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REPAIR MANUAL 2008

450 XC ATV
525 XC ATV
ART. NO. 3206058en

INTRODUCTION

Read this repair manual carefully and in its entirety before beginning work.
INTRODUCTION

Only use ORGINALKTM 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. In particular, the KTM Sportmotorcycle AG reserves the right to change or cancel technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without giving reasons, and to
adapt the technical specifications to local conditions as well as terminating the production of a specific 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: TV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS
CONTENTS

MEANS OF REPRESENTATION ............................................ 5


IMPORTANT NOTES ............................................................ 6
Overview of warning labels................................................ 8
VIEW OF VEHICLE............................................................. 10
Vehicle view, front left ................................................... 10
View of vehicle, rear right ............................................... 11
LOCATION OF SERIAL NUMBERS ...................................... 12
Chassis number............................................................. 12
Type label..................................................................... 12
Key number .................................................................. 12
Engine number.............................................................. 12
Setting number, front shock absorber .............................. 12
Setting number, rear shock absorber ............................... 13
VEHICLE .......................................................................... 14
Jacking up the vehicle ................................................... 14
Removing the vehicle from the work stand ....................... 14
02/HANDLEBAR, CONTROLS ............................................. 15
Adjusting handlebar position .......................................... 15
Adjusting basic position of clutch lever............................ 15
Checking play in gas Bowden cable ................................. 16
Adjusting play in gas Bowden cable................................. 16
Checking the play in the Bowden cable using the reverse
gear release lever........................................................... 16
Adjusting the play in the Bowden cable using the reverse
gear release lever........................................................... 16
Detaching the reverse gear Bowden cable ........................ 17
Attaching the reverse gear Bowden cable ......................... 17
03/FRAME........................................................................ 18
Removing the engine guard ............................................ 18
Installing the engine guard ............................................. 18
04/SHOCK ABSORBER, SWINGARM................................... 19
Front shock absorber - adjusting the compression
damping ....................................................................... 19
Front shock absorber - adjusting the rebound damping...... 19
Front shock absorber - adjusting the cross over................. 20
Front shock absorber - spring preload .............................. 20
Removing the front shock absorber.................................. 21
Installing the front shock absorber .................................. 22
Front shock absorber - removing the spring ...................... 22
Front shock absorber - installing the spring ...................... 23
Front shock absorber - disassembling the shock
absorber ....................................................................... 24
Front shock absorber - assembling the shock absorber ...... 25
Bleeding and filling shock absorber ................................. 28
Front shock absorber - disassembling the piston rod ......... 31
Front shock absorber - assembling the piston rod.............. 32
Front shock absorber - removing the heim joint ................ 33
Front shock absorber - installing the heim joint ................ 34
Rear shock absorber - adjusting the compression
damping ....................................................................... 34
Rear shock absorber - adjusting the rebound damping....... 35
Rear shock absorber - spring preload ............................... 35
Removing the rear shock absorber ................................... 36
Installing the rear shock absorber.................................... 37
Rear shock absorber - removing the spring ....................... 37
Rear shock absorber - installing the spring ....................... 37
Rear shock absorber - disassembling the shock absorber ... 38
Rear shock absorber - assembling the shock absorber ....... 40
Rear shock absorber - disassembling the piston rod .......... 42
Rear shock absorber - assembling the piston rod .............. 44
Rear shock absorber - removing the heim joint ................. 46
Rear shock absorber - installing the heim joint ................. 47

2
05/EXHAUST ....................................................................
Removing the main silencer............................................
Installing the main silencer ............................................
Removing the manifold ..................................................
Installing the manifold ...................................................
06/AIR FILTER..................................................................
Removing the air filter ...................................................
Installing the air filter ....................................................
Cleaning air filter...........................................................
Removing the air filter box lid with the carburetor
connection boot ............................................................
Installing the air filter box lid and the carburetor
connection boot ............................................................
07/FUEL TANK, SEAT, TRIM..............................................
Removing the seat .........................................................
Mounting the seat .........................................................
Removing the radiator spoiler .........................................
Installing the radiator spoiler ..........................................
Removing the fuel tank ..................................................
Installing the fuel tank ...................................................
Fuel tap........................................................................
08/MASK, FENDER ...........................................................
Removing the front cover................................................
Installing the front cover ................................................
Removing the front trim .................................................
Installing the front trim ..................................................
Removing the rear fender ...............................................
Installing the rear fender ................................................
09/FRONT WHEEL ............................................................
Checking tire air pressure ...............................................
Tire condition checking..................................................
Removing wheel/wheels..................................................
Mounting wheel/wheels ..................................................
Checking brake discs .....................................................
10/REAR WHEEL ..............................................................
Checking chain dirt .......................................................
Cleaning the chain.........................................................
Checking chain wear ......................................................
Checking rear sprocket / engine sprocket for wear .............
Checking the chain tension ............................................
Adjusting chain tension..................................................
Adjusting the toe width of rear axle .................................
Removing the rear axle...................................................
Installing the rear axle ...................................................
Changing the rear axle bearing........................................
11/WIRING HARNESS, BATTERY .......................................
Ignition curve plug connection ........................................
Changing ignition curve..................................................
Removing the battery .....................................................
Installing the battery......................................................
Recharging the battery ...................................................
Changing the main fuse .................................................
Changing the fuses of individual power-consuming
components ..................................................................
Checking the battery voltage...........................................
Checking the charging voltage ........................................
Checking the closed-circuit current .................................
Checking the starter relay ...............................................
13/BRAKE SYSTEM...........................................................
Handbrake lever, parking brake.......................................
Checking free play of hand brake lever.............................
Adjusting basic position of handbrake lever......................

48
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74
74
74

CONTENTS
Checking the brake fluid level of the front brake ............... 75
Adding brake fluid for the front brake .............................. 75
Checking the front brake linings...................................... 76
Removing the front brake linings..................................... 76
Mounting front brake linings........................................... 76
Changing the front brake linings ..................................... 77
Checking free play of foot brake lever .............................. 77
Adjusting basic position of footbrake lever ....................... 78
Checking the brake fluid level of the rear brake ................ 78
Adding brake fluid for the rear brake ............................... 79
Checking the rear brake linings ....................................... 79
Removing the rear brake linings ...................................... 80
Mounting rear brake linings ............................................ 80
Changing the rear brake linings....................................... 81
30/ENGINE....................................................................... 82
Removing the engine ..................................................... 82
Installing the engine ...................................................... 84
30/DISASSEMBLING THE ENGINE..................................... 87
Preparations.................................................................. 87
Draining the engine oil ................................................... 87
Removing the oil filter.................................................... 87
Removing the starter motor ............................................ 87
Removing the shift lever................................................. 88
Removing the clutch cover ............................................. 88
Removing the clutch discs.............................................. 88
Removing the outer clutch hub ....................................... 89
Removing the starter idler gear/torque limiter ................... 90
Removing the shift shaft ................................................ 90
Removing the shift drum locating.................................... 90
Removing the locking lever ............................................. 90
Removing the oil pump gear ........................................... 90
Removing the primary gear with the free-wheel-gear.......... 91
Removing the spark plug ................................................ 91
Removing the generator cover ......................................... 91
Installing the crankshaft locking bolt ............................... 91
Removing the ignition pulse generator ............................. 92
Removing the rotor ........................................................ 92
Removing the oil pumps................................................. 93
Removing the oil line ..................................................... 93
Removing the timing chain tensioner............................... 94
Removing the water pump cover ..................................... 94
Removing the cylinder head top section........................... 94
Removing the camshaft.................................................. 94
Removing the cylinder head............................................ 95
Removing the cylinder ................................................... 95
Removing the piston ...................................................... 96
Removing the timing chain............................................. 96
Removing the timing chain sprocket................................ 96
Removing the locking shaft lever..................................... 96
Removing the gear sensor............................................... 97
Taking off the left section of the engine case ................... 97
Remove the shift rails and forks. ..................................... 98
Removing the shift drum ................................................ 98
Removing the transmission shaft..................................... 99
Removing the balancer shaft .......................................... 99
Removing the crankshaft ................................................ 99
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 100
Work on the right section of the engine case .................. 100
Removing the oil pressure regulator valve....................... 101
Checking the spring length of the oil pressure regulator
valve .......................................................................... 101
Installing the oil pressure regulator valve ....................... 101

3
Work on the left section of the engine case ....................
Changing the crankshaft seal ring in the clutch cover......
Disassembling the autodecompressor ............................
Assembling the autodecompressor.................................
Changing the camshaft bearing.....................................
Checking the rocker arms and rocker arm shafts .............
Removing the valves ....................................................
Checking the valves .....................................................
Checking the valve springs ...........................................
Checking the lower valve spring retainer ........................
Checking the cylinder head ..........................................
Installing the valves .....................................................
Checking the timing assembly ......................................
Preparing the timing chain tensioner for installation .......
Changing the conrod bearing ........................................
Checking the crankshaft run-out on the bearing pin ........
Measuring the axial clearance of the crankshaft..............
Correcting the axial clearance of the crankshaft..............
cylinder - Nikasil coating ............................................
Checking/measuring the cylinder...................................
Checking/measuring the piston .....................................
Checking the piston ring end gap ..................................
Checking the piston/cylinder mounting clearance............
Checking the oil pumps for wear ...................................
Checking the shift mechanism ......................................
Disassembling the shift shaft........................................
Preassembling the shift shaft........................................
Checking the clutch.....................................................
Disassembling the main shaft .......................................
Checking the main shaft ..............................................
Assembling the main shaft ...........................................
Disassembling the countershaft ....................................
Checking the countershaft............................................
Assembling the countershaft.........................................
Checking/premounting the reverse gear shaft..................
Checking electric starter operation ................................
Removing the free-wheel ..............................................
Checking the free-wheel ...............................................
Installing the free-wheel...............................................
30/ASSEMBLING THE ENGINE ........................................
Installing the crankshaft...............................................
Installing the balancer shaft .........................................
Installing the transmission shaft ...................................
Installing the shift forks ...............................................
Installing the shift drum...............................................
Installing the shift rails ................................................
Installing the left engine case .......................................
Installing the timing chain sprocket...............................
Installing the timing chain rails.....................................
Installing the piston.....................................................
Installing the cylinder ..................................................
Installing the cylinder head ..........................................
Installing the camshaft ................................................
Installing the cylinder head top section..........................
Installing the timing chain tensioner .............................
Installing the rotor .......................................................
Checking the valve clearance ........................................
Adjusting the valve clearance........................................
Installing the valve cover ..............................................
Installing the water pump cover ....................................
Installing the oil line....................................................

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136

CONTENTS
Installing the spark plug...............................................
Installing the primary gear with the free-wheel-gear ........
Installing the oil pumps ...............................................
Installing the ignition pulse generator............................
Installing the generator cover........................................
Installing the gear sensor .............................................
Installing the locking shaft lever ...................................
Installing the locking lever............................................
Installing the shift drum locating ..................................
Installing the shift shaft ...............................................
Installing the starter idler gear/torque limiter..................
Removing the crankshaft locking bolt ............................
Installing the outer clutch hub and clutch discs .............
Installing the clutch cover ............................................
Installing the starter motor ...........................................
Installing the oil drain plug...........................................
Installing the oil screen................................................
Mounting the oil filter ..................................................
Filling up with engine oil..............................................
Installing the shift lever ...............................................
Installing the clutch push rod .......................................
Removing the engine from the universal mounting
rack ...........................................................................
31/CARBURETOR ...........................................................
Choke.........................................................................
Hot start button...........................................................
Removing the carburetor ..............................................
Disassembling the carburetor........................................
Checking/adjusting the carburetor components...............
Checking/adjusting the accelerator pump.......................
Checking the hot start slide ..........................................
Checking the choke slide..............................................
Checking the jet needle................................................
Checking the throttle slide............................................
Checking the needle jet................................................
Checking the float needle valve.....................................
Checking the throttle valve sensorTPS ..........................
Adjusting the position of throttle valve sensorTPS ..........
Checking/adjusting the throttle slide opening .................
Checking/adjusting the float level..................................
Assembling the carburetor ............................................
Installing the carburetor ...............................................
Carburetor - adjusting idle ............................................
Checking the throttle valve sensor position.....................
Emptying the carburetor float chamber ..........................
32/CLUTCH ....................................................................
Checking 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 ..........................................................
Filling coolant / bleeding cooling system ........................
38/LUBRICATION SYSTEM ..............................................
Changing engine oil and oil filter, cleaning oil screens ....
Draining engine oil, cleaning oil screens ........................
Removing the oil filter..................................................
Mounting oil filter........................................................
Filling up with engine oil..............................................
Checking engine oil level..............................................

4
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169

Topping up engine oil ..................................................


39/IGNITION SYSTEM .....................................................
Checking the generator ................................................
Checking the ignition pulse generator ............................
Checking the ignition coil.............................................
Checking the spark plug connector................................
61/ATV FRONT SECTION .................................................
Toe, checking .............................................................
Adjusting the toe .........................................................
Checking/adjusting camber...........................................
Adjusting the fork offset ...............................................
Removing the wheel carrier ..........................................
Installing the wheel carrier ...........................................
Removing the A-arms...................................................
Installing the A-arms ...................................................
A-Arm top - changing the bearing..................................
A-Arm bottom - changing the bearing ............................
TECHNICAL DATA - ENGINE ............................................
Capacity - engine oil ....................................................
Capacity - coolant........................................................
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE .........................................................................
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........
TECHNICAL DATA - CARBURETOR...................................
450/525XCATV .........................................................
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES.......................................................................
TECHNICAL DATA - CHASSIS ..........................................
Lighting equipment .....................................................
Tires ..........................................................................
Capacity - fuel.............................................................
TECHNICAL DATA - FRONT SHOCK ABSORBER................
TECHNICAL DATA - REAR SHOCK ABSORBER..................
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......
CLEANING......................................................................
Cleaning the vehicle ....................................................
STORAGE .......................................................................
Storage.......................................................................
Putting the vehicle into operation after storage ...............
GREASING AND SERVICE TABLE .....................................
Important maintenance work to be carried out by an
authorized KTM workshop. ...........................................
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 ..........................................................
450/525XCATV .........................................................
SUBSTANCES.................................................................
AUXILIARY SUBSTANCES................................................
SPECIAL TOOLS..............................................................
STANDARDS...................................................................
INDEX ............................................................................

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216
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MEANS OF REPRESENTATION
MEANS OF REPRESENTATION
1

Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies a page reference (more information is provided on the specified page).

Formats used
The typographical and other formats used are explained in the following.
Name

Identifies a specific name.

Registered trademark

Identifies a protected name.

Trademark

Identifies a brand in merchandise traffic.

IMPORTANT NOTES

IMPORTANT NOTES
2

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 vehicle.

Fuel, oils, etc.


You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories


Only use spare parts and accessory products that have been released by KTM. KTM accepts no liability for other products and any
resulting damage or loss.

Work rules
When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers)
must be replaced with new parts.
If a thread locker (e.g.Loctite) is used for screw connections, follow the instructions for use from the manufacturer.
Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear. Replace damaged or worn
parts.
After finishing the repair and maintenance work, ensure that the vehicle is roadworthy.

IMPORTANT NOTES

IMPORTANT NOTES

Overview of warning labels


2.1

100106-10

IMPORTANT NOTES
Notes/warning notes
Pay attention to the specified notes and warnings.

Info
Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.

Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.

Warning
Danger that will probably lead to severe and permanent injury or death.

Note
Danger of serious damage to machine or material.

Warning
Risk of environmental damage.

Repair manual

Read this repair manual carefully and in its entirety before beginning work. It contains a lot of information and tips to help you
repair and maintain the vehicle.

It is assumed that the necessary KTM special tools and workshop equipment are available to you.

VIEW OF VEHICLE

10

VIEW OF VEHICLE
3

Vehicle view, front left

3.1

600148-10

Hand brake lever

Fuse box

Headlight

Front shock absorber

Right-hand brake caliper

Steering damper holder (steering damper is optional)

Front left shock absorber

Outside brake disk guard

Shift lever

10

Left footrest

11

Heel protector

12

Emergency OFF switch with rip cord

13

Clutch lever

VIEW OF VEHICLE

11

View of vehicle, rear right


3.2

600149-10

Light switch, electric starter button, ENG.STOPswitch

Filler cap

Main silencer

Rear shock absorber

Rear sprocket with chain

Rear wheel eccentric element

Rear brake

Foot brake pedal

Compensating tank for coolant

10

Manifold

11

Top A-arm

12

Front right fender

13

Throttle lever

14

Ignition switch

LOCATION OF SERIAL NUMBERS

12

LOCATION OF SERIAL NUMBERS


4

Chassis number

4.1

The chassis number is stamped on the right side of the frame in the vicinity of the
upper control arm.

100002-10

Type label
4.2

The type label is located on the frame tube on the right in front of the radiator.

100034-10

Key number
4.3

The key number is indicated on theKEYCODECARD.

Info
You need the key number to order a replacement key. Keep theKEYCODECARD in
a safe place.

100089-10

Engine number
4.4

The engine number is stamped on the left side of the engine under the engine
sprocket.

100001-10

Setting number, front shock absorber


4.5

The setting number is stamped into the top of the shock absorber.

100033-10

LOCATION OF SERIAL NUMBERS


Setting number, rear shock absorber
4.6

The setting number is stamped into the top of the shock absorber.

100032-10

13

VEHICLE

14

VEHICLE
5

Jacking up the vehicle

5.1

Note
Danger of damageDanger of damage from tipping of vehicle.

Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand.

Jack up the vehicle on the frame underneath the engine. The wheels must no
longer touch the ground.

Secure the vehicle.

100054-10

Removing the vehicle from the work stand


5.2

Note
Danger of damageDanger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

Lower the vehicle.

Remove the work stand.

02/HANDLEBAR, CONTROLS

15

02/HANDLEBAR, CONTROLS
6

Adjusting handlebar position

6.1

Pull the instrument support off the handlebar and swing it to the side.

Info
Protect the vehicle and its attachments from damage by covering them.
Do not bend the cables and lines.

100100-10

Remove the four screws. Remove the handlebar clamps, swing the handlebar
forward and set it down.

Remove the nuts and remove the handlebar support with the screws.

Remove screws and.

Remove screws. Remove the handlebar bridge.

Check parts for damage and wear. Replace damaged or worn parts.

Place the handlebar bridge onto the steering column in the desired position.
Mount and tighten screw.
Specification
Screw, steering bridge

M8

20Nm
(14.8lbfft)

M20x1,5

25Nm
(18.4lbfft)

M8

20Nm
(14.8lbfft)

Mount and tighten screw.


Specification
Screw, steering column, top

Mount and tighten screws.


Specification

100099-10

Screw, steering bridge

Mount the handlebar support in the desired position using the screws. Mount
new self-locking nuts and tighten.
Specification
Nut, handlebar support

M10

45Nm
(33.2lbfft)

Position the handlebar and fix it with the handlebar clamps. Mount and tighten
screws.
Specification
Screw, handlebar clamp

M8

20Nm
(14.8lbfft)

Info
Make sure cables and wiring are positioned correctly.

Position the instrument support on the handlebar.

Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw.

Adjusting basic position of clutch lever


6.2

Info

100039-10

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

02/HANDLEBAR, CONTROLS

16

Checking play in gas Bowden cable


6.3

Move the handlebar to the straight-ahead position. Move the throttle lever back and
forth slightly to ascertain the play in the gas Bowden cable.
Specification
Play in gas Bowden cable

3 5mm (0.12 0.2in)

If the gas Bowden cable play does not meet specifications:

Adjust the play in the gas Bowden cable. (

P. 16)

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

600142-10

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:

Adjust the play in the gas Bowden cable. (

P. 16)

Adjusting play in gas Bowden cable


6.4

Check gas Bowden cable route.

Move the handlebar to the straight-ahead position.

Loosen the nut and use the screw to adjust the play in the gas Bowden
cable.
Specification
Play in gas Bowden cable

3 5mm (0.12 0.2in)

Tighten nut.

600142-11

Checking the play in the Bowden cable using the reverse gear release lever
6.5

Move the handlebar to the straight-ahead position. Move the reverse gear release
lever back and forth slightly to ascertain the play in the Bowden cable.
Specification
Play in the Bowden cable on the
reverse gear release lever

If the Bowden cable play on the reverse gear release lever does not agree with
the specifications:

600141-10

10mm (0.39in)

Adjust the play in the Bowden cable using the reverse gear release lever.
( P. 16)

Adjusting the play in the Bowden cable using the reverse gear release lever
6.6

Check that the Bowden cable is correctly laid from the reverse gear release lever.

Move the handlebar to the straight-ahead position.

Release the nut and using the screw, adjust the play of the Bowden cable
on the reverse gear release lever.
Specification
Play in the Bowden cable on the
reverse gear release lever

600141-11

Tighten nut.

10mm (0.39in)

02/HANDLEBAR, CONTROLS

17

Detaching the reverse gear Bowden cable


6.7

Loosen nut.

Detach the Bowden cable from abutment plate and locking shaft lever.

600181-10

Attaching the reverse gear Bowden cable


6.8

Attach the Bowden cable to locking shaft lever and abutment plate.

Mount nut in such a way that the specified play is present in the Bowden cable.
Specification
Play in the Bowden cable on the
reverse gear release lever

600181-11

10mm (0.39in)

Tighten nut.

Check the play in the Bowden cable using the reverse gear release lever. (

P. 16)

03/FRAME

18

03/FRAME
7

Removing the engine guard

7.1

Remove screws and. Remove the engine guard.

Check parts for damage and wear. Replace damaged or worn parts.

Position the engine guard on the frame bearer. Mount and tighten screws
and.

600133-10

Installing the engine guard


7.2

Specification

600133-10

Remaining screws, chassis

M6

10Nm (7.4lbfft)

Remaining screws, chassis

M8

25Nm
(18.4lbfft)

04/SHOCK ABSORBER, SWINGARM

19

04/SHOCK ABSORBER, SWINGARM


8

Front shock absorber - adjusting the compression damping

8.1

Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.

Only make adjustments within the recommended range.

Info
The compression damping setting has an impact on the compression of the shock absorber.

Turn the adjusting wheel clockwise until it stops.

Turn it back counterclockwise by the number of clicks corresponding to the shock


absorber type.
Specification
Compression damping
Standard

14clicks

Maximum deviation from standard


value

5 5clicks

100027-10

Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.

Info
Turning clockwise increases damping, while turning counterclockwise
lessens damping.
The left and right shock absorbers should have the same settings.

Front shock absorber - adjusting the rebound damping


8.2

Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.

Only make adjustments within the recommended range.

Info
The rebound damping setting has an impact on the compression of the shock absorber.

Turn adjusting screw clockwise until it stops.

Turn it back counterclockwise by the number of clicks corresponding to the shock


absorber type.
Specification
Rebound damping
Standard

20clicks

Maximum deviation from standard


value

5 5clicks

100028-10

Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.

Info
Turning clockwise increases damping, while turning counterclockwise
lessens damping
The left and right shock absorbers should have the same settings.

04/SHOCK ABSORBER, SWINGARM

20

Front shock absorber - adjusting the cross over


8.3

Info
The cross over setting is used to adjust the suspension travel of the short (soft) spring.
Greater cross over makes the suspension at the front softer and the front of the vehicle lies lower. The suspension travel and
the progressive part of the long (hard) spring are not fully utilized.
Less cross over makes the suspension at the front harder and the front of the vehicle lies higher.

Jack up the vehicle. (

Clean the shock absorber thoroughly.

Loosen adjusting ring using special tool.

P. 14)

Hook wrench, hlins (83019001000) (

P. 210)

100084-10

Cross over setting is measured between sliding bushing and the collar of
spring retainer.
Specification
Cross over

171.5mm (0.670.059in)

Change the settings accordingly and lock the adjusting ring.

Info

The sliding bushing is made of plastic. Therefore, do not lock it too tightly
to avoid damaging the thread.
The left and right shock absorbers should have the same settings.

400348-11

Remove the vehicle from the work stand. (

P. 14)

Front shock absorber - spring preload


8.4

Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.

Make adjustments in small steps only.

Info
Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.

Tip
Before you change the spring preload, make a note of the groove in which the securing clip is positioned. When making adjustments, always start from the standard setting.

100083-10

Jack up the vehicle. (

Clean the shock absorber thoroughly.

Press the spring pack and spring retainer down to make securing clip accessible.

Using pliers, position the securing clip in one of the upper grooves. Do not overstrain the securing clip.

Release the spring pack and measure the length of the unloaded spring pack.

P. 14)

04/SHOCK ABSORBER, SWINGARM

21

Press together the spring pack, position the securing clip in the corresponding
groove and release the spring pack.
Specification

A
0

Clip position, spring preload


Standard

7 th position from top

Corresponds to a spring preload of

5mm (0.2in)

Info
The spring preload is the difference in length between the spring pack
when it is unloaded and when it is installed.
The securing clip must be positioned entirely within the cut-out of the
spring retainer.
The spring pack should never be installed loosely (without preload). The
standard setting is the lowest permissible spring preload. Therefore, you can
only increase the spring preload.
If you increase the spring preload, you should also slightly increase the
rebound damping.
The left and right shock absorbers should have the same settings.
400347-10

Remove the vehicle from the work stand. (

P. 14)

Removing the front shock absorber


8.5

Info
The operations are the same on the left and right sides.

Jack up the vehicle. (

Secure the upper A-arm on the frame using tension belt.

Remove screw.

Remove screw. Remove the shock absorber.

P. 14)

600473-10

600474-10

600475-10

04/SHOCK ABSORBER, SWINGARM

22

Installing the front shock absorber


8.6

Info
The operations are the same on the left and right sides.

Position the front shock absorber with the reservoir toward the rear. Mount and
tighten screw.
Specification
Screw, front shock absorber

M10

45Nm
(33.2lbfft)

600475-11

Position the shock absorber in the lower A-arm. Mount and tighten screw.
Specification
Screw, front shock absorber

M10

Remove the tension belt.

Remove the vehicle from the work stand. (

45Nm
(33.2lbfft)

P. 14)

600474-11

Front shock absorber - removing the spring


8.7

Remove the front shock absorber. (

Measure the spring length in its preloaded state and determine the position of the
locking clip. Note down both values.

Pull spring down and remove spring retainer.

Remove the spring.

Remove protecting sleeve.

Remove threaded bush with the spring and washer.

Remove the spring retainer.

P. 21)

200277-10

200278-10

200279-10

04/SHOCK ABSORBER, SWINGARM

23

Front shock absorber - installing the spring


8.8

Alternative1
Measure the overall spring length when not under tension.

Info

A
0

The spring preload is the difference in length between the spring


pack when it is unloaded and when it is installed.

Insert the locking clip into the corresponding groove.


Specification
Clip position, spring preload
Standard

7 th position from top

Corresponds to a spring preload


of

5mm (0.2in)

Alternative2
Position the locking clip in the position determined upon disassembly.

400347-10

Position the spring retainer with the groove facing the locking clip.

Position the washer.

Position threaded bush with the spring.

Mount protecting sleeve.

Position spring.

Pull the spring down and mount spring retainer.

Adjust the cross over of the front shock absorbers. (

Install the front shock absorber. (

200279-11

200278-11

200277-11

P. 22)

P. 20)

04/SHOCK ABSORBER, SWINGARM

24

Front shock absorber - disassembling the shock absorber


8.9

Remove the spring of the front shock absorber. (

Note down the current state of the rebound and compression damping.

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

Remove screw of the reservoir.

Pierce the membrane using needle of the special tool.

P. 22)

200280-10

Filling adapter (83019050016) (

P. 215)

The nitrogen pressure is relieved.

200281-10

Push in locking cap of the reservoir. Remove lock ring.

Info
Do not scratch the inner surface.

200282-10

Remove the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004) (

P. 213)

200283-10

Remove locking cap of the shock absorber tube using the special tool.
Disassembly fork (83019050006) (

200284-10

P. 213)

04/SHOCK ABSORBER, SWINGARM

25

Push in seal ring holder. Remove lock ring.

Info
Do not scratch the inner surface.

200285-10

Remove the piston rod. Drain the oil.

Remove the floating piston of the reservoir using the special tool.

200286-10

Disassembly/assembly tool (83019050005) (

P. 213)

200287-10

Front shock absorber - assembling the shock absorber


8.10

Fill the reservoir all the way to the rim.


Shock absorber oil hlins (

Grease the O-ring and piston ring of the floating piston.


Lubricant (T158) (

200300-10

P. 203)

P. 205)

04/SHOCK ABSORBER, SWINGARM

26

Mount the floating piston using the special tool and slide it all the way into the
reservoir.
Disassembly/assembly tool (83019050005) (

P. 213)

200301-10

Measure and note down the distance from the upper rim of the reservoir to the
upper edge of the floating piston.

Info
Ensure that the floating piston has been pushed all the way in.

200302-10

Fill the shock absorber tube about half way.


Shock absorber oil hlins

Carefully mount the piston rod.

Remove the special tool.


Disassembly/assembly tool (83019050005) (

P. 213)

200303-10

Grease the O-ring of the seal ring holder.


Lubricant (T158) (

P. 205)

Mount seal ring holder.

Mount lock ring.

Info
Do not scratch the inner surface.
200285-11

Pull out the piston rod until the seal ring holder is flush with the lock ring.

04/SHOCK ABSORBER, SWINGARM

27

Mount locking cap of the shock absorber tube.

Grease the O-ring of the locking cap of the reservoir.

200304-10

Lubricant (T158) (

P. 205)

Mount the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004) (

P. 213)

Mount the lock ring.

Info
Do not scratch the inner surface.

200283-10

Pull out the locking cap of the reservoir using the special tool to the point where
the locking cap is flush with the lock ring.

Remove the special tool.


Disassembly/assembly tool (83019050004) (

P. 213)

Pierce the membrane using needle of the special tool.


Filling adapter (83019050016) (

P. 215)

Info
Leave the needle of the special tool inserted in the membrane to ensure that
the floating piston is able to move freely during the filling process.

Bleed and fill the shock absorber. (

Attach the rest of the special tool and connect it to the pressure regulator of the
filling cylinder.

P. 28)

200281-11

Filling adapter (83019050016) (

P. 215)

Filling gas - nitrogen

Adjust the pressure regulator.


Specification
Gas pressure

200305-10

12bar (174psi)

Insert the needle of the special tool through the membrane of the reservoir again.

Open valve of the special tool and leave it open for several seconds until the
required pressure is reached.
Specification
Gas pressure

12bar (174psi)

Close valve and remove the special tool.

Mount and tighten screw of the reservoir.


Specification
Reservoir screw

200280-11

M4

Install the spring of the front shock absorber. (

3Nm (2.2lbfft)
P. 23)

04/SHOCK ABSORBER, SWINGARM

28

Bleeding and filling shock absorber


8.11

Info
Before working with the vacuum pump, read the operating manual provided for the vacuum pump carefully.
Fully open the adjusting wheel of the rebound and compression damping.
Leave the needle of the special tool inserted in the membrane to ensure that the floating piston is able to move freely during
the filling process.

Remove the plug from the filling port.

Mount special tool on adapter of the vacuum pump.


Adapter WP vacuum pump (83019050002) (
Vacuum pump (T1240S) (

P. 213)

P. 215)

Mount special tool on the shock absorber.


Adapter WP vacuum pump (83019050002) (

P. 213)

Info

200272-11

Tighten by hand only, do not use a tool.

Connect adapter to connector of the vacuum pump.

Clamp or hold the shock absorber as shown in the photo.

Info
Clamp the shock absorber only lightly.
The filling port must be located at the highest position.
The piston rod moves in and out during the filling procedures - do not hold
it with your hand!

200274-10

Position the control lever as shown in the photo.


Control levelExternaltank is set toClosed, Damper toVacuum
andOilreservoir to Vacuum.

Press theOn/Off switch.


The suction process begins.
Pressure gauge drops to the specified value.
<0bar

200271-10

Low pressure gauge drops to the specified value.


4mbar

As soon as the low pressure gauge has reached the specified value, set control
leverOilreservoir to Equalizepressure.
Specification
4mbar
The pressure gauge rises to the specified value.
0bar

200267-10

As soon as the pressure gauge has reached the specified value, set control lever
Damper to Pressure.
Specification
0bar
Oil is pumped into the shock absorber.
The pressure gauge rises to the specified value.
3bar

200268-10

04/SHOCK ABSORBER, SWINGARM

29

As soon as the pressure gauge has reached the specified value, set control lever
Damper to Vacuum.
Specification
3bar
The pressure gauge drops to the specified value.
0bar

200269-10

As soon as the pressure gauge has reached the specified value, set control lever
Oilreservoir to Vacuum.
Specification
0bar
The low pressure gaugedrops to the specified value.
8mbar

200270-10

As soon as the low pressure gauge has reached the specified value, set control lever
Oilreservoir to EqualizePressure.
Specification
8mbar
The pressure gauge drops to the specified value.
0bar

200267-10

As soon as the pressure gauge has reached the specified value, set control lever
Damper to Pressure.
Specification
0bar
Oil is pumped into the shock absorber.
The pressure gauge rises to the specified value.
3bar

200268-10

As soon as the pressure gauge has reached the specified value, set control lever
Damper to Vacuum.
Specification
3bar
The pressure gauge drops to the specified value.
0bar

200269-10

As soon as the pressure gauge has reached the specified value, press the On/Off
switch.
Specification
0bar
The vacuum pump is switched off.

04/SHOCK ABSORBER, SWINGARM

30

Remove the needle of the special tool.


Filling adapter (83019050016)

Press in locking cap of the reservoir and remove lock ring.

Info
Do not scratch the inner surface.

200237-11

Remove the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)

200238-10

Reduce the dimension determined during assembly by the specified value and slide
the floating piston into the reservoir up to the reduced dimension using the special
tool.
Specification
7mm
Disassembly/assembly tool (83019050005)

Info
200265-10

The floating piston must have the specified distance to the bottom stop.
The floating piston must be at precisely this position, as otherwise damage
may occur when the shock absorber moves.

Remove the special tool.


Disassembly/assembly tool (83019050005)

Remove adapter from connector of the vacuum pump.

Remove special tool.


Adapter WP vacuum pump (83019050002) (

P. 213)

Mount and tighten the plug.


Specification
Plug for filling port

M5

3Nm (2.2lbfft)

200272-10

Grease the O-ring of the locking cap of the reservoir.


Lubricant (T158)

Mount the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)

Mount the lock ring.

Info
Do not scratch the inner surface.

200238-10

Pull out the piston rod to the point where the seal ring holder is flush with the lock
ring.

Remove special tool.


Disassembly/assembly tool (83019050004)

04/SHOCK ABSORBER, SWINGARM

31

Front shock absorber - disassembling the piston rod


8.12

Disassemble the front shock absorber. (

Clamp the piston rod with the heim joint in a vise.

Remove nut.

Remove washer and rebound shim set together with piston.

Remove compression damping shim set with supporting plate.

Remove lock ring.

Remove the plates.

Remove seal ring holder.

P. 24)

200288-10

200289-10

200290-10

200291-10

200292-10

200293-10

04/SHOCK ABSORBER, SWINGARM

32

Remove the locking cap and bump rubber.

200294-10

Front shock absorber - assembling the piston rod


8.13

Clamp the piston rod with the heim joint in a vise.

Mount the bump rubber and locking cap.

Position special tool on the piston rod.

200294-10

Mounting sleeve (83019050001) (

P. 213)

Grease the seal ring and slide seal ring holder onto the piston rod.
Lubricant (T625) (

P. 205)

Remove the special tool.

Mount the plates.

Mount lock ring.

Mount supporting plate and compression damping shim set.

200298-10

200292-10

200291-11

Info
The compression damping shim set must be mounted with the smaller disks
facing downward.

200290-11

04/SHOCK ABSORBER, SWINGARM

33

Smooth the piston on both sides using 1200-grit sandpaper on a straightening


plate.

Clean the piston.

Mount the piston.

Info
The side of the piston with partitions must face down and the side with
rectangular surfaces must face up.
200299-10

Mount rebound shim set with supporting plate.

Info
The rebound shim set must be mounted with the smaller disks facing
upward.

200289-11

Mount and tighten piston rod nut.


Specification
Piston rod nut

M8

Assemble the front shock absorber. (

22Nm
(16.2lbfft)

Loctite 243

P. 25)

200288-11

Front shock absorber - removing the heim joint


8.14

Info
The operations are the same on the upper and lower heim joint.

Remove the front shock absorber. (

Clamp the shock absorber into the vise with soft jaws.

Remove flange adapter of the heim joint with a pin.

Turn over the shock absorber and remove flange adapter of the heim joint with a
pin.

Remove seal rings on both sides.

200295-10

200296-10

P. 21)

04/SHOCK ABSORBER, SWINGARM

34

Place special tool underneath and press out the heim joint using special tool.
Press drift (83019050015) (

P. 214)

Mounting sleeve (83019050013) (

P. 214)

200297-10

Front shock absorber - installing the heim joint


8.15

Info
The operations are the same on the upper and lower heim joint.

Place special tool underneath and push the heim joint to the middle using special tool.
Mounting sleeve (83019050013) (
Press drift (83019050014) (

P. 214)

P. 214)

200297-11

Mount and grease seal rings on both sides.


Lubricant (T158) (

P. 205)

200296-10

Press in both flange adapters of the heim joint.

200295-11

Rear shock absorber - adjusting the compression damping


8.16

Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.

Only make adjustments within the recommended range.

Info
The compression damping setting has an impact on the compression of the shock absorber.

04/SHOCK ABSORBER, SWINGARM

35

Turn the adjusting wheel clockwise until it stops.

Turn it back counterclockwise by the number of clicks corresponding to the shock


absorber type.
Specification
Compression damping
Standard

15clicks

Maximum deviation from standard


value

5 5clicks

100080-10

Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.

Info
Turning clockwise increases damping, while turning counterclockwise
lessens damping.

Rear shock absorber - adjusting the rebound damping


8.17

Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.

Only make adjustments within the recommended range.

Info
The rebound damping setting has an impact on the compression of the shock absorber.

Turn adjusting wheel to the right until it stops.

Turn it back to the left by the number of clicks corresponding to the shock absorber
type.
Specification
Rebound damping
Standard

15clicks

Maximum deviation from standard


value

5 5clicks

100081-10

Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.

Info
Turning to the right increases damping, while turning to the left lessens
damping.

Rear shock absorber - spring preload


8.18

Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.

Make adjustments in small steps only.

Info
Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.

Tip
Before changing the spring preload, make a note of the present setting, e.g. by measuring the length of the spring.

Remove the rear shock absorber. (

After removing the shock absorber, clean it thoroughly.

P. 36)

04/SHOCK ABSORBER, SWINGARM

36

Loosen lock nut. Hold adjusting ring while doing so. Use special tool.
Hook wrench (83019002000) (

P. 210)

Info
Do not loosen lock nut at the top of the shock absorber.

Turn the adjusting ring until the spring is no longer under tension.

Measure the overall spring length when not under tension.

100082-10

Info
The spring preload is the difference in length between the spring when it
is unloaded and when it is installed.

Tighten the spring by turning the adjusting ring to the specified measurement.
Specification
Spring preload
Standard

3mm (0.12in)

Tighten the lock nut and the adjusting ring.

Info
Adjusting ring is made of plastic. Therefore, do not lock the adjusting
ring too tightly to avoid damaging the thread.
If you increase the spring preload, you should also slightly increase the
rebound damping.

Install the rear shock absorber. (

Jack up the vehicle. (

Remove the rear fender. (

P. 37)

400363-11

Removing the rear shock absorber


8.19

P. 14)
P. 57)

Note
Danger of damageThe chain sliding piece and frame can be damaged from incorrect handling.

When removing the rear shock absorber, secure the swingarm with a tension
belt to prevent it from swinging down further.

Attach the swingarm to the subframe with a tension belt to relieve the shock
absorber.

Remove the bottom screw of the shock absorber.

Tip
Press the screw out of the swingarm with a screw driver while moving the
tension belt.

100078-10

Remove the top screw of the shock absorber and carefully remove the shock
absorber out of the vehicle toward the rear.

04/SHOCK ABSORBER, SWINGARM

37

Installing the rear shock absorber


8.20

Check parts for damage and wear. Replace damaged or worn parts.

Position the shock absorber in the vehicle with the reservoir on the right. Mount
and tighten the top screw.
Specification
Screw, rear top shock absorber

M12

60Nm
(44.3lbfft)

Position the shock absorber in the swingarm. Mount and tighten the bottom screw.
Specification
Screw, rear bottom shock absorber

M12

Remove the tension belt.

Install the rear fender. (

Remove the vehicle from the work stand. (

70Nm
(51.6lbfft)

P. 58)
P. 14)

100079-10

Rear shock absorber - removing the spring


8.21

Remove the rear shock absorber. (

Measure and note down the spring length in the preloaded state.

Loosen lock nut. Hold adjusting ring while doing so.

P. 36)

Hook wrench (83019002000)

Turn the adjusting ring until the spring is no longer under tension.

Remove spring retainer.

Remove the spring with the washer.

200232-10

200233-10

Rear shock absorber - installing the spring


8.22

200233-11

Position the washer under the adjusting ring.

Position the spring.

Mount spring retainer.

04/SHOCK ABSORBER, SWINGARM

38

Alternative1
Measure the overall spring length when not under tension.

Info
The spring preload is the difference in length between the spring
when it is unloaded and when it is installed.

Tighten the spring by turning the adjusting ring to the specified measurement.
Specification
Spring preload
Standard

3mm (0.12in)

Hook wrench (83019002000)


Alternative2
Tighten the spring by turning the adjusting ring to the measurement determined
upon removal.
Hook wrench (83019002000)

400363-11

Tighten lock nut and adjusting ring.

Info
Adjusting ring is made of plastic. Therefore, do not lock the adjusting
ring too tightly to avoid damaging the thread.
If you increase the spring preload, you should also slightly increase the
rebound damping.

Install the rear shock absorber. (

P. 37)

200232-11

Rear shock absorber - disassembling the shock absorber


8.23

Remove the spring of the rear shock absorber. (

Note down the current state of the rebound and compression damping.

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

Remove lock ring.

Remove protecting sleeve.

Remove screw of the reservoir.

200234-10

200235-10

P. 37)

04/SHOCK ABSORBER, SWINGARM

Pierce the membrane using needle of the special tool.


Filling adapter (83019050016)
The nitrogen pressure is relieved.

200236-10

Push in locking cap of the reservoir. Remove lock ring.

Info
Do not scratch the inner surface.

200237-10

Remove the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)

200238-10

Remove locking cap of the shock absorber tube.

Push in seal ring holder. Remove lock ring.

200239-10

Info
Do not scratch the inner surface.

200240-10

200241-10

Remove the piston rod. Drain the oil.

39

04/SHOCK ABSORBER, SWINGARM

40

Remove the floating piston of the reservoir using the special tool.
Disassembly/assembly tool (83019050005)

200242-10

Rear shock absorber - assembling the shock absorber


8.24

Fill the reservoir all the way to the rim.


Shock absorber oil hlins

Grease the O-ring and piston ring of the floating piston.


Lubricant (T158) (

P. 205)

200264-10

Mount the floating piston using the special tool and slide it all the way into the
reservoir.
Disassembly/assembly tool (83019050005)

200263-10

Measure and note down the distance from the upper rim of the reservoir to the
upper edge of the floating piston.

Info
Ensure that the floating piston has been pushed all the way in.

200265-10

04/SHOCK ABSORBER, SWINGARM

41

Fill the shock absorber tube about half way.


Shock absorber oil hlins

Carefully mount the piston rod.

Remove the special tool.


Disassembly/assembly tool (83019050005)

200266-10

Grease the O-ring of the seal ring holder.


Lubricant (T158) (

P. 205)

Mount seal ring holder.

Mount lock ring.

Info
Do not scratch the inner surface.
200240-11

Pull out the piston rod to the point where the seal ring holder is flush with the lock
ring.

Mount locking cap of the shock absorber tube.

Grease the O-ring of the locking cap of the reservoir.

200239-11

Lubricant (T158) (

P. 205)

Mount the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)

Mount the lock ring.

Info
Do not scratch the inner surface.

200238-10

Pull out the locking cap of the reservoir using the special tool to the point where
the locking cap is flush with the lock ring.

Remove the special tool.


Disassembly/assembly tool (83019050004)

04/SHOCK ABSORBER, SWINGARM

42

Pierce the membrane using needle of the special tool.


Filling adapter (83019050016)

Info
Leave the needle of the special tool inserted in the membrane to ensure that
the floating piston is able to move freely during the filling process.

Bleed and fill the shock absorber. (

Attach the rest of the special tool and connect it to the pressure regulator of the
filling cylinder.

P. 28)

200236-10

Filling adapter (83019050016)


Filling gas - nitrogen

Adjust the pressure regulator.


Specification
Gas pressure

200275-10

12bar (174psi)

Insert the needle of the special tool through the membrane of the reservoir again.

Open valve of the special tool and leave it open for several seconds until the
required pressure is reached.
Specification
Gas pressure

12bar (174psi)

Close valve and remove the special tool.

Mount screw of the reservoir and tighten.


Specification
Reservoir screw

M4

3Nm (2.2lbfft)

200235-11

Mount protecting sleeve and lock ring.

Install the spring of the rear shock absorber. (

P. 37)

200234-11

Rear shock absorber - disassembling the piston rod


8.25

200244-10

Disassembling the rear shock absorber. (

Clamp the piston rod with the heim joint in a vise.

Remove nut.

P. 38)

04/SHOCK ABSORBER, SWINGARM

Remove washer and the upper rebound shim set together with the upper piston.

Remove the upper compression damping shim set with the supporting plate.

Remove piston rod adapter.

Remove the lower piston with the lower rebound shim set and supporting
plate.

Remove the lower compression damping shim set with supporting plate.

Remove the plates.

200245-10

200246-10

200247-10

200248-10

200249-10

200250-10

43

04/SHOCK ABSORBER, SWINGARM

44

Remove seal ring holder.

Remove the locking cap and bump rubber.

200251-10

200252-10

Rear shock absorber - assembling the piston rod


8.26

Clamp the piston rod with the heim joint in a vise.

Mount the bump rubber and locking cap.

Position special tool on the piston rod.

200252-10

Mounting sleeve (83019050012) (

P. 214)

Grease the seal ring and slide seal ring holder onto the piston rod.
Lubricant (T625) (

P. 205)

Remove the special tool.

Mount the plates.

Mount supporting plate and the lower compression damping shim set.

200257-10

200250-10

Info
The compression damping shim set must be mounted with the smaller disks
facing downward.

200249-11

04/SHOCK ABSORBER, SWINGARM

45

Smooth the lower piston on both sides using 1200-grit sandpaper on a straightening plate.

Clean the piston.

Mount the lower piston.

Info
The side of the piston with rectangular surfaces must face down and the
side with partitions must face up.
200258-10

Mount the lower rebound shim set with supporting plate.

Info
The rebound shim set must be mounted with the smaller disks facing
upward.

200248-11

Ensure that the components are arranged as shown in the figure.

Mount and tighten piston rod adapter.

200259-10

Specification
Piston rod adapter

M12x1

30Nm
(22.1lbfft)

Loctite2701

200247-11

Mount the supporting plate and the upper compression damping shim set.

Info
Mount the triangular plates of the upper compression damping shim set
facing upward and align them precisely to each other.
The triangular plates should be oil-free to prevent them from slipping
against each other when they are tightened.

200246-11

Smooth the upper piston on both sides using 1200-grit sandpaper on a straightening plate.

Clean the piston.

Mount the upper piston.

Info
The side of the piston with the single drill hole must face down and the
side with the double drill hole must face up.
200260-10

04/SHOCK ABSORBER, SWINGARM

46

Ensure that the triangular plates precisely cover the single drill holes.

Mount the upper rebound shim set with washer.

200261-10

Info
Mount triangular plates of the upper rebound damping shim set facing
downward and align them precisely to each other.
The triangular plates should be oil-free to prevent them from slipping
against each other when they are tightened.
Ensure that the triangular plates precisely cover the double drill holes.
200262-10

Mount and tighten piston rod nut.


Specification
Piston rod nut

M8

22Nm
(16.2lbfft)

Ensure that the triangular plates do not slip when being tightened.

Assemble the rear shock absorber. (

P. 40)

200244-11

Rear shock absorber - removing the heim joint


8.27

Info
The operations are the same on the upper and lower heim joint.

200253-10

Remove the rear shock absorber. (

Clamp the shock absorber into the vise with soft jaws.

Remove flange adapter of the heim joint using a pin.

Turn over the shock absorber and remove flange adapter of the heim joint using
a pin.

P. 36)

04/SHOCK ABSORBER, SWINGARM

47

Remove seal rings on both sides.

Place special tool underneath and press out the heim joint using special tool.

200254-10

Press drift (83019050014)


Mounting sleeve (83019050007) (

P. 214)

200255-10

Rear shock absorber - installing the heim joint


8.28

Info
The operations are the same on the upper and lower heim joint.

Place special tool underneath and push the heim joint to the middle using special tool .
Press drift (83019050014)
Mounting sleeve (83019050007) (

P. 214)

200255-11

Mount and grease seal rings on both sides.


Lubricant (T158) (

P. 205)

200254-10

200256-10

Press in both flange adapters of the heim joint.

Install the rear shock absorber. (

P. 37)

05/EXHAUST

48

05/EXHAUST
9

Removing the main silencer

9.1

Remove spring.
Spring hooks (50305017000) (

P. 207)

600153-10

Remove screws and and take off the main silencer.

Insert the main silencer and position and tighten screws and.

600154-10

Installing the main silencer


9.2

Specification
Remaining screws, chassis

M6

600154-11

Reconnect spring.
Spring hooks (50305017000) (

P. 207)

600153-11

Removing the manifold


9.3

Remove the main silencer. (

Remove both springs.

P. 48)

Spring hooks (50305017000) (

600155-10

P. 207)

10Nm (7.4lbfft)

05/EXHAUST

49

Remove screws and.

Remove screws and take off heel guard.

Remove manifold.

Position manifold and mount springs.

600156-10

600157-10

Installing the manifold


9.4

Spring hooks (50305017000) (

P. 207)

600155-11

Position heel guard. Mount and tighten screws.


Specification
Remaining screws, chassis

M6

10Nm (7.4lbfft)

M8

25Nm
(18.4lbfft)

600157-11

Mount and tighten screws and.


Specification
Remaining screws, chassis

600156-11

Install the main silencer. (

P. 48)

06/AIR FILTER

50

06/AIR FILTER
10

Removing the air filter


10.1

Note
Engine failureUnfiltered intake air has a negative effect on the service life of the engine.

Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning
Environmental hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Remove the seat (

Raise the rear of the air filter box lid. At the same time, use your other hand to
press on the carburetor connection boot to kink it at that location. This prevents
the carburetor connection boot from disconnecting from the carburetor.

Unhook the air filter holder and swing it to the side. Remove the air filter with
the air filter support.

Remove the air filter from the air filter support.

Check parts for damage and wear. Replace damaged or worn parts.

Mount the clean air filter onto the air filter support.

Put in both parts together, position them and fix them with the air filter support.

P. 52)

100077-10

Installing the air filter


10.2

Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.

100086-10

Mount the air filter box lid.

Mount the seat (

P. 52)

Cleaning air filter


10.3

Warning
Environmental hazardProblem materials cause environmental damage.

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.

Remove the air filter. (

Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner (

P. 50)

P. 205)

Info
Only press the air filter to dry it, never wring it out.

06/AIR FILTER

51

Oil the dry air filter with a high/quality filter oil.


Oil for foam air filter (

P. 205)

Clean the air filter box.

Check carburetor connection boot for damage and tightness.

Install the air filter (

P. 50)

Removing the air filter box lid with the carburetor connection boot
10.4

Remove the seat (

Remove hose clip.

Raise the air filter box lid and remove with carburetor connection boot.

P. 52)

600152-10

Installing the air filter box lid and the carburetor connection boot
10.5

600152-10

Attach the air filter box lid with carburetor connection boot and hose clip to
the carburetor.

Position the air filter box lid.

Position hose clamp and tighten.

Mount the seat (

P. 52)

07/FUEL TANK, SEAT, TRIM

52

07/FUEL TANK, SEAT, TRIM


11

Removing the seat

11.1

Pull the release hook back. Lift up the seat at the rear, pull it back and then
remove from above.

Check parts for damage and wear. Replace damaged or worn parts.

Hook the slot on the seat into the collar sleeve of the fuel tank, lower the rear
of the seat and slide the tab under the fuel tank.

Push down the rear of the seat until the release hook engages.

Make sure that the seat is correctly locked in.

100041-10

Mounting the seat


11.2

100046-10

100043-10

Removing the radiator spoiler


11.3

Info
The operations are the same on the left and right.

Remove the seat (

Remove the screws on the fuel tank.

Remove the screws on the radiator.

Unhinge and remove the radiator spoiler and the fuel tank.

P. 52)

100056-10

100057-10

07/FUEL TANK, SEAT, TRIM

53

Installing the radiator spoiler


11.4

Info
The operations are the same on the left and right.

Check parts for damage and wear. Replace damaged or worn parts.

Hook the catch of the radiator spoiler into the holder of the fuel tank and
position it on the radiator.

Fit and tighten screws on the radiator.

100058-10

Specification
Remaining screws, chassis

M6

10Nm (7.4lbfft)

M6

6Nm (4.4lbfft)

Fit and tighten screws on the fuel tank.


Specification
Screw on fuel tank

Mount the seat (

P. 52)

100059-10

Removing the fuel tank


11.5

Danger
Fire hazardFuel can easily catch fire.

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.

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 poisoningFuel is poisonous and a health hazard.

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.

Remove the front trim. (

Remove the radiator spoiler. (

Turn the handle of the fuel tap toOFF. (Figure100013-10

Undo hose clip.

Pull off fuel hose.

P. 56)
P. 52)

Info
Remaining fuel may run out of the fuel hose.

600150-10

P. 55)

07/FUEL TANK, SEAT, TRIM

54

Remove screw and take off the fuel tank.

600151-10

Installing the fuel tank


11.6

Danger
Fire hazardFuel can easily catch fire.

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.

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 poisoningFuel is poisonous and a health hazard.

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.

Position the fuel tank, insert screw with the bushing and tighten.
Specification
Remaining screws, chassis

M6

600151-11

600150-11

Connect fuel hose.

Position hose clip.

Install the radiator spoiler. (

Install the front trim. (

P. 53)

P. 57)

10Nm (7.4lbfft)

07/FUEL TANK, SEAT, TRIM

55

Fuel tap
11.7

The fuel tap is on the right 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 off OFF No fuel can flow from the tank to the carburetor.
Fuel supply on ON Fuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.
Reserve fuel supply on RES Fuel can flow from the tank to the carburetor. The
fuel tank empties completely.

100013-10

08/MASK, FENDER

56

08/MASK, FENDER
12

Removing the front cover

12.1

Remove screw.

Slide the front cover up and remove it.

Check parts for damage and wear. Replace damaged or worn parts.

Position the front cover in the slots on both sides of the front trim.

Mount and tighten screw .

Remove the front cover. (

Remove screws.

Raise the front trim and disconnect the plug-in connectors from the head light and
the emergency OFF switch with the rip cord.

Remove the front trim.

100053-10

Installing the front cover


12.2

100055-10

Removing the front trim


12.3

100075-10

P. 56)

08/MASK, FENDER

57

Installing the front trim


12.4

Check parts for damage and wear. Replace damaged or worn parts.

Connect the plug-in connectors of the head light and the emergency OFF switch
with the rip cord and position the front trim.

Mount all screws.

Fully tighten screws.


Specification
Screw on fuel tank

M6

6Nm (4.4lbfft)

M6

10Nm (7.4lbfft)

Fully tighten screws.


Specification
Remaining screws, chassis

Install the front cover. (

Remove the seat (

Remove screws. Remove the collar sleeves.

Raise the rear of the air filter box lid. At the same time, use your other hand to
press on the carburetor connection boot to kink it at that location. This prevents the
carburetor connection boot from disconnecting from the carburetor.

Raise the fender at the rear and remove it.

P. 56)

100076-10

Removing the rear fender


12.5

P. 52)

200149-10

200148-10

08/MASK, FENDER

58

Installing the rear fender


12.6

Check parts for damage and wear. Replace damaged or worn parts.

Raise the rear of the air filter box lid. At the same time, use your other hand to
press on the carburetor connection boot to kink it at that location. This prevents the
carburetor connection boot from disconnecting from the carburetor.

Position the front fender.

Fix the air filter box lid in the fender.

Fit and tighten screws with collar sleeves.

200148-11

Specification
Remaining screws, chassis

200149-11

Mount the seat (

P. 52)

M6

10Nm (7.4lbfft)

09/FRONT WHEEL

59

09/FRONT WHEEL
13

Checking tire air pressure


13.1

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.
The tire pressure must be checked and corrected on all wheels.

Remove dust cap.

Check tire air pressure when tires are cold.


Tire air pressure off road

If the tire pressure does not meet specifications:

0.3bar (4psi)

Correct tire pressure.

Mount dust cap.

100044-10

Tire condition checking


13.2

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 vehicle.
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.

Examine the tires for cuts, foreign bodies and other damage.

Check the depth of the tread.


2mm (0.08in)

Minimum tread depth

If the minimum tread depth is insufficient:

Change the tire.

Removing wheel/wheels
13.3

Info
Proceed in the same way on the other wheels if necessary.

Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure100006-10 P. 74)

Loosen the wheel nuts.

Jack up the vehicle. (

Remove the wheel nuts. Remove the wheel.

P. 14)

Info
Carefully remove the wheel, making sure it does not become jammed with
the threads of the screws.

700001-01

09/FRONT WHEEL

60

Mounting wheel/wheels
13.4

Note
Material damageDamage and destruction of components from incorrect positioning and mounting.

Do not swap the wheels; the tire valves must always be on the outside when the wheels are positioned and mounted.

Info
Proceed in the same way on the other wheels if necessary.

Position the wheel on the hub.

Info
Carefully position the wheel on the hub, being careful not to damage the
threads of the screws.

Mount the wheel nuts but do not tighten.

Remove the vehicle from the work stand. (

Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure100006-10 P. 74)

Tighten the wheel nuts crosswise.

700002-01

P. 14)

Specification
Wheel nut

M10x1,25

45Nm
(33.2lbfft)

Checking brake discs


13.5

Warning
Danger of accidentsReduced braking due to worn brake discs.

Worn brake discs should be replaced immediately in an authorized KTM workshop.

Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement.

Info
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Wear limit of brake discs
400362-10

Front

3.5mm (0.138in)

Rear

3.5mm (0.138in)

If the brake disc thickness is less than the specified value.

Change the brake disc.

10/REAR WHEEL

61

10/REAR WHEEL
14

Checking chain dirt

14.1

Check the chain for coarse dirt accumulation.

If the chain is very dirty:

Clean the chain. (

P. 61)

Cleaning the chain


14.2

Warning
Environmental hazardProblem materials cause environmental damage.

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.

Clean the chain regularly and then treat with chain spray.
Chain cleaner (

P. 205)

Offroad chain spray (

P. 205)

Checking chain wear


14.3

Park the vehicle on a horizontal surface and shift gears to neutral.

Pull the lower chain section with the specified weight.


Specification
Chain-wear measuring weight

10 15kg (22 33lb.)

Measure the distance of 18 chain links in the upper 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

272mm (10.71in)

If the distance is greater than the specified measurement:

Replace the chain.

Info
When you replace the chain, you should also replace the rear
sprocket and engine sprocket.
New chains wear out faster on old, worn sprockets.
100096-10

Checking rear sprocket / engine sprocket for wear


14.4

Check rear sprocket / engine sprocket for wear.

If the rear sprocket / engine sprocket are worn:

Replace the 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

Check that the chain guides are tight.

10/REAR WHEEL

62

Checking the chain tension


14.5

Warning
Danger of accidentsDanger caused by incorrect chain tension.

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 eccentric element) 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 wheels or damage the engine. Check for correct
chain tension and adjust if necessary.

Park the vehicle on a horizontal surface and shift gears to neutral.

Push the upper chain section at the end of the chain sliding component upwards to
measure the chain tension.

Info
The lower chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
100093-10

140 145mm (5.51 5.71in)

If the chain tension does not meet specifications:

Adjust the chain tension. (

P. 62)

Adjusting chain tension


14.6

Warning
Danger of accidentsDanger caused by incorrect chain tension.

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 eccentric element) 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 wheels or damage the engine. Check for correct
chain tension and adjust if necessary.

Park the vehicle on a horizontal surface and shift gears to neutral.

Push the upper chain section at the end of the chain sliding component upwards to
measure the chain tension.

Info
The lower chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

100093-10

10/REAR WHEEL

63

Loosen the screws by four turns.

Alternative1
Insert the tool from the tool set into the hole of the rear wheel eccentric
element.
Alternative2
Use a special tool on the rear wheel eccentric.
Hook wrench (83019011000) (

P. 210)

To adjust the chain tension, use the special tool to slowly turn at the rear wheel
to rotate the rear wheel eccentric element forward or backward.
Specification
Chain tension

140 145mm (5.51 5.71in)

Info
Rotating the rear wheel eccentric element forward increases chain tension.
Rotating the rear wheel eccentric element backward reduces chain tension.
The rear wheel eccentric element should always be positioned such that the
grease nipple is visible. This ensures that the vehicle has the greatest
ground clearance.
100094-10

Fully tighten screws.


Specification
Screw, rear wheel eccentric element

M8

20Nm
(14.8lbfft)

Remove tool.

Adjusting the toe width of rear axle


14.7

Warning
Danger of accidentsChanges to the chassis can strongly influence how the vehicle handles.

After making changes, always ride slowly to allow yourself to respond to vehicle handling.

Engage 1st gear.

Loosen nuts of the wheel hubs on both sides.

Jack up the vehicle. (

Remove the nuts on both sides and take all parts off of the rear axle.

Check parts for damage and wear. Replace damaged or worn parts.

P. 14)

Info
The left and right toe width should have the same settings.
100102-10

2
3
00

Setting a narrow toe width:


Mount the wheel hub.

0
1

100103-10

Mount the conical ring with the cone facing outward.

Mount the spacing sleeve with the cone facing inward.

Mount the washer and the new self-locking nut.

10/REAR WHEEL

64
Setting a wide toe width:
Mount the spacing sleeve with the cone facing inward.

2 3
0
0
0
1

Mount the conical ring with the cone facing outward.

Mount the wheel hub.

Mount the washer and the new self-locking nut.

100104-10

Remove the vehicle from the work stand. (

Tighten nuts on both sides.

P. 14)

Specification
Nut, rear wheel hub

M18x1,5

130Nm
(95.9lbfft)

Shift gear to neutral.

Engage 1st gear.

Loosen nuts of the wheel hubs on both sides.

Jack up the vehicle. (

Remove nuts on both sides and take all parts off of the rear axle.

Remove chain joint. Remove the chain from the rear sprocket.

Loosen screw.

Turn clamping nut counterclockwise using the special tool until lock rings are
freely accessible. Remove the lock rings.

100102-10

Removing the rear axle


14.8

P. 14)

100102-12

600409-10

Open-end wrench accessory 46mm (83019010461) (

P. 210)

Turn clamping nut clockwise using the special tool and remove.

Remove screws.

Push back the brake linings by tilting brake caliper slightly to one side on the
brake disc. Carefully pull the brake caliper off of the brake disc and let it hang to
one side.

600410-10

Info
Do not operate the foot brake when the brake caliper has been removed.

600411-10

10/REAR WHEEL

65

Take brake disc off the rear axle with the holder.

Remove the O-ring.

Push the rear axle slightly to the left. Using a plastic hammer, lightly strike against
the chain sprocket carrier to release the chain sprocket carrier from the lock
rings. Remove lock rings.

Pull the rear axle out of the swingarm in the direction of the arrow.

600412-10

Info
Hold the rear sprocket carrier.

Remove rear sprocket carrier with the O-ring.

600414-10

Installing the rear axle


14.9

Warning
Danger of accidentsReduced braking 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.

Slide on the rear axle from the left to the right all the way.

Info
The machined surfaces must be to the right of bearing seat.

600422-10

Position O-ring. Attach chain sprocket carrier with the nuts facing outward.

Carefully insert sealing area on the chain sprocket carrier into the shaft seal ring
of the rear wheel eccentric by lightly turning and tilting the rear axle.

Info
Do not damage the sealing lip of the shaft seal ring.

600423-10

600424-10

Position lock ring with the high collar facing to the left. Slide the main shaft all
the way in in the direction of the arrow.

Check that the lock rings are seated properly.

10/REAR WHEEL

66

Position O-ring. Attach brake disc holder with the thread facing outward.

Carefully insert sealing area on the brake disc carrier into the shaft seal ring of
the rear wheel eccentric by lightly turning and tilting the rear axle.

Info
Do not damage the sealing lip of the shaft seal ring.

600425-10

Lightly grease the thread of the clamping nut.


Long-life grease (

P. 203)

Ensure that the rear axle and the brake disc holder have been correctly installed.

Turn clamping nut all the way onto the brake disc holder.

Info
LH thread!
600426-10

Position lock rings.

Tighten the clamping nut in the direction of the arrow using the special tool.

600427-10

Specification
Clamping nut, rear axle

2"-10UNS2B-LH

25Nm
(18.4lbfft)

Open-end wrench accessory 46mm (83019010461) (

600428-10

Only applies when


using:
Open-end wrench
accessory 46mm
(83019010461)
( P. 210)

P. 210)

Tighten screw.
Specification
Screw, clamping nut, rear axle

M6

10Nm (7.4lbfft)

Position the brake caliper. Mount and tighten screws.


Specification
Screw, rear brake caliper

600429-10

M6

10Nm
(7.4lbfft)

Loctite 243

Clean the brake disc and brake disc holder.

Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.

Fill the rear wheel eccentric with grease via grease nipple.
Long-life grease (

P. 203)

10/REAR WHEEL

67

Place the chain on the sprocket. Mount chain joint.

Info
When installing the chain joint, always make sure that the closed side of the
joint is facing forward (direction of travel).

600409-11

bp
b0q
0 bq

Setting a narrow toe width:


Mount wheel hub.

0
bo

Mount conical ring with the cone facing outward.

Mount spacing sleeve with the cone facing inward.

Mount the washer and the new self-locking nut.

100103-11

Setting a wide toe width:


Mount spacing sleeve with the cone facing inward.

b0p bbq
bp
0q
0
bo

Mount conical ring with the cone facing outward.

Mount wheel hub.

Mount the washer and the new self-locking nut.

100104-11

Remove the vehicle from the work stand. (

Tighten nuts on both sides.

P. 14)

Specification
Nut, rear wheel hub

M18x1,5

130Nm
(95.9lbfft)

Check the chain tension. (

Remove the rear axle. (

Remove lock ring.

Remove brake caliper support.

Mark the position of the rear wheel eccentric in the swingarm.

Loosen screw. Remove the rear wheel eccentric in the direction of the arrow.

P. 62)

100102-11

Changing the rear axle bearing


14.10

P. 64)

600415-10

600416-10

10/REAR WHEEL

68

Take out shaft seal rings on both sides and remove inner bearing races.

Remove old grease and clean the rear wheel eccentric.

Heat the rear wheel eccentric.

600417-10

Specification
100C (212F)

Remove outer bearing races on both sides.

Mount the new outer bearing races using the special tool.
Press mandrel (83019012000) (

600418-10

P. 211)

After the rear wheel eccentric has cooled, check that the bearing races are firmly
seated.

Insert the inner bearing race in rear wheel eccentric on the left side.

Mount shaft seal ring with the blue marking on the left side. Use the special
tool.
Press mandrel (83019012000) (

P. 211)

Insert the inner bearing race in rear wheel eccentric on the right side.

Mount shaft seal ring with the green marking on the right side. Use the special tool.
Press mandrel (83019012000) (

P. 211)

Info
Do not swap the shaft seal rings, as otherwise grease may get onto the brake
disc from the rear wheel eccentric.

Lightly grease the sealing lips of the shaft seal rings.


Long-life grease (

P. 203)

600420-10

Insert the rear wheel eccentric into the swingarm and align it with the marking
made when it was dismantled.

Tighten screws.
Specification
Screw, rear wheel eccentric element

M8

20Nm
(14.8lbfft)

Info
The rear wheel eccentric element should always be positioned such that the
grease nipple is visible. This ensures that the vehicle has the greatest
ground clearance.

600416-11

600415-11

Position brake caliper support.

Mount lock ring.

Install the rear axle. (

P. 65)

11/WIRING HARNESS, BATTERY

69

11/WIRING HARNESS, BATTERY


15

Ignition curve plug connection

15.1

The plug-in connector is located under the trim at the front on the frame tube.
Possible states
Soft The plug-in connector is connected for better driveability.
Performance The plug-in connector is disconnected for better performance.

100105-10

Changing ignition curve


15.2

Remove the front trim. (

P. 56)

Changing the ignition curve from Performance to Soft.


Connect the plug-in connector. (Figure100105-10

P. 69)

Soft The plug-in connector is connected for better driveability. (


Change the ignition curve from Performance to Soft.
Disconnect the plug-in connector. (Figure100105-10

P. 69)

P. 69)

Performance The plug-in connector is disconnected for better performance. (

Install the front trim. (

P. 69)

P. 57)

Removing the battery


15.3

Warning
Risk of injuryBattery acid and battery gases cause serious cauterization.

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

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.

Switch off all power-consuming components and switch off the engine.

Remove the rear fender. (

Disconnect the negative (minus) cable of the battery.

Pull back the plus pole cover and disconnect the positive (plus) cable of the battery.

Loosen the rubber band.

Remove the battery.

Check parts for damage and wear. Replace damaged or worn parts.

Place the battery in the battery holder.

P. 57)

200150-10

Installing the battery


15.4

4Ah battery(YTX5L-BS) (

200150-11

P. 190)

Reconnect the rubber band.

Attach the plus cable and replace the plus pole cover.

Connect the negative (minus) cable of the battery.

Install the rear fender. (

P. 58)

11/WIRING HARNESS, BATTERY

70

Recharging the battery


15.5

Warning
Risk of injuryBattery acid and battery gases cause serious cauterization.

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

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 hazardComponents and battery acid are a danger to the environment.

Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning
Environmental hazardProblem materials cause environmental damage.

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.

Switch off all power-consuming components and switch off the engine.

Remove the rear fender. (

Disconnect the minus (negative) cable of the battery to avoid damage to the vehicle's electronics.

Connect the battery charger to the battery. Switch on the battery charger.

P. 57)

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.

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
vehicle is not in use.

100087-10

Install the rear fender. (

P. 58)

3months

11/WIRING HARNESS, BATTERY

71

Changing the main fuse


15.6

Switch off all power-consuming components and switch off the engine.

Main fuse is located in starter relay in front of the battery.

Remove protection covers.

Remove the faulty main fuse.

Info
You can recognize a blown fuse by its broken filament.

Warning
Fire hazardThe electrical system can be overloaded by the use of incorrect
fuses.

Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.

Insert the new fuse.


Fuse(58011109120)

Tip
Replacement fuse should always be present in the starter relay to make
sure it is available when needed.

100091-10

Replace the protection covers.

Changing the fuses of individual power-consuming components


15.7

Remove the front cover. (

Switch off all power-consuming components and switch off the engine.

Open cover of fuse box.

P. 56)

Info
The designation of the fuses is located on the inside cover of the fuse
box.

Remove the faulty fuse.


Specification
Fuse1 - 10A - Ignition, CDI controller, indicator lamps ON, N, R
Fuse2 - 15A - High beam, low beam, parking light, tail light, brake light, high
beam indicator lamp
Fuse3 - 10A - Radiator fan
Fuse4 - 10A - For auxiliary devices (permanent positive)
Fuse5 - 10A - For auxiliary devices (positive terminal switched on with ignition
switch)
Fuseres. - 10A/15A - Replacement fuses

Info
100090-10

You can recognize a blown fuse by its broken filament.

11/WIRING HARNESS, BATTERY

72

Warning
Fire hazardThe electrical system can be overloaded by the use of incorrect
fuses.

Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.

Insert a new fuse of the appropriate strength.


Fuse(58011109110)
Fuse(58011109115)

Tip
The replacement fuses should always be present in the fuse box to make
sure they are available when needed.

Close the cover of the fuse box.

Install the front cover. (

Turn the key in the ignition switch to theposition .

Remove the rear fender. (

Place the measuring leads of the multimeter to the battery terminals.

Make the measurement when there is no load on the battery (no electrical components are switched on).

P. 56)

Checking the battery voltage


15.8

P. 57)

Battery voltage
unloaded:

12.4 12.8V

If the displayed value does not correspond to the nominal value:

Recharge the battery.

600405-01

Checking the charging voltage


15.9

Condition
All plug connectors must be in corrosion-free condition and the plug-in connectors
must be tight-fitting.
The battery must be charged enough to start the engine but not fully charged. If the
battery is already fully charged, start the engine a few times.

Remove the rear fender. (

Connect the multimeter. The black measuring lead is connected to the negative
pole (ground) of the battery. Place the red measuring lead on the positive terminal.

Measurement when loaded (light switched on, brake pressed)

P. 57)

Charging voltage
under load at: 5,000rpm

If the displayed value does not correspond to the nominal value:

600405-01

13.5 15V

Check the generator. (

P. 170)

If the generator is working properly:

Change the voltage regulator.

Checking the closed-circuit current


15.10

Switch off all power-consuming components and switch off the engine.

Remove the rear fender. (

P. 57)

11/WIRING HARNESS, BATTERY

73

Disconnect the negative (minus) cable of the battery.

Connect the multimeter between the negative cable and the negative terminal of
the battery. Check the closed-circuit current.
Maximum closed-circuit current

<1mA

If the measured value is higher than the specified value:

Check the plug-in connectors and wiring harness.

Disconnect and reconnect power-consuming components one by one from


the wiring harness and monitor the closed-circuit current until you can
identify the power-consuming component.

600404-01

Info
Typical power-consuming components are a defective voltage regulator or rectifier or leakage currents in the plug connectors.

Checking the starter relay


15.11

Remove the rear fender. (

Disconnect the negative (minus) cable of the battery.

Detach the starter relay from bracket on the side of the battery.

Detach plug from the starter relay.

Detach cables and on the starter relay.

Connect the starter relay as shown to a 12 V voltage source. Use a multimeter to


check the current between the clamps.

P. 57)

600406-10

Info
When the relay switches, you hear a click.
Resistance of activated starter relay

700089-01

If the displayed value does not correspond to the nominal value:

Change the starter relay.

13/BRAKE SYSTEM

74

13/BRAKE SYSTEM
16

Handbrake lever, parking brake

16.1

The hand brake lever is located on the right side of the handlebar and operates the
front wheel brakes.
The parking brake is combined with the handbrake lever so that the front wheels can
be blocked to prevent the vehicle from rolling.
To actuate the parking brake, pull the handbrake lever, push the locking pawl downwards, and release the handbrake lever.
Possible states
Handbrake lever in basic position Front wheels not blocked.
Handbrake lever pulled and latched Front wheels blocked.

100006-10

Checking free play of hand brake lever


16.2

Warning
Danger of accidentsBrake system failure.

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.

Push the hand brake lever forwards and check free play.
Free play of hand brake lever

3mm (0.12in)

Wenn der Leerweg nicht mit der Vorgabe bereinstimmt:

Adjust the basic position of the handbrake lever. (

P. 74)

100088-10

Adjusting basic position of handbrake lever


16.3

Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw.

Info
Pull the brake lever forward and turn the adjusting screw.
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!

100052-10

Check the free play of the hand brake lever. (

P. 74)

13/BRAKE SYSTEM

75

Checking the brake fluid level of the front brake


16.4

Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

Check the brake fluid level in the viewer.

When the brake fluid level has dropped to the bottom of the viewer:

Add brake fluid for the front brake. (

P. 75)

100035-10

Adding brake fluid for the front brake


16.5

Warning
Skin irritationsBrake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of children.

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning
Environmental hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

Remove screws.

Remove cover with membrane.

Add brake fluid to level.


Specification
Measurement of
Brake fluid DOT4/DOT5.1 (

5mm (0.2in)
P. 203)

Position the cover with the membrane. Mount and tighten screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.

100036-10

13/BRAKE SYSTEM

76

Checking the front brake linings


16.6

Remove the wheel/wheels. (

Check the brake linings of both front brake calipers for minimum thickness.

P. 59)
1mm (0.04in)

Minimum thickness

If the minimum thickness is less than specified:

Change the front brake linings. (

Mount the wheel/wheels. (

P. 77)

P. 60)

100074-10

Removing the front brake linings


16.7

Info
The operations are the same on the left and right sides.

Remove the wheel/wheels. (

Pull and release the handbrake lever.

P. 59)

Locking pawl moves into its basic position, parking brake is deactivated.

Push the brake piston back to release pressure on the brake linings.

Remove locking split pins, withdraw the bolt and take out the brake pads.

Clean the brake caliper and bolts.

100071-10

Mounting front brake linings


16.8

Warning
Danger of accidentsReduced braking due to oil or grease on the brake discs.

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning
Danger of accidentsReduced braking due to use of non-approved brake linings.

Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The 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.

Info
The operations are the same on the left and right.

100072-10

Check the brake discs. (

Check parts for damage and wear. Replace damaged or worn parts.

Insert the inside brake lining into the brake caliper and fix with bolt.

Insert the external brake lining into the brake caliper and slide the bolts in all the
way.

P. 60)

13/BRAKE SYSTEM

77

Mount the locking split pins.

Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.

Mount the wheel/wheels. (

P. 60)

100073-10

Changing the front brake linings


16.9

Warning
Skin irritationsBrake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of children.

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning
Environmental hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

Remove the front brake linings. (

Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

Remove screws.

Remove cover with membrane.

Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.

Mount the front brake linings. (

Add brake fluid to level.

P. 76)

P. 76)

Specification
Measurement of
Brake fluid DOT4/DOT5.1 (

5mm (0.2in)
P. 203)

Position the cover with the membrane. Mount and tighten screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.

100036-10

Checking free play of foot brake lever


16.10

Warning
Danger of accidentsBrake system failure.

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.

13/BRAKE SYSTEM

78

Disconnect spring.

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

If the free travel does not meet specifications:

100085-10

3 5mm (0.12 0.2in)

Adjust the basic position of the footbrake lever. (

P. 78)

Reconnect spring.

Adjusting basic position of footbrake lever


16.11

Warning
Danger of accidentsBrake system failure.

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.

Disconnect spring.

Loosen nut and with push rod, turn it back until you have maximum free play.

To adjust the basic position of the footbrake lever individually, loosen nut and
turn screw accordingly.

Info
The range of adjustment is limited.

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

3 5mm (0.12 0.2in)

Hold screw and tighten nut.


Specification
Remaining nuts, chassis

M8

30Nm
(22.1lbfft)

M6

15Nm
(11.1lbfft)

Hold push rod and tighten nut.


Specification

100061-10

Remaining nuts, chassis

Reconnect spring.

Checking the brake fluid level of the rear brake


16.12

Park the vehicle on a horizontal surface.

Check the brake fluid level in viewer.

When the brake fluid level has dropped to the bottom of the viewer:

100040-10

Add brake fluid for the rear brake. (

P. 79)

13/BRAKE SYSTEM

79

Adding brake fluid for the rear brake


16.13

Warning
Skin irritationsBrake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of children.

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning
Environmental hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

Remove screw with membrane.

Add brake fluid to level.

100049-10

Brake fluid DOT4/DOT5.1 (

P. 203)

Mount screw with membrane.

Info
Clean up overflowed or spilt brake fluid immediately with water.

100050-10

Checking the rear brake linings


16.14

Check the brake linings for minimum thickness.


Minimum thickness

If the minimum thickness is less than specified:

100038-10

1mm (0.04in)

Change the rear brake linings. (

P. 81)

13/BRAKE SYSTEM

80

Removing the rear brake linings


16.15

Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.

Loosen screw while holding hexagonal head of the bearing bolt. Unscrew the
screw by approx. 10 turns and use the screw to press the bearing bolt out of the
brake caliper. Remove screw.

100063-10

100064-10

Note
Danger of damageKinking of brake line.

100066-10

Position and handle the brake line without straining it. The brake line must be
replaced if it is kinked.

Swing the brake caliper up, unhook it from brake caliper support and set it
down.

Remove brake linings.

Clean the brake caliper and brake caliper support.

Mounting rear brake linings


16.16

Warning
Danger of accidentsReduced braking due to oil or grease on the brake discs.

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning
Danger of accidentsReduced braking due to use of non-approved brake linings.

Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The 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.

Check the brake discs. (

Check parts for damage and wear. Replace damaged or worn parts.

Check that the sliding plate is seated correctly in the brake caliper support and
insert the brake linings.

P. 60)

Info
Make sure that the decoupling plate is mounted on the piston side of the
brake pad.

100067-10

13/BRAKE SYSTEM

81

Grease the bearing bolt and insert the brake caliper with the bearing bolt into
the brake caliper support.

Swing the brake caliper downwards. Mount and tighten screw .

100068-10

Specification
Screw, rear brake caliper

M6

10Nm
(7.4lbfft)

Loctite 243

Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.

100069-10

Changing the rear brake linings


16.17

Warning
Skin irritationsBrake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of children.

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning
Environmental hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

Remove the rear brake linings. (

Remove screw with membrane.

Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.

Mount the rear brake linings. (

Add brake fluid to level.


Brake fluid DOT4/DOT5.1 (

100070-10

P. 80)

P. 80)
P. 203)

Mount screw with membrane.

Info
Clean up overflowed or spilt brake fluid immediately with water.

30/ENGINE

82

30/ENGINE
17

Removing the engine

17.1

Remove the engine guard. (

Drain the coolant. (

Remove the rear shock absorber. (

Remove the manifold. (

Remove the carburetor. (

Remove the engine sprocket. (

Detach the reverse gear Bowden cable. (

Disconnect the negative (minus) cable of the battery.

Remove screws and take off slave cylinder.

P. 18)

P. 163)
P. 36)

P. 48)
P. 145)
P. 161)
P. 17)

Info
Do not activate the clutch lever if the slave cylinder of the clutch has been
removed.

600166-10

Open cable clamps and remove sleeves.

Disconnect plug-in connectors. Place the cables on top of the engine.

Remove screw. Hang the ground wire to one side.

Slide back the cover. Remove nut from the electrical connection on the starter
motor and take off the cable.

600167-10

600168-10

600169-10

30/ENGINE

83

Release hose clamps and take off the radiator hoses and hose clamps.

Push back the clamp on engine breather hose.

Pull the engine breather hose off of the engine case.

Pull off the spark plug connector.

Detach spring and remove screw.

600170-10

Spring hooks (50305017000) (

P. 207)

600171-10

Lower the mounting platform until all wheels touch the ground.

Remove tension belt.

Remove nut. Remove the swingarm bolt.

Take the rear brake line out of the guides of the swingarm.

Carefully push the swingarm back and set it on the ground.

600172-10

600173-10

Info
Do not kink the brake line.

600174-01

600175-10

Remove screws and take off the engine bearer.

30/ENGINE

84

Remove screws and take off the engine bearer.

Remove screw and take the engine out of the frame toward the front right.

600179-10

Info
Having an assistant is helpful in this step.

600177-10

Installing the engine


17.2

Position the engine in the frame. Mount screw but do not tighten it yet.

Info
Having an assistant is helpful in this step.

600177-11

Position the engine bearer on the frame. Mount screws but do not tighten them
yet.
Specification
Engine bracket screw

M10

60Nm
(44.3lbfft)

Insert screw.

Position the engine bearer on the frame. Mount screws but do not tighten them
yet.

600178-10

Specification
Engine bracket screw

M10

60Nm
(44.3lbfft)

M10

60Nm
(44.3lbfft)

Mount screw but do not tighten it yet.


Specification
Engine bracket screw

600176-11

600180-10

Raise the swingarm and position it between the frame and the engine. Insert
swingarm pivot.

Attach the rear brake line to holder.

30/ENGINE

85

Mount and tighten nut.


Specification
Nut, swingarm pivot

M16x1,5

100Nm
(73.8lbfft)

Engine carrying screw

M10

60Nm
(44.3lbfft)

Engine bracket screw

M10

60Nm
(44.3lbfft)

Tighten all previously mounted screws.


Specification

600173-11

If the vehicle is to be raised, secure the swingarm to the subframe with a tension
belt.

Position the footbrake cylinder. Mount and tighten screws.

600172-11

Specification
Screw, foot brake cylinder

M6

7Nm
(5.2lbfft)

Loctite 243

Reconnect spring.
Spring hooks (50305017000) (

P. 207)

600171-11

Attach the cooler hoses. Position hose clamps and tighten.

Attach engine breather hose and secure with a hose clip.

Attach the spark plug connector.

Position the electrical connection on the starter motor. Mount and tighten nut.
Slide on the cover.

Position the ground wire. Mount and tighten screw.

600170-11

Specification
Screw, starter engine

M6

10Nm (7.4lbfft)

600169-11

600168-11

Position the cable and connect connector to the wiring harness.

30/ENGINE

86

Fix the cable with cable clamps and sleeves.

Position the slave cylinder of clutch. Mount and tighten screws.

600167-11

Specification
Slave cylinder of the clutch on engine
case

600166-11

M6

Connect the negative (minus) cable of the battery.

Install the engine sprocket. (

Install the carburetor. (

Attach the reverse gear Bowden cable. (

Install the manifold. (

Install the rear shock absorber. (

Fill coolant / bleed cooling system. (

Install the engine guard. (

Make a short test ride.

Check the engine for leakage.

Check the engine oil level. (

Check the cooling system for leakage.

Check the coolant level. (

P. 161)

P. 156)
P. 17)

P. 49)
P. 37)

P. 18)

P. 169)
P. 162)

P. 164)

10Nm (7.4lbfft)

30/DISASSEMBLING THE ENGINE

87

30/DISASSEMBLING THE ENGINE


18

Preparations

18.1

Thoroughly clean the outside of the engine and attach it to the universal mounting
rack using the special tool.
Engine holder (83112001050) (

P. 215)

Universal mounting rack (56012001000) (

P. 207)

Place a container suitable for draining oil beneath the engine.

Remove oil drain plug.

Remove plug and the small oil screen with both O-rings.

Remove plug and the large oil screen with both O-rings.

Completely drain the engine oil.

Remove screws. Take off oil filter cover with the O-ring.

Pull oil filters and out of the engine housing.

600441-01

Draining the engine oil


18.2

600183-10

Removing the oil filter


18.3

600184-10

Circlip pliers reverse (51012011000) (

P. 207)

Completely drain the engine oil.

Remove screw and take off starter motor.

600185-10

Removing the starter motor


18.4

600186-10

30/DISASSEMBLING THE ENGINE


Removing the shift lever
18.5

Remove screw. Take off shift lever.

Remove screws. Remove the spring holder. Take off the clutch cover.

Remove centering pin and dowels. Take off the clutch cover seal.

Undo screws and remove them with the washers and springs.

Take off pressure cap.

Take out clutch discs entirely.

Remove pressure piece and the clutch push rod.

600182-10

Removing the clutch cover


18.6

600187-10

600188-10

Removing the clutch discs


18.7

600189-10

600190-11

88

30/DISASSEMBLING THE ENGINE

89

Removing the outer clutch hub


18.8

Bend open lock washer.

Apply counterpressure against the inner clutch hub using special tool. Loosen
nut.

600193-10

Clutch holder (59029003100) (

P. 208)

Remove nut with lock washer.

Block the primary drive with special tool and remove nut.

600194-10

Clutch holder (59029003100) (

P. 208)

Info
LH thread!

600195-10

Remove inner clutch hub sleeves and inner clutch hub. Remove the stepped
washer and half washers.

Info
Behind the inner clutch hub are two half washers that can fall off.

600196-10

600197-10

Take off outer clutch hub and remove both needle bearings from the main shaft.

Remove the supporting plate.

30/DISASSEMBLING THE ENGINE

90

Removing the starter idler gear/torque limiter


18.9

Remove lock ring.


Circlip pliers reverse (51012011000) (

P. 207)

Take off disk and starter idler gear.

Remove torque limiter with bearing bolt and both needle bearings.

Press sliding plate away from the shift drum locating. Remove shift shaft with
the washer.

Remove screw.

Press locking lever away from shift drum locating and take off the shift drum
locating.

Release the locking lever.

Undo screw and take off it together with locking lever, washer, sleeve and
spring.

Remove shaft retainer.

Remove washer, oil pump gear and pin.

600198-01

Removing the shift shaft


18.10

600199-10

Removing the shift drum locating


18.11

600200-11

Removing the locking lever


18.12

600271-10

Removing the oil pump gear


18.13

Info
Make sure that the pin remains in place.

600202-10

30/DISASSEMBLING THE ENGINE

91

Removing the primary gear with the free-wheel-gear


18.14

Remove primary gear and free-wheel-gear using the special tool.


Extractor (59029033000) (

P. 209)

Info
Make sure that the washer spring remains in place.

600204-10

Removing the spark plug


18.15

Remove the spark plug using special tool.


Spark plug wrench (75029172000) (

P. 210)

600207-10

Removing the generator cover


18.16

Remove screws. Take off generator cover.

Remove centering pins. Remove the generator cover seal.

Set the engine to ignition top dead center.

600205-10

600206-10

Installing the crankshaft locking bolt


18.17

Info
In the top dead center position, conductive element is located above the
ignition pulse generator.

600208-10

30/DISASSEMBLING THE ENGINE

92

Remove screw.

Screw in special tool until the crankshaft is blocked.

600209-11

Crankshaft locking bolt (113080802) (

P. 207)

Info
With perceptible resistance, move the flywheel back and forth so that the
special tool can engage in the recess of the crankshaft.

600210-10

Removing the ignition pulse generator


18.18

Remove screws.

Pull the cable support sleeve out of the engine case. Take off ignition pulse generator.

Remove nut with the spring washer.

Attach special tool to the rotor. Apply counterpressure with the special tool and
pull off rotor by turning in the screw.

600211-10

Removing the rotor


18.19

600212-10

Extractor (58012009000) (

P. 207)

Info
Make sure that the washer spring remains in place.

600213-10

30/DISASSEMBLING THE ENGINE


Removing the oil pumps
18.20

Remove screws.

Remove oil pump cover.

Remove oil pump shaft together with pin, internal rotor and external
rotor.

Remove screws.

Remove oil pump cover.

Remove internal rotor with pin and external rotor.

Remove screws with the sealing discs and oil line.

600214-10

600215-10

600216-10

600217-10

Removing the oil line


18.21

600218-10

93

30/DISASSEMBLING THE ENGINE

94

Removing the timing chain tensioner


18.22

Remove screw with the sealing disc.

Info
Screw is spring loaded!

600221-10

Pull out spring.

Remove screws and pull out timing chain tensioner.

Remove screws. Take off water pump cover.

Take off the water pump cover seal.

Remove screws and take off the valve cover.

Remove screws and .

Take off the cylinder head top section.

Separate the timing chain using the special tool.

600222-10

Removing the water pump cover


18.23

600219-10

Removing the cylinder head top section


18.24

600220-10

Removing the camshaft


18.25

Timing chain separating and riveting tool (59029020000) (

P. 209)

Info
Ensure that the bolt that is pushed out does not drop into the engine.
Hold the timing chain so that it does not fall into the timing chain shaft.

600223-01

30/DISASSEMBLING THE ENGINE

Prevent the timing chain from falling down using cable ties.

Remove the camshaft with camshaft gear.

Remove screws.

Remove screws in crisscross pattern. Remove the screws and washers.

Take off the cylinder head.

Take off dowels.

Remove cylinder head gasket.

Remove cylinder toward the top. Hold the piston in place while doing so.

600224-10

Removing the cylinder head


18.26

600225-10

600226-10

Removing the cylinder


18.27

Info
Make sure that the pins on the cylinder base remain in place.

600227-10

Remove the cylinder base gasket.

95

30/DISASSEMBLING THE ENGINE

96

Removing the piston


18.28

Remove piston pin retainer.

Remove piston pin.

Remove piston.

Remove screws. Remove timing chain guide rail and timing chain tensioning
rail.

Remove screws. Remove timing chain securing guide.

Remove the timing chain.

600228-10

Removing the timing chain


18.29

Info
Mark the direction of travel of the timing chain.

600229-10

Removing the timing chain sprocket


18.30

Remove lock ring.


Circlip pliers reverse (51012011000)

600230-10

Pull timing chain sprocket off of the crankshaft using special tool.
Extractor (59029033000)

Info
Make sure that the washer spring remains in place.

600231-10

Removing the locking shaft lever


18.31

600232-10

Remove screw. Take off locking shaft lever.

30/DISASSEMBLING THE ENGINE

97

Removing the gear sensor


18.32

Remove screws with abutment plate. Remove gear sensor.

Remove contact bolts with the springs behind them.

600233-10

600234-10

Taking off the left section of the engine case


18.33

600235-10

Remove screws.

600210-10

Remove special tool.

30/DISASSEMBLING THE ENGINE

Swing the left section of the engine case upward.

Remove nut and screw.

Take off the left section of the engine case.

98

600236-10

Info
The bosses on the engine case can be used for lightly striking with the plastic hammer.

Remove dowels.

Remove spacing sleeve.

Remove shift rail with the springs and disassemble shift fork with the shift
roller.

600237-10

Remove the shift rails and forks.


18.34

Info
Make sure not to misplace the shift roller.

600238-10

Remove the shift railwith locking lever and dismantle shift forks with the
shift rollers.

Info
Make sure not to misplace the shift rollers.

600239-10

Removing the shift drum


18.35

600240-10

Take out shift drum.

30/DISASSEMBLING THE ENGINE


Removing the transmission shaft
18.36

Take off O-ring with inner bearing race.

Pull main shaft and countershaft out of the bearing seats together with the
axle for the reverse gear.

600241-10

Info
Some of the gear wheels are not firmly attached to the shaft and can fall
off.
Make sure that the stop disks remains in place.

600242-10

Removing the balancer shaft


18.37

Turn balancer shaft to the marking and pull out of the bearing.

Remove crankshaft.

Take off the right section of the engine case.

600243-10

Removing the crankshaft


18.38

600244-10

99

30/ENGINE - WORK ON INDIVIDUAL PARTS

100

30/ENGINE - WORK ON INDIVIDUAL PARTS


19

Work on the right section of the engine case

19.1

Remove oil jet.

Remove bearing retainers.

Remove the shaft seal ring of crankshaft.

Remove oil jet.

Remove any sealing compound remnants and clean the engine case section thoroughly.

Warm the engine case section in an oven.


Specification
150C (302F)

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.

Check parts for damage and wear. Replace damaged or worn parts.

Warm the engine case section again.


Specification

600247-10

150C (302F)

Insert the new cold 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.

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.

Press the shaft seal ring of the crankshaft from the outside to the inside with the
open side facing inward.

Info
The shaft seal ring must be flush with the outside.

Position all bearing retainers. Mount and tighten the screws.


Specification
Locking screw for bearing

M5

6Nm
(4.4lbfft)

Loctite 243

M6x0,75

4Nm
(3lbfft)

Loctite 243

Mount and tighten oil jet.


Specification
Oil jet, piston cooling

Mount and tighten oil jet.


Specification
Oil jet for conrod lubrication

M5

2Nm (1.5lbfft)

30/ENGINE - WORK ON INDIVIDUAL PARTS

101

Blow though all oil holes with compressed air and check that they are clear.

600249-01

Removing the oil pressure regulator valve


19.2

Remove plug with seal rings.

Remove pressure spring and piston valve.

600250-10

Checking the spring length of the oil pressure regulator valve


19.3

Remove the oil pressure regulator valve. (

Measure the spring length of the oil pressure regulator valve.

P. 101)

Bypass valve - minimum length of pres- 23.5mm (0.925in)


sure spring

If the measured value does not equal the specified value:

Change the spring.

Install the oil pressure regulator valve. (

P. 101)

200155-10

Installing the oil pressure regulator valve


19.4

Check parts for damage and wear. Replace damaged or worn parts.

Insert piston valve with pressure spring.

Mount plug with seal rings and tighten.


Specification
Plug, oil pressure regulator valve

600250-11

M12x1.5

20Nm
(14.8lbfft)

30/ENGINE - WORK ON INDIVIDUAL PARTS

102

Work on the left section of the engine case


19.5

Remove all dowels.

Remove the shaft seal ring of countershaft, shift rail with locking lever and
shift shaft.

Remove any sealing compound remnants and clean the engine case section thoroughly.

Warm the engine case section in an oven.


Specification
150C (302F)

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.

Check parts for damage and wear. Replace damaged or worn parts.

Warm the engine case section again.


Specification
150C (302F)

600246-10

Insert the new cold 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.

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.

Press in the shaft seal ring of countershaft, shift rail with lock and shift
shaft with the open side facing inward until they are flush.

Mount the dowels.

Blow though all oil holes with compressed air and check that they are clear.

600248-01

Changing the crankshaft seal ring in the clutch cover


19.6

600251-10

Remove crankshaft seal ring.

Press the new crankshaft seal ring into the clutch cover with the open side facing inward until it is flush.

Grease the sealing lip.

Blow though oil hole with compressed air and check that it is clear.

30/ENGINE - WORK ON INDIVIDUAL PARTS

103

Disassembling the autodecompressor


19.7

Remove lock ring.


Circlip pliers reverse (51012011000) (

P. 207)

Pull off water pump wheel.

Remove pin. Pull seal holder from the camshaft.

600261-10

Info
After removing, always replace the shaft seal rings in the seal holder.

600262-10

Take off washer.

Remove camshaft bearing using special tool.

600263-10

Extractor (59029033000) (

P. 209)

600264-10

Disconnect spring.

Remove autodecompression shaft and take off spring.

600260-10

600266-10

30/ENGINE - WORK ON INDIVIDUAL PARTS

104

Assembling the autodecompressor


19.8

Check parts for damage and wear. Replace damaged or worn parts.

Position autodecompression spring and insert autodecompression shaft.


Preload the autodecompression spring by approx. turn in the direction of the
arrow and slide onto the autodecompression shaft.

Ensure that the autodecompression spring engages in the groove.

Check that the autodecompression shaft moves easily.

600266-11

If the autodecompression spring does not push the autodecompression shaft


back in the original position:

Tighten the autodecompression spring or replace it.

600260-11

Mount camshaft bearing. Mount washer.

Attach special tool to the camshaft. Mount the seal holder with the new shaft
seal rings and O-rings.

600263-11

Mounting sleeve (59029005010) (

P. 208)

Info
When mounting the seal holder, the threads in the seal holder must be at
the top.

Remove the special tool.

Mount pin.

Position water pump wheel and mount lock ring.

600267-10

600262-11

Circlip pliers reverse (51012011000) (

600261-11

P. 207)

30/ENGINE - WORK ON INDIVIDUAL PARTS

105

Changing the camshaft bearing


19.9

Remove lock ring.


Circlip pliers reverse (51012011000) (

P. 207)

Pull off water pump wheel.

Remove pin. Pull seal holder from the camshaft.

600261-10

Info
After removing, always change the shaft seal rings in the seal holder.

600262-10

Take off washer.

Remove camshaft bearing using special tool.

600263-10

Extractor (59029033000) (

P. 209)

600264-10

Check parts for damage and wear. Change damaged or worn parts.

Mount the new camshaft bearing. Mount washer.

Attach special tool to the camshaft. Mount seal holder with the new shaft seal
rings and O-rings.

600263-12

Mounting sleeve (59029005010) (

P. 208)

Info
When mounting the seal holder, the threads in the seal holder must be at
the top.

600267-11

Remove the special tool.

30/ENGINE - WORK ON INDIVIDUAL PARTS

106

Mount pin.

Position water pump wheel and mount lock ring.

Remove camshaft bearing using special tool.

600262-12

600261-12

Extractor (59029033000) (

P. 209)

600321-10

Mount the new camshaft bearing.

600322-10

Checking the rocker arms and rocker arm shafts


19.10

Pull end caps out of the cylinder head top section.

Pull rocker arm shafts out of the cylinder head top section.

Remove the rocker arms.

600273-10

600274-10

30/ENGINE - WORK ON INDIVIDUAL PARTS

Check rocker arm shafts for damage and wear.

If there is damage or wear:

If there is damage or wear:

Change the adjusting screws.

Check rocker arm rollers for smooth operation and radial clearance.

600275-10

Change the rocker arm shafts.

Check the contact surface of adjusting screws for damage and wear.

107

If rocker arm rollers are stiff or if there is radial clearance:

Change the rocker arms.

Install the short rocker arm shaft and the long rocker arm shaft.

Align the holes in the shafts with the holes in the cylinder head top section.

Clean the end caps thoroughly and check for damage and wear. Replace damaged
or worn parts.

Install the end caps with the O-rings.

600276-10

Info
The hole in the end cap must be aligned with the hole in the cylinder
head top section and the rocker arm shaft.

600277-10

Removing the valves


19.11

Pretension the valve springs using the special tool.


Valve spring mounter (59029019000) (

P. 208)

Remove the valve keys and release the tension on the valve springs.

Remove the spring retainer and springs.

Pull valve downward out of the valve guide, remove the valve stem seal and
remove the lower valve spring retainer.

Mark the valve to indicate the installation position.

600278-01

600279-10

Info
Place the valve into a box according to the installation position and label the
box.

200189-10

30/ENGINE - WORK ON INDIVIDUAL PARTS

108

Checking the valves


19.12

Info
The valve stem is chrome-hardened, and wear normally takes place in the valve guide.

Check for valve retainer run-out.


Valves
Run-out on valve plate

0.05mm (0.002in)

If the measured value does not equal the specified value:

Change the valve.

200193-10

Check sealing seat on the valve.


Valves
Sealing seat width, intake

1.50mm (0.0591in)

Valves

0
A

Sealing seat width, exhaust

If the sealing area is not in the center of the valve seat or if it differs from the
specified value:

400373-10

2.00mm (0.0787in)

Machine the valve seat.

Checking the valve springs


19.13

Check the valve springs for breakage and wear (visual check).

If the valve spring is broken or worn:

Change the valve spring.

Measure the valve spring length.


Valve springs

600280-01

Minimum length of outside spring

39.20mm (1.5433in)

Minimum length of inside spring

36.45mm (1.435in)

If the measured value does not equal the specified value:

Change the valve spring.

Checking the lower valve spring retainer


19.14

Check the lower valve spring retainer for breakage and wear (visual check).

If the lower valve spring retainer is broken or worn:

Change the valve spring retainer.

Measure the thickness of the lower valve spring retainers.


Lower valve spring retainer - strength

If the measured value does not equal the specified value:

600281-01

0.4 0.5mm (0.016 0.02in)

Change the valve spring retainer.

30/ENGINE - WORK ON INDIVIDUAL PARTS

109

Checking the cylinder head


19.15

Check the valve guides using special tool.


Limit plug gauge (59029026006) (

If the special tool is easy to insert into the valve guide:

Change the valve guide and valve.

Check the sealing area of the spark plug thread and the valve seats for damage and
cracking.

If there is wear or cracking:

600282-10

P. 209)

Change the cylinder head.

Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) (

P. 209)

Cylinder/cylinder head - sealing area


distortion

0.10mm (0.0039in)

If the measured value does not equal the specified value:

Change the cylinder head.

400375-10

Check sealing seat of the valves.


Valves
Sealing seat width, intake

1.50mm (0.0591in)

Valves

0
A

Sealing seat width, exhaust

If the measured value does not equal the specified value:

400373-10

2.00mm (0.0787in)

Machine the valve seat.

Blow though all oil holes with compressed air and check that they are clear.

Check parts for damage and wear. Replace damaged or worn parts.

Position the lower valve spring retainers. Mount the new valve stem seals.

Mount valves according to their position in the engine.

Mount outer valve spring, inner valve spring and upper valve spring
retainer.

Installing the valves


19.16

600283-10

600284-10

30/ENGINE - WORK ON INDIVIDUAL PARTS

Tension the valve springs with a special tool.


Valve spring mounter (59029019000) (

110

P. 208)

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.
600285-01

Checking the timing assembly


19.17

Clean all parts well.

Check timing chain crankshaft sprocket and timing chain camshaft sprocket
for damage and wear.

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

Change the timing chain.

Check that the timing chain links move easily. Let the timing chain hang down
freely.

If the chain links no longer straighten out:

600269-10

Change the timing chain guide rail.

Check timing chain for damage and wear.

Change the timing chain tensioning rail.

Check timing chain guide rail for damage and wear.

Change the timing chain wheel/timing chain sprocket.

Check timing chain tensioning rail for damage and wear.

Change the timing chain.

Check timing chain securing guide for damage and wear.

If there is damage or wear:

Change the timing chain securing guide.

Preparing the timing chain tensioner for installation


19.18

Check the timing chain tensioner for damage and wear.

If there is damage or wear:

If the pressure bolt is stiff:

Change the timing chain tensioner.

Press on the ratcheting pawl and check that the pressure bolt moves easily.
Change the timing chain tensioner.

To mount the timing chain tensioner, press ratcheting pawl and push pressure
bolt all the way into the housing.

600270-10

Changing the conrod bearing


19.19

Press the crank pin out of the crank web.

Take off the connecting rod and bearing.

Press the crank pin out of the second crank web.

30/ENGINE - WORK ON INDIVIDUAL PARTS

111

A
600455-01

Position the new crank pin and press it into the first crank web.
The oil hole in the crank web is aligned with the oil hole in the crank pin.

Info
If the oil holes are not correctly aligned, the conrod bearing will not be provided with oil.

Check the oil hole with compressed air to ensure it is clear.

Mount the bearing and connecting rod.

Info
Oil the bearing thoroughly.

Press in the second crank web.

Measure the external dimensions of the crankshaft - crank web.


Crankshaft - external crank web dimension

If the specified value is not reached:

650.05mm (2.560.002in)

Correct to the specified value.

Check the crankshaft run-out on the bearing pin. (

P. 111)

Checking the crankshaft run-out on the bearing pin


19.20

Position the crankshaft on a roller block.

Turn the crankshaft slowly.

Check the crankshaft run-out on both bearing pins.


Crankshaft - run-out on bearing pin

If the crankshaft run-out on the bearing pin is greater than the specified value:

600254-01

0.12mm (0.0047in)

Align the crankshaft.

30/ENGINE - WORK ON INDIVIDUAL PARTS

112

Measuring the axial clearance of the crankshaft


19.21

Clamp the right section of the engine case into the engine work stand.
Universal mounting rack (56012001000) (

P. 207)

Install crankshaft.

Mount the left section of the engine case. Mount and tighten the screws.

600244-10

Specification

600437-10

Screw, engine housing

M6x30

10Nm (7.4lbfft)

Screw, engine housing

M6x45

10Nm (7.4lbfft)

Screw, engine housing

M6x60

10Nm (7.4lbfft)

Screw, engine housing

M6x65

10Nm (7.4lbfft)

Screw, engine housing

M6x75

10Nm (7.4lbfft)

Using a dial gauge, measure and note down the axial clearance of crankshaft.
Crankshaft - axial clearance

0.25 0.35mm (0.0098


0.0138in)

If the measured value does not equal the specified value:

Correct the axial clearance of the crankshaft. (

P. 112)

Correcting the axial clearance of the crankshaft


19.22

Measure the axial clearance of the crankshaft. (

Calculate the thickness of the correction shims.

Remove the crankshaft and clamp in a vice as shown in the figure.

P. 112)

Specification
Use soft jaws.

Info
Do not strike the inner bearing race!
600440-01

Heat the special tool.


Specification
150C (302F)
Tool for inner bearing race (58429037037) (

P. 208)

Slide the heated special tool onto the inner bearing race, press together firmly and
pull both off of the crankshaft.

Add or remove correction shims.

Info
If the axial clearance is too large, correction shims need to be added. If the
axial clearance is too small, correction shims need to be removed.
Only add the correction shims on the ignition side.

Heat the special tool. Mount the inner bearing race.


Specification
150C (302F)
Tool for inner bearing race (58429037037) (

Measure the axial clearance of the crankshaft. (

P. 208)
P. 112)

30/ENGINE - WORK ON INDIVIDUAL PARTS

113

cylinder - Nikasil coating


19.23

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.

600272-01

Checking/measuring the cylinder


19.24

Check the cylinder bearing surface for damage.

If the cylinder bearing surface is damaged:

Change the cylinder and piston.

Measure the cylinder diameter at several places on the and axes using a
micrometer to check for oval wear.
Specification
Cylinder - bore diameter (450 XC ATV)
Diameter size I

89.000 89.012mm (3.50393


3.5044in)

Diameter size II

89.013 89.025mm (3.50444


3.50491in)

600252-01

Cylinder - bore diameter (525 XC ATV)


Diameter size I

95.000 95.012mm (3.74015


3.74062in)

Diameter size II

95.013 95.025mm (3.74066


3.74113in)

Cylinder size is marked on the side of the cylinder.

Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.

600255-10

Feeler gauge (59029041100) (

P. 209)

Cylinder/cylinder head - sealing area


distortion

If the measured value does not equal the specified value:

400376-10

0.10mm (0.0039in)

Change the cylinder.

30/ENGINE - WORK ON INDIVIDUAL PARTS

114

Checking/measuring the piston


19.25

Check the piston bearing surface for damage.

If the piston sliding surface is damaged:

Change the piston and, if necessary, the cylinder.

Check that the piston rings can move easily in the piston ring grooves.

If the piston ring is stiff:

Clean the piston ring groove.

Tip
Use an old piston ring to clean the piston ring groove.

600253-01

Check the piston rings for damage.

If the piston ring is damaged:

Change the piston ring.

Info
Mount the piston ring with the marking facing upward.

Check the piston pin for discoloration or signs of wear.

If the piston pin has strong discoloration or signs of wear:

If the piston pin bearing has too much play:

Change the piston pin.

Insert the piston pin into the connecting rod and check the bearing for play.
Change the connecting rod and the piston pin.

Measure the piston at the piston skirt, at right-angles to the piston pin.
Specification
Piston diameter (450 XC ATV)
Size I

88.916 88.946mm (3.50062


3.5018in)

Size II

88.926 88.958mm (3.50102


3.50228in)

Piston diameter (525 XC ATV)


200161-10

Size I

94.932 94.960mm (3.73747


3.73858in)

Size II

94.940 94.968mm (3.73779


3.73889in)

Info
Piston size is marked on the piston head.

Checking the piston ring end gap


19.26

Remove the piston ring from the piston.

Place the piston ring in the cylinder and align it with the piston.
Specification
under the upper edge of the cylinder

10mm (0.39in)

Measure the end gap with feeler gauge.


Specification
Piston ring - end gap

200163-10

Oil scraper ring

<1.00mm (<0.0394in)

Check/measure the cylinder. (

P. 113)

If the cylinder wear is within the tolerance range:

<0.80mm (<0.0315in)

If the end gap is greater than the specified value:

Compression ring

Change the piston ring.

Mount the piston ring with the marking facing toward the piston head.

30/ENGINE - WORK ON INDIVIDUAL PARTS

115

Checking the piston/cylinder mounting clearance


19.27

Check/measure the cylinder. (

Check/measure the piston. (

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.

P. 113)
P. 114)

Specification
Piston/cylinder - mounting clearance (450 XC ATV)
Size I

0.054 0.096mm (0.00213 0.00378in)

Size II

0.056 0.099mm (0.0022 0.0039in)

Wear limit

0.120mm (0.00472in)

Piston/cylinder - mounting clearance (525 XC ATV)


Size I

0.040 0.080mm (0.00157 0.00315in)

Size II

0.044 0.085mm (0.00173 0.00335in)

Wear limit

0.120mm (0.00472in)

Checking the oil pumps for wear


19.28

Info
An example of how to check the oil pumps for wear is shown in the figures here, but the method applies to all pumps.

Use feeler gauge to measure the clearance between the external rotor and the
engine case.
Oil pump - clearance between external
rotor and engine housing

0.20mm (0.0079in)

If the measured value does not equal the specified value:

Change the oil pump and, if necessary, the engine case.

600324-10

Use feeler gauge to measure the clearance between the external rotor and the
internal rotor.
Oil pump - clearance between external
rotor and internal rotor

If the measured value does not equal the specified value:

600325-10

0.20mm (0.0079in)

Change the oil pump.

30/ENGINE - WORK ON INDIVIDUAL PARTS

116

Checking the shift mechanism


19.29

1
A
3
6

4
7
6

3
4

2
3

Check sliding plate in contact areas for wear.

If the sliding plate is worn:

Change the sliding plate.

Check that guide pin is firmly seated and check it for wear.

If the guide pin is loose and/or worn:

600287-01

Change the sliding plate.

Check the shift fork at leaf for wear.


Shift fork
Thickness at leaf

If the measured value does not equal the specified value:

If the shift roller has surface damage and cracks:

If there is run-out:

If the shift rail is worn on the locking lever:

If the shift roller is not seated correctly:

Change the shift drum and/or the bearing.

Check bearing for smooth operation and wear.

If the bearing is stiff or worn:

Change the shift rail with the locking lever.

Check the seat of the shift roller in bearing.

Change the shift rail with the locking lever.

Check the shift rail with locking lever for wear on the locking lever.

Change the shift roller.

Check the shift rail with locking lever for run-out.

Change the shift fork.

Check shift rollers for surface damage and cracks.

4.20 4.45mm (0.1654 0.1752in)

Change the bearing.

Check the shift grooves of shift roller for wear.

If the shift groove is worn:

Change the shift roller.

30/ENGINE - WORK ON INDIVIDUAL PARTS

Check springs of the shift rails for damage and wear.

If the spring is broken or worn:

If there is run-out:

Change the shift rail.

Check shift rail for grooving, signs of corrosion and smooth operation in shift fork.

The shift rail has grooving or signs of corrosion or is not smooth in operation in the shift fork:

Change the spring of the shift rail.

On a flat surface, check shift rail for run-out.

117

Change the shift rail.

Preassemble the shift shaft. (

P. 118)

Check clearance between the sliding plate and shift quadrant.


Shift shaft - play in sliding plate/shift
quadrant

B
0

0.40 0.80mm (0.0157


0.0315in)

If the measured value does not equal the specified value:

Change the sliding plate.

400372-10

Disassembling the shift shaft


19.30

Fix the short end of the shift shaft in a vise.


Specification
Use soft jaws.

Detach spring and remove it.

Remove spring guide and pressure spring.

Remove sliding plate.

600288-10

600289-10

600290-10

30/ENGINE - WORK ON INDIVIDUAL PARTS

118

Preassembling the shift shaft


19.31

5
0

2
0

Fix the short end of the shift shaft in a vise.


Specification

1
0
6
0

Use soft jaws.

30
0
4
200175-01

Mount sliding plate with the guide pin facing downward and attach the guide pin
to the shift quadrant.

Mount pressure spring.

Push on spring guide, push return spring over the spring guide with the offset
end facing upward and lift the offset end over abutment bolt.

Mount stop disk.

Checking the clutch


19.32

1
LOCTITE 243

bk

87

LOCTITE 243

3
6

2
5

bl

600286-01

Check clutch facing discs for discoloration and scoring.

If there is discoloration or scoring:

Change all clutch facing discs.

Check the thickness of clutch facing discs.


Clutch facing disc - thickness

If the clutch facing disc does not meet specifications:

If the clutch discs are not level and have pittings:

Change all clutch discs.

Check needle bearing for damage and wear.

If there is damage or wear:

Change all clutch facing discs.

Check clutch disks and for damage and wear.

>1.90mm (>0.0748in)

Change the needle bearing.

Check the contact surfaces of the clutch facing discs in outer clutch hub for wear.

If the contact surface is very worn:

Change the clutch facing discs and the outer clutch hub.

30/ENGINE - WORK ON INDIVIDUAL PARTS

Check inner clutch hub for damage and wear.

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

Change the axial bearing.

Check the contact surface of pressure cap for damage and wear.

If there is damage or wear:

Change the pressure piece.

Check axial bearing for damage and wear.

Change the inner clutch hub.

Check pressure piece for damage and wear.

Change the pressure cap.

Check the length of clutch springs.


Clutch spring - length

41.50 43.00mm (1.6339 1.6929in)

If the clutch spring length is less than the specified value:

119

Change all clutch springs.

Place push rod on a level surface and check for run-out.

If there is run-out:

Change the push rod.

Disassembling the main shaft


19.33

0
1
bbl
0l
b0m
bm
0
70
6

0
5

4
0

bbk
0k 0
9

8
0

3
0
0
2
600316-01

Clamp main shaft in the vise with the toothed end of the coupling side facing downward.
Specification
Use soft jaws.

Remove stop disk and fixed gear of the second gear.

Remove the fourth-gear idler gear and needle bearing.

Remove stop disk and lock ring.

Remove the third-gear sliding gear and lock ring.

Remove stop disk.

Remove the fifth-gear idler gear and needle bearing.

Take the main shaft out of the vise.

30/ENGINE - WORK ON INDIVIDUAL PARTS

120

Checking the main shaft


19.34

1
0
0
2
0
3
50
0
4

0
3

0
2

0
4

5
0

6
0

0
6
0
7
600295-01

Check the pivot points of main shaft for damage and wear.

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

Change the idler/fixed gear pair.

Check needle bearings for damage and wear.

If there is damage or wear:

Change the idler/fixed gear pair.

Check the tooth faces of idler gears and fixed gears for damage and wear.

Change the idler/fixed gear pair.

Check the dog teeth of idler gears and fixed gears for damage and wear.

Change the main shaft.

Check the pivot points of idler gears for damage and wear.

Change the main shaft.

Check the tooth profiles of main shaft for damage and wear.

Change the needle bearing.

Check stop disks for damage and wear.

If there is damage or wear:

Change the stop disk.

Use new lock rings in every repair job.

Check the tooth profiles of fixed gears for damage and wear.

If there is damage or wear:

Check fixed gears for smooth operation in the profile of the main shaft.

If the fixed gear does not move easily:

Change the idler/fixed gear pair.

Change the fixed gear or the main shaft.

Check stop disk for damage and wear.

If there is damage or wear:

Change the stop disk.

30/ENGINE - WORK ON INDIVIDUAL PARTS

121

Assembling the main shaft


19.35

Info
Use new lock rings in every repair job.

Oil all parts carefully before assembling.

Check the countershaft. (

P. 123)

0
1
0
3
2
0
0
70
8

9
0

b0k
bk

40
0
5

6
0

b0l
bl
0m
bbm
600316-11

Clamp main shaft in the vise with the toothed end of the coupling side facing downward.
Specification
Use soft jaws.

Mount needle bearing and fifth-gear idler gear with the recesses facing upward.

Mount stop disk and lock ring.

Mount the third-gear sliding gear with the shift groove facing upward.

Mount lock ring.

Mount stop disk and needle bearing .

Mount the fourth-gear idler gear with the shift dogs facing downward.

Mount the second-gear fixed gear with the chamfered teeth facing downward.

Mount stop disk.

Take the main shaft out of the vise.

Finally, check all gear wheels for smooth operation.

30/ENGINE - WORK ON INDIVIDUAL PARTS

122

Disassembling the countershaft


19.36

0
2

0
3

6
0
00
4
5

bbn
0n

bbo
0o

9
0
0
70
8

b0s
bbp
0p bq
b0qbr
b0r bs

0k bbl
bbk
0l bbm
0m
0l
bbt
0tck
c0k ccl

0m
ccm

1
0
600311-01

Fix countershaft in the vise with the geared end facing downward.
Specification
Use soft jaws.

Remove stop disk and first-gear idler gear.

Remove needle bearing and stop disk.

Remove sliding sleeve.

Remove lock ring and stop disk.

Remove reverse gear idler gear and needle bearing.

Remove stop disk.

Remove spacer disk and fixed gear of the fifth gear.

Remove the third-gear idler gear.

Remove needle bearing and stop disk.

Remove lock ring and the fourth-gear sliding gear.

Remove lock ring and stop disk.

Remove the second-gear idler gear and needle bearing.

Take the countershaft out of the vise.

30/ENGINE - WORK ON INDIVIDUAL PARTS

123

Checking the countershaft


19.37

0
8

0
2

0
6

7
30
0
8 0
0
2

2
0

0
50
4

00
3
40
5

0
6

00
3
4

50
0
40
3

0
2

1
0
600296-01

Check the pivot points of countershaft for damage and wear.

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

Change the idler/fixed gear pair.

Check needle bearings for damage and wear.

If there is damage or wear:

Change the idler/fixed gear pair.

Check the tooth faces of idler gears and fixed gears for damage and wear.

Change the idler/fixed gear pair.

Check the dog teeth of idler gears and fixed gears for damage and wear.

Change the countershaft.

Check the pivot points of idler gears for damage and wear.

Change the countershaft.

Check the tooth profiles of countershaft for damage and wear.

Change the needle bearing.

Check stop disks for damage and wear.

If there is damage or wear:

Change the stop disk.

Use new lock rings in every repair job.

Check the tooth profiles of fixed gears for damage and wear.

If there is damage or wear:

Check fixed gears for smooth operation in the profile of countershaft.

If the fixed gear does not move easily:

Change the fixed gear or the countershaft.

Check sliding sleeve for smooth operation in the profile of the countershaft.

If the sliding sleeve is stiff:

Change the idler/fixed gear pair.

Change the sliding sleeve or the countershaft.

Check the dog teeth of sliding sleeve for damage and wear.

If there is damage or wear:

Change the sliding sleeve and idler gear.

30/ENGINE - WORK ON INDIVIDUAL PARTS

124

Check stop disk for damage and wear.

If there is damage or wear:

Change the stop disk.

Assembling the countershaft


19.38

Info
Use new lock rings in every repair job.

Oil all parts carefully before assembling.

Check the countershaft. (

ccm
0m

0l
ccl

0l
bbl

P. 123)

0s
bbs
cck
0k bt
b0t
bbk
0k

b0p
bp
0r bq
bbr
b0q

6
0
0
90
80
7

0o bbn
bbo
0n bbm
0m
3
0
0
50
4

0
2

1
0
600311-11

Fix countershaft in the vise with the geared end facing downward.
Specification
Use soft jaws.

Mount needle bearing and second-gear idler gear with the recesses facing upward.

Mount stop disk and lock ring.

Mount the fourth-gear sliding gear with the shift groove facing upward.

Mount lock ring.

Mount stop disk and needle bearing.

Mount the third-gear idler gear with the shifting dogs facing downward.

Mount the fifth-gear idler gear with the sleeve facing downward.

Mount spacer disk and stop disk.

Mount needle bearing and reverse-gear idler gear with the recesses facing upward.

Mount stop disk and lock ring.

Mount sliding sleeve and stop disk.

Mount needle bearing and first-gear idler gear with the collar facing upward.

Mount stop disk.

Take the countershaft out of the vise.

Finally, check all gear wheels for smooth operation.

30/ENGINE - WORK ON INDIVIDUAL PARTS

125

Checking/premounting the reverse gear shaft


19.39

0
1

0
5

3 4
0
0

6 0
0
7
600319-01

Check the pivot points of reverse gear shaft for damage and wear.

If there is damage or wear:

Check that pin is firmly seated in reverse gear shaft.

If the pin is loose:

If there is damage or wear:

Change the needle bearing.

Check the tooth faces and pivot point of reverse gear wheel for damage and wear.

If there is damage or wear:

Change the pin or the reverse gear shaft.

Check needle bearing for damage and wear.

Change the reverse gear shaft.

Change the reverse gear wheel.

Check stop disk and for damage and wear.

If there is damage or wear:

Change the stop disk.

Mount stop disk and the needle bearing.

Mount reverse gear wheel with the smaller recess first. Mount stop disk.

Info
After installation, stop disk is flush with surface .
Stop disk is somewhat lower in the reverse gear wheel and is not flush.

600320-10

Mount lock ring.

30/ENGINE - WORK ON INDIVIDUAL PARTS

126

Checking electric starter operation


19.40

0
2
0
3

1
0

0
4

0
5
0
6
0
7
0
A

600323-01

Check the toothing of starter motor for damage and wear.

If there is damage or wear:

Change the starter motor.

Clamp the negative cable of a 12 volt supply to the starter motor housing. Connect the positive cable of the voltage supply briefly
to the connectionof the starter motor.

If the starter motor does not turn when you close the circuit:

Change the starter motor.

Change O-ring of the electric starter motor.

Check the toothing and seating of starter idler gear for damage and wear.

If there is damage or wear:

If there is damage or wear:

If there is damage or wear:

Change the primary gear.

Check free-wheel when removed for damage and wear.

If there is damage or wear:

Change the torque limiter with the bearing bolt.

Check the toothing of primary gear and contact surface for damage and wear.

Change the starter idler gear.

Check the toothing or seating of torque limiter and the bearing bolt for damage and wear.

Change the free-wheel.

Check free-wheel-gear and the bearing when removed for damage and wear.

If there is damage or wear:

Change the free-wheel-gear and/or the bearing.

30/ENGINE - WORK ON INDIVIDUAL PARTS

127

Removing the free-wheel


19.41

Press together spreader ring with suitable pliers and take it off.

Take free-wheel out of the primary pinion.

Place free-wheel-gear in primary pinion while rotating the free-wheel-gear


clockwise, but do not tilt it!

Check the locking action of free-wheel-gear.

600435-10

600436-11

Checking the free-wheel


19.42

The primary pinion cannot be rotated clockwise or does not block counterclockwise:

Remove the free-wheel. (

Turn the free-wheel 180.

Install the free-wheel. (

P. 127)
P. 127)

600313-10

Installing the free-wheel


19.43

Oil all parts well.

Slide free-wheel into the primary pinion.

Info
Note the direction of rotation.

600436-10

600435-11

Mount spreader ring.

Ensure that all protrusions of the spreader ring engage through slots of the freewheel in the groove of the primary pinion.

30/ASSEMBLING THE ENGINE

128

30/ASSEMBLING THE ENGINE


20

Installing the crankshaft

20.1

Clamp the right section of the engine case into the engine work stand.
Universal mounting rack (56012001000) (
Engine holder (83112001050) (

P. 207)

P. 215)

Slide crankshaft all the way into the bearing seat of the right section of the
engine case.

Align the marking on balancer shaft and the crankshaft to each other and insert
the balancer shaft.

Position the reverse gear shaft with pin aligned to notch.

Slide both transmission shafts, and reverse gear shaft into the bearing
seats together.

600244-10

Installing the balancer shaft


20.2

600243-10

Installing the transmission shaft


20.3

600328-10

Info
Make sure not to misplace the washers.

600331-10

600332-10

Slide on inner bearing race.

30/ASSEMBLING THE ENGINE

129

Installing the shift forks


20.4

Oil all parts well.

For all shift forks, secure shift rollers with a small amount of grease.

Mount the short shift fork with the long side of the guide facing downward.

Mount shift forks with the long side of the guide facing toward each other.

Insert shift drum.

Attach the shift forks with the shift rollers to the shift grooves.

Oil all parts well.

Install shift rail with the spring at the bottom and top.

Install shift rail with the locking lever.

Attach special tool to the shift rail with the locking lever.

600329-10

600330-10

Installing the shift drum


20.5

600443-10

Installing the shift rails


20.6

600333-10

Installing the left engine case


20.7

Mounting sleeve (59029005010) (

600334-10

P. 208)

30/ASSEMBLING THE ENGINE

130

Insert dowels.

Grease the sealing areas. Apply sealing compound to the left section of the engine
case.
Loctite5910

Mount the left section of the engine case. If necessary, tap it lightly with a rubber
hammer and turn the transmission shaft.

Info
600335-10

Do not tighten the engine case sections using the screws.

600235-11

Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing

M6x30

10Nm (7.4lbfft)

Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing

M6x45

10Nm (7.4lbfft)

Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing

M6x60

10Nm (7.4lbfft)

Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing

M6x65

10Nm (7.4lbfft)

M6x75

10Nm (7.4lbfft)

Mount screw and tighten all screws in a crisscross pattern.


Specification
Screw, engine housing

30/ASSEMBLING THE ENGINE

131

Remove the special tool.


Mounting sleeve (59029005010) (

P. 208)

Position O-ring and mount spacing sleeve with the phase facing downward.

Using a dial gauge, check the axial clearance of the crankshaft.

600336-10

Specification
Crankshaft - axial clearance

0.25 0.35mm (0.0098


0.0138in)

600327-01

Installing the timing chain sprocket


20.8

Ensure that the spring washer is mounted or mount if necessary.

Heat timing chain sprocket and install with the collar facing inward.
Specification
80C (176F)

Mount lock ring.

Thread timing chain rail from above. Mount and tighten screw.

600230-11

Installing the timing chain rails


20.9

Specification
Screw, timing chain tensioning rail

M6

6Nm
(4.4lbfft)

Loctite 243

Thread timing chain guide rail from above. Mount and tighten screw.
Specification
Screw, timing chain guide
rail

M6

6Nm
(4.4lbfft)

Loctite 243

600337-10

Installing the piston


20.10

Fix the crankshaft using the special tool in the top dead center position.
Crankshaft locking bolt (113080802) (

600338-10

P. 207)

Ensure that both pins are mounted or mount them if necessary.

30/ASSEMBLING THE ENGINE

132

Mount piston on connecting rod and insert piston pin.

Info
Note the orientation of the piston when installing it. The arrow on the piston
must point in the direction of travel.

600228-11

Position the new piston pin retainer at 6 hours or 12 hours.

Mount cylinder base gasket.

Shift the joint of the compression ring and oil scraper ring by 180.

Oil special tool on the inside and the piston on its sliding surface.

600445-01

Installing the cylinder


20.11

Assembly ring (58012015095) (

P. 208)

Slide the special tool onto the piston.

Mount cylinder onto the piston using the special tool and slide both over the piston.

Remove the special tool. Carefully slide the cylinder down.

Mount dowels. Fit the new cylinder head gasket.

600339-10

600340-10

Installing the cylinder head


20.12

600341-10

30/ASSEMBLING THE ENGINE

133

Mount the cylinder head. Mount screws and tighten in a crisscross pattern.
Specification
Screw, cylinder head

M10

Step 1
40Nm
(29.5lbfft)
Step 2
50Nm
(36.9lbfft)

M6

10Nm (7.4lbfft)

600342-10

Mount and tighten screws.


Specification
Screw, cylinder head

600343-10

Installing the camshaft


20.13

Insert the camshaft. Drill hole in the seal holder must face upward and autdecompression stop must be at the top.

Align camshaft marking with the cylinder head.

Place the timing chain over the camshaft gear and connect with a new rivet link.
Clamp tab with the special tool.

600346-10

600347-10

Timing chain separating and riveting tool (59029020000) (

600348-10

P. 209)

30/ASSEMBLING THE ENGINE

134

Reconfigure the special tool. Rivet the rivet link until the edges of the pins are visibly flattened.
Timing chain separating and riveting tool (59029020000) (

P. 209)

600349-10

Installing the cylinder head top section


20.14

Insert dowels. Grease the sealing area. Apply the sealing compound.
Loctite5910

600350-10

0
7
0
7

00
4
5

Mount the cylinder head. Mount screw with the new seal ring but do not tighten
yet.
Specification

0
2
0
3

Screw on cylinder head top section

M6x75

10Nm (7.4lbfft)

M6x45

10Nm (7.4lbfft)

Mount screw but do not tighten it yet.


Specification
Screw on cylinder head top section

6
00
4

600350-01

Mount screws but do not tighten them yet.


Specification
Screw, cylinder head top section

M6x30

10Nm (7.4lbfft)

M6x50

10Nm (7.4lbfft)

M6x45

10Nm (7.4lbfft)

Mount screw but do not tighten it yet.


Specification
Screw on cylinder head top section

Mount screw but do not tighten it yet.


Specification
Screw on cylinder head top section

Tighten screws to in a crisscross pattern.

With the special tool inserted, press end caps in the direction of the arrow to
adjust the axial clearance.
Specification
Rocker arm - axial clearance
Feeler gauge (59029041100) (

0.02 0.10mm (0.0008


0.0039in)
P. 209)

Mount screws with a new seal ring and tighten.


Specification

600351-10

Screw on cylinder head top section

Remove the special tool.

M6x55 10.9

10Nm (7.4lbfft)

30/ASSEMBLING THE ENGINE

135

Installing the timing chain tensioner


20.15

With timing chain tensioner in the installation position, install it with a new seal.
Mount and tighten screws.
Specification
Screw, timing-chain tensioner

M6

10Nm (7.4lbfft)

Mount and tighten spring with seal ring and screw.


Specification
Plug, timing chain tensioner

M8

10Nm (7.4lbfft)

600352-10

Installing the rotor


20.16

Ensure that spring washer is seated properly.

Degrease the cone of the crankshaft and rotor.

Mount rotor. Mount spring washer and nut. Tighten the nut.

600354-10

Specification
Ignition rotor nut

M12x1

60Nm
(44.3lbfft)

600355-10

Checking the valve clearance


20.17

Unscrew special tool by several turns.

Crank the engine several times.

Set the engine to ignition top dead center again and screw in special tool.
Crankshaft locking bolt (113080802) (

P. 207)

600210-11

On all valves, check valve clearance between the valve and rocker arm using special
tool.
Specification
Valve clearance, cold, intake

0.10 0.15mm (0.0039


0.0059in)

Valve clearance, cold, exhaust

0.10 0.15mm (0.0039


0.0059in)

Feeler gauge (59029041100) (


600353-11

P. 209)

If valve clearance does not meet specifications:

Adjust the valve clearance. (

P. 136)

30/ASSEMBLING THE ENGINE

136

Adjusting the valve clearance


20.18

Set the valve clearance by turning adjusting screw between the valve and rocker
arm using special tool.
Specification
Valve clearance, cold, intake

0.10 0.15mm (0.0039


0.0059in)

Valve clearance, cold, exhaust

0.10 0.15mm (0.0039


0.0059in)

Nut, adjusting screw, valve clearance

M6x0,75

11Nm (8.1lbfft)

600353-10

Installing the valve cover


20.19

Clean the sealing areas.

Position valve cover with the seal. Mount and tighten the screws.
Specification
Screw, valve cover

M6

10Nm (7.4lbfft)

600356-10

Installing the water pump cover


20.20

Clean the sealing areas.

Position water pump cover with the seal.

Mount and tighten screws.


Specification
Screw, water pump cover

M6

10Nm (7.4lbfft)

600219-11

Installing the oil line


20.21

Position oil line.

Mount and tighten banjo bolt and jet screw with the seal rings.
Specification
Banjo bolt, oil line

M8

10Nm (7.4lbfft)

Jet screw, oil line

M8

10Nm (7.4lbfft)

600218-11

Installing the spark plug


20.22

Mount and tighten the spark plug using special tool.


Specification
Spark plug
Spark plug wrench (75029172000) (

600207-10

M12x1,25
P. 210)

17Nm
(12.5lbfft)

30/ASSEMBLING THE ENGINE

137

Installing the primary gear with the free-wheel-gear


20.23

Ensure that spring washer is seated properly.

Oil the free-wheel in the primary gear.

Slide the primary gearwith the free-wheel onto free-wheel-gear and mount them
both on the crankshaft.

600357-10

Info
The free-wheel-gear must rotate counterclockwise when it is mounted.

Mount and tighten nut.


Specification

600358-10

Nut, primary gear

M20LHx1,5

150Nm
(110.6lbfft)

Loctite 243

Installing the oil pumps


20.24

Mount external rotor and internal rotor with marking facing inward.
The marking should not be visible after installation.

Fill the oil pump with engine oil.

Insert pin in the second drill hole of the oil pump shaft.

Insert the oil pump shaft into the engine case. Ensure that the pin engages in the
internal rotor.

Position oil pump cover. Mount and tighten screws.

600359-10

600360-10

Specification
Screw, oil pump cover

600361-10

M5

Insert the long pin into the oil pump shaft.

6Nm
(4.4lbfft)

Loctite 222

30/ASSEMBLING THE ENGINE

138

Position oil pump gear and washer. Mount shaft retainer.

Mount external rotor and internal rotor with marking facing inward.

Fill the oil pump with engine oil.

Insert pin.

Position oil pump cover. Mount and tighten screws.

600362-10

The marking should not be visible after installation.

600363-10

Specification
Screw, oil pump cover

M5

6Nm
(4.4lbfft)

Loctite 222

6Nm
(4.4lbfft)

Loctite 243

600364-10

Installing the ignition pulse generator


20.25

Position the ignition pulse generator.

Mount and tighten screws.


Specification
Screw, ignition pulse generator

Position the cable and insert cable support sleeve into the engine case.

Mount centering pins.

600365-10

Installing the generator cover


20.26

600367-11

M5

30/ASSEMBLING THE ENGINE

139

Mount the generator cover seal.

Position generator cover. Mount and tighten screws.


Specification
Screw, generator cover

M8

10Nm (7.4lbfft)

600366-10

Installing the gear sensor


20.27

Insert contact bolts with the springs.

Position gear sensor with the O-ring and abutment plate.

Mount and tighten screws.

600369-10

Specification
Screw, gear sensor

M5

6Nm
(4.4lbfft)

Loctite 243

600368-10

Installing the locking shaft lever


20.28

Position locking shaft lever. Mount and tighten screw with the washer.
Specification
Screw, locking shaft lever

M5

6Nm
(4.4lbfft)

Loctite 243

600370-10

Installing the locking lever


20.29

Mount locking lever with washer, sleeve and spring.

Mount and tighten screw.


Specification
Screw, locking lever

600371-10

M5

6Nm
(4.4lbfft)

Loctite 243

30/ASSEMBLING THE ENGINE

140

Installing the shift drum locating


20.30

Push locking lever away from the shift drum locatingand position shift drum
locating.

Info
The flat surfaces of the shift drum locating are not symmetric.

Release the locking lever.

Mount and tighten screw.


Specification

600372-10

Screw, shift drum locating

M6

10Nm
(7.4lbfft)

Loctite 243

Installing the shift shaft


20.31

Slide the premounted shift shaft with the washer into the bearing seat.

Press the sliding plate away from the shift drum locating. Insert the shift shaft all
the way.

Let the sliding plate engage in the shift drum locating.


The ends of the return spring must be in contact with the engine housing projection.

600373-10

Installing the starter idler gear/torque limiter


20.32

Slide on starter idler gear with the recess facing outward.

Slide on washer. Mount lock ring.

Insert the bearing bolt.

Mount both needle bearings. Slide on torque limiter.

Remove special tool.

600374-10

600375-10

Removing the crankshaft locking bolt


20.33

Crankshaft locking bolt (113080802) (

P. 207)

Mount screw with a new seal and tighten.


Specification
Plug, crankshaft location

600384-10

M8

10Nm (7.4lbfft)

30/ASSEMBLING THE ENGINE

141

Installing the outer clutch hub and clutch discs


20.34

Mount washer and both needle bearings.

Mount outer clutch hub and insert the two half washers into the main shaft
with grease.

Position stepped washer with the recess facing the half washers.

Slide on inner clutch hub. Position the new lock washer and mount nut.

Mount the inner clutch hub sleeves and attach special tool.

600376-10

600377-10

600378-10

600379-10

Clutch holder (59029003100) (

P. 208)

Tighten nut.
Clutch holder (59029003100) (

P. 208)

Secure the nut with lock washer.

Remove the special tool.

Thoroughly oil clutch facing discs.

Beginning with a thin clutch disc, place all further clutch facing discs and clutch
discs alternately into the outer clutch hub.

600380-10

bl

Info
The two outer clutch discs are thinner than the four inner clutch
discs.

bm

bn

bm

600439-01

30/ASSEMBLING THE ENGINE

142

Insert pressure piece.

Mount the pressure cap. Mount screws with washers and springs. Tighten all
screws in a crisscross pattern.

600381-10

Specification
Screw, clutch spring

M6

8Nm
(5.9lbfft)

Loctite 243

600382-10

Installing the clutch cover


20.35

Clean the sealing areas.

Mount centering pin.

Mount dowels. Mount the new clutch cover seal.

Fill hole of crankshaft with engine oil.

600385-10

Specification
30ml (1.01fl.oz.)

Ensure that oil jet is not closed.

Mount the clutch cover. Position spring holder. Mount and tighten screws.

600386-10

Specification
Screw, clutch cover

600387-10

M6

10Nm (7.4lbfft)

30/ASSEMBLING THE ENGINE

143

Installing the starter motor


20.36

Grease the O-ring. Mount starter motor.


Long-life grease (

P. 205)

Mount and tighten screw.


Specification
Screw, starter engine

M6

10Nm (7.4lbfft)

600388-10

Installing the oil drain plug


20.37

Mount oil drain plug with seal ring and tighten it.
Specification
Oil drain plug with magnet

M12x1,5

20Nm
(14.8lbfft)

600393-10

Installing the oil screen


20.38

Oil the O-rings, mount them on oil screen and using a long hexagon socket
wrench insert them carefully until the O-ring is seated in the housing with the oil
screen.

Mount plug with the seal ring and tighten.

600391-10

Specification
Locking screw, oil sieve, long

M20x1,5

15Nm
(11.1lbfft)

Insert oil screen with the O-rings into plug and tighten.
Specification
Locking screw, oil sieve,
short

M16x1,5

10Nm
(7.4lbfft)

lubricated with
engine oil

600392-10

Mounting the oil filter


20.39

600389-10

Tilt the engine sideways and fill the oil filter housing about full with engine oil.

Fill the oil filter with engine oil and place it in the oil filter container.

30/ASSEMBLING THE ENGINE

144

Oil the O-rings of oil filter covers and mount them with the oil filter covers.

Mount and tighten screws.


Specification
Screw, oil filter cover

M5

6Nm (4.4lbfft)

600390-10

Filling up with engine oil


20.40

Remove screw cap on the clutch cover and fill up with engine oil.
Engine oil

2.00l (2.11qt.)

External temperature: 0C
(32F)

Engine oil
(SAE 10W/50)
( P. 203)

External temperature: <0C


(<32F)

Engine oil
(SAE 5W/40)
( P. 203)

Mount and tighten screw cap.

Position shift lever. Mount and tighten screw with washers.

600187-11

Installing the shift lever


20.41

Specification
Screw, shift lever

M6

10Nm
(7.4lbfft)

600394-10

Installing the clutch push rod


20.42

Insert clutch push rod.

600395-10

Removing the engine from the universal mounting rack


20.43

Remove the screw/nut from the special tool.


Engine holder (83112001050) (

600441-01

P. 215)

Remove the engine from the universal mounting rack.

Loctite 243

31/CARBURETOR

145

31/CARBURETOR
21

Choke

21.1

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.

100014-10

Possible states
Choke function activated The choke lever is pulled out to the stop.
Choke function deactivated The choke lever is pushed in to the stop.

Hot start button


21.2

The hot start button (red) is fitted on the left side of the carburetor.
Activating the hot start function frees an opening in the carburetor through which the
engine can draw extra air. This gives a leaner fuel-air mixture, which is needed for a
hot start.

Info
If the engine is cold, the hot start function must be deactivated.

100015-10

Possible states
Hot start function activated The hot start button is pulled out to the stop.
Hot start function deactivated The hot start button is pushed in as far as possible.

Removing the carburetor


21.3

Remove the fuel tank. (

Remove the air filter box lid with the carburetor connection boot. (

Unplug the connector of theTPS throttle valve sensor.

Remove screw. Take off the holder for the carburetor vent hoses.

Pull engine breather hose off of the carburetor.

P. 53)

600158-10

600442-10

600159-10

P. 51)

31/CARBURETOR

146

Undo hose clip.

Take carburetor out of the frame toward the rear and set it on the frame.

Remove screws. Remove carburetor cover.

Loosen nut. Detach the gas Bowden cable and hang it to one side.

Remove the carburetor.

Remove the carburetor. (

Remove screws and detach all vent hoses from the carburetor.

Remove screws. Take off the throttle slide cover and seal.

600160-10

600161-10

600162-10

600163-10

Disassembling the carburetor


21.4

P. 145)

700034-10

700035-10

31/CARBURETOR

147

Remove screw with the spring and washer.

Pull the jet needle out of the throttle slide.

Remove screw.

Pull up throttle slide arm. Take throttle slide out of the carburetor along with
throttle slide roller and the throttle slide plate.

Remove screws. Take off the accelerator pump cover with the seal ring.

Remove seal rings, spring and membrane.

Remove screws and take off the float chamber body.

Remove fulcrum pin. Take off the float and float needle valve.

Remove main jet.

Remove idling jet, cold start jet, needle jet and buffer plate.

Screw in mixture control screw to the stop, counting and noting down the number of rotations.

Remove the mixture control screw with the spring, washer and O-ring.

600444-10

700037-10

700038-10

700039-10

700044-12

700045-12

31/CARBURETOR

148

Screws should not be removed.

Remove screw. Pull the hose connector out of the carburetor.

Remove screw. Take off throttle valve sensor.

700046-11

700047-12

Info
Only remove the throttle valve sensor if necessary. If screw is loosened,
the throttle valve sensor must be readjusted.

Screw out the choke slide and hot start slide.

Remove idle air jet.

Clean all jets and other parts thoroughly and blow out with compressed air.

600398-11

Carburetor cleaner (

Clean the carburetor housing and blow out all channels in the carburetor with compressed air.
Carburetor cleaner (

700049-12

P. 205)

P. 205)

Info
Do not use nitro thinner to clean the carburetor.

31/CARBURETOR

149

Checking/adjusting the carburetor components


21.5

600397-02

Disassemble the carburetor. (

Check/adjust the accelerator pump. (

Check the hot start slide. (

Check the choke slide. (

Check the jet needle. (

Check the throttle slide. (

Check the needle jet. (

Check the float needle valve. (

Check/adjust the float level. (

Check/adjust the throttle slide opening. (

Check the throttle valve sensorTPS. (

Assemble the carburetor. (

P. 146)
P. 149)

P. 150)
P. 150)

P. 150)
P. 151)
P. 151)
P. 151)
P. 153)
P. 153)

P. 152)

P. 153)

Checking/adjusting the accelerator pump


21.6

Check the membrane for damage and brittleness.

If the membrane is damaged or brittle:

Change the membrane.

Check that bores are clear.

If the bores are not clear:

Clean the bores.


Carburetor cleaner (

700051-10

P. 205)

31/CARBURETOR

150

Check/adjust the throttle slide opening. (

P. 153)

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.

Check piston rod overhang.


Specification
Piston rod overhang

700065-10

0.9 1.0mm (0.035 0.039in)

If piston rod overhang does not equal the specified value:

Correct the piston rod overhang by turning adjusting screw.

Carburetor - adjust the idle speed. (

Check the hot start slide for smooth operation.

P. 157)

Checking the hot start slide


21.7

If the hot start slide cannot be moved easily or is soiled:

Clean the hot start slide.


Carburetor cleaner (

The piston of the hot start slide should not be damaged.

If the piston of the hot start slide is damaged or worn:

600400-01

P. 205)

Change the hot start slide.

Check the rubber sleeve and lock.

If the rubber sleeve is damaged or brittle, or if the lock does not function:

Change the hot start slide.

Checking the choke slide


21.8

Check the choke slide for smooth operation.

If the choke slide cannot be moved easily or is soiled:

Clean the choke slide.


Carburetor cleaner (

The piston of the choke slide should not be damaged.

If the piston of the choke slide is damaged or worn:

600399-01

P. 205)

Change the choke slide.

Check the rubber sleeve and lock.

If the rubber sleeve is damaged or brittle, or if the lock does not function:

Change the choke slide.

Checking the jet needle


21.9

Check the jet needle for bending and wear of the coating.

If the jet needle is bent or the coating is damaged or worn:

Check that the needle clip is tight.

If the needle clip is not tight:

700052-10

Change the jet needle.

Change the needle clip or the jet needle.

31/CARBURETOR

151

Checking the throttle slide


21.10

Check the throttle slide rollers for damage and wear.

If the throttle slide rollers do not turn easily, are worn or have flat areas:

Except for throttle slide roller (removable), all rollers must rest flush against the
throttle slide.

If the throttle slide rollers are loose:

700055-10

If the coating is damaged or worn:

Change the throttle slide.

Check membrane of the throttle slide plate for damage, brittleness and tightness.

If the membrane is damaged or brittle:

Change the throttle slide.

Check the coating of the throttle slide and throttle slide plate for damage and
wear.

Change the throttle slide.

Change the membrane.

Check that membrane is seated properly.

If the membrane is not seated properly:

Position the membrane correctly.

700056-10

Checking the needle jet


21.11

Use a new jet needle as a gauge. Apply a marking on the jet needle above
step at a distance of.
Specification
Distance

3mm (0.12in)

Info
The marking should come off completely when cleaned away.
700053-10

Insert the marked jet needle into the needle jet being tested. Push the two pieces
together carefully.

Check the needle jet.

If marking on the jet needle is not visible on top edge of the needle jet:

Change the needle jet.

700054-10

Checking the float needle valve


21.12

Check the float needle valve including the valve seat for deposits or wear.

If there are deposits or wear:

Clean the valve seat. Clean or change the float needle valve.
Carburetor cleaner (

Check the float needle valve for wear and the sealing areas of indentations.

If the sealing area is damaged or if there is wear:

700057-10

P. 205)

Change the float needle valve.

31/CARBURETOR

152

Checking the throttle valve sensorTPS


21.13

Info
The value in the figure is an example only!

Remove the carburetor. (

Check the throttle slide. (

P. 145)
P. 151)

Condition
Component temperature: 20C (68F)

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 sensorTPS.
Measure the total resistanceRtot of the throttle valve sensor.
Specification
Total resistanceRtot of the throttle
valve sensor

4 6k

700063-10

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 sensorTPS.

Slowly open the throttle slide and measure the variable resistanceRvar of the
throttle valve sensor.
Variable resistanceRvar of the throttle valve sensor (throttle slide fully
opened)

If the value does not increase smoothly:

700064-10

Change throttle valve sensorTPS.

If the value is outside of the specification:

3 4.5k

Adjust the position of throttle valve sensorTPS. (

Install the carburetor. (

P. 152)

P. 156)

Adjusting the position of throttle valve sensorTPS


21.14

Info
The value in the figure is an example only!

Remove the carburetor. (

Check/adjust the throttle slide opening. (

P. 145)
P. 153)

Conditions
Component temperature: 20C (68F)

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 sensorTPS.
Measure the total resistanceRtot of the throttle valve sensor.
Specification
Total resistanceRtot of the throttle
valve sensor

4 6k

700063-10

700064-10

Multiply the total resistanceRtot of the throttle valve sensor by 0.17. This generates the variable resistanceRvar for the setting of the throttle valve sensor.

Rtot x 0.17 = Rvar (tolerance0.05k)

31/CARBURETOR

153

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 sensorTPS.

Measure the variable resistanceRvar of the throttle valve sensor.

Info
The throttle slide must be in the neutral position.

700066-10

Loosen screw. Set throttle valve sensorTPS by turning it to the calculated


value.

Tighten screw.
Specification
Screw, throttle valve sensor

3.5Nm
(2.58lbfft)

Check the variable resistanceRvar of the throttle valve sensor again.

If the measured value is not equal to the calculated value:

M5

Repeat the adjustment procedure.

Install the carburetor. (

P. 156)

Checking/adjusting the throttle slide opening


21.15

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.

Remove the carburetor. (

Check the throttle slide opening using a wire or a drill shank.

P. 145)

Throttle slide opening

1mm (0.04in)

If the throttle slide opening does not equal the specified value:

Adjust the throttle slide opening with adjusting screw.

700062-10

Checking/adjusting the float level


21.16

Hold the carburetor at a slant, securing the pin against falling out of the float.

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:

Adjust the float level by bending float lever.

700061-10

Assembling the carburetor


21.17

Mount and tighten idle air jet.


Specification
Idle air jet
Idle air jet(100)

700049-11

M4,5x0.75

2Nm (1.5lbfft)

31/CARBURETOR

154

Mount and tighten the choke slide and hot start slide.
Specification
Choke slide

M12

2.5Nm
(1.84lbfft)

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.

600398-10

Position the hose connection. Mount and tighten screw.


Specification
Screw, hose connection

M4

2Nm
(1.5lbfft)

Loctite 243

Info
The hose connection must be easy to turn when it is mounted.
700047-11

Screw in mixture control screw together with the spring, washer and O-ring to
the stop.
Specification
Mixture control screw

M6x0.5

1Nm (0.7lbfft)

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

700045-11

Open

1.0turn

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.

Position buffer plate. Mount and tighten needle jet, cold start jet and
idling jet.
Specification
Needle jet

M7x0.75

3.5Nm
(2.58lbfft)

Cold start jet

M5x0.75

2Nm (1.5lbfft)

Idling jet

M6x0.75

2Nm (1.5lbfft)

M5x0.75

2Nm (1.5lbfft)

Cold start jet(85)


(450 XC ATV)
Idling jet(40)
(525 XC ATV)
Idling jet(42)

Mount and tighten main jet.


Specification
Main jet
Main jet(170)

700044-11

Position the float and float needle valve, and mount fulcrum pin.

Check/adjust the float level. (

P. 153)

31/CARBURETOR

155

Position the float chamber and adjustment screw.

Mount screws but do not tighten them yet.

Insert throttle slide with throttle slide roller and the throttle slide plate into
throttle slide arm and position them in the carburetor.

Position the needle clip on the jet needle.

700067-10

Specification
Needle position (450 XC ATV)

2nd position from top

Needle position (525 XC ATV)

3rd position from top

Jet needle(OBEKR)
700037-12

Insert the jet needle.

Mount and tighten screw with the spring and washer.


Specification
Needle screw

M8

3.5Nm
(2.58lbfft)

Mount and tighten screw.


Specification
Screw, throttle slide arm

M4

2Nm
(1.5lbfft)

Loctite 243

600444-11

Position the throttle slide cover with the seal. Mount and tighten screws.
Specification
Other screws, carburetor

M4

Check/adjust the throttle slide opening. (

Check/adjust the accelerator pump. (

Position seal ring, membrane and spring.

2Nm (1.5lbfft)

P. 153)

700035-12

P. 149)

Info
The label on the membrane must be visible when mounted.

700060-10

700059-10

Position seal ring in the accelerator pump cover with the rounded side facing
outward.

31/CARBURETOR

156

Position the accelerator pump cover. Mount and tighten screws.


Specification
Other screws, carburetor

M4

2Nm (1.5lbfft)

700038-12

Position and mount the vent hoses.

Position the hose holder. Mount the screws and tighten all screws in a crisscross
pattern.
Specification
Other screws, carburetor

M4

2Nm (1.5lbfft)

Adjust the position of throttle valve sensorTPS. (

Install the carburetor. (

Set the carburetor on the frame and attach the gas Bowden cable.

P. 152)

P. 156)

700034-12

Installing the carburetor


21.18

Info
Ensure that the gas Bowden cable has been laid correctly.

Adjust the gas Bowden cable play and tighten nut.


Specification
Play in gas Bowden cable

3 5mm (0.12 0.2in)

600163-11

Position carburetor cover. Mount and tighten screws.


Specification
Other screws, carburetor

600162-11

Insert carburetor into the rubber sleeve.

Position hose clamp and tighten.

600161-11

600160-11

M5

5Nm (3.7lbfft)

31/CARBURETOR

157

Attach engine breather hose to the carburetor.

Info
Ensure that the engine breather hose has been laid correctly.

600159-11

Attach connector of throttle valve sensorTPS.

Lay the engine breather hose toward the bottom and secure with a retaining
bracket. Mount and tighten screw.

600158-11

Specification
Screw, vent hose bracket

M6

10Nm
(7.4lbfft)

Loctite 243

Install the air filter box lid and the carburetor connection boot. (

Install the fuel tank. (

Check play in the gas Bowden cable. (

Screw in the idle adjusting screw until it stops and then to the prescribed basic
setting.

P. 51)

P. 54)
P. 16)

600442-11

Carburetor - adjusting idle


21.19

Specification
Idle mixture adjusting screw
Open

1.0turn

Adjustment tool for mixture control screw (59029034000) (

P. 209)

Run the engine until warm.


Specification

600145-10

Warm-up time

5min

Adjust the idle speed with the adjusting screw.


Specification
Choke function deactivated The choke lever is pushed in to the stop.
( P. 145)
Idle speed

1,500 1,600rpm

Info
If the idle speed is set significantly higher, the engine does not start. When
the electric starter button is activated, the electric starter turns over the
engine, but the engine does not start because there is no ignition spark.

Turn the idle adjusting screw slowly until the idle speed begins to fall.

Note the position and turn the idle adjusting screw slowly counterclockwise until
the idle speed falls.

31/CARBURETOR

158

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.

Adjust the idle speed with the adjusting screw.


Specification
Choke function deactivated The choke lever is pushed in to the stop.
( P. 145)
Idle speed

1,500 1,600rpm

Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.

Checking the throttle valve sensor position


21.20

Remove the fuel tank. (

Unplug the connector of throttle valve sensor TPS.

Connect the special tool to both plug-in connectors.

P. 53)

600401-10

Adapter cable (83029043000) (

P. 215)

Switch on the ignition.

Connect the positive cable of the multimeter to the yellow cable and the ground
wire to the black cable of the special tool. Measure the throttle valve sensor voltage.
Variable throttle valve sensor
voltageVvar (throttle slide closed)

600403-10

If the specified value is not reached:

Carburetor - adjust the idle speed. (

Adjust the position of throttle valve sensorTPS. (

P. 157)
P. 152)

If the specified value is reached:

Switch off the ignition.

Remove the special tool.


Adapter cable (83029043000) (

0.505 0.855V

P. 215)

Attach the connector of the throttle valve sensorTPS.

Install the fuel tank. (

P. 54)

31/CARBURETOR

159

Emptying the carburetor float chamber


21.21

Danger
Fire hazardFuel can easily catch fire.

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.

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 poisoningFuel is poisonous and a health hazard.

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 hazardImproper handling of fuel is a danger to the environment.

Do not allow fuel to get into the ground water, the ground, or the sewage system.

Info
Carry out this work with a cold engine.

Turn the handle of the fuel tap toOFF. (Figure100013-10

Guide the hose coming down behind the engine into a suitable container.

P. 55)

No more fuel flows from the tank to the carburetor.

Info
Water in the float chamber results in malfunctioning.

100051-10

Undo the screw (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.

Tighten screw.

32/CLUTCH

160

32/CLUTCH
22

Checking fluid level of hydraulic clutch


22.1

Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.

Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

Remove screws.

Remove cover with membrane.

Check the fluid level.


Fluid level under top level of container.

If the level of the cooling liquid does not meet specifications:

100037-10

4mm (0.16in)

Correct the fluid level of the hydraulic clutch.


Hydraulic fluid (15) (

P. 204)

Check parts for damage and wear. Replace damaged or worn parts.

Position the cover with the membrane. Mount and tighten screws.

33/TRANSMISSION

161

33/TRANSMISSION
23

Removing the engine sprocket

23.1

Remove screws and. Take off engine sprocket cover.

Press the rear brake and remove screw with spring washer.

Pull engine sprocket with chain off of the countershaft. Remove the engine
sprocket.

With the collar facing the engine, mount engine sprocket in the chain and
slide both onto the countershaft.

Press the rear brake. Mount and tighten screw with spring washer.

600164-10

600165-10

Installing the engine sprocket


23.2

Specification
Screw, engine sprocket

M10

60Nm
(44.3lbfft)

Loctite 243

600165-11

Position engine sprocket cover. Mount and tighten screws.


Specification

600164-11

Slave cylinder of the clutch on engine


case

M6

10Nm (7.4lbfft)

Remaining screws, chassis

M8

25Nm
(18.4lbfft)

35/WATER PUMP, COOLING SYSTEM

162

35/WATER PUMP, COOLING SYSTEM


24

Checking antifreeze and coolant level

24.1

Warning
Danger of scaldingThe coolant gets very hot and is under high pressure when the vehicle is driven.

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 poisoningCoolants are poisonous and a health hazard.

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.

Remove the front trim. (

Remove the radiator cap.

Check antifreeze of coolant.

P. 56)

25 45C (13 49F)

If the antifreeze of the cooling liquid does not meet specifications:

Correct antifreeze of coolant.

Completely fill the radiator with coolant and close the radiator cap.

Open the compensating tank cover.

Check antifreeze of coolant.

600123-12

25 45C (13 49F)

If the antifreeze of the cooling liquid does not meet specifications:

The coolant level must be between MIN andMAX.

If the level of the cooling liquid does not meet specifications:

600125-12

Correct antifreeze of coolant.

Correct the coolant level.


Alternative 1
Coolant (

P. 204)

Alternative 2
Coolant (mixed ready to use) (

P. 204)

Mount the compensating tank cover.

Install the front trim. (

P. 57)

Checking the coolant level


24.2

Warning
Danger of scaldingThe coolant gets very hot and is under high pressure when the vehicle is driven.

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 poisoningCoolants are poisonous and a health hazard.

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.

35/WATER PUMP, COOLING SYSTEM

163

Condition
The radiator must be completely full.

The coolant level must be between MIN andMAX.

If the level of the cooling liquid does not meet specifications:

Open the compensating tank cover and correct the coolant level.
Alternative 1
Coolant (

P. 204)

Alternative 2

600125-11

Coolant (mixed ready to use) (

P. 204)

Mount the compensating tank cover.

Draining coolant
24.3

Warning
Danger of scaldingThe coolant gets very hot and is under high pressure when the vehicle is driven.

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 poisoningCoolants are poisonous and a health hazard.

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.

Remove the front trim. (

Place a suitable container under the vehicle.

Remove screw.

Remove screw.

Remove the radiator cap. Completely drain the coolant.

P. 56)

600118-10

600119-10

600123-11

35/WATER PUMP, COOLING SYSTEM

164

Open the plug of the compensation tank.

Remove the screws and empty the compensating tank.

Check parts for damage and wear. Replace damaged or worn parts.

Position the compensating tank. Mount and tighten screws.


Specification
Remaining screws, chassis

600124-10

M6

10Nm (7.4lbfft)

Move the ventilation hose up.

Mount and tighten the screws and with new seal rings.
Specification
Remaining screws, chassis

M6

10Nm (7.4lbfft)

Filling coolant / bleeding cooling system


24.4

Warning
Danger of poisoningCoolants are poisonous and a health hazard.

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.

Position the vehicle as shown and secure it against rolling away. The height difference must be achieved.
Specification
Height difference

0
A

50cm (19.7in)

Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure100006-10 P. 74)
The front wheels are blocked.

400360-10

Fill the coolant into the radiator.


Coolant
With compensating tank

1.50l (1.59qt.)

Without compensating tank

1.30l (1.37qt.)

P. 204)

Coolant (mixed ready to use)


( P. 204)

600120-10

Coolant (

Coolant (

P. 204)

Coolant (mixed ready to use)


( P. 204)

Open the screw to bleed the cylinder head. Tighten the screw when coolant
emerges from the opening.
Specification
Remaining screws, chassis

M6

10Nm (7.4lbfft)

Info
Ensure that the radiator is always filled with a sufficient amount of coolant.
600121-10

Open the screw to bleed the radiator. Tighten the screw when coolant
emerges from the opening.
Specification
Remaining screws, chassis

600122-10

M6

10Nm (7.4lbfft)

35/WATER PUMP, COOLING SYSTEM

165

Completely fill the radiator and close the radiator cap.

Top up the compensating tank to level. Mount the cap.

Install the front trim. (

Make a short test ride.

Check the coolant level. (

600123-10

600125-10

P. 57)
P. 162)

38/LUBRICATION SYSTEM

166

38/LUBRICATION SYSTEM
25

Changing engine oil and oil filter, cleaning oil screens

25.1

Drain engine oil, clean oil screens. (

Remove the oil filter. (

Mount the oil filter. (

Fill up with engine oil. (

P. 166)

P. 167)
P. 168)
P. 168)

Draining engine oil, cleaning oil screens


25.2

Warning
Danger of scaldingEngine oil and gear oil get very hot when the vehicle is driven.

Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning
Environmental hazardProblem materials cause environmental damage.

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.

Park the vehicle on a horizontal surface.

Remove the engine guard. (

Place a suitable container under the engine.

Remove the oil drain plug.

Remove the plug screw and small oil screen with both O-rings.

Remove the plug screw and large oil screen with both O-rings.

Completely drain the engine oil.

P. 18)

600134-10

600135-10

600136-10

38/LUBRICATION SYSTEM

167

Check parts for damage and wear. Replace damaged or worn parts.

Thoroughly clean parts and sealing area.

Oil the O-rings, mount them on the oil screen and using a long hexagon key
insert them until the O-ring is seated in the housing with the oil screen.

Fit the plug screw with seal ring and tighten it.
Specification
Locking screw, oil sieve, long

M20x1,5

15Nm
(11.1lbfft)

600144-10

Insert the oil screen with the O-rings into the plug screw and tighten.
Specification
Locking screw, oil sieve,
short

M16x1,5

10Nm
(7.4lbfft)

lubricated with
engine oil

600140-10

Fit oil drain plug with seal ring and tighten it.
Specification
Oil drain plug with magnet

Install the engine guard. (

M12x1,5

20Nm
(14.8lbfft)

P. 18)

600134-11

Removing the oil filter


25.3

Warning
Danger of scaldingEngine oil and gear oil get very hot when the vehicle is driven.

Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning
Environmental hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

600137-10

Place a suitable container under the engine.

Disconnect the ground cable from the engine.

Remove screws and. Take off the oil filter cover with the O-ring.

38/LUBRICATION SYSTEM

168
Pull the oil filters and out of the engine housing.
Circlip pliers reverse (51012011000)

Completely drain the engine oil.

Thoroughly clean parts and sealing area.

Check parts for damage and wear. Replace damaged or worn parts.

Fill the oil filters and with engine oil and place in the oil filter container.

Oil the O-rings of the oil filter covers and mount them with the oil filter covers.
Mount and tighten screws and.

600138-10

Mounting oil filter


25.4

600147-10

Specification
Screw, oil filter cover

M5

6Nm (4.4lbfft)

Connect the ground cable on the engine and tighten the screw.
Specification
Screw, starter engine

M6

10Nm (7.4lbfft)

600137-10

Filling up with engine oil


25.5

Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.

Remove the screw cap on the clutch cover and fill up with engine oil.
Engine oil

600132-10

2.00l (2.11qt.)

External temperature: 0C
(32F)

Engine oil
(SAE 10W/50)
( P. 203)

External temperature: <0C


(<32F)

Engine oil
(SAE 5W/40)
( P. 203)

Mount and tighten screw cap.

Danger
Danger of poisoningExhaust 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.

Start the engine and check that it is oil-tight.


Specification
Switch off the engine when the radiator fan switches on.

Check the engine oil level. (

P. 169)

38/LUBRICATION SYSTEM

169

Checking engine oil level


25.6

Info
The engine oil level can be checked on a cold or hot engine.

Park the vehicle on a horizontal surface.

Condition
The engine is at operating temperature.

Check the engine oil level.

Info
After switching off the engine, wait one minute before checking the
level.
The engine oil reaches the middle of the viewer.
600131-10

When the engine oil does not reach the middle of the viewer:

Top up the engine oil. (

P. 169)

Condition
Engine is cold.

Check the engine oil level.


The engine oil reaches the bottom of the viewer.

When the engine oil does not reach the bottom of the viewer:

Top up the engine oil. (

P. 169)

600131-11

Topping up engine oil


25.7

Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.

Check the engine for leakage.

Remove the screw cap on the clutch cover and fill up with engine oil.
Condition
External temperature: 0C (32F)
Engine oil (SAE 10W/50) (

P. 203)

Condition
External temperature: <0C (<32F)
Engine oil (SAE 5W/40) (

600132-10

P. 203)

Info
To ensure optimal engine oil performance, it is advisable to not use different
engine oils.
We recommend making an oil change in this case.

Mount and tighten screw cap.

39/IGNITION SYSTEM

170

39/IGNITION SYSTEM
26

Checking the generator

26.1

Remove the fuel tank. (

Disconnect the electric plug-in connector of the stator coil.

Using a multimeter, measure the stator coil on connector.

P. 53)

600408-10

Stator coil - resistance

black - black

0.0 1.0

Ground - black

If the displayed value does not correspond to the nominal value:

Change the stator.

600407-10

Checking the ignition pulse generator


26.2

Remove the fuel tank. (

Disconnect the plug-in connector of the ignition pulse generator coil to the CDI
unit.

On ignition pulse generator, use a multimeter to measure the resistance of the


ignition pulse generator coil.

P. 53)

Pulse generator

600432-10

red - green

80 120

Ground - red

If the displayed value does not correspond to the nominal value:

Change the ignition pulse generator.

Checking the ignition coil


26.3

Condition
All plug connectors must be in corrosion-free condition and the plug-in connectors
must be tight-fitting.

Remove the radiator spoiler. (

Remove the spark plug connector.

Use a multimeter to measure the primary coil value.

P. 52)

Primary coil
ground - ignition coil input at:
20C (68F)

If the measured value differs from the nominal value:

600456-10

0.25 0.35

Change the ignition coil.

39/IGNITION SYSTEM

171

Use a multimeter to measure the secondary coil value.


Secondary coil
ignition coil - ignition coil input at:
20C (68F)

5.0 7.5k

If the measured value differs from the nominal value:

Change the ignition coil.

600434-01

Use a multimeter to check the power supply of the ignition coil. Measurement
between the positive terminal of the battery and the unplugged connector of the
ignition coil.
Battery voltage
unloaded:

600476-01

12.4 12.8V

If the measured value differs from the nominal value:

Check the battery voltage. (

Check the wiring harness.

P. 72)

Checking the spark plug connector


26.4

Use a multimeter to measure the disconnected spark plug connector.


Spark plug connector
at component temperature: 25C
(77F)

If the displayed value does not correspond to the nominal value:

700085-01

3.75 6.25k

Change the spark plug connector.

61/ATV FRONT SECTION

172

61/ATV FRONT SECTION


27

Toe, checking
27.1

Park the vehicle on a horizontal surface.

Check the tire condition. (

Checking the tire air pressure. (

Check the chassis parts for damage, play and wear.

Load the vehicle with the specified weight.

P. 59)
P. 59)

Specification
Standard rider weight

70 80kg (154 176lb.)

Turn the steering to the straight-ahead position and fix it.


Steering fixing for straight-ahead position (83019015000) (

P. 211)

500228-01

400333-10

Measure distances and.

If distances and are not equal:

Adjust the toe. (

P. 173)

Measure distances and.


Specification
Toe
Front

0mm (0in)

Info
The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when
driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange.

If the toe does not meet specifications:

Adjust the toe. (

P. 173)

61/ATV FRONT SECTION

173

Adjusting the toe


27.2

Park the vehicle on a horizontal surface.

Check the tire condition. (

Checking the tire air pressure. (

Check the chassis parts for damage, play and wear. Replace damaged or worn
parts.

Load the vehicle with the specified weight.

P. 59)
P. 59)

Specification
Standard rider weight

70 80kg (154 176lb.)

Turn the steering to the straight-ahead position and fix it.


Steering fixing for straight-ahead position (83019015000) (

P. 211)

500228-01

400333-11

Loosen nuts and.

Adjust the distances and to the same value by rotating the tie rods.

Adjust the distances and to the specified value by evenly rotating the tie rods.
Specification
Toe
Front

0mm (0in)

Info
The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when
driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange.

Tighten nuts and.


Specification
Lock nut, tie rod, outside

M12x1,25

20Nm (14.8lbfft)

Lock nut, tie rod, inside

M12LHx1,25

20Nm (14.8lbfft)

Info
The tie rods must still be freely movable.

61/ATV FRONT SECTION

174

Checking/adjusting camber
27.3

Info
The left and right camber should have the same settings.
The operations are the same on the left and right.

Jack up the vehicle. (

Loosen nuts.

Remove screws with bushings.

Check parts for damage and wear. Replace damaged or worn parts.

Insert the tool in the heim joint and clip onto the A-arm.

P. 14)

600128-10

600126-10

Camber gauge (83019014000) (

P. 211)

Check the camber on both heim joints.

If the marking is not aligned with the top edge of the A-arm:

Turn the tool with the heim joint in steps of 180 until the marking is in
line with the top edge of the A-arm.

Remove the tool.

Position the A-arm with the bushings. Mount and tighten screws.

600127-10

Specification
Screw, A-arm top

M10x52

45Nm
(33.2lbfft)

600126-10

Align the heim joint at right angles to the screws and tighten the nut.
Specification
Nut, A-arm top

M12x1,25

30Nm
(22.1lbfft)

Info
All four heim joints must be checked and adjusted if necessary.
600128-10

Remove the vehicle from the work stand. (

P. 14)

61/ATV FRONT SECTION

175

Adjusting the fork offset


27.4

Info
The left and right fork offset should have the same settings.
The operations are the same on the left and right.

Jack up the vehicle. (

Remove screws with bushings.

Check parts for damage and wear. Replace damaged or worn parts.

Place the A-arm with the bushings in the desired position. Mount and tighten
screws.

P. 14)

Specification
Screw, A-arm top

M10x52

Remove the vehicle from the work stand. (

45Nm
(33.2lbfft)

P. 14)

600126-11

Removing the wheel carrier


27.5

Info
The operations are the same on the left and right sides.

Remove the wheel/wheels. (

Remove brake disc guard.

Remove cable clamp and take off brake line guide.

Pull and release the handbrake lever.

P. 59)

600445-10

Locking pawl moves into its basic position, parking brake is deactivated.

Remove screws. Press the brake caliper by hand on to the brake disc in order to
press back the brake piston.

Remove the brake caliper.

Info
600446-10

Do not operate the hand brake lever when the brake caliper has been
removed.

61/ATV FRONT SECTION

176

Unthread the brake caliper.

Hang the brake caliper and the brake line loosely to one side.

Remove nut and take the tie rod out of the wheel carrier.

Remove nuts.

Position special tool. Press the lower ball head out of the wheel carrier.

400401-10

600447-10

600449-10

Push-out tool (83019021000) (

P. 212)

600450-10

600451-10

Turn and position special tool. Press the upper ball head out of the wheel carrier.

Remove the wheel carrier.

61/ATV FRONT SECTION

177

Installing the wheel carrier


27.6

Info
The operations are the same on the left and right sides.

Insert the wheel carrier between the A-arms. Mount and tighten nuts.
Specification
Nut, ball head, A-arm bottom

M12x1,5

40Nm
(29.5lbfft)

Nut, ball head, A-arm top

M10x1,25

35Nm
(25.8lbfft)

600449-11

Insert the tie rod in the wheel carrier. Mount and tighten nut.
Specification
Nut, tie rod end

M10x1,25

45Nm
(33.2lbfft)

600447-11

Thread the brake caliper and position it.

Mount and tighten screws.

400401-11

Specification
Screw, front brake caliper

600446-11

M8

20Nm
(14.8lbfft)

Loctite 243

When both Brake calipers have been mounted, activate the hand brake lever several
times until the brake linings are in contact with brake disc and there is a pressure
point.

61/ATV FRONT SECTION

178

Position brake line guide and secure it with cable clamp.

Info
Note the holding lug of the brake line guide.

Mount brake disc guard.

Mount the wheel/wheels. (

Check the toe. (

P. 60)

P. 172)

600445-11

Removing the A-arms


27.7

Info
The operations are the same on the left and right sides.

Remove the wheel carrier. (

Remove screws and take off upper A-arm.

P. 175)

Info
When removing screws, make sure that bushings remain in place.

600453-10

Remove screw and the shock absorber out of the guide.

Remove screws and take off lower A-arm.

600454-10

Installing the A-arms


27.8

Info
The operations are the same on the left and right sides.

Position lower A-arm. Mount and tighten screws.


Specification
Screw, A-arm bottom

M10x70

45Nm
(33.2lbfft)

Position the shock absorber in the lower A-arm. Mount and tighten screw.
Specification
Screw, front shock absorber

M10

45Nm
(33.2lbfft)

600454-11

Insert tool in the heim joint and clip onto the A-arm.
Camber gauge (83019014000) (

Check the camber on both heim joints.

600127-10

P. 211)

If the marking is not flush with the top edge of the A-arm:

Remove the nuts on the heim joint.

Turn tool with the heim joint in steps of 180 until the marking is in line
with the top edge of the A-arm.

Remove tool.

61/ATV FRONT SECTION

179

Position upper A-arm with bushings. Mount and tighten screws.


Specification
Screw, A-arm top

M10x52

45Nm
(33.2lbfft)

Info
The fork offset is set using the bushings.
600453-11

When the nuts on the heim joint have been released, align the heim joint at right
angles to the screws and tighten nut.
Specification
Nut, A-arm top

M12x1,25

Install the wheel carrier. (

P. 177)

600128-11

A-Arm top - changing the bearing


27.9

Info
The operations are the same on the left and right sides.

Remove the A-arms. (

Remove lock ring.

P. 178)

Circlip pliers reverse (51012011000)

600467-10

Press out ball head using special tool.


Disassembly/assembly holder (83019020150) (

600468-10

Press in the ball head using the special tool.


Press mandrel (83019020130) (
Mounting sleeve (83019020100) (

600469-01

P. 212)
P. 212)

P. 212)

30Nm
(22.1lbfft)

61/ATV FRONT SECTION

180

Mount lock ring.


Circlip pliers reverse (51012011000)

Info
When mounting the lock ring, do not damage the rubber boot.

600467-10

Loosen nuts. Remove heim joint. Screw the nuts off of the heim joints.

Screw the nuts on the new heim joints. Mount the heim joints.

Insert the tool in the heim joint and clip onto the A-arm.

600470-10

600471-10

Camber gauge (83019014000) (

P. 211)

Align marking with the upper edge of the A-arm by rotating the heim joint.

Info
Nuts are tightened when the A-arm is installed.

Install the A-arms. (

600472-10

A-Arm bottom - changing the bearing


27.10

Info
The operations are the same on the left and right sides.

Remove the A-arms. (

P. 178)

P. 178)

61/ATV FRONT SECTION

181

6
7
600457-01

Remove flange adapters and bearing sleeves.

Remove shaft seal rings.

Remove spacing washers.

Info
The spacing washers are only installed at the front pivot point.

Press out needle bearing using the thin long side of the special tool.
Press mandrel (83019020170) (

P. 212)

Press mandrel (83019020130) (

P. 212)

Clean the pivot point.

Press in a new needle bearing on all pivot points using the thick end of the special
tool.

600458-01

Press mandrel (83019020170) (

P. 212)

Info
The needle bearing cannot be pushed through from one side.

600459-01

Grease the needle bearing.

On the front pivot point, insert the two spacing washers.

Install the new shaft seal rings. Lightly grease the sealing lips of the shaft seal
rings.

Mount the bearing sleeves and flange adapters.

61/ATV FRONT SECTION

182

Remove lock ring.


Circlip pliers reverse (51012011000)

600464-10

Press out ball head using the special tool.


Disassembly/assembly holder (83019020150) (

P. 212)

600465-10

Press in the ball head using the special tool.


Press mandrel (83019020130) (

P. 212)

Disassembly/assembly holder (83019020150) (

P. 212)

600466-01

Mount lock ring.


Circlip pliers reverse (51012011000)

Info
When mounting the lock ring, do not damage the rubber boot.

600464-10

Install the A-arms. (

P. 178)

TECHNICAL DATA - ENGINE

183

TECHNICAL DATA - ENGINE


28

Design

1-cylinder 4-stroke engine with balancer, water-cooled

Displacement (450 XC ATV)

448cm (27.34cuin)

Displacement (525 XC ATV)

510cm (31.12cuin)

Stroke

72mm (2.83in)

Bore (450 XC ATV)

89mm (3.5in)

Bore (525 XC ATV)

95mm (3.74in)

Compression ratio

11:1

Idle speed

1,500 1,600rpm

Control

4 valves controlled via rocker arm and overhead camshaft,


camshaft drive via simplex chain

Valve diameter, intake

35mm (1.38in)

Valve diameter, exhaust

30mm (1.18in)

Valve clearance, cold, intake

0.10 0.15mm (0.0039 0.0059in)

Valve clearance, cold, exhaust

0.10 0.15mm (0.0039 0.0059in)

Crankshaft bearing

2 cylinder roller bearing

Conrod bearing

Needle bearing

Piston pin bearing

Bronze bush

Pistons (450 XC ATV)

Cast light alloy

Pistons (525 XC ATV)

Forged light alloy

Piston rings

1 compression ring, 1 oil scraper ring

Engine lubrication

Pressure circulation lubrication with 2 rotor pumps

Primary transmission

31:78 straight tooth spur gears

Clutch

Multidisc clutch in oil bath / hydraulically activated

Transmission ratio
1st gear

14:35

2nd gear

17:33

3rd gear

19:30

4th gear

21:28

5th gear

23:26

Reverse gear

14:19:34

Generator

12V, 200W

Ignition

Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan

Spark plug

NGK DCPR8E

Spark plug electrode gap

0.6mm (0.024in)

Cooling

Water cooling, permanent circulation of coolant by water pump

Starting aid

Electric starter

Capacity - engine oil


28.1

Engine oil

2.00l (2.11qt.)

External temperature: 0C
(32F)

Engine oil (SAE 10W/50)


( P. 203)

External temperature: <0C


(<32F)

Engine oil (SAE 5W/40)


( P. 203)

TECHNICAL DATA - ENGINE

184

Capacity - coolant
28.2

Coolant
With compensating tank

1.50l (1.59qt.)

Coolant (

P. 204)

Coolant (mixed ready to use) (


Without compensating tank

1.30l (1.37qt.)

Coolant (

P. 204)

P. 204)

Coolant (mixed ready to use) (

P. 204)

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE


TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE
29

Rocker arm - axial clearance

0.02 0.10mm (0.0008 0.0039in)

Valves
Sealing seat width, intake

1.50mm (0.0591in)

Sealing seat width, exhaust

2.00mm (0.0787in)

Run-out on valve plate

0.05mm (0.002in)

Valve springs
Minimum length of outside spring

39.20mm (1.5433in)

Minimum length of inside spring

36.45mm (1.435in)

Lower valve spring retainer - strength

0.4 0.5mm (0.016 0.02in)

Cylinder/cylinder head - sealing area distortion

0.10mm (0.0039in)

Piston diameter (450 XC ATV)


Size I

88.916 88.946mm (3.50062 3.5018in)

Size II

88.926 88.958mm (3.50102 3.50228in)

Piston diameter (525 XC ATV)


Size I

94.932 94.960mm (3.73747 3.73858in)

Size II

94.940 94.968mm (3.73779 3.73889in)

Cylinder - bore diameter (450 XC ATV)


Diameter size I

89.000 89.012mm (3.50393 3.5044in)

Diameter size II

89.013 89.025mm (3.50444 3.50491in)

Cylinder - bore diameter (525 XC ATV)


Diameter size I

95.000 95.012mm (3.74015 3.74062in)

Diameter size II

95.013 95.025mm (3.74066 3.74113in)

Piston/cylinder - mounting clearance (450 XC ATV)


Size I

0.054 0.096mm (0.00213 0.00378in)

Size II

0.056 0.099mm (0.0022 0.0039in)

Wear limit

0.120mm (0.00472in)

Piston/cylinder - mounting clearance (525 XC ATV)


Size I

0.040 0.080mm (0.00157 0.00315in)

Size II

0.044 0.085mm (0.00173 0.00335in)

Wear limit

0.120mm (0.00472in)

Piston ring - end gap


Compression ring

<0.80mm (<0.0315in)

Oil scraper ring

<1.00mm (<0.0394in)

Balancer shaft - run-out on bearing pin

0.06mm (0.0024in)

Crankshaft - run-out on bearing pin

0.12mm (0.0047in)

Crankshaft - axial clearance

0.25 0.35mm (0.0098 0.0138in)

Crankshaft - external crank web dimension

650.05mm (2.560.002in)

Conrod bearing - axial clearance

1.10mm (0.0433in)

Conrod bearing - radial clearance

0.05mm (0.002in)

Clutch facing disc - thickness

>1.90mm (>0.0748in)

Clutch spring - length

41.50 43.00mm (1.6339 1.6929in)

Bypass valve - minimum length of pressure spring

23.5mm (0.925in)

Oil pump - clearance between external rotor and internal rotor

0.20mm (0.0079in)

Oil pump - clearance between external rotor and engine housing

0.20mm (0.0079in)

Oil pumps - axial clearance

0.15mm (0.0059in)

Shift fork
Thickness at leaf

4.20 4.45mm (0.1654 0.1752in)

Shift shaft - play in sliding plate/shift quadrant

0.40 0.80mm (0.0157 0.0315in)

Transmission shaft - run-out

0.06mm (0.0024in)

Transmission shaft - axial clearance

0.10 0.40mm (0.0039 0.0157in)

185

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

186

TECHNICAL DATA - ENGINE TIGHTENING TORQUES


30

Loctite 243

Screw, cable holder in generator cover

M4

Oil jet for conrod lubrication

M5

2Nm (1.5lbfft)

Screw, timing chain securing guide

M5

6Nm (4.4lbfft)

Loctite 243

Screw, locking lever

M5

6Nm (4.4lbfft)

Loctite 243

Screw, ignition pulse generator

M5

6Nm (4.4lbfft)

Loctite 243

Screw, gear sensor

M5

6Nm (4.4lbfft)

Loctite 243

Screw, rocker arm shaft

M5

6Nm (4.4lbfft)

Locking screw for bearing

M5

6Nm (4.4lbfft)

Loctite 243

Screw, oil pump cover

M5

6Nm (4.4lbfft)

Loctite 222

Screw, oil filter cover

M5

6Nm (4.4lbfft)

Screw, locking shaft lever

M5

6Nm (4.4lbfft)

Loctite 243

Screw, stator bracket

M5

6Nm (4.4lbfft)

Loctite 243

Nut, adjusting screw, valve clearance

M6x0,75

11Nm (8.1lbfft)

Oil jet, piston cooling

M6x0,75

4Nm (3lbfft)

Loctite 243

Screw, drive wheel for balancer

M6

10Nm (7.4lbfft)

Loctite 243

Screw, exhaust flange

M6

10Nm (7.4lbfft)

Loctite 243

Screw, vent hose bracket

M6

10Nm (7.4lbfft)

Loctite 243

Screw, timing chain guide rail

M6

6Nm (4.4lbfft)

Loctite 243

Slave cylinder of the clutch on engine


case

M6

10Nm (7.4lbfft)

Screw, clutch cover

M6

10Nm (7.4lbfft)

Screw, clutch spring

M6

8Nm (5.9lbfft)

Loctite 243

Screw, bearing stud, starter engine

M6

10Nm (7.4lbfft)

Loctite 243

Screw, engine housing

M6x30

10Nm (7.4lbfft)

Screw, engine housing

M6x45

10Nm (7.4lbfft)

Screw, engine housing

M6x60

10Nm (7.4lbfft)

Screw, engine housing

M6x65

10Nm (7.4lbfft)

Screw, engine housing

M6x75

10Nm (7.4lbfft)

Screw, shift drum locating

M6

10Nm (7.4lbfft)

Loctite 243

Screw, shift lever

M6

10Nm (7.4lbfft)

Loctite 243

Screw, timing chain tensioning rail

M6

6Nm (4.4lbfft)

Loctite 243

Screw, starter engine

M6

10Nm (7.4lbfft)

Screw, timing-chain tensioner

M6

10Nm (7.4lbfft)

Plug, timing chain tensioner

M8

10Nm (7.4lbfft)

Screw, cylinder head top section

M6x30

10Nm (7.4lbfft)

Screw on cylinder head top section

M6x45

10Nm (7.4lbfft)

Screw on cylinder head top section

M6x50

10Nm (7.4lbfft)

Screw on cylinder head top section

M6x55 10.9

10Nm (7.4lbfft)

Screw on cylinder head top section

M6x75

10Nm (7.4lbfft)

Screw, water pump cover

M6

10Nm (7.4lbfft)

Screw, cylinder head

M6

10Nm (7.4lbfft)

Screw, valve cover

M6

10Nm (7.4lbfft)

Jet screw, oil line

M8

10Nm (7.4lbfft)

Banjo bolt, oil line

M8

10Nm (7.4lbfft)

Screw, generator cover

M8

10Nm (7.4lbfft)

Plug, crankshaft location

M8

10Nm (7.4lbfft)

Screw, camshaft gear

M8

28Nm (20.7lbfft)

Loctite 243

Screw, engine sprocket

M10

60Nm (44.3lbfft)

Loctite 243

Screw, cylinder head

M10

Step 1
40Nm (29.5lbfft)
Step 2
50Nm (36.9lbfft)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

187

Ignition rotor nut

M12x1

60Nm (44.3lbfft)

Spark plug

M12x1,25

17Nm (12.5lbfft)

Bleeder flange, engine case

M12x1,5

Oil drain plug with magnet

M12x1,5

20Nm (14.8lbfft)

Plug, oil pressure regulator valve

M12x1.5

20Nm (14.8lbfft)

Locking screw, oil sieve, short

M16x1,5

10Nm (7.4lbfft)

lubricated with engine oil

Nut, inner clutch hub

M18x1,5

120Nm (88.5lbfft)

Loctite 243

Nut, primary gear

M20LHx1,5

150Nm (110.6lbfft)

Loctite 243

Screw-in fitting, cooling system in


cylinder head top

M20x1,5

Locking screw, oil sieve, long

M20x1,5

Loctite 243

Loctite 577
15Nm (11.1lbfft)

TECHNICAL DATA - CARBURETOR

188

TECHNICAL DATA - CARBURETOR


31

450/525XCATV

31.1

Carburetor type

KEIHIN FCR-MX 39

Carburetor identification number

3925H

Needle position (450 XC ATV)

2nd position from top

Needle position (525 XC ATV)

3rd position from top

Idle mixture adjusting screw


Open

1.0turn

Pump membrane stop

2.15mm (0.0846in)

Main jet

170

Jet needle

OBEKR

Idling jet (450 XC ATV)

40

Idling jet (525 XC ATV)

42

Main air jet

200

Idle air jet

100

Cold start jet

85

Throttle slide

15

TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES

189

TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES


32

Screw, throttle slide arm

M4

2Nm (1.5lbfft)

Loctite 243

Screw, hose connection

M4

2Nm (1.5lbfft)

Loctite 243

Other screws, carburetor

M4

2Nm (1.5lbfft)

Idle air jet

M4,5x0.75

2Nm (1.5lbfft)

Main jet

M5x0.75

2Nm (1.5lbfft)

Cold start jet

M5x0.75

2Nm (1.5lbfft)

Screw, throttle valve sensor

M5

3.5Nm (2.58lbfft)

Other screws, carburetor

M5

5Nm (3.7lbfft)

Idling jet

M6x0.75

2Nm (1.5lbfft)

Needle jet

M7x0.75

3.5Nm (2.58lbfft)

Needle screw

M8

3.5Nm (2.58lbfft)

Choke slide

M12

2.5Nm (1.84lbfft)

Hot start activation

M12

2.5Nm (1.84lbfft)

TECHNICAL DATA - CHASSIS

190

TECHNICAL DATA - CHASSIS


33

Frame

Double cradle of chromium molybdenum steel tubes, powdercoated

Wheel suspension
Front

Single wheel suspension with double transverse control arm

Rear

Rigid axle

Suspension travel
Front

257mm (10.12in)

Rear

265mm (10.43in)

Fork offset
Front

46mm (1.81in)

Front

0mm (0in)

Toe
Camber
Front

Toe width
Front

1,115mm (43.9in)

Rear

1,148mm (45.2in)

Wheelbase

1,28010mm (50.390.39in)

Turning radius

5,625mm (221.46in)

Fording depth

330mm (12.99in)

Seat height unloaded

820mm (32.28in)

Ground clearance unloaded

290mm (11.42in)

Weight
fuel tank empty

163kg (359lb.)

fuel tank full

173kg (381lb.)

Maximum allowable axle load


Front

144kg (317lb.)

Rear

149kg (328lb.)

Maximum permissible overall weight

293kg (646lb.)

Vehicle length

1,810mm (71.26in)

Vehicle width

1,148mm (45.2in)

Vehicle height

1,125mm (44.29in)

Brake system
Front

Disc brakes, brake calipers fixed, 4 brake pistons per brake


caliper

Rear

Disc brake, brake caliper floating, 1 brake piston

Diameter of brake discs


Front

180mm (7.09in)

Rear

200mm (7.87in)

Wear limit of brake discs


Front

3.5mm (0.138in)

Rear

3.5mm (0.138in)

Tire air pressure off road

0.3bar (4psi)

Rim
Front

5x10"DWTAl 6061

Rear

8x9"DWTAl6601

Rear wheel gearing

14:38

Chain

5/8 x 1/4"

Rear sprockets available

36, 37, 38, 39

4Ah battery

YTX5L-BS

Battery voltage: 12V


Nominal capacity: 4Ah
maintenance-free

TECHNICAL DATA - CHASSIS

191

Lighting equipment
33.1

Headlight

BA20d

12V
35/35W

Parking light

W2,1x9,5d

12V
5W

Indicator lights

W2x4,6d

12V
1.2W

Brake / tail light

LED

Tires
33.2

Front tire

Rear tire

21x7.00-10
MAXXIS RazrM931

20x11.00-9
MAXXIS RazrM932

For further information, see the Service section under:


http://www.ktm.com

Capacity - fuel
33.3

Tank capacity
Fuel reserve

13.4l (3.54USgal)

Super unleaded (ROZ 95 / RON 95 / PON 91) (


3l (3qt.)

P. 204)

TECHNICAL DATA - FRONT SHOCK ABSORBER


TECHNICAL DATA - FRONT SHOCK ABSORBER
34

Shock absorber type

36PRC

Setting number

KT 7702

Compression damping
Standard

14clicks

Maximum deviation from standard value

5 5clicks

Rebound damping
Standard

20clicks

Maximum deviation from standard value

5 5clicks

Cross over

171.5mm (0.670.059in)

Clip position, spring preload


Standard

7 th position from top

Corresponds to a spring preload of

5mm (0.2in)

Spring preload

5mm (0.2in)

Spring rate, main spring

21 30N/mm (120 171lb/in)

Spring rate, auxiliary spring

30N/mm (171lb/in)

Spring length, main spring

275mm (10.83in)

Spring length, auxiliary spring

60mm (2.36in)

Fitted length

463mm (18.23in)

192

TECHNICAL DATA - REAR SHOCK ABSORBER


TECHNICAL DATA - REAR SHOCK ABSORBER
35

Shock absorber type

46PRCQ

Setting number

KT 7710

Compression damping
Standard

15clicks

Maximum deviation from standard value

5 5clicks

Rebound damping
Standard

15clicks

Maximum deviation from standard value

5 5clicks

Spring preload
Standard

3mm (0.12in)

Spring rate

62N/mm (354lb/in)

Spring length

250mm (9.84in)

Fitted length

457mm (17.99in)

193

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

194

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES


36

Remaining nuts, chassis

M6

15Nm (11.1lbfft)

Remaining screws, chassis

M6

10Nm (7.4lbfft)

Screw on fuel tank

M6

6Nm (4.4lbfft)

Screw, rear brake caliper

M6

10Nm (7.4lbfft)

Loctite 243

Screw, foot brake cylinder

M6

7Nm (5.2lbfft)

Loctite 243

Screw, clamping nut, rear axle

M6

10Nm (7.4lbfft)

Remaining nuts, chassis

M8

30Nm (22.1lbfft)

Remaining screws, chassis

M8

25Nm (18.4lbfft)

Screw, front brake disc

M8

25Nm (18.4lbfft)

Loctite 243

Screw, rear brake disc

M8

25Nm (18.4lbfft)

Loctite 243

Screw, front brake caliper

M8

20Nm (14.8lbfft)

Loctite 243

Screw, rear brake caliper

M8

20Nm (14.8lbfft)

Loctite 243

Screw, bearing support, steering

M8

25Nm (18.4lbfft)

Screw, steering bridge

M8

20Nm (14.8lbfft)

Screw, handlebar clamp

M8

20Nm (14.8lbfft)

Screw, subframe

M8

35Nm (25.8lbfft)

Loctite 243

Screw, rear wheel eccentric element

M8

20Nm (14.8lbfft)

Nut, ball head, A-arm top

M10x1,25

35Nm (25.8lbfft)

Nut, rear sprocket screw

M10x1,25

45Nm (33.2lbfft)

Loctite 243

Nut, tie rod end

M10x1,25

45Nm (33.2lbfft)

Wheel nut

M10x1,25

45Nm (33.2lbfft)

Nut, handlebar support

M10

45Nm (33.2lbfft)

Remaining nuts, chassis

M10

50Nm (36.9lbfft)

Remaining screws, chassis

M10

45Nm (33.2lbfft)

Engine carrying screw

M10

60Nm (44.3lbfft)

Screw, A-arm top

M10x52

45Nm (33.2lbfft)

Screw, A-arm bottom

M10x70

45Nm (33.2lbfft)

Screw, front shock absorber

M10

45Nm (33.2lbfft)

Screw, footrest

M10

45Nm (33.2lbfft)

Screw, steering column at bottom of


steering lever

M10

25Nm (18.4lbfft)

Engine bracket screw

M10

60Nm (44.3lbfft)

Nut, A-arm top

M12x1,25

30Nm (22.1lbfft)

Lock nut, tie rod, outside

M12x1,25

20Nm (14.8lbfft)

Lock nut, tie rod, inside

M12LHx1,25

20Nm (14.8lbfft)

Nut, ball head, A-arm bottom

M12x1,5

40Nm (29.5lbfft)

Nut, front wheel hub

M12

70Nm (51.6lbfft)

Screw, rear top shock absorber

M12

60Nm (44.3lbfft)

Screw, rear bottom shock absorber

M12

70Nm (51.6lbfft)

Nut, swingarm pivot

M16x1,5

100Nm (73.8lbfft)

Nut, rear wheel hub

M18x1,5

130Nm (95.9lbfft)

Screw, steering column, top

M20x1,5

25Nm (18.4lbfft)

Screw, steering column, bottom

M20x1,5

40Nm (29.5lbfft)

Clamping nut, rear axle

2"-10UNS-2B-LH

25Nm (18.4lbfft)

Only applies when using:


Open-end wrench accessory
46mm (83019010461)
( P. 210)

CLEANING

195

CLEANING
37

Cleaning the vehicle

37.1

Note
Material damageDamage and destruction of components by high-pressure cleaning equipment.

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 hazardProblem materials cause environmental damage.

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info
If you clean the vehicle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the vehicle during cleaning.

Info
Do not place the vehicle onto the rear frame bracket to clean it since it could fall over.
Never raise the vehicle on your own, even if a gear is engaged.
Fuel can leak out of the fuel tank.

Before you clean the vehicle, seal the exhaust system to prevent penetration by water.

First remove coarse dirt particles with a gentle water spray.

Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner (

P. 206)

Info
Use warm water containing normal motorcycle cleaner and a soft sponge.

After rinsing the vehicle with a gentle water spray, allow it to dry thoroughly.

Clean and dry the air filter box.

Empty the carburetor float chamber. (

P. 159)

Warning
Danger of accidentsReduced braking due to wet or dirty brakes.

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.

Push back the protection covers on the handlebar instruments to allow water to evaporate.

After the vehicle has cooled off, oil or grease all moving parts and bearings.

Clean the chain. (

Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

P. 61)

Cleaning and polishing materials for metal, rubber and plastic (

Treat all painted parts with a mild paint polish.


High-luster polish for paint (

P. 206)

P. 206)

To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray (

P. 206)

STORAGE

196

STORAGE
38

Storage
38.1

Warning
Danger of poisoningFuel is poisonous and a health hazard.

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 store the vehicle for a longer period, take the following actions.

Info
Before storing the vehicle, 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.

Clean the vehicle. (

Change the engine oil and oil filter, clean the oil screens. (

Check the antifreeze and coolant level. (

Drain the fuel from the tank into a suitable container.

Empty the carburetor float chamber. (

Checking the tire air pressure. (

Remove the battery. (

Recharge the battery. (

P. 195)
P. 166)

P. 162)
P. 159)

P. 59)

P. 69)
P. 70)

Specification
Storage temperature of battery without direct sunshine.

0 35C (32 95F)

The storage place should be dry and not subject to large temperature differences.

Cover the vehicle 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 of a vehicle in storage 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 the vehicle into operation after storage


38.2

Install the battery. (

Fill up with fuel.

Checks before putting into operation

Make a cautious test ride.

P. 69)

GREASING AND SERVICE TABLE

197

GREASING AND SERVICE TABLE


39

Important maintenance work to be carried out by an authorized KTM workshop.

39.1

Engine

Change the engine oil and oil filter, clean the oil screens. (

P. 166)

S3N

S15A

S30A

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 shift lever screw for tightness.

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. 162)

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. 160)

P. 50)

Check cables for damage and routing without sharp bends.


Check that the electrical equipment is functioning properly.

Check the headlamp setting.


Brakes

Check speed limitation in reverse gear.

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 brake system function.

Check screws and guide bolts of brake system for tightness.

Check shock absorbers for cracks and proper functioning.

Check the steering column bearing for wear and smooth operation.

Clean and grease bearing and sealing elements of steering column.

Check steering for smooth operation and play.

Check the bearing of the handlebar bridge of excessive play.

Check tie rods and tie rod ends for damage and play.

Check front wheel suspension for wear and tightness.

Check that front and rear wheel hubs are tight.

P. 60)

Check brake lines for damage and leakage.


Check the free play of the hand brake lever. (
Check the free play of the foot brake lever. (

Chassis

P. 74)
P. 77)

Check swingarm bearing.


Check the bearing of the rear axle for play.

Grease the rear wheel eccentric element.


Wheels

Check all screws to see if they are tight.

Check rim run-out.

Check the tire condition. (

P. 59)

Checking the tire air pressure. (


Check the chain wear. (

P. 61)

Check the chain tension. (


Clean the chain. (

P. 59)

P. 62)

P. 61)

Check front wheel bearing for play.


S3N: After 3 service hours - corresponds to about 21 liters of fuel

GREASING AND SERVICE TABLE

198

S15A: Every 15 service hours - corresponds to about 105 liters of fuel / after every race
S30A: Every 30 service hours - corresponds to about 210 liters of fuel

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
39.2

Competition use
S15A

S30A

Hobby use

S45A

S30A

S60A

J1A

J2A

S90A

Carry out a complete shock absorber service.

Clean and adjust carburetor.

Treat electric contacts with contact spray.

Change hydraulic clutch fluid.

Change brake fluid.

Clean spark arrestor.

Check wear of clutch discs.

Check long clutch springs.

Check clutch slave cylinder for dents.

Check outer clutch hub for dents.

Check cylinder and piston wear.

Check camshaft wear. (visual check)

Change the camshaft bearing support.

Check wear of valve spring seat.

Check wear of valve guides.

Check valves.

Check valve springs.

Check the radial clearance of the rocker arm rollers.

Measure length of timing chain.

Check the timing-chain tensioner function.

Check crankshaft and crankshaft journal for run-out.

Change conrod bearing.

Change the crankshaft main bearing.

Change the balancer bearing.

Check wear of all transmission components including


shafts and bearings.

Check long bypass valve spring.

Change glass fiber yarn filling of main silencer.

Replace foot brake cylinder seals.

Check carburetor components.

S15A: Every 15 service


S30A: Every 30 service
S45A: Every 45 service
S60A: Every 60 service
S90A: Every 90 service
J1A: annually
J2A: every 2 years

hours
hours
hours
hours
hours

corresponds
corresponds
corresponds
corresponds
corresponds

to
to
to
to
to

about
about
about
about
about

105
210
315
420
630

liters
liters
liters
liters
liters

of
of
of
of
of

fuel / after every race


fuel
fuel
fuel
fuel

Important checks and maintenance work to be carried out by the rider.


39.3

NB1A
Check the engine oil level. (

P. 169)

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.

Clean the chain. (

P. 61)

Check the chain tension. (

P. 62)

GREASING AND SERVICE TABLE

199
NB1A

Check the chain wear. (

P. 61)

Check rear sprocket / engine sprocket for wear. (


Clean the air filter. (

P. 61)

P. 50)

Checking the tire air pressure. (

P. 59)

Check the tire condition. (

P. 59)

Check the coolant level. (

P. 162)

Check that all operating elements for smooth operation.

Check braking force (incl. parking brake).

Check all screws, nuts and hose clamps regularly for tightness.

NB1A: Depending on conditions of use according to requirements.

29

40

30

42

HI

LO

-S9

-S2

C_CV/4

C_BY/4

-X4

1,2,3,4

-F1 -F2 -F3 -F4 -F5

10A 15A 10A 10A 10A

-X3
34,19,35

-M2
M
C_BI/2

-X2

-X1

-S4

16,17,25,31,32

72

C_AV/2

24

26

-X102

-S3

C_AK/2

-X200

C_AH/2

2.1 2.2 2.3 2.4


C_AN/4

C_CU/4

-X24

C_AT/2

C_AY/1

C_AL/2

-X23

ACC1

-S6

C_AY/1

-X22

C_AY/1

C_AY/1

-M1

ACC2

-X21

-K1

C_AT/2

C_AL/2

C_AE/4

20
A

C_AU/2

20,21,28,29,30

13

41,42

2.1

10 11 12 13 14 15 16 17 18

70

C_BK/4

C_BR/4

34,38,37

19

-X201

22

C_BC/6

22

C_AC/6

-X6

1
C_BO/2

12
2

-X300
C_EI/1
C_EH/1

-G1

5,6,7,10,8,9

38

10

44

48

57

49

56,57

C_BI/2

-S5

35

C_DG/4

28

56
36,39

-X101

C_BV/2

2.2 2.1

47,49

-X5

C_BG/3

43,44

C_AH/2

51

36

51,52

-X302

45,46

-X301

-H5

-G2

-N1

-S10

C_AU/2

C_AK/2

45
54

50
53

1
4

-L2

37
23

25

C_AR/3

68

5
15

C_EJ/2
C_EK/2

C_AM/3

14

-B1

67

55

1
C_CA/4

C_BU/18

16

2
14

23
15

-A1

69

70

17
71

4
N

71

6
11

50,48
2

46

C_CE/4

GND

-L1

69

32
58

27
27
66

33
60

31
67

68

24

66

18
41

1st

-S1

59

21
R

61

33
58

3
13
47

-S7

43

26
65

63

64

65
63

53

52

450/525 XC ATV 2008

20

62

-H1
-H2
-H3

12

64

54,55
C_AK/2

11
40

18

39

C_AH/2

4
3
2
1

C_BC/4

1
2
1

-S8
low
high
pos.

-H6
-H4

60
61

62

200

WIRING DIAGRAM
WIRING DIAGRAM
40

40.1

450/525XCATV

C_AJ/3

600146-10

WIRING DIAGRAM
Components
A1

CDI controller

ACC1

Socket connector for auxiliary devices (switching on with ignition)

ACC2

Socket connector for auxiliary devices (permanent positive)

B1

Throttle valve sensor TPS

G1

Battery

G2

Generator

H1

Idling speed indicator lamp

H2

Reverse gear indicator lamp

H3

Ignition indicator lamp

H4

High beam indicator light

H5

Brake / tail light

H6

Headlight

K1

Starter relay with fuse

L1

Ignition coil

L2

Pulse generator

M1

Starter motor

M2

Radiator fan

N1

Voltage regulator/rectifier

S1

Switch for throttle lever

S2

Ignition switch

S3

Emergency OFF switch with rip cord

S4

Temperature switch for radiator fan

S5

Light switch

S6

Clutch switch

S7

Gear sensor switch

S8

Front brake light switch

S9

Electric starter button, ENG.STOPswitch

S10

Rear brake light switch

X201

Ignition curve plug connection

Cable colors
1

green

green

green

green

white-red

white-red

white-red

white-red

white-red

10

white-red

11

red

12

yellow

13

white-black

14

yellow-red

15

black-red

16

brown

17

brown

18

yellow-red

19

brown

20

orange

21

orange

201

WIRING DIAGRAM
22

yellow

23

blue-red

24

orange

25

brown

26

yellow-green

27

black-yellow

28

orange

29

orange

30

orange

31

brown

32

brown

33

black

34

brown

35

brown

36

brown

37

brown

38

brown

39

brown

40

black-green

41

yellow-green

42

yellow-green

43

brown

44

brown

45

brown

46

brown

47

yellow

48

white

49

yellow

50

white

51

yellow

52

yellow

53

green

54

blue

55

blue

56

white-green

57

white-green

58

white-blue

59

brown

60

white

61

blue-red

62

green

63

white-red

64

white-black

65

yellow-green

66

black-yellow

67

red

68

green

69

blue

70

yellow

71

black

202

SUBSTANCES

203

SUBSTANCES
41

Shock absorber oil hlins

Specification
Only use oils from hlins with the appropriate properties (see specifications on container).
Viscosity at 40C

14.0cSt

Supplier
hlins
ShockAbsorberFluid

Long-life grease
according to
NLGI
Specification
Use only grease that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex products.
Supplier
Motorex
LongTherm2000

Brake fluid DOT4/DOT5.1


according to
DOT
Specification
Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommendsCastrol andMotorex products.
Supplier
Castrol
RESPONSEBRAKEFLUIDSUPERDOT4
Motorex
BrakeFluidDOT5.1

Engine oil (SAE 10W/50)


according to
JASOT903MA (

SAE (

P. 216)

P. 216) (SAE 10W/50)

Specification
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
CrossPower4T

Engine oil (SAE 5W/40)


according to
JASOT903MA (

SAE (

P. 216)

P. 216) (SAE 5W/40)

Specification
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
PowerSynt4T

SUBSTANCES

204

Hydraulic fluid (15)


according to
ISO VG (15)
Specification
Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the
corresponding properties. KTM recommends Motorex products.
Supplier
Motorex
HydraulicFluid75

Coolant
Specification
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 45C (13 49F)

50% Anti-corrosion/antifreeze
50% distilled water

Coolant (mixed ready to use)


Antifreeze

40C (40F)

Supplier
Motorex
AntiFreeze

Super unleaded (ROZ 95 / RON 95 / PON 91)


according to
DINEN228 (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES
AUXILIARY SUBSTANCES
42

Lubricant (T158)
Specification
KTM recommends Lubcon products.
Supplier
Lubcon
TurmogreasePP300

Lubricant (T625)
Specification
KTM recommends Molykote products.
Supplier
Molykote
33Medium

Air filter cleaner


Specification
KTM recommends Motorex products.
Supplier
Motorex
TwinAirDirtBioRemover

Oil for foam air filter


Specification
KTM recommends Motorex products.
Supplier
Motorex
TwinAirLiquidPower

Chain cleaner
Specification
KTM recommendsMotorex products.
Supplier
Motorex
ChainClean611

Offroad chain spray


Specification
KTM recommends Motorex products.
Supplier
Motorex
ChainLube622

Long-life grease
Specification
KTM recommendsMotorex products.
Supplier
Motorex
LongTherm2000

Carburetor cleaner
Specification
KTM recommends Motorex products.
Supplier
Motorex
Carburetor

205

AUXILIARY SUBSTANCES
Motorcycle cleaner
Specification
KTM recommendsMotorex products.
Supplier
Motorex
MotoClean900

Cleaning and polishing materials for metal, rubber and plastic


Specification
KTM recommendsMotorex products.
Supplier
Motorex
Protect&Shine645

High-luster polish for paint


Specification
KTM recommendsMotorex products.
Supplier
Motorex
MotoPolish

Contact spray
Specification
KTM recommendsMotorex products.
Supplier
Motorex
AccuContact

206

SPECIAL TOOLS

207

SPECIAL TOOLS
43

Crankshaft locking bolt


ART. NO.: 113080802

400035-01

Spring hooks
ART. NO.: 50305017000

400363-01

Circlip pliers reverse


ART. NO.: 51012011000

400059-01

Universal mounting rack


ART. NO.: 56012001000

400067-01

Extractor
ART. NO.: 58012009000

400073-01

SPECIAL TOOLS

208

Assembly ring
ART. NO.: 58012015095
Feature
95mm (3.74in)

400074-01

Tool for inner bearing race


ART. NO.: 58429037037

400082-01

Clutch holder
ART. NO.: 59029003100

400098-01

Mounting sleeve
ART. NO.: 59029005010

400095-01

Valve spring mounter


ART. NO.: 59029019000

400101-01

SPECIAL TOOLS

209

Timing chain separating and riveting tool


ART. NO.: 59029020000

400102-01

Limit plug gauge


ART. NO.: 59029026006

400104-01

Extractor
ART. NO.: 59029033000

400105-01

Adjustment tool for mixture control screw


ART. NO.: 59029034000

400106-01

Feeler gauge
ART. NO.: 59029041100
35

30

25
20

15

12
5

10

400110-01

SPECIAL TOOLS

210

Spark plug wrench


ART. NO.: 75029172000

400170-01

Hook wrench, hlins


ART. NO.: 83019001000

200224-10

Hook wrench
ART. NO.: 83019002000

200225-10

Open-end wrench accessory 46mm


ART. NO.: 83019010461

500172-01

Hook wrench
ART. NO.: 83019011000

600430-01

SPECIAL TOOLS

211

Press mandrel
ART. NO.: 83019012000

600421-01

Press mandrel
ART. NO.: 83019013000

600476-01

Camber gauge
ART. NO.: 83019014000

500229-01

Steering fixing for straight-ahead position


ART. NO.: 83019015000

200424-10

Extractor
ART. NO.: 83019020000

600477-01

SPECIAL TOOLS

212

Mounting sleeve
ART. NO.: 83019020100

600461-01

Press mandrel
ART. NO.: 83019020130

600462-01

Disassembly/assembly holder
ART. NO.: 83019020150

600463-01

Press mandrel
ART. NO.: 83019020170

600460-01

Push-out tool
ART. NO.: 83019021000

600452-01

SPECIAL TOOLS

213

Mounting sleeve
ART. NO.: 83019050001

200217-10

Adapter WP vacuum pump


ART. NO.: 83019050002

200218-10

Disassembly/assembly tool
ART. NO.: 83019050004

200220-10

Disassembly/assembly tool
ART. NO.: 83019050005

200221-10

Disassembly fork
ART. NO.: 83019050006

200222-10

SPECIAL TOOLS

214

Mounting sleeve
ART. NO.: 83019050007

200223-10

Mounting sleeve
ART. NO.: 83019050012

200228-10

Mounting sleeve
ART. NO.: 83019050013

200229-10

Press drift
ART. NO.: 83019050014

200230-10

Press drift
ART. NO.: 83019050015

200231-10

SPECIAL TOOLS

215

Filling adapter
ART. NO.: 83019050016

200276-10

Adapter cable
ART. NO.: 83029043000

600402-01

Engine holder
ART. NO.: 83112001050

600422-01

Vacuum pump
ART. NO.: T1240S

200273-10

STANDARDS

216

STANDARDS
44

JASOT903MA
Different technical development directions required a new specification for 4-stroke motorcycles 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

217
checking the choke slide . . . . . . . . . . .
checking the float needle valve . . . . . . .
checking the hot start slide . . . . . . . . .
checking the jet needle . . . . . . . . . . . .
checking the needle jet . . . . . . . . . . . .
checking/adjusting the accelerator pump
checking/adjusting the float level . . . . .

INDEX

A
A-Arm bottom
changing the bearing . . . . . . . . . . . . . . . . . . . . . . . . 180
A-arm top
changing the bearing . . . . . . . . . . . . . . . . . . . . . . . . 179
A-arms
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Air filter box lid with carburetor connection boot
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
B
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Battery voltage
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

150
151
150
150
151
149
153

Carburetor components
checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 149
Chain
cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chain wear
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Charging voltage
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Closed-circuit current
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Clutch
checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . 160
Clutch lever
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 15

Brake fluid level of front brake


checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Brake fluid of front brake


adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Brake fluid of rear brake


adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Cooling system
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Brake linings of front brake


changing . . . . . . . . .
checking . . . . . . . . .
installing . . . . . . . . .
removing . . . . . . . . .
Brake linings of rear brake
changing . . . . . . . .
checking . . . . . . . .
installing . . . . . . . .
removing . . . . . . . .

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77
76
76
76
81
79
80
80

C
Camber
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Carburetor
adjusting idle . . . . . . . . .
assembling . . . . . . . . . .
disassembling . . . . . . . .
emptying the float chamber
installing . . . . . . . . . . . .
removing . . . . . . . . . . . .

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157
153
146
159
156
145

Carburetor - Work on individual parts


checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

cylinder - Nikasil coating

. . . . . . . . . . . . . . . . . . . . . . . 113

E
Engine
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Engine - Work on individual parts
assembling the autodecompressor . . . . . . . . . . . . .
assembling the countershaft . . . . . . . . . . . . . . . .
assembling the main shaft . . . . . . . . . . . . . . . . . .
changing the camshaft bearing . . . . . . . . . . . . . . .
changing the conrod bearing . . . . . . . . . . . . . . . .
changing the crankshaft seal ring in the clutch cover
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
checking electric starter operation . . . . . . . . . . . .
checking the clutch . . . . . . . . . . . . . . . . . . . . . .
checking the countershaft . . . . . . . . . . . . . . . . . .
checking the crankshaft run-out on the bearing pin .
checking the free-wheel . . . . . . . . . . . . . . . . . . . .
checking the lower valve spring retainer . . . . . . . . .
checking the main shaft . . . . . . . . . . . . . . . . . . .
checking the oil pumps for wear . . . . . . . . . . . . . .
checking the piston ring end gap . . . . . . . . . . . . .
checking the piston/cylinder mounting clearance . . .
checking the rocker arm and rocker arm shafts . . . .

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104
124
121
105
110
102
109
126
118
123
111
127
108
120
115
114
115
106

INDEX

218

checking the shift mechanism . . . . . . . . . . . . . . . . .


checking the spring length of the oil pressure regulator
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
checking the timing assembly . . . . . . . . . . . . . . . . .
checking the valve springs . . . . . . . . . . . . . . . . . . . .
checking the valves . . . . . . . . . . . . . . . . . . . . . . . . .
checking/measuring the cylinder . . . . . . . . . . . . . . . .
checking/measuring the piston . . . . . . . . . . . . . . . . .
checking/premounting the reverse gear shaft . . . . . . .
correcting the axial clearance of the crankshaft . . . . . .
cylinder - Nikasil coating . . . . . . . . . . . . . . . . . . . .
disassembling the autodecompressor . . . . . . . . . . . . .
disassembling the countershaft . . . . . . . . . . . . . . . .
disassembling the main shaft . . . . . . . . . . . . . . . . . .
disassembling the shift shaft . . . . . . . . . . . . . . . . . .
installing the free-wheel . . . . . . . . . . . . . . . . . . . . .
installing the oil pressure regulator valve . . . . . . . . . .
installing the valves . . . . . . . . . . . . . . . . . . . . . . . .
left engine case section . . . . . . . . . . . . . . . . . . . . . .
measuring the axial clearance of the crankshaft . . . . .
preassembling the shift shaft . . . . . . . . . . . . . . . . . .
preparing the timing chain tensioner for installation . .
removing the free-wheel . . . . . . . . . . . . . . . . . . . . .
removing the oil pressure regulator valve . . . . . . . . . .
removing the valves . . . . . . . . . . . . . . . . . . . . . . . .
right engine case section . . . . . . . . . . . . . . . . . . . . .
Engine assembly
adjusting the valve clearance . . . . . . . . . . . . . . .
checking the valve clearance . . . . . . . . . . . . . . .
filling up with engine oil . . . . . . . . . . . . . . . . . .
installing the balancer shaft . . . . . . . . . . . . . . . .
installing the camshaft . . . . . . . . . . . . . . . . . . .
installing the clutch cover . . . . . . . . . . . . . . . . .
installing the clutch push rod . . . . . . . . . . . . . . .
installing the crankshaft . . . . . . . . . . . . . . . . . .
installing the cylinder . . . . . . . . . . . . . . . . . . . .
installing the cylinder head . . . . . . . . . . . . . . . .
installing the cylinder head top section . . . . . . . .
installing the gear sensor . . . . . . . . . . . . . . . . . .
installing the generator cover . . . . . . . . . . . . . . .
installing the ignition pulse generator . . . . . . . . .
installing the left engine case . . . . . . . . . . . . . . .
installing the locking lever . . . . . . . . . . . . . . . . .
installing the locking shaft lever . . . . . . . . . . . . .
installing the oil drain plug . . . . . . . . . . . . . . . .
installing the oil line . . . . . . . . . . . . . . . . . . . . .
installing the oil pumps . . . . . . . . . . . . . . . . . . .
installing the oil screen . . . . . . . . . . . . . . . . . . .
installing the outer clutch hub and clutch discs . .
installing the piston . . . . . . . . . . . . . . . . . . . . .
installing the primary gear with the free-wheel-gear
installing the rotor . . . . . . . . . . . . . . . . . . . . . .
installing the shift drum . . . . . . . . . . . . . . . . . .
installing the shift drum locating . . . . . . . . . . . .
installing the shift forks . . . . . . . . . . . . . . . . . . .
installing the shift lever . . . . . . . . . . . . . . . . . . .
installing the shift rails . . . . . . . . . . . . . . . . . . .
installing the shift shaft . . . . . . . . . . . . . . . . . . .
installing the spark plug . . . . . . . . . . . . . . . . . .
installing the starter idler gear/torque limiter . . . .
installing the starter motor . . . . . . . . . . . . . . . . .

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116
101
110
108
108
113
114
125
112
113
103
122
119
117
127
101
109
102
112
118
110
127
101
107
100
136
135
144
128
133
142
144
128
132
132
134
139
138
138
129
139
139
143
136
137
143
141
131
137
135
129
140
129
144
129
140
136
140
143

installing the timing chain rails . . . . . . . . . . . . . . .


installing the timing chain sprocket . . . . . . . . . . . . .
installing the timing chain tensioner . . . . . . . . . . . .
installing the transmission shaft . . . . . . . . . . . . . . .
installing the valve cover . . . . . . . . . . . . . . . . . . . .
installing the water pump cover . . . . . . . . . . . . . . .
mounting the oil filter . . . . . . . . . . . . . . . . . . . . . .
removing the crankshaft locking bolt . . . . . . . . . . . .
removing the engine from the universal mounting rack
Engine disassembly
draining the engine oil . . . . . . . . . . . . . . . . . . .
installing the crankshaft locking bolt . . . . . . . . . .
preparations . . . . . . . . . . . . . . . . . . . . . . . . . .
removing the balancer shaft . . . . . . . . . . . . . . . .
removing the camshaft . . . . . . . . . . . . . . . . . . .
removing the clutch cover . . . . . . . . . . . . . . . . .
removing the clutch discs . . . . . . . . . . . . . . . . .
removing the crankshaft . . . . . . . . . . . . . . . . . .
removing the cylinder . . . . . . . . . . . . . . . . . . . .
removing the cylinder head . . . . . . . . . . . . . . . .
removing the cylinder head top section . . . . . . . .
removing the gear sensor . . . . . . . . . . . . . . . . . .
removing the generator cover . . . . . . . . . . . . . . .
removing the ignition pulse generator . . . . . . . . .
removing the locking lever . . . . . . . . . . . . . . . . .
removing the locking shaft lever . . . . . . . . . . . . .
removing the oil filter . . . . . . . . . . . . . . . . . . . .
removing the oil line . . . . . . . . . . . . . . . . . . . . .
removing the oil pump gear . . . . . . . . . . . . . . . .
removing the oil pump gears . . . . . . . . . . . . . . .
removing the outer clutch hub . . . . . . . . . . . . . .
removing the piston . . . . . . . . . . . . . . . . . . . . .
removing the primary gear with the free-wheel-gear
removing the rotor . . . . . . . . . . . . . . . . . . . . . .
removing the shift drum . . . . . . . . . . . . . . . . . .
removing the shift drum locating . . . . . . . . . . . . .
removing the shift lever . . . . . . . . . . . . . . . . . . .
removing the shift shaft . . . . . . . . . . . . . . . . . . .
removing the shifting rails and forks . . . . . . . . . .
removing the spark plug . . . . . . . . . . . . . . . . . .
removing the starter idler gear/torque limiter . . . .
removing the starter motor . . . . . . . . . . . . . . . . .
removing the timing chain . . . . . . . . . . . . . . . . .
removing the timing chain sprocket . . . . . . . . . . .
removing the timing chain tensioner . . . . . . . . . .
removing the transmission shaft . . . . . . . . . . . . .
removing the water pump cover . . . . . . . . . . . . .
taking off the left section of the engine case . . . . .

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131
131
135
128
136
136
143
140
144

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87
91
87
99
94
88
88
99
95
95
94
97
91
92
90
96
87
93
90
93
89
96
91
92
98
90
88
90
98
91
90
87
96
96
94
99
94
97

Engine guard
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine oil
changing .
draining .
refilling . .
topping up

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166
166
168
169

Engine oil level


checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

INDEX

219

Engine sprocket
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Ignition curve
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Fender, rear
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Foot brake pedal


adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 78
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fork offset
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Front cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Front shock absorber
adjusting the compression damping
adjusting the cross over . . . . . . . .
adjusting the rebound damping . .
adjusting the spring preload . . . . .
assembling the piston rod . . . . . .
assembling the shock absorber . . .
disassembling the piston rod . . . .
disassembling the shock absorber .
installing . . . . . . . . . . . . . . . . . .
installing the heim joint . . . . . . . .
installing the spring . . . . . . . . . .
removing . . . . . . . . . . . . . . . . . .
removing the heim joint . . . . . . . .
removing the spring . . . . . . . . . .

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19
20
19
20
32
25
31
24
22
34
23
21
33
22

Front trim
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuse
changing fuses of individual power-consuming components 71
changing the main fuse . . . . . . . . . . . . . . . . . . . . . . . 71
G

M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main silencer
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Manifold
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Oil screens
cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

P
Parking brake

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Play in gas Bowden cable


adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pulse generator
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Putting into operation
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
R
Radiator spoiler
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rear axle
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Rear axle bearing
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Rear shock absorber


adjusting the compression damping
adjusting the rebound damping . .
adjusting the spring preload . . . . .
assembling the piston rod . . . . . .
assembling the shock absorber . . .
disassembling the piston rod . . . .
disassembling the shock absorber .
installing . . . . . . . . . . . . . . . . . .
installing the heim joint . . . . . . . .
installing the spring . . . . . . . . . .
removing . . . . . . . . . . . . . . . . . .
removing the heim joint . . . . . . . .
removing the spring . . . . . . . . . .

Ignition coil
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Rear sprocket / engine sprocket


checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Generator
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Greasing and service table

. . . . . . . . . . . . . . . . . . . . 197-199

H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 74
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Handlebar position
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hot start button

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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34
35
35
44
40
42
38
37
47
37
36
46
37

INDEX

220

Reverse gear release lever


adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wheel/wheels
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200


Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
shock absorber
bleeding and filling . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shock absorber
setting number, front . . . . . . . . . . . . . . . . . . . . . . . . 12
setting number, rear . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spare parts, accessories

.......................... 6

Spark plug connector


checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Starter relay
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

T
Technical data
carburetor . . . . . . . . . . . . .
carburetor tightening torques
chassis . . . . . . . . . . . . . . .
chassis tightening torques . .
engine . . . . . . . . . . . . . . .
engine - tolerance, wear limits
engine tightening torques . .
front shock absorber . . . . . .
rear shock absorber . . . . . . .

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. . . . 188
. . . . 189
. 190-191
. . . . 194
. 183-184
. . . . 185
. 186-187
. . . . 192
. . . . 193

Throttle slide opening


checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 153
Throttle valve sensor position
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Throttle valve sensorTPS
adjusting the position . . . . . . . . . . . . . . . . . . . . . . . 152
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Toe
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Adjusting the toe width of rear axle . . . . . . . . . . . . . . . 63
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V
Vehicle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
removing from work stand . . . . . . . . . . . . . . . . . . . . . 14
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel carrier
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

*3206058en*
3206058en

12/2007
Photo Mitterbauer

KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com