30/engine

Transcription

30/engine
REPAIR MANUAL 2008
450‘EXC-R‘EU
450‘EXC-R‘AUS/UK
450‘EXC-R‘SIX‘DAYS
450‘EXC-R‘USA
450‘XCR-W‘USA
450‘XCR-W‘ZA
530‘EXC-R‘EU
530‘EXC-R‘AUS/UK
530‘EXC-R‘SIX‘DAYS
530‘EXC-R‘USA
530‘XCR-W‘USA
530‘XCR-W‘ZA
ART. NO. 3206054en
INTRODUCTION
1
,1752'8&7,21
Read the repair manual before beginning work.
Only use ORGINAL‘KTM SPARE PARTS.
The engine 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. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified
here. It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes
that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS
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&217(176
MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES ............................................................ 7
MOTORCYCLE..................................................................... 8
Jacking up the motorcycle ................................................ 8
Removing the motorcycle from the work stand.................... 8
01/FORK, TRIPLE CLAMP.................................................... 9
Fork part number............................................................. 9
Adjusting spring preload of the fork................................... 9
Adjusting compression damping of fork ............................. 9
Adjusting rebound damping of fork.................................. 10
Cleaning dust boots of fork legs ...................................... 10
Removing the fork legs................................................... 11
Installing the fork legs ................................................... 11
Bleeding fork legs.......................................................... 12
Removing the fork protector............................................ 12
Installing the fork protector ............................................ 13
Loosening the fork protection.......................................... 13
Positioning the fork protection ........................................ 13
Removing the lower triple clamp (EXC-R‘SIX‘DAYS,
XCR-W‘USA) ................................................................. 13
Installing the lower triple clamp (EXC-R‘SIX‘DAYS,
XCR-W‘USA) ................................................................. 14
Removing the lower triple clamp (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA) ......................... 15
Installing the lower triple clamp (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA) ......................... 15
Fork offset (EXC-R‘SIX‘DAYS, XCR-W‘USA) ...................... 16
Setting the fork offset (EXC-R‘SIX‘DAYS, XCR-W‘USA) ...... 16
Checking play of steering head bearing ............................ 16
Adjusting play of steering head bearing
(EXC-R‘SIX‘DAYS, XCR-W‘USA) ...................................... 17
Adjusting play of steering head bearing (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA) ......................... 17
Greasing the steering head bearing.................................. 18
03/FRAME........................................................................ 19
Removing the engine sprocket cover................................ 19
Installing the engine sprocket cover................................. 19
04/SHOCK ABSORBER, SWINGARM................................... 20
Shock absorber part number........................................... 20
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 20
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 20
Adjusting rebound damping of the shock absorber ............ 21
Measuring rear wheel sag unloaded ................................. 21
Checking static sag of the shock absorber ........................ 22
Checking the riding sag of the shock absorber .................. 22
Adjusting spring preload of the shock absorber ................. 22
Adjusting riding sag ....................................................... 23
Removing the shock absorber ......................................... 23
Installing shock absorber................................................ 24
05/EXHAUST .................................................................... 25
Removing main silencer ................................................. 25
Fitting the main silencer ................................................ 25
Removing the manifold .................................................. 25
Installing the manifold ................................................... 25
06/AIR FILTER.................................................................. 26
Dismounting the air filter box lid..................................... 26
Installing the air filter box lid.......................................... 26
Removing the air filter ................................................... 26
Installing the air filter .................................................... 26
Cleaning air filter........................................................... 27
Removing the carburetor connection boot ........................
Installing the carburetor connection boot .........................
07/FUEL TANK, SEAT, TRIM..............................................
Opening filler cap..........................................................
Closing filler cap ...........................................................
Removing the seat .........................................................
Mounting the seat .........................................................
Dismounting the fuel tank ..............................................
Installing the fuel tank...................................................
Fuel tap........................................................................
08/MASK, FENDER ...........................................................
Dismounting the front fender ..........................................
Installing the front fender...............................................
Removing headlight mask with headlight (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA,
XCR-W‘ZA)....................................................................
Refitting the headlight mask with the headlight
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS,
EXC-R‘USA, XCR-W‘ZA) .................................................
Dismount the start number plate (XCR-W‘USA) ................
Fitting the start number plate (XCR-W‘USA).....................
09/FRONT WHEEL ............................................................
Removing front wheel ....................................................
Fitting front wheel .........................................................
Checking brake discs .....................................................
Removing the front brake disc ........................................
Installing the front brake disc .........................................
Tire condition checking..................................................
Checking tire air pressure...............................................
Checking spoke tension..................................................
10/REAR WHEEL ..............................................................
Removing rear wheel......................................................
Fitting rear wheel ..........................................................
Removing the rear brake disc..........................................
Installing the rear brake disc ..........................................
Checking the chain tension when fitting rear wheel...........
Adjusting chain tension - fitting rear wheel ......................
Checking the chain tension ............................................
Adjusting chain tension - after checking ..........................
Adjusting the chain tension ............................................
Adjusting chain guide ....................................................
Checking the rear sprocket / engine sprocket for wear .......
Checking chain wear ......................................................
Checking chain dirt .......................................................
Cleaning the chain.........................................................
11/WIRING HARNESS, BATTERY .......................................
Removing a fuse............................................................
Replacing the fuse.........................................................
Removing the battery .....................................................
Installing the battery......................................................
Recharging the battery ...................................................
13/BRAKE SYSTEM...........................................................
Checking the front brake linings......................................
Removing the front brake linings.....................................
Installing the front brake linings .....................................
Changing the front brake linings .....................................
Adjusting basic position of handbrake lever (Every XCR-W
models) ........................................................................
Checking free play of hand brake lever.............................
Adjusting free travel of handbrake lever (Every EXC-R
models) ........................................................................
Checking the front brake fluid level .................................
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CONTENTS
Add front brake fluid......................................................
Changing the front brake fluid ........................................
Checking rear brake linings ............................................
Removing the rear brake linings ......................................
Installing the rear brake linings.......................................
Changing the rear brake linings.......................................
Checking free play of foot brake lever ..............................
Adjusting basic position of footbrake lever .......................
Checking rear brake fluid level........................................
Adding rear brake fluid ..................................................
Changing the rear brake fluid..........................................
14/LIGHT SYSTEM, INSTRUMENTS ...................................
Adjusting speedometer functions ....................................
Setting kilometers or miles .............................................
Setting the clock ...........................................................
30/ENGINE.......................................................................
Removing the engine .....................................................
Installing the engine ......................................................
30/DISASSEMBLING ENGINE ............................................
Preparations..................................................................
Draining the engine oil...................................................
Removing the oil filter....................................................
Draining gear oil, cleaning gear oil screen ........................
Removing the starter engine ...........................................
Removing the valve cover ...............................................
Removing the shift lever.................................................
Removing the spark plug ................................................
Removing the generator cover .........................................
Setting the engine to ignition top dead center ..................
Removing the timing chain tensioner...............................
Removing the camshaft..................................................
Removing the cylinder head............................................
Removing the piston ......................................................
Removing the rotor ........................................................
Removing the balance weight .........................................
Removing the timing chain guide rail ..............................
Removing the timing chain tensioning rail........................
Removing the timing chain securing guide .......................
Removing the timing chain.............................................
Removing the ignition pulse generator .............................
Removing the suction pump ...........................................
Removing the kickstarter................................................
Removing the water pump cover .....................................
Removing the clutch cover .............................................
Removing the clutch discs..............................................
Removing the primary gear nut .......................................
Removing the outer clutch hub .......................................
Removing the balancer shaft ..........................................
Removing the torque limiter ...........................................
Removing the starter idler gear .......................................
Removing the kickstarter shaft........................................
Removing the kickstarter idler gear .................................
Removing the shift shaft ................................................
Removing the shift drum locating....................................
Removing the locking lever.............................................
removing the oil pump gears...........................................
Removing the oil pumps.................................................
Removing the primary gear with the free-wheel-gear..........
Removing the left section of the engine case....................
Removing the shift rails .................................................
Removing the shift roller ................................................
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Removing the shift forks ................................................
Removing the transmission shaft.....................................
Removing the crankshaft................................................
30/ENGINE - WORK ON INDIVIDUAL PARTS.......................
Work on the right section of the engine case ....................
Work on the left section of the engine case ......................
removing the oil pressure regulator valve..........................
Checking the spring length of the oil pressure regulator
valve ............................................................................
Installing the oil pressure regulator valve .........................
Removing the crankshaft seal ring in the clutch cover .......
Fitting the crankshaft seal ring into the clutch cover .........
Removing the water pump ..............................................
Installing the water pump...............................................
Checking the balancer shaft ...........................................
Removing the timing chain sprocket................................
Installing the timing chain sprocket.................................
Changing the conrod bearing ..........................................
Checking the crankshaft run-out on the bearing pin ..........
Cylinder - Nikasil® coating..............................................
Checking/measuring the cylinder.....................................
Checking/measuring the piston .......................................
Checking the piston ring end gap ....................................
Checking piston/cylinder mounting clearance ...................
Checking the oil pumps for wear .....................................
Checking the lubrication system......................................
Disassembling the autodecompressor ..............................
Assembling the autodecompressor...................................
Checking the camshaft...................................................
Checking the timing assembly ........................................
Preparing the timing chain tensioner for installation .........
Removing the rocker arm................................................
Removing the valves ......................................................
Replacing the camshaft bearing ......................................
Checking the valves .......................................................
Checking the valve springs .............................................
Checking the lower valve spring retainer ..........................
Checking the cylinder head ............................................
Installing valves ............................................................
Installing the rocker arm ................................................
Checking the clutch.......................................................
Checking the shift mechanism ........................................
Preassembling the shift shaft..........................................
Dismantling the main shaft ............................................
Assembling the main shaft .............................................
Dismantling the countershaft..........................................
Assembling the countershaft...........................................
Checking the transmission..............................................
Checking electric starter operation ..................................
Removing the free-wheel ................................................
Checking the free-wheel .................................................
Installing the free-wheel.................................................
30/ASSEMBLING ENGINE .................................................
Installing the crankshaft.................................................
Installing the transmission shaft .....................................
Installing the shift forks .................................................
Installing the shift roller.................................................
Installing the shift rails ..................................................
Installing the left engine case .........................................
Installing the primary gear with the free-wheel-gear ..........
Installing the oil pumps .................................................
Installing the oil pump gears ..........................................
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CONTENTS
Installing the locking lever.............................................. 99
Installing the shift drum locating .................................... 99
Installing the shift shaft ................................................. 99
Installing the kickstarter idler gear ................................ 100
Installing the kickstarter shaft ...................................... 100
Installing the starter idler gear ...................................... 100
Installing the torque limiter .......................................... 100
Installing the balancer shaft ......................................... 101
Installing the outer clutch hub...................................... 101
Installing the primary gear nut ...................................... 101
Installing the clutch discs ............................................ 102
Installing the clutch cover ............................................ 102
Installing the water pump cover .................................... 103
Installing the kickstarter............................................... 103
Installing the suction pump .......................................... 103
Installing the ignition pulse generator............................ 104
Installing the timing chain............................................ 104
Installing the timing chain securing guide...................... 104
Installing the timing chain tensioning rail ...................... 104
Installing the timing chain guide rail ............................. 105
Installing the balance weight ........................................ 105
Installing the rotor ....................................................... 105
Installing the piston..................................................... 105
Installing the cylinder head .......................................... 107
Installing the camshaft ................................................ 108
Installing the timing chain tensioner ............................. 108
Checking the valve clearance ........................................ 109
Adjusting the valve clearance........................................ 109
Installing the generator cover........................................ 109
Installing the shift lever ............................................... 110
Installing the valve cover .............................................. 110
Installing the spark plug............................................... 110
Installing the starter motor ........................................... 111
Mounting oil filter........................................................ 111
Filling up with engine oil.............................................. 111
Filling up with gear oil ................................................. 112
Removing the engine from the universal mounting
rack ........................................................................... 112
31/CARBURETOR ........................................................... 113
Choke (EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA,
XCR-W) ...................................................................... 113
Choke (EXC-R‘EU) ....................................................... 113
Checking the choke Bowden cable routing (EXC-R‘EU).... 113
Checking the choke Bowden cable for play (EXC-R‘EU) ... 113
Adjusting the choke Bowden cable play (EXC-R‘EU)........ 113
Checking gas Bowden cable route ................................. 114
Checking play in the gas Bowden cable ......................... 114
Adjusting the gas Bowden cable play............................. 114
Removing the carburetor .............................................. 115
Disassembling the carburetor........................................ 115
Checking the carburetor components............................. 118
Checking/adjusting the accelerator pump....................... 118
Checking the choke slide.............................................. 119
Checking the jet needle................................................ 119
Checking the throttle slide............................................ 119
Checking the needle jet................................................ 120
Checking the float needle valve..................................... 120
Checking/adjusting the float level.................................. 120
Checking/adjusting the throttle slide opening ................. 120
Checking throttle valve sensor‘TPS ................................ 121
Adjusting the position of throttle valve sensor‘TPS .......... 121
Assembling the carburetor............................................ 122
4
Installing the carburetor ...............................................
Carburetor - adjusting idle ............................................
Emptying the carburetor float chamber ..........................
32/CLUTCH ....................................................................
Checking fluid level of hydraulic clutch .........................
Changing fluid level of hydraulic clutch .........................
33/TRANSMISSION.........................................................
Removing the engine sprocket ......................................
Installing the engine sprocket .......................................
35/WATER PUMP, COOLING SYSTEM ..............................
Checking antifreeze and coolant level ............................
Checking the coolant level............................................
Draining coolant ..........................................................
Refilling coolant ..........................................................
38/LUBRICATION SYSTEM ..............................................
Oil cycle .....................................................................
Checking engine oil level..............................................
Changing engine oil and oil filter, cleaning engine oil
screen ........................................................................
Draining engine oil, cleaning engine oil screen ...............
Removing the oil filter..................................................
Mounting oil filter........................................................
Filling up with engine oil..............................................
Topping up engine oil ..................................................
Checking the engine oil pressure...................................
Checking gear oil level .................................................
Changing gear oil, cleaning gear oil screen.....................
Draining gear oil, cleaning gear oil screen ......................
Filling up with gear oil .................................................
Topping up with gear oil...............................................
TROUBLESHOOTING.......................................................
TECHNICAL DATA - ENGINE ............................................
Capacity- engine oil .....................................................
Capacity - gear oil........................................................
Capacity - coolant........................................................
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE .........................................................................
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........
TECHNICAL DATA - CARBURETOR...................................
450‘EXC-R‘EU, 450‘EXC-R‘AUS/UK (3900I) .................
450‘EXC-R‘SIX‘DAYS, 450‘EXC-R‘USA, 450‘XCR-W
(3900L) .....................................................................
530‘EXC-R‘EU, 530‘EXC-R‘AUS/UK (3900J).................
530‘EXC-R‘SIX‘DAYS, 530‘EXC-R‘USA, 530‘XCR-W
(3900M) ....................................................................
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES.......................................................................
TECHNICAL DATA - CHASSIS ..........................................
Lighting equipment .....................................................
Tires ..........................................................................
Capacity - fuel.............................................................
TECHNICAL DATA - FORK................................................
TECHNICAL DATA - SHOCK ABSORBER ...........................
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......
CLEANING......................................................................
Cleaning motorcycle ....................................................
STORAGE .......................................................................
Storage.......................................................................
Putting into operation after storage ...............................
GREASING AND SERVICE TABLE .....................................
Important maintenance work to be carried out by an
authorized KTM workshop. ...........................................
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157
CONTENTS
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)..............
Important checks and maintenance work to be carried
out by the rider. ..........................................................
WIRING DIAGRAM ..........................................................
Wiring diagram (EXC-R‘EU) ..........................................
Wiring diagram (EXC-R‘AUS/UK)...................................
Wiring diagram (EXC-R‘USA) ........................................
Wiring diagram (EXC-R‘SIX‘DAYS).................................
Wiring diagram (XCR-W‘USA) .......................................
Wiring diagram (XCR-W‘ZA) ..........................................
SUBSTANCES.................................................................
AUXILIARY SUBSTANCES................................................
SPECIAL TOOLS..............................................................
STANDARDS...................................................................
INDEX ............................................................................
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184
185
MEANS OF REPRESENTATION
0($16 2) 5(35(6(17$7,21
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).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name
Identifies a specific name.
Name®
Identifies a protected name.
Brand™
Identifies a brand in merchandise traffic.
6
IMPORTANT NOTES
7
,03257$17 127(6
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss.
MOTORCYCLE
8
02725&<&/(
Jacking up the motorcycle
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥ
ಥ
Always place the vehicle on a firm and even surface.
Jack up the motorcycle underneath the engine. The wheels must no longer touch
the ground.
Work stand (54829055000) (
500074-01
ಥ
P. 178)
Secure the motorcycle against falling over.
Removing the motorcycle from the work stand
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥ
Always place the vehicle on a firm and even surface.
ಥ
Remove the motorcycle from the work stand.
ಥ
Remove the work stand.
01/FORK, TRIPLE CLAMP
9
)25. 75,3/( &/$03
Fork part number
The fork part number‘ is stamped on the inner side of the fork stub.
500082-10
Adjusting spring preload of the fork
ಥ
Turn adjusting screws counterclockwise until they stop.
Info
Make the same adjustment on both fork legs.
ಥ
Turn back clockwise the number of turns corresponding to the fork type.
Specification
Spring preload - Preload‘Adjuster (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCRW)
100025-10
Comfort
2‘turns
Standard
4‘turns
Sport
7‘turns
Spring preload - Preload‘Adjuster (EXC-R‘SIX‘DAYS)
Comfort
2‘turns
Standard
2‘turns
Sport
7‘turns
Info
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.
Adjusting compression damping of fork
Info
The hydraulic compression damping determines the fork suspension behavior.
ಥ
Remove protection covers‘.
ಥ
Turn adjusting screws‘ clockwise until they stop.
Info
The adjusting screws‘ are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
100020-10
01/FORK, TRIPLE CLAMP
10
ಥ
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Compression damping (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
Comfort
24‘clicks
Standard
20‘clicks
Sport
18‘clicks
Compression damping (EXC-R‘SIX‘DAYS)
Comfort
24‘clicks
Standard
22‘clicks
Sport
18‘clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
ಥ
Mount protection covers‘.
Adjusting rebound damping of fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
ಥ
Turn adjusting screws‘ clockwise until they stop.
Info
The adjusting screws‘ are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
ಥ
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Rebound damping (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
100019-10
Comfort
20‘clicks
Standard
18‘clicks
Sport
18‘clicks
Rebound damping (EXC-R‘SIX‘DAYS)
Comfort
20‘clicks
Standard
20‘clicks
Sport
18‘clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Cleaning dust boots of fork legs
ಥ
Jack up the motorcycle. (
ಥ
Loosen the fork protection. (
ಥ
Push dust boots‘ of both fork legs downwards.
P. 8)
P. 13)
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
500088-10
01/FORK, TRIPLE CLAMP
11
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake
discs.
ಥ
ಥ
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.
Universal oil spray (
P. 175)
ಥ
Press the dust boots back into their normal position.
ಥ
Remove excess oil.
ಥ
Position the fork protection. (
ಥ
Remove the motorcycle from the work stand. (
ಥ
Remove front wheel. (
ಥ
Remove screws‘ and take off clamp.
P. 13)
P. 8)
Removing the fork legs
P. 33)
ಥ
Remove cable clip‘, remove screw‘ and take off the brake caliper.
ಥ
Hang the brake caliper and the brake line loosely to the side.
500093-10
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ Loosen screw‘. Remove the fork leg on the left.
ಥ
Loosen screw‘. Remove the fork leg on the right.
500094-10
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ Loosen screw‘. Remove the fork leg on the left.
ಥ
Loosen screw‘. Remove the fork leg on the right.
100023-11
Installing the fork legs
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the fork legs.
Info
The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position the bleeder screw‘ to the front.
100021-10
01/FORK, TRIPLE CLAMP
12
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ Fully tighten screw‘.
Specification
Screw, top triple clamp
ಥ
M8
17‘Nm
(12.54‘lbf‘ft)
M8
12‘Nm
(8.85‘lbf‘ft)
M8
20‘Nm
(14.75‘lbf‘ft)
M8
15‘Nm
(11.06‘lbf‘ft)
Fully tighten screw‘.
Specification
Screw, bottom triple clamp
500094-11
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ Fully tighten screw‘.
Specification
Screw, top triple clamp
ಥ
Fully tighten screw‘.
Specification
Screw, bottom triple clamp
100023-10
ಥ
Position brake caliper, mount and tighten screws‘.
Specification
Screw, front brake caliper
M8
25‘Nm
(18.44‘lbf‘ft)
Loctite® 243™
ಥ
Fit cable clip‘.
ಥ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screws‘.
ಥ
Fit front wheel. (
ಥ
Jack up the motorcycle. (
ಥ
Remove bleeder screws‘ briefly.
Any excess pressure escapes from the interior of the fork.
ಥ
Mount and tighten bleeder screws.
ಥ
Remove the motorcycle from the work stand. (
ಥ
Remove the fork legs. (
ಥ
Remove screws‘ on the left fork leg. Remove the fork protector upwards.
ಥ
Remove the screws on the right fork leg. Remove the fork protector upwards.
P. 33)
500093-11
Bleeding fork legs
P. 8)
P. 8)
100021-10
Removing the fork protector
500105-10
P. 11)
01/FORK, TRIPLE CLAMP
13
Installing the fork protector
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the fork protection on the left fork leg. Mount and tighten screws‘.
Specification
Remaining screws, chassis
ಥ
M6
10‘Nm
(7.38‘lbf‘ft)
Position the fork protection on the right fork leg. Mount and tighten screws.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
500105-10
ಥ
Install the fork legs. (
ಥ
Remove screws‘ and take off clamp.
ಥ
Remove screws‘ on left fork leg. Push the fork protection downwards.
ಥ
Remove the screws on the right fork leg. Push the fork protection downwards.
ಥ
Position the fork protection on the left fork leg. Mount and tighten screws‘.
Specification
P. 11)
Loosening the fork protection
500087-11
Positioning the fork protection
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
ಥ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screws‘.
ಥ
Position the fork protection on the right fork leg. Mount and tighten screws.
Specification
Remaining screws, chassis
500087-10
M6
10‘Nm
(7.38‘lbf‘ft)
Removing the lower triple clamp (EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ
Remove the fork legs. (
P. 11)
(XCR-W‘USA)
ಥ Dismount the start number plate. (
P. 32)
(EXC-R‘SIX‘DAYS)
ಥ Remove the headlight mask with the headlight. (
P. 31)
ಥ
Dismount the front fender. (
ಥ
Remove screws‘ and hang the CDI control unit to the side.
P. 31)
Info
Do not unplug the CDI control unit.
ಥ
Remove screw‘. Remove screw‘, take off top triple clamp with the handlebar
and place it on one side.
Info
500099-10
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
01/FORK, TRIPLE CLAMP
14
ಥ
Remove o-ring‘. Remove protector ring‘.
ಥ
Remove the lower triple clamp with the steering stem.
ಥ
Remove the upper steering head bearing.
500100-10
Installing the lower triple clamp (EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ
Clean the bearing and sealing elements, check for damage, and grease.
Long-life grease (
ಥ
3
0
2
0
1
0
P. 175)
Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
Info
Check whether the top steering head seal‘ is correctly positioned.
ಥ
Push up protective ring‘ and o-ring‘.
ಥ
Position the upper triple clamp with the steering.
ಥ
Mount and tighten screw‘.
Specification
500098-10
Screw, top steering head
ಥ
M20x1,5
Position the clutch line, wiring harness and CDI control unit. Mount and tighten
screws‘.
Specification
Remaining screws, chassis
500099-11
ಥ
Install the front fender. (
M6
10‘Nm
(7.38‘lbf‘ft)
P. 31)
(XCR-W‘USA)
ಥ Fit the start number plate. (
P. 32)
(EXC-R‘SIX‘DAYS)
ಥ Refit the headlight mask with the headlight. (
ಥ
Install the fork legs. (
ಥ
Mount and tighten screw‘.
Specification
P. 31)
P. 11)
Screw, top steering stem
500103-10
10‘Nm
(7.38‘lbf‘ft)
M8
17‘Nm
(12.54‘lbf‘ft)
Loctite® 243™
ಥ
Check the cable harness, cable, brake and clutch line for free movement and free
laying.
ಥ
Check play of steering head bearing.
01/FORK, TRIPLE CLAMP
15
Removing the lower triple clamp (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ
Remove the fork legs. (
ಥ
Remove the headlight mask with the headlight. (
ಥ
Dismount the front fender. (
ಥ
Remove screws‘ and hang the CDI control unit to the side.
P. 11)
P. 31)
P. 31)
Info
Do not unplug the CDI control unit.
ಥ
Remove screw‘. Loosen screw‘. Take off top triple clamp with the handlebar
and place it on one side.
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
500149-10
ಥ
Remove protector ring‘.
ಥ
Remove the lower triple clamp with the steering stem.
ಥ
Remove the upper steering head bearing.
500150-10
Installing the lower triple clamp (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ
Clean the bearing and sealing elements, check for damage, and grease.
Long-life grease (
ಥ
2
0
1
0
P. 175)
Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
Info
Check whether the top steering head seal‘ is correctly positioned.
ಥ
Push on protective ring‘.
ಥ
Position the upper triple clamp with the steering.
ಥ
Mount and tighten screw‘.
Specification
500151-10
Screw, top steering head
ಥ
M20x1,5
Position the clutch line, wiring harness and CDI control unit. Mount and tighten
screws‘.
Specification
Remaining screws, chassis
500149-11
10‘Nm
(7.38‘lbf‘ft)
M6
ಥ
Install the front fender. (
ಥ
Refit the headlight mask with the headlight. (
ಥ
Install the fork legs. (
10‘Nm
(7.38‘lbf‘ft)
P. 31)
P. 11)
P. 31)
01/FORK, TRIPLE CLAMP
16
Tighten screw‘.
Specification
ಥ
Screw, top steering stem
M8
20‘Nm
(14.75‘lbf‘ft)
ಥ
Check the cable harness, cable, brake and clutch line for free movement and free
laying.
ಥ
Check play of steering head bearing.
100022-11
Fork offset (EXC-R‘SIX‘DAYS, XCR-W‘USA)
You can see the currently set offset if you remove screw‘.
The fork offset‘ has an impact on the handling of the vehicle. It is calculated from
the center of the fork leg to the center of the steering head bearing.
The fork offset can optionally be adjusted.
Marking‘ to the front gives greater stability on fast racetracks.
B
0
A
0
Fork offset
Front marking
18‘mm (0.71‘in)
Marking‘ to the rear (condition at delivery) gives better handling in bends.
Fork offset
Rear marking
1
0
20‘mm (0.79‘in)
400188-10
Setting the fork offset (EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ
Remove the lower triple clamp. (
P. 13)
ಥ
Remove screw‘. Remove the steering stem.
ಥ
Clean the parts and check for damage.
ಥ
Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten
screw‘.
Specification
Screw, bottom steering
head
ಥ
M20x1,5
Install the lower triple clamp. (
60‘Nm
(44.26‘lbf‘ft)
Loctite® 243™
P. 14)
500104-10
Checking play of steering head bearing
Info
If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can
be damaged after time.
ಥ
Jack up the motorcycle. (
P. 8)
01/FORK, TRIPLE CLAMP
17
ಥ
Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
»
400189-10
ಥ
If there is noticeable play present:
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ Adjust play of the steering head bearing. (
P. 17)
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ Adjust play of the steering head bearing. (
P. 17)
Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
»
If click positions are noticeable:
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ Adjust play of the steering head bearing. (
P. 17)
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ Adjust play of the steering head bearing. (
P. 17)
ಥ
ಥ
Check the steering head bearing and replace if required.
Remove the motorcycle from the work stand. (
P. 8)
Adjusting play of steering head bearing (EXC-R‘SIX‘DAYS, XCR-W‘USA)
ಥ
Jack up the motorcycle. (
P. 8)
ಥ
Loosen screw‘. Remove screw‘.
ಥ
Loosen and retighten screw‘.
Specification
Screw, top steering head
M20x1,5
10‘Nm
(7.38‘lbf‘ft)
ಥ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
ಥ
Fully tighten screw‘.
Specification
500103-11
Screw, top triple clamp
ಥ
17‘Nm
(12.54‘lbf‘ft)
Mount and tighten screw‘.
Specification
Screw, top steering stem
ಥ
M8
M8
17‘Nm
(12.54‘lbf‘ft)
Loctite® 243™
Check play of steering head bearing.
Adjusting play of steering head bearing (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
ಥ
Jack up the motorcycle. (
ಥ
Loosen screws‘ and‘.
ಥ
Loosen and retighten screw‘.
Specification
P. 8)
Screw, top steering head
M20x1,5
10‘Nm
(7.38‘lbf‘ft)
ಥ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
ಥ
Fully tighten screw‘.
Specification
100022-10
Screw, top triple clamp
ಥ
20‘Nm
(14.75‘lbf‘ft)
M8
20‘Nm
(14.75‘lbf‘ft)
Tighten screw‘.
Specification
Screw, top steering stem
ಥ
M8
Check play of steering head bearing.
01/FORK, TRIPLE CLAMP
Greasing the steering head bearing
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
Remove the lower triple clamp. ( P. 13)
Install the lower triple clamp. ( P. 14)
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
Remove the lower triple clamp. ( P. 15)
Install the lower triple clamp. ( P. 15)
18
03/FRAME
19
)5$0(
Removing the engine sprocket cover
ಥ
Remove screw‘.
ಥ
Remove screw‘. Take off the engine sprocket cover.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the engine sprocket cover. Mount and tighten screw‘.
Specification
500113-10
Installing the engine sprocket cover
Remaining screws, chassis
ಥ
25‘Nm
(18.44‘lbf‘ft)
M6
10‘Nm
(7.38‘lbf‘ft)
Mount and tighten screw‘.
Specification
Screw, clutch slave cylinder
500113-11
M8
04/SHOCK ABSORBER, SWINGARM
20
6+2&. $%625%(5 6:,1*$50
Shock absorber part number
The shock absorber part number‘ is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
500129-10
Adjusting high-speed compression damping of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock
absorber.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
ಥ
Turn the adjusting screw‘ clockwise with a ring wrench until it stops.
Info
Do not loosen nut‘!
ಥ
Turn back counterclockwise the number of turns corresponding to the shock absorber type.
Specification
Compression damping, high-speed
400208-10
Comfort
2‘turns
Standard
1.5‘turns
Sport
1‘turn
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting the low-speed compression damping of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock
absorber.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
ಥ
Turn the adjusting screw‘ clockwise with a screwdriver until it stops.
Info
Do not loosen nut‘!
400209-10
04/SHOCK ABSORBER, SWINGARM
ಥ
21
Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
Specification
Compression damping, low-speed
Comfort
18‘clicks
Standard
15‘clicks
Sport
12‘clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting rebound damping of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock
absorber.
ಥ
Turn the adjusting screw‘ clockwise until it stops.
Info
Do not loosen nut‘!
ಥ
Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
Specification
Rebound damping
Comfort
400210-10
24‘clicks
Standard
22‘clicks
Sport
20‘clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Measuring rear wheel sag unloaded
A
0
400220-10
ಥ
Jack up the motorcycle. (
ಥ
Measure the distance ಥ as vertical as possible ಥ between the rear axle and a fixed
point, for example, a mark on the side cover.
ಥ
Make a note of the value as measurement‘.
ಥ
Remove the motorcycle from the work stand. (
P. 8)
P. 8)
04/SHOCK ABSORBER, SWINGARM
22
Checking static sag of the shock absorber
A
0
ಥ
Measure distance‘ of rear wheel unloaded. (
ಥ
Ask someone to help you by holding the motorcycle upright.
ಥ
Measure the distance between the rear axle and the fixed point again.
ಥ
Make a note of the value as measurement‘.
P. 21)
Info
The static sag is the difference between measurements‘ and‘.
ಥ
Check the static sag.
Static sag
»
35‘mm (1.38‘in)
If the static sag is less or more than the specified value:
ಥ Adjust the spring preload of the shock absorber.
B
0
400221-10
Checking the riding sag of the shock absorber
A
0
ಥ
Measure distance‘ of rear wheel unloaded. (
ಥ
With another person holding the motorcycle, sit on the saddle with full protective
clothing in a normal sitting position (feet on footrests) and bounce up and down a
few times until the rear suspension levels out.
ಥ
The other person now has to measure the distance between the rear axle and a
fixed point.
ಥ
Make a note of the value as measurement‘.
P. 21)
Info
The riding sag is the difference between measurements‘ and‘.
ಥ
Check the riding sag.
Riding sag
»
C
105‘mm (4.13‘in)
If the riding sag differs from the specified measurement:
ಥ Adjust the riding sag. ( P. 23)
400222-10
Adjusting spring preload of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock
absorber.
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
ಥ
Remove shock absorber. (
ಥ
After removing the shock absorber, clean it thoroughly.
P. 23)
04/SHOCK ABSORBER, SWINGARM
2
1
23
ಥ
Loosen screw‘.
ಥ
Turn adjusting ring‘ until the spring is no longer under tension.
Hook wrench (T106S)
A
ಥ
Measure the overall spring length when not under tension.
ಥ
Tighten the spring by turning adjusting ring‘ to measurement‘.
Specification
Spring preload
Standard
9‘mm
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
ಥ
Tighten screw‘.
Specification
Screw, shock absorber adjusting ring
ಥ
Installing shock absorber. (
M6
5‘Nm (3.69‘lbf‘ft)
P. 24)
400216-10
Adjusting riding sag
ಥ
Remove shock absorber. (
ಥ
After removing the shock absorber, clean it thoroughly.
ಥ
Choose and fit a suitable spring.
Specification
P. 23)
Spring rate
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
69‘N/mm (394‘lb/in)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
72‘N/mm (411.13‘lb/in)
Weight of rider: 85… 95‘kg (187.39… 209.44‘lb.)
76‘N/mm (433.97‘lb/in)
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.
ಥ
Installing shock absorber. (
ಥ
Check the static sag of the shock absorber. (
P. 22)
ಥ
Check the riding sag of the shock absorber. (
P. 22)
ಥ
Adjust the rebound damping of the shock absorber.
P. 24)
Removing the shock absorber
500075-10
ಥ
Jack up the motorcycle. (
ಥ
Remove screw‘ and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
ಥ
Remove screw‘, push splash protector‘ to the side, and remove the shock absorber.
P. 8)
04/SHOCK ABSORBER, SWINGARM
24
Installing shock absorber
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Push splash protector‘ to the side and position the shock absorber. Mount and
tighten screw‘.
Specification
Screw, top shock absorber
ಥ
80‘Nm
(59.01‘lbf‘ft)
Loctite® 243™
M12
80‘Nm
(59.01‘lbf‘ft)
Loctite® 243™
Mount and tighten screw‘.
Specification
Screw, bottom shock absorber
500075-11
M12
Info
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 dissolve the Teflon coating, thereby drastically reducing the service life.
ಥ
Remove the motorcycle from the work stand. (
P. 8)
05/EXHAUST
25
(;+$867
Removing main silencer
Warning
Danger of burnsಗThe exhaust system gets very hot when the vehicle is driven.
ಥ
Allow the exhaust system to cool down. Do not touch hot components.
ಥ
Disconnect spring‘.
ಥ
Remove screws‘ and take off main silencer.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the main silencer. Mount and tighten screws‘.
Specification
400337-10
Fitting the main silencer
Remaining screws, chassis
ಥ
Reconnect spring‘.
ಥ
Remove shock absorber. (
ಥ
Remove the main silencer. (
M6
10‘Nm
(7.38‘lbf‘ft)
400337-11
Removing the manifold
P. 23)
P. 25)
ಥ
Remove screw‘.
ಥ
Remove the springs‘ and take off the manifold.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the manifold and mount the springs‘.
ಥ
Mount and tighten screw‘.
Specification
500076-10
Installing the manifold
Remaining screws, chassis
500076-11
ಥ
Fit the main silencer. (
ಥ
Installing shock absorber. (
M8
P. 25)
P. 24)
25‘Nm
(18.44‘lbf‘ft)
06/AIR FILTER
26
$,5 ),/7(5
Dismounting the air filter box lid
ಥ
Pull off the air filter box lid in area‘ to the side and remove to the front.
ಥ
Insert the air filter box lid into the rear area‘ and clip it into the front area‘.
400338-10
Installing the air filter box lid
400338-11
Removing the air filter
Note
Engine failureಗUnfiltered intake air has a negative effect on the service life of the engine.
ಥ
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ಥ
Dismount the air filter box lid. (
ಥ
Hang the air filter holder‘ out to the bottom and swing it to the side. Remove the
air filter with the air filter support.
ಥ
Remove the air filter from the air filter support.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the clean air filter onto the air filter support.
ಥ
Put in both parts together, position them and fix them with the air filter support‘.
P. 26)
500107-10
Installing the air filter
Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
ಥ
500107-10
Install the air filter box lid. (
P. 26)
06/AIR FILTER
27
Cleaning air filter
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
ಥ
Remove the air filter. (
ಥ
Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
P. 26)
Cleaning substance for foam air filter (
P. 175)
Info
Only press the air filter to dry it, never wring it out.
ಥ
Oil the dry air filter with a high/quality filter oil.
Oil for foam air filter (
P. 175)
ಥ
Clean the air filter box.
ಥ
Check carburetor connection boot for damage and tightness.
ಥ
Install the air filter. (
P. 26)
Removing the carburetor connection boot
ಥ
Remove the air filter. (
ಥ
Loosen the hose clip‘. Unhang the carburetor connection boot‘ from the filter
wall and remove it.
P. 26)
500108-10
Installing the carburetor connection boot
500108-11
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the carburetor connection boot‘ and hang it into the filter wall. Position
the hose clip‘ and tighten it.
ಥ
Install the air filter. (
P. 26)
07/FUEL TANK, SEAT, TRIM
28
)8(/ 7$1. 6($7 75,0
Opening filler cap
ಥ
Press release button‘, turn filler cap counterclockwise and lift it free.
ಥ
Replace the filler cap and turn clockwise until the release button‘ locks in place.
400199-10
Closing filler cap
Info
Run the fuel tank breather hose‘ without kinks.
400199-11
Removing the seat
ಥ
Remove screw‘. Lift up the seat at the rear, pull it back and then remove from
above.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of
the seat and simultaneously push it forwards.
ಥ
Make sure that the seat is correctly locked in.
ಥ
Mount and tighten the screw of the seat fixing.
Specification
500080-10
Mounting the seat
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
500068-01
Dismounting the fuel tank
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
Never fill up 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.
ಥ
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
07/FUEL TANK, SEAT, TRIM
29
Warning
Danger of poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
ಥ
Remove the seat. (
ಥ
Turn the handle‘ of the fuel tap to the OFF position. (Figure‘500137-10‘
ಥ
Pull off the fuel hose.
P. 28)
P. 30)
Info
Remaining fuel may run out of the fuel hose.
ಥ
Remove screws‘ with collar sleeve.
(Every EXC-R models)
ಥ Hang the horn and horn bracket to one side.
500157-10
ಥ
Remove screw‘ with collar sleeve.
ಥ
Remove the tube from the fuel tank vent line.
ಥ
Pull both spoilers to the side of the radiator bracket‘ and take the fuel tank away
upwards.
500066-10
500067-10
Installing the fuel tank
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
Never fill up 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.
ಥ
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
07/FUEL TANK, SEAT, TRIM
30
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the fuel tank and fit the two spoilers to the side of the radiator fixing.
ಥ
Make sure that no cables or Bowden cables are trapped or damaged.
ಥ
Mount the fuel tank vent hose.
ಥ
Fit and tighten screw‘ with collar sleeve.
Specification
500067-01
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
(Every EXC-R models)
ಥ Position horn with horn bracket.
500066-11
ಥ
Fit and tighten screws‘ with collar sleeve.
Specification
Remaining screws, chassis
ಥ
Connect fuel hose.
ಥ
Mount the seat. (
M6
10‘Nm
(7.38‘lbf‘ft)
P. 28)
500157-11
Fuel tap
The fuel tap is on the left of the fuel tank.
With the tap handle‘ on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
• Fuel supply closed OFF ಥ‘No fuel can flow from the tank to the carburetor.
• Fuel supply open ON ಥ‘Fuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.
• Reserve fuel supply open RES ಥ‘Fuel can flow from the tank to the carburetor. The
fuel tank empties completely.
500137-10
08/MASK, FENDER
31
0$6. )(1'(5
Dismounting the front fender
ಥ
Remove screws‘. Remove the front fender.
ಥ
Make sure that the distance bushings remain in place.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Make sure that the distance bushings are mounted in the fender.
ಥ
Position the front fender. Mount and tighten screws‘.
Specification
500092-10
Installing the front fender
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
Info
Ensure that there is contact between the holding lugs and the start number
plate or headlight mask.
500092-10
Removing headlight mask with headlight (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W‘ZA)
ಥ
Switch off all electrical equipment.
ಥ
Remove screw‘ and take off clamp.
ಥ
Loosen the rubber band‘. Push up the headlight mask and swing it forwards.
ಥ
Pull out the electric plug connector‘ and remove the headlight mask with the
headlight.
500155-10
500156-10
Refitting the headlight mask with the headlight (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA,
XCR-W‘ZA)
500156-11
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Connect the electric plug connector‘.
08/MASK, FENDER
32
ಥ
Position the headlight mask and fix it with the rubber band‘.
Info
Take care with the contact of the holding lug at the fender.
ಥ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screw‘.
ಥ
Check the headlamp setting.
500155-11
Dismount the start number plate (XCR-W‘USA)
ಥ
Remove screw‘ and take off clamp.
ಥ
Remove screw‘ with distance bushing. Remove the start number plate.
500101-10
Fitting the start number plate (XCR-W‘USA)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the start number plate. Fit and tighten screw‘ with distance bushing.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
Info
Take care with the contact of the holding lug at the fender.
500101-11
ಥ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screw‘.
09/FRONT WHEEL
33
)5217 :+((/
Removing front wheel
ಥ
Jack up the motorcycle. (
ಥ
Press the brake caliper by hand on to the brake disc in order to press back the
brake pistons.
P. 8)
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
500089-10
ಥ
Remove screw‘.
ಥ
Loosen screw‘.
ಥ
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
500084-10
Info
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 damaged.
500085-10
ಥ
Remove distance bushing‘.
500086-10
Fitting front wheel
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake discs.
ಥ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Clean and grease shaft seal rings‘ and bearing surface‘ of the distance bushings.
Long-life grease (
ಥ
500086-11
P. 175)
Fit the distance bushings.
09/FRONT WHEEL
34
ಥ
Lift the front wheel into the fork, position it, and insert the wheel spindle.
ಥ
Mount and tighten screw‘.
Specification
Screw, front wheel spindle
500084-11
M24x1,5
40‘Nm
(29.5‘lbf‘ft)
ಥ
Operate the hand brake lever several times until the brake pads are lying correctly
on the brake disc.
ಥ
Remove the motorcycle from the work stand. (
ಥ
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
ಥ
Fully tighten screw‘.
Specification
Screw, fork stub
P. 8)
M8
15‘Nm
(11.06‘lbf‘ft)
Checking brake discs
ಥ
Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement‘.
Info
A
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Wear limit of brake discs
400257-10
»
front
2.5‘mm (0.1‘in)
Rear
3.5‘mm (0.14‘in)
The brake disc thickness is less than the specified value.
ಥ Replace the brake disc.
Removing the front brake disc
ಥ
Remove front wheel. (
ಥ
Remove screws‘. Take off the brake disc.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Clean the contact surface of the brake disc.
ಥ
Position the brake disc with the label facing outward. Mount and tighten screws‘.
Specification
P. 33)
500106-10
Installing the front brake disc
Screw, front brake disc
ಥ
500106-10
Fit front wheel. (
P. 33)
M6
14‘Nm
(10.33‘lbf‘ft)
09/FRONT WHEEL
35
Tire condition checking
Info
Fit only tires approved by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be fitted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
ಥ
Examine the tires for cuts, foreign bodies and other damage.
ಥ
Check the depth of the tread.
»
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth: 싩‘2‘mm (싩‘0.08‘in)
If the minimum tread depth is insufficient:
ಥ Replace the tire(s).
Checking tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
ಥ
Remove dust cap.
ಥ
Check tire air pressure when tires are cold.
Tire air pressure off road
front
1‘bar (14.5‘psi)
Rear
1‘bar (14.5‘psi)
Road tire pressure (Every EXC-R models)
400241-01
»
ಥ
front
1.5‘bar (21.76‘psi)
Rear
2‘bar (29.01‘psi)
If the tire pressure does not meet specifications:
ಥ Correct tire pressure.
Mount dust cap.
Checking spoke tension
Info
A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
ಥ
To check spoke tension, tap each spoke with a screwdriver.
Specification
You should hear a high note.
Spoke nipple, front wheel
M4,5
5‘Nm (3.69‘lbf‘ft)
Spoke nipple, rear wheel
M5
5‘Nm (3.69‘lbf‘ft)
Info
400228-01
If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.
10/REAR WHEEL
36
5($5 :+((/
Removing rear wheel
ಥ
Jack up the motorcycle. (
ಥ
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
P. 8)
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
ಥ
Remove nut‘.
ಥ
Remove chain adjuster‘. Withdraw the wheel spindle‘ only enough to allow the
rear wheel to be pushed forward.
ಥ
Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
ಥ
Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swing arm.
Info
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 damaged.
400258-10
ಥ
Remove distance bushing‘.
400260-11
Fitting rear wheel
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake discs.
ಥ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Clean and grease shaft seal rings‘ and bearing surface‘ of the distance bushings.
Long-life grease (
P. 175)
ಥ
Fit the distance bushings.
ಥ
Lift the rear wheel into the swing arm, position it, and insert the wheel spindle‘.
ಥ
Put the chain on.
400260-10
400259-10
10/REAR WHEEL
37
ಥ
Position the chain adjuster‘. Fit nut‘, but do not tighten it yet.
ಥ
Check the chain tension when fitting rear wheel. (
ಥ
Make sure that the chain adjusters‘ are fitted correctly on the adjusting
screws‘.
ಥ
Tighten nut‘.
Specification
Nut, rear wheel spindle
P. 37)
M20x1,5
80‘Nm
(59.01‘lbf‘ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters‘ can be turned by 180°.
ಥ
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
ಥ
Remove the motorcycle from the work stand. (
ಥ
Remove the rear wheel. (
ಥ
Remove screws‘. Take off the brake disc.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Clean the contact surface of the brake disc.
ಥ
Position the brake disc with the label facing outward. Mount and tighten screws‘.
Specification
P. 8)
400225-12
Removing the rear brake disc
P. 36)
700075-10
Installing the rear brake disc
Screw, rear brake disc
ಥ
Fit the rear wheel. (
M6
14‘Nm
(10.33‘lbf‘ft)
P. 36)
700075-10
Checking the chain tension when fitting rear wheel
Warning
Danger of accidentsಗDanger caused by incorrect chain tension.
ಥ
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
10/REAR WHEEL
38
ಥ
Make sure that the chain adjusters are fitted correctly on the adjusting screws.
ಥ
Push the chain at the end of the chain sliding component upwards to measure
chain tension‘.
Info
The upper chain section‘ must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
400213-10
»
8… 10‘mm (0.31… 0.39‘in)
If the chain tension does not meet specifications:
ಥ Adjust the chain tension when fitting rear wheel. (
P. 38)
Adjusting chain tension - fitting rear wheel
ಥ
Loosen nuts‘.
ಥ
Adjust the chain tension by turning the adjusting screws‘ left and right.
Specification
Chain tension
8… 10‘mm (0.31… 0.39‘in)
Turn the adjusting screws‘ left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks‘.
The rear wheel is then correctly aligned.
ಥ
Tighten nuts‘.
400225-11
Checking the chain tension
Warning
Danger of accidentsಗDanger caused by incorrect chain tension.
ಥ
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ಥ
Jack up the motorcycle. (
ಥ
Push the chain at the end of the chain sliding component upwards to measure the
chain tension‘.
P. 8)
Info
The upper chain section‘ must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
»
400213-10
ಥ
8… 10‘mm (0.31… 0.39‘in)
If the chain tension does not meet specifications:
ಥ Adjusting chain tension - after checking. ( P. 39)
Remove the motorcycle from the work stand. (
P. 8)
10/REAR WHEEL
39
Adjusting chain tension - after checking
ಥ
Loosen nut‘.
ಥ
Loosen nuts‘.
ಥ
Adjust the chain tension by turning the adjusting screws‘ left and right.
Specification
Chain tension
8… 10‘mm (0.31… 0.39‘in)
Turn the adjusting screws‘ left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks‘.
The rear wheel is then correctly aligned.
ಥ
Tighten nuts‘.
ಥ
Make sure that the chain adjusters‘ are fitted correctly on the adjusting
screws‘.
ಥ
Tighten nut‘.
Specification
Nut, rear wheel spindle
M20x1,5
80‘Nm
(59.01‘lbf‘ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters‘ can be turned by 180°.
400225-13
Adjusting the chain tension
Warning
Danger of accidentsಗDanger caused by incorrect chain tension.
ಥ
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ಥ
Jack up the motorcycle. (
ಥ
Push the chain at the end of the chain sliding component upwards to measure
chain tension‘.
P. 8)
Info
The upper chain section‘ must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
400213-10
10/REAR WHEEL
40
ಥ
Loosen nut‘.
ಥ
Loosen nuts‘.
ಥ
Adjust the chain tension by turning the left and right adjusting screws‘.
Specification
Chain tension
8… 10‘mm (0.31… 0.39‘in)
Turn the left and right adjusting screws‘ so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks‘.
The rear wheel is then correctly aligned.
ಥ
Tighten nuts‘.
ಥ
Make sure that chain adjusters‘ are fitted correctly on the adjusting screws‘.
ಥ
Tighten nut‘.
Specification
Nut, rear wheel spindle
M20x1,5
80‘Nm
(59.01‘lbf‘ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
Chain adjusters‘ can be turned by 180°.
400225-10
ಥ
Remove the motorcycle from the work stand. (
ಥ
Remove screws‘ and‘. Take off the chain guide.
P. 8)
Adjusting chain guide
Conditions
Number of teeth: 싨‘44‘teeth
ಥ Insert nut‘ in hole‘. Position the chain guide.
ಥ
Mount and tighten screws‘ and‘.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
Conditions
Number of teeth: 싩‘45‘teeth
ಥ Insert nut‘ in hole‘. Position the chain guide.
ಥ
Mount and tighten screws‘ and‘.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
400252-10
Checking the rear sprocket / engine sprocket for wear
ಥ
Check the rear sprocket / engine sprocket for wear.
» If the rear sprocket / engine sprocket are worn:
ಥ Replace rear sprocket / engine sprocket.
Info
When fitting the chain joint, always make sure that the closed side
of the joint faces forward (riding direction).
The engine sprocket, rear sprocket and chain should always be replaced together.
400227-01
ಥ
Check that the chain guide is firmly seated and not worn.
10/REAR WHEEL
41
Checking chain wear
ಥ
Jack up the motorcycle. (
ಥ
Shift to neutral and pull the upper chain length with the specified tension‘.
Specification
P. 8)
Chain tension
A
0
ಥ
10… 15‘kg (22.05… 33.07‘lb.)
Measure distance‘ of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance‘ at the longest
chain section
»
272‘mm (10.71‘in)
If distance‘ is greater than the specified measurement:
ಥ Replace the chain.
Info
B
0
When you replace the chain, you should also replace the rear and
engine sprockets.
New chains wear out faster on old, worn sprockets.
1 2 3
16 17 18
ಥ
Remove the motorcycle from the work stand. (
P. 8)
400226-10
Checking chain dirt
ಥ
Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
ಥ Clean the chain. ( P. 41)
Cleaning the chain
Warning
Danger of accidentsಗOil or grease on the tires reduces their grip.
ಥ
Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake discs.
ಥ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
The service life of the chain depends largely on its maintenance.
ಥ
Clean the chain regularly and then treat with chain spray.
Chain cleaner (
P. 175)
Offroad chain spray (
P. 175)
11/WIRING HARNESS, BATTERY
42
:,5,1* +$51(66 %$77(5<
Removing a fuse
ಥ
Switch off all power-consuming components and switch off the engine.
ಥ
Dismount the air filter box lid. (
ಥ
Remove the protection cover‘.
P. 26)
Info
The fuse‘ is located in the starter relay‘ under the filter box cover.
ಥ
Remove the fuse‘.
400270-10
Replacing the fuse
Warning
Fire hazardಗThe electrical system can be overloaded by the use of incorrect fuses.
ಥ
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Info
A reserve fuse‘ is located in the starter relay.
Replace a burned-out fuse‘ only by an equivalent fuse.
ಥ
Refit the fuse.
Fuse‘(58011109110)
Info
400273-10
If the new fuse burns out, contact an authorized KTM workshop.
ಥ
Replace the protection cover.
ಥ
Install the air filter box lid. (
P. 26)
Removing the battery
Warning
Risk of injuryಗBattery acid and battery gases cause serious cauterization.
ಥ
Keep batteries out of the reach of children.
ಥ
Wear suitable protective clothing and goggles.
ಥ
Avoid contact with battery acid and battery gases.
ಥ
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ಥ
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
500069-10
ಥ
Switch off all power-consuming components and switch off the engine.
ಥ
Remove the seat. (
ಥ
Disconnect the negative (minus) cable‘ of the battery.
ಥ
Pull back the plus pole cover‘ and disconnect the positive (plus) cable of the battery.
ಥ
Hang the rubber band‘ out to the bottom.
ಥ
Lift the battery up.
P. 28)
11/WIRING HARNESS, BATTERY
43
Installing the battery
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Place the battery in the battery holder.
4Ah battery‘(YTX5L-BS) (
P. 150)
ಥ
Reconnect the rubber band‘.
ಥ
Attach the plus cable and replace the plus pole cover‘.
ಥ
Attach the minus cable‘.
ಥ
Mount the seat. (
P. 28)
500069-11
Recharging the battery
Warning
Risk of injuryಗBattery acid and battery gases cause serious cauterization.
ಥ
Keep batteries out of the reach of children.
ಥ
Wear suitable protective clothing and goggles.
ಥ
Avoid contact with battery acid and battery gases.
ಥ
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ಥ
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Warning
Environmental hazardಗComponents and battery acid are a danger to the environment.
ಥ
Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
ಥ
Switch off all power-consuming components and switch off the engine.
ಥ
Remove the seat. (
ಥ
Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics.
ಥ
Connect the battery charger to the battery. Switch on the battery charger.
P. 28)
Battery charger‘(58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the battery.
Info
Never remove the lid‘.
Charge the battery according to the instructions‘ on the battery casing.
400240-10
ಥ
Switch off the charger after charging. Disconnect the battery.
Specification
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use.
3‘months
11/WIRING HARNESS, BATTERY
ಥ
Mount the seat. (
44
P. 28)
13/BRAKE SYSTEM
45
%5$.( 6<67(0
Checking the front brake linings
ಥ
Check the brake linings for minimum thickness‘.
» Minimum thickness‘: 싩‘1‘mm (싩‘0.04‘in)
If the minimum thickness is less than specified:
ಥ Change the front brake linings.
ಥ
Press the brake caliper by hand on to the brake disc in order to press back the
brake pistons.
400235-10
Removing the front brake linings
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
500089-11
ಥ
Remove the locking split pins‘, withdraw the bolt‘, and take out the brake
pads.
ಥ
Remove cable clip‘. Remove screws‘ and take off brake caliper.
ಥ
Clean brake caliper and brake caliper support.
Installing the front brake linings
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake discs.
ಥ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsಗReduced braking due to use of non-approved brake linings.
ಥ
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
ಥ
Check the brake discs.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Check that leaf spring‘ in the brake caliper and sliding plate‘ in the brake
caliper support are seated correctly.
Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.
500091-10
ಥ
Fit the brake linings, insert bolt‘, and mount locking split pins‘.
ಥ
Position brake caliper, mount and tighten screws‘.
Specification
Screw, front brake caliper
500089-12
M8
25‘Nm
(18.44‘lbf‘ft)
Loctite® 243™
ಥ
Fit cable clip‘.
ಥ
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
13/BRAKE SYSTEM
46
Changing the front brake linings
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
Never user DOT‘5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT‘5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ಥ
Remove the front brake linings.
ಥ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ಥ
Remove screws‘.
ಥ
Remove cover‘ with membrane‘.
ಥ
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
ಥ
Install the front brake linings. (
ಥ
Add brake fluid to level‘.
Specification
Measurement of‘
Brake fluid DOT 5.1 (
P. 45)
5‘mm (0.2‘in)
P. 174)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400230-10
Adjusting basic position of handbrake lever (Every XCR-W models)
ಥ
Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw‘.
Info
Turn the adjusting screw clockwise to increase the distance between the
handbrake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the handbrake 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!
400196-12
ಥ
Check the free play of the hand brake lever. (
P. 47)
13/BRAKE SYSTEM
47
Checking free play of hand brake lever
Warning
Danger of accidentsಗBrake system failure.
ಥ
If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake
can fail due to overheating. Adjust free travel on hand brake lever according to specifications.
(Every XCR-W models)
ಥ Push the hand brake lever forwards and check free play.‘.
Free play of hand brake lever
»
싩‘3‘mm (싩‘0.12‘in)
If the free travel does not meet specifications:
ಥ adjust the basic position of handbrake lever. (
P. 46)
400196-11
(Every EXC-R models)
ಥ Push the hand brake to the handlebar and check free play‘.
Free play of hand brake lever
»
싩‘3‘mm (싩‘0.12‘in)
If the free travel does not meet specifications:
ಥ Adjust the free travel of the handbrake lever. (
P. 47)
400196-13
Adjusting free travel of handbrake lever (Every EXC-R models)
ಥ
Adjust the free travel of the handbrake lever with the adjustment screw‘.
Info
Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure 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!
400196-12
ಥ
Check the free play of the hand brake lever. (
ಥ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ಥ
Check the brake fluid level in the viewer‘.
» If the brake fluid is below the‘MIN mark:
ಥ Add front brake fluid.
P. 47)
Checking the front brake fluid level
400231-10
13/BRAKE SYSTEM
48
Add front brake fluid
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
Never user DOT‘5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT‘5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ಥ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ಥ
Remove screws‘.
ಥ
Remove cover‘ with membrane‘.
ಥ
Add brake fluid to level‘.
Specification
Measurement of‘
Brake fluid DOT 5.1 (
5‘mm (0.2‘in)
P. 174)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400230-10
Changing the front brake fluid
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from‘Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
Never user DOT‘5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT‘5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
13/BRAKE SYSTEM
49
ಥ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ಥ
Remove screws‘.
ಥ
Remove cover‘ with membrane‘.
ಥ
Extract the old brake fluid from the brake fluid reservoir with a syringe and add new
brake fluid.
Bleed syringe (50329050000) (
Brake fluid DOT 5.1 (
P. 177)
P. 174)
400378-10
ಥ
Pull off dust cap‘ and connect a commercially available suction device (workshop
equipment).
ಥ
Remove bleeder screw‘ and suck out the old brake fluid.
ಥ
During suction, ensure that the brake fluid reservoir is always sufficiently filled with
new brake fluid.
ಥ
Tighten the bleeder screw. Remove the suction device and attach the dust cap.
ಥ
Add brake fluid to level‘.
Specification
700069-10
Measurement of‘
Brake fluid DOT 5.1 (
5‘mm (0.2‘in)
P. 174)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the cover with the membrane. Mount and tighten the screws.
ಥ
Repeatedly activate the hand brake lever until a firm pressure point is reached.
400379-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
Checking rear brake linings
ಥ
Check the brake linings for minimum thickness‘.
» Minimum thickness‘: 싩‘1‘mm (싩‘0.04‘in)
If the minimum thickness is less than specified:
ಥ Change the rear brake linings.
ಥ
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
400238-10
Removing the rear brake linings
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
400236-10
ಥ
Remove locking split pins‘, withdraw bolt‘, and take out the brake pads.
ಥ
Clean the brake caliper and brake caliper support.
13/BRAKE SYSTEM
50
Installing the rear brake linings
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake discs.
ಥ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsಗReduced braking due to use of non-approved brake linings.
ಥ
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
ಥ
Check the brake discs.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Check that leaf spring‘ in the brake caliper and sliding plate‘ in the brake
caliper support are seated correctly.
Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.
500122-10
ಥ
Fit the brake linings, insert bolt‘, and mount locking split pins‘.
Info
Make sure that the decoupling plate‘ is mounted on the piston side of the
brake pad.
ಥ
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
400237-10
Changing the rear brake linings
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
Never user DOT‘5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT‘5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
13/BRAKE SYSTEM
51
ಥ
Remove the rear brake linings.
ಥ
Stand the vehicle upright.
ಥ
Remove screw cap‘ with membrane‘ and the O-ring.
ಥ
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
ಥ
Install the rear brake linings. (
ಥ
Add brake fluid to level‘.
Brake fluid DOT 5.1 (
400233-10
P. 50)
P. 174)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the screw cap with the membrane‘and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
Checking free play of foot brake lever
Warning
Danger of accidentsಗBrake system failure.
ಥ
If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake
can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.
ಥ
Disconnect spring‘.
ಥ
Move the foot brake lever backwards and forwards between the end stop and the
foot brake cylinder piston bracket and check free play‘.
Specification
Free play at foot brake lever
»
ಥ
3… 5‘mm (0.12… 0.2‘in)
If the free travel does not meet specifications:
ಥ Adjust the basic position of the footbrake lever. (
P. 51)
Reconnect spring‘.
500139-11
Adjusting basic position of footbrake lever
Warning
Danger of accidentsಗBrake system failure.
ಥ
If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake
can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.
ಥ
Disconnect spring‘.
ಥ
Loosen nut‘ and with push rod‘, turn it back until you have maximum free play.
ಥ
To adjust the basic position of the footbrake lever individually, lossen nut‘ and
turn screw‘ accordingly.
Info
The range of adjustment is limited.
ಥ
500154-10
Turn push rod‘ accordingly until you have free play‘. If necessary, adjust the
basic position of the footbrake lever.
Specification
Free play at foot brake lever
ಥ
Hold screw‘ and tighten nut‘.
Specification
Remaining nuts, chassis
ಥ
M8
30‘Nm
(22.13‘lbf‘ft)
M6
15‘Nm
(11.06‘lbf‘ft)
Hold push rod‘ and tighten nut‘.
Specification
Remaining nuts, chassis
ಥ
3… 5‘mm (0.12… 0.2‘in)
Reconnect spring‘.
13/BRAKE SYSTEM
52
Checking rear brake fluid level
ಥ
Stand the vehicle upright.
ಥ
Check the brake fluid level in the viewer‘.
» When in the viewer‘ an air bubble is visible:
ಥ Add rear brake fluid.
400234-10
Adding rear brake fluid
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from‘Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
Never user DOT‘5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT‘5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ಥ
Stand the vehicle upright.
ಥ
Remove screw cap‘ with membrane‘ and the O-ring.
ಥ
Add brake fluid to level‘.
Brake fluid DOT 5.1 (
P. 174)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the screw cap with the membrane‘and the O-ring.
Info
400233-10
Clean up overflowed or spilt brake fluid immediately with water.
Changing the rear brake fluid
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from‘Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
Never user DOT‘5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT‘5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
13/BRAKE SYSTEM
53
ಥ
Stand the vehicle upright.
ಥ
Remove screw cap‘ with membrane‘ and the O-ring.
ಥ
Extract the old brake fluid from the brake fluid reservoir with a syringe and add new
brake fluid.
Bleed syringe (50329050000) (
Brake fluid DOT 5.1 (
P. 177)
P. 174)
400380-10
ಥ
Pull off dust cap‘ and connect a commercially available suction device (workshop
equipment).
ಥ
Remove bleeder screw‘ and suck out the old brake fluid.
Info
During suction, ensure that the reservoir is always sufficiently filled with
new brake fluid.
ಥ
Tighten the bleeder screw. Remove the suction device and attach the dust cap.
ಥ
Add brake fluid to level‘.
700068-10
Brake fluid DOT 5.1 (
ಥ
P. 174)
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the screw cap with the membrane‘and the O-ring.
ಥ
Repeatedly activate the foot brake lever until a firm pressure point is reached.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400381-10
14/LIGHT SYSTEM, INSTRUMENTS
54
/,*+7 6<67(0 ,167580(176
Adjusting speedometer functions
Info
In the condition at delivery, only the SPEED‘/‘H display mode and SPEED‘/‘ODO are active.
Condition
The motorcycle is standing.
400318-01
ಥ
Press the button‘
display.
ಥ
Press the button‘ for 3 - 5 seconds.
The Setup menu opens and the active functions are displayed.
ಥ
Switch to the function you require by briefly pressing the button‘ .
The selected function flashes.
briefly and repeatedly until H appears at the bottom right of the
Activating a function
ಥ Press the button‘"+".
The icon remains in the display and the display changes to the next function.
Deactivating a function
ಥ Press the button‘"ಣ".
The icon disappears from the display and the display changes to the next
function.
ಥ
Activate or deactivate all functions accordingly.
ಥ
Press the button‘ for 3 - 5 seconds.
The settings are saved and the Setup menu 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 closed.
Setting kilometers or miles
Info
If you change the unit, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are deleted at the changeover.
Condition
The motorcycle is standing.
ಥ
Press the button‘
display.
ಥ
Press the button‘ for 3 - 5 seconds.
The Setup menu opens and the active functions are displayed.
ಥ
Press the button ‘
briefly and repeatedly until H appears at the bottom right of the
repeatedly until the Km/h / Mphdisplay flashes.
Setting Km/h
ಥ Press the button‘"+".
400329-01
Setting Mph
ಥ Press the button‘"ಣ".
ಥ
Press the button‘ for 3 - 5 seconds.
The settings are saved and the Setup menu 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 closed.
14/LIGHT SYSTEM, INSTRUMENTS
55
Setting the clock
Condition
The motorcycle is standing.
ಥ
Press the button ‘
the display.
ಥ
Press the button‘ for 3 - 5 seconds.
The hour display flashes.
briefly and repeatedly until CLK appears at the bottom right of
ಥ
Set the hour display with the button‘"+" and/or button‘"ಣ".
ಥ
Press the button‘ briefly.
The next segment of the display flashes and can be set.
ಥ
You can set the following segments in the same way as the hours by pressing the
button‘"+" and the button‘"ಣ".
400330-01
Info
The seconds can only be set to zero.
ಥ
Press the button‘ for 3 - 5 seconds.
The settings are saved and the Setup menu 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 closed.
30/ENGINE
56
(1*,1(
Removing the engine
ಥ
Drain the coolant. (
ಥ
Remove the carburetor. (
ಥ
Remove the engine sprocket. (
ಥ
Jack up the motorcycle. (
ಥ
Disconnect the negative (minus) cable of the battery.
ಥ
Remove screws‘. Remove the foot brake cylinder and hang it on one side without
tension.
P. 133)
P. 115)
P. 131)
P. 8)
Info
The brake line connection does not need to be disconnected.
To not kink the brake line. Do not damage the bellows on the foot brake
cylinder.
500116-10
ಥ
Detach spring‘ and take if off.
ಥ
Prop up the rear wheel. Remove screw‘.
ಥ
Remove nut‘.
ಥ
Remove the swingarm pivot. Remove the swingarm, shock absorber and rear wheel
together.
Info
Having an assistant is helpful in this step.
Ensure that the engine is adequately secured and will not fall over.
500117-10
ಥ
Remove the main silencer. (
ಥ
Remove screw‘.
ಥ
Remove springs‘ and take off the manifold.
ಥ
Undo hose clamps‘
. Take off the radiator hoses together.
ಥ
Undo hose clamps‘. Remove the radiator hoses together along with the thermostat.
P. 25)
500076-13
500118-10
500119-10
ಥ
Pull engine vent hose‘ from the valve cover and engine case.
ಥ
Pull off the spark plug connector.
30/ENGINE
57
ಥ
Remove the cable binder and disconnect all connectors of the engine wiring harness in area‘.
ಥ
Remove screws‘(1. Take off the slave cylinder of the clutch and hang it to one side.
Info
To not kink the clutch line.
Do not activate the clutch lever if the slave cylinder of the clutch has been
removed.
500120-10
ಥ
Take out the clutch push rod.
ಥ
Slide back cover‘(2. Remove the nut from the electrical connection on the starter
engine and take off the cable.
ಥ
Remove screws‘(3. Lift the engine out of the frame.
Info
Having an assistant is helpful in this step.
Ensure that the engine is adequately secured and will not fall over.
Protect the frame and attachments against damage.
Installing the engine
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the engine in the frame. Mount screws‘ but do not tighten them yet.
Info
Having an assistant is helpful in this step.
Ensure that the engine is adequately secured and will not fall over.
Protect the frame and attachments against damage.
ಥ
500120-11
Position the electrical connection on the starter engine. Mount and tighten the nut.
Slide on cover‘.
Specification
Remaining nuts, chassis
M6
ಥ
Insert the clutch push rod with the small diameter facing the clutch side.
ಥ
Position the slave cylinder of the clutch. Mount and tighten screws‘.
Specification
Screw, clutch slave cylinder
M6
10‘Nm
(7.38‘lbf‘ft)
ಥ
Attach all connectors of the engine wiring harness in area‘.
ಥ
Position the connectors, wiring harness and clutch line and fix them with cable
binders.
ಥ
Attach the spark plug connector.
ಥ
Attach the engine vent hose‘ on the valve cover and engine case.
ಥ
Attach the cooler hose with the thermostat. Position hose clamps‘ and tighten.
ಥ
Attach the cooler hoses. Position hose clamps‘ and tighten.
500119-11
500118-11
15‘Nm
(11.06‘lbf‘ft)
30/ENGINE
58
ಥ
Position the manifold and mount springs‘
.
ಥ
Mount and tighten screw‘.
Specification
Remaining screws, chassis
M8
25‘Nm
(18.44‘lbf‘ft)
ಥ
Fit the main silencer. (
ಥ
Position the swingarm, shock absorber and rear wheel together. Insert the swingarm
pivot.
P. 25)
500076-14
Info
Having an assistant is helpful in this step.
Ensure that the engine is adequately secured and will not fall over.
ಥ
Mount nut‘ and tighten.
Specification
Nut, swingarm pivot
500117-11
ಥ
M16x1,5
100‘Nm
(73.76‘lbf‘ft)
M10
60‘Nm
(44.26‘lbf‘ft)
Fully tighten screws‘.
Specification
Engine carrying screw
500121-10
ಥ
Position the shock absorber. Mount and tighten screw‘(1.
Specification
Screw, top shock absorber
M12
80‘Nm
(59.01‘lbf‘ft)
ಥ
Reconnect spring‘(2.
ಥ
Position the foot brake cylinder. Mount and tighten screws‘(3.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
500116-11
ಥ
Position the bellows on the foot brake cylinder.
ಥ
Connect the negative (minus) cable of the battery.
ಥ
Remove the motorcycle from the work stand. (
ಥ
Install the engine sprocket. (
ಥ
Install the carburetor. (
ಥ
Refill the coolant. (
ಥ
Make a short test ride.
ಥ
Check the engine for leakage.
ಥ
Check the engine oil level. (
ಥ
Check the gear oil level. (
ಥ
Check the cooling system for leakage.
ಥ
Check the coolant level. (
P. 131)
P. 125)
P. 133)
P. 134)
P. 138)
P. 132)
Loctite® 243™
P. 8)
30/DISASSEMBLING ENGINE
59
',6$66(0%/,1* (1*,1(
Preparations
ಥ
Thoroughly clean the outside of the engine and attach it to the universal mounting
rack using the special tool.
Engine holder (78029002000) (
P. 182)
Universal mounting rack (56012001000) (
P. 178)
ಥ
Place a container suitable for draining oil beneath the engine.
ಥ
Remove engine oil plug screen‘.
ಥ
Completely drain the engine oil.
ಥ
Remove screws‘. Take off oil filter cover‘ with the O-ring.
ಥ
Pull the oil filter insert‘ out of the oil filter casing.
700020-01
Draining the engine oil
700021-10
Removing the oil filter
700022-10
Circlip pliers reverse (51012011000) (
700023-10
Draining gear oil, cleaning gear oil screen
ಥ
700025-10
Remove the gear oil drain plug‘.
P. 177)
30/DISASSEMBLING ENGINE
60
ಥ
Plug - remove the gear oil screen‘.
ಥ
Completely drain the gear oil.
ಥ
Remove screws‘ and take off the starter engine.
ಥ
Remove screws‘. Take off the valve cover with the valve cover seal.
ಥ
Remove screw‘. Take off the shift lever.
ಥ
Remove the spark plug using the special tool.
700024-10
Removing the starter engine
200064-10
Removing the valve cover
700013-10
Removing the shift lever
700017-11
Removing the spark plug
Spark plug wrench (75029172000) (
700030-10
P. 181)
30/DISASSEMBLING ENGINE
61
Removing the generator cover
ಥ
Remove screws‘. Take off the generator cover.
ಥ
Remove centering pins‘. Take off generator cover seal‘ and dispose of it.
700011-10
700010-10
Setting the engine to ignition top dead center
ಥ
Align camshaft marking‘ with marking‘ on the cylinder head.
ಥ
Remove screw‘.
ಥ
Screw in special tool‘.
200063-10
200061-10
Crankshaft locking bolt (113080802) (
200062-10
P. 177)
30/DISASSEMBLING ENGINE
62
Removing the timing chain tensioner
ಥ
Remove screw‘. Take off seal ring‘.
ಥ
Pull out timing chain tensioner‘. Remove O-ring‘.
ಥ
Remove screw‘. Take off camshaft bracket‘.
ಥ
Pull the camshaft out of the bearing seats. Take the timing chain off of the
camshaft gear. Remove the camshaft.
ಥ
Remove screw‘.
ಥ
Alternately loosen screws‘ and remove them.
ಥ
Take off the cylinder head.
ಥ
Take off the dowels. Dispose of the cylinder head gasket.
ಥ
Slide the cylinder upward.
200074-10
Removing the camshaft
200076-10
200077-01
Removing the cylinder head
200082-10
Removing the piston
Info
Slide the cylinder up only as far as necessary to remove the piston pin.
200083-10
ಥ
Remove piston pin retainer‘.
ಥ
Remove the piston pin.
ಥ
Take off the cylinder with the piston.
ಥ
Slide the piston up and out of the cylinder.
Info
If no further work is necessary on the cylinder and piston, the piston can
remain in the cylinder.
30/DISASSEMBLING ENGINE
63
ಥ
Remove dowels‘ and cylinder base gasket‘.
ಥ
Remove nut‘ with the spring washer.
ಥ
Attach special tool‘ to the rotor. Apply counterpressure with the special tool and
pull off the rotor by turning in the screw.
200090-11
Removing the rotor
200100-10
Extractor (58012009000) (
P. 178)
200101-10
Removing the balance weight
ಥ
Bend open lock washer‘.
ಥ
Undo nut‘ and remove it. Remove the lock washer.
Info
Make sure that the crankshaft is blocked.
ಥ
Take off the balance weight.
ಥ
Remove screws‘. Remove timing chain guide rail‘ toward the top.
700040-10
Removing the timing chain guide rail
700006-10
30/DISASSEMBLING ENGINE
64
Removing the timing chain tensioning rail
ಥ
Remove screw‘. Remove the timing chain guide rail‘toward the top.
700005-10
Removing the timing chain securing guide
ಥ
Remove screws‘. Remove the timing chain securing guide.
ಥ
Take off the timing chain.
700026-10
Removing the timing chain
Info
Mark the direction of travel.
200108-12
Removing the ignition pulse generator
ಥ
Remove screws‘.
ಥ
Pull the cable support sleeve out of the engine case. Take off the ignition pulse
generator.
ಥ
Remove screws‘.
ಥ
Take off oil pump cover‘ of the suction pump.
200107-12
Removing the suction pump
200128-10
30/DISASSEMBLING ENGINE
ಥ
Remove internal rotor‘ with pin‘ and external rotor‘.
ಥ
Remove O-ring‘.
ಥ
Remove screw‘. Take off the kickstarter.
ಥ
Remove screws‘. Take off the water pump cover.
ಥ
Take off the water pump cover seal and dispose of it.
ಥ
Remove crankshaft fixation element‘.
ಥ
Remove screws‘. Take off the clutch cover.
ಥ
Take out dowels‘. Take off clutch cover seal‘ and dispose of it.
200129-10
Removing the kickstarter
200067-10
Removing the water pump cover
200071-10
Removing the clutch cover
700015-10
200073-12
65
30/DISASSEMBLING ENGINE
66
Removing the clutch discs
ಥ
Undo screws‘ and remove them with the washers and springs.
ಥ
Take off the pressure cap.
ಥ
Take out clutch discs‘ entirely.
ಥ
Block the outer clutch hub and primary gear using special tool‘.
200093-10
200094-11
Removing the primary gear nut
Gear segment (80029004000) (
P. 183)
Info
LH thread
ಥ
Remove nut.
ಥ
Take off the pressure piece.
ಥ
Bend open the lock washer.
ಥ
Apply counterpressure against the inner clutch hub using the special tool. Loosen
nut‘.
700041-10
Removing the outer clutch hub
Clutch holder (51129003000) (
P. 178)
ಥ
Remove the nut with the lock washer. Dispose of the lock washer.
ಥ
Take off inner clutch hub‘ and washer‘.
200095-10
Info
The washer usually sticks to the inner clutch hub.
ಥ
200096-10
Remove outer clutch hub‘.
30/DISASSEMBLING ENGINE
Removing the balancer shaft
ಥ
Pull balancer shaft‘ out of the bearing seats and remove it.
ಥ
Remove the screw with the washer. Take off torque limiter‘.
ಥ
Remove the lock ring. Take off the washer. Take off starter idler gear‘.
ಥ
Apply counterpressure to kickstarter spring‘. Remove screw‘.
ಥ
Remove spring hanger‘. Release tension on the kickstarter spring.
ಥ
Turn kickstarter shaft‘ counterclockwise and pull it out.
ಥ
Remove the lock ring. Take off the washer. Take off kickstarter idler gear‘.
700029-10
Removing the torque limiter
200120-11
Removing the starter idler gear
200121-12
Removing the kickstarter shaft
200110-10
Removing the kickstarter idler gear
200120-12
67
30/DISASSEMBLING ENGINE
68
Removing the shift shaft
ಥ
Press sliding plate‘ away from the shift drum locating. Remove shift shaft‘ with
the washer.
200109-10
Removing the shift drum locating
ಥ
Remove screw‘.
ಥ
Press locking lever‘ away from shift drum locating‘ and take off the shift drum
locating.
ಥ
Release the locking lever.
ಥ
Undo screw‘ and take off it together with locking lever‘, washer, sleeve and
spring.
ಥ
Remove lock washers‘.
ಥ
Take off washers‘.
ಥ
Take off oil pump gears‘.
ಥ
Remove pins‘.
200122-10
Removing the locking lever
200123-10
removing the oil pump gears
200124-10
200127-10
30/DISASSEMBLING ENGINE
69
Removing the oil pumps
ಥ
Remove screws‘.
ಥ
Take off oil pump covers‘ of the force pumps.
ಥ
Remove oil pump shaft‘ of the gear oil force pump together with pin‘, internal
rotor‘ and external rotor‘.
ಥ
Remove internal rotor‘
and external rotor‘ of the engine oil force pump.
200125-10
200126-10
Removing the primary gear with the free-wheel-gear
ಥ
Remove the primary gear and free-wheel-gear using the special tool.
Extractor (78029033100) (
P. 183)
Info
The special tool must engage beneath the toothing for balancer shaft‘.
200135-10
Removing the left section of the engine case
ಥ
Take off needle bearing‘ and collar‘ of the outer clutch hub.
ಥ
Remove all engine case screws M6.
ಥ
Swing the left section of the engine case upward and remove the nut or screw of
the engine holder.
200136-10
200137-10
30/DISASSEMBLING ENGINE
ಥ
70
Mount special tool‘ with suitable screws.
Extractor (75029048000) (
P. 180)
Info
Use the bore labeled‘780.
ಥ
Pull off the engine case section.
Info
Do not warp the engine case section.
200138-10
ಥ
Remove the special tool.
ಥ
Remove distance bushing‘.
ಥ
Take off the left section of the engine case.
ಥ
Remove shift rails‘ together with top springs‘ and lower springs.
ಥ
Swing shift forks‘ to one side.
200139-10
Removing the shift rails
200141-10
Removing the shift roller
Info
Make sure not to misplace the shift drums.
ಥ
200142-10
Remove shift roller‘.
30/DISASSEMBLING ENGINE
71
Removing the shift forks
ಥ
Take shift forks‘ out of the shift grooves.
Info
Make sure not to misplace shift drums‘.
200144-10
Removing the transmission shaft
ಥ
Place the engine in an upright position.
ಥ
Remove lock ring‘.
ಥ
Pull both transmission shafts out of the bearing seats together.
200145-10
Info
Make sure not to misplace the washers.
200146-10
Removing the crankshaft
ಥ
Attach the special tool to the crankshaft.
Protection cover (75029090000) (
ಥ
Mount special tool‘ onto the engine case with suitable screws.
Press-out device (78029049100) (
200147-10
P. 181)
P. 183)
ಥ
Press the crankshaft out of the bearing seat.
ಥ
Remove the crankshaft.
ಥ
Remove the special tools.
ಥ
Take off the right section of the engine case.
30/ENGINE - WORK ON INDIVIDUAL PARTS
72
(1*,1( :25. 21 ,1',9,'8$/ 3$576
Work on the right section of the engine case
ಥ
Remove the oil pressure regulator valve. (
ಥ
Remove oil jet‘ and‘.
ಥ
Remove the bearing retainer of crankshaft bearing‘, drive shaft bearing‘, countershaft bearing‘ and shift drum bearing‘.
ಥ
Remove any sealing mass remnants and clean the engine case section thoroughly.
ಥ
Warm the engine case section in an oven.
Specification
P. 75)
150‘°C (302‘°F)
ಥ
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
ಥ
Press out the shaft seal ring of crankshaft‘
from the inside to the outside.
Info
Do not press the shaft seal ring from the outside to the inside because there
is a small collar on the inside.
200153-10
ಥ
Remove the shaft seal ring of balancer shaft‘ without damaging the engine case.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Treat the new shaft seal ring of the crankshaft and the seat of the shaft seal ring in
the engine case section with activator.
Loctite®‘7471
Loctite®‘7649
ಥ
Apply adhesive to the outside of the shaft seal ring.
Loctite® 648™
ಥ
Press the shaft seal ring of the crankshaft from the outside to the inside with the
open side facing inward.
Mounting sleeve (78029005000) (
P. 182)
Info
The shaft seal ring must be flush with the outside.
ಥ
Press in the shaft seal ring of the balancer shaft with the open side facing out.
ಥ
Warm the engine case section again.
Specification
150‘°C (302‘°F)
ಥ
Slide the new bearing into the bearing seat of the hot engine case section and, if
necessary, use a suitable press drift to push the bearing from the inside to the outside all the way or so it is flush.
Info
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.
ಥ
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 house when warm. In this case, the engine case must
be renewed.
ಥ
Position all bearing retainers. Mount and tighten screws.
Specification
Locking screw for bearing
M5
6‘Nm
(4.43‘lbf‘ft)
Loctite® 243™
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
Mount and tighten oil jet‘.
Specification
Oil jet, piston cooling
ಥ
73
M5
2‘Nm
(1.48‘lbf‘ft)
Loctite® 243™
M6x0,75
4‘Nm
(2.95‘lbf‘ft)
Loctite® 243™
Mount and tighten oil jet‘.
Specification
Oil jet, conrod lubrication
400368-01
ಥ
Blow though all oil holes with compressed air and check that they are clear.
ಥ
Install the oil pressure regulator valve. (
P. 75)
Work on the left section of the engine case
ಥ
Remove all dowels.
ಥ
Remove oil jet‘.
ಥ
Remove the bearing retainer from crankshaft bearing‘and balancer shaft bearing‘.
ಥ
Remove the shaft seal ring of countershaft‘ and shift shaft‘ without damaging
the engine case.
Info
Because of a small external collar, the shaft seal ring of crankshaft‘ can
only be removed after the crankshaft bearing has been taken out.
ಥ
Remove any sealing mass remnants and clean the engine case section thoroughly.
ಥ
Warm the engine case section in an oven.
Specification
150‘°C (302‘°F)
ಥ
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
200152-10
ಥ
Press out the shaft seal ring of crankshaft‘ from the outside to the inside.
Info
Do not press the shaft seal ring from the inside to the outside because there
is a small collar on the outside.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
74
Treat the new shaft seal ring of the crankshaft and the seat of the shaft seal ring in
the engine case section with activator.
Loctite®‘7471
Loctite®‘7649
ಥ
Apply adhesive to the outside of the shaft seal ring.
Loctite® 648™
ಥ
Press the shaft seal ring from the inside to the outside with the open side facing
out.
Info
The shaft seal ring must be flush with the outside.
ಥ
Warm the engine case section again.
Specification
150‘°C (302‘°F)
ಥ
Slide the new bearing into the bearing seat of the hot engine case section and, if
necessary, use a suitable press drift to push the bearing in all the way or so it is
flush.
Info
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.
ಥ
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 house when warm. In this case, the engine case must
be renewed.
ಥ
Position all bearing retainers. Mount and tighten screws.
Specification
Locking screw for bearing
M5
6‘Nm
(4.43‘lbf‘ft)
Loctite® 243™
ಥ
Press in the shaft seal ring of countershaft‘ and shift shaft‘ with the open side
facing inward until it is flush.
ಥ
Mount and tighten oil jet‘.
Specification
Oil jet, piston cooling
ಥ
Mount the dowels.
M5
2‘Nm
(1.48‘lbf‘ft)
Loctite® 243™
30/ENGINE - WORK ON INDIVIDUAL PARTS
75
400367-01
ಥ
Blow though all oil holes with compressed air and check that they are clear.
removing the oil pressure regulator valve
ಥ
Remove plug‘ with sealing disc‘.
ಥ
Remove preload spring‘ and ball‘.
200154-10
Checking the spring length of the oil pressure regulator valve
ಥ
Remove the oil pressure regulator valve. (
ಥ
Measure the spring length of the oil pressure regulator valve.
P. 75)
Oil pressure regulator valve
Minimum length of preload spring
»
ಥ
23.5‘mm (0.93‘in)
If the measured value does not equal the specified value:
ಥ Change the spring.
Install the oil pressure regulator valve. (
P. 75)
200155-10
Installing the oil pressure regulator valve
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Insert ball‘ and preload spring‘.
ಥ
Mount plug‘ with sealing disc‘ and tighten.
Specification
Oil pressure control valve plug
200154-11
M12x1,5
20‘Nm
(14.75‘lbf‘ft)
30/ENGINE - WORK ON INDIVIDUAL PARTS
76
Removing the crankshaft seal ring in the clutch cover
ಥ
Remove the crankshaft seal ring in clutch cover‘.
200194-10
Fitting the crankshaft seal ring into the clutch cover
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Press crankshaft seal ring‘ into the clutch cover with the open side facing inwards until it is flush.
ಥ
Grease the sealing lip.
ಥ
Remove nut‘.
ಥ
Remove lock ring‘. Remove the drive wheel.
ಥ
Take off water pump wheel‘ and the spacing washer.
200194-10
Removing the water pump
200195-10
Info
If it is not possible to take off the water pump wheel, the water pump shaft
can be pressed inward.
ಥ
Remove water pump shaft‘.
ಥ
Remove shaft seal ring‘.
ಥ
Remove shaft seal ring‘.
200196-10
200197-10
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
77
Press out bearing‘
of the water pump shaft using a suitable tool.
Info
Support the clutch cover as necessary when pressing it out.
200198-10
Installing the water pump
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Press in bearing‘ of the water pump shaft using a suitable tool until it is flush.
Info
Support the clutch cover suitably when pressing it in.
200198-11
ಥ
Press in shaft seal ring‘ fully with the open side facing inwards.
Info
Spacers‘ must face outwards.
ಥ
Press in shaft seal ring‘ with the open side facing inwards until it is flush with
spacer‘.
ಥ
Mount water pump shaft‘.
200197-11
Info
Do not damage the shaft seal rings.
ಥ
Mount spacing washer and water pump wheel‘.
ಥ
Mount the drive wheel. Mount lock ring‘.
ಥ
Mount and tighten nut‘
.
Specification
200196-11
Nut, water-pump wheel
200195-11
M6
6‘Nm
(4.43‘lbf‘ft)
Loctite® 648™
30/ENGINE - WORK ON INDIVIDUAL PARTS
78
Checking the balancer shaft
ಥ
Check bearing surface of the balancer shaft for pitting corrosion.
» If there is pitting corrosion:
ಥ Change the balancer shaft.
ಥ
Check the remaining areas of the balancer shaft for damage and wear.
» If there is damage or wear:
ಥ Change the balancer shaft.
200205-10
Removing the timing chain sprocket
ಥ
Warm timing chain sprocket‘ using a blow dryer.
ಥ
Pull off the timing chain sprocket.
Info
The timing chain sprocket usually becomes damaged when it is disassembled and needs to be replaced.
200156-10
Installing the timing chain sprocket
Info
Never place the crankshaft with a crankshaft journal in a vise to try to force on the timing chain sprocket.
If you do so, the crank webs will be compacted, making the crankshaft unusable.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Heat up the new timing chain sprocket and immediately push it on to the
crankshaft.
Specification
150‘°C (302‘°F)
200157-10
Changing the conrod bearing
ಥ
Position special tool‘ between the crank webs and place them on a press.
Separator plate (78029009000) (
ಥ
P. 183)
Press the crank pin out of the upper crank web using special tool‘.
Press drift (75029047000) (
P. 180)
Info
Hold the bottom crank web.
200208-10
ಥ
Take off the connecting rod and bearing.
ಥ
Place connecting rod‘ onto special tool‘ without the bearing.
Plate - Pressing device (78029008000) (
ಥ
Press out the crank pin using the special tool.
Press drift (75029047000) (
200210-10
P. 180)
P. 182)
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
79
When the crank pin is pressed in, oil hole‘ must be aligned with oil hole‘.
Marking‘ is opposite from oil hole‘ and must be on the outside after mounting.
Info
If the oil holes are not correctly aligned, the conrod bearing will not be provided with oil.
200212-10
ಥ
Place the crank web onto special tool‘.
Plate - Pressing device (78029008000) (
P. 182)
Info
The special tool must be positioned with the flat surface facing downward.
ಥ
Press the new crank pin‘ all the way in.
ಥ
Check the oil hole with compressed air to ensure it is clear.
ಥ
Mount bearing‘ and connecting rod‘
.
200213-10
Info
Oil the bearing thoroughly.
200214-10
ಥ
Position special tool‘and‘ onto the press.
Press drift (75029047000) (
P. 180)
Plate - Pressing device (78029008000) (
P. 182)
ಥ
Fit the crank web with the connecting rod and bearing. Position the second crank
web.
ಥ
Insert special tool‘.
200215-10
Plate - Pressing device (78029008000) (
P. 182)
Info
The flat surface of the special tool must face upward.
200216-10
ಥ
Press the upper crank web all the way in.
Info
The press mandrel must be positioned above the crank pin.
ಥ
200209-10
Take the crankshaft out of the special tool and check that the connecting rod can
move freely.
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
Measure the external dimensions of the crankshaft - crank web.
Crankshaft - external crank web dimension
»
ಥ
80
63¢0.05‘mm (2.48¢0.002‘in)
If the specified value is not reached:
ಥ Correct to the specified value.
Check the crankshaft run-out on the bearing pin. (
P. 80)
200211-10
Checking the crankshaft run-out on the bearing pin
ಥ
Position the crankshaft on a roller block.
ಥ
Turn the crankshaft slowly.
ಥ
Check the crankshaft run-out on both bearing pins.
Crankshaft - run-out on bearing pin
»
싨‘0.16‘mm (싨‘0.01‘in)
If the crankshaft run-out on the bearing pin is greater than the specified value:
ಥ Align the crankshaft.
200207-10
Cylinder - Nikasil® coating
Nikasil® is a surface protection layer for a coating procedure developed by the Mahle
company. The name is derived from the two materials used in this procedure - a layer
of nickel into which is embedded the particularly hard silicone carbide.
The most important advantages of the Nikasil® coating are very good heat conductivity,
resulting in much improved performance, low wear, and a lightweight cylinder.
200158-10
Checking/measuring the cylinder
ಥ
Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
ಥ Change the cylinder and piston.
ಥ
Measure the cylinder diameter at several places on the‘$ and‘% axes using a micrometer to check for oval wear.
Specification
Cylinder - bore diameter
400374-10
ಥ
200162-10
Size I
95… 95.012‘mm (3.74… 3.74‘in)
Size II
95.013… 95.025‘mm (3.74…
3.74‘in)
Cylinder size‘ is marked on the side of the cylinder.
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
81
Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041000) (
P. 179)
Cylinder/cylinder head - sealing area
distortion
»
싨‘0.1‘mm (싨‘0.0039‘in)
If the measured value does not equal the specified value:
ಥ Change the cylinder.
400376-10
Checking/measuring the piston
ಥ
Check the piston bearing surface for damage.
» If the piston bearing surface is damaged:
ಥ Change the piston and, if necessary, the cylinder.
ಥ
Check that the piston rings can move easily in the piston ring grooves.
» If the piston ring is stiff:
ಥ Clean the piston ring groove.
Tip
Use an old piston ring to clean the piston ring groove.
200160-10
ಥ
Check the piston rings for damage.
» If the piston ring is damaged:
ಥ Change the piston ring.
Info
Mount the piston ring with the marking facing upward.
ಥ
Check the piston pin for discoloration or signs of wear.
» If the piston pin has strong discoloration/signs of wear:
ಥ Change the piston pin.
ಥ
Insert the piston pin into the connecting rod and check the bearing for play.
» If the piston pin bearing has too much play:
ಥ Change the connecting rod and the piston pin.
ಥ
Measure the piston at the piston skirt, at right-angles to the piston pin.
Specification
Piston - diameter
Size I
94.93… 94.96‘mm (3.74… 3.74‘in)
Size II
94.95… 94.97‘mm (3.74… 3.74‘in)
Info
Piston size‘ is marked on the piston head.
200161-10
Checking the piston ring end gap
ಥ
Remove the piston ring from the piston.
ಥ
Place the piston ring in the cylinder and align it with the piston.
Specification
Under the upper edge of the cylinder
ಥ
10‘mm (0.39‘in)
Measure the end gap with e feeler gauge‘.
Specification
Piston ring end gap
200163-10
ಥ
Compression ring
싨‘1‘mm (싨‘0.04‘in)
Oil scraper ring
싨‘1.2‘mm (싨‘0.05‘in)
»
If the end gap is more than the specified value:
ಥ Check/measure the cylinder. ( P. 80)
»
If the cylinder wear is within the tolerance range:
ಥ Change the piston ring.
Mount the piston ring with the marking facing toward the piston head.
30/ENGINE - WORK ON INDIVIDUAL PARTS
82
Checking piston/cylinder mounting clearance
ಥ
Check/measure the cylinder. (
ಥ
Check/measure the piston. (
ಥ
The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston
diameter.
Specification
P. 80)
P. 81)
Piston/cylinder - mounting clearance
Size I
0.04… 0.082‘mm (0.0016… 0.0032‘in)
Size II
0.043… 0.075‘mm (0.0017… 0.003‘in)
Wear limit
싨‘0.12‘mm (싨‘0.0047‘in)
Checking the oil pumps for wear
Info
The following figures show how to check the oil pumps for wear using the suction pump as an example, but the method applies
to all pumps.
ಥ
Use feeler gauge‘ to measure the play between the external rotor and the engine
case.
Oil pump
Clearance between external rotor
and engine housing
»
싨‘0.2‘mm (싨‘0.01‘in)
The measured value does not equal the specified value.
ಥ Change the oil pump and, if necessary, the engine case.
200164-10
ಥ
Use feeler gauge‘ to measure the play between the external rotor and the internal
rotor.
Oil pump
Clearance between external rotor
and internal rotor
»
싨‘0.2‘mm (싨‘0.01‘in)
The measured value does not equal the specified value.
ಥ Change the oil pump.
200165-10
Checking the lubrication system
1
30
0
4
0
8
0
3
0
3
60
0
8
0
1
0
3 0
0
40
3
1
0
5
0
9
0
2 0
0
1
3
0
7
0
30
0
6
200186-01
ಥ
Renew the O-rings or seal ring‘ with every oil change.
ಥ
Renew oil filter‘ with every oil change.
ಥ
Renew the O-rings or shaft seal ring‘ with every engine repair.
ಥ
Clean and check oil screens‘. Replace damaged or worn parts.
ಥ
Thoroughly clean the gear oil drain plug with magnet‘.
ಥ
Check oil pump cover‘ and the engine case in the vicinity of the oil pumps for
grooves.
» If there are grooves:
ಥ Change the oil pump cover and, if necessary, the engine case.
ಥ
Check the oil pumps for wear. (
ಥ
Place oil pump shaft‘
on a level surface and check for run-out.
» If there is run-out:
ಥ Change the oil pump shaft.
ಥ
Check oil pump gears‘ for wear.
» If the oil pump gear is worn:
ಥ Change the oil pump gear.
ಥ
Check ball‘ of the oil pressure regulator valve and its seat in the engine case for
wear and scoring.
» If there is wear or scoring:
ಥ Change the ball and, if necessary, the engine case.
P. 82)
30/ENGINE - WORK ON INDIVIDUAL PARTS
83
ಥ
Check the spring length of the oil pressure regulator valve. (
ಥ
Take lock ring‘ off of the autodecompressor shaft and dispose of it.
ಥ
Pull autodecompression shaft‘ out of the camshaft.
ಥ
Detach autodecompression spring‘ and remove it.
P. 75)
Disassembling the autodecompressor
200166-10
200167-10
Info
Autodecompression weight‘ cannot be removed.
200168-10
Assembling the autodecompressor
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Insert the long prong‘ of the autodecompression spring in the bore, push the autodecompression spring over bearing bolt‘ and insert it into the autodecompression weight‘.
ಥ
Mount the autodecompression shaft‘ in the camshaft.
200169-10
200167-11
30/ENGINE - WORK ON INDIVIDUAL PARTS
84
ಥ
Mount a new lock ring‘.
ಥ
Check for correct functioning.
» The autodecompression spring does not turn the autodecompression shaft fully
back to the stop:
ಥ Tighten the autodecompression spring or replace it.
ಥ
Check the camshaft for damage and wear.
» If there is damage or wear:
ಥ Change the camshaft.
200166-11
Checking the camshaft
ಥ
ಥ
If the cam surface is damaged, check the oil supply to the camshaft and
rocker arm.
Measure the cams of the camshaft.
Camshaft - cam height
Intake
33… 33.2‘mm (1.3… 1.31‘in)
Camshaft - cam height (Every 450 models)
200206-10
Exhaust
33.9… 34.1‘mm (1.33… 1.34‘in)
Camshaft - cam height (Every 530 models)
Exhaust
»
34.2… 34.4‘mm (1.35… 1.35‘in)
If the measured value does not equal the specified value:
ಥ Change the camshaft.
Checking the timing assembly
1
0
5
0
2
0
3
0
1
0
4
0
ಥ
Clean all parts well.
ಥ
Check the timing chain wheel/timing chain sprocket‘ for damage and wear.
» If there is damage or wear:
ಥ Change the timing chain wheel/timing chain sprocket.
ಥ
Check timing chain tensioning rail‘ for damage and wear.
» If there is damage or wear:
ಥ Change the timing chain tensioning rail.
ಥ
Check timing chain guide rail‘ for damage and wear.
» If there is damage or wear:
ಥ Change the timing chain guide rail.
ಥ
Check timing chain securing guide‘ for damage and wear.
» If there is damage or wear:
ಥ Change the timing chain securing guide.
ಥ
Check timing chain‘ for damage and wear.
» If there is damage or wear:
ಥ Change the timing chain.
ಥ
Check that the timing chain links move easily. Let the timing chain hang down
freely.
» If the chain links no longer straighten out:
ಥ Change the timing chain.
200173-01
Preparing the timing chain tensioner for installation
ಥ
Fully compress the timing chain tensioner.
Info
This requires considerable force since the oil has to be pressed out.
Without pressure, the timing chain tensioner expands fully.
200171-10
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
85
Place 2 spacing washers or similar aids next to the piston of the timing chain tensioner. This should ensure that when pushed down, the piston does not fully withdraw.
Specification
Thickness of spacers
2… 2.5‘mm (0.08… 0.1‘in)
200172-10
ಥ
Release the timing chain tensioner.
The latching system locks and the piston stops moving.
End position of piston after latching
3‘mm (0.12‘in)
Info
This position is necessary for installation.
If the timing chain tensioner is now pressed in once more and then pulled
out maximum halfway (preventing it to come out fully), the latching system locks and the timing chain tensioner can no longer be compacted - this
function is necessary to ensure sufficient tension of the timing chain, even
at low oil pressure.
200173-10
Removing the rocker arm
ಥ
Remove screws‘ of the rocker arm shafts. Remove plugs‘.
ಥ
Screw a fitting screw‘ into the rocker arm shafts. Pull out rocker arm shafts‘.
ಥ
Take off rocker arm‘.
ಥ
Take the shims out of the valve spring retainers and set them down according to
their installation position.
ಥ
Pretension the valve springs using the special tool.
200203-10
200204-10
Removing the valves
Valve spring mounter (59029019000) (
P. 178)
Valve spring mounting device (78029060000) (
ಥ
200187-10
P. 183)
Remove the valve keys and release the tension on the valve springs.
30/ENGINE - WORK ON INDIVIDUAL PARTS
86
ಥ
Remove the spring retainer and spring.
ಥ
Pull the valve downward out of the valve guide, pry off the valve stem seal and remove the lower valve spring retainer.
ಥ
Mark the valve to indicate the installation position.
200188-10
Info
Place the valve into a box according to the installation position and label the
box.
200189-10
Replacing the camshaft bearing
ಥ
Clamp the cylinder head.
Clamping plate (75029050000) (
ಥ
P. 180)
Remove the camshaft bearing using the special tool.
Bearing puller (15112017000) (
P. 177)
Push-out drift (75029051000) (
P. 180)
200202-10
ಥ
Remove the small camshaft bearing‘ using the special tool.
Bearing puller (15112017000) (
P. 177)
Insert for bearing puller (15112018100) (
P. 177)
200199-10
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Press the small camshaft bearing all the way in using special tool‘.
Push-in drift (75029044020) (
P. 180)
200200-10
ಥ
Press the large camshaft bearing all the way in using special tool‘.
Push-in drift (75029044010) (
200201-10
P. 179)
30/ENGINE - WORK ON INDIVIDUAL PARTS
87
Checking the valves
Info
The valve stem is chrome-hardened, and wear normally takes place in the valve guide.
ಥ
Check for valve retainer run-out.
Valve
Run-out on valve plate
»
싨‘0.05‘mm (싨‘0.002‘in)
If the measured value does not equal the specified value:
ಥ Change the valve.
200193-10
ಥ
Check sealing seat‘ on the valve.
Valve
Sealing seat width, intake
1.5‘mm (0.06‘in)
Valve
0
A
Sealing seat width, exhaust
»
2‘mm (0.08‘in)
If the sealing area is not in the center of the valve seat or if it differs from the
specified value:
ಥ Machine the valve seat.
400373-10
Checking the valve springs
ಥ
Check the valve springs for breakage and wear (visual check).
» If the valve spring is broken or worn:
ಥ Change the valve spring.
ಥ
Measure the valve spring length.
Valve spring
Minimum length, intake (without
bottom valve spring retainer)
46.5‘mm (1.83‘in)
Valve spring
Minimum length, exhaust (without
bottom valve spring retainer)
200190-10
»
43‘mm (1.69‘in)
If the measured value does not equal the specified value:
ಥ Change the valve spring.
Checking the lower valve spring retainer
ಥ
Check the lower valve spring retainer for breakage and wear (visual check).
» If the lower valve spring retainer is broken or worn:
ಥ Change the valve spring retainer.
ಥ
Measure the thickness of the lower valve spring retainers.
Valve spring
Bottom valve spring retainer
»
500173-01
0.9… 1‘mm (0.04… 0.04‘in)
If the measured value does not equal the specified value:
ಥ Change the valve spring retainer.
30/ENGINE - WORK ON INDIVIDUAL PARTS
88
Checking the cylinder head
ಥ
Check the exhaust valve guides using special tool‘.
Limit plug gauge (59029026006) (
»
ಥ
P. 179)
If the special tool is easy to insert into the valve guide:
ಥ Change the valve guide and valve.
Check the intake valve guides using the special tool.
Limit plug gauge (77029026000) (
»
200192-10
P. 181)
If the special tool is easy to insert into the valve guide:
ಥ Change the valve guide and valve.
ಥ
Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
» If there is wear or tearing:
ಥ Change the cylinder head.
ಥ
Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041000) (
P. 179)
Cylinder/cylinder head - sealing area
distortion
»
싨‘0.1‘mm (싨‘0.0039‘in)
If the measured value does not equal the specified value:
ಥ Change the cylinder head.
400375-10
ಥ
Check sealing seat‘ of the valves.
Valve
Sealing seat width, intake
1.5‘mm (0.06‘in)
Valve
0
A
Sealing seat width, exhaust
»
400373-10
2‘mm (0.08‘in)
If the measured value does not equal the specified value:
ಥ Machine the valve seat.
ಥ
Blow though all oil holes with compressed air and check that they are clear.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount new valve stem seals. Position the lower valve spring retainers.
ಥ
Mark the valves according to their position in the engine.
ಥ
Mount the spring and spring retainer.
ಥ
Tension the valve springs with a special tool.
Installing valves
200188-10
Valve spring mounter (59029019000) (
P. 178)
Valve spring mounting device (78029060000) (
200187-10
P. 183)
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
89
Mount the valve keys.
Info
When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.
ಥ
Place the shims in the valve spring retainers according to their position in the engine.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position rocker arm‘ and slide in rocker arm shaft‘.
200191-10
Installing the rocker arm
Info
Ensure that the tapped hole of the rocker arm shaft is on the outside.
Align bores‘ of the rocker arm shafts with bores‘ of the cylinder head.
200204-11
ಥ
Mount and tighten screws‘ of the rocker arm shafts.
Specification
Screw, rocker arm bearing
ಥ
M7x1
15‘Nm
(11.06‘lbf‘ft)
M14x1,25
20‘Nm
(14.75‘lbf‘ft)
Mount and tighten plugs‘.
Specification
Plug, rocker arm
200203-11
Checking the clutch
ಥ
Check pressure piece‘ for damage and wear.
» If there is damage or wear:
ಥ Change the pressure piece.
ಥ
Check axial bearing‘ for damage and wear.
» If there is damage or wear:
ಥ Change the axial bearing.
ಥ
Place push rod‘ on a level surface and check for run-out.
» If there is run-out:
ಥ Change the push rod.
ಥ
Check the length of clutch springs‘.
b0k
bk
b0k
bk
4
0
9
0
b0l
bl
5
0
b0m
bm
»
2
0
6
0
10
0
3
Clutch spring - length
70
0
8
43… 44.03‘mm (1.69… 1.73‘in)
If the clutch spring length is less than the specified value:
ಥ Change all clutch springs.
ಥ
Check the contact surface of pressure cap‘ for damage and wear.
» If there is damage or wear:
ಥ Change the pressure cap.
ಥ
Check the contact surfaces of the clutch facing discs in outer clutch hub‘ for
wear.
Thrust surface, clutch facing discs in
outer clutch hub
200176-01
»
ಥ
싨‘0.5‘mm (싨‘0.02‘in)
If the contact surface is very worn:
ಥ Change the clutch facing discs and the outer clutch hub.
Check needle bearing‘
and collar‘ for damage and wear.
» If there is damage or wear:
ಥ Change the needle bearing and collar.
30/ENGINE - WORK ON INDIVIDUAL PARTS
90
ಥ
Check intermediate discs‘ for damage and wear.
» If the intermediate discs are not level and have pittings:
ಥ Change all intermediate discs.
ಥ
Check clutch facing discs‘(1 for discoloration and scoring.
» If there is discoloration or scoring:
ಥ Change all clutch facing discs.
ಥ
Check the thickness of clutch facing discs‘(1.
Clutch facing disc - thickness
»
2.6… 2.7‘mm (0.1… 0.11‘in)
If the clutch facing disc does not meet specifications:
ಥ Change all clutch facing discs.
ಥ
Check the pretension ring and support ring‘(2 for damage and wear.
» If there is damage or wear:
ಥ Change the pretension ring and support ring.
ಥ
Check inner clutch hub‘(3 for damage and wear.
» If there is damage or wear:
ಥ Change the inner clutch hub.
ಥ
Check shift forks‘ at leaf‘ for wear.
Checking the shift mechanism
Shift fork
7
0
Thickness at leaf
0
D
C
0
E0
0
A
»
1
0
5
0
4
0
6
0
3
0
5
0
B0
0
2
3
0
1
0
5
0
6 0
0
4
1
0
4
0
5
0
4.85… 4.95‘mm (0.19… 0.19‘in)
If the measured value does not equal the specified value:
ಥ Change the shift fork.
ಥ
Check shift grooves‘ of the shift roller‘ for wear.
» If the shift groove is worn:
ಥ Change the shift roller.
ಥ
Check the seat of the shift roller in the grooved ball bearing‘.
» If the shift roller is not seated correctly:
ಥ Change the shift roller and/or the grooved ball bearing.
ಥ
Check grooved ball bearing‘ for smooth operation and wear.
» If the grooved ball bearing does not move freely or is worn:
ಥ Change the grooved ball bearing.
ಥ
Check shift drums‘ for surface damage and cracks.
» If the shift drum has surface damage and cracks:
ಥ Change the shift drum.
ಥ
Check springs‘ of the shift rails for damage and wear.
» If the spring is broken or worn:
ಥ Change the spring of the shift rail.
ಥ
Check the shift rails‘ on a flat surface for run-out.
» If there is run-out:
ಥ Change the shift rail.
ಥ
Check shift rails for grooving, signs of corrosion and smooth operation in the shift
fork.
» The shift rail has grooving or signs of corrosion or is not smooth in operation in
the shift fork:
ಥ Change the shift rail.
ಥ
Check the sliding plate‘
in the contact areas‘ for wear.
» If the sliding plate is worn:
ಥ Change the sliding plate.
ಥ
Check return surface‘ on the sliding plate for wear.
» If deep notches are present:
ಥ Change the sliding plate.
ಥ
Check guide pin‘ for firm fitting and wear.
» If the guide pin is loose and/or worn:
ಥ Change the sliding plate.
ಥ
Preassemble the shift shaft. (
200174-01
P. 91)
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
91
Check clearance between sliding plate and shift quadrant.
Shift shaft - play in sliding plate/shift
quadrant
A
0
»
0.4… 0.8‘mm (0.02… 0.03‘in)
If the measured value does not equal the specified value:
ಥ Change the sliding plate.
400372-01
Preassembling the shift shaft
ಥ
5
0
Use vise protectors.
1
0
2
0
Fix the short end of the shift shaft in a vise.
Specification
ಥ
30
0
4
6
0
200175-01
Mount sliding plate‘ with the guide pin facing down and attach the guide pin to
the shift quadrant.
ಥ
Mount preload spring‘.
ಥ
Push on spring guide‘, push return spring‘ over the spring guide with the offset
end facing upwards and lift the offset end over abutment bolt‘.
ಥ
Mount stop disk‘.
Dismantling the main shaft
8 0
0
7
5 0
3
60
0
b0k bl
bk
b0l 0
9
4 0
0
20
1
200177-01
ಥ
Fix the main shaft in the vise with the geared end facing downwards.
Specification
Use vise protectors.
ಥ
Remove stop disk‘ and fixed gear‘ of the second gear.
ಥ
Remove the sixth-gear idler gear‘.
ಥ
Remove the divided needle bearing‘ and stop disk‘.
ಥ
Remove lock ring‘.
ಥ
Remove the third/fourth-gear sliding gear‘
.
ಥ
Remove lock ring‘.
ಥ
Remove stop disk‘ and the fifth-gear idler gear‘(1.
ಥ
Remove the divided needle bearing‘(2.
Assembling the main shaft
Info
Use new lock rings in every repair job.
ಥ
Oil all parts carefully before assembling.
ಥ
Check the transmission. (
P. 93)
30/ENGINE - WORK ON INDIVIDUAL PARTS
4 0
0
5
7 0
9
60
0
92
8 bbk
0
0k bbl
0l
2 0
0
10
3
200178-01
ಥ
Fix the main shaft in the vise with the geared end facing downwards.
Specification
Use vise protectors.
ಥ
Mount the divided needle bearing‘, put on the fifth-gear idler gear‘ with the shifting claws facing upwards.
ಥ
Mount stop disk‘ and lock ring‘.
ಥ
Put on the third/fourth-gear sliding gear‘ with the small gear wheel facing downwards and mount lock ring‘.
ಥ
Put on stop disk‘
and divided needle bearing‘.
ಥ
Put on the sixth-gear idler gear‘ with the shifting claws facing downwards.
ಥ
Put on the fixed gear‘(1 of the second-gear with the collar facing downwards and put on stop disk‘(2.
ಥ
Finally, check all gear wheels for smooth operation.
Dismantling the countershaft
5
40
0
6
0
1
0
2
0
3
0
7
0
9 bk
0
b0k
bbl
0lbm
b0r
b0m bbo
0o bbp
0p br
8
0
b0n
bn
b0s
bs
b0q
bq
200179-01
ಥ
Fix the countershaft in the vise with the geared end facing downwards.
Specification
Use vise protectors.
ಥ
Remove stop disk‘ and the first-gear idler gear‘.
ಥ
Remove needle bearing‘ and stop disk‘.
ಥ
Remove the fifth-gear sliding gear‘ and lock ring‘.
ಥ
Remove stop disk‘
and the third-gear idler gear‘.
ಥ
Remove needle bearing‘ and the fourth-gear idler gear‘(1.
ಥ
Remove needle bearing‘(2 and stop disk‘(3.
ಥ
Remove lock ring‘(4 and the sixth-gear sliding gear‘(5.
ಥ
Remove stop disk‘(6 and lock ring‘(7.
ಥ
Remove the second-gear idler gear‘(8 and needle bearing‘(9.
Assembling the countershaft
Info
Use new lock rings in every repair job.
ಥ
Oil all parts carefully before assembling.
ಥ
Check the transmission. (
P. 93)
30/ENGINE - WORK ON INDIVIDUAL PARTS
b0o
bbp
0pbo
b0n
bn
b0s
bs
b0r
br
b0q
bq
b0k 0
bk
9
b0m
bm
80
0
2
7 0
50
4 0
b0l
bl
6
0
93
1
0
3
0
200180-01
ಥ
Fix the countershaft in the vise with the geared end facing downwards.
Specification
Use vise protectors.
ಥ
Mount needle bearing‘ and the second-gear idler gear‘ on the countershaft with the protruding collar facing downwards.
ಥ
Fit lock ring‘ and stop disk‘.
ಥ
Mount the sixth-gear sliding gear‘ with the shift groove facing upwards.
ಥ
Mount lock ring‘ and stop disk‘
.
ಥ
Mount needle bearing‘ and fourth-gear idler gear‘ with the collar facing upwards.
ಥ
Mount needle bearing‘(1 and third-gear idler gear‘(2 with the collar facing downwards.
ಥ
Mount stop disk‘(3 and lock ring‘(4.
ಥ
Mount the fifth-gear sliding gear‘(5 with the shift groove facing downwards and stop disk‘(6.
ಥ
Mount needle bearing‘(7, first-gear idler gear‘(8 with the groove facing downwards and stop disk‘(9.
ಥ
Finally, check all gear wheels for smooth operation.
Checking the transmission
40
0
1
6
0
40
0
1
5
0
2
6
0
5
0
70
0
6
67
0
40
0
1
41
0
00
5
70
0
6
60
0
7
40
0
1
67
0
6
0
3
5
0
40
0
1
500174-01
ಥ
Check needle bearing‘ for damage and wear.
» If there is damage or wear:
ಥ Change the needle bearing.
ಥ
Check the pivot points of main shaft‘ and countershaft‘ for damage and wear.
» If there is damage or wear:
ಥ Change the main shaft and/or countershaft.
ಥ
Check the tooth profiles of main shaft‘ and countershaft‘ for damage and wear.
» If there is damage or wear:
ಥ Change the main shaft and/or countershaft.
ಥ
Check the pivot points of idler gears‘ for damage and wear.
» If there is damage or wear:
ಥ Change the idler/fixed gear pair.
ಥ
Check the shift dogs of idler gears‘ and fixed gears‘ for damage and wear.
» If there is damage or wear:
ಥ Change the idler/fixed gear pair.
30/ENGINE - WORK ON INDIVIDUAL PARTS
ಥ
Check the tooth faces of idler gears‘ and fixed gears‘ for damage and wear.
» If there is damage or wear:
ಥ Change the idler/fixed gear pair.
ಥ
Check the tooth profiles of fixed gears‘ for damage and wear.
» If there is damage or wear:
ಥ Change the idler/fixed gear pair.
ಥ
Check fixed gears‘ for smooth operation in the profile of main shaft‘.
» If the fixed gear does not move easily:
ಥ Change the fixed gear or the main shaft.
ಥ
Check fixed gears‘ for smooth operation in the profile of countershaft‘.
» If the fixed gear does not move easily:
ಥ Change the fixed gear or the countershaft.
ಥ
Check stop disks‘ for damage and wear.
» If there is damage or wear:
ಥ Change the stop disk.
ಥ
Use new lock rings‘
in every repair job.
94
Checking electric starter operation
ಥ
Check the toothing or seating of idler‘ and the bearing bolt for wear.
» The parts are worn:
ಥ Change the idler with the bearing bolt.
ಥ
Check the toothing or seating of idler‘ with the torque limiter and the bearing bolt
for wear.
» The parts are worn:
ಥ Change the idler with the bearing bolt.
ಥ
Check the toothing and bearing of free-wheel gear‘ for wear.
» The parts are worn:
ಥ Change the free-wheel gear and/or bearing.
ಥ
Check free-wheel‘ when removed for wear and damage.
» The free-wheel is damaged or worn:
ಥ Change the free-wheel.
ಥ
Check the toothing of electric starter‘ for wear.
» The toothing is worn:
ಥ Change the electric starter.
ಥ
Change the O-ring‘ of the electric starter.
ಥ
Press together spreader ring‘ with suitable pliers and take it off.
ಥ
Take free-wheel‘ out of the primary pinion.
5
0
6
0
2
0
1
0
3
0
4
0
200181-01
Removing the free-wheel
200183-10
200184-10
30/ENGINE - WORK ON INDIVIDUAL PARTS
95
Checking the free-wheel
ಥ
Place the free-wheel gear‘ in primary pinion‘ while rotating the primary pinion
clockwise, but do not tilt it!
ಥ
Check the locking action of free-wheel gear‘.
» The primary pinion cannot be rotated clockwise or does not block counterclockwise:
ಥ Remove the free-wheel. ( P. 94)
ಥ
Turn the free-wheel 180°.
ಥ
Install the free-wheel. (
P. 95)
200182-10
Installing the free-wheel
ಥ
Clean the parts thoroughly and check for damage and wear. Replace damaged or
worn parts.
ಥ
Oil all parts well.
ಥ
Slide free-wheel‘ into the primary pinion.
Info
Note the direction of rotation.
200184-11
ಥ
Mount spreader ring‘.
ಥ
Ensure that all protrusions of the spreader ring engage through slots‘ of the freewheel in groove‘ of the primary pinion.
200183-11
200185-10
30/ASSEMBLING ENGINE
96
$66(0%/,1* (1*,1(
Installing the crankshaft
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Clamp the right section of the engine case into the engine work stand.
ಥ
Heat the inner ring of the crankshaft bearing.
Specification
80‘°C (176‘°F)
Info
Do not damage the seal ring.
700014-01
ಥ
Slide the crankshaft all the way into the bearing seat of the right section of the engine case.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide both transmission shafts into the bearing seats together.
Installing the transmission shaft
Info
Make sure not to misplace the washers.
200146-10
ಥ
Mount lock ring‘.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Oil all parts well.
ಥ
Shift fork‘ has a smaller inner diameter. Mount it in the shift groove of the main
shaft.
ಥ
Mount shift fork‘ in the lower shift groove of the countershaft.
ಥ
Mount shift fork‘ in the upper shift groove of the countershaft.
ಥ
Slide on shift drums‘.
200145-10
Installing the shift forks
200143-10
30/ASSEMBLING ENGINE
97
Installing the shift roller
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide shift roller‘ into the bearing seat.
ಥ
Hang the shift forks‘ into the shift roller.
Info
Make sure not to misplace the shift drums.
200142-11
Installing the shift rails
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Install shift rails‘ together with upper springs‘ and the lower springs.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
200141-10
Installing the left engine case
ಥ
Mount dowels‘ on the left section of the engine case.
ಥ
Grease the sealing surfaces. Apply sealing compound to the left section of the engine case.
Loctite®‘5910
Info
To prevent sealing compound from entering into the oil drill holes, dowels‘
must be mounted first.
200140-10
ಥ
Mount the left section of the engine case. If necessary, knock it lightly with a rubber hammer.
Info
Do not tighten the engine case sections using the screws.
ಥ
Mount screws‘ and tighten them when all screws have been mounted on the left
section of the engine case.
Specification
Screw, engine housing
200137-11
ಥ
700003-01
10‘Nm
(7.38‘lbf‘ft)
Mount screws‘ and tighten all screws in a crisscross pattern.
Specification
Screw, engine housing
ಥ
M6x80
M6x65
Mount distance bushing‘ with the O-ring.
10‘Nm
(7.38‘lbf‘ft)
30/ASSEMBLING ENGINE
98
ಥ
Mount collar‘ and needle bearing‘.
200136-12
Installing the primary gear with the free-wheel-gear
ಥ
Oil the free-wheel in the primary gear.
ಥ
Slide primary gear‘ with the free-wheel onto free-wheel-gear‘ and mount them
both on crankshaft‘.
Info
The free-wheel-gear must rotate counterclockwise when it is mounted.
700004-01
Installing the oil pumps
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Oil the oil pump shaft, internal rotor and external rotor before fitting.
Engine oil (SAE 10W/50) (
P. 174)
ಥ
Mount oil pump shaft‘.
ಥ
Mount pin‘ of the engine oil force pump. Slide on the internal rotor with marking‘ facing outward.
Info
The marking should be visible after installation.
200131-11
ಥ
Mount external rotor‘ with the marking facing inward.
Info
The marking should not be visible after installation.
ಥ
Mount oil pump shaft‘ of the gear oil force pump with pin‘ and internal rotor‘
.
ಥ
Mount external rotor‘ with the marking facing inward.
Info
The marking should not be visible after installation.
200126-11
ಥ
Position oil pump cover‘. Mount and tighten screws‘(1.
Specification
Screw, oil pump cover
200125-11
M5
6‘Nm
(4.43‘lbf‘ft)
Loctite® 222
30/ASSEMBLING ENGINE
99
Installing the oil pump gears
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Insert pins‘.
ಥ
Position oil pump gears‘.
200127-11
Info
Ensure that the pins are seated correctly.
ಥ
Position washers‘.
ಥ
Mount shaft retainer‘.
ಥ
Crank the oil pump gears and check that they can be easily moved.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the locking lever‘ with washer, sleeve and spring.
ಥ
Mount and tighten screw‘.
Specification
200124-11
Installing the locking lever
Screw, locking lever
M5
6‘Nm
(4.43‘lbf‘ft)
Loctite® 243™
200123-11
Installing the shift drum locating
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Push locking lever‘ away from the shift drum locating‘and position shift drum
locating‘.
Info
The flat surfaces of the shift drum locating are not symmetric.
ಥ
Release the locking lever.
ಥ
Mount and tighten screw‘.
Specification
200122-11
Screw, shift drum locating
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
Installing the shift shaft
200109-11
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide shift shaft‘ with the washer into the bearing seat.
ಥ
Push sliding plate‘ away from the shift drum locating. Insert the shift shaft all
the way.
ಥ
Let sliding plate‘ engage in the shift drum locating.
30/ASSEMBLING ENGINE
100
Installing the kickstarter idler gear
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide on kickstarter idler gear‘ with the collar facing the engine case.
ಥ
Slide on the washer. Mount the lock ring.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide the premounted kickstarter shaft‘ into the bearing seat.
200120-12
Installing the kickstarter shaft
Info
The kickstarter ratchet wheel‘ should not be in contact with stop plate‘.
200111-10
ಥ
Turn kickstarter shaft‘ clockwise all the way.
ಥ
Pretension kickstarter spring‘, and attach and position spring hanger‘.
ಥ
Mount and tighten screw‘.
Specification
Screw, kickstarter spring hanger
M6
10‘Nm
(7.38‘lbf‘ft)
200110-11
Installing the starter idler gear
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide on the starter idler gear‘ with the collar facing the engine case.
ಥ
Slide on the washer. Mount the lock ring.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide on torque limiter‘. Mount and tighten the screw with washer.
Specification
200121-12
Installing the torque limiter
Screw, torque governor
200120-11
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
30/ASSEMBLING ENGINE
101
Installing the balancer shaft
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide balancer shaft‘ into the bearing seats. Align the marking on balance
weight‘ with the marking on primary pinion‘.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Slide the outer clutch hub onto the main shaft. Turn oil pump gear‘ and kickstarter gear‘ until the gearing of the outer clutch hub engages.
ಥ
Slide on washer‘ and inner clutch hub‘.
ಥ
Position the new lock washer and mount nut‘. Fix the inner clutch hub using the
special tool and tighten the nut.
Specification
200134-11
Installing the outer clutch hub
200097-10
200096-12
Nut, inner clutch hub
M18x1,5
Clutch holder (51129003000) (
200095-01
80‘Nm
(59.01‘lbf‘ft)
P. 178)
ಥ
Secure the nut with lock washer.
ಥ
Insert the pressure piece.
ಥ
Block the outer clutch hub and primary gear using special tool‘.
Installing the primary gear nut
Gear segment (80029004000) (
ಥ
Mount and tighten the nut.
Specification
Nut, primary gear
200099-11
P. 183)
M20LHx1,5
150‘Nm
Loctite® 648™
(110.64‘lbf‘ft)
30/ASSEMBLING ENGINE
102
Installing the clutch discs
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Oil the clutch facing discs well.
Engine oil (SAE 10W/50) (
400377-10
P. 174)
ಥ
Insert support ring‘ into the outer clutch hub.
ಥ
Insert pretension ring‘ with the open side facing outward.
ಥ
Place the machined clutch facing disc‘ with the recess for the pretension ring
into the outer clutch hub.
ಥ
Beginning with an intermediate disc, place all further clutch facing discs and intermediate discs alternately into the outer clutch hub.
ಥ
Fit the pressure cap. Mount screws‘ with washers and springs. Tighten the screws
diagonally.
Specification
Screw, clutch spring
M6
10‘Nm
(7.38‘lbf‘ft)
200093-11
Installing the clutch cover
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount dowels‘. Fit the new clutch cover seal‘.
ಥ
Mount the clutch cover.
200073-11
Info
Turn the water pump wheel lightly to engage the water pump drive.
ಥ
Mount screws‘ and tighten them after all screws of the clutch cover have been
mounted.
Specification
Screw, clutch cover
M6x25
700015-11
ಥ
10‘Nm
(7.38‘lbf‘ft)
Mount screws‘ and tighten all screws in a crisscross pattern.
Specification
Screw, clutch cover
M6x30
10‘Nm
(7.38‘lbf‘ft)
Info
Mount the left screw with the seal ring.
ಥ
Set the crankshaft to top dead center and block it using the special tool.
Crankshaft locking bolt (113080802) (
P. 177)
30/ASSEMBLING ENGINE
103
Installing the water pump cover
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Fit the water pump cover seal.
ಥ
Install the water pump cover. Mount screw‘ with the seal washer and tighten it
after all screws of the water pump cover have been mounted.
Specification
Screw, water pump cover
ಥ
200071-11
M6x25
Mount screws‘ and tighten them after all screws of the water pump cover have
been mounted.
Specification
Screw, water pump cover
ಥ
10‘Nm
(7.38‘lbf‘ft)
M6x25
10‘Nm
(7.38‘lbf‘ft)
Mount screw‘ and tighten all screws in a crisscross pattern.
Specification
Screw, water pump cover
M6x55
10‘Nm
(7.38‘lbf‘ft)
Installing the kickstarter
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the kickstarter. Mount and tighten screw‘.
Specification
Screw, kickstarter
M8
25‘Nm
(18.44‘lbf‘ft)
Loctite® 243™
200067-10
Installing the suction pump
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Oil the internal rotor and external rotor before mounting.
Engine oil (SAE 10W/50) (
P. 174)
ಥ
Insert O-ring‘.
ಥ
Position pin‘ in oil pump shaft‘ and slide on the internal rotor.
Info
Marking‘ of the internal rotor faces outward.
200130-10
ಥ
Mount the external rotor‘ with the marking facing inward.
Info
The marking should not be visible after installation.
200129-11
ಥ
Check that the pin of the suction pump is seated properly.
ಥ
Position oil pump cover‘. Mount and tighten screws‘
.
Specification
Screw, oil pump cover
200128-11
M5
6‘Nm
(4.43‘lbf‘ft)
Loctite® 222
30/ASSEMBLING ENGINE
104
Installing the ignition pulse generator
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the ignition pulse generator.
Info
Use the outermost pair of drill holes.
ಥ
Mount and tighten screws‘.
Specification
Screw, ignition pulse generator
200107-12
M5
6‘Nm
(4.43‘lbf‘ft)
Loctite® 243™
ಥ
Position the cable and insert the cable support sleeve into the engine case.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Thread the timing chain and place it over the timing chain sprocket.
Installing the timing chain
Info
Note the running direction if installing a used timing chain.
200108-12
Installing the timing chain securing guide
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position ignition pulse generator cable‘ in the timing chain securing guide.
ಥ
Mount cable support sleeve‘.
ಥ
Position the timing chain securing guide. Mount and tighten screws‘.
Specification
200106-10
Screw, timing chain securing guide
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
200105-12
Installing the timing chain tensioning rail
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Thread the timing chain tensioning rail from above. Mount and tighten screw‘.
Specification
Screw, timing chain tensioning rail
700005-10
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
30/ASSEMBLING ENGINE
105
Installing the timing chain guide rail
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Thread timing chain guide rail‘ from above. Mount and tighten screws‘.
Specification
Screw, timing chain guide
rail
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
700006-11
Installing the balance weight
ಥ
Mount balance weight‘.
Info
The shape of the gearing prevents incorrect mounting of the balance weight.
ಥ
Mount and tighten the lock washer and nut. Tighten nut.
Specification
Balancer shaft nut
700007-11
M10x1
40‘Nm
(29.5‘lbf‘ft)
ಥ
Secure the nut with lock washer.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Ensure that the spring washer is seated properly. Mount the rotor.
ಥ
Mount and tighten the spring washer and nut. Tighten nut.
Specification
Installing the rotor
Ignition rotor nut
M12x1
60‘Nm
(44.26‘lbf‘ft)
200102-01
Installing the piston
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Shift the joint of the compression ring and oil scraper ring by 180°.
ಥ
Place the oiled piston on the cylinder. Tighten the piston rings using the special
tool.
Piston ring mounting tool (60029015000) (
P. 179)
200086-01
ಥ
200087-01
Using a plastic hammer, lightly hit the piston tension band from above until it is
flush with the cylinder.
30/ASSEMBLING ENGINE
106
ಥ
Carefully knock the piston into the cylinder using the hammer shaft.
Info
The piston tension band must press the piston rings together firmly and
must be flush with the cylinder; the piston rings should not catch or else
they will be damaged.
200088-01
ಥ
Mount dowels‘ and fit the cylinder base gasket‘.
ಥ
Ensure that piston marking‘ faces the outfeed side.
ಥ
Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
200090-10
200089-01
Info
For clarity, the following steps are illustrated using a disassembled piston.
200091-10
ಥ
400366-10
Position the piston pin retainer.
30/ASSEMBLING ENGINE
107
ಥ
Insert the special tool and firmly press it toward the piston.
ಥ
Turn the special tool counterclockwise, thereby pressing the piston pin retainer into
the groove.
Insert for piston pin retainer (77329030100) (
P. 181)
200084-10
ಥ
Remove the cloth. Keep the timing chain tensioned.
ಥ
Push the cylinder down carefully and let the dowels engage.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount the dowels. Fit the new cylinder head gasket.
ಥ
Fit the cylinder head.
ಥ
Insert the washers of the cylinder-head bolts.
ಥ
Mount cylinder-head bolts and tighten all screws in a crisscross pattern.
Specification
200092-01
Installing the cylinder head
Screw, cylinder head
M10x1,25
Tightening
sequence:
Tighten diagonally, beginning with
the rear screw
on the chain
shaft.
Step 1
10‘Nm
(7.38‘lbf‘ft)
Step 2
30‘Nm
(22.13‘lbf‘ft)
Step 3
50‘Nm
(36.88‘lbf‘ft)
200082-11
ಥ
Engine oil (any)
Mount and tighten screw‘.
Specification
Screw, cylinder head
M6
10‘Nm
(7.38‘lbf‘ft)
30/ASSEMBLING ENGINE
108
Installing the camshaft
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Place the timing chain over the camshaft. Slide the camshaft into the bearing
seats. The markings on camshaft‘ and cylinder head‘ must be aligned.
Info
Ensure that the crankshaft is located at top dead center.
200078-10
ಥ
Position the camshaft support plate. Mount and tighten screw‘.
Specification
Screw, camshaft bearing
support
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
700016-11
Installing the timing chain tensioner
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
After it has been positioned in the installation location, insert timing chain tensioner‘ with new O-ring‘.
ಥ
Mount plug‘ with the new seal ring‘ and tighten.
Specification
Plug, timing chain tensioner
M24x1,5
25‘Nm
(18.44‘lbf‘ft)
200074-12
ಥ
Remove screw‘ and use the special tool to push the timing chain tensioner toward the timing chain.
Release device for timing chain tensioner (77329051000) (
ಥ
Mount and tighten screw‘.
Specification
Screw, unlocking of timing chain tensioner
200075-01
P. 182)
M10x1
10‘Nm
(7.38‘lbf‘ft)
30/ASSEMBLING ENGINE
109
Checking the valve clearance
ಥ
Remove special tool‘.
ಥ
Crank the engine several times.
ಥ
Set the engine to ignition top dead center. (
ಥ
On all valves, check valve clearance between the valve and rocker arm.
Specification
P. 61)
200062-11
Valve clearance
Outfeed at: 20‘°C (68‘°F)
0.12… 0.17‘mm (0.0047… 0.01‘in)
Infeed at: 20‘°C (68‘°F)
0.1… 0.15‘mm (0.0039… 0.01‘in)
Feeler gauge (59029041000) (
»
700042-10
ಥ
P. 179)
If valve clearance does not meet specifications:
ಥ Adjust the valve clearance. ( P. 109)
Mount and tighten screw‘.
Specification
Plug, crankshaft location
M8
10‘Nm
(7.38‘lbf‘ft)
200061-11
Adjusting the valve clearance
ಥ
Remove the timing chain tensioner. (
ಥ
Remove the camshaft. (
P. 62)
P. 62)
ಥ
Raise rocker arm‘ on the outside.
ಥ
Remove shims‘ and set them down according to the installation position.
ಥ
Correct the shims as indicated by the results of the valve clearance check.
ಥ
Insert fitting shims‘.
ಥ
Install the camshaft. (
ಥ
Install the timing chain tensioner. (
ಥ
Check the valve clearance. (
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount centering pins‘. Fit generator cover seal‘.
P. 108)
P. 108)
P. 109)
700043-10
Installing the generator cover
700010-11
30/ASSEMBLING ENGINE
110
ಥ
Position the generator cover. Mount screws‘ and tighten them after all screws of
the generator cover have been mounted.
Specification
Screw generator cover
ಥ
M6x25
Mount screws‘ and tighten all screws in a crisscross pattern.
Specification
Screw generator cover
M6x40
700011-11
ಥ
10‘Nm
(7.38‘lbf‘ft)
10‘Nm
(7.38‘lbf‘ft)
Mount and tighten screw‘.
Specification
Screw, generator cover
(through-hole for chain
shaft)
M6x25
10‘Nm
(7.38‘lbf‘ft)
Loctite® 222
Installing the shift lever
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the shift lever. Fit and tighten screw‘ with collar sleeve.
Specification
Screw, shift lever
M6
10‘Nm
(7.38‘lbf‘ft)
Loctite® 243™
700017-11
Installing the valve cover
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the valve cover seal.
ಥ
Fit the valve cover. Mount and tighten screws‘.
Specification
Screw, valve cover
M6
10‘Nm
(7.38‘lbf‘ft)
700013-10
Installing the spark plug
ಥ
Fit and tighten the spark plug using a special tool.
Specification
Spark plug
Spark plug wrench (75029172000) (
700031-11
M12x1,25
P. 181)
15… 20‘Nm
(11.06…
14.75‘lbf‘ft)
30/ASSEMBLING ENGINE
111
Installing the starter motor
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Grease the O-ring. Mount the starter engine.
Long-life grease (
ಥ
P. 175)
Mount and tighten screws‘.
Specification
Screw, starter motor
M6
10‘Nm
(7.38‘lbf‘ft)
200064-10
Mounting oil filter
ಥ
Tilt the engine sideways and fill the oil filter housing to about 1/3 full with engine
oil.
ಥ
Fill the oil filter‘ with engine oil and place it in the oil filter container.
ಥ
Lubricate the o/ring of the oil filter cover.
ಥ
Refit the oil filter cover‘.
ಥ
Mount and tighten screws‘.
Specification
700027-11
Screw, oil filter cover
M5
6‘Nm (4.43‘lbf‘ft)
700022-11
Filling up with engine oil
ಥ
Thoroughly clean the plug and gear oil screen. Check parts for damage and wear.
Replace damaged or worn parts.
ಥ
Clean the sealing area on the engine.
ಥ
Refit the plug of engine oil screen with O-rings and tighten it.
Specification
Plug, engine oil screen
M17x1,5
20‘Nm
(14.75‘lbf‘ft)
400364-10
ಥ
Remove the screw cap‘ on the generator cover and fill up with engine oil.
Engine oil
ಥ
700032-11
0.6‘l (0.63‘qt.)
Mount and tighten screw cap‘.
Engine oil (SAE 10W/50) (
P. 174)
30/ASSEMBLING ENGINE
112
Filling up with gear oil
ಥ
Thoroughly clean the plug, gear oil screen and gear oil drain plug. Check parts for
damage and wear. Replace damaged or worn parts.
ಥ
Clean the sealing surfaces on the engine.
ಥ
Refit gear oil drain plug with seal ring and tighten it.
Specification
Gear oil drain plug with magnet
ಥ
400365-10
M12x1,5
Refit plug of gear oil screen with O-rings and tighten it.
Specification
Plug, gear oil screen
ಥ
M16x1,5
0.9‘l (0.95‘qt.)
Engine oil (SAE 10W/50) (
Mount and tighten screw cap‘.
700033-11
Removing the engine from the universal mounting rack
ಥ
Remove the screw/nut from the special tool.
Engine holder (78029002000) (
ಥ
700020-01
20‘Nm
(14.75‘lbf‘ft)
Remove the screw cap‘ and fill up with gear oil.
Gear oil
ಥ
20‘Nm
(14.75‘lbf‘ft)
P. 182)
Remove the engine from the universal mounting rack.
P. 174)
31/CARBURETOR
113
&$5%85(725
Choke (EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W)
The choke‘ is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
500135-10
Possible states
• Choke function activated ಥ‘The choke lever is pulled out to the stop.
• Choke function deactivated ಥ‘The choke lever is pushed in to the stop.
Choke (EXC-R‘EU)
The flasher switch‘ is fitted on the left side of the handlebar.
Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
500136-10
Possible states
• Choke function activated ಥ‘The choke lever is pulled to the stop.
• Choke function deactivated ಥ‘The choke lever is pushed back to the stop.
Checking the choke Bowden cable routing (EXC-R‘EU)
ಥ
The choke Bowden cable must run behind the handlebar down to the frame. The
choke Bowden cable runs to the carburetor behind the CDI controller directly on
the left side of the frame.
700078-10
Checking the choke Bowden cable for play (EXC-R‘EU)
ಥ
Move the handlebar to the straight-ahead position.
ಥ
Loosen screw‘ but do not remove it. It must be possible to move the choke lever
slightly.
ಥ
Move the choke lever back and forth slightly to ascertain the play in the choke Bowden cable.
Choke Bowden cable play
»
2… 3‘mm (0.08… 0.12‘in)
If the choke Bowden cable play does not meet specifications:
ಥ Adjust the choke Bowden cable play. ( P. 113)
700076-10
Adjusting the choke Bowden cable play (EXC-R‘EU)
ಥ
Move the handlebar to the straight-ahead position.
ಥ
Check the choke Bowden cable routing. (
ಥ
Push back bellows‘.
ಥ
Loosen screw‘ but do not remove it. It must be possible to move the choke lever
slightly.
ಥ
Turn nut‘ in as far as possible. Turn adjusting screw‘ until the choke lever exhibits the required choke Bowden cable play.
Specification
Choke Bowden cable play
700077-10
P. 113)
2… 3‘mm (0.08… 0.12‘in)
ಥ
Tighten nut‘.
ಥ
Tighten screw‘. The choke lever must remain in position when it is activated.
31/CARBURETOR
114
ಥ
Push bellows‘ on.
ಥ
The two gas Bowden cables must run parallel behind the handlebar down to the
frame. They must be routed directly on the frame above the tank bearing to the carburetor.
ಥ
Move the handlebar to the straight-ahead position. Move the throttle grip back and
forth slightly to ascertain the play in the gas Bowden cable.
Checking gas Bowden cable route
500152-10
Checking play in the gas Bowden cable
Play in gas Bowden cable
»
3… 5‘mm (0.12… 0.2‘in)
If the gas Bowden cable play does not meet specifications:
ಥ Adjust the gas Bowden cable play. ( P. 114)
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
400192-10
ಥ
ಥ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
»
If the idle speed changes:
ಥ Adjust the gas Bowden cable play. (
P. 114)
Adjusting the gas Bowden cable play
ಥ
Dismount the fuel tank. (
ಥ
Check gas Bowden cable route. (
ಥ
Move the handlebar to the straight-ahead position.
P. 28)
P. 114)
ಥ
Push back bellows‘.
ಥ
Loosen nut‘. Turn adjusting screw‘ in as far as possible.
ಥ
Loosen nut‘. Turn adjusting screw‘ so that there is play in the gas Bowden cable at the throttle grip.
Specification
Play in gas Bowden cable
500153-10
3… 5‘mm (0.12… 0.2‘in)
ಥ
Tighten nut‘.
ಥ
Press and hold the throttle grip in the closed setting. Turn adjusting screw‘ out
until there is no play in the Bowden cable‘.
ಥ
Tighten nut‘.
ಥ
Push bellows‘ on. Check the throttle grip for smooth operation.
ಥ
Install the fuel tank. (
ಥ
Check play in the gas Bowden cable. (
P. 29)
P. 114)
31/CARBURETOR
115
Removing the carburetor
ಥ
Dismount the fuel tank. (
ಥ
Remove the carburetor connection boot. (
ಥ
Remove screw‘. Remove the carburetor cover.
ಥ
Push back bellows‘.
ಥ
Undo nuts‘, detach the Bowden cables and hang them to one side.
ಥ
Undo hose clip‘.
ಥ
Pull engine vent hose‘ off of the carburetor.
ಥ
Unplug the connector of throttle valve sensor‘TPS‘.
ಥ
Unthread the carburetor vent hoses. Pull the carburetor out of the rubber sleeve
and remove it.
P. 28)
P. 27)
500109-10
500110-10
(EXC-R‘EU)
ಥ Twist out the choke slide and hang it to one side together with the Bowden cable.
500111-10
Disassembling the carburetor
ಥ
Remove the carburetor. (
ಥ
Remove screws‘ and detach all vent hoses from the carburetor.
ಥ
Remove screws‘. Take off the throttle slide cover and seal.
P. 115)
700034-10
700035-10
31/CARBURETOR
116
ಥ
Remove screws‘ with the spring and washer and slide stop‘.
ಥ
Pull the jet needle out of the throttle slide.
ಥ
Remove screw‘.
ಥ
Pull up throttle slide arm‘. Take throttle slide‘
out of the carburetor along with
throttle slide roller‘ and the throttle slide plate.
ಥ
Remove screws‘. Take off the accelerator pump cover with the seal ring.
ಥ
Remove seal rings‘(1, spring‘(2 and membrane‘(3.
ಥ
Remove screws‘(4 and take off the float chamber body.
ಥ
Take leakage nozzle‘(5 out of the float chamber body.
ಥ
Remove fulcrum pin‘(6. Take off the float and float needle valve.
ಥ
Remove main jet(7.
700036-10
700037-10
700038-10
700039-10
700058-10
700044-10
31/CARBURETOR
117
ಥ
Remove idling jet‘(8, cold start jet‘(9, needle jet‘(: and buffer plate‘)1.
ಥ
Screw in mixture control screw‘)2 to the stop, counting and noting down the number of rotations.
ಥ
Remove the mixture control screw with the spring, washer and O-ring.
ಥ
Screws‘)3 should not be removed.
ಥ
Remove screw‘)4. Pull the hose connector out of the carburetor.
ಥ
Remove screw‘)5. Take off throttle valve sensor‘)6.
700045-10
700046-10
700047-10
Info
Only remove the throttle valve sensor if necessary. If screw‘)5 is loosened,
the throttle valve sensor must be readjusted.
(EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W)
ಥ Unscrew choke slide‘)7.
700048-10
ಥ
Remove idle air jet‘)8.
ಥ
Clean all jets and other parts thoroughly and blow out with compressed air.
Carburetor cleaner (
ಥ
P. 175)
Clean the carburetor housing and blow out all channels in the carburetor with compressed air.
Carburetor cleaner (
P. 175)
Info
700049-10
Do not use nitro thinner to clean the carburetor.
31/CARBURETOR
118
Checking the carburetor components
700073-01
ಥ
Disassemble the carburetor. (
ಥ
Check/adjust the accelerator pump. (
ಥ
Check the choke slide. (
ಥ
Check the jet needle. (
ಥ
Check the throttle slide. (
ಥ
Check the needle jet. (
ಥ
Check the float needle valve. (
ಥ
Check/adjust the float level. (
ಥ
Check/adjust the throttle slide opening. (
ಥ
Check throttle valve sensor‘TPS. (
ಥ
Assemble the carburetor. (
P. 115)
P. 118)
P. 119)
P. 119)
P. 119)
P. 120)
P. 120)
P. 120)
P. 120)
P. 121)
P. 122)
Checking/adjusting the accelerator pump
ಥ
Check the membrane for damage and brittleness.
» If the membrane is damaged or brittle:
ಥ Change the membrane.
ಥ
Check that the bores‘ are clear.
» If the bores are not clear:
ಥ Clean the bores.
Carburetor cleaner (
700051-10
P. 175)
31/CARBURETOR
119
ಥ
Check/adjust the throttle slide opening. (
P. 120)
Info
Adjusting the play of the accelerator pump changes the time at which injection starts and does not influence the injection rate or the intensity of the
accelerator pump.
ಥ
Check piston rod overhang‘.
Specification
Piston rod overhang
700065-10
»
0.9… 1‘mm (0.04… 0.04‘in)
If piston rod overhang‘ does not equal the specified value:
ಥ Correct the piston rod overhang by turning adjusting screw‘.
ಥ
Carburetor - adjust the idle speed. (
ಥ
Check the choke slide for smooth operation.
» If the choke slide cannot be moved easily or is soiled:
ಥ Clean the choke slide and check the Bowden cable and lever if necessary.
P. 126)
Checking the choke slide
Carburetor cleaner (
P. 175)
ಥ
The piston of the choke slide should not be damaged.
» If the piston of the choke slide is damaged or worn:
ಥ Change the choke slide.
ಥ
Check the rubber sleeve and lock.
» If the rubber sleeve is damaged or brittle, or if the lock does not function:
ಥ Change the choke slide.
ಥ
Check the jet needle for bending and wear of the coating.
» If the jet needle is bent or the coating is damaged or worn:
ಥ Change the jet needle.
ಥ
Check that the needle clip is tight.
» If the needle clip is not tight:
ಥ Change the needle clip or the jet needle.
ಥ
Check the throttle slide rollers for damage and wear.
» If the throttle slide rollers do not turn easily, are worn or have flat area:
ಥ Change the throttle slide.
ಥ
Except for throttle slide roller‘ (removable), all rollers must rest flush against the
throttle slide.
» If the throttle slide rollers are loose:
ಥ Change the throttle slide.
ಥ
Check the coating of the throttle slide and throttle slide plate‘ for damage and
wear.
» If the coating is damaged or worn:
ಥ Change the throttle slide.
ಥ
Check membrane‘ of the throttle slide plate for damage, brittleness and tightness.
» If the membrane is damaged or brittle:
ಥ Change the membrane.
ಥ
Check that membrane‘ is seated properly.
» If the membrane is not seated properly:
ಥ Position the membrane correctly.
700050-10
Checking the jet needle
700052-10
Checking the throttle slide
700055-10
700056-10
31/CARBURETOR
120
Checking the needle jet
ಥ
Use a new jet needle as a gauge. Apply a marking‘ on the jet needle above
step‘ at a distance of‘.
Specification
Distance‘
3‘mm (0.12‘in)
Info
The marking should come off completely when cleaned away.
700053-10
ಥ
Insert the marked jet needle into the needle jet being tested. Push the two pieces
together carefully.
ಥ
Check the needle jet.
» If marking‘ on the jet needle is not visible on top edge‘ of the needle jet:
ಥ Change the needle jet.
ಥ
Check the float needle valve including the valve seat for deposits or wear.
» If there are deposits or wear:
ಥ Clean the valve seat. Clean or change the float needle valve.
700054-10
Checking the float needle valve
Carburetor cleaner (
P. 175)
ಥ
Check the float needle valve for wear and the sealing areas of indentations.
» If the sealing area is damaged or if there is wear:
ಥ Change the float needle valve.
ಥ
Hold the carburetor at a slant, securing the pin against falling out of the float.
ಥ
Hold the carburetor at a slant so that the float lies against the float needle valve
but does not press it together.
» In this position, if the edge on the float is not parallel to the sealing area of the
float chamber:
ಥ Adjust the float level by bending float lever‘.
700057-10
Checking/adjusting the float level
700061-10
Checking/adjusting the throttle slide opening
Info
The basic setting of the throttle slide controls the time at which injection begins at the accelerator pump and the basic setting
of the throttle valve sensor.
ಥ
Remove the carburetor. (
P. 115)
31/CARBURETOR
121
ಥ
Check the throttle slide opening using a wire or a drill shank.
Throttle slide opening
»
1‘mm (0.04‘in)
If the throttle slide opening does not equal the specified value:
ಥ Adjust the throttle slide opening with adjusting screw‘.
700062-10
Checking throttle valve sensor‘TPS
Info
The value in the figure is an example only!
ಥ
Remove the carburetor. (
ಥ
Check/adjust the throttle slide opening. (
P. 115)
P. 120)
Condition
Component temperature: 20‘°C (68‘°F)
ಥ Connect the positive wire of the multimeter to the blue (bu) cable and the
ground wire to the black‘(bl) cable of the connector of throttle valve sensor‘TPS.
Measure the total resistance Rtot of the throttle valve sensor.
Specification
Total resistance Rtot of the throttle
valve sensor
4… 6‘k൉
700063-10
ಥ
Connect the positive wire of the multimeter to the yellow (ye) cable and the
ground wire to the black‘(bl) cable of the connector of throttle valve sensor‘TPS.
ಥ
Slowly open the throttle slide and measure the variable resistance Rvar of the
throttle valve sensor.
Variable resistance Rvar of the throttle valve sensor (throttle slide fully
opened)
»
If the value does not increase smoothly:
ಥ Change throttle valve sensor‘TPS.
»
If the value is outside of the specification:
ಥ Adjust the position of throttle valve sensor‘TPS. (
700064-10
ಥ
3… 4.5‘k൉
Install the carburetor. (
P. 121)
P. 125)
Adjusting the position of throttle valve sensor‘TPS
Info
The value in the figure is an example.
ಥ
Remove the carburetor. (
ಥ
Check/adjust the throttle slide opening. (
P. 115)
P. 120)
Conditions
Component temperature: 20‘°C (68‘°F)
ಥ Connect the positive wire of the multimeter to the blue (bu) cable and the
ground wire to the black‘(bl) cable of the connector of throttle valve sensor‘TPS.
Measure the total resistance Rtot of the throttle valve sensor.
Specification
Total resistance Rtot of the throttle
valve sensor
700063-10
4… 6‘k൉
31/CARBURETOR
122
ಥ
Multiply the total resistance Rtot of the throttle valve sensor by 0.17. This generates the variable resistance‘Rvar for the setting of the throttle valve sensor.
ಥ
Rtot x 0.17 = Rvar (tolerance‘¢‘0.05‘k˖)
ಥ
Connect the positive wire of the multimeter to the yellow (ye) cable and the
ground wire to the black‘(bl) cable of the connector of throttle valve sensor‘TPS.
ಥ
Measure the variable resistance Rvar of the throttle valve sensor.
700064-10
Info
The throttle slide must be in the neutral position.
700066-10
ಥ
Loosen screw‘. Set throttle valve sensor‘TPS‘ by turning it to the calculated
value.
ಥ
Tighten screw‘.
Specification
Screw, throttle valve sensor
ಥ
M5
3.5‘Nm
(2.58‘lbf‘ft)
Check the variable resistance Rvar of the throttle valve sensor again.
» If the measured value is not equal to the calculated value:
ಥ Repeat the adjustment procedure.
ಥ
Install the carburetor. (
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Mount and tighten idle air jet‘.
Specification
P. 125)
Assembling the carburetor
Idle air jet
M4,5x0,75
2‘Nm (1.48‘lbf‘ft)
Idle air jet‘(100)
700049-11
(EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W)
ಥ Mount and tighten choke slide‘.
Specification
Choke slide
ಥ
M12
2.5‘Nm
(1.84‘lbf‘ft)
Position throttle valve sensor‘. Mount screw‘ with the spring ring and washer
but do not tighten yet.
Info
When installing the throttle valve sensor, ensure that the flat area of the inner clutch hub engages in the recess of the throttle valve sensor.
700048-11
ಥ
Position the hose connection. Mount and tighten screw‘.
Specification
Screw, hose connection
M4
2‘Nm
(1.48‘lbf‘ft)
Loctite® 243™
Info
The hose connection must be easy to turn when it is mounted.
700047-11
31/CARBURETOR
123
ಥ
Screw in mixture control screw‘ together with the spring, washer and O-ring to
the stop.
Specification
Mixture control screw
ಥ
M6x0,5
1‘Nm (0.74‘lbf‘ft)
Unscrew mixture control screw‘ again by the number of turns that was noted
down earlier when it was disassembled or to the specified basic setting.
Specification
Idle mixture adjusting screw (XCR-W‘USA)
Open
700045-11
0.5‘turn
Idle mixture adjusting screw (EXC-R‘SIX‘DAYS)
Open
1‘turn
Idle mixture adjusting screw (XCR-W‘ZA, 530‘EXC-R‘EU, 530‘EXC-R‘AUS/UK)
Open
1.5‘turns
Idle mixture adjusting screw (450‘EXC-R‘EU, 450‘EXC-R‘AUS/UK, 450‘EXCR‘USA)
Open
1.75‘turns
Idle mixture adjusting screw (530‘EXC-R‘USA)
Open
2‘turns
Info
The mixture control screw may be open by no more than 2 turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
ಥ
Position buffer plate‘
. Mount and tighten needle jet‘, cold start jet‘ and
idling jet‘(1.
Specification
Needle jet
M7x0,75
3.5‘Nm
(2.58‘lbf‘ft)
Cold start jet
M5x0,75
2‘Nm (1.48‘lbf‘ft)
Idling jet
M6x0,75
2‘Nm (1.48‘lbf‘ft)
(EXC-R‘EU, EXC-R‘AUS/UK)
Cold start jet‘(65 (85))
(EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W)
Cold start jet‘(85)
(EXC-R‘EU, EC-R AUS/UK, EXC-R‘SIX‘DAYS, XCR-W)
Idling jet‘(40)
(EXC-R‘USA)
Idling jet‘(48)
ಥ
Mount and tighten main jet‘(2.
Specification
Main jet
M5x0,75
2‘Nm (1.48‘lbf‘ft)
(All EXC-R‘models, XCR-W‘USA)
Main jet‘(180)
(XCR-W‘ZA)
Main jet‘(185)
700044-11
ಥ
Position the float and float needle valve, and mount fulcrum pin‘(3.
ಥ
Check/adjust the float level. (
ಥ
Mount and tighten leakage nozzle‘(4.
Specification
Leakage nozzle
Leakage nozzle‘(40)
700058-11
P. 120)
M4x0,7
2‘Nm (1.48‘lbf‘ft)
31/CARBURETOR
124
ಥ
Position the float chamber and adjustment screw.
ಥ
Mount screws‘(5 but do not tighten them yet.
ಥ
Insert throttle slide‘(6 with throttle slide roller‘(7 and the throttle slide plate into
throttle slide arm‘(8 and position them in the carburetor.
ಥ
Position the needle clip on the jet needle.
Specification
700067-11
700037-11
Needle position (XCR-W‘USA)
1st position from top
Needle position (EXC-R‘SIX‘DAYS,
530‘EXC-R‘USA)
3rd position from top
Needle position (XCR-W‘ZA, 450‘EXCR‘EU, 450‘EXC-R‘AUS/UK, 450‘EXCR‘USA)
4th position from top
Needle position (530‘EXC-R‘EU,
530‘EXC-R‘AUS/UK)
5th position from top
(450‘XCR-W, 450‘EXC-R‘SIX‘DAYS)
Jet needle‘(OBDTQ)
(530‘XCR-W, 530‘EXC-R‘SIX‘DAYS)
Jet needle‘(OBDTR)
(450‘EXC-R‘USA)
Jet needle‘(OBDYU)
(450‘EXC-R‘EU, 450‘EXC-R‘AUS/UK)
Jet needle‘(OBDYU (OBDTQ))
(530‘EXC-R‘USA)
Jet needle‘(OBDZT)
(530‘EXC-R‘EU, 530‘EXC-R‘AUS/UK)
Jet needle‘(OBDZT (OBDTR))
ಥ
Insert the jet needle.
ಥ
Mount and tighten screw‘(9 or slide stop‘(: with the spring and washer.
Specification
Needle screw/slide stop
ಥ
M8
3.5‘Nm
(2.58‘lbf‘ft)
Mount and tighten screw‘)1.
Specification
Screw, throttle slide arm
M4
2‘Nm
(1.48‘lbf‘ft)
Loctite® 243™
700036-11
ಥ
Position the throttle slide cover with the seal. Mount and tighten screws‘)2.
Specification
Other screws, carburetor
ಥ
700035-11
Check/adjust the throttle slide opening. (
M4
P. 120)
2‘Nm (1.48‘lbf‘ft)
31/CARBURETOR
125
ಥ
Check/adjust the accelerator pump. (
ಥ
Position seal ring‘)3, membrane‘)4 and spring‘)5.
P. 118)
Info
The label on the membrane must be visible when mounted.
700060-11
ಥ
Position seal ring‘)6 in the accelerator pump cover with the rounded side facing
outward.
ಥ
Position the accelerator pump cover. Mount and tighten screws‘)7.
Specification
700059-11
Other screws, carburetor
M4
2‘Nm (1.48‘lbf‘ft)
700038-11
ಥ
Position and mount the vent hoses.
ಥ
Position the hose holder. Mount the screws‘)8 and tighten all screws in a crisscross
pattern.
Specification
Other screws, carburetor
M4
2‘Nm (1.48‘lbf‘ft)
ಥ
Adjust the position of throttle valve sensor‘TPS. (
ಥ
Install the carburetor. (
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
P. 121)
P. 125)
700034-11
Installing the carburetor
(EXC-R‘EU)
ಥ Mount and tighten the choke slide.
Specification
Choke slide
ಥ
M12
2.5‘Nm
(1.84‘lbf‘ft)
Insert the carburetor into the rubber sleeve.
Info
500111-11
Align nose‘ on the carburetor with the notch in the rubber sleeve. The carburetor must be positioned vertically.
ಥ
Position the carburetor vent hoses.
ಥ
Attach the connector of throttle valve sensor‘TPS‘.
31/CARBURETOR
126
500110-11
ಥ
Position hose clamp‘ and tighten.
ಥ
Attach engine vent hose‘ to the carburetor.
ಥ
Connect the Bowden cables.
ಥ
Check gas Bowden cable route. (
ಥ
Move the handlebar to the straight-ahead position.
P. 114)
ಥ
Turn adjusting screw‘ in as far as possible.
ಥ
Turn adjusting screw‘ so that there is play in the gas Bowden cable at the throttle
grip.
ಥ
Tighten nut‘.
ಥ
Press and hold the throttle grip in the closed setting. Turn adjusting screw‘ out
until there is no play in the Bowden cable‘
.
ಥ
Tighten nut‘.
ಥ
Position the carburetor cover. Mount and tighten screw‘.
ಥ
Push bellows‘(1 on. Check the throttle grip for smooth operation.
ಥ
Install the carburetor connection boot. (
ಥ
Install the fuel tank. (
ಥ
Check play in the gas Bowden cable. (
P. 27)
P. 29)
P. 114)
(EXC-R‘EU)
ಥ Check the choke Bowden cable for play. (
P. 113)
500109-11
Carburetor - adjusting idle
ಥ
Screw in the idle adjusting screw‘ until it stops and then to the prescribed basic
setting.
Specification
Idle mixture adjusting screw (XCR-W‘USA)
Open
0.5‘turn
Idle mixture adjusting screw (EXC-R‘SIX‘DAYS)
Open
1‘turn
Idle mixture adjusting screw (XCR-W‘ZA, 530‘EXC-R‘EU, 530‘EXC-R‘AUS/UK)
400341-10
Open
1.5‘turns
Idle mixture adjusting screw (450‘EXC-R‘EU, 450‘EXC-R‘AUS/UK, 450‘EXCR‘USA)
Open
1.75‘turns
Idle mixture adjusting screw (530‘EXC-R‘USA)
Open
2‘turns
Adjustment tool for mixture control screw (77329034000) (
ಥ
P. 182)
Run the engine until warm.
Specification
Warm-up time
싩‘5‘min
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
ಥ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Adjust the idle speed with the adjusting screw‘.
Specification
Choke function deactivated ಥ‘The choke lever is pushed in to the stop.
( P. 113)
Choke function deactivated ಥ‘The choke lever is pushed back to the stop.
( P. 113)
Idle speed
ಥ
1550… 1650‘rpm
Turn the idle adjusting screw‘ slowly until the idle speed begins to fall.
31/CARBURETOR
127
ಥ
Note the position and turn the idle adjusting screw slowly counterclockwise until
the idle speed falls.
ಥ
Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extremely sporty rider will set the mixture about 1/4 of a turn back from
this ideal value (leaner, in a clockwise direction) since the engine becomes
hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to fit a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
ಥ
Adjust the idle speed with the adjusting screw‘.
Specification
Choke function deactivated ಥ‘The choke lever is pushed in to the stop.
( P. 113)
Choke function deactivated ಥ‘The choke lever is pushed back to the stop.
( P. 113)
Idle speed
1550… 1650‘rpm
Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.
Emptying the carburetor float chamber
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
Never fill up 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.
ಥ
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Warning
Environmental hazardಗImproper handling of fuel is a danger to the environment.
ಥ
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.
ಥ
Turn the handle‘ of the fuel tap to the OFF position. (Figure‘500137-10‘
No more fuel flows from the tank to the carburetor.
P. 30)
31/CARBURETOR
128
ಥ
Guide the hose coming down behind the engine into a suitable container.
Info
Water in the float chamber results in malfunctioning.
400341-11
ಥ
Undo the screw‘ (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.
ಥ
Tighten screw‘.
32/CLUTCH
129
&/87&+
Checking fluid level of hydraulic clutch
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Info
The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ಥ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
ಥ
Remove screws‘.
ಥ
Take off cover‘ with membrane‘.
ಥ
Check the fluid level.
Fluid level under top level of container.
»
If the level of the cooling liquid does not meet specifications:
ಥ Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 5.1 (
400339-10
4‘mm (0.16‘in)
P. 174)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt fluid immediately with water.
Changing fluid level of hydraulic clutch
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
ಥ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
400339-10
ಥ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
ಥ
Remove screws‘.
ಥ
Take off cover‘ with membrane‘.
32/CLUTCH
130
ಥ
Fill the bleeding syringe‘ with the appropriate hydraulic fluid.
Bleed syringe (50329050000) (
Brake fluid DOT 5.1 (
P. 177)
P. 174)
ಥ
On the slave cylinder, remove the bleeder screw‘ and fit the bleeding syringe‘.
ಥ
Inject the liquid into the system until it escapes from the bore hole‘ of the master cylinder without bubbles.
ಥ
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
ಥ
Remove the bleeding syringe. Mount and tighten screws bleeder screw.
ಥ
Correct the fluid level of the hydraulic clutch.
Specification
500158-10
Fluid level under top level of container.
400340-10
4‘mm (0.16‘in)
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt fluid immediately with water.
33/TRANSMISSION
131
75$160,66,21
Removing the engine sprocket
ಥ
Remove the engine sprocket cover. (
ಥ
Press the rear brake and remove screw‘ with spring washer.
ಥ
Pull the engine sprocket with the chain off of the countershaft. Remove the engine
sprocket.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
P. 19)
500115-10
Installing the engine sprocket
Info
The engine sprocket, rear sprocket and chain should always be replaced together.
ಥ
With the collar facing the engine, mount the engine sprocket in the chain and slide
both onto the countershaft.
ಥ
Press the rear brake. Fit and tighten screw‘ with spring washer.
Specification
500115-10
Screw, engine sprocket
M10
ಥ
Check the chain tension. (
ಥ
Install the engine sprocket cover. (
60‘Nm
(44.26‘lbf‘ft)
P. 38)
P. 19)
Loctite® 243™
35/WATER PUMP, COOLING SYSTEM
132
:$7(5 3803 &22/,1* 6<67(0
Checking antifreeze and coolant level
Warning
Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ಥ
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
Stand the motorcycle upright on a horizontal surface.
ಥ
Remove the radiator cap.
ಥ
Check antifreeze of coolant.
-25… -45‘°C (-13… -49‘°F)
»
ಥ
If the antifreeze of the cooling liquid does not meet specifications:
ಥ Correct antifreeze of coolant.
Check the coolant level in the radiator.
Coolant level‘ above radiator fins.
400243-10
»
If the level of the cooling liquid does not meet specifications:
ಥ Correct the coolant level.
Alternative 1
Coolant ( P. 174)
Alternative 2
Coolant (mixed ready to use) (
ಥ
10‘mm (0.39‘in)
P. 174)
Refit the radiator cap.
Checking the coolant level
Warning
Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ಥ
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
Stand the motorcycle upright on a horizontal surface.
ಥ
Remove the radiator cap.
ಥ
Check the coolant level in the radiator.
Coolant level‘ above radiator fins.
»
400243-10
If the level of the cooling liquid does not meet specifications:
ಥ Correct the coolant level.
Alternative 1
Coolant ( P. 174)
Alternative 2
Coolant (mixed ready to use) (
ಥ
10‘mm (0.39‘in)
Refit the radiator cap.
P. 174)
35/WATER PUMP, COOLING SYSTEM
133
Draining coolant
Warning
Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ಥ
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
Stand the vehicle upright.
ಥ
Place a suitable container under the water pump cover.
ಥ
Remove screw‘. Remove the radiator cap‘.
ಥ
Completely drain the coolant.
ಥ
Fit screw‘ with a new seal and tighten it.
Specification
Screw, water pump cover
M6x25
10‘Nm
(7.38‘lbf‘ft)
400335-11
Refilling coolant
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
Make sure that the screw‘ is tightened.
ಥ
Stand the vehicle upright.
ಥ
Pour coolant in up to measurement‘ above the radiator fins.
Specification
10‘mm (0.39‘in)
Coolant
0.95‘l (1‘qt.)
Coolant (
P. 174)
Coolant (mixed ready to use)
( P. 174)
400244-10
ಥ
Refit the radiator cap.
ಥ
Make a short test ride.
ಥ
Check the coolant level. (
P. 132)
38/LUBRICATION SYSTEM
134
/8%5,&$7,21 6<67(0
Oil cycle
400283-10
1
engine oil screen
2
Engine oil force pump
3
Oil pressure regulator valve
4
Oil filter insert
5
Oil jet, conrod lubrication
6
Oil jet, piston cooling
7
Timing chain tensioner
8
Lubrication, rocker arm shaft
9
Oil jet, rocker arm lubrication
10
Gear oil screen
11
Gear oil force pump
12
Oil channel, transmission lubrication
13
Lubrication, clutch push rod
14
Suction pump
Checking engine oil level
Info
The engine oil level must be checked when the engine is cold.
ಥ
Stand the motorcycle upright on a horizontal surface.
38/LUBRICATION SYSTEM
135
Condition
Engine is cold.
ಥ Check the engine oil level.
The engine oil must be between the halfway mark and the top of the oil level
viewer‘.
»
If the engine oil level is below the specified level:
ಥ Top up the engine oil. ( P. 137)
200119-10
Changing engine oil and oil filter, cleaning engine oil screen
ಥ
Drain the engine oil and clean the engine oil screen. (
ಥ
Remove the oil filter. (
ಥ
Mount the oil filter. (
ಥ
Fill up with engine oil. (
P. 135)
P. 135)
P. 136)
P. 136)
Draining engine oil, cleaning engine oil screen
Warning
Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven.
ಥ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the engine oil only when the engine is warm.
ಥ
Stand the motorcycle on its side stand on a horizontal surface.
ಥ
Place a suitable container under the engine.
ಥ
Remove engine oil plug screen‘.
ಥ
Completely drain the engine oil.
ಥ
Thoroughly clean the plug and gear oil screen.
ಥ
Clean the sealing area on the engine.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Fit plug‘ for the engine oil screen and tighten it.
Specification
200112-10
Plug, engine oil screen
M17x1,5
20‘Nm
(14.75‘lbf‘ft)
Removing the oil filter
Warning
Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven.
ಥ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ಥ
Place a suitable container under the engine.
38/LUBRICATION SYSTEM
136
ಥ
Remove screws‘. Remove oil filter cover‘ with O-ring.
ಥ
Pull the oil filter insert‘ out of the oil filter casing.
200113-10
Circlip pliers reverse (51012011000)
ಥ
Completely drain the engine oil.
ಥ
Thoroughly clean parts and sealing area.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with
engine oil.
ಥ
Fill the oil filter‘ with engine oil and place it in the oil filter container.
ಥ
Lubricate the O/ring‘ of the oil filter cover.
ಥ
Refit the oil filter cover‘.
ಥ
Mount and tighten screws‘.
Specification
200114-10
Mounting oil filter
200114-11
Screw, oil filter cover
ಥ
M5
6‘Nm (4.43‘lbf‘ft)
Stand the motorcycle up.
200113-11
Filling up with engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ಥ
Remove the screw cap‘ on the generator cover and fill up with engine oil.
Engine oil
ಥ
0.6‘l (0.63‘qt.)
Engine oil (SAE 10W/50) (
P. 174)
Mount and tighten screw cap‘.
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
200115-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ಥ
Start the engine and check that it is oil-tight.
ಥ
Check the engine oil level. (
P. 134)
38/LUBRICATION SYSTEM
137
Topping up engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ಥ
Remove the screw cap‘ on the generator cover and fill up with engine oil.
Engine oil (SAE 10W/50) (
ಥ
P. 174)
Mount and tighten screw cap‘.
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
200115-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ಥ
Start the engine and check that it is oil-tight.
ಥ
Check the engine oil level. (
P. 134)
ಥ
Check the engine oil level. (
P. 134)
ಥ
Remove the release screw of the chain adjuster.
ಥ
Mount and tighten special tool‘.
Specification
Checking the engine oil pressure
700074-10
ಥ
Oil pressure adapter
M10x1
Oil pressure adapter (77329006000) (
P. 181)
10‘Nm
(7.38‘lbf‘ft)
Connect pressure testing tool‘ without the T-plate to the special tool.
Pressure testing tool (61029094000) (
P. 179)
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ಥ
Start the engine and let it warm up.
ಥ
Check the engine oil pressure.
Engine oil pressure
»
ಥ
Engine oil temperature: 80‘°C
(176‘°F)
Engine speed: 1600‘rpm
0.9‘bar (13.05‘psi)
Engine oil temperature: 80‘°C
(176‘°F)
Engine speed: 6000‘rpm
2.5‘bar (36.26‘psi)
If the specified value is not reached:
ಥ Check the oil pumps for wear. Check that all oil holes are clear.
Switch off the engine.
Warning
Danger of burnsಗSome vehicle components get very hot when the machine
is driven.
ಥ
Wear suitable protective clothing and gloves. If you scald yourself, hold
the affected area under cold water immediately.
ಥ
Detach the special tool.
ಥ
Mount and tighten the release screw of the chain adjuster.
Specification
Screw, unlocking of timing chain tensioner
M10x1
10‘Nm
(7.38‘lbf‘ft)
38/LUBRICATION SYSTEM
138
Checking gear oil level
Info
The gear oil level must be checked when the engine is cold.
ಥ
Stand the motorcycle upright on a horizontal surface.
Condition
Engine is cold.
ಥ Remove gear oil level check screw‘. Stand the vehicle upright.
ಥ
Check the gear oil level.
A small amount of gear oil should flow out.
»
ಥ
If no gear oil flows out:
ಥ Top up with gear oil. (
P. 139)
Mount and tighten the gear oil level check screw.
Specification
200116-10
Screw, gear oil level check
M6
10‘Nm
(7.38‘lbf‘ft)
Changing gear oil, cleaning gear oil screen
ಥ
Drain the gear oil and clean the gear oil screen. (
ಥ
Fill up with gear oil. (
P. 138)
P. 139)
Draining gear oil, cleaning gear oil screen
Warning
Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven.
ಥ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the gear oil only when the engine is warm.
ಥ
Stand the motorcycle on its side stand on a horizontal surface.
ಥ
Place a suitable container under the engine.
ಥ
Remove the gear oil drain plug‘.
ಥ
Remove the gear oil screen plug‘.
ಥ
Completely drain the gear oil.
ಥ
Thoroughly clean the gear oil drain plug with a magnet.
ಥ
Thoroughly clean the drain plug and gear oil screen with a magnet.
ಥ
Clean the sealing surface on the engine.
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
ಥ
Refit gear oil drain plug‘ with seal ring and tighten it.
Specification
Gear oil drain plug with magnet
ಥ
20‘Nm
(14.75‘lbf‘ft)
Fit the plug‘ for the gear oil screen and tighten it.
Specification
Plug, gear oil screen
500159-10
M12x1,5
M16x1,5
20‘Nm
(14.75‘lbf‘ft)
38/LUBRICATION SYSTEM
139
Filling up with gear oil
Info
Too little gear oil or poor-quality oil results in premature wear to the transmission.
ಥ
Remove the screw cap‘ and fill up with gear oil.
Gear oil
ಥ
0.9‘l (0.95‘qt.)
Engine oil (SAE 10W/50) (
P. 174)
Mount and tighten screw cap‘.
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
200118-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ಥ
Start the engine and check that it is oil-tight.
ಥ
Check the gear oil level. (
P. 138)
Topping up with gear oil
Info
Too little gear oil or poor-quality oil results in premature wear to the transmission.
ಥ
Remove gear oil level check screw‘.
200116-10
ಥ
Remove screw cap‘. Stand the vehicle upright.
ಥ
Top up with gear oil until it flows out of the bore of the gear oil level screw.
Engine oil (SAE 10W/50) (
ಥ
P. 174)
Mount and tighten the gear oil level check screw.
Specification
Screw, gear oil level check
200118-11
ಥ
M6
10‘Nm
(7.38‘lbf‘ft)
Mount and tighten screw cap‘.
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
ಥ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Start the engine and check that it is oil-tight.
TROUBLESHOOTING
140
7528%/(6+227,1*
Faults
Possible cause
Measure
The engine cannot be cranked (electric
starter).
Operating error
ಥ
Perform the steps necessary to start
the engine.
Battery discharged
ಥ
Recharge the battery. (
ಥ
Check the cause of discharging.
ಥ
Remove the fuse. (
P. 42)
ಥ
Replace the fuse. (
P. 42)
ಥ
Start the engine with the kickstarter.
ಥ
Recharge the battery. Establish the
reason for discharging or have it
checked in a KTM workshop.
Operating error
ಥ
Perform the steps necessary to start
the engine.
Motorcycle was out of use for a long time
and there is old fuel in the float chamber
ಥ
Empty the carburetor float chamber.
( P. 127)
Fuel feed interrupted
ಥ
Check tank vent.
ಥ
Clean fuel tap.
ಥ
Clean carburetor.
Engine flooded
ಥ
Clean and dry spark plug or replace if
necessary.
Spark plug oily or wet
ಥ
Clean and dry spark plug or replace if
necessary.
Electrode distance (plug gap) of spark
plug too wide
ಥ
Adjust plug gap.
Specification
Spark plug electrode gap
0.8… 0.9‘mm (0.03… 0.04‘in)
Fuse blown
Low external temperature
Engine turns but does not start.
Spark plug connector or spark plug defective
P. 43)
Warning
Risk of injuryಗThe ignition
system is under high voltage.
ಥ
Do not touch parts of the ignition system. Have work on
the ignition system carried
out in an authorized KTM
workshop.
ಥ
Remove spark plug, connect ignition
cable, hold spark plug to ground (bare
metal area on engine), and try to start
the engine.
Specification
You should see a strong spark on the
spark plug.
ಥ
If there is no spark, change the spark
plug.
ಥ
If there is still no spark, remove the
spark plug cap from the ignition cable,
hold it at the specified distance from
the ground contact, and try to start the
engine.
Specification
5‘mm (0.2‘in)
ಥ
If you now have a spark, replace the
spark plug connector.
ಥ
If there is no spark, have the ignition
system checked.
Short-circuit cable in cable harness
frayed, short-circuit button or emergency
OFF switch defective
ಥ
Check wiring harness. (visual check)
ಥ
Check electrical system.
Socket connector of CDI control device,
pulse generator or ignition coil oxidized.
ಥ
Clean socket connector and treat it
with contact spray.
TROUBLESHOOTING
Faults
141
Possible cause
Measure
Engine turns but does not start.
Water in carburetor or jets blocked
ಥ
Clean carburetor.
Engine has no idle.
Idling jet blocked
ಥ
Clean carburetor.
Adjusting screws on carburetor distorted
ಥ
Have the carburetor adjusted.
Spark plug defective
ಥ
Change spark plug.
Ignition system defective
ಥ
Have ignition system checked.
Carburetor running over because float
needle dirty or worn.
ಥ
Have carburetor checked.
Loose carburetor jets
ಥ
Have carburetor checked.
Electronic ignition adjustment defective
ಥ
Have ignition system checked.
Fuel feed interrupted
ಥ
Check tank vent.
ಥ
Clean fuel tap.
ಥ
Clean carburetor.
Air filter very dirty
ಥ
Clean the air filter. (
Exhaust system leaky, deformed or too
little glass fiber yarn filling in main silencer.
ಥ
Check exhaust system for damage.
ಥ
Change glass fiber yarn filling of main
silencer.
Valve clearance too little
ಥ
Have valve clearance adjusted.
Engine does not speed up.
Engine has too little power.
Engine stalls or is popping into the carburetor.
Engine overheats.
P. 27)
Electronic ignition adjustment defective
ಥ
Have ignition system checked.
Lack of fuel
ಥ
Clean and check the fuel system and
carburetor.
Engine takes in bad air
ಥ
Check rubber sleeves and carburetor
for tightness.
Too little coolant in cooling system
ಥ
Check the cooling system for leakage.
ಥ
Check the coolant level. (
Too little air stream
ಥ
Switch off engine when standing.
Radiator fins very dirty
ಥ
Clean radiator fins.
Foam formation in cooling system
ಥ
Drain the coolant. (
P. 133)
P. 133)
P. 132)
ಥ
Refill the coolant. (
Bent radiator hose
ಥ
Replace the radiator hose.
Thermostat defective
ಥ
Have thermostat removed and checked.
Specification
Opening temperature: 70‘°C (158‘°F)
Defect in radiator fan system
(EXC-R‘SIX‘DAYS, XCR-W‘ZA)
ಥ
Have the radiator fan system checked.
Engine vent hose bent
ಥ
Route the vent hose without bends or
replace it if necessary.
Engine oil level too high
ಥ
Check the engine oil level. (
Engine oil too thin (low viscosity)
ಥ
Change the engine oil and oil filter
and clean the engine oil screen.
( P. 135)
Battery discharged
Battery is not charged by generator
ಥ
Check electrical system.
Speedometer values deleted (time, stop
watch, lap times)
The battery in the speedometer ist empty.
ಥ
Change the battery in the speedometer.
High oil consumption
P. 134)
TECHNICAL DATA - ENGINE
142
7(&+1,&$/ '$7$ (1*,1(
Design
1-cyliner 4-stroke engine, water-cooled
Displacement (Every 450 models)
449.3‘cm³ (27.42‘cu‘in)
Displacement (Every 530 models)
510.4‘cm³ (31.15‘cu‘in)
Stroke (Every 450 models)
63.4‘mm (2.5‘in)
Stroke (Every 530 models)
72‘mm (2.83‘in)
Bore
95‘mm (3.74‘in)
Compression ratio
11,9:1
Idle speed
1550… 1650‘rpm
Control
4 valves controlled via rocker arm, drive via tooth/wheel chain
Valve diameter, intake
39.5‘mm (1.56‘in)
Valve diameter, exhaust
31.7‘mm (1.25‘in)
Valve clearance
Outfeed at: 20‘°C (68‘°F)
0.12… 0.17‘mm (0.0047… 0.01‘in)
Infeed at: 20‘°C (68‘°F)
0.1… 0.15‘mm (0.0039… 0.01‘in)
Crankshaft bearing
2 grooved ball bearings
Conrod bearing
Needle bearing
Piston pin bearing
not a bearing bush - DLC-plated piston pins
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with 2 rotor pumps (engine) / 1
rotor pump (transmission)
Primary transmission
33:76
Clutch
Multidisc clutch in oil bath / hydraulically activated
Transmission ratio
1st gear
14:36
2nd gear
17:32
3rd gear
19:28
4th gear
22:26
5th gear
24:23
6th gear
26:21
Generator
12‘V, 150‘W
Ignition
Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan
Spark plug
NGK LK AR 8A - 9
Spark plug electrode gap
0.8… 0.9‘mm (0.03… 0.04‘in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Starting aid
Electric starter / kickstarter
Capacity- engine oil
Engine oil
0.6‘l (0.63‘qt.)
Engine oil (SAE 10W/50) (
P. 174)
0.9‘l (0.95‘qt.)
Engine oil (SAE 10W/50) (
P. 174)
Capacity - gear oil
Gear oil
TECHNICAL DATA - ENGINE
143
Capacity - coolant
Coolant
0.95‘l (1‘qt.)
Coolant (
P. 174)
Coolant (mixed ready to use) (
P. 174)
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE
7(&+1,&$/ '$7$ 72/(5$1&( :($5 /,0,76 2) (1*,1(
Camshaft - cam height
Intake
33… 33.2‘mm (1.3… 1.31‘in)
Camshaft - cam height (Every 450 models)
Exhaust
33.9… 34.1‘mm (1.33… 1.34‘in)
Camshaft - cam height (Every 530 models)
Exhaust
34.2… 34.4‘mm (1.35… 1.35‘in)
Valve
Sealing seat width, intake
1.5‘mm (0.06‘in)
Sealing seat width, exhaust
2‘mm (0.08‘in)
Run-out on valve plate
싨‘0.05‘mm (싨‘0.002‘in)
Valve spring
Minimum length, intake (without bottom valve spring retainer)
46.5‘mm (1.83‘in)
Minimum length, exhaust (without bottom valve spring retainer)
43‘mm (1.69‘in)
Bottom valve spring retainer
0.9… 1‘mm (0.04… 0.04‘in)
Cylinder/cylinder head - sealing area distortion
싨‘0.1‘mm (싨‘0.0039‘in)
Piston - diameter
Size I
94.93… 94.96‘mm (3.74… 3.74‘in)
Size II
94.95… 94.97‘mm (3.74… 3.74‘in)
Cylinder - bore diameter
Size I
95… 95.012‘mm (3.74… 3.74‘in)
Size II
95.013… 95.025‘mm (3.74… 3.74‘in)
Piston/cylinder - mounting clearance
Size I
0.04… 0.082‘mm (0.0016… 0.0032‘in)
Size II
0.043… 0.075‘mm (0.0017… 0.003‘in)
Wear limit
싨‘0.12‘mm (싨‘0.0047‘in)
Piston ring end gap
Compression ring
Oil scraper ring
Conrod bearing - axial clearance
싨‘1‘mm (싨‘0.04‘in)
싨‘1.2‘mm (싨‘0.05‘in)
싨‘1.1‘mm (싨‘0.04‘in)
Conrod bearing - radial clearance
싨‘0.05‘mm (싨‘0.002‘in)
Crankshaft - run-out on bearing pin
싨‘0.16‘mm (싨‘0.01‘in)
Crankshaft - external crank web dimension
63¢0.05‘mm (2.48¢0.002‘in)
Clutch facing disc - thickness
2.6… 2.7‘mm (0.1… 0.11‘in)
Clutch spring - length
43… 44.03‘mm (1.69… 1.73‘in)
Thrust surface, clutch facing discs in outer clutch hub
싨‘0.5‘mm (싨‘0.02‘in)
Oil pressure regulator valve
Minimum length of preload spring
23.5‘mm (0.93‘in)
Oil pump
Clearance between external rotor and engine housing
싨‘0.2‘mm (싨‘0.01‘in)
Clearance between external rotor and internal rotor
싨‘0.2‘mm (싨‘0.01‘in)
Axial clearance
싨‘0.15‘mm (싨‘0.01‘in)
Shift fork
Thickness at leaf
4.85… 4.95‘mm (0.19… 0.19‘in)
Shift shaft - play in sliding plate/shift quadrant
0.4… 0.8‘mm (0.02… 0.03‘in)
Transmission shaft - run-out
싨‘0.06‘mm (싨‘0.0024‘in)
144
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
145
7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6
Screw, cable holder in generator cover
M4
4‘Nm (2.95‘lbf‘ft)
Loctite® 243™
Oil jet, rocker arm lubrication
M5
2‘Nm (1.48‘lbf‘ft)
Loctite® 243™
Oil jet, piston cooling
M5
2‘Nm (1.48‘lbf‘ft)
Loctite® 243™
Screw, locking lever
M5
6‘Nm (4.43‘lbf‘ft)
Loctite® 243™
Screw, ignition pulse generator
M5
6‘Nm (4.43‘lbf‘ft)
Loctite® 243™
Screw, clutch spring
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Locking screw for bearing
M5
6‘Nm (4.43‘lbf‘ft)
Loctite® 243™
Screw, oil filter cover
M5
6‘Nm (4.43‘lbf‘ft)
ಥ
Screw, oil pump cover
M5
6‘Nm (4.43‘lbf‘ft)
Loctite® 222
Oil jet, conrod lubrication
M6x0,75
4‘Nm (2.95‘lbf‘ft)
Loctite® 243™
Nut, water-pump wheel
M6
6‘Nm (4.43‘lbf‘ft)
Loctite® 648™
Screw, kickstarter stop
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, timing chain securing guide
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, exhaust flange
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, torque governor
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, starter motor
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, kickstarter spring hanger
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, timing chain guide rail
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, generator cover (through-hole
for chain shaft)
M6x25
10‘Nm (7.38‘lbf‘ft)
Loctite® 222
Screw generator cover
M6x25
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw generator cover
M6x40
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, gear oil level check
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, clutch cover
M6x25
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, clutch cover
M6x30
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, clutch cover
M6x55
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, clutch slave cylinder
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, engine housing
M6x65
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, engine housing
M6x80
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, camshaft bearing support
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, shift drum locating
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, shift lever
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, timing chain tensioning rail
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, stator bracket
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, valve cover
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, water pump cover
M6x25
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, water pump cover
M6x55
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, idler
M6
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Screw, cylinder head
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, rocker arm bearing
M7x1
15‘Nm (11.06‘lbf‘ft)
ಥ
Plug, oil channel
M7
9‘Nm (6.64‘lbf‘ft)
Loctite® 243™
Screw, kickstarter
M8
25‘Nm (18.44‘lbf‘ft)
Loctite® 243™
Plug, crankshaft location
M8
10‘Nm (7.38‘lbf‘ft)
ಥ
Balancer shaft nut
M10x1
40‘Nm (29.5‘lbf‘ft)
ಥ
Screw, unlocking of timing chain tensioner
M10x1
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, engine sprocket
M10
60‘Nm (44.26‘lbf‘ft)
Loctite® 243™
Plug, oil channel
M10
15‘Nm (11.06‘lbf‘ft)
Loctite® 243™
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
146
Screw, cylinder head
M10x1,25
Tightening sequence:
Tighten diagonally, beginning with the rear screw on
the chain shaft.
Step 1
10‘Nm (7.38‘lbf‘ft)
Step 2
30‘Nm (22.13‘lbf‘ft)
Step 3
50‘Nm (36.88‘lbf‘ft)
Engine oil (any)
Gear oil drain plug with magnet
M12x1,5
20‘Nm (14.75‘lbf‘ft)
ಥ
Ignition rotor nut
M12x1
60‘Nm (44.26‘lbf‘ft)
ಥ
Plug, SLS
M12x1,5
20‘Nm (14.75‘lbf‘ft)
ಥ
Oil pressure control valve plug
M12x1,5
20‘Nm (14.75‘lbf‘ft)
ಥ
Spark plug
M12x1,25
15… 20‘Nm (11.06…
14.75‘lbf‘ft)
ಥ
Plug, rocker arm
M14x1,25
20‘Nm (14.75‘lbf‘ft)
ಥ
Plug, gear oil screen
M16x1,5
20‘Nm (14.75‘lbf‘ft)
ಥ
Plug, engine oil screen
M17x1,5
20‘Nm (14.75‘lbf‘ft)
ಥ
Nut, inner clutch hub
M18x1,5
80‘Nm (59.01‘lbf‘ft)
ಥ
Nut, primary gear
M20LHx1,5
150‘Nm (110.64‘lbf‘ft)
Loctite® 648™
Plug, timing chain tensioner
M24x1,5
25‘Nm (18.44‘lbf‘ft)
ಥ
TECHNICAL DATA - CARBURETOR
147
7(&+1,&$/ '$7$ &$5%85(725
450‘EXC-R‘EU, 450‘EXC-R‘AUS/UK (3900I)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3900I
Needle position
4th position from top
Idle mixture adjusting screw
Open
Pump membrane stop
1.75‘turns
2.15‘mm (0.08‘in)
Main jet
180
Jet needle
OBDYU (OBDTQ)
Idling jet
40
Main air jet
200
Idle air jet
100
Cold start jet
65 (85)
Leakage nozzle
40
Throttle slide
15
Slide stop
present
450‘EXC-R‘SIX‘DAYS, 450‘EXC-R‘USA, 450‘XCR-W (3900L)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identfication number
3900L
Needle position (450‘XCR-W‘USA)
1st position from top
Needle position (450‘EXC-R‘SIX‘DAYS)
3rd position from top
Needle position (450‘EXC-R‘USA, 450‘XCR-W‘ZA)
4th position from top
Idle mixture adjusting screw (450‘XCR-W‘USA)
Open
0.5‘turn
Idle mixture adjusting screw (450‘EXC-R‘SIX‘DAYS)
Open
1‘turn
Idle mixture adjusting screw (450‘XCR-W‘ZA)
Open
1.5‘turns
Idle mixture adjusting screw (450‘EXC-R‘USA)
Open
1.75‘turns
Pump membrane stop
2.15‘mm (0.08‘in)
Main jet (450‘EXC-R‘SIX‘DAYS, 450‘EXC-R‘USA, 450‘XCRW‘USA)
180
Main jet (450‘XCR-W‘ZA)
185
Jet needle (450‘XCR-W, 450‘EXC-R‘SIX‘DAYS)
OBDTQ
Jet needle (450‘EXC-R‘USA)
OBDYU
Idling jet (450‘XCR-W, 450‘EXC-R‘SIX‘DAYS)
40
Idling jet (450‘EXC-R‘USA)
48
Main air jet
200
Idle air jet
100
Cold start jet
85
Leakage nozzle
40
Throttle slide
15
TECHNICAL DATA - CARBURETOR
148
530‘EXC-R‘EU, 530‘EXC-R‘AUS/UK (3900J)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identfication number
3900J
Needle position
5th position from top
Idle mixture adjusting screw
Open
Pump membrane stop
1.5‘turns
2.15‘mm (0.08‘in)
Main jet
180
Jet needle
OBDZT (OBDTR)
Idling jet
40
Main air jet
200
Idle air jet
100
Cold start jet
65 (85)
Leakage nozzle
40
Throttle slide
15
Slide stop
present
530‘EXC-R‘SIX‘DAYS, 530‘EXC-R‘USA, 530‘XCR-W (3900M)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identfication number
3900M
Needle position (530‘XCR-W‘USA)
1st position from top
Needle position (530‘EXC-R‘SIX‘DAYS, 530‘EXC-R‘USA)
3rd position from top
Needle position (530‘XCR-W‘ZA)
4th position from top
Idle mixture adjusting screw (530‘XCR-W‘USA)
Open
0.5‘turn
Idle mixture adjusting screw (530‘EXC-R‘SIX‘DAYS)
Open
1‘turn
Idle mixture adjusting screw (530‘XCR-W‘ZA)
Open
1.5‘turns
Idle mixture adjusting screw (530‘EXC-R‘USA)
Open
2‘turns
Pump membrane stop
2.15‘mm (0.08‘in)
Main jet (530‘EXC-R‘SIX‘DAYS, 530‘EXC-R‘USA, 530‘XCRW‘USA)
180
Main jet (530‘XCR-W‘ZA)
185
Jet needle (530‘XCR-W, 530‘EXC-R‘SIX‘DAYS)
OBDTR
Jet needle (530‘EXC-R‘USA)
OBDZT
Idling jet (530‘XCR-W, 530‘EXC-R‘SIX‘DAYS)
40
Idling jet (530‘EXC-R‘USA)
48
Main air jet
200
Idle air jet
100
Cold start jet
85
Leakage nozzle
40
Throttle slide
15
TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES
149
7(&+1,&$/ '$7$ &$5%85(725 7,*+7(1,1* 72548(6
Leakage nozzle
M4x0,7
2‘Nm (1.48‘lbf‘ft)
ಥ
Screw, throttle slide arm
M4
2‘Nm (1.48‘lbf‘ft)
Loctite® 243™
Screw, hose connection
M4
2‘Nm (1.48‘lbf‘ft)
Loctite® 243™
Other screws, carburetor
M4
2‘Nm (1.48‘lbf‘ft)
ಥ
Idle air jet
M4,5x0,75
2‘Nm (1.48‘lbf‘ft)
ಥ
Main jet
M5x0,75
2‘Nm (1.48‘lbf‘ft)
ಥ
Cold start jet
M5x0,75
2‘Nm (1.48‘lbf‘ft)
ಥ
Screw, throttle valve sensor
M5
3.5‘Nm (2.58‘lbf‘ft)
ಥ
Idling jet
M6x0,75
2‘Nm (1.48‘lbf‘ft)
ಥ
Needle jet
M7x0,75
3.5‘Nm (2.58‘lbf‘ft)
ಥ
Needle screw/slide stop
M8
3.5‘Nm (2.58‘lbf‘ft)
ಥ
Choke slide
M12
2.5‘Nm (1.84‘lbf‘ft)
ಥ
TECHNICAL DATA - CHASSIS
150
7(&+1,&$/ '$7$ &+$66,6
Frame
Central tube frame made of chrome molybdenum steel tubing
Fork
WP 4860 MXMA PA
Suspension travel
front
300‘mm (11.81‘in)
Rear
335‘mm (13.19‘in)
Fork offset (EXC-R‘SIX‘DAYS, XCR-W‘USA)
Front marking
18‘mm (0.71‘in)
Rear marking
20‘mm (0.79‘in)
Fork offset (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W‘ZA)
20‘mm (0.79‘in)
Shock absorber
WP PDS 5018 DCC
Brake system
Disc brakes, brake calipers on floating bearings
Diameter of brake discs
front
260‘mm (10.24‘in)
Rear
220‘mm (8.66‘in)
Wear limit of brake discs
front
2.5‘mm (0.1‘in)
Rear
3.5‘mm (0.14‘in)
Tire air pressure off road
front
1‘bar (14.5‘psi)
Rear
1‘bar (14.5‘psi)
Road tire pressure (Every EXC-R models)
front
1.5‘bar (21.76‘psi)
Rear
2‘bar (29.01‘psi)
Rear wheel gearing (450‘EXC-R‘EU, 450‘EXC-R‘AUS/UK,
450‘EXC-R‘USA)
15:45 (14:52)
Rear wheel gearing (450‘EXC-R‘SIX‘DAYS, XCR-W‘ZA)
14:52
Rear wheel gearing (530‘EXC-R‘SIX‘DAYS, XCR-W‘USA)
14:50
Rear wheel gearing (530‘EXC-R‘EU, 530‘EXC-R‘AUS/UK)
15:45 (14:50)
Chain
5/8 x 1/4"
Rear sprockets available
38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle
63.5°
Wheelbase
1475¢10‘mm (58.07¢0.39‘in)
Seat height unloaded
925‘mm (36.42‘in)
Ground clearance unloaded
380‘mm (14.96‘in)
Weight without fuel (EXC-R‘EU, EXC-R‘AUS/UK,
EXC-R‘SIX‘DAYS)
113.9‘kg (251.1‘lb.)
Weight without fuel (XCR-W‘USA)
112.2‘kg (247.36‘lb.)
Weight without fuel (XCR-W‘ZA)
113‘kg (249.12‘lb.)
Weight without fuel (EXC-R‘USA)
114.8‘kg (253.09‘lb.)
Maximum permissible front axle load
145‘kg (319.67‘lb.)
Maximum permissible rear axle load
190‘kg (418.87‘lb.)
Maximum permissible overall weight
335‘kg (738.54‘lb.)
4Ah battery
YTX5L-BS
Battery voltage: 12‘V
Nominal capacity: 4‘Ah
maintenance-free
TECHNICAL DATA - CHASSIS
151
Lighting equipment
Headlight (EXC-R‘EU, EXC-R‘AUS/UK,
EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W‘ZA)
BA20d
12‘V
35/35‘W
Parking light (EXC-R‘EU, EXC-R‘AUS/UK,
EXC-R‘SIX‘DAYS, EXC-R‘USA, XCR-W‘ZA)
W2,1x9,5d
12‘V
5‘W
Indicator lights (Every EXC-R models)
W2x4,6d
12‘V
1.2‘W
Flasher light (EXC-R‘EU, EXC-R‘AUS/UK)
BA15s
12‘V
10‘W
Flasher light (EXC-R‘USA)
BAU15s
12‘V
10‘W
Brake / tail light (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘SIX‘DAYS,
XCR-W‘ZA)
LED
Brake / tail light (EXC-R‘USA)
BAY15d
12‘V
21/5‘W
Licence plate lamp (EXC-R‘EU, EXCR‘AUS/UK)
W2,1x9,5d
12‘V
5‘W
Validity
Front tire
Rear tire
(Every EXC-R models)
90/90‘-‘21‘48‘M+S‘M‘TT
Metzeler MCE‘6‘DAYS‘EXTREME
140/80‘-‘18‘70‘M+S‘M‘TT
Metzeler MCE‘6‘DAYS‘EXTREME
(Every XCR-W models)
80/100‘-‘21‘51‘M‘TT
Bridgestone M59
110/100‘-‘18‘64‘M‘TT
Bridgestone M402
Tires
For further information, see:
http://www.ktm.com
Capacity - fuel
Tank capacity (EXC-R‘EU,
EXC-R‘AUS/UK,
EXC-R‘SIX‘DAYS, XCR-W‘ZA)
9‘l (2.38‘US‘gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
P. 174)
Tank capacity (EXC-R‘USA,
XCR-W‘USA)
9.2‘l (2.43‘US‘gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
P. 174)
TECHNICAL DATA - FORK
152
7(&+1,&$/ '$7$ )25.
Fork part number (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCRW)
14.18.7D.06
Fork part number (EXC-R‘SIX‘DAYS)
14.18.7D.35
Fork
WP 4860 MXMA PA
Compression damping (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
Comfort
24‘clicks
Standard
20‘clicks
Sport
18‘clicks
Compression damping (EXC-R‘SIX‘DAYS)
Comfort
24‘clicks
Standard
22‘clicks
Sport
18‘clicks
Rebound damping (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
Comfort
20‘clicks
Standard
18‘clicks
Sport
18‘clicks
Rebound damping (EXC-R‘SIX‘DAYS)
Comfort
20‘clicks
Standard
20‘clicks
Sport
18‘clicks
Spring length with preload spacer(s)
510‘mm (20.08‘in)
Spring rate (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
4.4‘N/mm (25.12‘lb/in)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
4.6‘N/mm (26.27‘lb/in)
Weight of rider: 85… 95‘kg (187.39… 209.44‘lb.)
4.8‘N/mm (27.41‘lb/in)
Spring rate (EXC-R‘SIX‘DAYS)
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
4.6‘N/mm (26.27‘lb/in)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
4.8‘N/mm (27.41‘lb/in)
Air chamber length
+1.18
100+30
-20 ‘mm (3.94-0.79 ‘in)
Spring preload - Preload‘Adjuster (EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
Comfort
2‘turns
Standard
4‘turns
Sport
7‘turns
Spring preload - Preload‘Adjuster (EXC-R‘SIX‘DAYS)
Comfort
2‘turns
Standard
2‘turns
Sport
7‘turns
Fork length
Fork oil (
940‘mm (37.01‘in)
P. 174)
SAE 5
TECHNICAL DATA - SHOCK ABSORBER
7(&+1,&$/ '$7$ 6+2&. $%625%(5
Shock absorber part number (EXC-R‘EU, EXC-R‘AUS/UK, EXCR‘USA, XCR-W)
12.18.7D.06
Shock absorber part number (EXC-R‘SIX‘DAYS)
12.18.7D.35
Shock absorber
WP PDS 5018 DCC
Compression damping, low-speed
Comfort
18‘clicks
Standard
15‘clicks
Sport
12‘clicks
Compression damping, high-speed
Comfort
2‘turns
Standard
1.5‘turns
Sport
1‘turn
Rebound damping
Comfort
24‘clicks
Standard
22‘clicks
Sport
20‘clicks
Spring preload
Standard
9‘mm
Spring rate
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
69‘N/mm (394‘lb/in)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
72‘N/mm (411.13‘lb/in)
Weight of rider: 85… 95‘kg (187.39… 209.44‘lb.)
76‘N/mm (433.97‘lb/in)
Spring length
250‘mm (9.84‘in)
Gas pressure
10‘bar (145.04‘psi)
Static sag
35‘mm (1.38‘in)
Riding sag
105‘mm (4.13‘in)
Fitted length
411‘mm (16.18‘in)
153
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
154
7(&+1,&$/ '$7$ &+$66,6 7,*+7(1,1* 72548(6
Spoke nipple, front wheel
M4,5
5‘Nm (3.69‘lbf‘ft)
ಥ
Spoke nipple, rear wheel
M5
5‘Nm (3.69‘lbf‘ft)
ಥ
Remaining nuts, chassis
M6
15‘Nm (11.06‘lbf‘ft)
ಥ
Remaining screws, chassis
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, rear brake disc
M6
14‘Nm (10.33‘lbf‘ft)
ಥ
Screw, front brake disc
M6
14‘Nm (10.33‘lbf‘ft)
ಥ
Screw, shock absorber adjusting ring
M6
5‘Nm (3.69‘lbf‘ft)
ಥ
Screw, ball joint of push rod on footbrake cylinder
M6
10‘Nm (7.38‘lbf‘ft)
ಥ
Nut, rear sprocket screw
M8
35‘Nm (25.82‘lbf‘ft)
Loctite® 243™
Nut, rim lock
M8
10‘Nm (7.38‘lbf‘ft)
ಥ
Remaining nuts, chassis
M8
30‘Nm (22.13‘lbf‘ft)
ಥ
Remaining screws, chassis
M8
25‘Nm (18.44‘lbf‘ft)
ಥ
Screw, front brake caliper
M8
25‘Nm (18.44‘lbf‘ft)
Loctite® 243™
Screw, top triple clamp
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
M8
17‘Nm (12.54‘lbf‘ft)
ಥ
Screw, top triple clamp (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCRW‘ZA)
M8
20‘Nm (14.75‘lbf‘ft)
ಥ
Screw, bottom triple clamp
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
M8
12‘Nm (8.85‘lbf‘ft)
ಥ
Screw, bottom triple clamp (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCRW‘ZA)
M8
15‘Nm (11.06‘lbf‘ft)
ಥ
Screw, fork stub
M8
15‘Nm (11.06‘lbf‘ft)
ಥ
Screw, top steering stem
(EXC-R‘SIX‘DAYS, XCR-W‘USA)
M8
17‘Nm (12.54‘lbf‘ft)
Loctite® 243™
Screw, top steering stem (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCRW‘ZA)
M8
20‘Nm (14.75‘lbf‘ft)
ಥ
Screw, handlebar clamp (EXC-R‘EU,
EXC-R‘AUS/UK, EXC-R‘USA, XCR-W)
M8
20‘Nm (14.75‘lbf‘ft)
ಥ
Screw, handlebar clamp
(EXC-R‘SIX‘DAYS)
M8
16‘Nm (11.8‘lbf‘ft)
ಥ
Screw, engine brace
M8
33‘Nm (24.34‘lbf‘ft)
ಥ
Screw, subframe
M8
35‘Nm (25.82‘lbf‘ft)
Loctite® 243™
Screw, side stand fixing
M8
40‘Nm (29.5‘lbf‘ft)
Loctite® 243™
Engine carrying screw
M10
60‘Nm (44.26‘lbf‘ft)
ಥ
Remaining nuts, chassis
M10
50‘Nm (36.88‘lbf‘ft)
ಥ
Remaining screws, chassis
M10
45‘Nm (33.19‘lbf‘ft)
ಥ
Screw, handlebar support
M10
40‘Nm (29.5‘lbf‘ft)
Loctite® 243™
Nut, seat fixing
M12x1
20‘Nm (14.75‘lbf‘ft)
ಥ
Screw, top shock absorber
M12
80‘Nm (59.01‘lbf‘ft)
Loctite® 243™
Screw, bottom shock absorber
M12
80‘Nm (59.01‘lbf‘ft)
Loctite® 243™
Nut, swingarm pivot
M16x1,5
100‘Nm (73.76‘lbf‘ft)
ಥ
Screw-in nozzles, cooling system
M20x1,5
12‘Nm (8.85‘lbf‘ft)
Loctite® 243™
Nut, rear wheel spindle
M20x1,5
80‘Nm (59.01‘lbf‘ft)
ಥ
Screw, top steering head
M20x1,5
10‘Nm (7.38‘lbf‘ft)
ಥ
Screw, bottom steering head (EXCR‘SIX‘DAYS, XCR-W‘USA)
M20x1,5
60‘Nm (44.26‘lbf‘ft)
Loctite® 243™
Screw, front wheel spindle
M24x1,5
40‘Nm (29.5‘lbf‘ft)
ಥ
CLEANING
155
&/($1,1*
Cleaning motorcycle
Note
Material damageಗDamage and destruction of components by high-pressure cleaning equipment.
ಥ
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
ಥ
Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
ಥ
First remove coarse dirt particles with a gentle water spray.
ಥ
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner (
P. 175)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
ಥ
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
ಥ
Empty the carburetor float chamber. (
P. 127)
Warning
Danger of accidentsಗReduced braking due to wet or dirty brakes.
ಥ
ಥ
Clean or dry dirty or wet brakes by riding and braking gently.
After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
ಥ
Push back the protection covers on the handlebar instruments to allow water to evaporate.
ಥ
After the motorcycle has cooled off, oil or grease all moving parts and bearings.
ಥ
Clean the chain. (
ಥ
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
P. 41)
Cleaning and polishing materials for metal, rubber and plastic (
ಥ
Treat all painted parts with a mild paint polish.
High-luster polish for paint (
ಥ
P. 176)
P. 176)
To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray (
P. 176)
(EXC-R‘EU, EXC-R‘AUS/UK, EXC-R‘USA)
ಥ Lubricate the steering lock.
Universal oil spray (
P. 175)
STORAGE
156
6725$*(
Storage
Warning
Danger of poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Info
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.
ಥ
Clean the motorcycle. (
ಥ
Change the engine oil and oil filter and clean the engine oil screen. (
ಥ
Check the antifreeze and coolant level. (
ಥ
Drain the fuel from the tank into a suitable container.
ಥ
Empty the carburetor float chamber. (
ಥ
Checking the tire air pressure. (
ಥ
Remove the battery. (
ಥ
Recharge the battery. (
Specification
P. 155)
P. 135)
P. 132)
P. 127)
P. 35)
P. 42)
P. 43)
Storage temperature of battery without direct sunshine.
0… 35‘°C (32… 95‘°F)
ಥ
The storage place should be dry and not subject to large temperature differences.
ಥ
Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Info
Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.
Putting into operation after storage
ಥ
Install the battery. (
ಥ
Fill up with fuel.
ಥ
Checks before putting into operation
ಥ
Take a short, careful test drive.
P. 43)
GREASING AND SERVICE TABLE
157
*5($6,1* $1' 6(59,&( 7$%/(
Important maintenance work to be carried out by an authorized KTM workshop.
Engine
Change the engine oil and oil filter and clean the engine oil screen. (
Change the gear oil and clean the gear oil screen. (
P. 135)
P. 138)
S3N
S15A
•
•
•
•
Replace spark plug.
Carburetor
Attachments
•
Check and adjust valve clearance.
•
•
Check engine mounting screws for tightness.
•
•
Clean spark plug connectors and check for tightness.
•
•
Check that the screws in the shift lever and the kickstarter are tight.
•
•
Check carburetor connection boots for cracks and leakage.
•
Check vent hoses for damage and routing without sharp bends.
•
•
Check idle.
•
•
Check the cooling system for leakage.
•
•
•
•
Check the antifreeze and coolant level. (
P. 132)
Check the exhaust system for leakage and looseness.
•
Check Bowden cables for damage, smooth operation and routing without sharp
bends.
•
•
Check the fluid level of the hydraulic clutch. (
•
•
•
•
Clean the air filter. (
P. 129)
P. 27)
Check cables for damage and routing without sharp bends.
Check that the electrical equipment is functioning properly.
•
•
Check the headlamp setting.
Brakes
Check the front brake linings.
•
•
Check the rear brake linings.
•
•
Check the brake discs.
•
•
Check the front brake fluid level.
•
•
Check the rear brake fluid level.
•
•
•
•
•
•
•
•
Check the free play of the hand brake lever. (
Check the free play of the foot brake lever. (
P. 47)
P. 51)
Check brake system function.
•
•
Check screws and guide bolts of brake system for tightness.
•
•
Check shock absorber and fork for leakage and functioning.
•
•
Clean dust boots of fork legs. (
Bleed fork legs. (
P. 10)
•
P. 12)
•
Check swingarm bearing.
Wheels
•
•
Check brake lines for damage and leakage.
Chassis
•
Check play of steering head bearing.
•
•
Check all screws to see if they are tight.
•
•
Check the spoke tension.
•
•
Check rim run-out.
•
•
•
•
•
•
Check the tire condition. (
P. 35)
Checking the tire air pressure. (
Check the chain wear. (
P. 35)
P. 41)
Check the chain tension. (
Clean the chain. (
S30A
P. 38)
P. 41)
•
•
•
•
•
•
Check wheel bearing for play.
•
•
Clean and grease adjusting screws of chain adjuster.
•
•
S3N: After 3 service hours
S15A: Every 15 service hours / after every race
S30A: Every 30 service hours
GREASING AND SERVICE TABLE
158
Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
Competition use
S15A
S30A
Hobby use
S45A
S30A
S60A
J1A
S90A
Carry out a complete fork service.
•
Carry out a complete shock absorber service.
Grease the steering head bearing. (
•
P. 18)
•
Clean and adjust carburetor.
•
Treat electric contacts with contact spray.
•
Change hydraulic clutch fluid. (
•
P. 129)
Change the front brake fluid. (
P. 48)
Change the rear brake fluid. (
•
P. 52)
•
Clean spark arrestor. (EXC-R‘USA, XCR-W‘USA)
Check wear of clutch discs.
Check the clutch. (
•
•
P. 89)
•
•
Check/measure the cylinder. (
P. 80)
Change the piston.
Check the camshaft. (
P. 84)
Change the camshaft bearing. (
P. 86)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the radial clearance of the rocker arm rollers.
•
•
Check the timing chain tensioner function.
•
•
Check the balancer shaft. (
•
•
•
•
Check the lower valve spring retainer. (
Check the cylinder head. (
Check the valves. (
P. 87)
P. 88)
P. 87)
Check the valve springs. (
P. 87)
P. 78)
Check the crankshaft run-out on the bearing pin.
( P. 80)
Change conrod bearing. (
P. 78)
Change the crankshaft main bearing.
Check the transmission. (
J2A
P. 93)
Check the shift mechanism. (
P. 90)
Check the spring length of the oil pressure regulator
valve. ( P. 75)
•
•
•
•
•
•
•
•
•
•
Change glass fiber yarn filling of main silencer.
•
•
Replace foot brake cylinder seals.
•
•
•
•
Check the carburetor components. (
P. 118)
S15A: Every 15 service hours / after every race
S30A: Every 30 service hours
S45A: Every 45 service hours
S60A: Every 60 service hours
S90A: Every 90 service hours
J1A: annually
J2A: every 2 years
Important checks and maintenance work to be carried out by the rider.
NB1A
Check the engine oil level. (
P. 134)
•
Check the front brake fluid level.
•
Check the rear brake fluid level.
•
Check the front brake linings.
•
Check the rear brake linings.
•
Check and adjust Bowden cables.
•
Bleed fork legs. (
•
P. 12)
GREASING AND SERVICE TABLE
159
NB1A
Clean dust boots of fork legs. (
Clean the chain. (
P. 10)
•
P. 41)
Check the chain tension. (
Check the chain wear. (
•
P. 38)
•
P. 41)
•
Check the rear sprocket / engine sprocket for wear. (
Clean the air filter. (
P. 40)
P. 27)
Checking the tire air pressure. (
•
•
P. 35)
•
Check the tire condition. (
P. 35)
•
Check the coolant level. (
P. 132)
•
Empty the carburetor float chamber. (
P. 127)
•
Check that all operating elements for smooth operation.
•
Check braking.
•
Check all screws, nuts and hose clamps regularly for tightness.
•
NB1A: Depending on conditions of use according to requirements.
br
dk
pu
bl
4
2
wh
bu
re
ye-re
br
1
br
br -bl
1
3
1
bt
bu
gn
1
9
ye
C_ BC / 6
5
2
C_BF1/1
C _ BA1 / 1
2
1
ck
C _ B G/ 3
C_BT/3
3
6
C_B K /4
4
3 2 1
C_BR/4
8
M
2
10
A
7
C_AF/4
4 3
bl
cl
G
1
C_AH2/2
2
wh
br
2
4
3
1
2
3
ye
cs
C _ A K/ 2
C_AH/2
1 2
br
bl
pu
1
ye-re
1
C_CR1/1
6 4
re
C_ A C/ 6
cq
br
3
ye-re
re
C _ B S/ 2
dl
2 1
1
C_A T 1 / 2
2
C _A L 1 / 2
br
bl
1
2
wh-gn
wh
br
2
U
C _ B S/ 2
C _ B V/ 2
2.2 2.1
5
C_BG/3
3
2
bl
C _ B V/ 2
C _B O / 2
1
br
2
ye-re
br
bl
C_AK1/2
2
ye
ye-bl
1
C _A L /2
2
C_BG1/3
bs v
bu
1
ye -b l
1
1
wh
wh-gn
2.1
2
C_AM/3
3
br
br
2
br
bl
6 11 10 12 13 14
bl
7
pu
C_CX/2
C_CX1/2
bl
br
gn
bu
C _ EI / 1
C_BA2/1
ye
5
C_A T /2
G
1
2
ye-bl
C_EH/1
1
gr
4
C_ AR/ 3
3
ye-re
2
3
2
1
C_CW/2
C_AJ/3
C_CW1/2
ye
ye-re
or
bu-wh
2
ye-bl
bl
C_BU/18
4
wh
C_AJ1/3
C_CA/4
main harness 594.11.075.150
CDI harness 780.39.032.000
wh-gn
ye-re
br
1
re
bm
bk
re-wh
wh-re
re-bl
1
2
2
wh
br
1
4
br
bu
wiring diagram
ye-re
gn
br
re
br
cr
C_CX2/2
C_DB/4
C_DA/4
bl
bl
bu
3
2
pu
wh
1
br
ct
bo
C_CW2/2
C_BP/4
C_CZ/3
C_CY/3
wh-re
ye
C_BF/1
bu-wh
3
pu
re-bl
ye
C_CR/1
or
gn
ye-bl
re-wh
gr
bl-wh
co
bn
cm
C_DG/4
C_CX3/2
C_AH1/2
C_CW3/2
C_CX/2
C_CW/2
ye-re
bl
160
WIRING DIAGRAM
:,5,1* ',$*5$0
Wiring diagram (EXC-R‘EU)
C_BA/1
br
C_CE/4
C_DI/2
cp
cn
bq
bp
400308-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Light switch, horn button, short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Licence plate lamp
17
Speedometer
18
Wheel speed sensor
19
Tripmaster switch (optional)
20
Flasher switch
21
Flasher relay
22
Left front flasher
23
Left rear flasher
24
Right front flasher
25
Right rear flasher
26
Horn
27
Front brake light switch
28
Rear brake light switch
29
High beam indicator light
30
Flasher indicator light
31
Plug connector for radiator fan (optional)
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gr
gray
or
orange
pu
violet
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
161
cn
1
2
1
3
2
2
4
3
1
bl
bl
ye-re
b r -b l
br
re
bu
wh
br
cp
ye
wh-gn
bu
gn
br
wh
C _ BC / 6
9
C_BF1/1
C _BA1 /1
cq
ye - b l
bs
G
6
C_ BG/ 3
C _BT/ 3
3 2 1
C_AH2/2
2 1
or
pu
bl
C_ A C/ 6
ye-re
re
y e- bl
C _ B V/ 2
C _ BO / 2
2 1
C_BA2/1
ye-bl
1 2 4 5 7 6 11 10 12 13 14
C_BU/18
br
C _ BK / 4
2 1
C_B R/ 4
4 3
2 1
C_AM/3
3
C_ A R/ 3
8
M
C _ B S/ 2
dl
2 1
1
C _A L /2
2
C _A T /2
4
7
30
A
2
C_ A F /4
4 3
C_A T 1 / 2
2 1
C _A L 1 / 2
3
ye
wh
G
2
1
br
ye-re
ye
wh
cs
C _ A K/ 2
C_AH/2
1 2
br
bl
pu
1
3
2
1
4
3
2
bl
br
br
pu
1
2
br
wh
wh-gn
2
1
U
C _ B V/ 2
C _ B S/ 2
2 .2 2 .1
5
C_BG/3
3 6 4 5 1 2
2 .1
C _EI/ 1
bl
ye-bl
C_EH/1
1
C_BA/1
ye-re
or
bm
bk
C_BG1/3
co v
pu
bl
1
2
2
1
4
3
wh
bu
gn
ye
re
br
br
pu
3
wh
br
C_CX/2
C_CX1/2
dk
C_AK1/2
ye-re
re-bl
re-wh
C_CR1/1
C_AJ1/3
C_CA/4
main harness 594.11.075.150
CDI harness 780.39.032.000
C_AJ/3
C_CW/2
3 2 1
C_CW1/2
ye
wh-gn
C_DB/4
C_DA/4
bl
wh-re
C_CR/1
C_BF/1
bu-wh
ye-re
br
ye-re
br
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
wiring diagram
gn
ye-re
br
re
1 bl
2 br
2
1
br
bu
br
cr
C_CX2/2
ct
bo
C_CW2/2
C_BP/4
C_CZ/3
C_CY/3
br
bl
ye
bu
gr
bl-wh
cl
bn
bt
C_DG/4
C_CX3/2
C_AH1/2
C_CW3/2
C_CX/2
C_CW/2
ye-re
wh-re
bl
162
WIRING DIAGRAM
Wiring diagram (EXC-R‘AUS/UK)
br
C_CE/4
2 1
C_DI/2
cm
ck
bq
bp
400334-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Flasher switch
7
Starter relay with fuse
8
Starter motor
9
Light switch, horn button, short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Licence plate lamp
17
Electric starter button, emergency OFF switch
18
Flasher relay
19
Left front flasher
20
Left rear flasher
21
Right front flasher
22
Right rear flasher
23
Speedometer
24
Wheel speed sensor
25
Tripmaster switch (optional)
26
Horn
27
Front brake light switch
28
Rear brake light switch
29
High beam indicator light
30
Flasher indicator light
31
Plug connector for radiator fan (optional)
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gr
gray
or
orange
pu
violet
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
163
cn
dm
4
2
br
wh
bu
re
ye-re
bl
cp
bq cq br
2
3
2
1
C _B G/ 3
1
bs
6
4 3
C_ B R / 4
G
1
C_AH2/2
C _BK/4
2
2
1
cs
C_BY/4
C _C V/ 4
8
3
9
4
M
C_B K /4
2
1
C_BR/ 4
2
10
A
7
C_AF/4
4 3
wh
br
2
4
3
1
2
3
ye
dk
C _ A K/ 2
C_AH/2
1 2
br
bl
pu
1
ye-re
1
C_CR1/1
C _ BC/ 6
5
cr
br
C_B T /3
6 4
br
C_ A C / 6
3
ye-re
re
C _ B S/ 2
2 1
dn
1
C_A T 1 / 2
2
C _A L 1 / 2
br
bl
1
2
2
2
1
1
wh
gn- w h 3
br
br
pu
5
C_CW/2
1
br
br -bl
bl
C _ B V/ 2
C _B O / 2
1
ye-bl
3
2
3
1
2
2
1
C_A T /2
C _A L /2
2
C_BG1/3
1
ye
ye-bl
1
C_AM/3
C_ A R / 3
G
wh-gn
co v
1
wh-gn
ye-bl
br
2
3
ye-re
wh
2
ye
pu
bl
2
1
bl
ye-re
3
C_BU/18
bl
C_AJ1/3
main harness 594.11.075.244
CDI harness 780.39.032.000
C_CX/2
C_CX1/2
C_AJ/3
C_BG/3
C_CW1/2
bl
br
gn
OFF
ON
C_BF/1
6 11 10 12 13 14
ye
7
bl
5
re-wh
C_EI/1
br
or
C_EH/1
2.1
gr
4
4
wh-re
re-bl
2
1
wh
br
2
or
br
bl
bm
ye-re
bk
ye
C_CR/1
ye-re
gn
bl
4
3
1
ye-re
br
ye
re
black
re
bu
re-bl
bu
C_AK1/2
wh
br
bu-wh
C_DB/4
C_DA/4
bu
pu
bu-wh
3
gn
ye-re
or
wiring diagram
re
ye-re
ye-bl
1
2
2
1
gn bu
br
ct
C_CX2/2
br
re-wh
dl
bo
C_CW2/2
C_BP/4
C_CZ/3
C_CY/3
bl
br
cl
bn
bt
C_DG/4
C_CX3/2
C_AH1/2
C_CW3/2
C_CX/2
C_CW/2
pu
gr
bl-wh
ye-bl
C_BA/1
ye
bu
164
WIRING DIAGRAM
Wiring diagram (EXC-R‘USA)
C_CA/4
C_CE/4
U
ck
bp
cm
400309-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Emergency OFF switch
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Light switch
17
Flasher switch
18
Flasher relay
19
Left front flasher
20
Left rear flasher
21
Right front flasher
22
Right rear flasher
23
Speedometer
24
Wheel speed sensor
25
Tripmaster switch (optional)
26
Horn button
27
Horn
28
Ignition switch
29
Front brake light switch
30
Rear brake light switch
31
High beam indicator light
32
Flasher indicator light
33
Plug connector for radiator fan (optional)
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gn-wh
green-white
gr
gray
or
orange
pu
violet
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
165
WIRING DIAGRAM
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
166
WIRING DIAGRAM
167
cn
1
3
2
2
4
3
1
bl
bl
ye-re
b r -b l
br
re
bu
wh
br
bt
ye
wh-gn
9
6
C _B K / 4
4 3 2 1
C_BR /4
5
7
br
C_BU/18
6 11 10 12 13 14
M
bq
5A
cq
t
C _B L /2
C _ C V/ 2
br
co
C _ B V/ 2
C _ B S/ 2
2 1
2 1
C_ AR / 3
C_AM/3
3
8
M
1
C_A T /2
C _A L /2
2
7
10
A
2
C_AF/4
4 3
C_A T 1 / 2
2 1
C _A L 1 / 2
3
ye
wh
G
2
1
br
ye-re
ye
wh
cm
C_AH/2
C _ A K/ 2
1 2
1
4
3
2
br
wh
wh-gn
5
C_BG/3
C_BF1/1
4
4
C_AJ/3
C _ BC / 6
C _ BA1 / 1
ck
C _B O / 2
cp
2 1
2
bk
3 2 1
C_ A C/ 6
ye-re
ye- b l
1
bm
C_CR1/1
bl
ye-re
wh-re
br
bl
br
bl
bl
br
ye-re
br
re
ye - bl
C_BA/1
3 6 4 5 1 2
2 .1
C _ EI / 1
C_EH/1
ye-bl
bl
wh
bu
gn
ye
re
br
ye-re
re-bl
re-wh
C_CA/4
main harness 594.11.075.000
CDI harness 780.39.032.000
ye
wh-gn
1
2
bs v
C_AK1/2
bl
wh-re
C_CR/1
1
2
bu
gn
br
wh
3
gn
C_DB/4
C_DA/4
C_BA2/1
ye-bl
ye-re
br
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
wiring diagram
re
C_BF/1
bu-wh
bu
br
cl
2
1
4
3
1
br
br
bn
bo
C_BP/4
C_CZ/3
C_CY/3
br
ye
bu
gr
bl-wh
C_AH1/2
C_DG/4
C_CX/2
C_CW/2
bl
bl
168
WIRING DIAGRAM
Wiring diagram (EXC-R‘SIX‘DAYS)
C_CE/4
U
C _ B S/ 2
bp
400307-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Light switch, horn button, short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Thermoswitch
17
Speedometer
18
Wheel speed sensor
19
Tripmaster switch (optional)
20
Horn
21
Front brake light switch
22
Rear brake light switch
23
High beam indicator light
24
Radiator fan
25
Plug connector for flasher cable harness (optional)
26
Fuse, radiator fan
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gr
gray
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
169
WIRING DIAGRAM
170
Wiring diagram (XCR-W‘USA)
bo
v
bl
bl
re
bu
wh
br
bp
bs
bq
br
ye-re
wh
br
wh
bl
gr
bl-wh
br
9
3
ye-bl
bu-wh
ye -bl
wh
bn
bm
ye
ye-re
wh-re
6
wirin g di ag ram m
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
bl
bl
bk
ye
bu
br
8
M
4
ye-re
br
gn
br
re
10
A
G
ye-re
7
3
2
ye
wh
1
br
ye-re
ye
wh
main harness 594.11.075.100
CDI harness 780.39.032.000
br
wh-re
re-bl
re-wh
wh
br
5
bt
U
400310-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Light switch
14
Speedometer
15
Wheel speed sensor
16
Tripmaster switch (optional)
17
Plug connector for radiator fan (optional)
18
Plug connector, headlight (optional)
19
Plug connector, brake / tail light (optional)
21
Thermoswitch
Cable colors
bl
black
bl-wh
black-white
br
brown
bu
blue
bu-wh
blue-white
gn
green
gr
gray
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
171
WIRING DIAGRAM
172
Wiring diagram (XCR-W‘ZA)
br
bn
bo
v
bl
bl
re
bu
wh
br
bs
bt
br
ye-re
wh
br
wh
bl
gr
bl-wh
br
9
3
ye-bl
bu-wh
ye -bl
wh
bq
bm
ye
6
wirin g di ag ram m
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
ye-re
wh-re
bl
br
bl
br
bl
M
br
t
cl
ck
bk
ye
bu
cm
bl
br
5A
ye-re
br
br
bl
8
re
M
4
gn
10
A
G
ye-re
7
3
2
ye
wh
1
br
ye-re
ye
wh
main harness 594.11.075.100
CDI harness 780.39.032.000
br
wh-re
re-bl
re-wh
br
wh
5
C _ B S/ 2
U
bp
400311-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Light switch
17
Speedometer
18
Wheel speed sensor
19
Tripmaster switch (optional)
20
Radiator fan
21
Thermoswitch
22
Fuse, radiator fan
Cable colors
bl
black
bl-wh
black-white
br
brown
bu
blue
bu-wh
blue-white
gn
green
gr
gray
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
173
SUBSTANCES
174
68%67$1&(6
Brake fluid DOT 5.1
according to
ಥ DOT
Specification
ಥ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Brake‘Fluid‘DOT‘5.1
Engine oil (SAE 10W/50)
according to
ಥ JASO‘T903‘MA (
ಥ
SAE (
P. 184)
P. 184) (SAE 10W/50)
Specification
ಥ Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex
ಥ Motorex®‘Cross‘Power‘4T
Coolant
Specification
ಥ Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze: -25… -45‘°C (-13… -49‘°F)
50‘% Anti-corrosion/antifreeze
50‘% distilled water
Coolant (mixed ready to use)
Antifreeze
-40‘°C (-40‘°F)
Supplier
Motorex
ಥ Motorex®‘Anti‘Freeze
Super unleaded (ROZ 95 / RON 95 / PON 91)
according to
ಥ DIN‘EN‘228 (ROZ 95 / RON 95 / PON 91)
Fork oil (SAE 5)
according to
ಥ SAE (SAE 5)
Specification
ಥ Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding
properties. KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Racing‘Fork‘Oil
AUXILIARY SUBSTANCES
$8;,/,$5< 68%67$1&(6
Universal oil spray
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Joker‘440‘Universal
Long-life grease
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Long‘Therm‘2000
Cleaning substance for foam air filter
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Twin‘Air‘Dirt‘Bio‘Remover
Oil for foam air filter
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Twin‘Air‘Liquid‘Power
Chain cleaner
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Chain‘Clean‘611
Offroad chain spray
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Chain‘Lube‘622
Carburetor cleaner
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Carburetor
Motorcycle cleaner
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Moto‘Clean‘900
175
AUXILIARY SUBSTANCES
Cleaning and polishing materials for metal, rubber and plastic
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Protect‘&‘Shine‘645
High-luster polish for paint
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Moto‘Polish
Contact spray
Specification
ಥ KTM recommends Motorex® products.
Supplier
Motorex
ಥ Motorex®‘Accu‘Contact
176
SPECIAL TOOLS
177
63(&,$/ 722/6
Crankshaft locking bolt
ART. NO.: 113080802
400035-01
Bearing puller
ART. NO.: 15112017000
400037-01
Insert for bearing puller
ART. NO.: 15112018100
Feature
18… 23‘mm (0.71… 0.91‘in)
400038-01
Bleed syringe
ART. NO.: 50329050000
400058-01
Circlip pliers reverse
ART. NO.: 51012011000
400059-01
SPECIAL TOOLS
178
Clutch holder
ART. NO.: 51129003000
400289-01
Work stand
ART. NO.: 54829055000
500071-01
Universal mounting rack
ART. NO.: 56012001000
400067-01
Extractor
ART. NO.: 58012009000
400073-01
Valve spring mounter
ART. NO.: 59029019000
400101-01
SPECIAL TOOLS
179
Limit plug gauge
ART. NO.: 59029026006
400104-01
Feeler gauge
ART. NO.: 59029041000
35
30
25
20
15
12
5
10
400110-01
Piston ring mounting tool
ART. NO.: 60029015000
400123-01
Pressure testing tool
ART. NO.: 61029094000
400149-01
Push-in drift
ART. NO.: 75029044010
500163-01
SPECIAL TOOLS
180
Push-in drift
ART. NO.: 75029044020
500162-01
Press drift
ART. NO.: 75029047000
400185-01
Extractor
ART. NO.: 75029048000
400162-01
Clamping plate
ART. NO.: 75029050000
400163-01
Push-out drift
ART. NO.: 75029051000
400164-01
SPECIAL TOOLS
181
Protection cover
ART. NO.: 75029090000
400167-01
Spark plug wrench
ART. NO.: 75029172000
400170-01
Limit plug gauge
ART. NO.: 77029026000
400104-01
Oil pressure adapter
ART. NO.: 77329006000
400176-01
Insert for piston pin retainer
ART. NO.: 77329030100
400160-01
SPECIAL TOOLS
182
Adjustment tool for mixture control screw
ART. NO.: 77329034000
400274-01
Release device for timing chain tensioner
ART. NO.: 77329051000
400181-01
Engine holder
ART. NO.: 78029002000
500161-01
Mounting sleeve
ART. NO.: 78029005000
500167-01
Plate - Pressing device
ART. NO.: 78029008000
500170-01
SPECIAL TOOLS
183
Separator plate
ART. NO.: 78029009000
500169-01
Extractor
ART. NO.: 78029033100
500166-01
Press-out device
ART. NO.: 78029049100
500168-01
Valve spring mounting device
ART. NO.: 78029060000
500165-01
Gear segment
ART. NO.: 80029004000
500164-01
STANDARDS
184
67$1'$5'6
JASO‘T903‘MA
Different technical development directions required a new specification for 4-stroke motorcycles ಥ the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the 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 viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
185
,1'(;
A
Accessories .
Air filter
cleaning
fitting . .
removing
.................................. 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air filter box lid
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
B
Battery
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brake disc
of front brake, mounting .
of front brake, removing .
of rear brake, mounting . .
of rear brake, removing . .
.
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.
.
34
34
37
37
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake fluid
of front brake, adding .
of front brake, changing
of rear brake, adding . .
of rear brake, changing
..
.
..
..
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.
48
48
52
52
Brake fluid level
of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 47
of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 52
Brake linings
of front brake, changing
of front brake, checking
of front brake, installing
of rear brake, changing
of rear brake, checking
of rear brake, installing
of rear brake, removing
Bremsbeläge
of front brake, removing
.
..
.
..
..
..
..
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46
45
45
50
49
50
49
. . . . . . . . . . . . . . . . . . . . . . 45
C
Carburetor
adjusting idle . . . . . . . . . .
assembling . . . . . . . . . . .
disassembling . . . . . . . . .
emptying the float chamber
installing . . . . . . . . . . . . .
removing . . . . . . . . . . . . .
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126
122
115
127
125
115
Carburetor - Work on individual parts
checking . . . . . . . . . . . . . . . . . . . . . .
checking the choke slide . . . . . . . . . . .
checking the float needle valve . . . . . . .
checking the jet needle . . . . . . . . . . . .
checking the needle jet . . . . . . . . . . . .
checking/adjusting the accelerator pump
checking/adjusting the float level . . . . .
.
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.
119
119
120
119
120
118
120
Carburetor components
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Carburetor connection boot
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chain
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chain guide
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chain wear
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Choke Bowden cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Choke Bowden cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Clutch
changing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . 129
Compression damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compression damping, high-speed
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 20
Compression damping, low-speed
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 20
Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . . . . 80
Cylinder head
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
D
Dust boots
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E
Engine
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Engine - Work on individual parts
assembling the autodecompressor . . . . . . . . . . . .
assembling the countershaft . . . . . . . . . . . . . . .
assembling the main shaft . . . . . . . . . . . . . . . . .
changing the conrod bearing . . . . . . . . . . . . . . .
checking electric starter operation . . . . . . . . . . .
checking piston/cylinder mounting clearance . . . .
checking the balancer shaft . . . . . . . . . . . . . . . .
checking the camshaft . . . . . . . . . . . . . . . . . . .
checking the clutch . . . . . . . . . . . . . . . . . . . . .
checking the crankshaft run-out on the bearing pin
checking the free-wheel . . . . . . . . . . . . . . . . . . .
checking the lower valve spring retainer . . . . . . . .
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83
92
91
78
94
82
78
84
89
80
95
87
INDEX
186
checking the lubrication system . . . . . . . . . . . . . . . . . 82
checking the oil pumps for wear . . . . . . . . . . . . . . . . . 82
checking the piston ring end gap . . . . . . . . . . . . . . . . 81
checking the shift mechanism . . . . . . . . . . . . . . . . . . 90
checking the spring length of the oil pressure regulator
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
checking the timing assembly . . . . . . . . . . . . . . . . . . 84
checking the transmission . . . . . . . . . . . . . . . . . . . . . 93
checking the valve springs . . . . . . . . . . . . . . . . . . . . . 87
checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . . 87
checking/measuring the cylinder . . . . . . . . . . . . . . . . . 80
checking/measuring the piston . . . . . . . . . . . . . . . . . . 81
Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . 80
disassembling the autodecompressor . . . . . . . . . . . . . . 83
dismantling the countershaft . . . . . . . . . . . . . . . . . . . 92
dismantling the main shaft . . . . . . . . . . . . . . . . . . . . 91
fitting the crankshaft seal ring into the clutch cover . . . . 76
installing the free-wheel . . . . . . . . . . . . . . . . . . . . . . 95
installing the oil pressure regulator valve . . . . . . . . . . . 75
installing the rocker arm . . . . . . . . . . . . . . . . . . . . . . 89
installing the timing chain sprocket . . . . . . . . . . . . . . . 78
installing the water pump . . . . . . . . . . . . . . . . . . . . . 77
installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
left engine case section . . . . . . . . . . . . . . . . . . . . . . . 73
preassembling the shift shaft . . . . . . . . . . . . . . . . . . . 91
preparing the timing chain tensioner for installation . . . 84
removing the crankshaft seal ring in the clutch cover . . . 76
removing the free-wheel . . . . . . . . . . . . . . . . . . . . . . 94
removing the oil pressure regulator valve . . . . . . . . . . . 75
removing the rocker arm . . . . . . . . . . . . . . . . . . . . . . 85
removing the timing chain sprocket . . . . . . . . . . . . . . . 78
removing the valves . . . . . . . . . . . . . . . . . . . . . . . . . 85
removing the water pump . . . . . . . . . . . . . . . . . . . . . 76
replacing the camshaft bearing . . . . . . . . . . . . . . . . . . 86
right engine case section . . . . . . . . . . . . . . . . . . . . . . 72
Engine assembly
adjusting the valve clearance . . . . . . . . . . . . . . .
checking the valve clearance . . . . . . . . . . . . . . .
cleaning the gear oil screen . . . . . . . . . . . . . . . .
Filling up with engine oil . . . . . . . . . . . . . . . . . .
Filling up with gear oil . . . . . . . . . . . . . . . . . . . .
installing the balance weight . . . . . . . . . . . . . . .
installing the balancer shaft . . . . . . . . . . . . . . . .
installing the camshaft . . . . . . . . . . . . . . . . . . .
installing the clutch cover . . . . . . . . . . . . . . . . .
installing the clutch discs . . . . . . . . . . . . . . . . .
installing the crankshaft . . . . . . . . . . . . . . . . . .
installing the cylinder head . . . . . . . . . . . . . . . .
installing the generator cover . . . . . . . . . . . . . . .
installing the ignition pulse generator . . . . . . . . .
installing the kickstarter . . . . . . . . . . . . . . . . . .
installing the kickstarter idler gear . . . . . . . . . . .
installing the kickstarter shaft . . . . . . . . . . . . . .
installing the left engine case . . . . . . . . . . . . . . .
installing the locking lever . . . . . . . . . . . . . . . . .
Installing the oil pump gears . . . . . . . . . . . . . . .
installing the oil pumps . . . . . . . . . . . . . . . . . . .
installing the outer clutch hub . . . . . . . . . . . . . .
installing the piston . . . . . . . . . . . . . . . . . . . . .
installing the primary gear nut . . . . . . . . . . . . . .
installing the primary gear with the free-wheel-gear
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109
109
. 59
111
112
105
101
108
102
102
. 96
107
109
104
103
100
100
. 97
. 99
. 99
. 98
101
105
101
. 98
installing the rotor . . . . . . . . . . . . . . . . . . . . . . . .
installing the shift drum locating . . . . . . . . . . . . . .
installing the shift forks . . . . . . . . . . . . . . . . . . . . .
installing the shift lever . . . . . . . . . . . . . . . . . . . . .
installing the shift rails . . . . . . . . . . . . . . . . . . . . .
installing the shift roller . . . . . . . . . . . . . . . . . . . .
installing the shift shaft . . . . . . . . . . . . . . . . . . . . .
installing the spark plug . . . . . . . . . . . . . . . . . . . .
installing the starter idler gear . . . . . . . . . . . . . . . .
Installing the starter motor . . . . . . . . . . . . . . . . . . .
installing the suction pump . . . . . . . . . . . . . . . . . .
installing the timing chain . . . . . . . . . . . . . . . . . . .
installing the timing chain guide rail . . . . . . . . . . . .
installing the timing chain securing guide . . . . . . . .
installing the timing chain tensioning rail . . . . . . . . .
installing the timing chain tensioner . . . . . . . . . . . .
installing the transmission shaft . . . . . . . . . . . . . . .
installing the valve cover . . . . . . . . . . . . . . . . . . . .
installing the water pump cover . . . . . . . . . . . . . . .
mounting oil filter . . . . . . . . . . . . . . . . . . . . . . . . .
removing the engine from the universal mounting rack
Engine disassembly
Draining the engine oil . . . . . . . . . . . . . . . . . . .
draining the gear oil . . . . . . . . . . . . . . . . . . . . .
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . .
removing the balance weight . . . . . . . . . . . . . . .
removing the balancer shaft . . . . . . . . . . . . . . . .
removing the camshaft . . . . . . . . . . . . . . . . . . .
removing the clutch cover . . . . . . . . . . . . . . . . .
removing the clutch discs . . . . . . . . . . . . . . . . .
removing the crankshaft . . . . . . . . . . . . . . . . . .
removing the cylinder head . . . . . . . . . . . . . . . .
removing the generator cover . . . . . . . . . . . . . . .
removing the ignition pulse generator . . . . . . . . .
removing the kickstarter . . . . . . . . . . . . . . . . . .
removing the kickstarter idler gear . . . . . . . . . . .
removing the left section of the engine case . . . . .
removing the locking lever . . . . . . . . . . . . . . . . .
Removing the oil filter . . . . . . . . . . . . . . . . . . . .
removing the oil pump gears . . . . . . . . . . . . . . .
Removing the oil pump gears . . . . . . . . . . . . . . .
removing the outer clutch hub . . . . . . . . . . . . . .
removing the piston . . . . . . . . . . . . . . . . . . . . .
removing the primary gear nut . . . . . . . . . . . . . .
removing the primary gear with the free-wheel-gear
removing the rotor . . . . . . . . . . . . . . . . . . . . . .
removing the shift drum locating . . . . . . . . . . . . .
removing the shift forks . . . . . . . . . . . . . . . . . . .
removing the shift lever . . . . . . . . . . . . . . . . . . .
removing the shift rails . . . . . . . . . . . . . . . . . . .
removing the shift roller . . . . . . . . . . . . . . . . . . .
removing the shift shaft . . . . . . . . . . . . . . . . . . .
removing the spark plug . . . . . . . . . . . . . . . . . .
Removing the starter engine . . . . . . . . . . . . . . . .
removing the starter idler gear . . . . . . . . . . . . . .
removing the suction pump . . . . . . . . . . . . . . . .
removing the timing chain . . . . . . . . . . . . . . . . .
removing the timing chain guide rail . . . . . . . . . .
removing the timing chain securing guide . . . . . .
removing the timing chain tensioner . . . . . . . . . .
removing the timing chain tensioning rail . . . . . . .
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105
. 99
. 96
110
. 97
. 97
. 99
110
100
111
103
104
105
104
104
108
. 96
110
103
111
112
. . . 59
. . . 59
. . . 59
. . . 63
. . . 67
. . . 62
. . . 65
. . . 66
. . . 71
. . . 62
. . . 61
. . . 64
. . . 65
. . . 67
. . . 69
. . . 68
. . . 59
. 68-69
. 68-69
. . . 66
. . . 62
. . . 66
. . . 69
. . . 63
. . . 68
. . . 71
. . . 60
. . . 70
. . . 70
. . . 68
. . . 60
. . . 60
. . . 67
. . . 64
. . . 64
. . . 63
. . . 64
. . . 62
. . . 64
INDEX
187
removing the torque limiter . . . . . . . . . . . .
removing the transmission shaft . . . . . . . . .
removing the valve cover . . . . . . . . . . . . . .
removing the water pump cover . . . . . . . . .
setting the engine to ignition top dead center
Engine oil
changing .
draining .
refilling . .
topping up
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67
71
60
65
61
gear oil
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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135
135
136
137
gear oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Engine oil pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
engine oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Engine oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Engine sprocket
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Engine sprocket cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Foot brake pedal
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 51
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fork legs
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fork offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fork protector
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front fender
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Front wheel
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel tap . . .
Fuel, oils, etc.
Fuse
fitting . .
removing
Gear oil
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
gear oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Gear oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
GREASING AND SERVICE TABLE
. . . . . . . . . . . . . . . . . 157-159
H
Hand brake lever
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 46
adjusting free travel . . . . . . . . . . . . . . . . . . . . . . . . . 47
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 47
L
Lower triple clamp
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13, 15
M
Main silencer
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Manifold
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Motorcycle
cleaning
O
Oil cycle . . .
Oil filter
changing
fitting . .
removing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Oil pressure regulator valve
checking the spring length . . . . . . . . . . . . . . . . . . . . . 75
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
P
Play in choke Bowden cable
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Play in gas Bowden cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Putting into operation
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
................................. 7
R
Rear sprocket / engine sprocket
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rear wheel
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
G
Gas Bowden cable route
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INDEX
188
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 21
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
S
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shock absorber
checking riding sag
checking static sag
fitting . . . . . . . . .
removing . . . . . . .
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Spare parts . . . . . . . . . . . . .
Speedometer
adjusting . . . . . . . . . . . .
Setting kilometers or miles
Setting the clock . . . . . .
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22
22
24
23
...................... 7
. . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . 55
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Spring preload
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 22
Start number plate
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering head bearing
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
T
Technical data
Carburetor . . . . . . . . . . . . . .
Carburetor tightening torques .
Chassis . . . . . . . . . . . . . . . .
chassis tightening torques . . .
Engine . . . . . . . . . . . . . . . .
Engine - tolerance, wear limits
Engine tightening torques . . .
Fork . . . . . . . . . . . . . . . . . .
Shock absorber . . . . . . . . . .
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. 147-148
. . . . 149
. 150-151
. . . . 154
. 142-143
. . . . 144
. 145-146
. . . . 152
. . . . 153
Throttle slide opening
checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 120
Throttle valve sensor‘TPS
adjusting the position . . . . . . . . . . . . . . . . . . . . . . . 121
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 140-141
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 160-173
*3206054en*
3206054en
08.10.2007
Photo Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com

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