KTM 690 Duke (2010) manual

REPA IR M ANUA L 2010 690 Duke EU 690 Duke AUS/U K 690 Duke JP 690 Duke USA 690 Duke R EU 690 Duke R AUS/UK 690 Duke R JP Article no. 3206084 en[...]

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INTRODUC TION 1 INTRODUCTION Read this repair manual carefully and thoroughly befor e beginning work. Only use ORIGINAL KTM SPARE PARTS . The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this series. W[...]

CONTENT S 2 CONTENTS MEANS OF REPRESENTATION ............................ ................ 5 IMPORTANT NOTES ............................ ................................ 6 LOCATION OF SERIAL NUMBERS ............................ ............ 7 Chassis number/type label (Duke R, 690 Duke EU, 690 Duke AUS/UK, 690 Duke JP) ............................[...]

CONTENT S 3 Removing headlight mask with headlig ht ......................... 86 Installing the headlight mask with the headlight ............... 86 Changing the parking light bulb ...................................... 87 Changing the low beam bulb............ ............................... 88 Changing the turn signal bulb .......................[...]

CONTENT S 4 Installing clutch cover ................................................. . 156 Mounting water pump cover .......................... ................ 157 Installing thermostat ............. ................................ ....... 157 Installing the oil filter ............. ................................ ..... 157 Installing gear posi[...]

MEANS OF REPRE SENTATIO N 5 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page ). Indicates information with more details[...]

IMPORTA NT NOTES 6 Warranty The work prescribed in the service plan must only be carried out in an au thorized KTM workshop and confirmed in the service record; otherwise all warranty claims will be disregarded. No warran ty cl aim ca n be met for damag e res ulting from manipulation and/or other changes to the vehicle. Fuel, oils, etc. You should [...]

LOCATION OF SER IAL NUMBERS 7 3.1 Chassis number/ty pe label (Duke R, 690 Duke EU, 690 Duke AUS/ UK, 690 Duke JP) 500006-01 The chassis number  is stamped on the right of the steering head. The type label  is on the right of the frame behind the steering head. 3.2 Chassis number/ty pe label (690 Duke USA) 500006-01 The chassis number  is s[...]

LOCATION OF SER IAL NUMBERS 8 3.5 Fork part number 700126-01 The fork part number  is stamped on the inner side of the fork stub. 3.6 Shock absorber part nu mber 700128-01 The shock absorber part number  is sta mped on t he to p of the shock absor ber above the adjusting ring toward the rear.[...]

MOTORCY CLE 9 4.1 Raising the motorcycl e with the rear wheel stand Note Danger of damage   The p arked vehicle may roll away or fall over. – Always place the vehicle on a firm an d eve n su rface. 700142-01 – Insert the adapter into the rear wheel stand and screw into the swingarm on both sides. Adapter (61029055110 ) ( p. 248) Rear wheel st[...]

MOTORCY CLE 10 4.5 Raising the motorcycl e with the work stand Note Danger of damage   The p arked vehicle may roll away or fall over. – Always place the vehicle on a firm an d eve n su rface. 300602-10 – Remove the nuts  on both sides. – Take off the footrest rubber and holder. 300603-10 – Mount the special tool  and  . Work sta[...]

MOTORCY CLE 11 4.7 Starting Danger Danger of poisoning   Exhaust gases are poisonous and inhaling them may result in unconscious ness and/or death. – When running the engine, always make sure there is sufficient ventilati on, and d o not star t or run the engine in an enclosed space without an effective exhaust extracti on sy stem. Caution Dang[...]

01/FORK, TR IPLE CLAMP 12 5.1 Adjusting the compres sion damping of the fork Info The hydraulic compression dampi ng de termines the fork suspension behavior. 700146-01 – Turn adjusting screws  clock wise until they stop. Info The adjusting screws are located at the bottom end of the fork l egs. Make the same adjustment on both fork legs. – [...]

01/FORK, TR IPLE CLAMP 13 5.3 Bleeding the fork legs – Lean the motorcycle on the side stand. 100849-10 – Remove bleeder screws  briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both f ork le gs. 5.4 Removing fork legs – Raise the motorcycle with the wor[...]

01/FORK, TR IPLE CLAMP 14 200711-10 – Remove screw  . T ake the br ake l ine a nd wi ring h arness out of the c lamp. 200712-10 – Loosen the screws  of the triple clamp. Remov e the fork leg downwar ds. 200713-10 – Loosen the screws  of the triple clamp. Remov e the fork leg downwar ds. 5.5 Installing the fork legs 200713-11 – Push[...]

01/FORK, TR IPLE CLAMP 15 200710-11 – Position the wheel speed sensor. Mount and tighten screws  . Guideline Screw, wheel speed sensor M4 2 N m (1.5 lbf ft) Loctite ® 243™ 200711-11 – Position the brake line, wiring harness and clamp. – Mount and tighten screw  . Guideline Screw, plastic clamp of brake line on fork leg M5 2 N m (1. 5[...]

01/FORK, TR IPLE CLAMP 16 200717-10 – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Tighten screws  . Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) 5.6 Servicing the fork Info These operations are the same on both fork legs. Condition The fork legs have been removed. 201244-01 – Disassem[...]

01/FORK, TR IPLE CLAMP 17 200643-10 – Clamp the fork leg i n the area of the lower triple clamp. Clamping stand (T1403S) ( p. 25 7) 200644-12 – Loosen the screw cover  . Info The screw cover cannot be removed yet. 200661-01 – Release the fork leg and clamp it w ith th e fork stub . Info Use soft jaws. 200729-10 – Push the outer tube down[...]

01/FORK, TR IPLE CLAMP 18 200732-10 – Pull the tube downwards. Remove the special tool. – Remove the tube, washer and spring. 200650-01 – Drain the fork oil. Info Pull out and push in th e pis ton ro d a few times to empty the cartridge. 200662-01 – Clamp the fork leg w ith th e for k stu b. – Remove screws  o f the axle clam p. 200667[...]

01/FORK, TR IPLE CLAMP 19 200655-12 – Remove dust boot  . 200656-12 – Remove lock ring  . Info The lock ring has a beve led e nd wh ere a scre wdriver can be applied. 200668-10 – Heat up the outer tube in are a  o f th e low er s liding bushing. Guideline 50 °C (12 2 °F) – Pull the fork outer tube with a jerk from the inner tu[...]

01/FORK, TR IPLE CLAMP 20 200686-10 – Check the inner tube and the axle c lamp for damage. » If damage is found: – Replace the inner tube. 200684-10 – Measure the external diameter of the inner tube in several places. External diameter of inner tube 47.975… 48.005 mm (1.88878… 1.88996 in) » If the m easured value is less than the s peci[...]

01/FORK, TR IPLE CLAMP 21 5.9 Assembling the fork legs (Duk e) Info These operations are the same on both fork legs. – Check the fork legs. ( p. 19) 200669-10 – Clamp the inner tube with the axle c lamp. – Mount the special tool. Protecting sleeve (T1401) ( p. 25 6) – Grease and push on dust boot  . Lubricant (T511) ( p. 244) Info Always[...]

01/FORK, TR IPLE CLAMP 22 200673-10 – Position the support ring. – Hold the seal ring with t he sh orter side of t he sp ecial tool. Assembly tool (T1402S) ( p. 257) – Press on the o uter tube as fa r as it will go. 200656-11 – Mount lock ring  . Info The lock ring must engage audibly. 200655-11 – Install dust boot  . 200674-10 – [...]

01/FORK, TR IPLE CLAMP 23 200683-10 – Push the cartridge with the spring seat and preload spacer into the inner tube. – Mount screw  of t he ca rtridge with the s eal ring a nd ti ghten it. Guideline Cartridge screw M12x1 25 Nm (18.4 lbf ft) 200682-10 – Grease and mount screws  of the axle clamp but do not tighten. Lubricant (T152[...]

01/FORK, TR IPLE CLAMP 24 Info The screw cover must be screwed to the stop before the p iston rod s tarts to turn. If th e thre ad o f the pisto n rod is stiff, it must be held to prevent it from tu rning. If the s crew c over is n ot s crewed to t he st op, the re bound adjustment will not work correctly. – Tighten the screw cover. Guideline Scr[...]

01/FORK, TR IPLE CLAMP 25 – Turn the adjusting screws to the position they were in before dismantling. 5.10 Assembling the fork legs (Duk e R) Info These operations are the same on both fork legs. – Check the fork legs. ( p. 19) 200669-10 – Clamp the inner tube with the axle c lamp. – Mount the special tool. Protecting sleeve (T1401) ( p. 2[...]

01/FORK, TR IPLE CLAMP 26 200673-10 – Position the support ring. – Hold the seal ring with t he sh orter side of t he sp ecial tool. Assembly tool (T1402S) ( p. 257) – Press on the o uter tube as fa r as it will go. 200656-11 – Mount lock ring  . Info The lock ring must engage audibly. 200655-11 – Install dust boot  . 200674-10 – [...]

01/FORK, TR IPLE CLAMP 27 200683-10 – Push the cartridge with the spring seat and preload spacer into the inner tube. – Mount screw  of t he ca rtridge with the s eal ring a nd ti ghten it. Guideline Cartridge screw M12x1 25 Nm (18.4 lbf ft) 200682-10 – Grease and mount screws  of the axle clamp but do not tighten. Lubricant (T152[...]

01/FORK, TR IPLE CLAMP 28 Info The screw cover must be screwed to the stop before the p iston rod s tarts to turn. If th e thre ad o f the pisto n rod is stiff, it must be held to prevent it from tu rning. If the s crew c over is n ot s crewed to t he st op, the re bound adjustment will not work correctly. – Tighten the screw cover. Guideline Scr[...]

01/FORK, TR IPLE CLAMP 29 – Turn the adjusting screws to the position they were in before dismantling. 5.11 Checking the steering hea d bearing play Warning Danger of accidents   Unstable vehicle handling from incorrect steering head bear ing p lay. – Adjust the steering head bearing play without delay. Info If the b ike is ridde n wit h pla [...]

02/HANDL EBAR, INSTR UMENTS 30 6.1 Checking the play in the throttle cabl e 400192-10 – Move the handlebar to the straight-ahead position . Mo ve th e thr ottle grip b ack- wards and forwards to ascertain the play in the t hrottle cable. Throttle cable play 3… 5 mm (0.12… 0.2 in) » If the th rottle cable play does not meet specifications: ?[...]

04/SHOCK AB SORBER, SWI NGARM 31 7.1 Adjusting the high-spe ed compression dampi ng of the shock absorber Danger Danger of accidents   Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provide d. Info The high-speed setting can be seen during the fast compre[...]

04/SHOCK AB SORBER, SWI NGARM 32 Guideline Compression damping, low- speed (Duke) Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Compression damping, low- speed (Duke R) Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterc lockwise to reduce d[...]

04/SHOCK AB SORBER, SWI NGARM 33 300605-10 – Remove the nut  with the screw. – Loosen screw  . – Remove the nut  with the screw. 300606-10 – Lift the link f ork. – Swing the connecting lever downwards. – Remove screw  . – Take off deflector  . 300604-10 – Remove screw  . 300607-10 – Lift the link f ork a nd ta ke[...]

04/SHOCK AB SORBER, SWI NGARM 34 300606-11 – Lift the link f ork. – Position deflector  . – Mount screw  but do no t tig hten it ye t. Guideline Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite ® 243™ 300605-11 – Mount and tighten screw with nut  . Guideline Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft)[...]

04/SHOCK AB SORBER, SWI NGARM 35 201269-01 – Remove the spring. ( p. 35) – Disassemble the damper. ( p. 3 5) – Disassemble the piston rod. ( p. 37) – Check the damper. ( p. 38) – Remove the heim joint. ( p. 3 9) – Install the heim joint. ( p. 39) – Assemble the piston rod. ( p. 40 ) – Assemble the damper. ( p. 41) – Install the sp[...]

04/SHOCK AB SORBER, SWI NGARM 36 201256-10 – Remove locking cap  . 201255-10 – Press in seal ring retainer  . Remove lock ring  . Info Do not scratch the inner surface. 201254-10 – Remove screw  . D rain the oi l. 201253-10 – Remove the piston rod. Drain the remaining oil. 201252-10 – Remove compression dampi ng ad juster  [...]

04/SHOCK AB SORBER, SWI NGARM 37 7.9 Disassembling the pis ton rod – Disassemble the damper. ( p. 3 5) 300540-10 – Clamp the piston rod with the h eim jo int i n a vise. – Remove nut  . 300541-10 – Remove supporting plate  and rebound shim stack  toget her with p iston  . Info Thread the rebound shim set on a sc rewdriver and se[...]

04/SHOCK AB SORBER, SWI NGARM 38 7.10 Checking the damper Condition The damper has been disassembled. 201268-10 – Measure the inside diameter at both ends and in the center of the damper car- tridge. Damper cartridge Minimum diameter 46.10 mm (1.815 in) » If the m easured value is greater than the specified value: – Change the damper cartridge[...]

04/SHOCK AB SORBER, SWI NGARM 39 7.11 Removing the heim joint Condition The shock absorber has been removed. 200577-10 – Clamp the shock absorber in the vise using soft jaws for protection. – Remove collar bushing  of the heim joint. Pin (T120) ( p. 255) – Turn over the shock absorber and remove collar bushing  of t he he im joi nt. Pin[...]

04/SHOCK AB SORBER, SWI NGARM 40 200579-11 – Mount lock rings  on both sides. 200578-11 – Mount seal rings  on both sides and grease them. Lubricant (T158) ( p. 244) 200582-10 – Press in both collar sleeves  of the heim joint. 7.13 Assembling the piston rod – Check the damper. ( p. 38) 300543-11 – Clamp the piston rod with the h [...]

04/SHOCK AB SORBER, SWI NGARM 41 201270-10 – Sand both sides of the p iston on a surfa ce pl ate u sing 1200-grit sandpaper. – Clean the piston. – Assemble the piston. Guideline View  Piston from above View  Piston from below 300541-11 – Mount the rebound shim stack  with the s maller shims facing upward. – Install supporting pla[...]

04/SHOCK AB SORBER, SWI NGARM 42 201254-11 – Mount and tighten screw  . Guideline Filling port screw M10x1 14 Nm (10.3 lbf ft) 201260-10 – Fill the damper cartridge about half full. Shock absorber oil (SAE 2,5) (50180342S1 ) ( p. 243) 201253-11 – Grease O-ring  of th e sea l rin g ret ainer. Lubricant (T158) ( p. 244) – Mount the pist[...]

04/SHOCK AB SORBER, SWI NGARM 43 – Turn adjusting screw  all the way clockwise using a socket wrench. – Turn back counterclockwise by the number of turns correspo nding to th e sh ock absorber type. Guideline Compression damping, high -speed Comfort 2.0 turns Standard 1.5 turns Sport 1.0 turn Full payload 1.0 turn – Turn adjusting screw ?[...]

04/SHOCK AB SORBER, SWI NGARM 44 200271-10 – Place the control lever as shown in the photo. The Ext ernal tank  con trol lever is on Closed , Damper  on Vacuum , and Oil res ervoir  on Vacuum . – Operate the On/Off sw itch  . The vacuum pump process starts. Pressure gauge  f alls t o the spec ified value. < 0 bar Vacuum gauge [...]

04/SHOCK AB SORBER, SWI NGARM 45 200267-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser - voir contr ol le ver  to Equalize Pres sure . Guideline 4 m bar The pressure gauge falls to the specified value. 0 b ar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever ?[...]

04/SHOCK AB SORBER, SWI NGARM 46 7.16 Filling the damper with nitrog en 201266-10 – Screw in screw  by appro x. 2 rotat ions but d o no t tig hten. Info The piston rod is fu lly ex tended. 201267-10 – Clamp special tool in the vise. Nitrogen filling tool (T170S1) ( p. 258) – Connect the special tool to the pressure regulator of the filling[...]

04/SHOCK AB SORBER, SWI NGARM 47 201250-11 Alternative 1 – Tension the spring to the prescribed amount by turning the adjusting ring. Guideline Spring preload Comfort 12 mm (0 .47 in ) Standard 12 mm (0 .47 in ) Sport 12 mm (0 .47 in ) Full payload 15 mm (0 .59 in ) Hook wrench (T106S) ( p. 255) Hook wrench (T157S) ( p. 257) Alternative 2 Warning[...]

05/EXHAU ST 48 8.1 Removing the exhaus t system Condition Fuel tank is reset or r emoved. – Remove the front spoiler. ( p. 54) 300283-10 – Unplug connector  of the lambda senso r. O pen t he ca ble b inder. 300284-10 – Remove nuts  of t he ex haust manifold. Info Do not misplace the spacers. 300285-10 – Remove screw  . 300286-10 ?[...]

05/EXHAU ST 49 300286-11 – Mount screws  but d o no t tig hten them y et. 300285-10 – Mount screws  but d o no t tig hten yet. – Tighten the nuts  even ly. Guideline Nut, manifold on cylinder head M8 25 Nm (18.4 lbf ft) Copper paste – Fully tighten screws  . Guideline Screw, main silencer fixation M8 25 Nm (18.4 lbf ft) – Full[...]

06/AIR FILTE R 50 9.1 Removing the air filter Note Engine failure   Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the e ngine and result in i ncreased wear. – Remove the seat. ( p. 51) 600721-10 – Remove screws  . – Take off[...]

07/FUEL TAN K, SEAT, TRIM 51 10.1 Opening filler cap 500023-10 – Lift the cover of the fi ller cap  and i nsert the ignition key. – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent syste m. 10.2 Closing filler cap 500023-01 – Put the filler cap back on an d turn the ignitio n ke[...]

07/FUEL TAN K, SEAT, TRIM 52 Warning Danger of poisoning   Fuel is poi sonous and a he alth hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immed i- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed[...]

07/FUEL TAN K, SEAT, TRIM 53 Warning Danger of poisoning   Fuel is poi sonous and a he alth hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immed i- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed[...]

07/FUEL TAN K, SEAT, TRIM 54 700160-10 – Lay a cl oth  over the subframe and straighten the steering. – Carefully raise the fuel tank and move it backwards. – Place the fuel tank on th e ve hicle so th at th e lef t sp oiler is st ill ly ing o n the com - pensating tank  (s ee il lustration). Place a cloth  between the compensating t[...]

07/FUEL TAN K, SEAT, TRIM 55 10.10 Fitting front spoiler 300026-10 – Position the front spoiler to the retaining bracket  . Mount screws  with the col- lar bushings and insulating washers, but do not tighten yet. 300027-10 – Fit and tighten screw  with a flange adapter on both sides. Guideline Screw, bug spoiler M6 7 N m (5. 2 lbf ft) [...]

07/FUEL TAN K, SEAT, TRIM 56 – Switch on the ignition. – Select model. – Select "ECU Diagn ostics" . – Highlight the "Injection manage ment EFI LC4" control unit. – Press "Conti nue" . – Select "Actua tor test" . – "Please enter the password: " – Press "Conti nue" . – Sel[...]

07/FUEL TAN K, SEAT, TRIM 57 302128-10 – Remove screws  . – Pull out the fuel pump. 302129-10 – Remove hose clamps  . – Remove fuel filter  . 302130-10 – Press lock  . – Remove fuel pump housing  . 302131-10 – Change fuel screen  . – Mount the fuel pump housing. 302129-11 – Mount fuel filter  . Arrow  point[...]

09/FRONT WH EEL 58 11.1 Removing the front whee l – Raise the motorcycle with the rear wheel stand. ( p. 9) – Raise the motorcycle with the front wheel stand. ( p. 9) 700155-10 – Remove screws  a nd sp acers  . – Press back the brake linings with a l ight lateral tilting of the brake caliper on the brake disc. Pull the brake caliper c[...]

09/FRONT WH EEL 59 600826-10 – Take the motorcycle off of the front wheel stand. ( p. 9) – Pull the front wheel brake and push down hard on the fo rk se veral times to a lign the fork legs. – Fully tighten screws  . Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) – Take the motorcycle off of the rear wheel stand. ( p. 9 ) 11.3 Checking[...]

09/FRONT WH EEL 60 400602-10 – Check the front and rear tires for cuts, run-in objects and other damage. » If the ti res e xhibit cuts, run-in objects or other damage: – Change the tires. – Check the depth of the t read. Info Note local national regulations conce rning the m inimum tread depth. Minimum tread depth ≥ 2 mm ( ≥ 0.08 in) » [...]

10/REAR WHE EL 61 12.1 Removing rear wheel – Raise the motorcycle with the rear wheel stand. ( p. 9) 100144-10 – Remove nut  . Remove chain adjuster  . Holding the rear wheel, withd raw th e wheel spindle  . – Push the rear wheel forward as far as p ossible and take the c hain off t he re ar sprocket. 100145-10 – Pull the rear whee[...]

10/REAR WHE EL 62 Guideline In order for the re ar w heel to be corre ctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks  . Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings are in contact with the brak[...]

10/REAR WHE EL 63 100131-10 – Loosen nut  . – Loosen nuts  . – Adjust the chain tension by turning adjusting screws  on the left and right. Guideline Chain tension 5 m m (0. 2 in) Turn the left and ri ght adjusting screws  so that the markings on the left and right chain adjusters  are in the same position relative to the refer[...]

10/REAR WHE EL 64 302113-10 – Check the chain sliding guard for wear. » If the c hain sliding guard is w orn: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated. » If the c hain sliding guard is l oose: – Tighten the chain sliding guard. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 12.6 C[...]

10/REAR WHE EL 65 100149-10 – Lay the rear wheel on a work bench with the re ar s procket facing upwards and insert the wheel spindle in the hub. – To check play  , ho ld the rear whee l tig ht a nd tr y to rotate the rear sprocke t. Info Measure the play on the outside of the re ar s procket. Play in r ubber dampers, rear wheel ≤ 5 mm ( ?[...]

11/WIRIN G HARNESS, BATT ERY 66 13.1 Removing the battery Warning Risk of injury   Battery acid and battery gases cause serious caute rization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggle s. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fi[...]

11/WIRIN G HARNESS, BATT ERY 67 13.2 Installing the battery 700165-11 – Push battery  from t he rig ht i nto th e fra me. Position the battery in the b attery rack. Info The battery terminals must be at the front. 700164-11 – Position cover  . – Connect plug-in connector  . 700163-11 – Secure the cover with rubber band  . – Co[...]

11/WIRIN G HARNESS, BATT ERY 68 13.4 Reconnecting neg ative (minus) cable of battery Condition Fuel tank is reset or r emoved. 300170-10 – Reconnect minus cable  . 13.5 Recharging the battery Warning Risk of injury   Battery acid and battery gases cause serious caute rization. – Keep batteries out of the reach of children. – Wear suitabl[...]

11/WIRIN G HARNESS, BATT ERY 69 100151-10 – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (584290740 00) You can also use th e ba ttery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharg e the bat- tery. Info Never remov[...]

11/WIRIN G HARNESS, BATT ERY 70 700166-01 – Remove protective cover  . 700167-01 – Remove a defective main fuse  with needle nose pliers. – Install a new main fuse. Fuse (58011109130) ( p. 191) Info A r eserve fuse  is loca ted in the starter rela y. – Replace the protective cover. – Position the fuel tank. ( p. 54) – Mount the[...]

11/WIRIN G HARNESS, BATT ERY 71 Warning Fire hazard   The electrical syste m can be overloa ded b y the use of incorrec t fuses. – Use only fuses with the p rescribed amperage. Never by-pa ss or repa ir fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 191) Fuse (75011088015) ( p. 191) Tip Replace the spare fuse i[...]

13/BRAKE SY STEM 72 14.1 Checking the front brake lini ngs Warning Danger of accidents   Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. Note Danger of accidents   Reduced braking efficiency caused by damaged brake discs . – If the b rake linings are not c hanged in time, the steel brake lin[...]

13/BRAKE SY STEM 73 301867-10 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with m embrane  . 301875-10 – Remove screws  a nd th e spa cers. – Press back the brake linings with a l ight lateral tilting of the brake caliper on the brake disc. Carefully pul[...]

13/BRAKE SY STEM 74 301875-10 – Position the brake calipers. Mount the screws with the spacers but do not tighten yet. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressu re po int. Fix th e han d bra ke le ver in the acti- vated position. The brake caliper straightens. – [...]

13/BRAKE SY STEM 75 14.5 Adding front brake fluid Warning Danger of accidents   Failure of t he br ake s ystem. – If the b rake fluid l evel falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. Warning Skin irritation   Brake fluid can cause skin i[...]

13/BRAKE SY STEM 76 Info Never use DOT 5 b rake fluid! It i s sili cone-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 pain t! Use only clean brake fluid from a sea led c ontainer. 301867-10 – Move the brake fluid reservoir mount[...]

13/BRAKE SY STEM 77 14.8 Changing the rear brake linin gs Warning Danger of accident   Brake system failure. – Maintenance work and repairs must be carried out professio nally. Warning Skin irritation   Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of c hildren. – Wear suit[...]

13/BRAKE SY STEM 78 301881-10 – Remove brake linings  . – Clean the brake caliper. 301882-10 – Position the brake linings  . – Mount the bolts  . 301883-10 – Mount locking clips  . 301869-11 – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressu re po int. ?[...]

13/BRAKE SY STEM 79 14.10 Adjusting the basic positi on of the foot brake lever Warning Danger of accidents   Brake system failure. – If there is no free travel on the foot brake lever, pressu re bu ilds up on the rear brake circuit . Th e rea r bra ke c an fa il du e to overheating. Adjust free travel on foot brake lever accord ing t o spe cif[...]

13/BRAKE SY STEM 80 14.12 Adding rear brake fluid Warning Danger of accidents   Failure of t he br ake s ystem. – If the b rake fluid l evel falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. Warning Skin irritation   Brake fluid can cause skin i[...]

13/BRAKE SY STEM 81 301869-10 – Remove screw cap  with washer  and membra ne  . – Draw the old br ake f luid o ut o f th e bra ke flu id re servoir using a syringe and fill with fresh brake fluid. Bleed syringe (50329050000 ) ( p. 246) Brake fluid DOT 4 / DOT 5.1 ( p. 242) 301870-10 – Pull off dust cap  and connect a comme rcially[...]

14/LIGHT SYS TEM, INSTRU MENTS 82 15.1 Setting kilometers or mil es Info If you c hange the unit, the v alue ODO is retained and conve rted a ccordingly. Making the setting according to the country. Condition The motorcycle is stationary. 400839-01 – Switch on the ignition by turning the ignition key to th e pos ition . – Press the MODE button [...]

14/LIGHT SYS TEM, INSTRU MENTS 83 400841-01 – Switch on the ignition by turning the ignition key to th e pos ition . – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRI P 2 display is set to 0.0 . 15.5 Combination instru ment - setting the wheel circum ference Danger Voiding of the govern[...]

14/LIGHT SYS TEM, INSTRU MENTS 84 – The rider, with luggage and a passenger if applicable, now sits down on the motor- cycle. – Check the low beam h eadlight adjustment. For a re ady-to-operate motorcycl e with a rider, and with luggage and a passenger if applicable, the light-dark boundary must lie exactly on the lower mark. » If the b oundar[...]

14/LIGHT SYS TEM, INSTRU MENTS 85 15.8 Checking the high beam headl ight adjustment 0 0 B B 0 0 A A 0 0 B B 400575-10 – Stand the vehicle upright on a horizontal surface in front of a light wall and make a mark at the h eight of the c enter of the hi gh be am he adlight. – Make another mark at a distance  un der the fi rst m ark. Guideline D[...]

14/LIGHT SYS TEM, INSTRU MENTS 86 15.10 Removing headlig ht mask with headlight 700169-10 – Remove screws  . 700170-10 – Swing the headlight mask forward. 700171-01 – Disconnect plug-in connect or. 700172-10 – Remove the screw fitting  on both sides. – Place the headlight mask to one side. 15.11 Installing the headligh t mask with t[...]

14/LIGHT SYS TEM, INSTRU MENTS 87 700171-01 – Connect the plug-in connector. 700170-11 – Fold the headlight mask up. 700169-11 – Position the headlight mask. Mount and tighten screw s  . Guideline Screw, headlight mask M6 5 N m (3. 7 lbf ft) – Check the lighting function. 15.12 Changing the parking ligh t bulb Note Damage to reflector ?[...]

14/LIGHT SYS TEM, INSTRU MENTS 88 15.13 Changing the low beam bulb Note Damage to reflector   Reduced luminance. – Grease on the lamp will evaporate due to the h eat and b e dep osited on the re flector. Clean the lamp and keep it fr ee of grea se before mounting. – Switch off all power consumers and switch off the engine. 700169-10 – Remov[...]

14/LIGHT SYS TEM, INSTRU MENTS 89 700169-12 – Position the headlight mask. Mount and tighten screw s  . Guideline Screw, headlight mask M6 5 N m (3. 7 lbf ft) – Check lighting function. 15.14 Changing the turn signal bul b Note Damage to reflector   Reduced luminance. – Grease on the lamp will evaporate due to the h eat and b e dep osite[...]

30/ENGIN E 90 16.1 Removing the engine – Raise the motorcycle with the rear wheel stand. ( p. 9) – Remove the seat. ( p. 51) – Remove the fuel tank. ( p. 51) – Disconnect the negative (minus) cabl e of the battery . ( p. 67) – Drain the coolant. ( p. 162) – Remove the exhaust system. ( p. 48) 300290-10 – Loosen the spring-loaded band-[...]

30/ENGIN E 91 300287-10 – Loosen nut  of the w heel spindle. – Remove nut  . Remove the chain adjuster. – Pull out the wheel spindle only far enough to allow the rear wheel to b e pus hed for- ward. – Push the rear wheel forward as far as p ossible and take the c hain off t he re ar sprocket. 300182-10 – Take off the engine sprocket[...]

30/ENGIN E 92 300188-10 – Pull of the s park plug connector. – Unplug the connector of the engine coolant temperat ure s ensor  . 300189-10 – Loosen the spring-loaded band-typ e cla mps  from the br eather, SLS and oil return feed with the special tool. Pliers for spring-loaded band-type clam p (60029057100) ( p. 248) – Pull off[...]

30/ENGIN E 93 300194-10 – Remove nut  of the s wingarm pivot. – Remove the swingarm pivot. – Loosen adjusting rings using special tool  . Mortise key (75029034000) ( p. 251) Info Fix the l ink fo rk in the frame using a suitable tool. 300289-10 – Lower the engine. Info You should have an assistant for this step. Make sure that t[...]

30/ENGIN E 94 300190-11 – Position the connecting bracket. – Mount and tighten screws  . Guideline Screw, linkage bracket, front engine bracket M8 25 Nm (18.4 lbf ft) Loctite ® 243™ – Mount and tighten screw  . Guideline Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite ® 243™ – Tighten the lower engine bracket. Guideline En[...]

30/ENGIN E 95 300187-11 – Reconnect the plug connectors  of the gear position sensor, the crankshaft posi- tion sensor and the alternator. 300186-11 – Slide the throttle valve body into the rubber sleeves. – Position and tighten the hose clamp  . 300185-11 – Position the foot brake lever and mount it with the spring. – Mount and tig[...]

30/ENGIN E 96 300181-11 – Have an assistant operate the rear brake. – Position the new lock washer. Mount and tighten the nut. Guideline Nut, engine sprocket (Duke) M20x1.5 60 Nm (44.3 lbf ft) Loctite ® 243™ Nut, engine sprocket (Duke R) M20x1.5 60 Nm (44.3 lbf ft) Loctite ® 243™ – Secure the nut with the l ock w asher. – Mount screw [...]

30/ENGIN E 97 – Take a s hort test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p. 166) – Check the coolant level. ( p. 16 4)[...]

30/DISAS SEMBLING THE EN GINE 98 17.1 Clamping engine into eng ine work stand 300144-10 – Mount special tool  on engine work stand  . Engine work stand (61229001000) ( p. 249) Support for engine work stand (7501200106 0) ( p. 250) Holder for engine work stand (75012001070 ) ( p. 250) – Mount the engine on special tool  . Info Have an a[...]

30/DISAS SEMBLING THE EN GINE 99 17.5 Removing the alternat or cover 300004-10 – Remove screws  . Ta ke o ff th e alte rnator cover. – Remove dowels. 17.6 Removing spacer 302124-10 – Remove the spacer  of the countersha ft. 17.7 Removing gear posit ion sensor 302126-10 – Remove screws. Remove the gear position senso r  . 300007-10 [...]

30/DISAS SEMBLING THE EN GINE 100 300011-10 – Remove screws. Remove the oil filter cover  with the O-ring. – Pull the oil filter element  out of the oil filter case. Circlip pliers reverse (5101201100 0) ( p . 24 6) 17.9 Removing thermos tat 300010-10 – Remove screws. Take off the thermostat case  with the radiator hose. – Pull out[...]

30/DISAS SEMBLING THE EN GINE 101 300013-10 – Remove screw  . T ake off th e wa ter p ump wheel  . – Take off the water pump cover seal. Info Do not lose t he ce ntering pins. 300014-10 – Remove the shaped washer  . 17.12 Removing clutch cove r 300015-10 – Remove screws  . Ta ke o ff th e clu tch c over. – Take off the dowels.[...]

30/DISAS SEMBLING THE EN GINE 102 17.15 Removing timing chai n tensioner 300017-10 – Remove screw  . T ake off th e se al ri ng. – Pull out timing chain tensioner  . 17.16 Removing camsha fts 300019-10 – Remove screw  . T ake off th e ca mshaft support plate  . 300020-10 – Pull the camshaft out of the bearing seats. Take the tim[...]

30/DISAS SEMBLING THE EN GINE 103 300031-10 – Remove piston pin retainer  . – Remove the piston pin. – Take off the cylinder with the piston. – Push the piston upward out of the cylinder. Info If no ot her work i s req uired on th e cyl inder and the p iston, you can leave the piston in the c ylinder. – Take off the cylinder base gaske[...]

30/DISAS SEMBLING THE EN GINE 104 302120-10 – Install the special tool  on the rotor. Hold it tight using the special tool and pull off the rotor by tu rning the s crew i n. Extractor (5842900900 0) ( p. 2 46) – Remove the special tool. 17.21 Removing timing chai n rails 300045-10 – Remove screws  . – Pull the timing chain guide rails[...]

30/DISAS SEMBLING THE EN GINE 105 17.23 Removing cranksh aft position sensor 300151-10 – Remove the screws of crankshaft position senso r  . – Pull cable support sleeve  out of the engine case. Take off the crankshaft posi- tion sensor. 17.24 Removing clutch cage 300051-10 – Compress the antihopping clutch with the special tool  . As[...]

30/DISAS SEMBLING THE EN GINE 106 302125-10 – Take off the stepped washer and remove the half-washers  . – Take off the clutch cage. 300056-10 – Remove needle bearing  and supporti ng pl ate  . 17.25 Removing primary gea r 300062-10 – Plug the special tool into the crankshaft. Protection cover (75029090 000) ( p. 253) – Screw [...]

30/DISAS SEMBLING THE EN GINE 107 17.27 Removing shift shaft 300066-10 – Push sliding plate  away from the shift drum locating  . Remove shift shaft  with the washer. 17.28 Removing shift drum loca ting 300067-10 – Remove screw  . – Press locking lever  away from shift drum locating  and take off the shift drum locating. –[...]

30/DISAS SEMBLING THE EN GINE 108 300072-10 – Remove both oil pump shafts  with internal rotors  . – Take the external rotors out of the engine case. 17.31 Removing left engine ca se (Duke) 300075-10 – Remove screws  . – Swing the left engine case up and r emove the nut or sc rew o f the engi ne ho lder. 300076-10 – Install the s[...]

30/DISAS SEMBLING THE EN GINE 109 300076-10 – Install the special tool  with suitable screw s. Extractor (7502904800 0) ( p. 2 52) Info Use the 750 drill hole. – Pull off the section of the e ngine case. Info Do not tension the section of the e ngine case. The balancer shaft and the main shaft have a stop disk, these usually stick to the be [...]

30/DISAS SEMBLING THE EN GINE 110 300080-10 – Swing shift forks  to one side. – Remove shift drum  . 300081-10 – Remove shift forks  . Info Ensure that the pins remain in place. 300082-10 – Remove the lock ring  and the stop disk. 300083-10 – Pull both transmission shafts  out of the bearing seats together. Info The stop di[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 111 18.1 Work on the right section of the engine ca se 300094-10 – Remove oil jet  . – Remove bearing locks of the main shaft bearing  , of the countershaft beari ng  , and of the sh ift d rum b earing  . – Remove any sealing mass remnants and clean the engine case section thorou ghly. – Pu[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 112 Guideline Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite ® 243™ – Blow compressed air through all oil holes and check that they are clear. – Position the cover plate  . Mount and tighten the screws. Guideline Screw, cover plate for oil return line M5 6 N m (4. 4 lbf ft) – Reinstall th[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 113 Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the ou ter 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 [...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 114 18.3 Work on the clutch cover 300097-10 – Remove the shaft seal ring  of the crankshaft. – Press in a new shaft sea l rin g with the open side facing inward until it stops. Info Support the clutch cover sufficiently when pressi ng in . – Blow compressed air through the oil channel and check that i[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 115 18.6 Removing balance r shaft drive wheel (Duke) – Remove the crankshaft bearing inner ring. ( p. 114) 300133-10 – Screw in 2 M6 screw s  in the threads. Tighten the two screws evenly to pull the drive wheel  off the c rankshaft. 18.7 Removing balance r shaft drive wheel (Duke R) – Remove the c[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 116 300140-10 – Press in the n ew cra nk p in  as far as possible. Info The crank pin must be p ressed in so tha t oi l ho le  is aligned with oil hole  . If the o il ho les a re no t co rrectly aligned, the conrod bearing will not be sup- plied with oil. – Blow compressed air through the oil pass[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 117 18.9 Changing the conrod bear ing (Duke R) – Remove the drive wheel of the balancer shaft. ( p. 115) 302151-10 – Position the crankshaft with the special tool  in the press. Under part, pressing-out tool (7502 9047051) ( p. 252) – Position the special tool  between the crankweb s. Upper part, p[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 118 302152-10 – Position the special tool  with the heel at the bottom. Pressing device for crankshaft, comp lete ( 75029047000) ( p. 252) – Press the upper crankweb in as far as p ossible. Info The press mandrel must be applied above the crank pin. – Take the crankshaft out of the special tool, and c[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 119 300159-10 – Place the drive wheel on the c rankshaft. The dowel of the crankshaft must fit in the drill hole  . The side of t he dr ive w heel with the pu nch mark  must be visible after assembly, and the side with the bevel  must be in contact with the crankweb. – Install the crankshaft beari[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 120 18.13 Installing cranksh aft bearing inner ring (Duke) 300134-10 – Fix the c rankshaft with special tools  and  in the vise. Upper part, pressing-out tool (7502 9047050) ( p. 252) Under part, pressing-out tool (7502 9047051) ( p. 252) – Push on the c ompensation shim. – Heat the special tool. I[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 121 – Install the crankshaft bearing inner ring. ( p. 120) 300164-10 – Mount the dial gauge support on the engine case and measure and note the axial clearance of the balancer shaft. Guideline Balancer shaft axial clearance 0 .05… 0 .20 m m (0.0 02… 0 .0079 in) » If the m easured value does not equal [...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 122 400376-10 – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100 ) ( p. 248) Cylinder/cylinder head - sealing area distortion ≤ 0 .10 m m ( ≤ 0.0039 in) » If the m easured value does not equal the specified value: – Change[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 123 18.19 Checking/mea suring the piston (Duke R) 0 0 A A 0 0 A A 0 0 A A 400484-10 – Use the special tool to measure clearance  of the piston rings in the piston ring groove. Guideline Piston ring - groove clearance ≤ 0 .08 m m ( ≤ 0.0031 in) Feeler gauge (59029041100 ) ( p. 248) » If clearance  [...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 124 » If the e nd ga p is more than the specifie d val ue: – Check/measure the cylinder. ( p. 121) » If the c ylinder wear is within the tolerance range: – Change the piston ring. – Mount the piston ring with the marking facing toward the piston head. 18.21 Checking piston/c ylinder mounting clear ance[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 125 300109-10 – Disconnect the autodecomp ression spring. Loosen the screw  and remove it together with the autodecompress ion s pring and the au todecompression weight  . 300110-10 – When assembling, first connect the autod ecompression spring and then insert the screw through the autodecompress ion[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 126 18.25 Checking timing asse mbly 0 0 1 1 0 0 1 1 0 0 2 2 0 0 3 3 0 0 4 4 0 0 5 5 300113-01 – Clean all parts well. – Check the timing chain gear / timing chain sprocket  for damage and wear. » If there is da mage or w ear: – Replace the timing chain gear / timing chain sprocket. – Check timing c[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 127 300228-10 – Remove the small camshaft bearing  usi ng th e spe cial tool. Insert for bearing puller (1511201810 0) ( p. 246) Bearing puller (1511201700 0) ( p. 246) 300229-10 – Press in the s mall camshaft bearing as far as possible using the special tool  . Push-in drift (75029044020) ( p. 251) [...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 128 18.29 Checking valves 200193-10 – Check the run-out at the valve plate. Valve - run-out On the v alve plate ≤ 0.05 mm ( ≤ 0.002 in) » If the m easured value does not equal the specified value: – Change the valve. 0 0 A A 400373-10 – Check the sealing seat  on the valve. Valve - sealing seat w[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 129 400375-10 – Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041100 ) ( p. 248) Cylinder/cylinder head - sealing area distortion ≤ 0 .10 m m ( ≤ 0.0039 in) » If the m easured value does not equal the specified value: – Change the [...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 130 18.34 Installing rocker arm 300114-11 – Position the rocker arm  and push in the rocker arm shafts  . Info Make sure that the tapped hole of the ro cker arm s haft is po sitioned facing outwards. The small drill hole and the flat s urface must point upwards. 300113-11 – Install and tighten the sc[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 131 18.36 Checking the clutch – Dismantle the antihopping clutch. ( p. 130) 0 0 9 9 0 0 bk bk 0 0 7 7 0 0 1 1 0 0 2 2 0 0 3 3 0 0 4 4 0 0 5 5 0 0 6 6 0 0 8 8 0 0 bl bl 0 0 bm bm 0 0 bn bn 0 0 bo bo 300123-01 – Check pressure piece  for damag e an d wea r. » If there is da mage or w ear: – Replace the[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 132 » If the in termediate discs are not level or are pitted: – Replace all intermediate discs. – Check clutch facing discs  for discoloration and scorin g. » If there is dis coloration or scoring: – Change all clutch facing discs. – Check the thickness of clutch facing discs  . Clutch fa[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 133 18.38 Checking shift mech anism 0 0 B B 0 0 3 3 0 0 2 2 0 0 C C 0 0 E E 0 0 D D 0 0 5 5 0 0 1 1 0 0 1 1 0 0 A A 0 0 3 3 0 0 6 6 0 0 4 4 0 0 4 4 0 0 1 1 300120-01 – Check the shift forks  (see  ) for damage and wear (visual check). » If there is da mage or w ear: – Change the shift fork and the i[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 134 18.40 Disassembling the ma in shaft 3 3 5 5 7 7 8 8 9 9 bk bk bl bl 1 1 4 4 6 6 2 2 301980-01 – Fix the m ain shaft in th e vis e with the geared end facing down ward. Guideline Use soft jaws. – Remove stop disk  and second -gear fixed gear  . – Remove the sixth-gear idler gear  . – Remove[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 135 – Remove stop disk  and the first-gear idle r ge ar  . – Remove needle bearing  and stop disk  . – Remove the fifth-gear sliding gear  a nd lo ck rin g  . – Remove stop disk  and the third-gea r idl er g ear  . – Remove the needle bearing  and the fourth-gear idler gear[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 136 » If the fi xed g ear does not move easily: – Change the fixed gear or the main shaft. – Check fixed gears  for smooth oper ation in the profi le of coun tershaft  . » If the fi xed g ear does not move easily: – Change the fixed gear or the countershaft. – Check stop disks  for dama ge a[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 137 18.44 Assembling count ershaft Info Use new lock rings in eve ry re pair job. – Oil all parts carefully before assembling. – Check the transmission. ( p. 135) 1 1 2 2 4 4 5 5 6 6 7 7 9 9 8 8 bl bl bk bk bm bm 8 8 bo bo bn bn bp bp bq bq br br 3 3 300128-02 – Fix the c ountershaft in the vise with the[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 138 18.45 Checking electric star ter drive 5 5 6 6 1 1 2 2 4 4 3 3 300129-01 – Check the teeth and seating of the starter idler gear  for damage and wear. » If there is da mage or w ear: – Replace the starter idler gear and/or needle bushing . – Check the teeth and seating of the torque limiter  f[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 139 300128-10 – Compress the expansion ring  and remove it, using suitable pliers. – Take the freewheel  out of the primary gear. 18.47 Checking freewhee l 300131-10 – Insert the freewheel gear  in the primary gear  , tu rning the p rimary gear clock- wise; do not twist! – Check the locking[...]

30/ENGIN E - WORK ON INDIVIDUAL PAR TS 140 300127-11 – Insert the lock ring  into the groove with suitable pliers and check that it is seated correctly.[...]

30/ASSEM BLING THE ENGIN E 141 19.1 Installing transmis sion shafts 300087-10 – Clamp the right section of the engine case. Holder for engine work stand (75012001070 ) ( p. 250) Support for engine work stand (7501200106 0) ( p. 250) Engine work stand (61229001000) ( p. 249) – Make sure that both stop disks  are in stalled. – Mount the inne[...]

30/ASSEM BLING THE ENGIN E 142 19.2 Installing cranksh aft and balancer shaft (Duke ) 300085-10 – Mount the special tool  on the alternator side of the crankshaft. Mounting sleeve (750290800 00) ( p. 253) – Mount the special tool  on the balancer shaft. Mounting sleeve (585290050 00) ( p. 247) 300165-10 – Push the crankshaft into the be[...]

30/ASSEM BLING THE ENGIN E 143 302135-10 – Push the crankshaft into the bearing seat and take off the special tool. – Grease the shaft seal rings of the balancer shaft. – Push the balancer shaft  into the bearing seat and take off the special tool. Align marks  and  . – Mount stop disk  . 19.4 Installing left engine cas e (Duke)[...]

30/ASSEM BLING THE ENGIN E 144 300075-11 – Put on the le ft en gine case half. If n ecessary, tap lightly with a rubber mallet and turn the transmission shafts. Info Do not tighten the engine case sections using the screws. – Install the screws  and tighten them diagon ally. Guideline Screw, engine case M6 10 Nm (7 .4 lbf ft) Info Install th[...]

30/ASSEM BLING THE ENGIN E 145 19.8 Installing shift drum locat ing 300068-10 – Press locking lever  down and position shift drum locati ng. Info The flat surfaces  of the shift drum locating are not symmetr ic. 300067-11 – Release the locking lever. – Mount and tighten screw  . Guideline Screw, shift drum locating M6 10 Nm (7.4 lbf [...]

30/ASSEM BLING THE ENGIN E 146 19.11 Installing primary gea r 300063-10 – Ensure that the spring washer is seated properly. – Mount primary gear  . Info Turn the freewheel gear backwards and forwards to ease meshing. 19.12 Installing clutch cage (Du ke) 300057-10 – Install supporting plate  and needle bearin g  . 300058-10 – Instal[...]

30/ASSEM BLING THE ENGIN E 147 302122-10 – Lock the clutch cage and primary gear using the special tool. Gear segment (750290810 00) ( p. 253) – Mount and tighten the nut  . Guideline Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite ® 243™ 300061-10 – Insert the pressure piece  . 300052-11 – Place the pressure cap on. – In[...]

30/ASSEM BLING THE ENGIN E 148 302121-10 – Position a new lock washer and install the nut  . – Lock the clutch cage and primary gear using the special tool, and tighten the nut. Guideline Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ Gear segment (750290810 00) ( p. 253) Info Make sure that the crankshaft is not blocke[...]

30/ASSEM BLING THE ENGIN E 149 19.15 Installing timing chain an d timing chain sprocket 300150-10 – Heat the timing chain sprocket and push it immediately on to the crankshaft. Guideline 100 °C (2 12 °F ) – Mount lock ring  . 300148-11 – Thread the timing chain  in and lay it over the timing chain sprocket. Info If the ti ming chain i[...]

30/ASSEM BLING THE ENGIN E 150 300043-10 – Mount the tab washer and the nut  . Tighte n nu t. Guideline Rotor nut M18x1 .5 100 Nm (73.8 lbf ft) 19.18 Adjusting cranksh aft position sensor distan ce 300048-10 – Adjust the distance between the crankshaft posit ion s ensor  and the conductive element of the rotor using the special tool  .[...]

30/ASSEM BLING THE ENGIN E 151 300035-10 – Ensure that piston marking  faces the outfeed side. 300034-10 – Apply a thin la yer of s ealing compound in area  . Loctite ® 5910 – Place the cylinder base gasket on. Info Make sure the grooved pins are seated correctly. 300036-10 – Cover the engine case opening with a cloth. Thread the tim[...]

30/ASSEM BLING THE ENGIN E 152 300039-10 – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the grooved pins engage. 19.21 Installing piston (Duke R) 302600-10 – Shift the joint of the p iston rings by 12 0°. – Push the oiled piston into the s pecial tool. Piston assembly ring (7502901510 2) ( p[...]

30/ASSEM BLING THE ENGIN E 153 400366-10 – Position the piston pin retainer. 300038-10 – Insert the special tool and firmly press it toward the piston. – Turn the special tool counterclockwis e, th ereby pressing the piston pin retainer into the groove. Piston pin lock ring insert (75029035000) ( p. 251) – Make sure that the piston pin reta[...]

30/ASSEM BLING THE ENGIN E 154 Guideline Cylinder head screw M10 Tightening sequence: Tighten diag- onally, begin- ning with the rear screw on the c hain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft) Lubricated with engine oil Info Always use new cylinder head screws. – Mount an[...]

30/ASSEM BLING THE ENGIN E 155 300018-10 – Remove screw  and u se th e spe cial tool to pu sh th e tim ing c hain tensioner toward the timing chain. Release device for timing chain tensioner (77329 051000) ( p. 25 4) The timing chain tensioner unlocks. – Mount and tighten screw  . Guideline Screw, unlocking of timing chain ten- sioner M10[...]

30/ASSEM BLING THE ENGIN E 156 300158-10 – Remove shims  a nd s et th em do wn a ccording to the i nstallation position. – Correct the shims as indicated by the results of the valve clearance check. – Insert suitable shims. – Position the rocker arms and push in the rocker arm shafts. Info Make sure that the tapped hole of the ro cker ar[...]

30/ASSEM BLING THE ENGIN E 157 19.30 Mounting water pump co ver 300014-11 – Push on the s haped washer  . 300013-12 – Attach the water pump wheel  . Mount and tighten screw  Guideline Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Loctite ® 243™ – Lay on t he wa ter pump cover seal  . 300012-12 – Put on the w[...]

30/ASSEM BLING THE ENGIN E 158 300011-11 – Insert the oil filter  . – Lubricate the O-ring of the oil filter cover. Install the oil filter cover  . – Mount and tighten the screws. Guideline Screw, oil filter cover M5 6 N m (4. 4 lbf ft) 19.33 Installing gear positi on sensor 300007-11 – Mount the contact springs  and contact bolt ?[...]

30/ASSEM BLING THE ENGIN E 159 19.35 Installing oil screens 300152-10 – Push the oil screen with O-rings on to a pin wrench. Push the pin wrench through the opening into the drill hole of th e op posite engine case wall and push the oil screen as far as p ossible into the engine case. 300008-10 – Install the oil drain plug with magnet  and a[...]

30/ASSEM BLING THE ENGIN E 160 300024-11 – Remove special tool  . Engine blocking screw (773290100 00) ( p. 254 ) – Mount and tighten screw  . Guideline Plug, crankshaft location M8 20 Nm (14.8 lbf ft) 19.37 Installing starter mot or (Duke) 300001-01 – Grease O-ring. Mount the starter motor. Long-life grease ( p. 244) – Mount and tigh[...]

32/CLUTC H 161 20.1 Checking/recti fying the fluid level of the hydraulic clut ch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use b rake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position . 100194-10 – Check the fluid level. The fuel level must be between MIN and MAX [...]

35/WATE R PUMP, COOLING SY STEM 162 21.1 Draining the coolant 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 compon ents when the e ngine is ho t. A llow th e engine and cooling system to cool down. In case of sc[...]

35/WATE R PUMP, COOLING SY STEM 163 Fuel tank is reset. – Move the fuel tank forward. The fuel tank is removed. – Connect and position the fuel tank. Danger Danger of poisoning   Exhaust gases are poisonous and inhaling them may result in unconsciousness and/o r de ath. – When running the engine, always make sure there is sufficient ventila[...]

35/WATE R PUMP, COOLING SY STEM 164 700182-11 – Screw off the radiator cap  . – Check antifreeze of coolant. − 25… − 45 °C ( − 13… − 49 °F) » If the a ntifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. – Check the coolant level in the radiator. The radiator must be completely fi[...]

35/WATE R PUMP, COOLING SY STEM 165 » If you h ad to add more coola nt th an th e sp ecified amount: > 0 .50 l (> 0.53 qt.) – Fill/bleed the cooling system. ( p. 162) – Mount the radiator cap. – Position the fuel tank. ( p. 54) – Mount the seat. ( p. 51)[...]

38/LUBRI CATION SYSTE M 166 22.1 Oil circuit 400500-60 1 Oil screen 2 Force pum p 3 Oil filter 4 Oil pressu re re gulator valve 5 Timin g ch ain te nsioner 6 Rock er a rm sha ft 7 Trans mission 8 Clutc h 9 Oil jet for piston cooling 10 Oil filter 11 Crankshaft 12 Oil screen 13 Suction pump 7 Trans mission 22.2 Checking the engine oil leve l Info Th[...]

38/LUBRI CATION SYSTE M 167 700185-01 – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil l evel viewer. » If the e ngine oil level is no t at the speci fied l evel: – Add the engine oil. ( p. 171) 22.3 Checking the engi[...]

38/LUBRI CATION SYSTE M 168 – Change the oil filter. Check oil pumps for wear. Check that all oil holes are clear. – Switch off the engine. Warning Danger of burns   Some vehicle components get very hot when the machine is driven. – Wear appropriate protective cloth ing a nd sa fety gloves. In case of b urns, rinse immediately with lukewarm[...]

38/LUBRI CATION SYSTE M 169 700187-01 – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the m agnet and seal ring and tighten it. Guideline Oil drain plug with magnet (Duke) M12x1.5 20 Nm (14.8 lbf ft) Oil drain plug with magnet (Duke R) M12x1.5 20 Nm (14.8 lbf ft) 22.6 Removing the oil filter Warning Danger o[...]

38/LUBRI CATION SYSTE M 170 22.7 Installing the oil filter 700190-01 – Insert oil filters  and  . – Oil the O-rings of the oi l filt er c overs. Mount oil filter covers  and  . – Mount and tighten the screws. Guideline Screw, oil filter cover (Duke) M5 6 N m (4. 4 lbf ft) Screw, oil filter cover (Duke R) M5 6 N m (4. 4 lbf ft) 22.[...]

38/LUBRI CATION SYSTE M 171 700193-01 – Position oil screen  with the O-rings. – Mount and tighten plug  with the O-ring. Guideline Plug, oil screen (Duke) M20x1.5 15 Nm (11.1 lbf ft) Plug, oil screen (Duke R) M20x1.5 15 Nm (11.1 lbf ft) 700194-01 – Position oil screen  with the O-rings. – Mount and tighten plug  with the O-ring[...]

38/LUBRI CATION SYSTE M 172 – Install and tighten the oil filler plug with O-ring  . Danger Danger of poisoning   Exhaust gases are poisonous and inhaling them may result in unconsciousness and/o r de ath. – When running the engine, always make sure there is sufficient ventila- tion, and do not s tart or ru n the engi ne in an enclose d sp[...]

39/IGNITI ON SYSTEM 173 23.1 Alternator - checkin g the stator winding Condition The stator is disconnected. – Reinstall the fuel tank. ( p. 5 3) 600894-10 Stator winding, measur ement I - check the resistance – Measure the resistance between the specified poin ts. Stator, connector EN pin 1 – Stator, connector EN pin 2 Alternator Resistance [...]

39/IGNITI ON SYSTEM 174 23.3 Ignition coil - checking the sec ondary winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. – Remove the fuel tank. ( p. 51) 600739-12 Ignition coil cylinder 1 - check the seco ndary winding resistance – Measure the resistance between the specified poin ts. I[...]

41/THROT TLE VALVE BODY 175 24.1 Checking the basic settin g of the motor drive Condition The diagnostics tool is connected. 400805-10 – Ensure that locking cap  was not opened. Info Sealing varnish  on the screws shou ld no t be dam aged. » If the s ealing varnish is damaged: – Contact customer service. – Select model. – Select &quo[...]

41/THROT TLE VALVE BODY 176 » If the d isplayed value is not equal to the se tpoint value: – Close the menu with "E xit" . – Adjust the basic setting of the motor drive. ( p. 176) 400537-51 – Use "Con tinue" to start the "Checking the position of the thr ottle grip sensor" menu. The throttle stepper motor keeps [...]

41/THROT TLE VALVE BODY 177 600945-10 – Carefully close the throttle valve with your finger and hold it. – Check the voltage value. Info The "Con tinue" button only appears if the measured value equals the set- point value. Throttle position sensor circuit A (Duke) Basic position - voltage "THA D" 0.50… 0.54 V Throttle pos[...]

41/THROT TLE VALVE BODY 178 600987-10 – Check the voltage value. Info The "Con tinue" button only appears if the measured value equals the set- point value. Throttle position sensor circuit A (Duke) Emergency running position - volt- age "THA D" 0.70… 0.74 V Throttle position sensor circuit A (Duke R) Emergency running posit[...]

41/THROT TLE VALVE BODY 179 300237-10 – Mount the intake flange. – Position and tighten the hose clamp  . – Install the EPT control unit holder. ( p . 18 0) 600946-10 – Use "Con tinue" to start the "Adjusting the position of the thr ottle grip sensor" menu. – Check the voltage value. Info The "Con tinue" b[...]

41/THROT TLE VALVE BODY 180 – Press "Conti nue" . – "Read trouble code" selected. – Complete the procedure with "Back" . – Select "Delete tro uble codes" . – Complete the procedure with "Back" . Danger Danger of poisoning   Exhaust gases are poisonous and inhaling them may result in unco[...]

41/THROT TLE VALVE BODY 181 24.5 Removing rollover se nsor 302162-10 – Pull the Map ‑ Select switch out of the holder. 302163-10 – Remove the two screws  . – Take off the rollover sensor  . Disconnect plug AP . 24.6 Installing rollover se nsor 302163-11 – Connect plug AP to the rollove r se nsor. Position the rollover sensor  . ?[...]

41/THROT TLE VALVE BODY 182 – Press "Sele ct file" and s elect a n ew ma pping. Info "The BLZ file and the exhaust system must ma tch!" – Press the "ECU flash process " button. – Read the prompt and confirm with "OK" . The new mapping is loaded. – Switch to the m ain menu. EPT control unit – Select [...]

41/THROT TLE VALVE BODY 183 – Fill out the protocol and send to "diagnostic@ktm.c om" . A r esponse mail containing the enabling code arrives. 24.9 Coding the EFI control unit an d/or EPT control unit Condition The ignition is on. The diagnostics tool is connected and running. Flashing of the EFI control unit and/or EPT control unit is [...]

41/THROT TLE VALVE BODY 184 – "Please enter the code" – Press "Con tinue" . The new VIN is transf erred to the EPT contro l un it. – Switch to the m ain menu. – Select "Show iden tification" . – Compare the old VIN to the new VIN. The new VIN is shown .[...]

TECHNICA L DATA - ENGINE 185 Design 1-cylinder 4-stroke engine, wate r-cooled Displacement (Duke) 654 cm³ (39.91 cu in) Displacement (Duke R) 690 cm³ (42.11 cu in) Stroke (Duke) 80 mm (3 .15 in ) Stroke (Duke R) 84.5 mm (3.327 in) Bore 102 mm ( 4.02 in) Compression ratio (Duke) 11.8:1 Compression ratio (Duke R) 12.5:1 Control OHC, 4 valves contro[...]

TECHNICA L DATA - ENGINE 186 25.2 Capacity - coolant Coolant 1.20 l ( 1.27 qt.) Coolant ( p. 242) Coolant (mixed ready to use) ( p. 242)[...]

TECHNICA L DATA - TOLERANCE , WEAR LIMITS OF ENGIN E 187 Camshafts - diameter, bearing pin Next to exhaust cam ≥ 3 9.95 mm ( ≥ 1.5728 in) Next to inlet cam ≥ 1 7.96 mm ( ≥ 0.7071 in) Valve spring Minimum length (without valve spring cap) 42.3 mm (1.665 in) Valve spring cap - thickness 2.4… 2.5 m m (0. 094… 0 .098 in) Valve - valve stem [...]

TECHNICA L DATA - TOLERANCE , WEAR LIMITS OF ENGIN E 188 Coolant temperature: ≥ 70 °C ( ≥ 158 °F ) Engine speed: 5,000 rpm ≥ 1 .5 ba r ( ≥ 22 psi) Main shaft axial clearance 0.10… 0.40 mm ( 0.0039… 0.0157 in) Transmission shaft run-out ≤ 0 .025 mm ( ≤ 0.00098 in) Shift shaft - play in sl iding plate/shift quadrant 0.4 0… 0.8 0 m[...]

TECHNICA L DATA - ENGINE TIGHTE NING TORQUES 189 Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, membrane fixation M3 2.5 Nm (1.84 lbf ft) Loctite ® 243™ Hose clamp, intake flange M4 1.5 Nm (1.11 lbf ft) – Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loc[...]

TECHNICA L DATA - ENGINE TIGHTE NING TORQUES 190 Oil hole plug M10x1 15 N m (11. 1 lbf ft) Loctite ® 243™ Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 N m (11 .1 lb f ft) – Screw, unlocking of timing chain ten- sioner M10x1 10 N m (7.4 lbf ft) – Spark plug M12x1.25 17 Nm (1 2.5 lb f ft[...]

TECHNICA L DATA - CHASSIS 191 Frame Lattice frame made of chrome molybdenum steel tubing , powder-coated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro ‑ Lever deflector Suspension travel Front 140 mm ( 5.51 in) Rear 140 mm ( 5.51 in) Brake system Front Disc brake with radially screwed four-piston brake calip[...]

TECHNICA L DATA - CHASSIS 192 Front tire Rear tire 120/70 R 17 M/C 58H TL Dunlop Sportmax GPR Alpha 10 160/60 R 17 M/C 69H TL Dunlop Sportmax GPR Alpha 10 Additional information is availabl e in the Service sectio n un der: http://www.ktm.com 28.2 Capacity - fuel Total fuel tank capacity, approx. 13.5 l ( 3.57 US ga l) Super unleaded (ROZ 95 / RON [...]

TECHNICA L DATA - FORK 193 29.1 Duke Fork part number 14.18.7J.09 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer(s) 352 m m (13 .86 i[...]

TECHNICA L DATA - SHOCK ABSORB ER 194 30.1 Duke Shock absorber part number 15.18.7J.09 Shock absorber WP Suspension 4618 with Pro ‑ Lever deflector Compression damping, high -speed Comfort 2.0 turns Standard 1.5 turns Sport 1.0 turn Full payload 1.0 turn Compression damping, low- speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full pay[...]

TECHNICA L DATA - SHOCK ABSORB ER 195 Spring preload Comfort 12 mm (0.47 in) Standard 12 mm (0 .47 in ) Sport 12 mm (0 .47 in ) Full payload 15 mm (0.59 in) Spring rate Medium (standard) 70 N/mm (400 lb/in) Hard 75 N/mm (428 lb/in) Spring length 185 mm ( 7.28 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0 .98 in ) Riding sag 60… 65 m m (2.[...]

TECHNICA L DATA - CHASSIS TIGHT ENING TORQUE S 196 Screw, combination instrum ent EJOT 1 N m (0. 7 lbf ft) – Screw, combination instrum ent holder EJOT 1 Nm (0. 7 lbf ft) – Remaining screws, chassis M4 4 Nm (3 lbf ft) – Screw, rollover sensor M4 2 Nm (1.5 lbf ft) – Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Bolt, foot b[...]

TECHNICA L DATA - CHASSIS TIGHT ENING TORQUE S 197 Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, rear footrest bracket M8 25 Nm (1 8.4 l bf ft ) Loctite ® 243™ Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, spring holder on side stand bracket M8 15 Nm (11.1 lbf ft) Loctite ® 243™ Screw, stee[...]

CLEANING /PROTECT IVE TREATMEN T 198 32.1 Cleaning the motorcyc le Note Material damage   Damage and destruction of components by high-pre ssure cleaning equipment. – Never clean the vehicle with high-pressure cleani ng eq uipment or a strong water-jet. The excessive pressure can penetra te ele ctri- cal components, socket conne cts, throttle c[...]

CLEANING /PROTECT IVE TREATMEN T 199 32.2 Protective treatme nt for winter operation Info If you u se th e mo torcycle in winter, you must expect salt on the roads. You should therefore take precautions again st a ggres- sive road salt. If the v ehicle was operated in road salt, clean it w ith c old w ater. Warm water would enhance the corrosive ef[...]

STORAGE 200 33.1 Storage Info If you w ant to ga rage the m otorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repa irs or repl acements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long works[...]

SERVICE PLA N 201 34.1 Service schedule K10N K75A K150A K300A Check that the electrical equipment is functioni ng co rrectly. • • • • Read out the fault memory using the KTM diagnostics tool. • • • • Change the engine oil and filter, clean the oil screens. ( p . 16 8) • • • • Check the front brake linings. ( p. 72) • • ?[...]

WIRING DIAGR AM 202 35.1 Page 1 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / M U G 3 /2.B1 /2.F1 1 10 -M10 -K10 30A 4 1 2 3 0 2 T - 0 1 G - BI/2 EM/3 1 2 3 2 1 -G20 2 3 EN/3 1 -K11 2 1 3 4 1 AE/4 -X13 2 1 a AE/4 -X13 3 EB/4 -X19 4 4 b 1 0 3 X - 2 0 3 X - /2.A1 -A50 4 DJ/18 -X20 4 EB/4 -X19 3 1 /2.A7 -A11 43 2 DS/44 -X18 43[...]

WIRING DIAGR AM 203 A11 EFI control unit A50 Alarm system (optional) F9 Fuse G10 Battery G20 Generator K10 Starter relay with main fuse K11 Start auxiliary relay M10 Starter motor T20 Voltage regula tor X291 Connector for accessory ground (term inal 31) ACC 1 (not assigned) X292 Connector for accessory plus (termina l 30 ) ACC 1 (not assigned)[...]

WIRING DIAGR AM 204 35.2 Page 2 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /1.B8 21 0 /1.F8 /3.F1 /3.B1 /7.C1 10A -F1 2 1 FJ/2 -X1 1 FJ/2 -X1 2 -K12 1 2 4 3 -K30 1 2 4 3 a EB/4 -X14 4 EB/4 -X15 4 -S11 BC/6 BC/6 3 5 6 1 4 2 AC/6 -X16 6 /1.A6 -A50 /5.A3 /3.A2 -P10 1 ED/32 -X34 1 AC/6 -X16 5 2 2 DJ/18 -X20 2 1 3 DJ/18 -X20 [...]

WIRING DIAGR AM 205 A11 EFI control unit A50 Alarm system (optional) F1 Fuse K12 Light relay K30 Power relay P10 Combination instru ment S11 Ignition/stee ring l ock S23 Emergency OFF switch, elec tric s tarter button X295 Diagnostics connector[...]

WIRING DIAGR AM 206 35.3 Page 3 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /2.F8 /4.F1 /4.F1 /4.F1 /2.B8 /4.B1 3 10 -E12 2 1 -P35 2 1 -P15 2 1 10A -F6 2 1 FJ/2 -X6 1 HI LO P.light FJ/2 -X6 2 1 b FF/1 -X24 1 8 FF/1 -X25 1 f g AD/12 -X23 5 b c c 1 BC/6 -X62 1 7 2 DI/2 -X66 1 DI/2 -X66 2 CJ/2 -X67 2 /2.A5 -P10 /5.A1 8 ED/32[...]

WIRING DIAGR AM 207 E11 Low beam E12 High beam F6 Fuse P10 Combination instru ment P15 Horn P35 Parking light S24 High beam/low beam switch, horn button, high beam flash er b utton, turn signal switch[...]

WIRING DIAGR AM 208 35.4 Page 4 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /3.F8 /3.F8 /5.F1 /5.F1 P 4 10 f b f b -B76 AK/2 AK/2 /3.F8 2 1 AH/2 /3.B8 /6.B1 -X26 1 AH/2 -X27 /5.B1 1 -B77 AK/2 AK/2 2 1 -P36 BG/3 BG/3 2 1 3 AJ/3 -X32 3 2 AJ/3 -X32 1 AH/2 -X27 2 AH/2 -X26 2 g c c FJ/2 -X7 1 15A -F7 2 1 FJ/2 -X7 2 g wh-gn wh-[...]

WIRING DIAGR AM 209 B76 Front brake light switch B77 Brake light switch, rear F7 Fuse P36 Brake/tail light[...]

WIRING DIAGR AM 210 35.5 Page 5 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / G /4.F8 5 10 /4.F8 /6.F1 -K20 2 1 -R10 1 2 -P45 2 CW/2 1 CW/2 -P41 1 CW/2 2 CW/2 -P46 2 CW/2 1 CW/2 -P42 1 R L CW/2 2 CW/2 AI/2 -X28 1 f /4.B8 AI/2 -X28 2 AH/2 -X29 1 AD/12 -X23 6 AH/2 -X29 2 CX/2 -X30 1 AD/12 -X23 3 /3.A2 -P10 /7.A1 9 ED/32 -X34 [...]

WIRING DIAGR AM 211 A50 Alarm system (optional) E60 Licence plate lamp K20 Turn signal relay P10 Combination instru ment P41 Turn signal, front left P42 Turn signal, front right P45 Turn signal, rear left P46 Turn signal, rear right R10 Diode S24 High beam/low beam switch, horn button, high beam flash er b utton, turn signal switch[...]

WIRING DIAGR AM 212 35.6 Page 6 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / M t° /5.F8 /4.B8 /7.F1 6 10 -M14 BL/2 BL/2 2 1 -B33 2 1 10A -F5 2 1 FJ/2 -X5 1 FJ/2 -X5 2 10A -F8 2 1 FJ/2 -X8 1 FJ/2 -X8 2 CD/2 -X10 1 CD/2 -X10 2 b c AV/2 -X33 1 AV/2 -X33 2 b CR/1 -X29 4 1 CR/1 -X293 1 /5.A3 -A50 /7.A5 15 16 9 15 DJ/18 -X20 16[...]

WIRING DIAGR AM 213 A50 Alarm system (optional) B33 Temperature s witch for r adiator fan B36 Alarm system switch (option al) F5 Fuse F8 Fuse M14 Radiator fan X293 Connector for accessory ground (term inal 31) ACC 2 (not assigned) X294 Connector for accessory plus (termina l 15 ) ACC 2 (not assigned)[...]

WIRING DIAGR AM 214 35.7 Page 7 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / M /2.C8 /6.F8 7 /8.F1 10 /10.F1 10A -F2 2 1 10A -F4 2 1 FJ/2 -X2 1 FJ/2 M -X4 1 FJ/2 -X4 2 FJ/2 -X2 2 -M13 2 1 d b DV/2 -X38 2 /2.A7 -A11 /8.A1 16 16 DV/2 -X38 1 19 19 35 36 1 1 1 DS/44 -X18 1 6 DS/44 -X18 6 h 11 5 5 11 12 28 28 12 17 21 21 17 20 [...]

WIRING DIAGR AM 215 A11 EFI control unit A12 EPT control unit A50 Alarm system (optional) F2 Fuse F3 Fuse F4 Fuse M13 Fuel pump M60 Motor drive P10 Combination instru ment X295 Diagnostics connector[...]

WIRING DIAGR AM 216 35.8 Page 8 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /7.F8 8 10 /9.E1 -M20 1 2 -M21 1 2 -M51 1 2 -R51 2 1 -B51 t° L 4 2 DY/4 3 1 DY/4 h DF/2 -X40 1 DW/2 -X42 1 DQ/2 -X43 1 FL/1 -X44 1 3 /7.A1 -P10 /9.A7 2 ED/32 -X34 2 -B70 AR/3 AR/3 1 3 2 AM/3 -X46 2 3 23 3 1 ED/32 -X34 23 AM/3 -X46 3 /7.A3 -A11 /9[...]

WIRING DIAGR AM 217 A11 EFI control unit B51 Lambda senso r (c ylinder 1) B70 Front wheel speed sens or M20 Fuel evaporation valve (USA version only) M21 Secondary air valve M51 Injector (cylinder 1) P10 Combination instru ment R51 Ignition coil (cylind er 1 )[...]

WIRING DIAGR AM 218 35.9 Page 9 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / 9 10 /10.E1 /8.E8 /10.E1 -B30 3 AM/3 1 2 AM/3 -B34 3rd 2nd N AR/3 2 3 1 -B26 1 4 5 3 2 6 t° -B12 2 1 /8.A1 -A11 /10.A1 26 AR/3 -X49 3 DS/44 -X18 26 32 31 10 32 1 31 2 DS/44 -X18 10 AM/3 -X50 3 /8.A7 -P10 /10.A7 11 ED/32 -X34 11 15 DS/44 -X18 15 A[...]

WIRING DIAGR AM 219 A11 EFI control unit B10 Throttle positio n se nsor circuit A B12 Intake air temperat ure s ensor B26 Rollover sens or B30 Side stand switch B31 Accelerator p osition sensor B34 Gear position sens or P10 Combination instru ment[...]

WIRING DIAGR AM 220 35.10 Page 10 of 10 (Duke) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / R 10 /7.F8 10 /9.E8 /9.E8 R p -B13 2 3 1 p -B41 3 2 1 1 DX/3 -X11 2 DX/3 -X11 3 -B38 1 AT/2 2 AT/2 t° t° -B21 2 1 3 -S55 2 1 -B37 1 2 AT/2 /9.A1 -A11 23 24 1 23 DS/44 -X18 24 AL/2 -X52 2 14 DP/3 -X53 3 DS/44 -X18 14 35 DS/44 -X18 35 b 44 20 DS[...]

WIRING DIAGR AM 221 A11 EFI control unit B13 Ambient air press ure s ensor B21 Engine coolan t tem perature sensor (cylinder 1) B32 Fuel level indicat or B37 Crankshaft po sition sensor B38 Clutch switch B41 Manifold abso lute p ressure sensor (cylinder 1) P10 Combination instru ment S55 Map ‑ Select Switch bl Black br Brown bu Blue gn Gr een gr [...]

WIRING DIAGR AM 222 35.11 Page 1 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / M U G 3 /2.B1 /2.F1 1 10 690 Duke R 2010 -M10 -K10 30A 4 1 2 3 0 2 T - 0 1 G - BI/2 EM/3 1 2 3 2 1 -G20 2 3 EN/3 1 -K11 2 1 3 4 1 AE/4 -X13 2 1 a AE/4 -X13 3 EB/4 -X19 4 4 b 1 0 3 X - 2 0 3 X - /2.A1 -A50 4 DJ/18 -X20 4 EB/4 -X19 3 1 /2.A7 -A11[...]

WIRING DIAGR AM 223 A11 EFI control unit A50 Alarm system (optional) F9 Fuse G10 Battery G20 Generator K10 Starter relay with main fuse K11 Start auxiliary relay M10 Starter motor T20 Voltage regula tor X291 Connector for accessory ground (term inal 31) ACC 1 (not assigned) X292 Connector for accessory plus (termina l 30 ) ACC 1 (not assigned)[...]

WIRING DIAGR AM 224 35.12 Page 2 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /1.B8 21 0 /1.F8 /3.F1 690 Duke R 2010 /3.B1 /7.C1 10A -F1 2 1 FJ/2 -X1 1 FJ/2 -X1 2 -K12 1 2 4 3 -K30 1 2 4 3 a EB/4 -X14 4 EB/4 -X15 4 -S11 BC/6 BC/6 3 5 6 1 4 2 AC/6 -X16 6 /1.A6 -A50 /5.A3 /3.A2 -P10 1 ED/32 -X34 1 AC/6 -X16 5 2 2 DJ/18 -X2[...]

WIRING DIAGR AM 225 A11 EFI control unit A50 Alarm system (optional) F1 Fuse K12 Light relay K30 Power relay P10 Combination instru ment S11 Ignition/stee ring l ock S23 Emergency OFF switch, elec tric s tarter button X295 Diagnostics connector[...]

WIRING DIAGR AM 226 35.13 Page 3 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /2.F8 /4.F1 /4.F1 /4.F1 /2.B8 /4.B1 3 10 690 Duke R 2010 -E12 2 1 -P35 2 1 -P15 2 1 10A -F6 2 1 FJ/2 -X6 1 HI LO P.light FJ/2 -X6 2 1 b FF/1 -X24 1 8 FF/1 -X25 1 f g AD/12 -X23 5 b c c 1 BC/6 -X62 1 7 2 DI/2 -X66 1 DI/2 -X66 2 CJ/2 -X67 2 /2.A5[...]

WIRING DIAGR AM 227 E11 Low beam E12 High beam F6 Fuse P10 Combination instru ment P15 Horn P35 Parking light S24 High beam/low beam switch, horn button, high beam flash er b utton, turn signal switch[...]

WIRING DIAGR AM 228 35.14 Page 4 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /3.F8 /3.F8 /5.F1 /5.F1 P 4 10 690 Duke R 2010 f b f b -B76 AK/2 AK/2 /3.F8 2 1 AH/2 /3.B8 /6.B1 -X26 1 AH/2 -X27 /5.B1 1 -B77 AK/2 AK/2 2 1 -P36 BG/3 BG/3 2 1 3 AJ/3 -X32 3 2 AJ/3 -X32 1 AH/2 -X27 2 AH/2 -X26 2 g c c FJ/2 -X7 1 15A -F7 2 1 FJ/[...]

WIRING DIAGR AM 229 B76 Front brake light switch B77 Brake light switch, rear F7 Fuse P36 Brake/tail light[...]

WIRING DIAGR AM 230 35.15 Page 5 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / G /4.F8 5 10 /4.F8 /6.F1 690 Duke R 2010 -K20 2 1 -R10 1 2 -P45 2 CW/2 1 CW/2 -P41 1 CW/2 2 CW/2 -P46 2 CW/2 1 CW/2 -P42 1 R L CW/2 2 CW/2 AI/2 -X28 1 f /4.B8 AI/2 -X28 2 AH/2 -X29 1 AD/12 -X23 6 AH/2 -X29 2 CX/2 -X30 1 AD/12 -X23 3 /3.A2 -P10 [...]

WIRING DIAGR AM 231 A50 Alarm system (optional) E60 Licence plate lamp K20 Turn signal relay P10 Combination instru ment P41 Turn signal, front left P42 Turn signal, front right P45 Turn signal, rear left P46 Turn signal, rear right R10 Diode S24 High beam/low beam switch, horn button, high beam flash er b utton, turn signal switch[...]

WIRING DIAGR AM 232 35.16 Page 6 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / M t° /5.F8 /4.B8 /7.F1 6 10 690 Duke R 2010 -M14 BL/2 BL/2 2 1 -B33 2 1 10A -F5 2 1 FJ/2 -X5 1 FJ/2 -X5 2 10A -F8 2 1 FJ/2 -X8 1 FJ/2 -X8 2 CD/2 -X10 1 CD/2 -X10 2 b c AV/2 -X33 1 AV/2 -X33 2 b CR/1 -X29 4 1 CR/1 -X293 1 /5.A3 -A50 /7.A5 15 16[...]

WIRING DIAGR AM 233 A50 Alarm system (optional) B33 Temperature s witch for r adiator fan B36 Alarm system switch (option al) F5 Fuse F8 Fuse M14 Radiator fan X293 Connector for accessory ground (term inal 31) ACC 2 (not assigned) X294 Connector for accessory plus (termina l 15 ) ACC 2 (not assigned)[...]

WIRING DIAGR AM 234 35.17 Page 7 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / M /2.C8 /6.F8 7 /8.F1 10 /10.F1 690 Duke R 2010 10A -F2 2 1 10A -F4 2 1 FJ/2 -X2 1 FJ/2 M -X4 1 FJ/2 -X4 2 FJ/2 -X2 2 -M13 2 1 d b DV/2 -X38 2 /2.A7 -A11 /8.A1 16 16 DV/2 -X38 1 19 19 35 36 1 1 1 DS/44 -X18 1 6 DS/44 -X18 6 h 11 5 5 11 12 28 28[...]

WIRING DIAGR AM 235 A11 EFI control unit A12 EPT control unit A50 Alarm system (optional) F2 Fuse F3 Fuse F4 Fuse M13 Fuel pump M60 Motor drive P10 Combination instru ment X295 Diagnostics connector[...]

WIRING DIAGR AM 236 35.18 Page 8 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / /7.F8 8 10 /9.E1 690 Duke R 2010 -M20 1 2 -M21 1 2 -M51 1 2 -R51 2 1 -B51 t° L 4 2 DY/4 3 1 DY/4 h DF/2 -X40 1 DW/2 -X42 1 DQ/2 -X43 1 FL/1 -X44 1 3 /7.A1 -P10 /9.A7 2 ED/32 -X34 2 -B70 AR/3 AR/3 1 3 2 AM/3 -X46 2 3 23 3 1 ED/32 -X34 23 AM/3 -[...]

WIRING DIAGR AM 237 A11 EFI control unit B51 Lambda senso r (c ylinder 1) B70 Front wheel speed sens or M20 Fuel evaporation valve (USA version only) M21 Secondary air valve M51 Injector (cylinder 1) P10 Combination instru ment R51 Ignition coil (cylind er 1 )[...]

WIRING DIAGR AM 238 35.19 Page 9 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / 9 10 /10.E1 /8.E8 /10.E1 690 Duke R 2010 -B30 3 AM/3 1 2 AM/3 -B34 3rd 2nd N AR/3 2 3 1 -B26 1 4 5 3 2 6 t° -B12 2 1 /8.A1 -A11 /10.A1 26 AR/3 -X49 3 DS/44 -X18 26 32 31 10 32 1 31 2 DS/44 -X18 10 AM/3 -X50 3 /8.A7 -P10 /10.A7 11 ED/32 -X34 11[...]

WIRING DIAGR AM 239 A11 EFI control unit B10 Throttle positio n se nsor circuit A B12 Intake air temperat ure s ensor B26 Rollover sens or B30 Side stand switch B31 Accelerator p osition sensor B34 Gear position sens or P10 Combination instru ment[...]

WIRING DIAGR AM 240 35.20 Page 10 of 10 (Duke R) E D C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 / R 10 /7.F8 10 /9.E8 /9.E8 R 690 Duke R 2010 p -B13 2 3 1 p -B41 3 2 1 1 DX/3 -X11 2 DX/3 -X11 3 -B38 1 AT/2 2 AT/2 t° t° -B21 2 1 3 -S55 2 1 -B37 1 2 AT/2 /9.A1 -A11 23 24 1 23 DS/44 -X18 24 AL/2 -X52 2 14 DP/3 -X53 3 DS/44 -X18 14 35 DS/44 [...]

WIRING DIAGR AM 241 A11 EFI control unit B13 Ambient air press ure s ensor B21 Engine coolan t tem perature sensor (cylinder 1) B32 Fuel level indicat or B37 Crankshaft po sition sensor B38 Clutch switch B41 Manifold abso lute p ressure sensor (cylinder 1) P10 Combination instru ment S55 Map ‑ Select Switch bl Black br Brown bu Blue gn Gr een gr [...]

SUBSTAN CES 242 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standard (see specificat ions on the cont ainer) and that possesses the corre- sponding properties. KTM recomm ends Castrol and Mot orex ® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPE R DOT 4 Motorex ® ?[...]

SUBSTAN CES 243 Fork oil (SAE 5) According to – SAE ( p. 25 9) ( SAE 5 ) Guideline – Use only oils that comply with the specified standards (see specificatio ns on the contai ner) and t hat possess the corresponding properties. KTM recommends Motorex ® products. Supplier Motorex ® – Racing Fork Oil Hydraulic fluid (15) According to – ISO [...]

AUXILIAR Y SUBSTANCES 244 Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean 611 Chain lube for road use Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Lube 622 Strong Cleaning and preservi ng materials for metal, rubbe r and plastic Guideline – KTM recommends Motor[...]

AUXILIAR Y SUBSTANCES 245 Lubricant (T152) Guideline – KTM recommends Bel ‑ Ray ® products. Supplier Bel ‑ Ray ® – Molylube ® Anti ‑ Seize Lubricant (T159) Guideline – KTM recommends Bel ‑ Ray ® products. Supplier Bel ‑ Ray ® – MC ‑ 11 ® Lubricant (T625) Guideline – KTM recommends Molykote ® products. Supplier Molykote [...]

SPECIAL TOO LS 246 Bearing puller 400037-01 Art. no.: 15112017000 Insert for bearing puller 400125-01 Art. no.: 15112018100 Feature 18… 23 m m (0.7 1… 0.9 1 in) Bleed syringe 400058-01 Art. no.: 50329050000 Circlip pliers reverse 400059-01 Art. no.: 51012011000 Extractor 400073-01 Art. no.: 58429009000[...]

SPECIAL TOO LS 247 Tool for inner bearing race 400082-01 Art. no.: 58429037043 Mounting sleeve 400095-01 Art. no.: 58529005000 Valve spring compres sor 400101-01 Art. no.: 59029019000 Limit plug gauge 400104-01 Art. no.: 59029026006 Extractor 400105-01 Art. no.: 59029033000[...]

SPECIAL TOO LS 248 Feeler gauge 2 5 20 30 15 10 1 2 5 3 5 400110-01 Art. no.: 59029041100 Hose clamp pliers 400142-01 Art. no.: 60029057000 Pliers for spring-load ed band-type clamp 400085-01 Art. no.: 60029057100 Rear wheel stand 500077-01 Art. no.: 61029055100 Adapter 500079-01 Art. no.: 61029055110[...]

SPECIAL TOO LS 249 Front wheel stand 500078-01 Art. no.: 61029055300 Testing hose 201314-01 Art. no.: 61029093000 Pressure testing tool 400149-01 Art. no.: 61029094000 Engine work stand 200306-01 Art. no.: 61229001000 Work stand 400151-01 Art. no.: 62529055000[...]

SPECIAL TOO LS 250 Support for engine work sta nd 400153-01 Art. no.: 75012001060 Holder for engine work stan d 400154-01 Art. no.: 75012001070 Piston assembly ring 400156-01 Art. no.: 75029015102 Extractor 400157-01 Art. no.: 75029021000 Assembly screws 400158-01 Art. no.: 75029033000[...]

SPECIAL TOO LS 251 Mortise key 400159-01 Art. no.: 75029034000 Piston pin lock ring insert 400160-01 Art. no.: 75029035000 Work stand adapter 400161-01 Art. no.: 75029036000 Push-in drift 500163-01 Art. no.: 75029044010 Push-in drift 500162-01 Art. no.: 75029044020[...]

SPECIAL TOO LS 252 Pressing device for cran kshaft, complete 400185-01 Art. no.: 75029047000 Upper part, pressing -out tool 400186-01 Art. no.: 75029047050 Under part, pressing -out tool 400187-01 Art. no.: 75029047051 Extractor 400162-01 Art. no.: 75029048000 Clamping plate 400163-01 Art. no.: 75029050000[...]

SPECIAL TOO LS 253 Push-out drift 400164-01 Art. no.: 75029051000 Floor jack attachmen t 400184-01 Art. no.: 75029055000 Mounting sleeve 400165-01 Art. no.: 75029080000 Gear segment 400068-01 Art. no.: 75029081000 Protection cover 400167-01 Art. no.: 75029090000[...]

SPECIAL TOO LS 254 Holding spanner 400168-01 Art. no.: 75029091000 Spark plug wrench 400170-01 Art. no.: 75029172000 Oil pressure adapter 400176-01 Art. no.: 77329006000 Engine blocking screw 400177-01 Art. no.: 77329010000 Release device for timin g chain tensioner 400181-01 Art. no.: 77329051000[...]

SPECIAL TOO LS 255 Valve spring mounting de vice 500165-01 Art. no.: 78029060000 Hook wrench 301085-01 Art. no.: T106S Depth micrometer 300577-10 Art. no.: T107S Pin 201235-10 Art. no.: T120 Pressing tool 200583-10 Art. no.: T1206[...]

SPECIAL TOO LS 256 Pressing tool 200585-01 Art. no.: T1207S Vacuum pump 200273-10 Art. no.: T1240S Pressing tool 200584-01 Art. no.: T129 Protecting sleeve 200635-10 Art. no.: T1401 Gripping tool 200639-10 Art. no.: T14026S1[...]

SPECIAL TOO LS 257 Assembly tool 200634-10 Art. no.: T1402S Open-end wrench 200640-10 Art. no.: T14032 Clamping stand 200637-10 Art. no.: T1403S Mounting sleeve 300569-10 Art. no.: T1515 Hook wrench 200899-10 Art. no.: T157S[...]

SPECIAL TOO LS 258 Nitrogen filling tool 300574-10 Art. no.: T170S1[...]

STANDAR DS 259 JASO T903 MA Different technical develop ment directions required a new specification for 4-stroke motor cycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycl es be cause there was no s eparate motorcycle specifi- cation. Whereas long service intervals are deman ded[...]

INDEX 260 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air filter installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Alternator stator winding, checking . . . . . . . . . . . . . . . . . . . . . 1[...]

INDEX 261 spacer, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 spark plug, removing . . . . . . . . . . . . . . . . . . . . . . . . 1 01 starter drive, removing . . . . . . . . . . . . . . . . . . . . . . . 106 starter motor, removing . . . . . . . . . . . . . . . . . . . . . . . 98 thermostat, removing . . . . . . . . . . . . [...]

INDEX 262 Fuel tank installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 reinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fuel, oils, etc. [...]

INDEX 263 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185-186 engine - tolerance, wear limits . . . . . . . . . . . . . . 187-188 engine tightening torques . . . . . . . . . . . . . . . . . 189-190 fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 shock absorber . . . . . . . . . . . . . . . . . .[...]

*320 6084 en* 3206084en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 02/2010 Photo: Mitterbauer[...]