aa 85 SHOCK ABSORBER, SWINGARW ... Installing the engine guard Checking the frame. 9.1 Measuring the rear wheel dimension unloaded 45, 9.2 Checking the static sag of the shock absorber... 45 9.3 Adjusting the spring pretension of the shock absorber. 9.4 Removing the shock absorber 9.5 Installing the shock absorber, 9.6 Removing the spring... 9.7 Installing the spring 9.8 Removing the heim joint. 9.9. Installing the heim joint.. 9.10 Checking the swingarm. 9.11 Checking the swingarm bearing for play. 9.12 Removing the swingarm.. 9.13 Changing the swingarm bearing, 9.14 Installing the swingarm, 9.18 Programming the shock absorber conta motor 59 9.16 Programming the swing angle sensor 59 EXHAUST... 60 10.1 Disassembling the main silence - 60 10.2 _ Installing the main silencer... 60 10.3 Removing the manifold 61 10.4 _ Installing the manifold... 63 AIR FILTER 66 11.1 Removing the upper pat of the air fiter box... 66 11.2 Changing the air filter, cleaning the air filter box... 11.3 Installing the upper part ofthe al iter Box. 11.4 Removing the lower part of the air filter box. 11.5 _ Installing the lower part of the air filter bok... FUEL TANK, SEAT, TRIN 12.1 Adjusting the front riders seat 12.2. Removing the front rider's seat. 12.3 Mounting the front rider's seat... 12.4 Removing the passenger seat 12.5 Mounting the passenger seat 12.6 Removing the fuel tank. 12.7 Installing the fuel tank 12.8 Checking the fuel pressure 12.9 Changing the fuel pump... 12.10 Changing the fuel filter... MASK, FENDER, DECAL. 13.1 Removing the front side cover 13.2 _ Installing the front side cover. 13.3. Removing the tank cover. 13.4 _ Installing the tank cover 13.5 Removing the mask spoiler 13.6 Installing the mask spoiler... 13.7. Removing the bottom triple clamp cover. 13.8 _ Installing the bottom triple clamp cover. 13.9 _ Removing the front fender... 13.10 Installing the front fender. 13.11 Removing the wind shield. 13.12 Installing the wind shield... 13.13. Adjusting the wind shield... 15.14 Austin te windshield adopter peston WHEELS 14.1 Checking the tre air pressure.TABLE OF CONTENTS 15 16 14.2 Checking the tie condition 14.3 Checking the rim run-out 14.4 Checking the whee! bearing for play 14.5 Checking spoke tension. 14.6 Programming the tire pressure sensor 14.7 Front wheel. 14.7.1 Removing the front whee 14.7.2 Installing the front wheel 14.7.3 Changing the front wheel bearing 14.7.4 Tubeless tire system... 14.7.5 Changing the front tubeless: sine profile 14.7.6 Changing the front tite pressure sensor 14.7.7 Checking the brake discs... 14.7.8 Changing the front brake dises. 148 Rear whee! 14.8.1 Removing the rear wheel. 14.8.2 Installing the rear wheel 14.8.3 Changing the rear wheel bearing. 14.8.4 Changing the rear tubeless sealing profile 14.8.5 Changing the rear tre pressure sensor.. 14.8.6 Changing the rear brake discs 14.8.7 Checking the chain tension. 14.8.8 Adjusting the chain tension .. 14.8.9 Checking the chain, ear sprocket and engine sprocket 14.8.10 Cleaning the chain... 148.11 Checking the rear hub rubber dampers. 14.8,12 Changing the rubber dampers in the rear ub 148.18. Changing te beeing ofthe rar post carrier. 14.8.14 Opening the chain 14.8.15 Riveting the chain.. . 14.8.16 Changing the drivetrain kit. WIRING HARNESS, BATTERY, 15.1 Removing the battery 15.2 _ Installing the battery. 153 Diszenncing the negative (in) edie oF the battery Connecting the negative cobe ofthe battery Recharging the battery Changing the main fuse Changing the fuses in the fuse box 15.8 Checking the charging voltage: 15.9 Checking the open-circuit current BRAKE SYSTEM 16.1 Checking the front brake linings... 16.2 Changing the front brake linings... 16.3 Checking the brake fluid level of the front brake ‘Adding front brake fluid. Changing the front brake fluid. ‘Adjusting the basic position of the hand brake lever... fn Checking the rear brake fnings. ‘Changing the rear brake linings ‘Adjusting the basic position of the foot brake lever... Checking the rear brake fluid level. ‘Adding rear brake fluid ‘Changing the rear brake fluid... 15.4 15.5 156 15.7 16.4 16.5 16.6 167 168 16.9 16.10 16.11 16.12 97 98 98, 99 98 99 99 100 101 103 103 105 106 107 107 107 108 109 uL 113 ua 118 us 6 7 118, 118 1g 120 120 121 125 128 125 126 127 128 129 130 132 133 134 134 . 134 136 . 136 137 139 139 139 141 142 142 143 3 17 LIGHTING SYSTEM, INSTRUMENTS 145, 17.1 Removing the headlight mask with the headlight. 145 17.2 Installing the headlight mask withthe. headlight 148, 17.3. Changing the low beam bulb. 146 17.4 Changing the high beam bulb. 147 17.5 Checking the setting ofthe lighting system... 148 17.6 Adjusting the headlight range 149 17.7 Adjusting the cornering light range .. 149 17.8 Activating/deactivating the ignition key 150 17.2 Programming the switch for the cruise control system. se 152 17.10 Resetting the service cisplay using the «TM iagnostic tool . sevens 153) 18 ENGINE 154 18.1 Removing the engine 154 18.2 _ Installing the engine. 160 18.3 Preparing the engine for installation 168, 18.4 Preparing the engine for clamping in the engine assembly stand .. 168 18.5 Setting the engine to ignition top dead center of the rear cylinder 169 18.6 Setting the engine to ignition top dead center Of the front cylinders vee 169 18.7 _ Engine isassemb\y... 170 18.7.1 Clamping the engine into the engine assembly stand. soeseusese 170 18.7.2 Removing the engine bearer. 170 18.7.3 Draining the engine cil 170 18.7.4 Removing the front valve cover. 17 18.7.5 Removing the rear valve cover 171 18.7.6 Setting the engine to ignition top dead center of the rear cylinder. 17 18.7.7 Removing the starter motor... 172 18.7.8 Removing the oil filler tube. 172 18.7.9 Removing the heat exchanger. 172 18.7.10 Removing the rear timing chain tensioner.... 172 18.7.1 Removing the rear camshaft. 173 18.7.12 Removing the rear cylinder head 173 18.7.13 Removing the rear piston.. 174 18.7,14 Setting the engine to ignition top dead Center of the front cylinder 174 18.7.15 Removing the font ing chain tensioner. 178 18,7.16 Removing the front camshats.. 175 18.7.17 Removing the front cylinder head 175 18.7.18 Removing the front piston. 176 18.7.19 Removing the alternator COVE sn 176 187.20 Removing the ignition pulse generator ..... 177 18.7.21 Removing the torque limiter. 77 18.7,22 Removing the rotor. 177 18.7,23 Removing the idler and imi chain on the left 7 187.24 Removing the ol filter 178 18.7.25 Removing the balancer shaft. 179 187.26 Removing the drive whee! of the balancer shaft 179 18.7,27 Removing the gear position sensor... 179 18.7,28 Removing the left suction pump.. 179 18.7.29 Removing the water pump wheel 180 18.7,30 Removing the clutch cover. oo 181 18.7.31 Removing the cluten dises. 181TABLE OF CONTENTS 187.32 18.7.3 187.34 187.35 18.7.36 187.37 18.7.38 18.7.39 187.40 187.41 18.7.42 18.7.43, 18.7.4¢ 18.7.45 Removing the clutch basket Removing the idler and timing chain on the right... . Removing the primary gear Removing the force pump. Removing the shift shaft... Removing the shift drum locating.. Removing the locking lever Removing the left engine case. Removing the crankshaft wre Removing the middle suction pump... Removing the transmission shaft. Removing the oil spray tube. Removing the timing chain rails of the right engine case section Removing the timing chain rails of the left engine case section... 18.8 Working on individual parts. 188.1 18.8.2 18.8.3 18.84 18.8.5 188.6 188.7 18.8.8 188.9 18.8.10 188,11 18.812 18.813 18.8.14 18.8.15 18.8.16 188.17 18.8.18 18.8.19 18.8,20 18.821 18.8.22 188.23 18.8,26 18.8,25 18.8.26 18.8.27 18.8.28 18.8,29 18.8.30 188.31 18.8,32 18.8.3 18.8.34 18.9 Engine assembly. 18.9.1 18.9.2 Work on the right section of the engine Removing the ight main bearing Selecting the main bearing shells. Installing the right main bearing... \Work on the left section of the engine case. Removing the left main bearing, Installing the left main bearing Changing the conrod bearing... Work on the clutch cover. Changing the suppert bearing of the crankshatt.. Checking the radial clearance of the bottom connecting rod bearing. Checking/measuring the cylinder... Checking/measuring the piston. Checking the piston ring end gap .. Checking the piston/cylinder mounting clearance. en Work on the cylinder head Checking the cylinder head. Work on the right idler Checking the timing assembly. Preparing the timing chain tensioner for installation Pretensioning the spread transmission Checking the oil pressure regulator valve Checking the lubrication system Checking the eluteh Checking the shift mechanism . Preassembling the shift shaft, Disassembling the main shaft. Disassembling the countershat. Checking the transmission . Assembling the main shaft. ‘Assembling the countershaft... Measuring the main shaft axial play. Checking electric starter operation Checking the freewheel Installing the timing chain rails of the lett engine case section. Installing the timing chain rails of the Fight engine case section . 182 183 183 183 . 184 . 184 184 186 185 185 186 . 187 187 187 187 . 187 189 190 190 191 193 193 194 - 196 197 197 198 199 200 200 203 208 205 206 . 206 207 207 208, 209 210 211 212 213 214 218 216 216 217 217 2u7 217 19 20 2 18.93 18.9.4 18.9.5 18.9.6 18.9.7 18.9.8 18.9.9 18.9.10 18.911 18.9.12 189.13 18.9.14 18.9.15 18.9.16 18.9.17 18.9.18 18.9,19 18.9,20 18.9.21 18.9,22 18.9,23 189.26 18.9.25 18.9,26 18.9.27 18.9.28 18.9,29 18.9,30 18.9.31 18.9.2 18.9.33 18.9.34 18.9,35 18.9,36 18.9.37 18.9.38 18.9.9 18.9.40 18.9.41 18.9,42 18.9.43 18.9.46 18.9,45 18.9.46 18.9.47 18.9.48 18.9.49 Installing the oll spray tube. Installing the transmission shaft. Installing the middle suction pump Installing the crankstat.. Installing the left engine case Installing the locking lever. Installing the shift drum locating. Installing the shift shaft Installing the force pump, Installing the left suction pump... Setting the engine to ignition top dead Center of the rear cylinder. Installing the primary gear Installing the clutch basket. Installing the clutch dises. Intaling he ele and ting cain oo the right Installing the clutch cover Installing the water pump wheel Installing the gear position sensor .. Installing the dive whee! of the balancer shaft Installing the balancer shaft. Installing the idler and timing chain on the left. « Installing te oil filter Installing the rotor. Installing the torque limiter Installing the ignition pulse generator Installing the alternator cover. Rear piston assembly Installing the rear cylinder head .. Installing the rear camshafts .nenee Installing the rear timing chain tensioner... Setting the engine to ignition top dead center of the front cylinder Installing the front piston Installing the front cylinder head. Installing the front camshafts. Installing the front timing chain tensioner. Installing the heat exchanger Installing the starter motor. Checking the rear valve clearance Adjusting the rear valve clearance Checking the front valve clearance... Adjusting the front valve clearance Installing the oil filler tube Installing front valve cover Installing rear valve cover Installing the oil drain plug. Mounting the engine bearer. Removing the engine from the engine assembly stand. SECONDARY AIR SYSTEM SAS. 19.1 CLUTCH. 20.1 Changing the SAS membrane. CCheckingrecitying the fluid level of the hydraulic clutch. 20.2 Changing the hydraulic clutch fluid Checking the clutch 20.3 SHIFT MECHANISM ala Checking the basic position of the shift lever... aig 21g 219) 219 219 221 221 pal 221 222 223 223 223 224 225 225 226 227 227 207 228 228 229 229 230 230 230 232 233 233, 234 234 236 236 237 237 238, 238, 238 238 239 230 240 240 241 241 241 242 242 244 244 244 245, 251 251TABLE OF CONTENTS 22 23 24 25 26 27 21.2 Adjusting the basic position of the shift lever 21.3. Changing the gear position sensor. 21.4 Programming gear position sensor WATER PUMP, COOLING SYSTEM 22.1 Checking the coolant level in the ‘compensating tank 22.2. Comecting the coolant level in the Compensating tank 22.3 Checking the cooant fil level and antfteeze. 22.4 Draining the coolant... 225 Adding coolantibleeding the cooling system. CYLINDER HEAD . 23.1. Checking the valve clearance 23.2. Checking the ve clearance (fier and spark plugs removed) Setting the valve clearance of the rear cylinder. Setting the valve clearance of the front cylinder... Disassembling the camshaft of the rear cylinder. Installing the camshafts of the rear cylinder Disassembling the camshafts of the front cylinder... 23.3 23.4 23.5 236 23.7 23.8 LUBRICATION SYSTEM... 24.1 Oil circuit 24.2 Checking the engine cil level 24.3 Changing the engine oil and filter, cleaning the oll sereens ‘Adding engine oil . Checking the engine oil pressure Removing the oil nozzle for the clutch lubrication 24.8 24.5 246 24.7 lubrication. Installing the oll nezze forthe clutch lubrication. nnn IGNITION SYSTEM. 25.1 Alternator - checking the stator winding 25.2 Changing spark plugs (air filter removed). THROTTLE VALVE BODY 26.1 Removing the throttle valve body 26.2 Installing the throttle valve body... 26.3. Executing the initialization run.. 26.4 Checking the CO adjustment using the KTM agnostics too. TECHNICAL DATA.. 27.1 engine . 27.2 Tolerance, engine wea limits. 27.3 Engine tightening torques. 27.4 Capacities, 27.4.1 Engine oil 27.4.2 Coolant. 27.4.3 Fuel 27.5 Chassis... 27.6 Electrical system. 27.7 Tires... 27.8 Fork... 27.9 Shock absorber 27.10 Chassis tightening torques 24.8 Installing the camshafts of the front cylinder Checking/leaning he oil nozzle for clutch 251 251 253 254 . 254 . 284 255 . 256 257 259) 259 . 267 270 271 27. 272 273 273 278 275 276 276 278 278 280 280 - 281 282 282 284 292 292 293 294 296 - 296 . 296 296 . 299 300 300 300 301 301 302 302 302 302 28 29 30 31 32 33 34 35 INDEX.. CLEANING/PROTECTIVE TREATMENT. 28.1 Cleaning motorcycle 28.2 Chace and maintenance steps for winter operation, STORAGE. 29.1 Storage 29.2 Preparing for use after storage. 29.3 Checks and maintenance measures when preparing for use. SERVICE SCHEDULE...... 30.1 Additional information 30.2 Required work 30.3 Recommended wark. WIRING DIAGRAM .. 31.1 Page 1 of 13, 31.2 Page 2 of 13 31.3 Page 3 of 13, 31M Page 4 of 13, 31.5 Page 5 of 13 31.6 Page 6 of 13 31.7 Page 7 of 13... 31.8 Page B of 13, 31.9 Page 9 of 13 31-10 Page 10 of 13... 31.11 Page 11 of 13, 31.12 Page 12 of 13 31.13 Page 13 of 13... SUBSTANCES .. AUXILIARY SUBSTANCES ... SPECIAL TOOLS STANDARDS 308, 305 306 307 307 307 307 309 309 309) . 310 312 312 314 316 318 320 322, 324 326 328 330 332 334, 336 338 340 342 358 3591 MEANS OF REPRESENTATION 6 Set Symbols wed ‘The meaning of specific symbols is described below. J Indicates an expected reaction (e.g. of a work step or a function). x Indicates an unexpected reaction (e.g, of a work step or a function), Indicates a page reference (more information is provided on the specified page) i Indicates information with more details or tps. » Indicates the result of a testing step. wi Indicates a voltage measurement. A Indicates a curtent measurement. oa Indicates a resistance measurement ‘The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name? Indicates a protected name. Brang™ Indicates a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 = SAFETY ADVICE Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle, This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. ‘A numberof safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully, The safety instructions are highlighted in the text and are referred to at the relevant passages, © Info The vericte nas various information and warning labels at prominent locations. Do not remove informationwarning labels. Ht they are missing, you or others may not recognize dangers and may therefore be injured. Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken, Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken. ote Indicates a danger that will ead to considerable machine and material damage if the eopropriate measures are not taken, Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken. ‘Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses, Ex: valve spring mounter (5029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. Where thread lockers are used on screw connections (eg, Loctte®), follow the instructions for use from the manufacturer. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn patts. Following repairs or servicing, the vehicle must be checked for roadworthiness.3 IMPORTANT NOTES ‘The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. No warranty claims can be con- sidered for damage resulting from manipulations and/or alterations to the vehicle. ‘Additional information on the manufacturer or implied warranty and the procedures involved can be found in the service & warranty = Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to enter the groundwater, the sol, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. Only use spare parts and accessories approved andior recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. ‘The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: inttp:/iwwwaktm.com ‘The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or m: ‘assemble the component to perform the activity in question, Please follow th ot be shown at all It is not always necessary to dis- instructions in the text.4 — SERIAL NUMBERS 40229410, 40217410 40217410 — 402293-11 ‘The chassis number @ is stamped on the bottom right of the frame behind the steer- ing head. The chassis number is alsa shown on the type label (Super Adventure EW/FR/AUAP/CN) The type label @ is on the top right of the frame behind the steering head. (Super Aavenure US) Type label USA @ right affixed to the frame behind the steering head at the top (Super Adventur US) Type abel Canada @ is afixed tothe frame behind the steering head at the top tet The key number Code number @ can be found on the KEYCODECARD. © Info HYou need the key number to order a spare key. Keep the KEYCODECARD in 2 safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions. 402240-19,4 — SERIAL NUMBERS 10 The engine number @ is starped on the rant side ofthe engine, snzboe10 The fork part number @ is stamped on the inner sie ofthe fork stu, 402295410 The shock absorber article number @) is marked on a sticker onthe shock absorber case under the spring. 40229710 Steering damper iter number @ is embossed onthe underside ofthe steering damper.5 MOTORCYCLE " 5.1 Lifting the motoreycle withthe front iting gear Note Danger of damage The parked vehicle can roll away or fall over, =. Park the vehicle on a firm and level surface. Preparatory work = Raise the motorcycle with the rear lifting gear. (®° p. 11), = Remove the bottom triple clamp cover. (== p. 93) Main work = Move the handlebar to the straight-ahead position. ~ Altach the front lifting gear with the adapters on the steering stem, ‘Mounting pin (69329965030) (= p. 353) Lifting gear, front (69329965000) (" p, 382) = Align the front lifting gear with the fork legs. Info Always raise the motorcycle at the rear first. = Raise the motorcycle at the front. Note Danger of damage The parked vehicle can roll away or fall over, = atk the vehicle on a firm and level surface. Main work = Secure the motorcycle against falling over = Remove the front lifting gear. 210561-10 hing work. Install the bottom triple clamp cover. (= p. 93) Note Danger of damage The parked vehicle can roll away or fal over =. Park the vehicle on a firm and level surface. Mount lifting bushings on the swingarm. é = Insert the adapter in the rear lifting geor. Retaining adapter (61029955144) (= p. 348) Lifting gear, rear (69329955000) (= p. 352) = Place the motorcycle vertically, use the adapters to direct the lifting gear towards oe the swingarm and lift the motorcycle. 310660-10,5 MOTORCYCLE 2 54 Removing the rear of motorcycle from the lifting gear Note Danger of damage The parked vehicle can roll away oF fall over, = Park the vehicle on a firm and level surface. ~ see ne mtg go Remove the rear lifting gear and lean the motorcycle on the side stand @. Y S) on Note Danger of damage The parked vehicle can roll away or fall over. — Park the vehicle on a firm and level surface, Note Material damage Damage and destruction of components from excessive load. — The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when itis resting fon the center stand. The center stand or the frame may become damaged and the motoreycle may fal over = Pull the motorcycle up onto the center stand at the grab handles. = Stand to the left of the vehicle. = Hold the handlebar with your left hand and push the center stand onto the ground with your right foot ~ Putyour entice weight on arm @ ofthe center stand while pulling the vehicle up atthe let grab handle. © 1 The center stand is folded out to the stop. 40203210, Note Danger of damage The parked vehicle can roll away or fall over. ~ Park the vehicle on a firm and level surface. = Make sure that the steering is unlocked. — Move the vehicle forward with both hands on the handleber. While the vehicle tips off of the center stand, activate the front brake to stop the vehicle from rolling away. = Check that the center stand @ is folded all the way up. © 402033:10,5 MOTORCYCLE 13 87 Sern Danger Dane epost ges ere nd ning them may eu in uncon ad eth. = Always make sure there is surficient ventilation when running the engine. = Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing Never operate the vehicle with a discharged batlery or without a battery. Note Engine damage High rewing speed with a cold engine negatively impacts the lifespan of the engine. = Always run the engine warm at a low speed. Press the emergency OFF switch to the position ON ©. = Switch on the ignition by turning the black ignition key to the position ON ©. 1% After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the ssame time, 7 The ABS lamp lights up and goes back out after starting of. = Shift the transmission to idle Mt The green idling speed indicator lamp Il lights up. 70082001 Press the electric starter button ©, © Info To not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle If you open the throttle during the: starting procedure, fuel is not injected by the engine management system and the engine cannot start. ress the electric starter button (for at most § seconds. Wait for a least § seconds before trying again. This motoreycle is equipped with a safety starting system, You can only start the engine if the transmission is in neutral or ifthe clutch lever is pulled when a gear is engaged. Ifthe side stand is folded out and you shift into Bear, the engine stops. wo0829-01, = Remove the motorcycle from the center stand or side stand. Danger Danger of poisoning Exhaust gases are toric and inhaling them may result in unconsciousness and death. — Always make sure there is suficient ventilation when running the engine, Use an effective exhaust extraction system when starting or running the engine in an enclosed space. © Info Tress the starter for a maximum of 5 seconds. Wait for a least § seconds before trying again, = Press the emergency OFF switch to the position ONO. = Switch on the ignition by turning the black ignition key to the position ON ©. = Shift the transmission to idle = Press the electric starter button ©. Q) ite I Do not open the throttle. 0782-10,6 — FORK, TRIPLE CLAMP 4 Preparatory work = Raise the vehicle with the center stand. (© p. 12) = Remove the front fender. (3 p. 94) work = Push dust boots @ of both fork legs downward, Info The dust boots should remave dust and coarse dirt particles fram the fork tubes. Over time, dirt can accumulate behind the cust boots. If this dirt is ‘not removed, the oil seals behind can start to leak, Warning Danger of accidents Oil or grease on the brake dises reduces the braking. effect. = Always keep the brake discs free of oil and grease, = Clean the brake discs with brake cleaner when necessary. = Clean and oil the dust boots and inner fork tubes of both fork legs. Universal oll spray (= p. 341) ~ Press dust bots @ back into thelr installation positon, = Remove excess ol inshing work = stall the front fender. (2 p. 94) = Remove the vehicle fom the center stand. (© p. 12) Preparatory work = Raise the vehicle with the center stand. (© p. 12) = Clamp down the rear ofthe veiele. = Remove the font fender. (3 p. 94) = Remove the front wheel. (2 p. 99) = Remove the bottom triple clamp cover. (=* p. 93) work = Detach connectors @ and @. wham6 — FORK, TRIPLE CLAMP 15 210788-10, = Loosen sorews @ cf the lover tripe clamp. ~ Remove screw @ of the steering damper. ~ Loosen sorew @ ofthe steering damper clamp. = Loosen screws @ of the lover triple lamp. = Loosen screws ( ofthe upper triple clamp, ~_Remeve the fork legs fom the bottom, Warning, Danger of accidents Mocifications to the suspension settings can seriously alter the vehicle's ride behavior = Following modifications, ride slowly at first to get the feel of the new ride behavior. 1079110 Main work = Slide the left-hand fork leg into the triple clamps and the steering damper clamp. ‘The left-hand fork leg has a white connector; the right-hand fork leg has a red connector. The connector faces forward at an angle tard the center of the veto = Push te ight fr leg into the triple camps 7 The left-hand fork leg has a white connector; the right-hand fork lg has a ed connector, The connector faces forward a an angle toward the center ofthe vehicle = Align the fork legs inthe specified postion by means of fork rings @) Guideline ‘Upper triple clamp flush with 2nd ring of Fork legs.6 FORK, TRIPLE CLAMP = Tighten screws @ ofthe upper triple clamp. Guideline 16 ‘Screw, top triple clamp me 20Nm (14.8 Ibe fh) ~ Tighten screws @ of the lover triple clamp, Guideline Screw, bottom tiple clamp ue 12 Nm (8.9 Toff) ~ Tighten serews @ of the lower tile lamp, Guideline ‘Screw, baitom Wriple clamp me 12 Nm (8.9 Tot = Align the steering damper clamp to the fo Guideline the lower triple clamp. yer triple clamp. The clamp is aligned with the contour ofthe lower triple clam ip and lies on top of = Tighten screw @. Guideline Screw, steering damper clamp 12Nm (8.9 it = Position the steering damper. ~ Mount and tighten screw @. Guideline Screw, steering damper | MB 25 Nm octite® 243 (18.4 Ibe ft) ~ Plugin comectors @ and @. Finishing work = Install the bottom triple clamp cover. ( Install the front wheel. (£5 p. 100) Install the front fender. (© p. 94) p.93) Con The fork legs have been removed.6 — FORK, TRIPLE CLAMP 7 = Disassemble the fork legs. (© p. 17) - Remove the spring. (== p. 19) BSSSS | — check the fork tgs. 02 p.20) Alani = Install the spring. 2p. 19) 2 | = Assemble the fork legs. p. 21) cs lB | Sp] |i Ss k A |S 1s S [= e\|e ‘s's So SG ees os057.01 © Into ‘These operations are the same on both fork legs. condition The for egs have been removed. = Clamp the fork le inthe area ofthe loner tile clamp. » e Clamping stand (714085) (= p. 357) ~ Release screw cover @ with special too! @ Special socket (T14071) (=* p, 357) Info The screw cover cannot be removed. [503005-01 a; 03001-10, = Unclamp the fork = Drain the fork oil. — Remove cartridge screw @ with the washer.6 — FORK, TRIPLE CLAMP 18 y 03002.01 p e252 202105-12 ~ Remove the cartridge. = Remove dust boot @. = Remove lock ring Info The tock ring has a beveled end where @ screwdriver can be applied. Heat up the outer tube in area @ of the lover sliding bushings. Guideline 50°C (122 °F) = Pull the outer tube from the inner tube with a jerk Info The lower sliding busing @ must be pulled from its bearing seat = Remove the upper sliding bushing @. © Info Without using @ tool, carefully pull the stack apart by hand, fevzio4-11 = Take off the lower siding bushing @. Take off support ring @. = Take off seal ring @. = Take off lock ring @. = Take otf dust boot @. = Unelamp the frk leg6 — FORK, TRIPLE CLAMP 19 T These operations only apply tothe left fork leg, 4 = ia x n e000 10 Preparatory work = Disassemble the fork legs. (88 p. 17) Main work = Clamp the cartridge into a vise Clamping stand (1140158) (& p. 356) ~ Hold nut securely and loosen threaded bushing @ with special tool. Pin wrench (T103) (© p. 356) = Remove threaded busting @. ~ Pull the spring down and remove nut @) withthe washer. — Remove spring guide © with preload spacer @. — Remove the spring. Unclamp the cartridge. Info ‘These work steps only apply to the left fork leg. — 02014-10 02006-10, = Observe the installation postion ofthe springs. ~ Tight coil @ points toward the spring guide. = Clamp the cartridge into a vise. Clamping stand (T14015S) (© p. 356) = Position the spring = Position spring guide with preload spacer @ ~ Pull tne spring down and mount nut @) with the washer, Screw the nu al the way down6 — FORK, TRIPLE CLAMP 20 103056-10, die 202134-10 20068510, zozi12:10, = Screw on threaded bushing @ all the way. ~ Hold threaded bushing @ and tighten nut @. Condition Fork disassembled. = Check the inner tube and axle clamp for damage. » there is damage: = Change the inner tube, = Measure the outside diameter at several locations on the inner tube. 47.575... 48,005 mm (1.88878. 1.88996 in) If the measured value is less than the specified value: = Change the inner tube. Outside diameter of inner tube Measure the run-out of the inner tube. Run-out of inner tube *=0.20 mim (= 0.0079 in) + I the measured value is greater than the specified value: = Change the inner tube, = Check the outer tube for damage. » there is damage: = Change the outer tube,6 FORK, TRIPLE CLAMP a = Check the surface ofthe sliding bushings. > tthe bronze-colred layer @ under the sliding layer @) is visible: = Replace the sling bushings. 200865-10 = Check the spring length. Guideline Spring length with preload spaceds) [440 mm (7-32 in) CORONAL + the measured value i greater than the specified value | ~ Reduce the thickness ofthe preload spacers. +H the measured value is less than the specified valve: — Increase the thickness af the preload spacers 202135:10 i Info ‘The procedures are the same on both fork legs. Preparatory work = Check the fork legs. (p. 20) = Install the spring. (© p. 19) work = Clamp the inner tube wit the axe clamp. Guideline ©) [veesoftinns ~ Mount the special tot —O Protecting sleeve (TH401) (™ p. 356) ~ Grease and push on dust boot @. focios10] ——[[ubriant TA0SA) Tp 340) Info T Avvays change the dust boot, seal ring, lock ring, and support ring. Mount the sealing lip with the spring expander facing down. ~ Push on tek ing @ = Grease and push on sea ing @. Tubscant (714034) (= p. 340) 7 The sealing ip points downward, the open side upward = Remove the special too = Push on support ring @. Sand the edges of the sliding bushings with 600 grit sandpaper; then clean and grease the bushings. Fork oll (SAE 4) (4860116651) (™ p. 339) = Push on lover siding busting @. = Mount upper slang bushing @. © Info H Without using a tool, pull the stack slightly apart by hand,6 — FORK, TRIPLE CLAMP 2 = 3 a 202098-10 @ 4 0. 202.1611 2011-10 02012-10 Heat up outer tube in area @ ofthe lower slicing bushings. Guideline [soca SSSOSOSOSOSOSSOSCSCSCSCSCSCSCSSSSd = Hold the lower sliding bushing with the longer side of the special tool ‘Mounting fool (1140408) = p. 357) Push on the outer tube, Press the sliding bushing all the way into the outer tube. = Position the support ring, = Hold the seal ring with the shorter side of the special tool ‘Mounting tool (1140408) (= p. 357) Press the seal ring and support ring all the way into the outer tube. = Mount lock ring @. Info HW The tock ring must engage audibly. — Mount dust boot @. = Assemble the individual components that belong togetner. Into Sensor side (let fork le): cartridge with spring and white plug @, axle clamp with abel L = Assemble the individual components that belong together. Actuator side (ight fork eg): carte without spring, red plug @), axle clamp with abel R @.6 FORK, TRIPLE CLAMP 23 Slide the cartridge into the inner tube, = Mount and tighten cartridge screw @ with the washer. Guideline Screw, cartridge Mi2x1 25Nm (18.4 ibe ft = Clamp right fork leg vertically rn Guideline . Use soft jaws. = Fill with fork oil. Fork oll per fork | 430 mi Fork oil (SAE 4) (4860116681) leg (24.54 f102) | (2 p.339) 02009-01 = Clamp left fork leg vertically. —— Guideline ~ Use soft jaws. = Fill with fork oil Fork oil per fork | 680 mi Fork oil (SAE 4) (4860116681) leg (22.99 11.02.) | (2 p.339) 1803055-10, = Push the outer tube upwerd, ‘The following work steps apply to both fork legs. = Grease the O-ring of the screw cover. Lubricant (7158) (= p. 340) = Screw on and tighten screw cap @. Guideline ‘Screw cover on outer tube MATHS 40.Nm (29.5 lof ft) Special socket (T14071) (= p. 357)6 FORK, TRIPLE CLAMP Pa Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components, = Correct incorrect steering head bearing play immediately. Info Tr the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time, Preparatory work = Raise the vehicle with the center stand, (2 p. 12) Main work = Place a load on the rear of the vehicle. ‘7 The front wheel isnot in contact with the ground. — Move the handlebar to the straight-ahead position. Move the fork legs back and forth in the direction of travel Pay should not be detectable on the steering head bearing. there is no detectable play: = Adjust the steering head bearing play. (= p. 24) = Move the handlebar to and fro over the entire steering range. Te must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions. » detent positions are detected: — Adjust the steering head bearing play. (%° p. 24) = Check the steering head bearing and adjust if necessary Finishing work = Remove the vehicle from the center stand. (! p. 12) Preparatory work = Raise the vehicle with the center stand. (© p. 12) Main work = Loosen screws @ and @, Loosen and retighten nut ©. Guideline ‘Nut, steering head, top M2Bx1.0 ‘Step 1 10 Nm (7.4 Inf ft) Step 2 (loosen, counterclockwise) 60" Torque wrench with various accessories in set (58429094000) (™ p. 345) oeara} ‘Mount for torque wrench (58429094100) (= p. 345) = Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.6 — FORK, TRIPLE CLAMP 25 = Tighten screw @. Guideline Screw, searing head, top | W22R5 [46.5 Nm] Only applies when a3 br 19 | sing Holding wrench forsteting head bearing (5229080000) (5 p. 343) = Tighten screws @. Guideline Sere, top Wipe clamp 1 20 Nin (14.8 Ibf ft) Fishing work = Check the steering head bearing play. (=! p. 24) — Remove the vehicle from the center stand. (®8 p. 12) 2848-10 = Remove the lower triple clamp. (=* p. 25) = Install the lower triple clamp. (© p. 26) Preparatory work = Raise the vehicle with the center stand. (%* p. 12) = Clamp down the rear of the vehicle. = Remove the front fender. (=" p. 94) = Remove the front wheel. (= p. 99), = Remove the bottom triple clamp cover. (® p. 93) — Remove the fork legs. (© p. 14) Main work — Remove screws @. Take off the brake line and hang it to the side.6 — FORK, TRIPLE CLAMP 26 210796-10, = Remove screws @ with the handleber clamps. = Remove the handlebar and ly it to one side Info Cover the components to protect them against damage. Do not bend the cables and lines Remove srew © ~ Remove upper trp clamp, = Remove aut @. Remove protective ring @ © Info Hold the lower tripe clamp. = Take out the lower triple clamp with the steering stem, ~ Take out upper steering heed bearing @ = Remove steering head seal @. 10797-11 21079611 Main work = Grease the bearing, clean the sealing elements, and check for damage. High viscosity grease ("7 p. 340) ~ Mount steering head seal @. Insert the lover triple clamp with the steering stem. Mount upper steering head bearing @. = Position protective ring @. = Mount and tighten nut @. Guideline ‘Nut, steering head, top 28x10 Step 1 10 Nm (7.4 lof ft) Step 2 (loosen, counterclockwise) 60" Torque wrench with various accessories In set (58429094000) (=p. 345)6 FORK, TRIPLE CLAMP ‘au079810} — 27 ‘Mount for torque wrench (58420004100) (= p. 345) Position the upper triple clamp. Mount screw @ but do not tighten yet. Guideline Screw, steering head, top M22K1.5 50 Nm (26.9 Ib fe Postion the brake lines. Mount and tighten screws @. Guideline Remaining chassis sevens M6 TO Nm (7.4 1oF ft) Slide the left-hand fork leg into the tripe clamps and the steering damper clamp. The left-hand fork leg has a white connector; the right-hand fork leg has a red connector. 7 The connector faces forward at an angle toward the center of the vehicle Push the right fork leg into the triple clamps. The left-hand fork leg has a white connector; the right-hand fork leg has a red connector. ‘The connector faces forward at an angle toward the center of the vehicle Align the fork legs in the specified position by means of fork rings @. Guideline Upper triple clamp flush with 2nd ring of Fork legs. Tighten screws @ ofthe loner tiple lamp Guideline Screw, bottom tiple clamp 1 12 Nm (8.9 iff) Align the steering damper clamp to the lower triple clamp. Guideline The clamp is aligned with the contour ofthe lower triple clamp and lies on top of the lower triple clamp. Tighten screw @. Guideline Screw, steering damper clamp Me 12 Nm (8.9 tot) Position the steering damper. Mount ang tighten screw @. Guideline ‘Screw, steering damper | MB 25 Nm (18.4 Ibe ft) loctite® 2436 FORK, TRIPLE CLAMP = Tighten screw @. Guideline Sore, searing head, top M22e1.5 30 Nm (36.9 Ibf ft) = Using plastic hammer, tap ighty on the upper tripe clamp to avoid stresses. = Tighten screws (@ of the upper triple clamp. Guideline Soret, top tiple clamp Me 20Nm (148 Ibe fh = Position the handlebar. = Position the handlebar clamps. Mount and tighten screws @. Guideline Screw, handlebar clamp me 20Nm (14.8 Ibe ft The markings @ face backwards ~ Plugin comectors @® and ®. Finishing work = Install the bottom triple clamp cover. ( Install the front wheel. (© p. 100) Install the front fender. (© p. 94) Check the steering head bearing play. ( = Remove the vehicle from the center stand. ( p.93) p. 24) p.12) Preparatory work = Raise the vehicle with the center stand. ( = Clamp down the rear of the vehicle. = Remove the front fender, (= p. 94) = Remove the front wheel, (= p. 99) = Remove the bottom triple clamp cover. ( = Remove the fork legs. (X p. 14) = Remove the lower triple clamp. ( Main work = Remove lower bearing ring @. Tool bracket (58429089000) ( Press-out tool (58429092000) ( p.12) p93) p.25) p. 348) p. 345)6 FORK, TRIPLE CLAMP 2 -310806-10, 310807-10, = Remove upper bearing ring @. = Press in the new bearing ring as far as it wil go. Press in the new bearing ring as far a it will go. Tool bracket (68429089000) (= p. 348) Press.in tool (58429091000) (/® p. 345) Tool bracket (58429089000) (© p. 344) Press-out tool (58429092000) (= p. 345) Tool bracket (58429089000) (= p. 344) Press.in tool (58429091000) (© p. 345) ~ Remove loner steering head bearing ©. = Press on the new bearing with a suitable tube as fara it wil go. Info Only press the bearing in via the inner ring. Preparatory work = Remove the botiom triple clamp cover. (& p. 93) Main work = Remove screw @.6 FORK, TRIPLE CLAMP 30 Remove screws @. Remove the stering damper Position the new string damper. Mount and tighten screws @. Guideline ‘Screw, steering damper | M6 10 Nm Loctite? 2437 (7.4 Ibe tt Check that the clamp is seated correctly Info For purposes of illustration, the following operations are shown with the headlight mask deinstalled, The clamp is aligned with the contour of the lower triple clamp and lies on top of the lower triple clamp. If the clamp is not aligned with the contour of the lower triple clamp or does. ‘ot lie on top of the lower triple clamp: = Loosen serew @ and the position clamp. = Mount and tighten serew @ Guideline Soren, steering damper clamp] MB T2Nm oi Mount and tighten screw @ Guideline Sere, steering damper | WS Ze Nim | Lanta 24 Ga. Wr #9 ishing work Install the bottom triple clamp cover. (© p. 93)7 HANDLEBAR, CONTROLS 31 Adjust the basic setting of the clutch lever to your hand size by turning adjusting, screw Info Turn the adjusting serew clockwise to increase the distance between the cluteh lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and donot apply any force ‘Do not make any adjustments while riding! A wens Danger of accidents A repaired handlebar poses a safety risk I the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result ‘Change the handlebar if the handlebar is damaged or bent. ~ Remove screws @. Remove the handlebar clamps. Remove the handlebar and lay itto one side T cover the components to protect them against damage, Do nat bend the eables and lines. ~ Remove screws @. Toke off the hanclebar support. r=) > > sii andi sappnite aed pci, owned ton Guideline Serew, handlebar support [M10 40 Nm octite® 243 (29.5 Ibe ft Info HPosition the lett and rignt handlebar supports evenly. Position the handlebar. Info Make sure the cables and wiring are positioned correctly. ~ Position the hanelebar clamps. Mount and evenly tighten screws @. Guideline Screw, handlebar clamp 20 Nm (148 Ibe ft) 00863-10 7 The markings @ ofthe handlebar scale are located centrally between the han- dlebar clamps. 7 Markings @ face backwards. © Info Make sure the gap widths are even.7 HANDLEBAR, CONTROLS 2 — Remove serew connections A 7, mae ~ Remove serews @ and take ofthe clamp halves ~ Remove scrow @. = Take ff the left rash bar, ~ Remove serens @ and takeoff the clamp hates ~ Remeve screw @ = Take ofthe right erash bar. Position the right erash bar with the frame protector. ‘Y The fuel tank support ring should be correctly positioned on the fuel tank. 0 Tcover the components to protect them against damage. = Mount screw @, but do not tighten yet. Guideline Remaining chassis screws me 25Nm (18.4 Ibe ft ~ Mount screws @, but do not tighten yet. Guideline Remaining chassis screws Me TO Nm (7-4 tof ft) = Position the left crash bar with the frame protector. ‘The fuel tank support ring should be correctly positioned on the fuel tank. © Info Cover the components to protect them against damage. = Mount screw @, but do not tighten yet. Guideline Remaining chassis screws ue 25 Nm (18.4 ib ft — Mount screws @, but do not tighten yet. Guideline Remaining chassis screws Me 10 Nm (7.4 Tot fb)7 HANDLEBAR, CONTROLS = Mount and tighten fittings © Guideline 33 Remaining chassis screws Me TONm (7-4 Tot) The crash bars are evenly aligned wit! Tighten all the screws of the crash bar. Guideline jh each other é 108e9-10 — : os 310887:10, Remaining chassis screws Me TO Nm (7-4 Tot A Remaining chassis screws Me 25m (18.4 Ibe ft Preparatory work = Switch off all power consumers and switch off the engine. = Remove the wind shield. (© p. 94) = Remove the passenger seat. (" p. 72) = Remove the front rider's seat. (© p. 71) = Remove the crash bar. (© p. 32) = Remove the front side cover. (®® p. 87) = Remove the tank cover. (© p. 89) = Remove the mask spoiler. (© p. 90) = Remove the headlight mask with the headlight. ( Main work = Remove intake snorkel @ = Remove the cable te(s) p. 145)7 HANDLEBAR, CONTROLS Remove the cable tie(s). ~ Disconnect plug-in connector @ ~ Remove plugin connectors @ and @ from the holder and disconnect. ~ Disconnect plugin connector @. = Disconnect plug-in connector @. = Slip out the cables. = Loosen screw @. = Push the hand guard slightly to the side. = Remove screws @. = Take off throttle grip with sensor unit. 0894-10,7 HANDLEBAR, CONTROLS 35 Position thrattle rip with sensor unit. A Pin @ engages in hole @ Y Projections @ eneage in ecesses @. = Mount and tighten screws @. Guideline [Remaining serews, haste To Sm 7 BFAD = Position hand guard = Tatton screw @. Guideline Hand parla 18 TEN (21.1 Ibe ft -310892:10 = Join pug.in connector @. = Join plug-in connector @. = Route the cable without tension, ~Join plug-in connector @. ~Join plug-in connectors @ and @® and position them in the holder. = Route the cable without tension and secure with cable tie().7 HANDLEBAR, CONTROLS 36 _310887:10 / ii = Route the cable without tension and secure with cable ties. = Mount intake snorkel @. Info Ensute that the seals are seated correctly Finishing work Install the headlight mask with the headlight. (°° p. 145) Install the mask spoiler. (© p. 92) Install the tank cover, (© p. 89) = Install the front side cover. (® p. 87) = Install the crash bar. (© p. 32) = Mount the front rider's seat. (°° p. 71) — Mount the passenger seat. (© p. 72) Install the wind shield. (© p. 95) = Check the setting of the lighting system. (© p. 148) = Program the switch for the cruise control system. (°2 p. 152) Preparatory work = Switch off all power consumers and switch off the engine. = Remove the wind shield. (= p. 94) ~ Remove the passenger seat. (=* p. 72) = Remove the front rider's seat. (= p. 71) = Remove the crash bar. (!! p. 32) = Remove the front side cover. (%° p. 87) = Remove the tank cover. (28 p. 89) = Remove the mask spoiler. (° p. 90), Remove the headlight mask with the headlight. (-* p. 145)7 HANDLEBAR, CONTROLS 37 Main work = Remove intake snorkel @). = Remove the cable tie(s) — Remove the cable te(s) = Remove the cable te(s)7 HANDLEBAR, CONTROLS 310902:10 y 310894-10, -310906-10 Disconnect plug-in connector @ Slip out cables. Disconnect plug-in connector @. Slip out cables. Loosen serew @. Push the hand guard slightly to the side. Remove screws @. Pull off throttle grip with sensor unit from the handlebar Remove the throttle grip. The sensor unit must not be disconnected. Ifthe sensor unit is disconnected, the switch of the speed control system must be programmed. Loosen screw @. Push the hand guard slightly to the side. Slightly raise the rubber grip. Remove screw @. 387 HANDLEBAR, CONTROLS 310306:10, -310902:10, Take off heated grip. Postion nested grip. Slightly rise the rubber arp Mount ana tignten screw @ Position hand guard, Tighten screw @. Guideline 39 Hand guard screw or 15 Nm (21.1 Ibe ft) Postion tattle grip with sensor unit. S Pin @ engazes in hole @ Y Projections @ engage in recesses @ Mount and tighten screws @. Guideline Remaining chassis screws Me TONm (7-4 tot) Position hand guard. Tighten screw @. Guideline Hand guard screw me 5 Nm (1.1 Ibe fo7 HANDLEBAR, CONTROLS = Connect plugin connector @ = Route the cable without tension. = Connect plug-in connector @ = Route the cable without tension 310901-10 = Route the cable without tension and secure with a cable binder. = Route the cable without tension and secure with a cable binder. = Route the cable without tension and secure with a cable binder. 310887-10,7 HANDLEBAR, CONTROLS a = Mount intake snorkel @. Info Ensure that the seals are seated correctly Finishing work = Install the headlight mask with the headlight. (" p. 145) Install the mask spailer. (® p. 92) Install the tank cover. (© p. 89) Install the front side cover. ("# p. 87) Install the crash bar. (© p. 32) Mount the front rider's seat, (© p. 71) Mount the passenger seat. (© p. 72) Install the wind shield. (© p. 95) Check the setting of the lighting system. (°* p. 148)a2 The rider fooiests can be mounted in one of two positions. Possible states © Rider tootests, ow @) + Rider tootests, nen @ 8.2 Adjusting = Info ‘The operations on the footrest brackets are the same for the left and right sides. = Remove screw @. ~The foot brake lever swings up to the stop. ~ Remove cotter pin @ with washer @ = Carefully remove the pin @ of the rider footrest. © Info ‘The spring is under high tension and can pop aut when the pin is removed. = Take off the rider footrest @ with the sprin = Remove scrows @. Adjust the footrest bracket to the desired position.8.3 Removing the engine guard @ 0033.10 84 Installing the engine guard > w00833.11 Mount and tighten screws @ Guideline Seren, front foarest | MB Tem | Laette™ 2a bracket, (18.4 Ibf ft) Mount the rider footrest with spring @ and oin @. Pliers for footrest spring (58429083000) (" p. 344) Mount washer @ and cotter pin @ Position the foot bake lever Mount ang tighten serew @ Guideline ‘Screw, ball joint of push | M6 10 Nm | Loctite® 24a" | rod or foot brake cinder (ratty Remove screws @ with bushings ang engine guard @. Position engine guard @, mount screws @ with bushings and tighten, Guideline Screw, engine guard TONM (740 Me8 FRAME ” 8.5 Checking the frame = Check the frame for cracks and deformation. Ifthe frame exhibits cracks or deformation due to @ mechanical impact: = Change the frame. © Info Always replace a frame that has been damaged due to a mechanical impact. Repair ofthe frame is not authorized by KTM. osi24-109 SHOCK ABSORBER, SWINGARM a St 40098810, Preparatory work = Raise the vehicle with the center stand. ( Main work = Measure the distance — as vertical as possible ~ between the rear axle and a fixed point, for example, a mark on the rear fairing. = Note down the value as dimension @. p12) Finishing work = Remove the vehicle from the center stand. (! p. 12) = Measure dimension @ of rear wheel unloaded. (2 p. 45) = Hold the motorcycle upright with the aid of an assistant. = Measure the distance between the rear axle and the fixed point again, Note dovin the value as dimension @. © Info The static sag is the difference between measurements @ and @. = Check the static sag. Full fuel tank 25 mm (0.98 in) Empty fuel tank 20 mm (0.79 ind yh 400999:10 401896-01 + the static sag is less or more than the specified value: — Adjust the spring pretension of the shock absorber. (© p. 45) Condition ‘The diagnostic tool is connected and running. ~ Execute "Damping system - SCU* > "Functions" > “Adjusting offset for sag” = Following the instructions in KTM diagnostics tool exactly.9 SHOCK ABSORBER, SWINGARM 46 (9.4 Removing the shock absorber Preparatory work = "alse the vehicle withthe center stan. (2 p. 12) = Romave the passenger seat © p. 72) = Remove the frontier’ seat. p. 71) Main work = Remove screw @. = Loner the swingarm, ~ Unplug connector @. Maneuver te wring hamess out = Unplug connector @ 03026-10, = Remove screw @. = Lift up heat protector @. = Remove screw @. Lower the shock absorber.9 SHOCK ABSORBER, SWINGARM a ~ Remove the shock absorber. Fis0302910) Main work — Use a commercially-available screw @ and 2 collar nuts, @ Guideline Screw Mio Length = 60 mm (2 2.36 in) ] 202029.10 = Position screw @ in the ceil hole of the swingarm, 10792410 = Mount both collar nuts @ and @ with the collar facing out = Hold screw @. Tighten collar mut @ until itis in contact withthe swingarm. Screw @ rests against the swingarm at collar nut @. Y Thecentering bushing ofthe shock absorber is pressed into the swingarm. = Remove the serew and nuts. = Position the shock absorber = Mount and tighten screw @ Guideline Miad.5 [60 Nm Thread greased ‘Screw, top shock absorber (59 Ibt At)9 SHOCK ABSORBER, SWINGARM 48 ~ Position heat protector @ = Mount and tighten serew @ Guideline Screw, cover part M5 35 Nm (2.58 lof ft) Lift the swingatm and position the shock absorber. = Mount ang tighten screw @. Guideline ‘Screw, bottom shock Midxi.5 [80 Nm Thread greased absorber (59 Ibt ft) = Position the wiring harness. = Plugin connector @. 02053:10, = Position the wiring harness. = Plugin connector © Finishing work = Program the shock absorber contral motor. (=! p. 89) = Mount the front rider's seat. (°° p. 71) — Mount the passenger seat. (© p. 72) - Remove the vehicle from the center stand. (%8 p. 12) Condition The shock absorber has been removed. = Clamp the shock absorber into the special tool. Spring compressor (T140508) (= p. 357) Info Use a fitting washer of the special tool as a spring pad. nl ~ Compress the spring. Remove spring retainer @) ae Be ecs024.109 SHOCK ABSORBER, SWINGARM 49 Oo feo2026-10 4 4 10 me 0304-10, = Release the soring. Unclamp the shock absorber. ~ Remove washer @ and spring ~ Remove washer @. = Remove preload adjuster Info T screw @ does not need to be loosened = Mount preload adjuster Y Screw @ is aligned with recess @. ~ Mount washer @. ~ Postion spring and washer @. = Clamp the shack absorber into the special tool Spring compressor (T140508) (™ p. 357) Info Use a fitting washer of the special tool as a spring pad. Compress the spring. Mount spring retainer = Release the spring. Unclamp the shock absorber9 SHOCK ABSORBER, SWINGARM 50 Info ‘The operations are the same for the top and bottom heim joints. pen 02043-10 0304410, Condition The shack absorber has been removed. = Clamp the shock absorber into the vise with sft jaws. = Remove both collar bushings @ ofthe heim joint witha dit. Pin (T120) (= p. 356) — Remove seal rings @ on both sides. ~ Press heim joint @) 10 the side, Pressing tool (712075) (=p. 356) ‘Y The heim joint rests against a lock ring = Remove the other lock ring @. — Place special tool @ underneath and press out the heim joint with special Pressing tool (T1207S) (" p. 356) Info ‘The operations are the same for the top and bottom heim joint.9 SHOCK ABSORBER, SWINGARM 51 ~ Place special too! @ underneath and press out the heim joint upto the lock ring bh, wath special tol @ s . iri = Mount a second lock ring @. ~ Mount sel rings @ on both sides and grease. Labrcant (7158) (=p. 340) 1 ee ~ Pres in both colar bushings @ ofthe heim joint 202047-10 = Check the swingarm for damage, cracking, and deformation. » If the swingarm shows signs of damage, cracking, or deformation = Change the swingarm. Info HAtvays change a damaged swingarm. Repair of the swingarm is not authorized by KTM. 2123-10 Preparatory work = Raise the vehicle with the center stand. (%® p. 12) = Place a load on the front of the vehicle. ‘7 The rear wheel is notin contact with the ground9 SHOCK ABSORBER, SWINGARM 52 Main work = Move the swingarm up and dawn, I there is detectable play: = Change the swingarm bearing. (© p. 54) Move the swingarm from one side to the other. 1» Hf there is detectable play = Change the swingarm bearing. (© p. 54) 310876:10, Preparatory work Raise the vehicle with the center stand. (= p. 12) = Remove the rear wheel. (2= p. 107) Main work = Remove screws @. Remove the splash protector. = Remove screw @. = Take ff the cable holder. = Remove sreus @. — Remove screw @. = Hang the foot brake cylinder to the side.9 SHOCK ABSORBER, SWINGARM 53 310750:10, 210754.10, Take the brake line aut of the holders Pull brake caliper back and hang to the si Take the cable out of holders. Unplug connector @. Remove screw @. Push the swingarm down and away from the shock absorber. Remove nut @. Remove the swingarm pivot. Take off the swingarm.9 SHOCK ABSORBER, SWINGARM 4 Preparatory work = Raise the vehicle with the center stand. (© p. 12) = Remove the rear wheel. (© p. 107) = Remove the swingarm. (23 p. 52) Right swingarm bearing = Remove the outer colar bushing @. = Remove the iner collar bushing @ together with the bushing Too ‘al 21075810, = Remove the shatt seal ings @ and @ ~ Pesition special toot @ in the needle bearing from the inside ress drift, swingarm bearing (61329004100) (= p. 351) ~ Postion special tot @ onthe swingarm ftom the outside Counterholder, swingarm bearing (61325004200) (= p. 351) = Push ut the needle bearing = Position the new needle bearing @ on special tool @. Press drift, swingarm bearing (61329004100) (—* p. 351) — Position the special too! with the bearing on the swingarm from the outside — Push in the needle bearing until itis flush,9 SHOCK ABSORBER, SWINGARM 55 Grease shaft sea rings @ and @ and press in until lsh e a Long-life grease (= p. 340) = Grease the needle bearing. p. 340) Mount the inner collar bushing @ together with the bushing. Mount the outer collar bushing @. 31075710, Let swingarm bearing = Remove the cuter collar bushing @ = Remove the inner collar bushing @ together with the bushing, -310762:10, ~ Remove the shaft sal rings @ anc @. 310763:10, Remove stop disks @® and ®. 31076410, — Position special tool @ in the needle bearing, Press drift, swingarm bearing (61329004100) (~* p. 361) Position special too! @ in the swingarm, Counterholder, swingarm bearing (61329004200) ("= p. 351) = Push out the needle bearing,9 SHOCK ABSORBER, SWINGARM 56 2076410, 310762.10 = Position the new needle bearing @) on special tool @ Press arf, swingarm Bearing (61320004100) (= p. 351) — Position the special tool with the bearing on the swingarm, = Push in the needle bearing until itis flush. = Position stop disks @® and ®. — Grease shatt seal rings @ and @ and press in until us, Tongelife grease (© p. 340) ~ Grease the needle bearing. — Mount the inner collar bushing @ together with the bushing. = Mount the outer ear bushing @ hing work = Install the swingarm. (© p. 57) = Install the rear wheel, ("9 p. 108) = Adjust the chain tension. (© p, 115) - Remove the vehicle from the center stand. (© p. 12) Program the swing angle sensor. p. 59)9 SHOCK ABSORBER, SWINGARM 37 31075410, Main work Position the swingarm. Mount the swingarm pivot. = Mount ang tighten nut @. Guideline ‘Nut, swingarm pivot M915 |130Nm Thread greased (95.9 Ibe ft) — Use a commercially-available screw @ and 2 collar nuts, suieline Seren wo e Length 2 60 mm (2 2.36 in) 209029:11 = Position screw @ in the dil hole ofthe swingarm, — Mount both collar nuts @ anc @ with the collar facing out. = Counterhold screw @ Tighten collar nut @) until tis in contact with the swingarm. Screw @ rests against the swingarm at collar nut @ The centering bushing of the shock absorber is pressed int the swingarm. = Remove the sere and nuts. = Lift the swingarm and position the shack absorber. = Mount and tighten screw @. Guideline Screw, bottom shock Mial.S | 80Nm Thread greased absorber (59 bt ft)9 SHOCK ABSORBER, SWINGARM ~ Position the splash protester. = Mount and tighten serens @. Guideline 58 Remaining screws, chassis MS 5 Nm (3.7 bff) = Plugin connector @. = Secure the cable in the holders, = Position the brake caliper Secure the brake line in the holders, ~ Position the fot brake eytinder ~ Mount and tignten screws @, Guideline Serew, foot brake cylinder | M6 10 Nm (7.4 Ibe fo) Loctite® 243 = Mount ans tignten serew @ Guideline ‘Screw, ball joint of push | M6 rod on foot brake cylinder 10 Nm (7.4 Ibe tt) Toctite® 243 = Position the cable holder = Mount and tighten serew @D. Guideline Remaining chassis nuts Me TO Nm (7-4 TOFD Finishing work = Install the rear wheel. (© p. 108)9 SHOCK ABSORBER, SWINGARM 59 = Adjust the chain tension. (Fp. 115) ~ Remove the vehicle from the center stand. (= p. 12) Program the swing angle sensor. (© p. 59) 401898.01 401898.01 Condition The diagnostic tool is connected and running. = Execute "Damping system > *Functions* » “Factory calibration” Info H The instructions must be followed precisely. = Clear the fault memory using the KTM diagnostics too! > Takea test ride. ~ Read out the trouble code memory using the KTM diagnostics tool Condition The diagnostic tool is connected and running, Execute "Damping system > "Functions" > “Rear suspension travel sensor calibration”. Info H The instructions must be followed precisely. = Clear the fault memory using the KTM diagnostics tool. + Take a test ride — Read out the trouble code memory using the KTM diagnostics tool.10 EXHAUST — Remeve screw @ = Pl off the heat protector toward the front. = Remove screw @. Remove the exhaust clamp. = Remove screw @ with the washer. = Remove the main silencer with the main silencer clamp. = Position the main silencer with the main silener clamp. ~ Mount screw @ wit the washer but donot ti = Position the exhaust clamp. = Mount and tighten serew @ Guideline Screw, exhaust clamp Me 8 Nm (5.9 It10 EXHAUST Tighten screw @. 81 Guideline ‘Screw, exhaust clamp me 25 Nm (18.4 tbr fb ~ Grease the absorbing elements @ slightly to ease assembly, 310665:10 = Position heat protector in the holder from the front. = Mount ang tighten screw @. Guideline Screw, heat guard on main silencer | MB 4 Nem (3 FF 0862-11 paratory work Disassemble the main silencer. (= p. 60) Remove the passenger seat. (=* p. 72) Remove the front rider's seat. (= p. 71) Remove the crash bar. (8! p. 32) Remove the front side cover. (© p. 87) Remove the tank cover. (8 p. 89) Remove the mask spoiler. (5 p. 90) Remove the fuel tank. (** p. 73) in work Remeve pin connector @ plug fom plug holder and disconnect. Remove the cable tie(s) and expose the cable.10 EXHAUST 120207810, ~ Disconnect plug-in connector @ ~ Expose the cable. = Remove screw @. = Take off the exhaust clamp. = Remove screus @ = Remove serene @ = Take off the retaining bracket. ~ Remove nuts ©. = Remove screw @. = Lower manifold and remove it in a forward direction. 6210 EXHAUST 83 = Remove nuts ©. = Remove the manifold in a downward direction = Remove exhaust gaskets @. Main work = Position exhaust gaskets @. = Position the manifold from below. = Mount nuts @ but do nt tighten yet. Guideline Tt, manifold on einer head We Tightening sequence Tighten the nuts een. Do not bend te meta 25m Ge. it 9 = Position the manifold atthe font. = Mount nuts @ but do et tighten yet. Guideline ‘Nut, manifold on eviner head ie Tightening sequence Tighten the nuts evenly. Do rot bend the metal 25m 8. ir 9 = Mount and tighten serew @ Guideline Sore, exhaust clamp we 25 Nm (ie. it #910 EXHAUST = Position the exhaust clamp. = Mount and tignten screw Guideline ‘Screw, exhaust clamp Me 8 Nm (5.9 IF) = Tighten nuts @ ans @ Guideline "Nut, manifold on cylinder head ue Tightening sequence: Tighten the nuts evenly. Do not bend the metal. 25Nm (18.4 Ibe ft) Route the cable without tension and secute with cable tits) Jain the plugin connector @ and poston inte pug node Route the cable without tension and secure with cable tie(s) Join plug-in connector @.10 EXHAUST Position the retaining bracket Mount and tighten screws @. Guideline 65 Sere, cooler retaining bracket iW 7m (EAH Mount ane tignten screws © Guideline Remaining serews, chests 15 Sm (B7 BER Finishing work Install the fuel tank, (© p. 74) Install the mask spailer. (® p. 92) Install the tank cover. (5 p. 89) Install the front side cover, (= p. 87) Install the crash bar. (© p. 32) Mount the front rider's sea, ( Mount the passenger seat. (© p. p.7) 72) Install the main silencer. (© p. 60)11 AIR FILTER Preparatory work ="Remeve the passenger seat. p. 72) = Remove the front riders seat. (2 p. 71) = Remove the ersh bar. (=p. 32) = Remove the front side cover. (© p. 87) = Remove the tanks cover (2p. 89) — Remove the mask spoiler. (© p. 90) = Remove the fuel tank. (25 p. 73) Main work = Detach connector @ = Expose cable @ — Push back hose clip @. = Pall off the vent hose. = Remove screws @. Remove the upper part of the air filter box. 310833:10, Preparatory work = Remove the passenger seat. (© p. 72) = Remove the front rider's seat. (= p. 71) = Remove the crash bar. (8 p. 32) - Remove the front side cover. (© p. 87) ~ Remove the tank cover. (= p. 89) ~ Remove the mask spoiler, (© p. 90) = Remove the fuel tank. (= p. 73) = Remove the upper part of the air filter box. (# p. 66) Main work = Remove air filter clamping wedge @) toward the top.11 AIR FILTER 2 —e 1011410 310835-10 o 31083610 310833.11 67 Remove air fiter frame @ withthe ar fiter. Clean the air filter box. Position the new air filter @ in the air filter frame. Postion ai fier frame @ inthe lower section ofthe ar fiter box together with the ar filter 1 The broad side of the air filter frame faces the engine. Mount air filter clamping wedge @. 7 The narow sie ofthe ar fte clamping wedge faces the engine. Finishing work Install the upper part of the air filter box. (2 p. 67) Install the fuel tank. (© p. 74) Install the mask spoiler. (© p. 92) Install the tank cover. (22 p. 89) Install the front side cover. (2 p. 87) Install the crash bar. (© p. 32) Mount the front rider's seat. (© p. 71) Mount the passenger seat. (© p. 72) Main work Poston the upper part ofthe at filler box. Mount anc tignten screws @AIR FILTER = Nount the vent hos, = Position hose clip @. ~ Plugin connector = Position cable @ hing work = Install the fuel tank. (© p. 74) = Install the mask spoiler. (© p. 92) = Install the tank cover. ("% p. 89) = Install the front side cover. (© p. 87) Install the crash bar. (© p. 32) Mount the front rider's seat. (-® p. 71) Mount the passenger seat. (© p. 72) Preparatory work = Remove the passenger seat. (§ p. 72) Remove the front rider's seat. (© p. 71) Remove the crash bar. (8 p. 32) Remove the front side cover. (© p. 87) Remove the tank cover. ("= p. 89) ~ Remove the mask spoiler, (®" p. 90) = Remove the fuel tank. (© p. 73) = Remove the upper part ofthe air filter box. (© p. 66) Main work = Remove spring band clamp @. Pliers for spring band clamp (60029057100) ("* p. 347) = Pull ff the vent hose. = Remove cable binder11 AIR FILTER f310866-10, [00367-10, = Remove screus @ = Remove the intake trumpet. = Raise the lower part ofthe air filter box and pull it back gently = Remove SLS valve @ from the holder. = Remove the lower part ofthe air filter box. Main work = Poston the loner prt fair fiter box @) in the frame © Info Ensure that the O-rings are seated correctly. = Mount SUS vane @ on holder. ~ Position intake ducts @. Info TEnsute that the seals are seated correctly.11 AIR FILTER 0 = Position the intake trumpet and mount and tighten screws @ with bushing Guideline Remaining srewe, chasse wi Biima7 era | Route the hase without kinks, ~ Mount cable binder @. = Mount the vent hose. = Position spring band clamp @ with special tool. Pliers for spring band clamp (60029057100) ("" p. 347) Finishing work Install the upper part of the air filter box. (22 p. 67) Install the fuel tank. (© p. 74) Install the mask spoiler. (= p. 92) Install the tank cover. (© p. 89) Install the front side cover. (™ p. 87) Install the crash bar. (© p. 32) Mount the front rider's seat. (©® p. 71) Mount the passenger seat. (© p. 72)12 FUEL TANK, SEAT, TRIM n 100856.10 Preparatory work = Remove the passenger seat. (© p. 72) Lower the fon rider's seat = Attach the front riders seat to the fuel tank atthe recesses @, and push the front rider's seat down and forward atthe same time. Raise the front rider’ seat = Attach the font riders seat t the fuel tank atthe recesses @., and push the rider seat up and forward atthe same time. = Finally, check thatthe front rider's seat is correctiy mounted. Finishing work = Mount the passenger seat. ("8 p. 72) Preparatory work = Remove the passenger seat. (" p. 72) Main work ~~ Lift the rider's seat back and unhook in the @ area. © Info Pay attention to the seat heating cable. = Disconnect plug-in connector @. Main work = Connect plugin connector @12 FUEL TANK, SEAT, 07680-11 TRIM n ~ Attach the recesses on the driver's seat to the fuel tank atthe desited seat posi- tion @ or @, and push the driver's seat forward while lowering it at the rear. Info Ensure that the seat heating cable is correctly routed, Finally, check that the driver's seat is correctly mounted. Finishing work = Mount the passenger seat. (© p. 72) ~ Insert the ignition key in seat lock @ and turn it clockwise. = Raise front of the passenger seat, pull toward the tank, and remove upward. ‘Info Pay attention to the seat heating cable. ~ Disconnect plugin connector @ = Remeve the ignition key ~ Connect plugin connector @ = Attach the hooks on the passenger seat to the hanger on the subframe, Info Ensure that the seat heating cable is corectly routed. Lower passenger seat and push back at the same time. Position locking pin @ in lock housing and press passenger seat forward until the locking pin engages with an audible click. = Check that the passenger seat is correctly mounted.12 FUEL TANK, SEAT, TRIM B 126 Removingthe fuel tame Danger Fire hazard Fuel is highly flammable, ‘The fuel in the fuel tank expands when warm and can escape if overlie. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switeh off the engine for refueling, = Make sure that no fuel is spilled; particularly not on hot parts of the vehicle = If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling A Warning, Danger of poisoning Fue! is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel = Immediately consult a doctor if you swallow fue. = Da not inhale fuel vapors. Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. — Change your clothing in case of fuel spills on them, Keep fuels correctly in a suitable canister, and out of the reach of children. Preparatory work = Remove the passenger seat. (=! p. 72) = Remove the front rider's seat. (© p. 71) = Remove the crash ber. (2 p. 32) = Remove the front side cover. ( p. 87) = Remove the tank cover. (® p, 89) = Remove the mask spoiler. (#2 p. 90) in work = Close fuel cocks @. ~ Push back hose eins @ and remove fuel hose @. © Info Remaining fuel may flow out of the fuel hose. = Thoroughly clean the plug-in connection of the fuel line using compressed air. © Info Under no circumstances should dirt enter into the fuel line, Dirt in the fuel line clogs the injection valve! — Press on the small metal plate and disconnect fuel hose connection @ Info Remaining fuel may flow out of the fuel hose.12 FUEL TANK, SEAT, TRIM "4 310828-10 Assemble the wash cap set Wash cap st (@121 2016000) Remove te cable tes). Disconnect plugin connector @ Unplug connector @ Detach vent nose @. Remove screw @ with bearing sleve and rubber bushings. Remove screws @. Take off the fuel tank. © Info Hay attention to the inside cover. Danger Fire ha rd Fuel is highly flammable ‘The fuel in the fuel tank expands when watm and can escape if overflle. (Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle, I any fuel is spilled, wipe it off immediately. Observe the specifications for refueling,12 FUEL TANK, SEAT, TRIM % Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel = Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors. Incase of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. Change your clothing in case of fuel spills on them, Keep fuels correctly in a suitable canister, and out of the reach of children. Main work = Position the fuel tank = Mount and tighten screw @ with bearing sleeve and rubber bushings, Guideline Screw, fuel tank a 15 Nm (2.1 Ibe ft ~ Plugin connector @ Sennen | ~ Mount vent hoses @ = Mount screws @ with bushings and tighten, Guideline Sere, foe Tank We Ton 74TH = Join plug-in connector @. ~ Mount the cable tet). = Remove the wash cap set = Thoroughly clean the plug-in connection of the fuel line using compressed air. © Info Under no circumstances should dirt enter into the fuel line, Dirt in the fuel line clogs the injection valve! = Join fuel hose connection @. ~ Mount ful nose @ ~ Postion hose clips ©12 FUEL TANK, SEAT, TRIM 16 = open fuel cocks @. Finishing work = Install the mask spoiler. (" p. 92) Install the tank cover. (™ p. 89) Install the front side cover. (© p. 87) Install the crash bar. (© p. 32) Mount the front rider's seat. (© p. 71) Mount the passenger seat. (© p, 72) Danger Fire hazard Fuel is highly flammable, ‘The fuel in the fuel tank expands when watm and can escape if overflle. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling, Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling rsing a rere ping Fut ptores on ahah hz ols, oe nd ling coat wth = redatel cna ads yo salon Incr of eli corter sis the aflesed ra ith leno wae = keeps conc na sual canter and athe each oe, Condition The fuel tank is full. Ensure that the battery voltage does not drop below 12.5 V, The ignition is off The diagnostic tool is connected. ~ Press down the metal pate and disconnect the fuel hose connection @. Info HRemaining fuel may flow out ofthe fuel hose. Law Fa10625-10,12 FUEL TANK, SEAT, TRIM 7 : an = Mount special tot Pressure tester (61029094000) ( 5388) ~ Mount special to! @ with nezle code 1,05 Testing hose (61029099000) (= 9. 347) = Position the hose end ina fuel can Gauicetine Minimum siz of Tool can 10 1(2.6 US gal) 400826-10 = Connect the diagnostic tool and start it Perform the “Engine Electronics" > “Actuator Test" > “Function test of fuel pump con- trol" = Check the fuel pressure with the filler cap closed. Fuel pressure When the fuel pump is active 3B. 42 bar (55... 61 psi) x +H the specification is not reached: = Open the filler cap. Ge = Check the tank air vent system, 400927.01 = Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pump is active 38... 4.2 bar (55... 61 psid 400928-01 a Fatose5-11 » If the specification is not reached = Check that the fuel line is clear. = Change the fuel filter, p. 80) ~ Change the fuel pump. (© p. 77) = Finish the actuator test. = Remove the special tools. = Thoroughly clean the plug-in connection of the fuel line using compressed air. Info H Under no circumstances should dirt enter into the fuel line. Dir in the fuel line clogs the injection valve. ~Join fuel hose connection @. Danger Fire hazard Fuel is highly flammable ‘The fuel in the fuel tank expands when wetm and can escape if overflle. = Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switeh off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. = If any fuel is spilled, wipe it off immediately. = Observe the specifications for refueling12 FUEL TANK, SEAT, TRIM 7% a Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fuel, = Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors. — Incase of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. Change your clothing in case of fuel spills on them, Keep fuels correctly in a suitable canister, and out of the reach of children. Preparatory work = Drain the fuel from the fuel tank into a suitable container, Main work = Remove screw connections @. = Remove screws @ and takeoff the clamp halves. = Remove screw . = Take off the lft crash bar = Thoroughly clean the plug-in connection of the fuel line using compressed air. Info H Under no circumstances should dirt enter into the fuel line, Dirt in the fuel line clogs the injection valve. ~ Presson the srl metal plate and disconnect fuel hose connection @) © Info BH Remaining fuel may flow out of the fuel hose. = Assemble the wash cap set. Wash cap set (81212016000)12 FUEL TANK, SEAT, TRIM Er) 310892:10 Remove the cable ties), Disconnect plug-in connector @ Remove screws @, Pullout the fuel pump. © Info Remaining fuel may flow out of the fuel tank. Place a suitable container under the engine. Postion the new fuel pump with Oxing inthe fuel tank Mount and tighten screws @. Guideline Sere, foe! pump 6 Shim Ga HD Connect plugin connector @ Secure the cable with the cable binders Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. info D. Unce-ocicumsanes sou tetra n,n the ue tins ost ce va Join fuel hose connection @. Position the left crash bar with the frame protector. ‘The fuel tank support ring should be correctly positioned on the fuel tank. Info Hover the components to protect them against damage. Mount screw @ but do not tighten yet. Guideline Remaining chassis screws Me 25m (18.4 Ibe fe) Postion the clamp halves. Mount screws @, but donot tighten yet. Guideline Remaining chassis serene 6 TON 7a et12 FUEL TANK, SEAT, TRIM 80 = Mount and tighten fitings @. Guideline Remaining chaste Sore 16 Ton 7a ‘The crash bars are aligned with each other. = Tighten screws @. Guideline Remaining chaste scree 6 TOR 7a oF A ~ Tighten serew @. Guideline Remaining chasse Sore 1 25 Nin (18.4 Io fh Danger Fire hazard Fuel is highly flammable, ‘The fuel in the fuel tank expands when warm and can escape if overfill. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling, = Make sure that no fuel is spilled; particularly not on hot parts of the vehicle, = If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling. a Warning Danger of poisoning Fuel is poisonous and a health hazard. Avoid skin, eye and clothing contact with fuel, = Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors. Incase of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. Change your clothing in case of fuel soils on ther, — Keep fuels correctly ina suitable canister, and out of the reach of children. a Preparatory work = "Drain the ful from the fuel tank int a suitable container. Main work = Remove screw connections @ 4 — = Remove screws @ and takeoff he clamp halves12 FUEL TANK, SEAT, TRIM 81 = Remove screw @. Takeoff the et crash ba = Thoroughly clean the plug-in connection of the fuel line using compressed air. Info TW Under no circumstances should dirt enter into the fuel line, Dirt in the fuel line clogs the injection valve, ~ Press onthe small metal pate and disconnect fuel hose connection @ © Info Hl Remaining tue! may flow out ofthe fuel hose. = Assemble the wash cap set. Wash cap set (61212016000) = Remove the cable te(s) = Disconnect plug-in connector @. = Remove screws @ = Pullout the fue! pump. © Info Remaining fuel may flow out of the fuel tank. Place a suitable container under the engine. = Push clamps @ outward, Take off the fuel filter housing = Remove gasket @. ~ Takeoff tut pine @.12 FUEL TANK, SEAT, TRIM 310896-10, 310899-10, Detach connectors QD and @. Remove screw @® with the washer. Remove sens @. Remove retaining brackets @ anc ®. Remove plastic housing with the distance sleeves, Take the fuel pump out ofthe fuel pump cover.12 FUEL TANK, SEAT, TRIM ~ Takeoff sealing element = Remove the fuel filter. = Mount the new fuel filter. = Release latch ©. = Pull off the outer fue! fier housing, = Take off tual fitter ®. = Mount the new fuel filter. '310705-10, = Mount the outer ful filter housing. ‘Locking mechanism @® engages in the fuel filter housing. = Mount sealing element ® = Position the fuel pump in the fuel pump cover.12 FUEL TANK, SEAT, TRIM ~ Mount plastic housing @ withthe cstance sleeves. ~The lugs of the plastic housing engage in the holes of the fuel pump cover. = Mount retaining brackets @® and ®. = Mount and tighten serews @. = Mount and tighten screw @® with the washer, ~ Plug in connectors @ and = Mount fuel pipe @. = Mount gasket @12 FUEL TANK, SEAT, TRIM 85 = Mount the fuel filter housing. Y Clamps @ must engage = Position the fuel pump with O-ring in the fuel tank, ~ Mount and tighten screws @. Guideline Screw, fuel pump Me 6 Nem (4.4 It ft) = conect plugin connector @ = Secure the cable wth the cable binders 310592:10 — Remove the wash cap set. = Thoroughly clean the plug-in connection of the fuel line using compressed ai. Info Under no circumstances should dirt enter into the fuel line. Dit in the fuel line clogs the injection valve. ~Join fuel hose connection @. = Position the left crash bar with the frame protector. The fuel tank support ring should be correctly positioned on the fuel tank. © Info Cover the components to protect them against damage, ~ Mount crew @ but donot tighten yet. Guideline Remaining chassis screws Me 25Nm (18.4 Ib ft) = Poston the clamp halves = Mount screns @, but donot tighten yt Gauiceine Remaining chassis screws Ne TO Nm (7.4 Toff)12 FUEL TANK, SEAT, TRIM = Mount and tighten fitings Guideline 86 Remaining chassis screws Me TONm (7-4 TotW, w The crash bars are aligned with each = Tighten screws @. Guideline other. Remaining chassis screws Me TO Nm (7.4 Tot AD ~ Tighten serew @. Guiding Remaining chassis screws me 25 Nm (18.4 Ibe fh13 MASK, FENDER, DECAL 87 Preparatory work = Remove the erash bar. (© p. 32) Main wrk — Remove screw @. = Remove screw @. = Remove screws ©. = Remove side cover @. Info ay attention to the cornering light cable, = Unplug connector @. = Repeat the operation on the oppsie side. N00766-10 Main work = Plugin connector @. T 4 UO766-1113 MASK, FENDER, DECAL 88 = Position the side cover in the @) area under the tank cover. Y The holes @ anc @ are adjacent to each other. = Attach catch @ of the side cover to bracket @ and position on the fuel tank. = Mount anc tighten srew @ Guideline Sere, cover pa WS 35Nn (2.58 lot = Mount and tighten screw @ Guideline Sere, cover pa WS 350m (2.58 lot = Mount and tighten serews @. Guideline Screw, over pat or 350m (2.58 lot Repeat the operation on the opposite side. Finishing work Install the crash bar. (© p. 32)13. MASK, FENDER, DECAL 13.3. Removing the tank cover Preparatory work — Remove the passenger seat. (© p. 72) = Remove the font rider's seat. ("> p. 71) = Remeve the crash bar. (© p. 32) = Remove the trot side cover. (= p. 87) Main work = Remove screw @. ~ Remove scrow @. n0757.10 = Remove screw @. = Remove screw @. 0075610 = Remove screw @, ~ Raise the tank cover at the rear and remove it in @ forward direction, 13.4 _ Installing the tank cover Main work = Position the tank cover. Y Catch @ engages under the tank @ © Info Pay altention to the sealing lip and the bleeder hose. soo7is-10 8913. MASK, FENDER, DECAL 80 = Mount and tighten serew @ Guideline Serew, cover part mB 35 Nim (258 bt 1) ~ Mount and tignten screw @ Guideline Serew, cover part m5 35 Nim (2.58 tot ~ Mount and tignten screw @ Guideline Screw, cover part M6 ENm 44 BIW) = Mount and tighten serew @ Guideline Screw, cover park 6 Shim Ga PRD = Mount and tighten serew @ Guideline Screw, cover part ME 35 Nm (2.58 tor Finishing work Install the front side cover, (©2 p. 87) = Install the crash bar. (© p. 32) = Mount the front rider's seat. (2 p. 71) ~ Mount the passenger seat. p. 72) 13.5 Removing the mask spoiler Preparatory work = "Remeve the passenger seat (© p. 72) = Remove te font riders seat. (© p. 72) = Remove the crash bar (5p. 32) = Remove the front side cover (© p. 87) = Remove the tank cover. (5p. 89) Main work = Remove screw @.13 MASK, FENDER, DECAL a ~ Remove screw @. Loosen holding lug @ from the inside cover, 00857-10 = Remove the mask spoiler laterally from the supports Remove catch @ upward trom the bracket @ © Info Pay attention to the turn signal cable. (Super Adventure EU/FR/AUAP) ~ Disconnect plug-in connector @. — Remove the mask spoiler with the turn signal. = Repeat these steps on the opposite side, (Super Adventure USC) Disconnect plugin connector @ = Remove the mask spoiler with the turn signal = Repeat these steps onthe opposite side.13 MASK, FENDER, DECAL 22 13,6 Installing the mask spoiler Main work (Super Adventure EVFVAWAP) = Connect plug-in connector @. (Super Adventure US/CN) ~ Connect plug-in connector @. — Position the catch @ in the bracket @ Info Ensure that the turn signal cable is placed correctly. = Press the mask spoiler laterally into the supports. MOOSEL-OL Position holding tug @ in the dril hol. 0057-11 ~ Mount and tighten serew @ Guideline ‘Screw, mask spoiler MBx17 3.5 Nm (2.58 lb ft 00859-1113 MASK, FENDER, DECAL = Mount and tigten screw @ Guideline ‘Screw, mask spoiler Mox17 35 Nm (2.58 lb fh Repeat the operation on the opposite side, Finishing work = Install the tank cover, (" p. 89) Install the front side cover. (E p. 87) Install the crash bar. (© p. 32) Mount the front rider's seat. (" p. 71) Mount the passenger seat. (© p. 72) ~ Remove seres @ ~ Lower triple lamp cover @ slighty ~ Disconnect plugs @) of the hon ~ betach temperature sensor @. = Remove the triple clamp cover = Plugin comectors @ of the hor = Attach temperature sensor @ = Position the triple clamp cover @. = Mount and tighten screws @. Guideline [Remaining chassis serena 16 10 Nm (7.4 Io ft) A O "We w00857-11,13 MASK, FENDER, DECAL (Super Adventure EUFRIP) open holder @ and tach the brake lines, = Remove screws @ = Take the fender ff to the fron Info Hay attention to the brake lines. (Super Adventure AUUS/CN) = Open holder @ and setcn the brake lines. ~ Remove screws @ = Take the fender off to the ron. © Info Tay attention to the brake lines. (Super Adventure EU/FRAP) = Position the fender Info Hay attention to where the brake lines are placed. = Mount and tighten serews @ Guideline Screw, fender Woxi2 3.5 Nm (2.58 tot ft) ~ Insert the brake tines in brackets @ and close the holder (Super Adventure AUMUS/CN) Position the fender. Info Pay attention to where the brake lines are placed. = Mount and tighten screws @. Guideline ‘Screw, fender Waxi2 3.5 Nm (2.58 tof ft ~ Insert the brake lines in brackets @ and close the holder. — Remove sereus @ and wind shield @ ni roe eh] reas13 MASK, FENDER, DECAL 95 — Position wind shield @ = Mount and tighten screws @. Guideline Screw, wind shield MS 3.5 Nm (2.58 lof fh) NOO769-10 ~ Pull clamping lever @ in the direction of the arrow, The windshield is unlocked. = To bring the windshield in the required position, turn the handwheel @ = Push clamping lever @ inthe ciection ofthe arrow Tho windshiel is locke Info To mount the windshield higher or lower the windshield adapter can be mounted in two positions. Preparatory work ="Remone the windshield (3p. 94) Main work = Remove scree @ ~ Take off windshield adapter @. Ele ol s00742-1013 MASK, FENDER, DECAL ~ Adjust windshield adapter tothe desired postion @ or @. © Info HL The handling side is marked on the rear ofthe windshield adapter. =] Mount and tighten screws @. Guideline Screw, cover part MS 3.5. Nm (2.58 Ib ft Finishing work = Install the wind shield. (© p. 95)14 WHEELS 37 © Info TLowtite air pressure leads to atnorml wear and overheating ofthe tie. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. = Remove the dust cap. = Check the tire air pressure when the tires are col. Tite air pressure, solofwith passenger/full payload Front: with cold tires 2.4 bar (35 psi) Rear with cold tires 2.9 bar (42 psi) Ifthe tire pressure does not meet specifications: = Correct the tire pressure. = Mount the dust cap. Warning Danger of accidents fa tre bursts whi ~ Ensure that damaged or worn tres are replaced immediately. Warning Danger of crashing Different tire tread patterns on the front and rear whee! impair the handling characteristic. Different tie tread patterns can make the vehicle significantly more difficult to contol riding, the vehicle becomes uncontrollable. = Make sure that only tires with a similar tire tread pattern are fited tothe front and rear wheel Warning Danger of accidents Non-approved or non-tecommended tires and wheels impact the handling characteristic. ~ Only use trestaneels approved by KTM with the corresponding speed index Warning Danger of accidents Now tres have reduced road grip. ‘The contact surface on new tres is not yet roughened. = Run in new tires with moderate riding at alternating angles. Running-in phase 200 km (124 mi T Tire type, tire condition, and tire air pressure influence the braking and handling characteristics of the vehicle. ‘Worn tires are particularly unfavorable on wet surfaces, Otek te font and ees cs tin tes, ad te aap D> rt tes hv cts rnin bet, ater Sovoe = change te, Info y Adhere to the legally required minimum tread depth. Lon scosopio| [Minimumtvead dept ——~—S~*dr mm OM SS~*&d If the tread depth is less than the minimum tread depth: = Change the tres.14 WHEELS 98 ~ Check the tire age. Info The tire date of manufacture is usually contained in the tire label and is a. indicated by the last tour digits of the DOT number. The first two digits indi- & cate the week of manufacture and the last two digits the year of manufac- ture, KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear, o1144-10 the tires are more than 5 years ok = Change the tres. Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage. ‘The spokes break due to being overloaded if they are to tightly tensioned. Ifthe tension in the spokes is too low, then lateral and racial run-out will form in the wheel. Other spokes will become looser as a result. Check spoke tension regularly, and in particular on a new vehicle, = Check for lateral and radial run-out of the rims. Lateral runout ‘outside the rim joint <1.8 mm (< 0.071 in) Radial runout ‘outside the rim joint < 18mm (0.071 im) » I the measured value is greater than the specified value: = Center the rim. © Info Center the rim by pulling the spoke nipple on the other side of the rim run-out. If there is significant deformation, change the rim, = Correct the spoke tension. 400998-01 Preparatory work = Raise the vehicle with the center stand. (= p. 12) = Place a load on the rear of the vehicle. ‘Y The front wheel is notin contact with the ground. Main work = Move the front wheel from side to side. Info Hoe te fork tog to check it. > H there is detectable play: = Change the front wheel bearing. (© p. 101) '310677-10,14 WHEELS 99 Place a load on the front of the vehicle. The rear wheel is not in contact with the ground. Move the rear wheel from side to side. Info THis the swingarm to check it ® I there is detectable play ‘= Change the rear whee! bearing. (°° p. 109) Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage. ‘The spokes break due to being overloaded if they are too tightly tensioned. Ifthe tension in the spokes is too low, then lateral and radial run-out will orm in the wheel, Other spokes will become looser as a result. = Check spoke tension regularly, and in particular on a new vehicle. Strike each spoke briefly using a screwdriver blade, © Info The frequency of the sound depends on the spoke lenath and spoke diame- ter. If spokes ofthe same length and diameter vibrate with a diferent tone, this is an indication thatthe spoke tensions differ. You should hear a high nota, I the spoke tension differs: — Correct the spoke tension Condition ‘The diagnostic tool is connected and running. = Execute "Tie pressure monitor" > "Functions" > "Program the tie pressure sensor" > "Select the whee! Info T The instructions must be followed precisely. = Clear the fault memory using the KTM diagnostics tool. + Take a test ride — Read out the trouble code memory using the KTM diagnostics tool. 401895.01 14.7.1 Removing the front wheel Preparatory work = Raise the vehicle with the center stand, (= p. 12) Main work = Place a load on the rear of the vehicle. A The front wheel isnot in contact withthe ground. ~ Remove screw @ and pull whee! speed sensor @ out ofthe hole.14 WHEELS 14.7.2 Installing the front wheel 100 ~ Remove screws @ from both brake calipers. Press back the brake linings with a slight lateral tilting of the brake calipers on the brake dise, = Pall the brake calipers carefully back from the brake dises and hang them to one side loosely. Info Toot pull the hand brake lever when the brake caliper has been removed. ~ Loosen sore @ by several rotations ~ Loosen screws @ ~ Press on screw @ to push the wheel spindle out of the ale clamp, = Remove screw @. Warning BEIM snc of ccitoms’ Doig oi ines ret ihe rang et ~ Always lay the wheel down in such a way that the brake discs are not damaged. — Hold the front whee! and remove the wheel spindle. Take the front wheel out of the fork. © Info Do nat pull the hand brake lever when the front wheel is removed. ~ Remove spacers @. ay Danger of accidents Oil or grease on Always keep the brake discs free = Clean the brake discs with brake the brake discs reduces the braking effect. of oll and grease. ‘cleaner when necessary. = Check the wheel bearing for damage and wear + Ifthe wheel bearing is damaged or wor: = Change the front wheel bearing. (© p. 101) = Clean and grease shaft seal rings @ and contact surface @ of the spacers. t fe grease (Sp. 340)14 WHEELS 101 ~ Insert wide spacer @ on the left in the direction of travel The arrow @ indicates the direction of travel ofthe front wheel The ABS sensor whee! is onthe lefthand sie when looking in the ection ctiravel ~ Insert the narrow spacer on the right in the direction of travel 14.7.3 Changing the front wheel bearing Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oll and grease. — Clean the brake dises with brake cleaner when necessary = Clean and grease screw @ and wheel spindle @. Longzlife grease (~ p. 340) = Lift the front wheel into the fork, position it, and insert the wheel spindle. ~ Mount ané tighten screw @. Guideline Screw, front wheel spindle | M25x1.5 | 45 Nm Thread greased (33.2 Ibe tt = Poston the brake calipers. 1 The brake linings are corecty positioned ~ Mount screws @ on both brake calipers but donot tighten vet. = Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is 2 pressure point. Fix the hand brake lever in the acti- vated position ~ The brake calipers straighten. = Tihten screws @ on both brake calipers Guideline ‘Screw, front brake caliper | M10 45 Nm | Loctite® 2a3™ (33.2 Ibe #9) = Remove the Fiat ofthe hand brake lever. = Pesition whee! speed sensor @ in the dil hole = Mount and tighten screw @ Guideline Remaining chassis serena [NS TONm (74 Tat — Remove the vehicle from the center stand. (! p. 12) ~ Operate the front brake and compress the fork a few times firmly. The fork legs straighten, = Tighten scrows @. Guideline ‘Screw, fork stub Me Preparatory work = Raise the vehicle with the center stand. (© p. 12)