1 2014 KTM 250-300 Exc XC-W Manual
1 2014 KTM 250-300 Exc XC-W Manual
TABLE OF CONTENTS 2
9.21 Assembling the rebound adjuster......................... 70 15.5 Connecting the negative cable of the battery.... 102
9.22 Assembling the seal ring retainer......................... 70 15.6 Removing the battery.......................................... 102
9.23 Assembling the piston rod..................................... 71 15.7 Installing the battery........................................... 103
9.24 Assembling the damper......................................... 72 15.8 Checking the charging voltage........................... 103
9.25 Bleeding and filling the damper.......................... 75 15.9 Checking the closed current............................... 103
9.26 Filling the damper with nitrogen.......................... 77 15.10 Checking the starter relay................................... 104
9.27 Installing the spring.............................................. 78 16 BRAKE SYSTEM............................................................... 105
9.28 Changing the heim joint........................................ 79 16.1 Checking the front brake linings........................ 105
10 EXHAUST............................................................................. 81 16.2 Changing the front brake linings........................ 105
10.1 Removing the main silencer................... 81 16.3 Checking the free travel of the hand brake
10.2 Installing the main silencer.................................. 81 lever...................................................................... 107
10.3 Changing the glass fiber yarn filling of the 16.4 Adjusting free travel of hand brake lever (All
main silencer.......................................................... 81 250/300 EXC EU/AU models)........................... 107
11 AIR FILTER..................................... 83 16.5 Adjusting the basic position of the hand
11.1 Removing the air filter box lid.............................. 83 brake lever (All 250/300 XC-W models)........... 107
11.2 Installing the air filter box lid............................... 83 16.6 Checking the front brake fluid level.................. 108
11.3 Removing the air filter........................................... 83 16.7 Adding front brake fluid...................................... 108
11.4 Installing the air filter............................................ 83 16.8 Changing the front brake fluid........................... 109
11.5 Cleaning the air filter and air filter box............... 84 16.9 Checking the rear brake linings......................... 110
11.6 Sealing the air filter box........ .............................. 84 16.10 Changing the brake linings of the rear brake .... Ill
12 FUEL TANK, SEAT, TRIM.................................................. 85 16.11 Checking the free travel of foot brake lever...... 112
12.1 Opening the filler cap............................................ 85 16.12 Adjusting the basic position of the foot brake
lever...................................................................... 112
12.2 Closing the filler cap............................................. 85
16.13 Checking the rear brake fluid level.................... 113
12.3 Removing the seat................................................. 85
16.14 Adding brake fluid for the rear brake................. 113
12.4 Mounting the seat.................................................. 86
16.15 Changing the rear brake fluid............................. 114
12.5 Removing the fuel tank.......................................... 86
17 LIGHTING SYSTEM, INSTRUMENTS............................. 116
12.6 Installing the fuel tank.......................................... 87
17.1 Checking the headlight setting.......................... 116
12.7 Fuel tap........ .......................................................... 88
17.2 Adjusting the headlight range............................. 116
13 MASK,FENDER................................................................. 89
17.3 EXC EU/AUS, XC-W....... ..................................... 116
13.1 Removing the front fender.................................... 89
17.3.1 Speedometer overview.................................... 116
13.2 Installing the front fender..................................... 89
17.3.2 Activation and test.......................................... 117
13.3 Removing the headlight mask with the
headlight................................................................. 89 17.3.3 Setting kilometers or miles........................... 117
13.4 Installing the headlight mask with the 17.3.4 Adjusting the speedometer functions........... 117
headlight................................................................. 90 17.3.5 Setting the clock.......................... 118
14 WHEELS.............................................................................. 91 17.3.6 Activating the additional functions.............. 118
14.1 Checking the tire air pressure............................... 91 17.3.7 Setting the wheel circumference.................. 119
14.2 Checking the tire condition................................... 91 17.3.8 Querying lap time........................................... 119
14.3 Checking the brake discs...................................... 92 17.4 250/300 SIX DAYS............................................. 120
14.4 Checking the spoke tension................................... 92 17.4.1 Speedometer overview.................................... 120
14.5 Front wheel............................................................. 93 17.4.2 Activation and test.......................................... 120
14.5.1 Removing the front wheel................................ 93 17.4.3 Setting kilometers or miles........................... 120
14.5.2 Installing the front wheel............................ 93 17.4.4 Setting the speedometer functions.............. 121
14.5.3 Removing the brake disc of the front brake.... 94 17.4.5 Setting the clock................................. 121
14.5.4 Installing the brake disc of the front brake .... 94 17.4.6 Setting the wheel circumference.................. 122
14.6 Rear wheel.............................................................. 94 17.4.7 Viewing the lap time...................................... 122
14.6.1 Removing the rear wheel................................. 94 18 ENGINE............................................................................. 123
14.6.2 Installing the rear wheel............................. 95 18.1 Removing the engine.......................................... 123
14.6.3 Removing the brake disc of the rear brake. 96 18.2 Installing the engine............................................ 127
14.6.4 Installing the brake disc of the rear brake. 96 18.3 Engine disassembly............................................. 132
14.6.5 Checking the chain for dirt......................... 96 18.3.1 Clamping the engine into the engine work
14.6.6 Cleaning the chain............................................ 97 stand................................................................ 132
14.6.7 Checking the chain tension.............................. 97 18.3.2 Draining the gear oil....................................... 132
14.6.8 Checking the chain, rear sprocket, engine 18.3.3 Removing the clutch push rod....................... 132
sprocket and chain guide................................. 98 18.3.4 Removing the shift lever................................ 132
14.6.9 Adjusting the chain tension.......................... 100 18.3.5 Removing the engine sprocket....................... 133
15 WIRING HARNESS, BATTERY......................................... 101 18.3.6 Removing the spacer...................................... 133
15.1 Plug-in connection, ignition timing map........... 101 18.3.7 Removing the starter motor........................... 133
15.2 Removing the main fuse..................................... 101 18.3.8 Removing the kick starter.............................. 135
15.3 Installing the main fuse...................................... 101 18.3.9 Removing the cylinder head.......................... 135
15.4 Disconnecting the negative cable of the 18.3.10 Removing the cylinder.................................... 135
battery................................................................... 101 18.3.11 Removing the piston...................................... 136
TABLE OF CONTENTS 4
18.3.12 Removing the water pump cover.................... 137 18.5.7 Installing the reed valve housing.................. 174
18.3.13 Removing the clutch cover............................. 137 18.5.8 Installing the rotor.......................................... 174
18.3.14 Removing the clutch discs............................. 138 18.5.9 Installing the locking lever............................. 175
18.3.15 Removing the clutch basket........................... 139 18.5.10 Installing the shift drum locating unit.......... 175
18.3.16 Removing the kick starter shaft..................... 140 18.5.11 Installing the shift shaft................................ 175
18.3.17 Removing the intermediate kick starter 18.5.12 Installing the intermediate kick starter
gear................................................................... 140 gear................................................................... 175
18.3.18 Removing the shift shaft................................. 140 18.5.13 Installing the kick starter shaft..................... 175
18.3.19 Removing the shift drum locating unit......... 140 18.5.14 Installing the clutch basket........................... 176
18.3.20 Removing the locking lever............................ 140 18.5.15 Installing the clutch discs.............................. 177
18.3.21 Removing the rotor........................................... 141 18.5.16 Installing the clutch cover............................. 178
18.3.22 Removing the reed valve housing................... 141 18.5.17 Installing the water pump cover.................... 179
18.3.23 Removing the left engine case section......... 141 18.5.18 Installing the piston....................................... 179
18.3.24 Removing the shift rails.................................. 142 18.5.19 Installing the cylinder..................................... 180
18.3.25 Removing the shift drum................................ 142 18.5.20 Checking the X-distance................................ 181
18.3.26 Removing the shift forks................................. 142 18.5.21 Adjusting the X-distance................................ 182
18.3.27 Removing the transmission shafts................. 142 18.5.22 Adjusting the Z-distance................................ 182
18.3.28 Removing the crankshaft................................ 143 18.5.23 Installing the cylinder head........................... 184
18.4 work on individual parts...................................... 143 18.5.24 Installing the kick starter............................... 184
18.4.1 Work on the right section of the engine 18.5.25 Installing the starter motor............................. 184
case................................................................. 143 18.5.26 Installing the spacer....................................... 186
18.4.2 Work on the left section of the engine 18.5.27 Installing the engine sprocket....................... 186
case................................................................. 144 18.5.28 Installing the shift lever................................. 186
18.4.3 Removing the crankshaft bearing inner 18.5.29 Installing the clutch push rod...................... 187
race................................................................... 145
18.5.30 Installing the gear oil drain plug................... 187
18.4.4 Installing the crankshaft bearing inner
18.5.31 Removing the engine from the work stand ... 187
race................................................................... 145
19 CARBURETOR................................................................... 188
18.4.5 Changing the connecting rod, conrod
19.1 Choke.................................................................... 188
bearing, and crank pin................................... 145
19.2 Carburetor - adjusting the idle speed ................ 188
18.4.6 Checking the crankshaft run-out at the
bearing pin....................................................... 146 19.3 Emptying the carburetor float chamber............ 189
18.4.7 Checking/measuring the cylinder.................. 147 19.4 Removing the carburetor..................................... 189
18.4.8 Removing the exhaust control....................... 147 19.5 Installing the carburetor..................................... 190
18.4.9 Checking the exhaust control........................ 149 19.6 Checking/adjusting the carburetor
components................................................ 191
18.4.10 Installing the exhaust control........................ 150
19.7 Disassembling the carburetor............................. 192
18.4.11 Cylinder - Nikasil® coating............................. 152
19.8 Checking the choke slide.................................... 193
18.4.12 Checking/measuring the piston..................... 152
19.9 Checking the jet needle...................................... 193
18.4.13 Checking the piston ring end gap................. 153
19.10 Checking the throttle slide................................. 193
18.4.14 Piston/cylinder - measuring the mounting
clearance......................................................... 153 19.11 Checking the float needle valve......................... 194
18.4.15 Disassembling the reed valve housing.......... 154 19.12 Assembling the carburetor................................. 194
18.4.16 Checking the reed valve housing, reed 19.13 Checking/adjusting the float level..................... 195
valve, and intake flange................................. 155 20 CLUTCH............................................................................. 196
18.4.17 Assembling the reed valve housing.............. 155 20.1 Checking/correcting the fluid level of the
18.4.18 Work on the clutch cover............................... 157 hydraulic clutch................................. 196
18.4.19 Checking the clutch....................................... 161 20.2 Changing the hydraulic clutchfluid................... 196
18.4.20 Preassembling the shift shaft........................ 162 21 WATER PUMP, COOLING SYSTEM................................ 197
18.4.21 Checking the shift mechanism..................... 163 21.1 Cooling system.................................................... 197
18.4.22 Disassembling the main shaft....................... 164 21.2 Checking the antifreeze and coolant level........ 197
18.4.23 Disassembling the countershaft.................... 165 21.3 Checking the coolant level................................. 197
18.4.24 Checking the transmission............................. 165 21.4 Draining the coolant............................................ 198
18.4.25 Assembling the main shaft............................. 166 21.5 Refilling with coolant.......................................... 198
18.4.26 Assembling the countershaft......................... 167 22 EXHAUST CONTROL........................................................ 200
18.4.27 Checking the kick starter............................... 169 22.1 Engine characteristic - setting the auxiliary
spring.................................................................... 200
18.4.28 Preassembling the kick starter shaft............ 169
23 LUBRICATION SYSTEM................................................... 201
18.4.29 Checking the electric starter drive................ 171
23.1 Changing the gear oil........................................... 201
18.5 Engine assembly.................................................. 172
23.2 Draining the gear oil............................................ 201
18.5.1 Installing the crankshaft................................ 172
23.3 Refilling with gear oil.......................................... 202
18.5.2 Installing the transmission shafts................. 172
23.4 Checking the gear oil level................................. 202
18.5.3 Installing the shift forks................................. 173
23.5 Adding gear oil.................................................... 202
18.5.4 Installing the shift drum................................ 173
24 IGNITION SYSTEM........................................................... 204
18.5.5 Installing the shift rails................................. 173
24.1 Checking the ignition system.............................. 204
18.5.6 Installing the left engine case section.......... 173
TABLE OF CONTENTS 5
24.2 Ignition coil - checking theprimarywinding........ 204 30.6 Page 1 of 5 (250 EXC SIX DAYS EU,
24.3 Ignition coil - checking the secondary 300 EXC SIX DAYS EU)...................................... 238
winding................................................................. 205 30.7 Page 2 of 5 (250 EXC SIX DAYS EU,
24.4 Checking the spark plug connector................... 205 300 EXC SIX DAYS EU)...................................... 240
24.5 Alternator - checking the charging coil of the 30.8 Page 3 of 5 (250 EXC SIX DAYS EU,
ignition................................................................. 206 300 EXC SIX DAYS EU)....................................... 242
24.6 Alternator - checking the battery winding........ 206 30.9 Page 4 of 5 (250 EXC SIX DAYS EU,
24.7 Alternator - checking the light winding............. 207 300 EXC SIX DAYS EU)....................................... 244
24.8 Checking the ignition pulse generator.............. 207 30.10 Page 5 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)....................................... 246
24.9 Removing the stator and crankshaft position
sensor.................................................................... 208 30.11 Page 1 of 5 (250/300 EXC AU)......................... 248
24.10 Installing the stator and crankshaft position 30.12 Page 2 of 5 (250/300 EXC AU)......................... 250
sensor.................................................................... 208 30.13 Page 3 of 5 (250/300 EXC AU)......................... 252
25 ELECTRIC STARTER........................................................ 209 30.14 Page 4 of 5 (250/300 EXC AU)......................... 254
25.1 Checking the starter motor................................. 209 30.15 Page 5 of 5 (250/300 EXC AU)......................... 256
26 TECHNICAL DATA............................................................. 210 30.16 Page 1 of 3 (250 XC-W USA,
26.1 Engine................................................................... 210 300 XC-W USA)................................................... 258
26.1.1 All 250 models................................................ 210 30.17 Page 2 of 3 (250 XC-W USA,
300 XC-W USA)................................................... 260
26.1.2 All 300 models................................................ 210
30.18 Page 3 of 3 (250 XC-W USA,
26.2 Engine tolerance, wear limits............................. 211
300 XC-W USA)................................................... 262
26.3 engine tightening torques................................... 212
30.19 Page 1 of 3 (300 XC-W SIX DAYS USA).......... 264
26.4 capacities............................................................. 212
30.20 Page 2 of 3 (300 XC-W SIX DAYS USA)........... 266
26.4.1 Gear oil............................................................. 212
30.21 Page 3 of 3 (300 XC-W SIX DAYS USA)........... 268
26.4.2 Coolant............................................................. 212
31 SUBSTANCES................................................................... 270
26.4.3 Fuel................................................................. 212
32 AUXILIARY SUBSTANCES.............................................. 272
26.5 Chassis..................................... 213
33 SPECIAL TOOLS............................................................... 274
26.6 electrical system................ 214
34 STANDARDS..................................................................... 284
26.7 Tires...................................................................... 214
35 LIST OF ABBREVIATIONS................................................ 285
26.8 Fork....................................................................... 214
INDEX................. ....................................................................... 286
26.8.1 EXC EU/AUS, XC-W................................ 214
26.8.2 250/300 SIX DAYS......................................... 215
26.9 shock absorber.................................................... 215
26.10 chassis tightening torques................................... 216
26.11 carburetor............................................................. 217
26.11.1 250 EXC EU, 250 EXC SIX DAYS EU.......... 217
26.11.2 250 EXC AUS................................................. 217
26.11.3 250 XC-W USA................................................ 217
26.11.4 300 EXC EU, 300 EXC SIX DAYS EU.......... 217
26.11.5 300 EXC AUS................................................. 218
26.11.6 300 XC-W USA,
300 XC-W SIX DAYS USA........................ 218
26.12 carburetor tuning................................................. 219
26.12.1 Carburetor tuning (All250 models)............... 219
26.12.2 Carburetor tuning (All300 models)............... 220
26.12.3 General carburetor tuning.............................. 221
27 CLEANING, CARE............................................................. 222
27.1 Cleaning the motorcycle..................................... 222
27.2 Checks and maintenance steps for winter
operation.............................................................. 223
28 STORAGE........................................................................... 224
28.1 Storage................................................................. 224
28.2 Preparing for use after storage........................... 224
29 SERVICE SCHEDULE....................................................... 225
29.1 Service schedule.................................................. 225
29.2 Service work (as additional order)..................... 226
30 WIRING DIAGRAM........................................................... 228
30.1 Page 1 of 5 (250 EXC EU, 300 EXC EU).......... 228
30.2 Page 2 of 5 (250 EXC EU, 300 EXC EU).......... 230
30.3 Page 3 of 5 (250 EXC EU, 300 EXC EU).......... 232
30.4 Page 4 of 5 (250 EXC EU, 300 EXC EU).......... 234
30.5 Page 5 of 5 (250 EXC EU, 300 EXC EU).......... 236
1 MEANS OF REPRESENTATION 6
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.
2 SAFETY ADVICE 7
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
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.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis
assemble the component to perform the activity in question. Please follow the instructions in the text.
4 SERIAL NUMBERS 9
Note
Danger of damage The parked vehicle may roll away or fall over.
- Always place the vehicle on a firm and even surface.
Note
Danger of damage The parked vehicle may roll away or fall over.
• Info
I When you are riding, the side stand must be folded up and secured with the
rubber band.
5.3 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
- Always warm up the engine at low engine speeds.
info
If the motorcycle does not start easily, there may be old fuel in the float chamber. The easily ignitable components of the fuel
evaporate during lengthy periods of disuse.
When the float chamber is filled with fresh, ignitable fuel, the engine will start immediately.
Condition
The motorcycle was stationary for more than 1 week.
- Empty the carburetor float chamber. (*" p. 189)
- Turn handle O of the fuel tap to the ON position. (Figure 602702-10*- p. 88)
y Fuel can flow from the fuel tank to the carburetor.
- Take the motorcycle off of the stand.
- Shift gear to neutral.
(250/300 EXC AU)
- Turn the emergency OFF switch to the position O.
Condition
The engine is cold.
- Pull out the choke lever all the way.
5 MOTORCYCLE 11
- Press the electric starter button or press the kick starter robustly through its full range
• Info
I Do not turn the throttle.
Danger
A Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Do not open the throttle.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
6 FORK, TRIPLE CLAMP 12
• Info
I The hydraulic compression damping determines the fork suspension behavior.
• Info
I Adjusting screws © are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
• Info
I The hydraulic rebound damping determines the fork suspension behavior.
• Info
I Adjusting screws O are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
• Info
I Make the same adjustment on both fork legs.
• Info
I Turn clockwise to increase spring preload; turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.
Finishing work
- Remove the motorcycle from the lift stand. p. 10)
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
- Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
- Clean and oil the dust boots and inner fork tube of both fork legs.
Position the brake line and wiring harness. Put on the clamp and mount and
tighten screws ©.
Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
• Info
I Grooves are milled into the side of the upper end of the fork legs. The sec
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
Position bleeder screws o toward the front.
6 FORK, TRIPLE CLAMP 15
- Tighten screws ©.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 Ibf ft)
Tighten screws ©.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 Ibf ft)
Finishing work
- Install the front wheel. (*" p. 93)
- Install the headlight mask with the headlight. (•" p. 90)
- Check the headlight setting. (*" p. 116)
Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
Finishing work
- Install the fork legs. (*" p. 14)
- Install the front wheel. (*" p. 93)
- Install the headlight mask with the headlight. (•" p. 90)
- Check the headlight setting. (*" p. 116)
6 FORK, TRIPLE CLAMP 16
• Info
I These operations are the same on both fork legs.
Condition
The fork legs have been removed.
- Disassemble the fork legs. (•" p. 16)
- Disassemble the cartridge. (•" p. 19)
- Check the fork legs. (•" p. 21)
- Assemble the cartridge. (•" p. 23)
- Assemble the fork legs. (*" p. 24)
• Info
I The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
- Remove protective cover ©.
- Note down the present state of rebound damping © and compression
damping ©.
- Note down of the present state of the spring preload.
- Completely open the adjusters of the rebound damping and compression damping.
Info
The Preload Adjuster cannot be taken off yet
Take out the fork leg and clamp with the axle clamp.
Info
Use soft jaws.
• Info
I The preload spacers © should be above the special tool.
Clamp the special tool in the bench vise. Loosen Preload Adjuster ©.
Info
Pull out and push in the piston rod a few times to empty the cartridge.
gy
Clamp the fork leg with the axle clamp.
Guideline
Use soft jaws.
^ h
; Unscrew and remove the compression damping fitting ©
• Info
li I Place a fluid collector beneath it, as usually some oil will drain out.
__________________________________________________
• Info
I The fork protector ring does not necessarily need to be disassembled for the
further repair.
• Info
I The lock ring has a coarsely finished end against which the screwdriver can
be placed.
• Info
I The lower sliding bushing © must be pulled out of its bearing seat when
doing this.
6 FORK, TRIPLE CLAMP 19
Info
Gently pull them apart without using any tool.
Info
The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. (•" p. 16)
Main work
- Remove fluid barrier o from the piston rod.
• Info
I This step is unnecessary for the further disassembly.
Remove nut ©
Remove shim stack e completely.
200698-10
Remove piston ©.
Remove shim stack © completely.
Remove spring ©.
Remove tap rebound ©
200700-10
Remove spring ©
Remove valve © of the rebound damping together with the spring.
Take out the piston rod.
6 FORK, TRIPLE CLAMP 21
Info
The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. (•" p. 16)
Main work
- Clamp the compression damping fitting in a bench vise using soft jaws.
- Remove nut O-
* \ - 4 k ' - Remove the spring.
- - Remove washer ©.
1
- Remove piston ©.
- Remove shim stack ©
- Remove O-ring © and seal ring © from the compression damping fitting.
- Extract the compression damping fitting.
Info
The steps are identical for both fork legs.
Clamp the compression damping fitting in a bench vise using soft jaws.
Mount 0-ring O and seal ring ©.
Grease the O-ring.
» '*!S '
m Info
1 The side with the largest inside diameter © faces upward.
— —»____ _2L____ ________ ___________ _
. 200705-10
Grease the piston O-ring.
Mount washer ©
-----------?i> ~ , 1
Compression damping fitting nut M6x0.5 3 Nm (2.2 Ibf ft)
1 —— 1
• Info
1 The washer © must have freedom of movement relative to the spring force.
■ T_____ '^“200706-10
Info
The steps are identical for both fork legs.
Mount valve O °f the rebound damping, with the spring and O-ring.
Grease the O-ring.
Mount spring ©
Position spring ©.
• Info
1 Mount the smaller shims below.
• Info
1 The shim stack must be pressed downward over the collar.
• Info
1 The side with the largest inside diameter faces downward.
• Info
1 Align the triangular plate exactly with the piston opening.
Info
Mount the nut with the collar facing downward.
200749-11
• Info
I The fluid barrier must be screwed on tightly against the stop. Do not use a
tool.
Info
The steps are identical for both fork legs.
6 FORK, TRIPLE CLAMP 25
Preparatory work
- Check the fork legs. (*" p. 21)
- Assemble the cartridge. (*" p. 23)
- Assemble the compression damping fitting. (*" p. 22)
Main work
- Clamp in the inner tube with the axle clamp.
Guideline
Use soft jaws.
• Info
1 Always change the dust boot, seal ring, lock ring, and support ring.
Mount the sealing lip with the spring expander facing downward.
• Info
1 The sealing lip should face downward and the open side upward.
200670-10
• Info
1 Gently pull them apart without using any tool.
Hold the lower sliding bushing with the longer shoulder of the special tool.
Info
The lock ring must audibly lock into place.
• Info
1 The special tool must be used in order that the adjustment tube is not
raised. Otherwise, oil will reach the piston rod.
Info
If the cartridge turns as well, press the piston rod slightly to the side.
6 FORK, TRIPLE CLAMP 27
Info
Pull out the piston rod and push back in a number of times to bleed the car
tridge.
Pull out the piston rod. Install the spring. Reinstall the pin.
Guideline
Spring rate
Weight of rider: 65... 75 kg (143... 4.0 N/mm (22.8 Ib/in)
165 lb.)
Weight of rider: 75... 85 kg (165... 4.2 N/mm (24 Ib/in)
187 lb.)
Weight of rider: 85... 95 kg (187... 4.4 N/mm (25.1 Ib/in)
209 lb.)
- Pull the spring downward. Place the special tool on the hexagonal part
Screw the Preload Adjuster with preload spacer onto the piston rod.
• Info
I The Preload Adjuster must be screwed in all the way before the piston rod
also begins to turn. In case of tight piston rod threads, it must be held to
keep it from turning. If the Preload Adjuster is not screwed in all the way,
the rebound adjustment will not function.
Take pressure off of the special tool. Pull the spring downward and remove the spe-
cial tool.
6 FORK, TRIPLE CLAMP 28
Alternative 1
- Turn adjusting screw of compression damping © and adjusting screw of
rebound damping © clockwise all the way.
- Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 18 clicks
Sport 16 clicks
Compression damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
- Turn the adjusting screw of spring preload © counterclockwise all the way.
- Turn clockwise by the number of turns corresponding to the fork type.
Guideline
Spring preload - Preload Adjuster
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Alternative 2
Warning
A Danger of accident Modifications to the suspension setting may seri
ously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious
deterioration in the handling characteristic and overload components.
• Info
I Protect the components against damage by covering them.
Do not bend the cables and lines.
- Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
- Check whether the top steering head seal Q is correctly positioned.
- Mount protective ring ©
500151-10
• Info
I Grooves are milled into the side of the upper end of the fork legs. The sec
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
Position bleeder screws o toward the front.
Tighten screws ©
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 Ibf ft)
Tighten screw ©
Guideline
Screw, top steering head M20xl.5 12 Nm (8.9 Ibf ft)
Tighten screw ©.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 Ibf ft)
Tighten screws O
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 Ibf ft)
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam
aged over time.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
Main work
- Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
The handlebar must be able to move easily over the entire steering range. There
should be no perceptible detent positions.
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Tighten screws O-
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 Ibf ft)
Tighten screw
Guideline
Screw, top steering stem M8 20 Nm
(14.8 Ibf ft)
6 FORK, TRIPLE CLAMP 32
Finishing work
- Check the play of the steering head bearing. (*" p. 31)
- Remove the motorcycle from the lift stand. (*" p. 10)
• Info
I The hydraulic compression damping determines the fork suspension behavior.
• Info
I Adjusting screw © is located at the upper end of the left fork leg.
The compression damping is located in the left fork leg (white adjusting
screw). The rebound damping is located in the right fork leg (red adjusting
screw).
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
• Info
I The hydraulic rebound damping determines the fork suspension behavior.
• Info
I Adjusting screw © is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg (red adjusting screw).
The compression damping is located in the left fork leg (white adjusting
screw).
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
Main work
- Release bleeder screws Q.
S Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
Finishing work
- Remove the motorcycle from the lift stand. (*" p. 10)
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
- Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
- Clean and oil the dust boots and inner fork tube of both fork legs.
Position the brake line and wiring harness. Put on the clamp and mount and
tighten screws ©
Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
• Info
I The rebound damping is located in the right fork leg REB (red adjusting
screw). The compression damping is located in the left fork leg COMP (white
adjusting screw).
Grooves are milled into the side of the upper end of the fork legs. The sec
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
Position bleeder screws o toward the front.
Tighten screws ©.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 Ibf ft)
Tighten screws ©.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 Ibf ft)
6 FORK, TRIPLE CLAMP
- Position the brake caliper and mount and tighten screws ©
Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 Ibf ft)
Finishing work
- Install the front wheel. (*" p. 93)
- Install the headlight mask with the headlight. (*" p. 90)
- Check the headlight setting. (•" p. 116)
c*'
101327-10
- Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
Finishing work
- Install the fork legs. (*" p. 34)
- Install the front wheel. (•" p. 93)
- Install the headlight mask with the headlight. (•" p. 90)
- Check the headlight setting. (•" p. 116)
• Info
I The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
- Note down the current state of rebound damping o REB (red adjuster of right fork
leg).
- Note down the current state of compression damping © COMP (white adjuster of
left fork leg).
- Fully open the adjusters of the rebound and compression damping.
- Clamp the fork leg in the area of the lower triple clamp.
• Info
1 The cartridge cannot be taken off yet.
201701-10
6 FORK, TRIPLE CLAMP 37
• Info
1 Do not use an impact wrench.
Place a pan underneath since oil will run out.
• Info
1 Removing the 0-ring seat from the cartridge usually requires the application
of force.
• Info
1 The fork protection ring does not necessarily need to be removed for repair
work.
• Info
1 The lock ring has a ground end against which a screwdriver can be posi
tioned.
201706-10
• Info
1 The lower sliding bushing © must be pulled out of its bearing seat.
6 FORK, TRIPLE CLAMP 38
Info
Do not use a tool; pull the ends apart slightly by hand.
Info
The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. (•" p. 36)
Main work
- Pull the spring down. Mount the open end wrench on the hexagonal part.
201722-11
- Clamp the open end wrench in the vise. Release screw cap o but do not remove it
yet.
• Info
I The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. (•" p. 36)
- Remove the spring. (*" p. 38)
Main work
- Degrease piston rod o and clamp it in the vise.
Clamping stand (T14049S) (•" p. 282)
201726-12
© © - Remove spring ©
JwJ
201795-10
6 FORK, TRIPLE CLAMP 40
• Info
I The steps are identical for both fork legs, except for the hydrostop needle and valve.
Preparatory work
- Disassemble the fork legs. (•" p. 36)
- Remove the spring. (*" p. 38)
- Disassemble the cartridge. (*" p. 39)
Main work
- Degrease the piston rod.
- Clamp the piston rod with the special tool as far up as possible.
• Info
I © - silver hydrostop needle on compression damping side,
o - red hydrostop needle on rebound damping side.
Info
The adjusting tube can be used for this.
Info
The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. (•" p. 36)
Main work
- Mount the hydrostop unit on a fitting hexagon socket and clamp into a vice.
- Remove sleeve ©.
- Remove shim stack ©
- Remove adapter ©.
- Remove hub o with washers 0
• Info
I It is possible that only one washer or no washer is present.
Info
The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. (*" p. 36)
- Remove the spring. (*“ p. 38)
- Disassemble the cartridge. (*" p. 39)
6 FORK, TRIPLE CLAMP 42
Main work
- Remove pilot bushing support ©
- Remove O-ring © and seal ring ©
200666-10
Info
The steps are identical for both fork legs.
Info
The steps are identical for both fork legs.
Mount washer ©.
Mount shim stack © with the smaller washers facing downward.
# Info
1 It is possible that only one or no washer is present.
201975-10
• Info
I The steps are identical for both fork legs, except for the hydrostop needle and valve.
Mount spring ©
Mount and tighten adapter © with spring O anc* washer.
Guideline
Adapter of piston rod M6x0.5 12 Nm (8.9 Ibf ft)
201791-10
Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper.
Clean the piston.
Lubricate the piston ring.
Mount the rebound shim stack © with the smaller washers facing upward.
• Info
i © - silver hydrostop needle on compression damping side,
o - red hydrostop needle on rebound damping side.
Info
The steps are identical for both fork legs.
Preparatory work
- Assemble the seal ring retainer. (*" p. 43)
- Assemble the piston rod. (•" p. 44)
Main work
- Mount and grease seal rings o and 0-ring ©
Lubricant (T158) (•" p. 272)
201795-11
6 FORK, TRIPLE CLAMP 46
• Info
I Hold the sleeve in the reservoir to prevent it from sliding out.
• Info
I Ensure that the piston ring is seated correctly.
Info
When assembling, ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is mounted
on the corresponding screw cap.
Compression damping side - screw cap with mark COMP, brake caliper holder, white adjuster.
Rebound damping side - screw cap with mark REB, no brake caliper holder, red adjuster.
Preparatory work
- Assemble the hydrostop unit. p. 43)
Main work
- Clamp the inner tube with the axle clamp.
Guideline
Use soft jaws.
• Info
1 Always change the dust boot, seal ring, lock ring and support ring.
Mount the sealing lip with the spring expander facing downward.
• Info
1 Mount with the sealing lip facing down and the open side facing up.
• Info
1 Do not use a tool; pull the ends apart slightly by hand.
Push the sliding bushing all the way into the outer tube.
Push the seal ring and support ring all the way into the outer tube.
6 FORK, TRIPLE CLAMP 48
Info
The lock ring must engage audibly.
Lubricate the O-ring. Slide the cartridge all the way into the fork leg.
Turn the fork. Have the entire filling quantity of fork oil available.
Add some of the fork oil while pulling out and pushing in the piston rod numerous
times.
Guideline
Fork oil quantity 510 ml (17.24 fl. oz.)
- Pull out the piston rod and push it back in numerous times while pressing it to one
side slightly.
Air bubbles emerge and the cartridge is bled.
- Keep bleeding until no more air bubbles emerge.
S The piston rod moves out automatically to the middle of the total stroke
distance.
• Info
I When fully bled, the correct air chamber length is achieved automatically.
202090-10
- Position spring.
- Pull the spring down. Mount screw cap ©.
• Info
I When assembling, ensure that the screw caps are correctly mounted accord
ing to the hydrostop needles.
Rebound damping side - red hydrostop needle, screw cap with mark REB.
Compression damping side - silver hydrostop needle, screw cap with
mark COMP.
- Pull the spring down. Mount the open end wrench on the hexagonal part.
- Hold the open end wrench. Tighten screw cap (•).
Guideline
Screw cap on piston rod M8x0.75 18 Nm
(13.3 Ibf ft)
Alternative 1
- Turn the adjuster of compression damping (mark COMP) and the adjuster of
rebound damping (mark REB) all the way clockwise.
6 FORK, TRIPLE CLAMP
Guideline
Rebound damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
Compression damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
Warning
Danger of accident Modifications to the suspension setting may seri
ously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious
deterioration in the handling characteristic and overload components.
Info
I Protect the components against damage by covering them.
Do not bend the cables and lines.
6 FORK, TRIPLE CLAMP 51
- Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
- Check whether the upper steering head seal Q is correctly positioned.
- Mount protective ring © and O-ring ©.
• Info
I The upper milled groove in the fork leg must be flush with the upper edge of
the upper triple clamp.
Position bleeder screws e toward the front.
- Tighten screws ©.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 Ibf ft)
6 FORK, TRIPLE CLAMP 52
- Tighten screw ©
Guideline
Screw, top steering head M20xl.5 12 Nm (8.9 Ibf ft)
Tighten screws @.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 Ibf ft)
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam
aged over time.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
6 FORK, TRIPLE CLAMP 53
Main work
- Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
The handlebar must be able to move easily over the entire steering range. There
should be no perceptible detent positions.
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Tighten screws Q-
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 Ibf ft)
Finishing work
- Check the play of the steering head bearing. (•" p. 52)
- Remove the motorcycle from the lift stand. (•“ p. 10)
7 HANDLEBAR, CONTROLS 54
The holes on the handlebar support are placed at a distance of © from the center.
The handlebar can be mounted in four different positions. In this way, the handlebar
can be mounted in the position that is most comfortable for the rider.
Warning
Danger of accidents Handlebar breakage.
- If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle
bar.
Remove screws o . Remove the handlebar clamp. Remove the handlebar and lay it
to one side.
• Info
I Protect the components against damage by covering them.
Do not bend the cables and lines.
• Info
I Position the left and right handlebar supports evenly.
• Info
I Make sure cables and wiring are positioned correctly.
• Info
I Make sure the gap widths are even.
• Info
I When the adjusting screw is turned counterclockwise, the clutch lever
moves closer to the handlebar.
When the adjusting screw is turned clockwise, the clutch lever moves away
from the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
7 HANDLEBAR, CONTROLS 55
The throttle cable must be routed behind the handlebar, on the right of the
upper frame tube, and to the carburetor.
Finishing work
- Install the fuel tank. (•" p. 87)
- Mount the seat. (•" p. 86)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventila
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
- Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
- Tighten nut 0
- Slide on sleeve o
Finishing work
- Check the throttle grip for smooth operation.
8 FRAME 57
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
- The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
Turn adjusting screw o all the way clockwise using a socket wrench.
• Info
I Do not loosen nut 0!
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
- The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
• Info
I Do not loosen nut @!
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
9 SHOCK ABSORBER, SWINGARM 59
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
- The shock absorber is filled with high density nitrogen. Adhere to the description provided.
• Info
I Do not loosen nut 0!
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
Finishing work
- Remove the motorcycle from the lift stand. (*" p. 10)
• Info
I The static sag is the difference between measurements © and ©.
• Info
1 The riding sag is the difference between measurements © and ©•
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
- The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
- Remove the shock absorber. (•" p. 61)
- After removing the shock absorber, clean it thoroughly.
Main work
- Loosen screw o
- Turn adjusting ring © until the spring is no longer under tension.
• Info
I Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
- Tighten screw O-
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft)
Finishing work
- Install the shock absorber. (•" p. 61)
- Remove the motorcycle from the lift stand. (•" p. 10)
9 SHOCK ABSORBER, SWINGARM 61
• Info
I The spring rate is shown on the outside of the spring.
Finishing work
- Install the shock absorber. (*~ p. 61)
- Remove the motorcycle from the lift stand. (•" p. 10)
- Check the static sag of the shock absorber. (•" p. 59)
- Check the riding sag of the shock absorber. (*“ p. 60)
- Adjust the rebound damping of the shock absorber. (*“ p. 59)
• Info
I The heim joint for the shock absorber at the swing arm is Teflon coated.
It must not be lubricated with grease or with other lubricants. Lubricants
dissolve the Teflon coating, thereby drastically reducing the service life.
Finishing work
- Remove the motorcycle from the lift stand. (•“ p. 10)
9 SHOCK ABSORBER, SWINGARM 62
Caution
A Danger of accidents Disassembly of pressurized parts can lead to injury.
- The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Condition
The shock absorber has been removed.
- Remove the spring. (*" p. 62)
- Disassemble the damper. (•" p. 63)
- Disassemble the piston rod. (*" p. 64)
- Disassemble the seal ring retainer. (*" p. 65)
- Check the damper. (*” p. 67)
- Disassemble the rebound adjuster. (•” p. 67)
- Remove the heim joint. (*" p. 68)
- Install the heim joint. (•" p. 69)
- Assemble the rebound adjuster. (•" p. 70)
- Assemble the seal ring retainer. (*" p. 70)
- Assemble the piston rod. (•" p. 71)
- Assemble the damper. (*“ p. 72)
- Install the spring. (** p. 78)
- Remove O-ring ©.
- Remove spring retainer © and intermediate washer ©.
- Remove the spring.
9 SHOCK ABSORBER, SWINGARM 63
201616-10
- Press seal ring retainer ® all the way in with the special tool.
• Info
I Do not scratch the inner surface.
- Remove nut O-
• Info
I If mount © is loosened, apply counteractive force.
Info
Guide the rebound damping shim stack onto a screwdriver and put them
aside together.
Remove piston ©.
Remove compression damping shim stack ©.
• Info
I Guide the compression damping shim stack onto a screwdriver and put
them aside together.
9 SHOCK ABSORBER, SWINGARM 65
• Info
I Guide the rebound damping shim stack onto a screwdriver and put them
aside together.
Remove piston
Remove compression damping shim stack ©
• Info
I Guide the compression damping shim stack onto a screwdriver and put
them aside together.
: —__________________________________________________________ •. — — — —-
•» r •
" 200785-10
1*. *
9 SHOCK ABSORBER, SWINGARM 66
a*)
1gpi - ■ »■ ~ w ©r • ■ ^ ^
l. #
200786-10
- Remove washer ©
© - Remove O-ring ©.
r - "W ^ *
~ 200787-10
____________________________________________________________________________________________________
% <
- ----- - 200796-10
Position the pilot bushing in the seal ring retainer using the special tool.
Support seal ring retainer © with the sleeve © of the special tool. Press the pilot
bushing all the way in.
Support seal ring retainer © with the sleeve © of the special tool.
Damper cartridge
Diameter 50.08 mm (1.9716 in)
Piston rod
Diameter 17.95 mm (0.7067 in)
Piston rod
200812-10
Run-out 0.02 mm (0.0008 in)
wII
-- - ■■■ — — —
'200805-10
9 SHOCK ABSORBER, SWINGARM 68
Remove screwsleeve ©
Remove adjusting screw ©
• Info
I Do not lose balls © and spring.
- Turn the shock absorber around and remove the second heim joint collar bushing.
- Press the heim joint against a lock ring using the special tool.
Place special tool Q underneath and press out heim joint © using special
tool ©.
Press the heim joint against the lock ring using the special tool.
• Info
I Push in the rebound needle to the point where it is possible to mount the
rebound damping adjusting screw.
• Info
I The rebound damping valve seat must be pressed inward before tightening.
_/ - Mount O-ring ©
1% - Mount washer ©.
(200793-10
9 SHOCK ABSORBER, SWINGARM 71
Grind piston © on both sides, using 1200 grit sandpaper on a surfacing plate.
Clean the piston.
Mount the piston.
Guideline
View © Top view of piston
Mount rebound damping shim stack 9 with the smaller shims at the top.
Apply thread locker to the threads of the piston rod.
Loctite® 2701™
Screw on mount © to the point where the piston can still be turned.
-200769-10
Mount the compression shim stack (s) with the smaller shims facing downward.
200770-10
Grind piston © on both sides on a surface plate using 1200 grit sandpaper.
Clean the piston.
Mount the piston.
Guideline
View Q Top view of piston
Mount rebound damping shim stack 9 with the smaller shims facing upward.
Grease the threads of the mount.
200772-10
Main work
- Slide the spring and piston onto compression adjuster ©
Grease the O-ring.
• Info
1 The adjusting ring cannot be mounted after the piston rod has been assem
bled!
- Mount seal ring retainer o and slide it under the ring groove.
- Mount lock ring ©
• Info
I Do not scratch the inner surface.
- Pull out the piston rod in order that the seal ring retainer fits closely against the
lock ring.
Alternative 1
- Turn adjusting screw © clockwise with a screwdriver up to the last perceptible
click.
- Turn counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
Comfort 25 clicks
* J 200780-10 Standard 20 clicks
Sport 15 clicks
- Turn adjusting screw © clockwise with an open end wrench until it stops.
- Turn counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Alternative 2
Warning
Danger of accident Modifications to the suspension setting may seri
ously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious
deterioration in the handling characteristic and overload components.
• Info
I Before working with the vacuum pump, carefully read the vacuum pump operating manual
Completely open the adjusters of the rebound and compression damping.
• Info
I Hand-tighten only without using a tool.
Clamp the damper with soft jaws or hold it as shown in the photo.
• Info
I Clamp the damper only lightly.
The filling port must be located at the highest point.
The piston rod moves in and out during filling; do not immobilize it by hold
ing it with your hand.
< 0 bar
4 mbar
Determine distance © between the floating piston and reservoir hole with the spe
cial tool.
When the vacuum gauge reaches the required value, turn control lever Oil reser
voir @ to Equalize pressure.
Guideline
4 mbar
0 bar
9 SHOCK ABSORBER, SWINGARM 76
When the pressure gauge reaches the required value, turn control lever Damper o
to Pressure.
Guideline
0 bar
3 bar
200268-10
When the pressure gauge reaches the required value, turn control lever Damper ©
to Vacuum.
Guideline
3 bar
0 bar
When the pressure gauge reaches the required value, turn control lever Oil reser
voir © to Vacuum.
Guideline
0 bar
8 mbar
When the vacuum gauge reaches the required value, turn control lever Oil reser
voir © to Equalize Pressure.
Guideline
8 mbar
0 bar
200268-10
When the pressure gauge reaches the required value, turn control lever Damper o
to Vacuum.
Guideline
3 bar
When the pressure gauge reaches the required value, activate the On/Off switch.
Guideline
0 bar
Slide O-ring © to the end of the special tool by the specified value (distance ©
minus specified value).
Guideline
Push the floating piston into the reservoir to the distance described above using the
special tool.
Info
When the piston rod is fully extended, the floating piston must be at pre
cisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.
Info
Hold the damper so that the filling port is at the highest point.
• Info
I The piston rod is completely extended.
201616-11
Connect the special tool to the pressure regulator of the filling cylinder.
Alternative 2
Warning
Danger of accident Modifications to the suspension setting may seri
ously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious
deterioration in the handling characteristic and overload components.
- Tighten the spring by turning the adjusting ring to the measured value deter
mined when it was removed.
Tighten screw ©
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft)
• Info
I Raise the wheel slightly to make it easier to remove the screw.
- Press in shaft seal rings © on both sides with the open side facing inward.
• Info
I The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis
solve the Teflon coating, thereby drastically reducing the service life.
• Info
I Raise the wheel slightly to make it easier to mount the screw.
Finishing work
- Remove the motorcycle from the lift stand. (*" p. 10)
10 EXHAUST 81
Warning
A Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down. Do not touch hot components.
Remove screws ©
Pull the main silencer off of the manifold at the rubber sleeve ©
10.3 Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down. Do not touch hot components.
Info
Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
- Remove the main silencer. (•" p. 81)
10 EXHAUST 82
Main work
- Remove screws o
- Pull out inner tube ©
- Remove glass fiber yarn filling © from the inner tube.
- Clean the parts that need to be reinstalled and check for damage.
- Mount the new glass fiber yarn filling © on the inner tube.
- Position outer tube o over the inner tube with the new glass fiber yarn filling.
- Mount and tighten screws ©
Guideline
Screws on the main silencer M5 7 Nm (5.2 Ibf ft)
Finishing work
- Install the main silencer. C*- p. 81)
11 AIR FILTER 83
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
- Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Preparatory work
- Remove the air filter box lid. (*" p. 83)
Main work
- Detach air filter holder o at the bottom and swing it to one side. Remove the air
filter with the air filter support.
- Remove the air filter from the air filter support.
- Insert both parts together, position them and fasten them using air filter holder O-
y The arrow of marking UP faces up.
• Info
I If the air filter is not correctly mounted, dust and dirt can enter the engine
and cause damage.
Finishing work
- Install the air filter box lid. (•" p. 83)
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
• Info
I Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the air filter box lid. (•" p. 83)
- Remove the air filter. (•" p. 83)
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
• Info
I Only squeeze the air filter to dry it; never wring it out.
- Oil the dry air filter with a high quality filter oil.
Finishing work
- Install the air filter box lid. ( p. 83)
12 FUEL TANK, SEAT, TRIM 85
Danger
Fire hazard Fuel is highly flammable.
- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
- The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to get into the ground water, the ground, or the sewage system.
Press release button 0>turn the filler cap counterclockwise and lift it free.
Info
Run the fuel tank breather hose © without kinks.
Danger
Fire hazard Fuel is highly flammable.
- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
- The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
Preparatory work
- Remove the seat. (•" p. 85)
Main work
- Turn handle O of the fuel tap to the OFF position. (Figure 602702-10*" p. 88)
- Pull off the fuel hose.
• Info
I Remaining fuel may run out of the fuel hose.
602720-11
12 FUEL TANK, SEAT, TRIM 87
Pull both spoilers off of the sides of the radiator bracket ® and lift off the fuel
tank.
Danger
Fire hazard Fuel is highly flammable.
- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
- The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Main work
- Check the routing of the throttle cable. (•" p. 55)
- Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
- Make sure that no cables are trapped or damaged.
Finishing work
- Mount the seat. (•" p. 86)
12 FUEL TANK, SEAT, TRIM 88
Finishing work
- Install the headlight mask with the headlight. (*" p. 90)
- Check the headlight setting. (•" p. 116)
Detach plug-in connector ® and take off the headlight mask with the headlight.
Finishing work
- Check the headlight setting. (*" p. 116)
14 WHEELS 91
info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
Check the front and rear tires for cuts, run-in objects and other damage.
» If the tire exhibits cuts, run-in objects or other damage:
- Change the tire.
Check the depth of the tread.
• Info
I Note local national regulations concerning the minimum tread depth.
• Info
I The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits indi
cate the week of manufacture and the last two digits the year of manufac
ture.
KTM recommends that the tires are changed at the latest after 5 years,
regardless of the actual state of wear.
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement ©
• Info
I Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Warning
Danger of accidents Instable handling due to incorrect spoke tension.
Info
A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
• Info
I The tone frequency depends on the length of the spoke and the spoke diam
eter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
Main work
- Press the brake caliper onto the brake disc by hand in order to push back the brake
pistons.
• Info
I Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
- Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
• Info
I Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam
aged.
- Remove spacers ©
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
- Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Lift the front wheel into the fork, position it, and insert the wheel spindle.
y The brake linings are correctly positioned.
Mount and tighten screw ©
Guideline
Screw, front wheel spindle M24xl.5 45 Nm
(33.2 Ibf ft)
Operate the hand brake lever several times until the brake linings are lying correctly
against the brake disc.
Remove the motorcycle from the lift stand. (*" p. 10)
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
Tighten screws ©.
Guideline
Screw, fork stub M8 15 Nm
(11.1 Ibf ft)
Finishing work
- Install the front wheel. (*" p. 93)
Preparatory work
- Raise the motorcycle with the lift stand. (*" p. 10)
14 WHEELS 95
Main work
- Press the brake caliper onto the brake disc by hand in order to push back the brake
piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
- Remove nut o
- Remove chain adjuster ©. Withdraw wheel spindle © only enough to allow the
rear wheel to be pushed forward.
- Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
• Info
I Protect the components against damage by covering them.
- Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
• Info
I Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam
aged.
- Remove spacers ©
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
- Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Main work
- Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change the wheel bearing.
- Clean and grease shaft seal rings o and bearing surface © of the spacers.
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
Chain adjusters © can be turned by 180°.
- Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
Finishing work
- Remove the motorcycle from the lift stand. (•" p. 10)
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
- Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
Main work
- Clean the chain regularly and then treat with chain spray.
Finishing work
- Remove the motorcycle from the lift stand. p. 10)
Warning
A Danger of accidents Danger caused by incorrect chain tension.
- If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
14 WHEELS 98
Main work
- Pull the chain at the end of the chain sliding piece upward to measure chain ten
sion O-
• Info
I The bottom chain section O must be taut.
When the chain guard is mounted, it must be possible to pull up the chain
at least to the point where it makes contact with chain guard ©.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Finishing work
- Remove the motorcycle from the lift stand. (•" p. 10)
14.6.8 Checking the chain, rear sprocket, engine sprocket and chain guide
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
Main work
- Shift gear to neutral.
- Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
- Change the drivetrain kit.
• Info
I The engine sprocket, rear sprocket, and chain should always be
changed together.
Pull on the upper part of the chain with the specified weight ©
Guideline
Weight, chain wear measurement 10... 15 kg (22... 33 lb.)
Info
Chain wear is not always even; repeat this measurement at different chain
positions.
• Info
I When you replace the chain, you should also change the rear
sprocket and engine sprocket.
12 3 16 17 18 New chains wear out faster on old, worn sprockets.
400987-10
14 WHEELS 99
• Info
I Wear can be seen on the front of the chain guide.
Finishing work
- Remove the motorcycle from the lift stand. (*~ p. 10)
14 WHEELS 100
Warning
Danger of accidents Danger caused by incorrect chain tension.
- If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.
Preparatory work
- Raise the motorcycle with the lift stand. ("•" p. 10)
- Check the chain tension. (•" p. 97)
Main work
- Loosen nut O-
- Loosen nuts ©.
- Adjust the chain tension by turning adjusting screws left and right.
Guideline
Chain tension 55... 58 mm (2.17... 2.28 in)
Turn adjusting screws ® on the left and right so that the markings on the
left and right chain adjusters are in the same position relative to reference
marks ©. The rear wheel is then correctly aligned.
- Tighten nuts ©
- Make sure that chain adjusters © are fitted correctly on adjusting screws ©
- Tighten nut o
Guideline
Nut, rear wheel spindle M20xl.5 80 Nm (59 Ibf ft)
• Info
I The wide adjustment range of the chain adjusters (32 mm (1.18 in))
enables different secondary ratios with the same chain length.
Chain adjusters o can be turned by 180°.
Finishing work
- Remove the motorcycle from the lift stand. (*" p. 10)
15 WIRING HARNESS, BATTERY 101
• Info
I The main fuse ^ is located in the starter relay © under the filter box
cover.
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
- Use only fuses with the prescribed amperage. Never bypass or repair fuses.
• Info
I Contact disk Q must be mounted between battery terminal © and cable
lugs with the claws facing up.
Finishing work
- Mount the seat. (*" p. 86)
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
Preparatory work
- Switch off all power consumers and the engine.
- Remove the seat. (*" p. 85)
Main work
- Disconnect the negative (minus) cable O °f the battery.
- Pull back the plus pole cover © and disconnect the positive (plus) cable of the
battery.
- Detach rubber band © at the bottom.
- Lift the battery out.
15 WIRING HARNESS, BATTERY 103
• Info
I Contact disk © must be mounted between screw © anc* cable socket ©
with the claws facing down.
• Info
I Contact disk © must be mounted between screw © and cable socket ©
with the claws facing down.
Finishing work
- Mount the seat. (*" p. 86)
Charging voltage
5,000 rpm 13.5... 15.0 V
• Info
I The value of the open-circuit current applies only to vehicles in the original
state, i.e. without additional power consumers.
601201-10
16 BRAKE SYSTEM 105
Warning
A Danger of accidents Reduced braking efficiency caused by worn brake linings.
Warning
Danger of accident Brake system failure.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Avoid contact with skin and eyes, and keep out of the reach of children.
- Wear suitable protective clothing and goggles.
- If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
- Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
- Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
16 BRAKE SYSTEM
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws ©
Remove cover © with membrane ©
Manually press the brake caliper toward the brake disc to push back the brake pis
tons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract
ing it by suction if it does.
• Info
I Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
Remove cotter pins ©, pull out pin ©, and remove the brake linings.
Clean the brake caliper and brake caliper support.
Check that leaf spring © in the brake caliper and sliding plate e in the brake
caliper support are seated correctly.
Insert the new brake linings, insert the pin, and mount the cotter pins.
• Info
I Always change the full set of brake linings.
Operate the hand brake lever several times until the brake linings are lying correctly
against the brake disc and there is a pressure point.
Position the cover with the membrane. Mount and tighten the screws.
• Info
1 Wash off overflowed or spilled brake fluid immediately with water.
16 BRAKE SYSTEM 107
Warning
Danger of accidents Brake system failure.
- If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due
to overheating. Adjust the free travel on hand brake lever according to specifications.
16.4 Adjusting free travel of hand brake lever (All 250/300 EXC EU/AU models)
- Check the free travel of the hand brake lever. (*" p. 107)
- Adjust the free travel of the hand brake lever with the adjustment screw ©
• Info
I Turn the adjusting screw clockwise to reduce free travel. The pressure point
moves away from the handlebar.
Turn the adjusting screw counterclockwise to increase free travel. The pres
sure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
16.5 Adjusting the basic position of the hand brake lever (All 250/300 XC-W models)
Check the free travel of the hand brake lever. (*“ p. 107)
Adjust the basic setting of the hand brake lever to your hand size by turning adjust
ing screw O-
• Info
I Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
16 BRAKE SYSTEM 108
Warning
Danger of accidents Brake system failure.
- If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Check the brake fluid level in the viewer ©
» If the brake fluid has dropped below marking 0:
- Add front brake fluid. (*~ p. 108)
Warning
Danger of accidents Brake system failure.
- If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Avoid contact with skin and eyes, and keep out of the reach of children.
- Wear suitable protective clothing and goggles.
- If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
16 BRAKE SYSTEM
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws ©
Remove cover © with membrane ©
Add brake fluid to level ©
Guideline
Dimension Q (brake fluid level below 5 mm (0.2 in)
top edge of container)
Position the cover with the membrane. Mount and tighten the screws.
• Info
I Clean up overflowed or spilt brake fluid immediately with water.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Avoid contact with skin and eyes, and keep out of the reach of children.
- Wear suitable protective clothing and goggles.
- If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Cover the painted parts.
Remove screws ©
Remove cover © with membrane.
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Info
Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is correctly set at pressure gauge © If necessary,
adjust the filling pressure at pressure regulator ©
Guideline
Filling pressure 2... 2.5 bar (29... 36 psi)
Pull off protection cap 0 of the brake caliper bleeder screw. Connect the hose of
the bleeder bottle.
Info
Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
• Info
I This prevents overfilling of the brake fluid reservoir.
Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro
tection cap.
Disconnect the bleeding device. Remove the bleeder cover.
Add brake fluid to level ©.
Guideline
Level © 5 mm (0.2 in)
Position the cover with the membrane. Mount and tighten the screws.
• Info
I Clean up overflowed or spilt brake fluid immediately with water.
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
Warning
Danger of accident Brake system failure.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Avoid contact with skin and eyes, and keep out of the reach of children.
- Wear suitable protective clothing and goggles.
- If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
- Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
• Info
I Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
Remove cotter pins ©, pull out pin ©, and remove the brake linings.
Clean the brake caliper and brake caliper support.
16 BRAKE SYSTEM
Check that leaf spring © in the brake caliper and sliding plate © in the brake
caliper support are seated correctly.
Insert the new brake linings, insert the pin, and mount the cotter pins.
• Info
I Always change the brake linings in pairs.
Operate the foot brake lever several times until the brake linings are lying against
the brake disc and there is a pressure point.
• Info
I Wash off overflowed or spilled brake fluid immediately with water.
Warning
Danger of accidents Brake system failure.
- If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.
Disconnect spring o
Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel ©
Guideline
Free travel at foot brake lever 3... 5 mm (0.12... 0.2 in)
Warning
Danger of accidents Brake system failure.
- If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.
16 BRAKE SYSTEM
Disconnect spring o
Loosen nut © and, with push rod e , turn it back until you have maximum free
travel.
To adjust the basic position of the foot brake lever individually, loosen nut © and
turn screw © accordingly.
• Info
1 The range of adjustment is limited.
Turn push rod © accordingly until you have free travel ©. If necessary, adjust
the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3... 5 mm (0.12... 0.2 in)
Reconnect spring ©
Warning
Danger of accidents Brake system failure.
- If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
1
[602760-10
Warning
Danger of accidents Brake system failure.
- If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
16 BRAKE SYSTEM 114
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
Preparatory work
- Check the rear brake linings. (*" p. 110)
Main work
- Stand the vehicle upright.
- Remove screw cap Q with membrane 0 and the O-ring.
- Add brake fluid to level ©
- Mount the screw cap with the membrane and the O-ring.
• Info
I Clean up overflowed or spilt brake fluid immediately with water.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Avoid contact with skin and eyes, and keep out of the reach of children.
- Wear suitable protective clothing and goggles.
- If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Info
Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is correctly set at pressure gauge © If necessary,
adjust the filling pressure at pressure regulator ©
Guideline
Filling pressure 2... 2.5 bar (29... 36 psi)
Pull off protection cap © of the bleeder screw. Connect the hose of the bleeder
bottle.
• Info
I This prevents overfilling of the brake fluid reservoir.
Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro
tection cap.
Disconnect the bleeding device. Remove the bleeder cover.
Stand the vehicle upright.
Add brake fluid to level ©.
Fit and tighten the screw cap with the membrane and O-ring.
• Info
I Clean up overflowed or spilt brake fluid immediately with water.
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with driver.
Info
The headlight range may need to be corrected if luggage is carried on the
vehicle.
- Tighten screw o
- Press the button O to change the display mode or change to one of the Setup
menus.
- Press the button + to control different functions.
- Press the button — to control different functions.
• Info
I When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
17 LIGHTING SYSTEM, INSTRUMENTS 117
400313-01
WS (wheel size)
After the display function check, the wheel size WS is displayed briefly.
• Info
I The number 2205 equals the circumference of the 21" front wheel with stan
dard tires.
Info
If you change the unit of measure, the 0D0 value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and SI are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
- Press the button O briefly and repeatedly until H appears at the bottom right of the
display.
- Press the button O for 3 - 5 seconds.
TR1 TR2 A1 A2 SI S2 S The Setup menu is displayed and the active functions are shown.
- Press the button O repeatedly until the Km/h/Mph display flashes.
\l/ \l/
^ Km/h Mph ^ LAP CLK H Adjusting Km/h
/IV /|\
- Press the button +.
Adjusting Mph
400329-01 - Press the button —.
- Press the button O for 3 - 5 seconds.
S The settings are stored and the Setup menu is closed.
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary
17 LIGHTING SYSTEM, INSTRUMENTS 118
- Press the button O briefly and repeatedly until H appears at the bottom right of the
display.
- Press the button O for 3 - 5 seconds.
. \(7
^TR1^TR2 A1 A2 SI S2 y The Setup menu is displayed and the activated functions are shown.
/\\
- Change to the desired function by pressing the button O briefly.
Km/h Mph 0D0 LAP CLK H y The selected function flashes.
Activating a function
- Press the button +.
400318-01 y The symbol remains on the screen and the display changes to the next
function.
Deactivating the function
- Press the button —.
y The symbol on the screen goes out and the display changes to the next
function.
- All desired functions are activated or deactivated accordingly.
- Press the button O for 3 - 5 seconds.
y The settings are stored and the Setup menu is closed.
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
Info
The seconds can only be set to zero.
• Info
I If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
Danger
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub-
lie roads in the homologated version.
- If the vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle
owner and rider of this.
- If you undertake any modifications, please insist on receiving a signed workshop order from your customer in which you
inform the customer in writing that these modifications are performed at the customer's own risk and that the vehicle will
no longer be approved for use on public roads once modified.
Preparatory work
- Remove the headlight mask with the headlight. (*" p. 89)
17 LIGHTING SYSTEM, INSTRUMENTS 119
Main work
- Expose connector CZ Q.
Finishing work
- Install the headlight mask with the headlight. p. 90)
- Check the headlight setting. (•" p. 116)
400315-01
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
Info
This function can be called up only if lap times are measured.
17 LIGHTING SYSTEM, INSTRUMENTS 120
Condition
The motorcycle is stationary.
- Press the button O briefly and repeatedly until LAP appears at the bottom right of
the display,
- Press the button O briefly.
LAP |
y LAP 1 appears on the left side of the display.
nnno jo - Laps 1-10 can be displayed by pressing the button +.
1 UUUODD
LAP - The button — has no function.
- Press the button O briefly.
y Next display mode
400321-01
• Info
I If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.
• Info
I When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
™
oooo
oooo 00 00-00
00-00 00
UK
TR1 TR2 A1 A2 SI S2
-
To enable you to check that the display is functioning properly, all display segments
light up briefly.
SPEED WS Km/h Mph Mies ODO LAP CLK H
400313-01
WS (wheel size)
After the display function check, the wheel size WS is displayed briefly.
• Info
I The number 2205 equals the circumference of the 21" front wheel with stan
dard tires.
400314-01
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1 , TR2 , A1 , A2 and SI are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
17 LIGHTING SYSTEM, INSTRUMENTS 121
- Repeatedly press the button + briefly until H appears at the bottom right of the
display.
- Press the button 4- for 2-3 seconds.
TR1 TR2 A1 A2 SI S2 y The Setup menu is displayed and the active functions are shown.
- Repeatedly press the button + briefly until Km/h/Mph flashes.
\l/ \l/
^ Km/h Mph ^ ODO LAP CLK H Setting the Km/h
—4W|-\---------------------------------------
- Press the button +.
Setting the Mph
400329-01 - Press the button —.
- Wait 3-5 seconds
y The settings are stored.
Info
If no button is pressed for 10-12 seconds, or if an impulse comes from
the wheel speed sensor, the settings are automatically saved and the setup
menu is closed.
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
- Repeatedly press the button + briefly until H appears at the bottom right of the
display.
- Press the button + for 2-3 seconds.
^TR1^TR2 A1 A2 SI S2 y The Setup menu is displayed and the active functions are shown.
/i\
• Info
Km/h Mph ODO LAP CLK H I If no button is pressed for 10-12 seconds, the settings are automatically
saved.
If no button is pressed for 20 seconds, or if an impulse comes from the
400318-01 wheel speed sensor, the settings are automatically saved and the setup
menu is closed.
- Repeatedly press the button + briefly until the desired function flashes.
y The selected function flashes.
Activating the function
- Press the button +.
y The symbol continues to appear in the display and the next function
appears.
Deactivating a function
- Press the button —.
y The symbol disappears in the display and the next function appears.
Info
The seconds can only be set to zero.
If no button is pressed for 15 -20 seconds, or if an impulse comes from
the wheel speed sensor, the settings are automatically saved and the setup
menu is closed.
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
Info
This function can only be opened if lap times have actually been timed.
Condition
The motorcycle is stationary.
- Repeatedly press the button + briefly until LAP appears at the bottom right of the
display.
- Briefly press the button +.
y LAP 1 appears on the left side of the display.
LAP |
nn.no. z*Q - The laps 1-10 can be viewed with the button —.
1 UUUODJ
LAP - Press and hold the button + for 3-5 seconds.
y The lap times are deleted.
- Briefly press the button +.
400321-01
y Next display mode
Info
When an impulse is received from the wheel speed sensor, the left side of
the display changes back to the SPEED mode.
18 ENGINE 123
- Loosen screw ©.
- Remove screw
- Loosen screw ©
- Remove screw ©
- Take off the exhaust manifold.
- Remove screw
- Remove the cable binders.
- Take off the frame protector.
- Remove screw ©
- Remove the cable binders.
- Take off the frame protector.
18 ENGINE 124
Remove screw
Loosen screw ©
Repeat these steps on the opposite side.
Swing up the subframe and secure it.
Remove screw ©
Remove screw ©
Take off the engine sprocket cover.
18 ENGINE 125
Remove screws ©.
Take off the clutch slave cylinder and hang it to one side.
• Info
I Do not kink the clutch line.
Do not activate the clutch lever while the clutch slave cylinder is removed.
Remove screw ©
Take off the shift lever.
Disconnect connector ©
Disconnect connector ©
Remove the cable binder and expose the cable.
Remove fittings
Take off the engine braces.
Remove nut
Remove the swingarm pivot.
Pull the swingarm toward the rear slightly.
18 ENGINE 127
Remove screws ©
• Info
I The help of an assistant is useful in this step.
Ensure that the motorcycle is sufficiently secured against falling over.
Protect the frame and attachments against damage.
Guideline
Engine bracket screw M10 60 Nm
(44.3 Ibf ft)
Nut, swingarm pivot M16xl.5 100 Nm
(73.8 Ibf ft)
Mount spring 0
18 ENGINE 129
Plug in connector ©.
Plug in connector ©.
Route the cable and secure with a cable binder.
• Info
1 Watch out for the intake flange.
Remove screw
Mount and tighten screw flj).
Guideline
Screw, subframe M8 35 Nm Loctite® 2701™
(25.8 Ibf ft)
Position cover ©
Tighten screw ©.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
Tighten screw
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
Gear oil 0.80 I (0.85 qt.) Engine oil (15W/50) (•" p. 270)
Finishing work
- Remove the motorcycle from the lift stand. (*" p. 10)
- Refill with coolant. (•" p. 198)
- Install the fuel tank. (•" p. 87)
- Connect the negative cable of the battery. (•” p. 102)
- Mount the seat. (*" p. 86)
- Take a short test ride.
- Check the engine for leakage.
- Check the gear oil level. (•” p. 202)
- Check the coolant level. (*" p. 197)
18 ENGINE 132
Remove O-ring ©.
Remove screws ©
Remove starter motor.
18 ENGINE 134
Remove screws ©
Remove the alternator cover.
308131-10
18 ENGINE 136
- Remove nuts ©
• Info
I Raise the cylinder slightly to be able to remove the front nuts.
• Info
I Left-handed thread!
• Info
I The washer usually sticks to the inner clutch hub.
• Info
I Turn the kick starter shaft slightly to the left.
Mount special tool apply counterpressure, and pull off the rotor by screwing in
the screw.
• Info
I Do not pry it apart with screwdrivers since the sealing areas are easily dam
aged.
18 ENGINE 142
Info
Do not misplace the shift rollers.
Info
Do not misplace the shift rollers.
Info
The stop disks of the transmission shafts usually stick to the bearings.
18 ENGINE 143
- Remove O-ring
308181-10
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section must be removed using
a suitable tool.
Blow out lubrication bore © with compressed air and check that it is clear.
Insert the new cold bearings in the bearing seats of the heated section of the
engine case; if necessary, use a suitable press drift to push them all the way in and
make them flush.
• Info
I When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
- After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
18 ENGINE 144
- Press in shaft seal ring O of the crankshaft so it is flush with the open side facing
in.
- Mount and tighten screws © with the bearing retainers.
Guideline
Screw, bearing retainer M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section must be removed using
a suitable tool.
Insert the new cold bearings in the bearing seats of the heated section of the
engine case; if necessary, use a suitable press drift to push them all the way in and
make them flush.
• Info
I When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
- After the engine case section has cooled, check that the bearings are firmly seated.
• Info
I If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
Press in shaft seal ring o of the crankshaft so it is flush with the open side facing
in.
Press in shaft seal ring © of the shift shaft so it is flush with the open side facing
in.
Press in shaft seal ring © of the countershaft so it is flush with the open side fac
ing in.
Blow out lubrication bore o with compressed air and check that it is clear.
Mount the dowels.
18 ENGINE 145
• Info
1 Use soft jaws.
- Push the warmed up special tool © onto the crankshaft bearing inner race, press
firmly together and pull jointly from the crankshaft.
• Info
1 Use soft jaws.
Fleat the crankshaft bearing inner race in special tool © and mount together.
Guideline
120 °C (248 °F)
18.4.5 Changing the connecting rod, conrod bearing, and crank pin
Main work
- Position crankshaft O in the press using special tool ©.
- Press the crank pin out of the upper crank web with a suitable tool.
• Info
I Hold the lower crank web.
Info
Thoroughly oil the bearing.
- Insert the crank web with connecting rod and bearing. Position the second crank
web.
• Info
I The press mandrel must be positioned over the crank pin.
- Take the crankshaft out of the special tool and check that the connecting rod can
move freely.
- Measure axial play © between the connecting rod and the crank webs using the
special tool.
Finishing work
- Check the crankshaft run-out at the bearing pin. (•" p. 146)
» If the crankshaft run-out at the bearing pin is larger than the specification:
- Align the crankshaft.
18 ENGINE 147
Info
The cylinder size o is labeled on the right side of the cylinder.
Using a straightedge and the special tool, check the sealing area of the cylinder
head for distortion.
Remove screws ©
303068-10
303069-10
Remove screw ©
Remove screw © with the washer.
Take off the stop plate.
303070-10
303071-10
Remove screws ©
Take off the retaining bracket.
______________________________________________________________________________________________ 303042-10
303620-10
303622-10
18 ENGINE 151
Loctite® 5910
• Info
1 Do not forget the spring hangers.
Position the spring with the short leg toward the outside.
Mount screw © with the bushing and spring but do not tighten yet.
Guideline
Screw, control flap, M6 10 Nm Loctite® 243™
exhaust control (7.4 Ibf ft)
• Info
I The screws are tightened when the Z-distance is adjusted.
18 ENGINE 152
Tip
An old piston ring can be used to clean the piston ring groove.
• Info
I Mount the piston ring with the marking facing upward.
Tip
An old piston ring can be used to clean the piston ring groove.
• Info
I Mount the piston ring with the marking facing upward.
- Place the piston pin in the connecting rod and check the seating for play.
» If the piston pin seating has excessive play:
- Change the connecting rod and piston pin.
Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance ©.
Guideline
Distance © 50 mm (1.97 in)
Piston - diameter (All 250 models)
Size 1 66.340... 66.350 mm (2.61181...
2.6122 in)
Size II 66.351... 66.360 mm (2.61224...
2.61259 in)
Piston - diameter (All 300 models)
Size 1 71.940... 71.950 mm (2.83228...
2.83267 in)
Size II 71.951... 71.960 mm (2.83271...
2.83307 in)
• Info
I Piston dimensions o are marked on the piston head.
G01315-11
G01316-10
G01317-10
Remove screws ©
Separate the reed valve holders. Remove holding strip ©.
18 ENGINE 155
• Info
1 Mount the screws at right angles to prevent damage.
GO1328-10
G01326-11
18 ENGINE 157
- Position gasket ®.
Info
Remove the outer clutch cover to avoid damage.
Remove screws o
Remove the locking cap.
f
Remove adjusting spring the auxiliary spring, and the spring insert.
18 ENGINE 158
Remove screw
Take off water pump impeller ©
Remove the centrifugal timer.
303037-10
______________________________________________________________________________________________ 303031-10
Press bearing all the way in to the stop from the inside.
303039-10
Turn the water pump impeller all the way around to ensure that it can move easily.
. ©
Position linkage 0
Mount angle lever ©.
18 ENGINE 161
303034-10
- Mount adjusting spring © with the auxiliary spring and spring insert.
303033-10
303032-10
Mount sliding plate o with the guide pin facing downward and put the guide pin
on the shift quadrant.
Mount pressure spring ©.
- Slide on spring guide © push return spring © , with the offset end facing
upward, over the spring guide and lift the offset end over abutment bolt ©.
303009-10
- Mount stop disk ©
18 ENGINE 163
______________________________________________________________________________________________ 303007-10
- Check shift forks o on disc © for damage and wear (visual check).
» If there is damage or wear:
- Change the shift fork and gear wheel pair.
- Check shift grooves © of shift drum © for wear.
» If the shift groove is worn:
- Change the shift drum.
- Check the seating of the shift drum in bearings ©
» If the shift drum is not correctly seated:
- Change the shift drum and/or bearings.
- Check bearings ® for smooth operation and wear.
» If the bearings are stiff or worn:
- Change the bearings.
- Check the shift rollers for damage and wear.
» If there is damage or wear:
- Change the shift rollers.
- Check the springs of shift rails © for damage and wear.
» If the spring is damaged or worn:
- Change the spring of the shift rail.
- Check the shift rails o for run-out on a flat surface.
» If there is run-out:
- Change the shift rail.
- Check the shift rails for scoring, wear and smooth operation in the shift forks.
» If scoring or wear is present or of the shift fork is stiff:
- Change the shift rail.
- Check sliding plate © for wear on contact areas ©
» If the sliding plate is worn:
- Change the sliding plate.
- Check return surface © on the sliding plate for wear.
» If there is severe grooving:
- Change the sliding plate.
- Check guide bolts for firm seating and wear.
» If the guide bolts are loose or worn:
18 ENGINE 164
303008-10
____
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws.
303335-10
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
Use soft jaws
0
©
303336-10
• Info
I Use new lock rings with every repair.
18 ENGINE 167
Preparatory work
- Carefully lubricate all parts before assembling.
- Check the transmission. (*" p. 165)
Main work
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws
Info
Use new lock rings with every repair.
Preparatory work
- Carefully lubricate all parts before assembling.
- Check the transmission. (•" p. 165)
18 ENGINE 168
Main work
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
Use soft jaws
- Mount needle bearing o and 2nd-gear idler gear © onto the countershaft with the protruding collar facing downward.
- Mount stop disk ® and lock ring ©
- Mount 5th-gear sliding gear with the shift groove facing up.
- Mount lock ring © and stop disk ©
______________________________________________________________________________________________ 303010-10
- Check the gear mesh and bearing of kick starter gear Q for damage and wear.
» If there is damage or wear:
- Change the kick starter gear.
- Check the gear mesh and bearing of intermediate kick starter gear © for damage and wear.
» If there is damage or wear:
- Change the intermediate kick starter gear.
- Check the gear mesh and contact surface of kick starter ratchet wheel © for damage and wear.
» If there is damage or wear:
- Change the kick starter ratchet wheel.
- Check the gear mesh and bearing of kick starter shaft © for damage and wear.
» If there is damage or wear:
- Change the kick starter shaft.
303049-10
Mount washer ©.
18 ENGINE 171
______________________________________________________________________________________________ 303006-10
- Check the gear mesh and bearing of starter idler gear Q for damage and wear.
» If there is damage or wear:
- Change the starter idler gear.
- Check the gear mesh and bearing of Bendix © for smooth operation, damage and wear.
» If damaged or worn, or if the Bendix does not move easily:
- Change the Bendix.
- Check the gear mesh of starter motor for damage and wear
» If there is damage or wear:
- Change the starter motor.
- Change 0-ring © of the starter motor.
- Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power
supply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is closed:
- Change the starter motor.
Mount and tighten a fitting screw © with the washer and nut.
Guideline
Screw, alternator cover M6 8 Nm (5.9 Ibf ft)
18 ENGINE 172
Move starter idler gear O back and forth in the direction of rotation.
Check for play.
Guideline
Play may not exceed half the tooth width.
308181-11
- Position the right section of the engine case in the engine work stand.
- Slide crankshaft © all the way into the bearing seat of the right section of the
engine case.
Assemble the two transmission shafts O and slide them into the bearing seats
together.
18 ENGINE 173
• Info
I Do not misplace the shift rollers.
Info
Do not use the screws to pull the two sections of the engine case together.
Mount screws © and, once all screws of the left section of the engine case have
been mounted, tighten them.
Guideline
Screw, engine case M6x40 10 Nm (7.4 Ibf ft)
Mount screws Q and, once all screws of the left section of the engine case have
been mounted, tighten them.
Guideline
Screw, engine case M6x55 10 Nm (7.4 Ibf ft)
Info
The flat surfaces © of the shift drum locating unit are not symmetrical.
Main work
- Mount the preassembled kick starter shaft o with the washer.
- Tension the kick starter spring and mount and tighten screw ©.
Guideline
Screw, kick starter spring M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
• Info
I Ensure that the distance from the kick starter spring to the kick starter shaft
is the same all around.
• Info
I Do not damage the shaft seal ring.
Position the new lock washer and mount nut Q. Tighten the nut, holding the inner
clutch hub with a special tool.
Guideline
Nut, inner clutch hub M18xl.5 120 Nm Loctite® 648™
r (88.5 Ibf ft)
18 ENGINE 177
Using a straightedge and the special tool, check the spring washers for distortion.
Loctite® 5910
• Info
I Ensure that the dowels are seated properly.
nuS Ensure that the piston pin retainer is seated properly on both sides.
Remove the cloth.
OCX
303082-10
Info
If neither the piston, cylinder, crankshaft, or engine case need to be
changed, the same gasket thickness can be used as before.
Info
If neither the piston, cylinder, crankshaft, or engine case need to be
changed, the same gasket thickness can be used as before.
Info
The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and the piston is at top
dead center.
The X-distance must be checked very carefully. If the X-distance is too large, the compression decreases and the engine loses
power. If the X-distance is too small, the engine knocks and overheats.
• Info
I The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses.
Preparatory work
- Check the X-distance. (•" p. 181)
Main work
- Remove nuts o
- Carefully slide the cylinder up and take it off.
- Replace cylinder base gasket © with a cylinder base gasket of the required X-
distance.
Info
Multiple cylinder base gaskets can be combined.
Finishing work
- Install the cylinder. (*“ p. 180)
Info
The Z-distance is the distance from the lower edge of the control flap to the upper edge of the cylinder, measured in the mid
dle of the exhaust port.
Mount gasket ©
Press the control flap all the way down.
Mount ball socket ©.
• Info
I The linkage may only be pulled up slightly.
The control flap may not be moved up.
• Info
I Ensure that the dowels are seated correctly.
- Put the cylinder head in place. Mount screws ® with the washers and tighten
them in a crisscross pattern.
Guideline
Screw, cylinder head M8 27 Nm
(19.9 Ibf ft)
• Info
I Use new washers.
Mount dowels ©
Position the gasket.
Mount dowels ©.
Position the gasket.
Position cover ©
Mount and tighten screws ©.
Guideline
Screw, alternator cover M6 8 Nm (5.9 Ibf ft)
302140-10
Push spacer © with the O-ring onto the countershaft with a twisting motion.
S The cut-out with the O-ring must face inward.
S The shaft seal ring rests against the spacer along the entire circumference.
- Activate the kick starter several times to check whether the engine turns over
freely.
19.1 Choke
The choke lever o
is fitted on the left side of the carburetor.
Activating the choke function frees an opening in the carburetor through which the
engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a
cold start.
• Info
I If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated - The choke lever is pulled out all the way.
• Choke function deactivated - The choke lever is pushed in all the way.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventila
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
- Turn idle air adjusting screw o slowly in a clockwise direction until the idle speed
begins to fall.
- Note the position and turn the idle air adjusting screw slowly counterclockwise until
the idle speed falls again.
- Adjust to the point between these two positions with the highest idle speed.
Info
If there is a large engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of
engine speed, you need to install a smaller idling jet.
After changing the idling jet, repeat the adjusting steps from the beginning.
Following extreme air temperature or altitude changes, adjust the idle speed
again.
19 CARBURETOR 189
Danger
Fire hazard Fuel is highly flammable.
- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
- The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.
Preparatory work
- Turn handle O of the fuel tap to the OFF position. (Figure 602702-10*' p. 88)
Fuel no longer flows from the fuel tank to the carburetor.
Main work
- Place a cloth beneath the carburetor to soak up emerging fuel.
- Remove plug ©
- Completely drain the fuel.
- Mount and tighten the plug.
Danger
Fire hazard Fuel is highly flammable.
- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
- The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to get into the ground water, the ground, or the sewage system.
Preparatory work
- Remove the seat. (*" p. 85)
- Remove the fuel tank. (*" p. 86)
19 CARBURETOR 190
Main work
- Loosen hose clip o
- Loosen hose clip ©
- Pull the carburetor out of the intake flange toward the rear.
- Remove screws ©
- Remove the throttle slide cover and pull the throttle slide out of the carburetor.
- Drain the remaining fuel.
Finishing work
- Install the fuel tank. (•" p. 87)
- Mount the seat. (•" p. 86)
- Check the play in the throttle cable. (•" p. 55)
- Carburetor - adjust the idle speed. (*" p. 188)
__________________________________________________________________________________________________________________________________________________ 303400-10
303352-10
• Info
I Make sure not to misplace the spring.
303354-10
Alternative 1
- Mount idle air adjusting screw © with the spring and O-ring.
- Set the idle air adjusting screw to the specified value.
Alternative 2
- Set the idle air adjusting screw to the value determined when it was disassem
bled.
303359-11
» If the edge of the float is not parallel (max. 1° deviation upwards) to the sealing
area of the float housing in this position:
- Adjust the float level by bending the float lever.
20 CLUTCH 196
Info
The fluid level rises with increasing wear of the clutch lining discs.
- Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
- Remove screws ©
- Remove cover © with membrane ©
- Check the fluid level.
- Position the cover with the membrane. Mount and tighten the screws.
Info
Wash off overflowed or spilled brake fluid immediately with water.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws o
Remove cover © with membrane ©
On the slave cylinder of the clutch, remove bleeder screw © and mount bleeding
syringe ©
Inject the liquid into the system until it escapes from hole © of the master cylin
der without bubbles.
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
Remove the bleeding syringe. Mount and tighten the bleeder screw.
Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level under top edge of container 4 mm (0.16 in)
Position the cover with the membrane. Mount and tighten the screws.
21 WATER PUMP, COOLING SYSTEM 197
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
- Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the coolant antifreeze.
» If the antifreeze in the coolant does not match the specified value:
- Correct the coolant antifreeze.
Check the coolant level in the radiator.
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
- Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
21 WATER PUMP, COOLING SYSTEM 198
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
- Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
- Position the motorcycle upright.
- Place a suitable container under the water pump cover.
- Remove screw o . Take off radiator cap ©
- Completely drain the coolant.
- Mount and tighten screw o with a new seal ring.
Guideline
Drain plug, water pump cover MlOxl 15 Nm
(11.1 Ibf ft)
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
- Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Position the vehicle as shown and secure it against rolling away. A height differ
ence of Q must be reached.
Guideline
To ensure that all of the air can escape from the cooling system, the front of
the vehicle must be jacked up. A poorly bled cooling system is less effective
at cooling and may result in overheating of the engine.
Finishing work
- Check the coolant level. (*" p. 197)
22 EXHAUST CONTROL 200
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
- Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Preparatory work
- Tilt the motorcycle approx. 45° to the left and secure it to prevent it from falling.
Main work
- Remove screws o
- Take cap ® , adjusting spring © auxiliary spring o , and spring insert 0 out of
the clutch cover.
- Pull both springs off of the spring insert.
- Mount the required auxiliary spring o and adjusting spring 0 and slide them
into the clutch cover together.
• Info
I Screw © must not be turned as this would worsen the engine characteris
tic.
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
- Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Preparatory work
- Park the motorcycle on a level surface.
- Place a suitable container under the engine.
Main work
- Remove the gear oil drain plug with magnet Q.
- Completely drain the gear oil.
- Clean the gear oil drain plug with the magnet thoroughly.
- Clean the sealing area on the engine.
- Mount the gear oil drain plug with magnet O and the seal ring and tighten.
Guideline
Gear oil drain plug with magnet M12xl.5 20 Nm
(14.8 Ibf ft)
23 LUBRICATION SYSTEM 202
• Info
I Too little gear oil or poor-quality oil results in premature wear of the transmission.
Main work
- Remove filler plug O anc* fill UP with gear oil.
Gear oil 0.80 I (0.85 qt.) Engine oil (15W/50) (•" p. 270)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventila
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Info
The gear oil level must be checked while the engine is cold.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Main work
- Remove screw from the opening used to check the gear oil level.
Check the gear oil level.
Info
Too little gear oil or poor-quality gear oil results in premature wear of the transmission.
The gear oil must be added while the engine is cold.
Preparatory work
- Park the motorcycle on a level surface.
Main work
- Remove screw Q from the opening used to check the gear oil level.
23 LUBRICATION SYSTEM 203
Mount and tighten the screw in the opening used to check the gear oil level.
Guideline
Screw, gear oil level check M6 10 Nm (7.4 Ibf ft)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventila
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Warning
Risk of injury The ignition system is under high voltage.
- To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme
diately after measuring.
# Info
1 Do not open the throttle.
Info
The CDI controller cannot be tested using simple methods but only
using an ignition test bench.
• Info
I Do not open the throttle.
Warning
A Risk of injury The ignition system is under high voltage.
- To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme
diately after measuring.
24 IGNITION SYSTEM 205
Condition
Ignition coil cylinder 1 is disconnected.
Ignition coil cylinder 1 - check the primary winding resistance
Measure the resistance between the specified points
Ignition coil pin 1 (+) - Ignition coil pin 2 (-)
Ignition coil
Primary winding resistance at: 0.255... 0.345 Q
20 °C (68 °F)
• Info
I When using the peak voltage adapter, adjust the measuring range of the
multimeter to DCV.
Info
Connect the black measuring lead to pin 1 and the red measuring lead
to pin 2 of the ignition coil.
Ignition coil
Voltage, primary winding 150... 200 V
Ignition coil
Secondary winding resistance at: 5.04... 7.56 kQ
20 °C (68 °F)
Alternator
Resistance of ignition charging coil 12... 16.5 a
at: 20 °C (68 °F)
Resistance 00 Q
Alternator
Battery winding resistance at: 20 °C (68 °F) 0.5... 0.9 Q
24 IGNITION SYSTEM 207
Alternator
Light winding resistance at: 20 °C 0.1... 0.2 Q
(68 °F)
Resistance 00 Q
• Info
I When using the peak voltage adapter, adjust the measuring range of the multimeter to DCV.
- Remove screw
- Remove the stator and crankshaft position sensor from the alternator cover.
Screw, membrane core plate EJOT DELTA PT® 30x12 1 Nm (0.7 Ibf ft) —
Screw, outer reed petals EJOT DELTA PT® 30x6 1 Nm (0.7 Ibf ft) —
Screw, angle lever, exhaust control M5 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, clutch spring retainer M5 6 Nm (4.4 Ibf ft) —
Screw, control flap, exhaust control M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, engine case M6x40 10 Nm (7.4 Ibf ft) —
Gear oil drain plug with magnet M12xl.5 20 Nm (14.8 Ibf ft) —
Nut, inner clutch hub M18xl.5 120 Nm (88.5 Ibf ft) Loctite® 648™
Nut, primary gear M18LHxl.5 150 Nm (110.6 Ibf ft) Loctite® 648™
Total fuel tank capacity, 9.5 1 (2.51 US gal) Super unleaded (95 octane) mixed with 2-stroke engine oil
approx. (250/300 EXC EU, (1:60) (•" p. 271)
EXC SIX DAYS)
26 TECHNICAL DATA 213
Total fuel tank capacity, 10 I (2.6 US gal) Super unleaded (95 octane) mixed with 2-stroke engine oil
approx. (250/300 EXC AU, All (1:60) (*- p. 271)
250/300 XC-W models)
Fuel reserve, approx. (250/300 EXC EU, EXC SIX DAYS) 2 1 (2 qt.)
Fuel reserve, approx. (250/300 EXC AU, All 2.5 1 (2.6 qt.)
250/300 XC-W models)
26.5 Chassis
Frame Central tube frame made of chrome molybdenum steel tubing
Fork (EXC EU/AUS, XC-W) WP Suspension Up Side Down 4860 MXMA PA
Fork (250/300 SIX DAYS) WP Suspension Up Side Down 4860 4CS
Suspension travel (EXC EU/AUS, XC-W)
Front 300 mm (11.81 in)
Suspension travel (250/300 SIX DAYS)
Front 292 mm (11.5 in)
Suspension travel
Rear 335 mm (13.19 in)
Fork offset 20 mm (0.79 in)
Shock absorber WP Performance Systems 5018 PDS DCC
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter
Front 260 mm (10.24 in)
Rear 220 mm (8.66 in)
Brake discs - wear limit
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
Tire air pressure, road (All 250/300 EXC EU/AU models)
Front 1.5 bar (22 psi)
Rear 1.5 bar (22 psi)
Tire air pressure off road
Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)
Secondary ratio (All 250/300 EXC EU/AU models) 14:50(13:50)
Secondary ratio (All 250/300 XC-W models) 13:50
Chain 5/8 x 1/4"
Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase 1,482±10 mm (58.35±0.39 in)
Seat height unloaded 960 mm (37.8 in)
Ground clearance unloaded 355 mm (13.98 in)
Weight without fuel, approx. (250 XC-W USA) 101.9 kg (224.6 lb.)
Weight without fuel, approx. (300 XC-W USA, 102.1 kg (225.1 lb.)
300 XC-W SIX DAYS USA)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)
26 TECHNICAL DATA 214
26.7 Tires
Validity Front tires Rear tires
(All 250/300 EXC EU/AU models) 80/100-21 M/C 51M 17 140/80- 18 M/C 70R TT
MAXXIS MAXX CROSS SI MAXXIS MAXX ENDURO
(All 250/300 XC-W models) 80/100-21 51M TT 110/100- 18 64M TT
Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51
Additional information is available in the Service section under:
http://www.ktm.com
Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) (•" p. 270)
Oil capacity per fork leg 635 ml (21.47 fl. oz.) Fork oil (SAE 4) (48601166S1) (•" p. 270)
Spoke nipple, rear wheel M4.5 5... 6 Nm (3.7... 4.4 Ibf ft) —
Screw, spoiler on fuel tank (All M5xl2 1.5 Nm (1.11 Ibf ft) —
Screw, ball joint of push rod on foot M6 10 Nm (7.4 Ibf ft) Loctite® 243™
brake cylinder
Screw, chain sliding guard M6 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, front brake disc M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Screw, rear brake disc M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Nut, foot brake lever stop M8 20 Nm (14.8 Ibf ft) —
XC-W)
Engine bracket screw M10 60 Nm (44.3 Ibf ft) —
Screw-in nozzles, cooling system M20xl.5 12 Nm (8.9 Ibf ft) Loctite® 243™
Screw, front wheel spindle M24xl.5 45 Nm (33.2 Ibf ft) —
26 TECHNICAL DATA 217
26.11.2 250EXCAUS
Carburetor type KEIHIN PWK 36S AG
Carburetor identification number 3600
Needle position 1. Position from top
Jet needle N3CJ (N8RW / N8RJ / N8RK / N4DW / N4DJ / N4DK)
Main jet 160 (165/168)
Idling jet 35 (38 / 40 / 42)
Starting jet 85
Idle air adjusting screw
Open 3.5 turns
Throttle slide 7 with cut-out
Slide stop Present
26.11.5 300EXCAUS
Carburetor type KEIHIN PWK 36S AG
Carburetor identification number 3600
Needle position 1. Position from top
Jet needle N3CJ (N8RW / N8RJ / N8RK / N4DW / N4DJ / N4DK)
Main jet 160 (165/ 168)
Idling jet 35 (38/40/42)
Starting jet 85
Idle air adjusting screw
Open 3.5 turns
Throttle slide 7 with cut-out
Slide stop Present
Danger
Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous
(reduced) version only.
- In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
-20°C ... -7°C -6°C ... 5°C 6°C ... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C
M/FT ASL TEMP
\\ ----------- ► -2°F... 20°F 19°F... 41 °F 42°F... 60°F 61 °F... 78°F 79°F... 98°F 99°F... 120°F
Danger
Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous
(reduced) version only.
- In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
-20°C ... -7°C -6°C ... 5°C 6°C... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C
M/FT ASL TEMP
\\ -----------► -2°F... 20°F 19°F... 41°F 42°F... 60°F 61°F... 78°F 79°F... 98°F 99°F... 120°F
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
- When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors,
cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component.
Excessive pressure can cause malfunctions or destroy these parts.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunlight on the motorcycle during cleaning.
• Info
1 Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to the dry vehicle; always rinse with water
first.
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
Empty the carburetor float chamber. (*" p. 189)
Remove the plug from the exhaust system.
Warning
A Danger of accidents Reduced braking efficiency due to a wet or dirty brake
system.
- Clean or dry a dirty or wet brake system by riding and braking gently.
After cleaning, take a short ride until the engine reaches operating temperature.
• Info
1 The heat produced causes water at inaccessible locations in the engine and
brake system to evaporate.
- After the motorcycle has cooled off, lubricate all moving parts and bearings.
- Clean the chain. (*" p. 97)
- Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
- Treat all plastic parts and powder-coated parts with a mild cleaning and care prod
uct.
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
P- 273)___________________________________________________________________
• Info
I If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro
sion.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of
salt.
• Info
I After EVERY trip on salted roads, thoroughly wash the brake calipers and
brake linings with cold water and dry carefully. This should be done after
the parts are cooled down and while they are installed.
After riding on salted roads, thoroughly wash the motorcycle with cold water
and dry it well.
Treat the engine, swingarm and all other bright and zinc-plated parts (except for
the brake discs) with a wax-based corrosion inhibitor.
• Info
I Corrosion inhibitor is not permitted to come in contact with the brake discs
as this would greatly reduce the braking force.
28.1 Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
Info
If you want to put the motorcycle into storage for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
Refuel.
Empty the carburetor float chamber. {•" pi. 189)
Check the tire air pressure. (*" p. 91)
Remove the battery. (*" p. 102)
Recharge the battery.
Guideline
Storage temperature of battery without 0... 35 °C (32... 95 °F)
direct sunlight
Store the vehicle in a dry location that is not subject to large fluctuations in tem
perature.
• Info
I KTM recommends raising the motorcycle.
• Info
I Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Because the engine will not
warm up sufficiently, the water vapor produced during combustion will con
dense, causing engine parts and the exhaust system to rust.
• Periodic interval
29 SERVICE SCHEDULE 226
o One-time interval
• Periodic interval
227
30 WIRING DIAGRAM 228
Components:
A15 CDI controller
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
S21 Electric starter button
T20 Voltage regulator
30 WIRING DIAGRAM 230
Components:
E13 Low beam, high beam
P15 Horn
P23 High beam indicator lamp
P35 Parking light
S22 Light switch, horn button, kill switch
30 WIRING DIAGRAM 232
Components:
B70 Wheel speed sensor, front
B76 Brake light switch, front
B77 Brake light switch, rear
E60 License plate lamp
P13 Speedometer
P36 Brake/tail light
S36 Tripmaster switch
X285 Connector for radiator fan (optional)
30 WIRING DIAGRAM 234
Components:
K20 Turn signal relay
P21 Turn signal indicator light
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S25 Turn signal switch
30 WIRING DIAGRAM 236
Components:
A15 CDI controller
B37 Crankshaft position sensor
R51 Ignition coil (cylinder 1)
S50 Map switch for ride mode (optional)
X280 Connector, ignition timing map
X281 Connector, ignition timing map
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30 WIRING DIAGRAM 238
30.6 Page 1 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU)
30 WIRING DIAGRAM 239
Components:
A15 CDI controller
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
S21 Electric starter button
T20 Voltage regulator
30 WIRING DIAGRAM 240
30.7 Page 2 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU)
30 WIRING DIAGRAM 241
Components:
E13 Low beam, high beam
P15 Horn
P23 High beam indicator lamp
P35 Parking light
S22 Light switch, horn button, kill switch
30 WIRING DIAGRAM 242
30.8 Page 3 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU)
30 WIRING DIAGRAM 243
Components:
B76 Brake light switch, front
B77 Brake light switch, rear
E60 License plate lamp
P13 Speedometer
P36 Brake/tail light
X285 Connector for radiator fan (optional)
30 WIRING DIAGRAM 244
30.9 Page 4 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU)
30 WIRING DIAGRAM 245
Components:
K20 Turn signal relay
P21 Turn signal indicator light
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S25 Turn signal switch
30 WIRING DIAGRAM 246
30.10 Page 5 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU)
30 WIRING DIAGRAM 247
Components:
A15 CDI controller
B37 Crankshaft position sensor
R51 Ignition coil (cylinder 1)
S50 Map switch for ride mode (optional)
X280 Connector, ignition timing map
X281 Connector, ignition timing map
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30 WIRING DIAGRAM 248
Components:
A15 CDI controller
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
S23 Emergency OFF switch, electric starter button
T20 Voltage regulator
30 WIRING DIAGRAM 250
Components:
A15 CDI controller
E13 Low beam, high beam
P15 Horn
P23 High beam indicator lamp
P35 Parking light
S22 Light switch, horn button, kill switch
S23 Emergency OFF switch, electric starter button
30 WIRING DIAGRAM
30.13 Page 3 of 5 (250/300 EXC AU)
30 WIRING DIAGRAM 253
Components:
B70 Wheel speed sensor, front
B76 Brake light switch, front
B77 Brake light switch, rear
E60 License plate lamp
P13 Speedometer
P36 Brake/tail light
S36 Tripmaster switch
X285 Connector for radiator fan
30 WIRING DIAGRAM 254
Components:
A15 CDI controller
B37 Crankshaft position sensor
R51 Ignition coil (cylinder 1)
S50 Map switch for ride mode
X280 Connector, ignition timing map
X281 Connector, ignition timing map
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30 WIRING DIAGRAM 258
Components:
A15 CDI controller
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
S21 Electric starter button
T20 Voltage regulator
30 WIRING DIAGRAM 260
m o CD
• •
n n *n
oo oo oo
o cr cu
wh
ro wh ro
N)
cn
o
W
o
o
X wh
0 wh
co
c co
C/>
>
N)
0 br
1
ro
o
O)
br
br
cn cn
cn CD
oo ro
cn
CO CO
ro
co
m o ro B00032-01
30 WIRING DIAGRAM 261
Components:
B70 Wheel speed sensor, front
Ell Low beam
S30 Light switch
S36 Tripmaster switch (optional)
P13 Speedometer
P35 Parking light
P37 Tail light
X285 Connector for radiator fan (optional)
30 WIRING DIAGRAM 262
Components:
A15 CDI controller
B37 Crankshaft position sensor
R51 Ignition coil (cylinder 1)
S20 Kill switch
S50 Map switch for ride mode (optional)
X280 Connector, ignition timing map
X281 Connector, ignition timing map
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30 WIRING DIAGRAM 264
Components:
A15 CDI controller
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
S21 Electric starter button
T20 Voltage regulator
30 WIRING DIAGRAM 266
m o CD
• •
■n -n -n
oo oo oo
O CT ttJ
w
ro o ro
o
X
0
co
X
0
D)
co < co
(/)
C
CO
>
K)
0
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1
N)
O
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cn CJ1
cr> CD
00 ro
CO
01 CO
ro
co
m o ro B00042-01
30 WIRING DIAGRAM 267
Components:
B70 Wheel speed sensor, front
Ell Low beam
S30 Light switch
P13 Speedometer
P35 Parking light
P37 Tail light
X285 Connector for radiator fan (optional)
30 WIRING DIAGRAM 268
Components:
A15 CDI controller
B37 Crankshaft position sensor
R51 Ignition coil (cylinder 1)
S20 Kill switch
S50 Map switch for ride mode (optional)
X280 Connector, ignition timing map
X281 Connector, ignition timing map
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
31 SUBSTANCES 270
Coolant
Guideline
- Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using infe
rior antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: -25... -45 °C (-13... anti-corrosion/antifreeze
-49 °F) distilled water
Recommended supplier
Motorex®
- COOLANT M3.0
Fully synthetic
Recommended supplier
Motorex®
- Cross Power 2T
• Info
I Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
Standard/classification
- DIN EN 228
- JASO FD (•" p. 284) (1:60)
Mixture ratio
1:60 Engine oil, 2-stroke (•" p. 270)
Super unleaded (ROZ 95/RON 95/PON 91) (•“ p. 271)
Recommended supplier
Motorex®
- Cross Power 2T
32 AUXILIARY SUBSTANCES 272
Chain cleaner
Recommended supplier
Motorex®
- Chain Clean
Fuel additive
Recommended supplier
Motorex®
- Fuel Stabilizer
Long-life grease
Recommended supplier
Motorex®
- Bike Grease 2000
Lubricant (T158)
Recommended supplier
Lubcon®
- Turmogrease® PP 300
Lubricant (T511)
Recommended supplier
Lubcon®
- Turmsilon® GTI 300 P
Lubricant (T159)
Recommended supplier
Bel-Ray®
- MC-11®
Lubricant (T625)
Recommended supplier
Molykote®
- 33 Medium
Lubricant (T152)
Recommended supplier
Bel-Ray®
- Molylube® Anti-Seize
Motorcycle cleaner
Recommended supplier
Motorex®
- Moto Clean
32 AUXILIARY SUBSTANCES 273
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
Motorex®
- Quick Cleaner
Bleeder cover
Art. no.: 00029013005
r^ m\
a li
■ 1■
201597-10
Bleeder cover
Art. no.: 00029013006
201598-10
Bleeding device
Art. no.: 00029013100
__ \ V i
Spring hooks
Art. no.: 50305017000
a]
Q>^
201428-01
33 SPECIAL TOOLS 275
Bleed syringe
Art. no.: 50329050000
& 400058-01
Clutch holder
Art. no.: 51129003000
fa
400289-01
Adjustment gauge
Art. no.: 54829001100
303079-10
Separator plate
Art. no.: 54829009000
303483-10
Lift stand
Art. no.: 54829055000
33 SPECIAL TOOLS 276
303484-10
Cl
\
302997-10
Gear segment
Art. no.: 56012004000
i 302982-10
302945-10
Extractor
Art. no.: 58012009000
33 SPECIAL TOOLS 277
1 Jki* * • '■ V 1
200910-10
Feeler gauge
Art. no.: 59029041100
10011M1
V 200306-01
33 SPECIAL TOOLS 278
V-
------------- 400185-01
Pin wrench
Art. no.: T103
200734-10
Hook wrench
Art. no.: T106S
Pin
Art. no.: T120
201235-10
33 SPECIAL TOOLS 279
Mounting sleeve
Art. no.: T1204
^ 7I
T120-* 1
V “ >*rie h Gstw™ y
200788-10
Calibration pin
Art. no.: T1205
200790-10
Pressing tool
Art. no.: T1206
200583-10
Pressing tool
Art. no.: T1207S
200585-01
Centering sleeve
Art. no.: T1214
200777-10
33 SPECIAL TOOLS 280
Mounting sleeve
Art. no.: T1215
300568-10
=i
Disassembly tool
Art. no.: T1216
200816-10
Vacuum pump
Art. no.: T1240S
kBU^T-" m 1
jjgggj 0
200273-10
Protecting sleeve
Art. no.: T1401
200635-10
Clamping stand
Art. no.: T14015S
3 f\
200733-10
33 SPECIAL TOOLS 281
Clamping stand
Art. no.: T14016S
200688-10
Gripping tool
Art. no.: T14026S1
V ^
200639-10
Assembly tool
Art. no.: T1402S
\
\V *
200634-10
Open-end wrench
Art. no.: T14032
200640-10
Clamping stand
Art. no.: T1403S
200637-10
33 SPECIAL TOOLS 282
Mounting tool
Art. no.: T14040S
200634-10
Special socket
Art. no.: T14047
201710-01
Clamping stand
Art. no.: T14049S
202338-10
Press-out tool
Art. no.: T14051
201779-10
Press drift
Art. no.: T1504
(-■■n— .i,
200789-10
33 SPECIAL TOOLS 283
Assembly tool
Art. no.: T150S
1 ^"■l tk—
if****"' ,-»
200791-10
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles - the JASO T903 MA Standard. Ear
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore
ground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis
cosity. The viscosity describes only one property of oil and says nothing about quality.
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
35 LIST OF ABBREVIATIONS 285
removing.................................... . . . 189
A technical data - carburetor . . , 217-218
Accessories.................................................................. ..................8 Carburetor - work on individual parts
Air filter choke slide, checking ............. . . . 193
cleaning ................................................................ ............... 84 float level, checking/adjusting . . . 195
installing................................................................ ............... 83 float needle valve, checking . . . . . 194
removing................................................................ ............... 83 jet needle, checking ............... . . . 193
Air filter box throttle slide, checking .......... . . . 193
cleaning ................................................................ ............... 84 Carburetor components
sealing .................................................................. ............... 84 checking/adjusting .................. . . . 191
Air filter box lid Cartridge
installing................................................................ ............... 83 fork legs, assembling ............. . 23,45
removing ................................................................ ............... 83 fork legs, disassembling . 19, 39
Alternator Chain
battery winding, checking ................................. .............206 checking.................................... ____ 98
charging coil of the ignition, checking............. .............206 cleaning .................................... ____ 97
light winding, checking ...................................... .............207 Chain guide
Antifreeze checking................................... ____ 98
checking................................................................ ............. 197 Chain tension
Auxiliary substances ................................................... ..................8 adjusting.................................... . . . 100
checking.................................... ____ 97
B
Charging voltage
Battery
checking.................................... . . . 103
installing................................................................ ............. 103
negative cable, connecting................................. ............. 102 Chassis number ............................... .......... 9
negative cable, disconnecting............................ ............. 101 Choke .............................................. . . . 188
removing................................................................ ............. 102 Clutch
Brake disc fluid level, checking/correcting......................................... 196
front brake, installing ......................................... ............... 94 fluid, changing..................................................................... 196
front brake, removing ......................................... ............... 94 Clutch lever
rear brake, installing........................................... ............... 96 basic position, adjusting .........................................................54
rear brake, removing ........................................... ............... 96 Compression damping
Brake discs fork, adjusting ................................................................ 12, 32
checking................................................................ ............... 92 Compression damping fitting
Brake fluid fork legs, assembling ..............................................................22
front brake, adding .............................................. .............108 fork legs, disassembling .........................................................21
front brake, changing ......................................... .............109 Compression damping, high-speed
rear brake, adding .............................................. ............. 113 shock absorber, adjusting ...................................................... 58
rear brake, changing ........................................... ............. 114
Compression damping, low-speed
Brake fluid level shock absorber, adjusting ...................................................... 58
front brake, checking ......................................... ............. 108
Coolant
rear brake, checking ........................................... ............. 113
draining ............................................................................... 198
Brake linings refilling.................................................................................. 198
front brake, changing ......................................... ............. 105
Coolant level
front brake, checking ......................................... ............. 105
checking............................................................................... 197
rear brake, changing ........................................... ............. Ill
rear brake, checking ........................................... ............. 110 Cooling system............................................................................. 197
Crankshaft position sensor
C
checking.................................................................................. 207
Capacity
Cylinder - Nikasil® coating ........................................................ 152
coolant ........................................................................ 198, 212
fuel ................................................................................. 212-213 E
gear oil ............................................................. 131,202,212 Engine
Carburetor assembling .................. 172
assembling .......................................................................... 194 disassembling ............. 132
disassembling ..................................................................... 192 installing....................... 127
float chamber, emptying ................................................... 189 removing....................... 123
idle speed, adjusting........................................................... 188 technical data - engine 210
installing............................................................................... 190 work on individual parts 143
INDEX 287
installing........................................................... . . 87 Motorcycle
removing........................................................... . . 86 cleaning ........................................................ .................... 222
Seat T
mounting ................................. .... 86
Technical data
removing.................................... ____ 85
Capacities ................................................................................212
Service schedule ............................ 225-226 carburetor tuning ................................................................... 219
Servicing the shock absorber .......... ____ 62 chassis ..................................................................................... 213
Shock absorber Chassis tightening torques....................................................216
damper, assembling ............... ____ 72 electrical system ................................................................... 214
damper, bleeding and filling . ____ 75 engine - tolerance, wear limits ............................................ 211
damper, checking.................... ____ 67 Engine tightening torques ....................................................212
damper, disassembling .......... ____ 63 Fork .......................................................................................... 214
damper, filling with nitrogen . ____ 77 shock absorber........................................................................ 215
heim joint, installing............... ____ 69 Tires.......................................................................................... 214
heim joint, removing............... ____ 68 Throttle cable play
installing.................................... ____ 61 adjusting.....................................................................................56
pilot bushing, replacing.......... ____ 66 checking..................................................................................... 55
piston rod, assembling .......... ____ 71
Throttle cable routing
piston rod, disassembling ____ 64
checking..................................................................................... 55
rebound adjuster, assembling . ____ 70
rebound adjuster, disassembling ____ 67 Tire air pressure
removing.................................... ____ 61 checking.....................................................................................91
riding sag, checking ............... ____ 60 Tire condition
seal ring retainer, assembling . ____ 70 checking...................................... 91
seal ring retainer, disassembling ____ 65 Type label............................................................................................ 9
shock absorber, servicing ____ 62
W
spring preload, setting............. ____ 60
spring, installing .................... ____ 78 Warranty............................................................................................... 8
spring, removing....................... ____ 62 Winter operation
static sag, checking ............... ____ 59 checks and maintenance steps............................................ 223
Shock absorber article number . . . .......... 9 Wiring diagram ......................... 228-269
Spare parts ...................................... .......... 8 page 1 of 3 ................................................................ 258, 264