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REPAIR MANUAL 2009

1190 RC8 R EU/UK 1190 RC8 R AUS 1190 RC8 R FR

1190 RC8 R JP

Article no. 3206077en

REPAIR MANUAL 2009 1190 RC8 R EU/UK 1190 RC8 R AUS 1190 RC8 R FR 1190

INTRODUCTION

1

INTRODUCTION

Read this repair manual carefully and thoroughly before beginning work.

Only use ORGINAL KTM SPARE PARTS.

The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.

This repair manual was written to correspond to the latest state of this series. 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 non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica- tions, 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 misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not form part of the regular scope of delivery.

© 2009 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.

with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the

ISO 9001(12 100 6061)

According to 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

2

CONTENTS

MEANS OF REPRESENTATION

6

IMPORTANT NOTES

7

LOCATION OF SERIAL NUMBERS

8

Vehicle identification number/type label

8

Key number

8

Engine number

8

Fork part number

8

Shock absorber part number

8

Steering damper part number

9

MOTORCYCLE

10

Jacking up motorcycle front

10

Taking front of motorcycle off work stand

10

Jacking up the motorcycle in the middle (screw-in type)

10

Removing the motorcycle from the work stand (screw-in

type)

11

Jacking up the motorcycle in the middle (insertable

type)

12

Removing the motorcycle from the work stand (insertable

type)

12

Jacking up motorcycle at the rear

13

Taking the rear from the workstand

13

Starting

13

01/FORK, TRIPLE CLAMP

15

Adjusting the compression damping of the fork

15

Adjusting the rebound damping of the fork

15

Adjusting the spring preload of the fork

16

Bleeding fork legs

16

Vehicle level

17

Adjusting front vehicle level

17

Removing the fork

18

Installing the fork

19

performing a fork service

21

Disassembling the fork legs

21

Disassembling the outer tubes

24

Checking the fork legs

25

changing the lower DU bush

26

Assembling the outer tubes

27

Assembling the fork legs

27

02/HANDLEBAR, CONTROLS AND INSTRUMENTS

32

Adjusting basic position of clutch lever

32

Adjusting the steering damper

32

Adjusting the handlebar height

32

Adjusting the play in the throttle cable

33

Throttle grip

34

Changing the throttle grip

34

Adjusting the throttle cable at the throttle valve

37

03/FRAME

40

Side stand switch

40

Footrest position

40

Adjusting footrest position

40

Rear frame position

41

Adjusting the rear frame position

41

04/SHOCK ABSORBER, SWINGARM

44

Adjusting the low-speed compression damping of the shock absorber

44

Adjusting the high-speed compression damping of the shock absorber

44

Adjusting the rebound damping of the shock absorber

45

Adjusting the spring preload of the shock absorber

45

Adjusting the vehicle level at the rear

46

Removing the shock absorber

46

Installing the shock absorber

47

Servicing the shock absorber

48

Removing the spring

48

Disassembling the damper

49

Disassembling the piston rod

50

Checking the damper

51

Assembling the piston rod

52

Assembling the damper

53

Bleeding and filling the damper

55

Filling the damper with nitrogen

58

Installing the spring

59

Removing the heim joint

59

Installing the heim joint

60

05/EXHAUST

62

Lambda sensor

62

Lambda sensor heater

62

Removing the exhaust cover completely

63

Installing the exhaust cover completely

63

Removing the exhaust system

63

Installing the exhaust system

65

06/AIR FILTER

67

Removing the air filter

67

Installing the air filter

67

Removing the filter box bottom

67

Installing the filter box bottom

68

07/FUEL TANK, SEAT, TRIM

70

Removing the seat

70

Fitting the seat

70

Removing the passenger seat

70

Mounting the passenger seat

70

Dismounting the fuel tank

70

Installing the fuel tank

71

Removing the fuel tank guard

72

Installing the fuel tank guard

73

Checking the fuel pressure

73

Checking the fuel pressure during the actuator test

74

08/MASK, FENDER, DECAL

75

Removing the side covers

75

Installing the side covers

75

Removing the inside cover

75

Installing the inside cover

76

09/FRONT WHEEL

77

Removing the front wheel

77

Installing the front wheel

77

Checking the tire condition

78

Checking the tire pressure

79

Checking the front brake discs

80

10/REAR WHEEL

81

Removing the rear wheel

81

Installing the rear wheel

81

Installing the rear wheel - when installing the engine

82

Checking the rear brake disc

83

Checking for chain dirt

83

Cleaning the chain

84

Checking the chain tension

84

Adjusting the chain tension

85

Checking rear sprocket / engine sprocket for wear

85

Checking chain wear

86

Checking chain sliding guard

86

Checking rear hub cush drive

86

11/WIRING HARNESS, BATTERY

88

Electric starter lock control unit

88

CONTENTS

3

Fuel pump relay Removing the battery Installing the battery Recharging the battery Changing the main fuse Changing the fuses of individual power consumers 13/BRAKE SYSTEM Brake linings Checking the front brake linings Changing the front brake linings Checking the front brake fluid level Adding front brake fluid

Adjusting the basic position of the hand brake lever

Checking the rear brake linings

Changing the rear brake linings

Checking the rear brake fluid level

Adding rear brake fluid

Adjusting the foot brake pedal stub

Adjusting the foot brake pedal

Removing the rear brake system

Installing the rear brake system

14/LIGHT SYSTEM, INSTRUMENTS

Immobilizer control unit

Activating/deactivating ignition key

Activating the ICU

Combination instrument - Activation of the

BOOTLOADER mode

Updating the combination instrument software

Setting ROAD or RACE mode

Setting the clock with SET CLOCK

Adjusting shift speed RPM1/2

Setting the blank time of the LAP button

LAP BLANK T

Setting the number of laps SET NUM LAPS

Setting the fuel reserve display TRIPF RESET

Setting the kilometers/miles SET KM/MILES

Setting the temperature unit SET °C/°F

Switching the external temperature display on/off

Resetting service display

Checking the headlight setting

Adjust the headlight range

Changing the parking light bulb

Changing the low beam bulb

Changing the high beam bulb

30/ENGINE

Removing the engine

Preparing the engine for installation

Installing the engine Setting the engine to ignition top dead center of the rear cylinder Setting the engine to ignition top dead center of the front cylinder 30/DISASSEMBLING THE ENGINE Clamping the engine into the engine work stand Removing the engine bracket Draining the engine oil Removing the front valve cover Removing the rear valve cover Setting the engine to ignition top dead center of the rear cylinder Removing the starter motor Removing the oil filler tube

88

88

89

90

91

91

93

93

93

93

95

95

96

96

97

99

99

100

100

101

101

102

102

102

104

105

105

106

106

106

107

107

108

108

109

109

110

110

111

111

112

113

115

115

117

117

120

121

122

122

122

122

123

123

123

124

124

Removing the heat exchanger

124

Removing the rear timing chain tensioner

124

Removing the rear camshaft

125

Removing the rear cylinder head

125

Removing the rear piston

125

Setting the engine to ignition top dead center of the front cylinder

126

Removing the front timing chain tensioner

126

Removing the front camshafts

126

Removing the front cylinder head

126

Removing the front piston

127

Removing the generator cover

127

Removing the ignition pulse generator

127

Removing the torque limiter and idler

128

Removing the rotor

128

Removing the idler and timing chain on the left

128

Removing the oil filter

129

Removing the balancer shaft

129

Removing the drive wheel of the balancer shaft

129

Removing the gear position sensor

130

Removing the left suction pump

130

Removing the water pump wheel

131

Removing the clutch cover

131

Removing the idler and timing chain on the right

132

Removing the clutch facing

132

Removing the outer clutch hub

132

Removing the primary gear

133

Removing the force pump

133

Removing the shift shaft

134

Removing the shift drum locating

134

Removing the locking lever

135

Removing the left engine case

135

Removing the crankshaft

135

Removing the middle suction pump

136

Removing the transmission shaft

136

Removing the oil spray tube

137

Removing the timing chain rails of the right engine case

section

137

Removing the timing chain rails of the left engine case

section

137

30/ENGINE - WORK ON INDIVIDUAL PARTS

138

Work on the right section of the engine case

138

Removing the main bearing of the right engine case

section

139

Selecting the main bearing shells

140

Installing the right main bearing

140

Work on the left section of the engine case

141

Removing the left main bearing

143

Installing the left main bearing

143

Changing the conrod bearing

144

Work on the clutch cover

145

Changing the step bearing of the crankshaft

146

Checking the radial clearance of the bottom connecting rod bearing

147

Checking/measuring the cylinder

147

Checking/measuring the piston

148

Checking the piston ring end gap

149

Checking the piston/cylinder mounting clearance

149

Work on the cylinder head

149

Checking the cylinder head

152

Work on the right idler

153

Checking the timing assembly

154

CONTENTS

4

Preparing the timing chain tensioner for installation

154

Checking the oil pressure regulator valve

155

Checking the oil pumps

155

Checking the clutch

156

Checking the shift mechanism

157

Preassembling the shift shaft

158

Dismantling the main shaft

158

Dismantling the countershaft

159

Checking the transmission

160

Assembling the main shaft

161

Assembling the countershaft

161

30/ASSEMBLING THE ENGINE

163

Installing the timing chain rails of the left engine case

section

163

Installing the timing chain rails of the right engine case

section

163

Installing the oil spray tube

164

Installing the transmission shaft

164

Installing the middle suction pump

165

Installing the crankshaft

165

Installing the left engine case

166

Installing the locking lever

167

Installing the shift drum locating

167

Installing the shift shaft

167

Installing the force pump

168

Installing the left suction pump

169

Setting the engine to ignition top dead center of the

rear cylinder

169

Installing the primary gear

170

Installing the outer clutch hub

170

Installing the clutch facing

171

Installing the idler and timing chain on the right

172

Installing the clutch cover

172

Installing the water pump wheel

173

Installing the gear position sensor

173

Installing the drive wheel of the balancer shaft

173

Installing the balancer shaft

174

Installing the idler and timing chain on the left

174

Installing the oil filter

175

Installing the rotor

175

Installing the torque limiter and idler

176

Installing the ignition pulse generator

176

Installing the generator cover

176

Installing the oil drain plug

176

Installing the rear piston

177

Installing the rear cylinder head

178

Installing the rear camshaft

179

Installing the rear timing chain tensioner

179

Setting the engine to ignition top dead center of the front cylinder

180

Installing the front piston

180

Installing the front cylinder head

182

Installing the front camshafts

182

Installing the front timing chain tensioner

183

Installing the heat exchanger

183

Installing the oil filler tube

184

Installing the starter motor

184

Checking the rear cylinder control time

184

Adjusting the rear cylinder control time

184

Checking the rear valve clearance

185

Adjusting the rear valve clearance

186

Checking the front cylinder control time

186

Adjusting the front cylinder control time

186

Checking the front valve clearance

187

Adjusting the front valve clearance

188

Installing the front valve cover

188

Installing the rear valve cover

188

Mounting the engine bracket

189

Dismounting the engine from the work stand

189

31/SECONDARY AIR SYSTEM

190

Exhaust air injection

190

32/CLUTCH

191

Checking fluid level of hydraulic clutch

191

Correcting fluid level of hydraulic clutch

191

34/SHIFT MECHANISM

192

Adjusting shift lever stub

192

Adjusting shift lever

192

35/WATER PUMP, COOLING SYSTEM

194

Checking the coolant level

194

Checking the antifreeze

194

Removing the radiator

195

Installing the radiator

195

Adding coolant/bleeding the cooling system

196

Filling the cooling system compensating tank

197

36/CYLINDER HEAD

198

Engine coolant temperature sensor cylinder 1

198

Engine coolant temperature sensor for cylinder 2

199

Checking the valve clearance

200

Adjusting the rear valve clearance

201

Adjusting the front valve clearance

202

Checking the rear cylinder control time

202

Checking the front cylinder control time

202

Adjusting the rear cylinder control time

203

Adjusting the front cylinder control time

204

Removing the rear camshaft

205

Installing the rear camshaft

205

Removing the front camshafts

206

Installing the front camshafts

206

Installing the rear timing chain tensioner

207

Installing the front timing chain tensioner

207

38/LUBRICATION SYSTEM

208

Oil circuit

208

Checking the engine oil level

209

Changing the engine oil and filter, cleaning the oil

screens

209

Draining engine oil, cleaning oil screens

209

Removing the oil filter

211

Installing the oil filter

212

Filling up with engine oil

212

Adding engine oil

213

Checking the engine oil pressure

213

Removing the oil jet for the clutch lubrication

215

Checking / cleaning the oil jet for clutch lubrication

216

Installing the oil jet for the clutch lubrication

216

39/IGNITION SYSTEM

218

Crankshaft position sensor

218

Ignition coil

218

41/THROTTLE VALVE BODY

219

Throttle position sensor circuit A

219

Throttle position sensor circuit A - checking in the "zero" position

219

Adjusting the position of the throttle position sensor in circuit A

220

Removing the throttle valve body to adjust

221

CONTENTS

5

Reinstalling the throttle valve body when the adjustments have been made

222

Throttle position sensor circuit B

223

Manifold absolute pressure sensor

223

Connecting the vacuum hand pump to the manifold absolute pressure sensor

224

Ambient air pressure sensor

225

Injector

225

Rollover sensor

226

EFI control unit

227

Requesting the EFI control unit activation code

227

Coding the EFI control unit

227

Flashing the EFI control unit

228

IMMOBILIZER BLINK CODE

229

ENGINE CONTROL TROUBLE CODE

238

CONNECTOR OVERVIEW

391

Motor drive circuit A connector AE

391

Connector AI

391

Crankshaft position sensor connector AL

391

Clutch switch, connector AL

391

Throttle position sensor circuit A, connector AM

391

Throttle position sensor circuit B, connector AM

392

Gear position sensor, connector AM

392

Fuel pump connector AM

392

Wheel speed sensor, connector AM

392

Connector AO

392

Diagnostic connection plug AP

393

Rollover sensor connector AP

393

Throttle position sensor circuit A, connector AR

393

Throttle position sensor circuit B, connector AR

394

Fuel pump connector AR

394

Side stand switch, connector AR

394

Ignition coil cylinder 1 connector AS

394

Ignition coil cylinder 2 connector AS

394

CAN bus terminating resistor connector AT

395

Crankshaft position sensor, connector AT

395

Clutch switch connector AT

395

Engine coolant temperature sensor cylinder 1 connector

AX

395

Throttle stepper motor circuit B, connector CA

395

Lambda sensor cylinder 1, connector CA

396

Lambda sensor cylinder 2, connector CA

396

Lambda sensor cylinder 1, connector CE

396

Lambda sensor cylinder 2, connector CE

396

Secondary air valve connector CK

396

Connector CM

397

Connector CO

397

Connector CP

398

Connector CQ

398

Connector CU

398

Fuel evaporation valve connector DF

399

Secondary air valve connector DF

399

Electric starter lock control unit, connector DN

399

Immobilizer control unit, connector DN

399

Electric starter lock control unit, connector DO

399

Immobilizer control unit, connector DO

400

Ambient air pressure sensor connector DP

400

Manifold absolute pressure sensor cylinder 1, connector DP

400

Manifold absolute pressure sensor cylinder 2 connector DP

400

Injector cylinder 1 connector DQ

400

Injector cylinder 2 connector DQ

401

ICU antenna connector DV

401

Fuel pump relay connector EB

401

ICU antenna connector EL

401

Connector EQ

401

Connector ER

402

Connector ES

402

Connector ET

402

Combination instrument connector EV

403

Exhaust air injection valve, connector FE

403

Fuel pump relay

404

CAN bus terminating resistor

404

TECHNICAL DATA - ENGINE

405

Capacity - engine oil

405

Capacity - coolant

406

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF

ENGINE

407

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

409

TECHNICAL DATA - CHASSIS

411

Lighting equipment

411

Capacity - fuel

412

TECHNICAL DATA - FORK

413

TECHNICAL DATA - SHOCK ABSORBER

414

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

415

CLEANING/CONSERVATION

417

Cleaning motorcycle

417

Conservation for winter operation

417

STORAGE

419

Storage

419

Putting into operation after storage

419

SERVICE SCHEDULE

420

Important service tasks to be carried out by an

authorized KTM-RC8

420

Important service tasks to be carried out by an

authorized KTM-RC8 workshop. (as additional job)

421

WIRING DIAGRAM

422

1 of 3

422

2 of 3

426

3 of 3

432

OPERATING SUBSTANCES

436

AUXILIARY SUBSTANCES

438

SPECIAL TOOLS

440

STANDARDS

452

INDEX

453

MEANS OF REPRESENTATION

6

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function). used The meaning of specific symbols is described below. Indicates an unexpected reaction (e.g. of a

Indicates an unexpected reaction (e.g. of a work step or a function). an expected reaction (e.g. of a work step or a function). Identifies a page reference (more

Identifies a page reference (more information is provided on the specified page).an unexpected reaction (e.g. of a work step or a function). Formats used The typographical formats

Formats used

The typographical formats used in this document are explained below.

Specific name

Identifies a proprietary name.

Name ®

Identifies a protected name.

Brand™

Identifies a brand available on the open market.

IMPORTANT NOTES

7

Warranty

The work described in the service schedule must be carried out exclusively in an authorized KTM-RC8 workshop and confirmed in the service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting from manipula- tion and/or other changes to the vehicle.

Materials

The fuels, lubricants and other materials named in this repair manual must be used according to specifications.

Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage.

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in

parentheses. Ex: valve spring mounter (59029019000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be

replaced by new parts.

If thread lock (e.g. Loctite

usage.

Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or

worn parts.

Following repairs or servicing, the vehicle must be checked for roadworthiness.

® ) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its

Notes/warnings

Pay close attention to the notes/warnings.

Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-

ing, you or others may not recognize sources of danger and may therefore be injured.

Grades of risks

Dangerof danger and may therefore be injured. Grades of risks Identifies a danger that will immediately

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures

are not taken.

Warningpermanent injury if the appropriate measures are not taken. Identifies a danger that is likely to

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Cautionor serious injury if the appropriate measures are not taken. Identifies a danger that may lead

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Repair manual

Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and service your motorcycle.

This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

LOCATION OF SERIAL NUMBERS

8

3.1Vehicle

identification

number/type label

100654-10
100654-10

The vehicle identification number is stamped on the frame behind the steering head on the right. The type label is on the frame above the vehicle identification number.

3.2Key

number

700222-01
700222-01

The key number Code number can be found on the KEYCODECARD.

number Code number  can be found on the KEYCODECARD . Info You need the key

Info

You need the key number to order a spare key. Keep the KEYCODECARD in a safe

place.

Use the orange programming key to activate and deactivate the black ignition

key. Keep the orange programming key in a safe place: it must only be used for

learning and programming functions.

3.3Engine

number

100655-10
100655-10

The engine number is stamped on the right side of the engine.

3.4Fork

part

number

100656-10
100656-10

The fork part number is stamped on the inner side of the fork stub.

3.5Shock

absorber

part

number

100657-10
100657-10

The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring towards the rear.

LOCATION OF SERIAL NUMBERS

9

3.6Steering

damper

part

number

100658-10
100658-10

The steering damper part number is stamped on the top of the steering damper.

MOTORCYCLE

10

4.1Jacking

up motorcycle

front

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

100679-10
100679-10

Jack up the motorcycle at the rear. (

Move the handlebar to the straight-ahead position. Align the work stand at the front with the adapters to the fork legs.

work stand at the front with the adapters to the fork legs. p. 13) Front work

p. 13)

Front work stand (61029055300) (

Front work stand (61029055300) ( p. 443)

p. 443)

fork legs. p. 13) Front work stand (61029055300) ( p. 443) Info Always jack up the

Info

Always jack up the rear of the motorcycle first.

Jack up the motorcycle at the front.

4.2Taking

front

of

motorcycle off work stand

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Secure the motorcycle against falling over.

Remove the work stand from the front.

4.3Jacking

up the motorcycle in the middle (screw-in type)

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

200598-01
200598-01
200599-01
200599-01

Remove screw .

Remove screws . Take off the footrest bracket.

Unplug connector of the brake light switch. Remove cable binder .

Remove screw . Hang the brake fluid reservoir to the side.

Remove screws . Hang the footrest bracket to the side.

MOTORCYCLE

11

200600-01
200600-01

Screw the holder of the special tool all the way into the lower drill holes of the footrest brackets. Select the required height and width of the work stand.

Work stand (62529055000) (

p. 447)Work stand (62529055000) (

Jack up the motorcycle.

(62529055000) ( p. 447) – Jack up the motorcycle. Info Check that the work stand is

Info

Check that the work stand is seated correctly.

4.4Removing

the

motorcycle from the work stand (screw-in type)

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

200600-01
200600-01
200599-11
200599-11

Remove the motorcycle from the work stand and rest it on the side stand.

Unscrew the holder of the special tool from the drill holes in the footrest brackets.

Remove the work stand.

Work stand (62529055000) (

p. 447)Work stand (62529055000) (

Position the footrest bracket. Mount and tighten screws .

Guideline

Screw, front footrest bracket

M8

25 Nm (18.4 lbf ft)

Loctite ® 243™

Position the brake fluid reservoir. Mount and tighten screw .

Guideline

Screw, brake fluid reser- voir of rear brake

M5

5 Nm (3.7 lbf ft)

Loctite ® 243™

Plug in connector of the brake light switch. Secure the cable with cable binder .

MOTORCYCLE

12

200598-11
200598-11

Position the footrest bracket. Mount and tighten screws .

Guideline

Screw, front footrest bracket

M8 25

Nm

Loctite ® 243™

(18.4 lbf ft)

Position the shift rod. Mount and tighten screw .

Guideline

Screw, shift rod

M6

12 Nm

(8.9 lbf ft)

Loctite ® 243™

4.5Jacking

up the motorcycle in the middle (insertable type)

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

200597-01
200597-01

Let the work stand engage in the opening of the swingarm pivot with the plastic

sleeve. Select the required height and width of the work stand.

Work stand (62529055000) (

Work stand (62529055000) ( p. 447)

p. 447)

Jack up the motorcycle.

stand (62529055000) ( p. 447) – Jack up the motorcycle. Info Check that the work stand

Info

Check that the work stand is seated correctly.

4.6Removing

the

motorcycle from the work stand (insertable

type)

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

MOTORCYCLE

13

200597-01
200597-01

Remove the motorcycle from the work stand and rest it on the side stand.

Remove the work stand.

Work stand (62529055000) (

Work stand (62529055000) ( p. 447)

p. 447)

4.7Jacking

up motorcycle

at

the rear

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

100680-10
100680-10

Insert the work stand adapter in the rear of the work stand.

Work stand adapter (61029055120) (

Work stand adapter (61029055120) ( p. 442)

p. 442)

Work stand rear (61029055100) (

p. 442)

p. 442)

 

Stand the motorcycle upright, align the work stand to the link fork and the

adapters, and jack up the motorcycle.

4.8Taking

the

rear

from the workstand

Note

Danger of damageThe parked vehicle can roll away or fall over.

Always place the vehicle on a firm and even surface.

Secure the motorcycle against falling over.

Remove the work stand from the rear and lean the vehicle on the side stand.

4.9Starting

Danger

Danger of poisoning  Exhaust gases are poisonous and can result in unconsciousness and/or death. Exhaust gases are poisonous and can result in unconsciousness and/or death.

When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an effective exhaust extraction system.

Caution

Danger of accidents  If the vehicle is operated with a discharged battery or without a battery, electronic If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.

Never operate the vehicle with a discharged battery or without a battery.

MOTORCYCLE

14

Note

Engine failureHigh engine speeds in cold engines have a negative effect on the service life of the engine.

Always warm up the engine at low engine speeds.

100677-10
100677-10

Press the emergency OFF switch into the position

Switch on the ignition by turning the black programming key to the position ON

.
.
.
.
by turning the black programming key to the position ON . . After you switch on

After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function test of the combination instrument is run at the same time.

Shift into neutral.

The green idling speed indicator lamp N  lights up. N lights up.

Press the electric starter button

.
.
N  lights up. – Press the electric starter button . Info Do not press the

Info

Do not press the electric starter button until the function test of the combi-

nation instrument is finished.

When starting the engine, DO NOT apply the throttle. If you apply the throttle

during the starting procedure, the engine management shuts off the injec-

tors and the engine will not start.

Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds

before trying again.

This motorcycle is equipped with a safety start system. You can only start

the engine if the transmission is in neutral or if the clutch is pulled when a

gear is engaged. If the side stand is folded down and you shift into gear and

release the clutch, the engine stops.

Take the weight off the side stand and swing it upwards with your foot as far as it

will go.

01/FORK, TRIPLE CLAMP

15

5.1Adjusting

the compression damping of

the fork

15 5.1 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the

Info

The hydraulic compression damping determines the fork suspension behavior. An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when the load shifts very fast. It gives the rider good feedback about the road conditions.

100682-10
100682-10

Turn adjusting screws clockwise until they stop.

– Turn adjusting screws  clockwise until they stop. Info The adjusting screws are located at

Info

The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Compression damping

Comfort

15

clicks

Standard

10

clicks

Sport

5

clicks

Full payload

5

clicks

Sport 5 clicks Full payload 5 clicks Info Turn clockwise to increase damping, turn

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus-

pension damping.

5.2Adjusting

the rebound damping of

the fork

damping. 5.2 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the

Info

The hydraulic rebound damping determines the fork rebound behavior.

An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to

the zero position.

100683-10
100683-10

Turn adjusting screws clockwise to the stop.

– Turn adjusting screws  clockwise to the stop. Info The adjusting screws are located at

Info

The adjusting screws are located at the top end of the fork legs.

Adjust both fork legs to the same setting.

Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Rebound damping

Comfort

15

clicks

Standard

10

clicks

Sport

5

clicks

Full payload

5

clicks

Sport 5 clicks Full payload 5 clicks Info Turn clockwise to increase suspension damping; turn

Info

Turn clockwise to increase suspension damping; turn counterclockwise to reduce damping.

01/FORK, TRIPLE CLAMP

16

5.3Adjusting

the spring preload of

the fork

16 5.3 Adjusting the spring preload of the fork Info Spring preload determines the initial fork

Info

Spring preload determines the initial fork position. The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and thus ensures a compromise between maneuverability and stability.

100683-11
100683-11

Turn adjusting screws clockwise to the stop.

– Turn adjusting screws  clockwise to the stop. Info The adjustment screws are located at

Info

The adjustment screws are located at the top end of the fork legs. Adjust both fork legs to the same setting.

Turn back counterclockwise by the number of turns according to the fork type.

Guideline

Spring preload - Preload Adjuster

Comfort

5

turns

Standard

5

turns

Sport

3

turns

Full payload

3

turns

turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload, turn

Info

Turn clockwise to increase preload, turn counterclockwise to reduce spring

preload.

Changing the spring preload has no influence on the rebound damping

although the adjustment screws turn during the adjustment work. However,

you should also adjust the rebound damping when you alter the spring

preload.

5.4Bleeding

fork legs

100684-10
100684-10

Lean the motorcycle on the side stand.

Remove bleeder screws briefly.

on the side stand. – Remove bleeder screws  briefly. Any excess pressure escapes from the

Any excess pressure escapes from the interior of the fork.

Mount and tighten bleeder screws.

escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Perform this

Info

Perform this action on both fork legs.

01/FORK, TRIPLE CLAMP

17

5.5Vehicle

level

100693-01
100693-01
01/FORK, TRIPLE CLAMP 17 5.5 Vehicle level 100693-01 Warning Danger of accidents   Modifications to the

Warning

Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior.

Following modifications, ride slowly at first to get the feel of the new ride behavior.

The vehicle level can be adjusted at the front by means of the fork leg clamp and at the rear by the eccentric shaft. The fork legs can be clamped at three positions in the triple clamps.

Upper triple clamp flush with upper edge of fork legs

0

mm (0 in)

Upper triple clamp flush

2.5 mm (0.098 in)

with 1st ring of fork legs

Upper triple clamp flush

5

mm (0.2 in)

with 2nd ring of fork legs

 

(standard)

The infinitely variable frame height setting can be adjusted by turning the eccentric

shaft.

Frame height difference

12 mm (0.47 in)

HIGH - LOW

Maximum adjustment range

180°

between HIGH - LOW

5.6Adjusting

front

vehicle level

between HIGH - LOW 5.6 Adjusting front vehicle level Warning Danger of accidents   Modifications to

Warning

Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior.

Following modifications, ride slowly at first to get the feel of the new ride behavior.

100694-10
100694-10
100695-01
100695-01

Loosen screws on the lower triple clamp.

Loosen screw on the upper triple clamp.

Loosen screw of the handlebar stub.

triple clamp. – Loosen screw  of the handlebar stub. Info Loosen the screws far enough

Info

Loosen the screws far enough to prevent damage to the lacquer when the

fork legs are moved.

Make the adjustments first on one fork leg and then on the other. When the

screws of both fork legs are loosened, the vehicle sags toward the front.

Align the fork leg in the desired position by means of the fork rings.

Guideline

Upper triple clamp flush with upper

0

mm (0 in)

edge of fork legs

 

Upper triple clamp flush with 1st ring of fork legs

2.5 mm (0.098 in)

Upper triple clamp flush with 2nd ring of fork legs (standard)

5

mm (0.2 in)

with 2nd ring of fork legs (standard) 5 mm (0.2 in) Info The standard adjustment is

Info

The standard adjustment is the setting that provides the best vehicle han- dling. When the fork is compressed, the suspension setting changes, caus- ing the vehicle to become more stable but also more difficult to handle.

01/FORK, TRIPLE CLAMP

18

100694-11
100694-11

Tighten screw .

Guideline

 

Screw, top triple clamp

M8

17

Nm

(12.5 lbf ft)

Tighten screws .

 
 

Guideline

Screw, bottom triple clamp

M8

15

Nm

(11.1 lbf ft)

Tighten screw .

 
 

Guideline

Screw, handlebar stub

M8

20

Nm

(14.8 lbf ft)

Repeat the adjustment on the other fork leg.

lbf ft) – Repeat the adjustment on the other fork leg. Info The vehicle level setting

Info

The vehicle level setting on both fork legs must be identical.

5.7Removing

the

fork

100719-10
100719-10
201056-10
201056-10

Jack up the motorcycle in the middle (insertable type). (

Clamp down the rear of the vehicle.

Remove the screws from both brake calipers.

Press back the brake linings with a light lateral tilting of the brake calipers on the

with a light lateral tilting of the brake calipers on the p. 12) brake disc. Pull

p. 12)

brake disc. Pull the brake caliper carefully back from the brake discs and hang it to

the side.

carefully back from the brake discs and hang it to the side. Info Do not pull

Info

Do not pull the hand brake lever when the brake calipers are removed.

Loosen screws and .

Unscrew screw about six turns and press your hand on the screw to push the

wheel spindle out of the axle clamp. Remove screw .

the wheel spindle out of the axle clamp. Remove screw  . Warning Danger of accidents

Warning

Danger of accidentsReduced braking efficiency caused by damaged brake

discs.

Always lay the wheel down in such a way that the brake discs are not

damaged.

Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

201057-10
201057-10

the fork.

Remove the screws on both sides of the fender . Take off the fender.

01/FORK, TRIPLE CLAMP

19

201058-10
201058-10
201059-10
201059-10

Remove screws . Hang the wheel speed sensor to the side.

Unscrew screws of the triple clamps and handlebar stubs. Remove the fork legs downward.

5.8Installing

the fork

Remove the fork legs downward. 5.8 Installing the fork Warning Danger of accidents   Modifications to

Warning

Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior.

Following modifications, ride slowly at first to get the feel of the new ride behavior.

100695-01
100695-01

Slide the fork legs into the triple clamps and handlebar stubs.

Align the fork leg in the desired position by means of the fork rings.

Guideline

Upper triple clamp flush with upper

0

mm (0 in)

edge of fork legs

 

Upper triple clamp flush with 1st ring

2.5 mm (0.098 in)

of fork legs

Upper triple clamp flush with 2nd ring

5

mm (0.2 in)

of fork legs (standard)

 
5 mm (0.2 in) of fork legs (standard)   Info The standard adjustment is the setting

Info

The standard adjustment is the setting that provides the best vehicle han-

dling. When the fork is compressed, the suspension setting changes, caus-

ing the vehicle to become more stable but also more difficult to handle.

201059-11
201059-11
201058-11
201058-11

Tighten screws of the triple clamps and handlebar stubs.

Guideline

 

Screw, top triple clamp

M8

17

Nm

(12.5 lbf ft)

Screw, bottom triple clamp

M8

15

Nm

(11.1 lbf ft)

Screw, handlebar stub

M8

20

Nm

(14.8 lbf ft)

Position the wheel speed sensor. Mount and tighten screws .

 
 

Guideline

Screw, wheel speed sensor

M4

2 Nm (1.5 lbf ft)

Loctite ® 243™

01/FORK, TRIPLE CLAMP

20

201057-11
201057-11
100781-11
100781-11
100780-11
100780-11
201060-10
201060-10

Position the fender. Mount and tighten screws .

Guideline

Remaining chassis screws

M6

10

Nm (7.4 lbf ft)

Clean and grease the shaft seal rings and mating surfaces of the spacers.

Long-life grease (

Long-life grease ( p. 438)

p. 438)

Insert the wide spacer on the left-hand side (when looking in the direction of

travel).

side  (when looking in the direction of travel). Info The arrow  indicates the direction

Info

The arrow indicates the direction of rotation of the front wheel.

Insert the narrow spacer on the right-hand side (when viewed in the direction of

travel).

right-hand side (when viewed in the direction of travel). Warning Danger of accidents   Reduced braking

Warning

Danger of accidentsReduced braking efficiency due to oil or grease on the

brake discs.

Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

Clean screw and the wheel spindle.

Lift the front wheel into the fork, position it, and insert the wheel spindle.

Mount and tighten screw .

Guideline

Bolt, front axle

M25x1.5

45

Nm

(33.2 lbf ft)

100719-12
100719-12

Position the brake calipers and check that the brake linings are seated correctly.

Mount screws on both brake calipers but do not tighten yet.

Operate the hand brake lever repeatedly until the brake lining presses up against

the brake disc and there is a pressure point. Fix the hand brake lever in the acti-

vated position.

point. Fix the hand brake lever in the acti- vated position. The brake calipers align themselves.

The brake calipers align themselves.

Tighten screws on both brake calipers.

Guideline

Screw, front brake caliper

M10x1.25

45 Nm (33.2 lbf ft)

Loctite ® 243™

Release the fixation of the hand brake lever.

Release the rear of the vehicle.

Remove the motorcycle from the work stand (insertable type). (

lever. – Release the rear of the vehicle. – Remove the motorcycle from the work stand

p. 12)

01/FORK, TRIPLE CLAMP

21

– Pull the front brake and compress the fork powerfully a few times. The fork
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws .
Guideline
Fork end pinch bolts
M8
15 Nm
(11.1 lbf ft)
100782-11
5.9performing
a
fork service
Info
These operations are the same on both fork legs.
201097-01

201097-01

Condition

The fork legs have been removed.

Disassemble the fork legs. (

p. 21)legs have been removed. – Disassemble the fork legs. ( – Disassemble the outer tubes. (

– Disassemble the outer tubes. ( p. 24) – Change the lower DU bush. (
– Disassemble the outer tubes. (
p. 24)
– Change the lower DU bush. (
p. 26)
– Check the fork legs. (
p. 25)

Assemble the outer tubes. (

Assemble the fork legs. (

Assemble the outer tubes. ( – Assemble the fork legs. ( p. 27) p. 27) 5.10

p. 27)Assemble the outer tubes. ( – Assemble the fork legs. ( p. 27) 5.10 Disassembling the

p. 27)

5.10Disassembling

the fork legs

legs. ( p. 27) p. 27) 5.10 Disassembling the fork legs Info These operations are the

Info

These operations are the same on both fork legs.

200605-10
200605-10

Condition

The fork legs have been removed.

Determine and note down the current setting of rebound damping and compres-

sion damping .

Completely open the adjusting elements of the rebound and compression damping.

Determine and note down the current setting of spring preload .

Completely open the adjusting elements of the spring preload.

01/FORK, TRIPLE CLAMP

22

200606-10
200606-10
200607-10
200607-10
200608-10
200608-10
200609-10
200609-10
200610-10
200610-10

Clamp the fork leg in the area of the lower triple clamp.

Clamping stand (T612S) (

p. 451)Clamping stand (T612S) (

Release Preload Adjuster .

Key (T524) (

Key (T524) ( p. 450)

p. 450)

– Release Preload Adjuster  . Key (T524) ( p. 450) Info The Preload Adjuster cannot

Info

The Preload Adjuster cannot be removed yet.

Unclamp the fork leg. Slide the outer tube down.

Clamp aluminum tube with the special tool.

Clamping stand (T526S) (

p. 450)Clamping stand (T526S) (

Pull up Preload Adjuster . Mount the special tool on the hexagonal piece.

Open-end wrench (T14032) (

Open-end wrench (T14032) ( p. 450)

p. 450)

Hold the hexagonal piece in place with the special tool. Release Preload Adjuster

and remove it with preload spacers .

01/FORK, TRIPLE CLAMP

23

200611-10
200611-10
200612-10
200612-10
200613-10
200613-10
200614-10
200614-10

Remove adjusting tube .

Screw special tool onto the piston rod and pull it up.

Gripping tool (T14026S1) (

p. 449)Gripping tool (T14026S1) (

Remove the special tool from the hexagonal piece.

Open-end wrench (T14032) (

Open-end wrench (T14032) ( p. 450)

p. 450)

Release special tool .

Gripping tool (T14026S1) (

p. 449)Gripping tool (T14026S1) (

Unclamp the fork leg and clamp it with the axle clamp.

Pull out pin of the special tool.

Pull collar bushing off of aluminum tube . Slide the aluminum tube over the

special tool.

Unscrew the special tool.

Remove the collar bushing.

Remove spring .

Unclamp the fork leg.

– Remove spring  . – Unclamp the fork leg. Info Hold the fork leg by

Info

Hold the fork leg by the axle clamp.

Drain the fork oil.

the fork leg by the axle clamp. – Drain the fork oil. Info Pull out the

Info

Pull out the piston rod and push back in a number of times to empty the

cartridge.

200615-10
200615-10

Pull outer tube  off of inner tube .

01/FORK, TRIPLE CLAMP

24

200616-10
200616-10
200617-10
200617-10
200618-10
200618-10

Clamp the fork leg with the axle clamp.

Remove screws .

Unscrew screws  of the cartridge and remove with the seal ring.

 of the cartridge and remove with the seal ring. Info Place a drain pan underneath.

Info

Place a drain pan underneath.

Remove the cartridge.

5.11Disassembling

the outer

tubes

Remove the cartridge. 5.11 Disassembling the outer tubes Info These operations are the same on both

Info

These operations are the same on both outer tubes.

200619-10
200619-10

Disassemble the fork legs. (

Clamp the outer tube in the area of the lower triple clamp.

p. 21)Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T612S) (

Clamping stand (T612S) (

p. 451)Clamping stand (T612S) (

Remove dust boot .

01/FORK, TRIPLE CLAMP

25

200620-10
200620-10
200621-10
200621-10
200622-10
200622-10

Remove lock ring .

Remove seal ring .

Remove support ring .

5.12Checking

the fork legs

200629-10
200629-10
200630-10
200630-10

Condition

The fork legs must be disassembled.

Check the inner tube and axle clamp for damage.

» If there is damage:

Change the inner tube.

Measure the outside diameter at several locations on the inner tube.

Outside diameter of inner tube

42.975… 43.005 mm (1.69193…

1.69311 in)

» If the measured value is less than the specified value:

Change the inner tube.

01/FORK, TRIPLE CLAMP

26

200631-10
200631-10
200632-10
200632-10
200665-10
200665-10
200666-10
200666-10

Measure the run-out of the inner tube.

Run-out of inner tube

0.20 mm (0.0079 in)

» If the measured value is greater than the specified value:

Change the inner tube.

Check the outer tube for damage.

» If there is damage:

Change the outer tube.

Check the surface of the upper DU bush.

» If the bronze-colored layer under the sliding layer is visible:

Change the outer tube.

Check the surface of the lower DU bush.

» If the bronze-colored layer under the sliding layer is visible:

Change the lower DU bush. (

sliding layer is visible: – Change the lower DU bush. ( p. 26) – Check the

p. 26)

Check the spring length.

Guideline

Spring length with preload spacer(s)

405 mm (15.94 in)

» If the measured value is greater than the specified value:

Reduce the thickness of the preload spacer.

» If the measured value is less than the specified value:

Increase the thickness of the preload spacer.

5.13changing

the lower

DU bush

200664-10
200664-10

Disassemble the outer tubes. (

Heat the outer tube in the area of the lower DU bush.

( – Heat the outer tube in the area of the lower DU bush. p. 24)

p. 24)

Guideline

50 °C (122 °F)

Remove DU bush .

Press the new DU bush all the way in.

Assemble the outer tubes. (

(122 °F) – Remove DU bush  . – Press the new DU bush all the

p. 27)

01/FORK, TRIPLE CLAMP

27

5.14Assembling

the outer

tubes

TRIPLE CLAMP 27 5.14 Assembling the outer tubes Info These operations are the same on both

Info

These operations are the same on both outer tubes.

200622-11
200622-11
200621-11
200621-11
200620-11
200620-11
200619-11
200619-11

Check the fork legs. (

Clamp the outer tube in the area of the lower triple clamp.

Clamp the outer tube in the area of the lower triple clamp. p. 25) Clamping stand

p. 25)

Clamping stand (T612S) (

p. 451)Clamping stand (T612S) (

Insert support ring .

Lubricate seal ring and mount it with the open side facing downward.

Lubricant (T511) (

p. 438)Lubricant (T511) (

Mount lock ring .

Lubricant (T511) ( p. 438) – Mount lock ring  . The lock ring engages audibly.

The lock ring engages audibly.

Lubricate and mount dust boot .

Lubricant (T511) (

p. 438)Lubricant (T511) (

5.15Assembling

the fork legs

(T511) ( p. 438) 5.15 Assembling the fork legs Info These operations are the same on

Info

These operations are the same on both fork legs.

Assemble the outer tubes. (

p. 27)5.15 Assembling the fork legs Info These operations are the same on both fork legs. –

01/FORK, TRIPLE CLAMP

28

200618-11
200618-11
200626-10