REPAIR MANUAL 2008 450EXC-REU 450EXC-RAUS/UK 450EXC-RSIXDAYS 450EXC-RUSA 450XCR-WUSA 450XCR-WZA 530EXC-REU 530EXC-RAUS/UK 530EXC-RSIXDAYS 530EXC-RUSA 530XCR-WUSA 530XCR-WZA ART. NO. 3206054en INTRODUCTION 1 ,1752'8&7,21 Read the repair manual before beginning work. Only use ORGINALKTM SPARE PARTS. The engine will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this manual. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified here. It is assumed that the repair work will be performed by a fully trained mechanic. All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria CONTENTS 2 &217(176 MEANS OF REPRESENTATION ............................................ 6 IMPORTANT NOTES ............................................................ 7 MOTORCYCLE..................................................................... 8 Jacking up the motorcycle ................................................ 8 Removing the motorcycle from the work stand.................... 8 01/FORK, TRIPLE CLAMP.................................................... 9 Fork part number............................................................. 9 Adjusting spring preload of the fork................................... 9 Adjusting compression damping of fork ............................. 9 Adjusting rebound damping of fork.................................. 10 Cleaning dust boots of fork legs ...................................... 10 Removing the fork legs................................................... 11 Installing the fork legs ................................................... 11 Bleeding fork legs.......................................................... 12 Removing the fork protector............................................ 12 Installing the fork protector ............................................ 13 Loosening the fork protection.......................................... 13 Positioning the fork protection ........................................ 13 Removing the lower triple clamp (EXC-RSIXDAYS, XCR-WUSA) ................................................................. 13 Installing the lower triple clamp (EXC-RSIXDAYS, XCR-WUSA) ................................................................. 14 Removing the lower triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ......................... 15 Installing the lower triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ......................... 15 Fork offset (EXC-RSIXDAYS, XCR-WUSA) ...................... 16 Setting the fork offset (EXC-RSIXDAYS, XCR-WUSA) ...... 16 Checking play of steering head bearing ............................ 16 Adjusting play of steering head bearing (EXC-RSIXDAYS, XCR-WUSA) ...................................... 17 Adjusting play of steering head bearing (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ......................... 17 Greasing the steering head bearing.................................. 18 03/FRAME........................................................................ 19 Removing the engine sprocket cover................................ 19 Installing the engine sprocket cover................................. 19 04/SHOCK ABSORBER, SWINGARM................................... 20 Shock absorber part number........................................... 20 Adjusting high-speed compression damping of the shock absorber ....................................................................... 20 Adjusting the low-speed compression damping of the shock absorber .............................................................. 20 Adjusting rebound damping of the shock absorber ............ 21 Measuring rear wheel sag unloaded ................................. 21 Checking static sag of the shock absorber ........................ 22 Checking the riding sag of the shock absorber .................. 22 Adjusting spring preload of the shock absorber ................. 22 Adjusting riding sag ....................................................... 23 Removing the shock absorber ......................................... 23 Installing shock absorber................................................ 24 05/EXHAUST .................................................................... 25 Removing main silencer ................................................. 25 Fitting the main silencer ................................................ 25 Removing the manifold .................................................. 25 Installing the manifold ................................................... 25 06/AIR FILTER.................................................................. 26 Dismounting the air filter box lid..................................... 26 Installing the air filter box lid.......................................... 26 Removing the air filter ................................................... 26 Installing the air filter .................................................... 26 Cleaning air filter........................................................... 27 Removing the carburetor connection boot ........................ 27 Installing the carburetor connection boot ......................... 27 07/FUEL TANK, SEAT, TRIM.............................................. 28 Opening filler cap.......................................................... 28 Closing filler cap ........................................................... 28 Removing the seat ......................................................... 28 Mounting the seat ......................................................... 28 Dismounting the fuel tank .............................................. 28 Installing the fuel tank................................................... 29 Fuel tap........................................................................ 30 08/MASK, FENDER ........................................................... 31 Dismounting the front fender .......................................... 31 Installing the front fender............................................... 31 Removing headlight mask with headlight (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-WZA).................................................................... 31 Refitting the headlight mask with the headlight (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-WZA) ................................................. 31 Dismount the start number plate (XCR-WUSA) ................ 32 Fitting the start number plate (XCR-WUSA)..................... 32 09/FRONT WHEEL ............................................................ 33 Removing front wheel .................................................... 33 Fitting front wheel ......................................................... 33 Checking brake discs ..................................................... 34 Removing the front brake disc ........................................ 34 Installing the front brake disc ......................................... 34 Tire condition checking.................................................. 35 Checking tire air pressure............................................... 35 Checking spoke tension.................................................. 35 10/REAR WHEEL .............................................................. 36 Removing rear wheel...................................................... 36 Fitting rear wheel .......................................................... 36 Removing the rear brake disc.......................................... 37 Installing the rear brake disc .......................................... 37 Checking the chain tension when fitting rear wheel........... 37 Adjusting chain tension - fitting rear wheel ...................... 38 Checking the chain tension ............................................ 38 Adjusting chain tension - after checking .......................... 39 Adjusting the chain tension ............................................ 39 Adjusting chain guide .................................................... 40 Checking the rear sprocket / engine sprocket for wear ....... 40 Checking chain wear ...................................................... 41 Checking chain dirt ....................................................... 41 Cleaning the chain......................................................... 41 11/WIRING HARNESS, BATTERY ....................................... 42 Removing a fuse............................................................ 42 Replacing the fuse......................................................... 42 Removing the battery ..................................................... 42 Installing the battery...................................................... 43 Recharging the battery ................................................... 43 13/BRAKE SYSTEM........................................................... 45 Checking the front brake linings...................................... 45 Removing the front brake linings..................................... 45 Installing the front brake linings ..................................... 45 Changing the front brake linings ..................................... 46 Adjusting basic position of handbrake lever (Every XCR-W models) ........................................................................ 46 Checking free play of hand brake lever............................. 47 Adjusting free travel of handbrake lever (Every EXC-R models) ........................................................................ 47 Checking the front brake fluid level ................................. 47 CONTENTS Add front brake fluid...................................................... 48 Changing the front brake fluid ........................................ 48 Checking rear brake linings ............................................ 49 Removing the rear brake linings ...................................... 49 Installing the rear brake linings....................................... 50 Changing the rear brake linings....................................... 50 Checking free play of foot brake lever .............................. 51 Adjusting basic position of footbrake lever ....................... 51 Checking rear brake fluid level........................................ 52 Adding rear brake fluid .................................................. 52 Changing the rear brake fluid.......................................... 52 14/LIGHT SYSTEM, INSTRUMENTS ................................... 54 Adjusting speedometer functions .................................... 54 Setting kilometers or miles ............................................. 54 Setting the clock ........................................................... 55 30/ENGINE....................................................................... 56 Removing the engine ..................................................... 56 Installing the engine ...................................................... 57 30/DISASSEMBLING ENGINE ............................................ 59 Preparations.................................................................. 59 Draining the engine oil................................................... 59 Removing the oil filter.................................................... 59 Draining gear oil, cleaning gear oil screen ........................ 59 Removing the starter engine ........................................... 60 Removing the valve cover ............................................... 60 Removing the shift lever................................................. 60 Removing the spark plug ................................................ 60 Removing the generator cover ......................................... 61 Setting the engine to ignition top dead center .................. 61 Removing the timing chain tensioner............................... 62 Removing the camshaft.................................................. 62 Removing the cylinder head............................................ 62 Removing the piston ...................................................... 62 Removing the rotor ........................................................ 63 Removing the balance weight ......................................... 63 Removing the timing chain guide rail .............................. 63 Removing the timing chain tensioning rail........................ 64 Removing the timing chain securing guide ....................... 64 Removing the timing chain............................................. 64 Removing the ignition pulse generator ............................. 64 Removing the suction pump ........................................... 64 Removing the kickstarter................................................ 65 Removing the water pump cover ..................................... 65 Removing the clutch cover ............................................. 65 Removing the clutch discs.............................................. 66 Removing the primary gear nut ....................................... 66 Removing the outer clutch hub ....................................... 66 Removing the balancer shaft .......................................... 67 Removing the torque limiter ........................................... 67 Removing the starter idler gear ....................................... 67 Removing the kickstarter shaft........................................ 67 Removing the kickstarter idler gear ................................. 67 Removing the shift shaft ................................................ 68 Removing the shift drum locating.................................... 68 Removing the locking lever............................................. 68 removing the oil pump gears........................................... 68 Removing the oil pumps................................................. 69 Removing the primary gear with the free-wheel-gear.......... 69 Removing the left section of the engine case.................... 69 Removing the shift rails ................................................. 70 Removing the shift roller ................................................ 70 3 Removing the shift forks ................................................ 71 Removing the transmission shaft..................................... 71 Removing the crankshaft................................................ 71 30/ENGINE - WORK ON INDIVIDUAL PARTS....................... 72 Work on the right section of the engine case .................... 72 Work on the left section of the engine case ...................... 73 removing the oil pressure regulator valve.......................... 75 Checking the spring length of the oil pressure regulator valve ............................................................................ 75 Installing the oil pressure regulator valve ......................... 75 Removing the crankshaft seal ring in the clutch cover ....... 76 Fitting the crankshaft seal ring into the clutch cover ......... 76 Removing the water pump .............................................. 76 Installing the water pump............................................... 77 Checking the balancer shaft ........................................... 78 Removing the timing chain sprocket................................ 78 Installing the timing chain sprocket................................. 78 Changing the conrod bearing .......................................... 78 Checking the crankshaft run-out on the bearing pin .......... 80 Cylinder - Nikasil® coating.............................................. 80 Checking/measuring the cylinder..................................... 80 Checking/measuring the piston ....................................... 81 Checking the piston ring end gap .................................... 81 Checking piston/cylinder mounting clearance ................... 82 Checking the oil pumps for wear ..................................... 82 Checking the lubrication system...................................... 82 Disassembling the autodecompressor .............................. 83 Assembling the autodecompressor................................... 83 Checking the camshaft................................................... 84 Checking the timing assembly ........................................ 84 Preparing the timing chain tensioner for installation ......... 84 Removing the rocker arm................................................ 85 Removing the valves ...................................................... 85 Replacing the camshaft bearing ...................................... 86 Checking the valves ....................................................... 87 Checking the valve springs ............................................. 87 Checking the lower valve spring retainer .......................... 87 Checking the cylinder head ............................................ 88 Installing valves ............................................................ 88 Installing the rocker arm ................................................ 89 Checking the clutch....................................................... 89 Checking the shift mechanism ........................................ 90 Preassembling the shift shaft.......................................... 91 Dismantling the main shaft ............................................ 91 Assembling the main shaft ............................................. 91 Dismantling the countershaft.......................................... 92 Assembling the countershaft........................................... 92 Checking the transmission.............................................. 93 Checking electric starter operation .................................. 94 Removing the free-wheel ................................................ 94 Checking the free-wheel ................................................. 95 Installing the free-wheel................................................. 95 30/ASSEMBLING ENGINE ................................................. 96 Installing the crankshaft................................................. 96 Installing the transmission shaft ..................................... 96 Installing the shift forks ................................................. 96 Installing the shift roller................................................. 97 Installing the shift rails .................................................. 97 Installing the left engine case ......................................... 97 Installing the primary gear with the free-wheel-gear .......... 98 Installing the oil pumps ................................................. 98 Installing the oil pump gears .......................................... 99 CONTENTS Installing the locking lever.............................................. 99 Installing the shift drum locating .................................... 99 Installing the shift shaft ................................................. 99 Installing the kickstarter idler gear ................................ 100 Installing the kickstarter shaft ...................................... 100 Installing the starter idler gear ...................................... 100 Installing the torque limiter .......................................... 100 Installing the balancer shaft ......................................... 101 Installing the outer clutch hub...................................... 101 Installing the primary gear nut ...................................... 101 Installing the clutch discs ............................................ 102 Installing the clutch cover ............................................ 102 Installing the water pump cover .................................... 103 Installing the kickstarter............................................... 103 Installing the suction pump .......................................... 103 Installing the ignition pulse generator............................ 104 Installing the timing chain............................................ 104 Installing the timing chain securing guide...................... 104 Installing the timing chain tensioning rail ...................... 104 Installing the timing chain guide rail ............................. 105 Installing the balance weight ........................................ 105 Installing the rotor ....................................................... 105 Installing the piston..................................................... 105 Installing the cylinder head .......................................... 107 Installing the camshaft ................................................ 108 Installing the timing chain tensioner ............................. 108 Checking the valve clearance ........................................ 109 Adjusting the valve clearance........................................ 109 Installing the generator cover........................................ 109 Installing the shift lever ............................................... 110 Installing the valve cover .............................................. 110 Installing the spark plug............................................... 110 Installing the starter motor ........................................... 111 Mounting oil filter........................................................ 111 Filling up with engine oil.............................................. 111 Filling up with gear oil ................................................. 112 Removing the engine from the universal mounting rack ........................................................................... 112 31/CARBURETOR ........................................................... 113 Choke (EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-W) ...................................................................... 113 Choke (EXC-REU) ....................................................... 113 Checking the choke Bowden cable routing (EXC-REU).... 113 Checking the choke Bowden cable for play (EXC-REU) ... 113 Adjusting the choke Bowden cable play (EXC-REU)........ 113 Checking gas Bowden cable route ................................. 114 Checking play in the gas Bowden cable ......................... 114 Adjusting the gas Bowden cable play............................. 114 Removing the carburetor .............................................. 115 Disassembling the carburetor........................................ 115 Checking the carburetor components............................. 118 Checking/adjusting the accelerator pump....................... 118 Checking the choke slide.............................................. 119 Checking the jet needle................................................ 119 Checking the throttle slide............................................ 119 Checking the needle jet................................................ 120 Checking the float needle valve..................................... 120 Checking/adjusting the float level.................................. 120 Checking/adjusting the throttle slide opening ................. 120 Checking throttle valve sensorTPS ................................ 121 Adjusting the position of throttle valve sensorTPS .......... 121 Assembling the carburetor............................................ 122 4 Installing the carburetor ............................................... 125 Carburetor - adjusting idle ............................................ 126 Emptying the carburetor float chamber .......................... 127 32/CLUTCH .................................................................... 129 Checking fluid level of hydraulic clutch ......................... 129 Changing fluid level of hydraulic clutch ......................... 129 33/TRANSMISSION......................................................... 131 Removing the engine sprocket ...................................... 131 Installing the engine sprocket ....................................... 131 35/WATER PUMP, COOLING SYSTEM .............................. 132 Checking antifreeze and coolant level ............................ 132 Checking the coolant level............................................ 132 Draining coolant .......................................................... 133 Refilling coolant .......................................................... 133 38/LUBRICATION SYSTEM .............................................. 134 Oil cycle ..................................................................... 134 Checking engine oil level.............................................. 134 Changing engine oil and oil filter, cleaning engine oil screen ........................................................................ 135 Draining engine oil, cleaning engine oil screen ............... 135 Removing the oil filter.................................................. 135 Mounting oil filter........................................................ 136 Filling up with engine oil.............................................. 136 Topping up engine oil .................................................. 137 Checking the engine oil pressure................................... 137 Checking gear oil level ................................................. 138 Changing gear oil, cleaning gear oil screen..................... 138 Draining gear oil, cleaning gear oil screen ...................... 138 Filling up with gear oil ................................................. 139 Topping up with gear oil............................................... 139 TROUBLESHOOTING....................................................... 140 TECHNICAL DATA - ENGINE ............................................ 142 Capacity- engine oil ..................................................... 142 Capacity - gear oil........................................................ 142 Capacity - coolant........................................................ 143 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE ......................................................................... 144 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 145 TECHNICAL DATA - CARBURETOR................................... 147 450EXC-REU, 450EXC-RAUS/UK (3900I) ................. 147 450EXC-RSIXDAYS, 450EXC-RUSA, 450XCR-W (3900L) ..................................................................... 147 530EXC-REU, 530EXC-RAUS/UK (3900J)................. 148 530EXC-RSIXDAYS, 530EXC-RUSA, 530XCR-W (3900M) .................................................................... 148 TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES....................................................................... 149 TECHNICAL DATA - CHASSIS .......................................... 150 Lighting equipment ..................................................... 151 Tires .......................................................................... 151 Capacity - fuel............................................................. 151 TECHNICAL DATA - FORK................................................ 152 TECHNICAL DATA - SHOCK ABSORBER ........................... 153 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 154 CLEANING...................................................................... 155 Cleaning motorcycle .................................................... 155 STORAGE ....................................................................... 156 Storage....................................................................... 156 Putting into operation after storage ............................... 156 GREASING AND SERVICE TABLE ..................................... 157 Important maintenance work to be carried out by an authorized KTM workshop. ........................................... 157 CONTENTS Important maintenance work to be carried out by an authorized KTM workshop. (as additional order).............. 158 Important checks and maintenance work to be carried out by the rider. .......................................................... 158 WIRING DIAGRAM .......................................................... 160 Wiring diagram (EXC-REU) .......................................... 160 Wiring diagram (EXC-RAUS/UK)................................... 162 Wiring diagram (EXC-RUSA) ........................................ 164 Wiring diagram (EXC-RSIXDAYS)................................. 168 Wiring diagram (XCR-WUSA) ....................................... 170 Wiring diagram (XCR-WZA) .......................................... 172 SUBSTANCES................................................................. 174 AUXILIARY SUBSTANCES................................................ 175 SPECIAL TOOLS.............................................................. 177 STANDARDS................................................................... 184 INDEX ............................................................................ 185 5 MEANS OF REPRESENTATION 0($16 2) 5(35(6(17$7,21 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained in the following. Specific name Identifies a specific name. Name® Identifies a protected name. Brand™ Identifies a brand in merchandise traffic. 6 IMPORTANT NOTES 7 ,03257$17 127(6 Warranty The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and alterations to the motorcycle. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss. MOTORCYCLE 8 02725&<&/( Jacking up the motorcycle Note Danger of damageಗDanger of damage by the vehicle running away or falling over. ಥ ಥ Always place the vehicle on a firm and even surface. Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground. Work stand (54829055000) ( 500074-01 ಥ P. 178) Secure the motorcycle against falling over. Removing the motorcycle from the work stand Note Danger of damageಗDanger of damage by the vehicle running away or falling over. ಥ Always place the vehicle on a firm and even surface. ಥ Remove the motorcycle from the work stand. ಥ Remove the work stand. 01/FORK, TRIPLE CLAMP 9 )25. 75,3/( &/$03 Fork part number The fork part number is stamped on the inner side of the fork stub. 500082-10 Adjusting spring preload of the fork ಥ Turn adjusting screws counterclockwise until they stop. Info Make the same adjustment on both fork legs. ಥ Turn back clockwise the number of turns corresponding to the fork type. Specification Spring preload - PreloadAdjuster (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCRW) 100025-10 Comfort 2turns Standard 4turns Sport 7turns Spring preload - PreloadAdjuster (EXC-RSIXDAYS) Comfort 2turns Standard 2turns Sport 7turns Info Turn clockwise to increase spring preload, turn counterclockwise to reduce spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload. Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. ಥ Remove protection covers. ಥ Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. 100020-10 01/FORK, TRIPLE CLAMP 10 ಥ Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Compression damping (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) Comfort 24clicks Standard 20clicks Sport 18clicks Compression damping (EXC-RSIXDAYS) Comfort 24clicks Standard 22clicks Sport 18clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. ಥ Mount protection covers. Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork suspension behavior. ಥ Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. ಥ Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Rebound damping (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) 100019-10 Comfort 20clicks Standard 18clicks Sport 18clicks Rebound damping (EXC-RSIXDAYS) Comfort 20clicks Standard 20clicks Sport 18clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. Cleaning dust boots of fork legs ಥ Jack up the motorcycle. ( ಥ Loosen the fork protection. ( ಥ Push dust boots of both fork legs downwards. P. 8) P. 13) Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak. 500088-10 01/FORK, TRIPLE CLAMP 11 Warning Danger of accidentsಗReduced braking due to oil or grease on the brake discs. ಥ ಥ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray ( P. 175) ಥ Press the dust boots back into their normal position. ಥ Remove excess oil. ಥ Position the fork protection. ( ಥ Remove the motorcycle from the work stand. ( ಥ Remove front wheel. ( ಥ Remove screws and take off clamp. P. 13) P. 8) Removing the fork legs P. 33) ಥ Remove cable clip, remove screw and take off the brake caliper. ಥ Hang the brake caliper and the brake line loosely to the side. 500093-10 (EXC-RSIXDAYS, XCR-WUSA) ಥ Loosen screw. Remove the fork leg on the left. ಥ Loosen screw. Remove the fork leg on the right. 500094-10 (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Loosen screw. Remove the fork leg on the left. ಥ Loosen screw. Remove the fork leg on the right. 100023-11 Installing the fork legs ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the fork legs. Info The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp. Position the bleeder screw to the front. 100021-10 01/FORK, TRIPLE CLAMP 12 (EXC-RSIXDAYS, XCR-WUSA) ಥ Fully tighten screw. Specification Screw, top triple clamp ಥ M8 17Nm (12.54lbfft) M8 12Nm (8.85lbfft) M8 20Nm (14.75lbfft) M8 15Nm (11.06lbfft) Fully tighten screw. Specification Screw, bottom triple clamp 500094-11 (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Fully tighten screw. Specification Screw, top triple clamp ಥ Fully tighten screw. Specification Screw, bottom triple clamp 100023-10 ಥ Position brake caliper, mount and tighten screws. Specification Screw, front brake caliper M8 25Nm (18.44lbfft) Loctite® 243™ ಥ Fit cable clip. ಥ Position the brake line and cable harness. Put the clamp on, mount and tighten screws. ಥ Fit front wheel. ( ಥ Jack up the motorcycle. ( ಥ Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. ಥ Mount and tighten bleeder screws. ಥ Remove the motorcycle from the work stand. ( ಥ Remove the fork legs. ( ಥ Remove screws on the left fork leg. Remove the fork protector upwards. ಥ Remove the screws on the right fork leg. Remove the fork protector upwards. P. 33) 500093-11 Bleeding fork legs P. 8) P. 8) 100021-10 Removing the fork protector 500105-10 P. 11) 01/FORK, TRIPLE CLAMP 13 Installing the fork protector ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the fork protection on the left fork leg. Mount and tighten screws. Specification Remaining screws, chassis ಥ M6 10Nm (7.38lbfft) Position the fork protection on the right fork leg. Mount and tighten screws. Specification Remaining screws, chassis M6 10Nm (7.38lbfft) 500105-10 ಥ Install the fork legs. ( ಥ Remove screws and take off clamp. ಥ Remove screws on left fork leg. Push the fork protection downwards. ಥ Remove the screws on the right fork leg. Push the fork protection downwards. ಥ Position the fork protection on the left fork leg. Mount and tighten screws. Specification P. 11) Loosening the fork protection 500087-11 Positioning the fork protection Remaining screws, chassis M6 10Nm (7.38lbfft) ಥ Position the brake line and cable harness. Put the clamp on, mount and tighten screws. ಥ Position the fork protection on the right fork leg. Mount and tighten screws. Specification Remaining screws, chassis 500087-10 M6 10Nm (7.38lbfft) Removing the lower triple clamp (EXC-RSIXDAYS, XCR-WUSA) ಥ Remove the fork legs. ( P. 11) (XCR-WUSA) ಥ Dismount the start number plate. ( P. 32) (EXC-RSIXDAYS) ಥ Remove the headlight mask with the headlight. ( P. 31) ಥ Dismount the front fender. ( ಥ Remove screws and hang the CDI control unit to the side. P. 31) Info Do not unplug the CDI control unit. ಥ Remove screw. Remove screw, take off top triple clamp with the handlebar and place it on one side. Info 500099-10 Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. 01/FORK, TRIPLE CLAMP 14 ಥ Remove o-ring. Remove protector ring. ಥ Remove the lower triple clamp with the steering stem. ಥ Remove the upper steering head bearing. 500100-10 Installing the lower triple clamp (EXC-RSIXDAYS, XCR-WUSA) ಥ Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( ಥ 3 0 2 0 1 0 P. 175) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. Info Check whether the top steering head seal is correctly positioned. ಥ Push up protective ring and o-ring. ಥ Position the upper triple clamp with the steering. ಥ Mount and tighten screw. Specification 500098-10 Screw, top steering head ಥ M20x1,5 Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws. Specification Remaining screws, chassis 500099-11 ಥ Install the front fender. ( M6 10Nm (7.38lbfft) P. 31) (XCR-WUSA) ಥ Fit the start number plate. ( P. 32) (EXC-RSIXDAYS) ಥ Refit the headlight mask with the headlight. ( ಥ Install the fork legs. ( ಥ Mount and tighten screw . Specification P. 31) P. 11) Screw, top steering stem 500103-10 10Nm (7.38lbfft) M8 17Nm (12.54lbfft) Loctite® 243™ ಥ Check the cable harness, cable, brake and clutch line for free movement and free laying. ಥ Check play of steering head bearing. 01/FORK, TRIPLE CLAMP 15 Removing the lower triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Remove the fork legs. ( ಥ Remove the headlight mask with the headlight. ( ಥ Dismount the front fender. ( ಥ Remove screws and hang the CDI control unit to the side. P. 11) P. 31) P. 31) Info Do not unplug the CDI control unit. ಥ Remove screw. Loosen screw. Take off top triple clamp with the handlebar and place it on one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. 500149-10 ಥ Remove protector ring. ಥ Remove the lower triple clamp with the steering stem. ಥ Remove the upper steering head bearing. 500150-10 Installing the lower triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( ಥ 2 0 1 0 P. 175) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. Info Check whether the top steering head seal is correctly positioned. ಥ Push on protective ring. ಥ Position the upper triple clamp with the steering. ಥ Mount and tighten screw. Specification 500151-10 Screw, top steering head ಥ M20x1,5 Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws. Specification Remaining screws, chassis 500149-11 10Nm (7.38lbfft) M6 ಥ Install the front fender. ( ಥ Refit the headlight mask with the headlight. ( ಥ Install the fork legs. ( 10Nm (7.38lbfft) P. 31) P. 11) P. 31) 01/FORK, TRIPLE CLAMP 16 Tighten screw. Specification ಥ Screw, top steering stem M8 20Nm (14.75lbfft) ಥ Check the cable harness, cable, brake and clutch line for free movement and free laying. ಥ Check play of steering head bearing. 100022-11 Fork offset (EXC-RSIXDAYS, XCR-WUSA) You can see the currently set offset if you remove screw. The fork offset has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing. The fork offset can optionally be adjusted. Marking to the front gives greater stability on fast racetracks. B 0 A 0 Fork offset Front marking 18mm (0.71in) Marking to the rear (condition at delivery) gives better handling in bends. Fork offset Rear marking 1 0 20mm (0.79in) 400188-10 Setting the fork offset (EXC-RSIXDAYS, XCR-WUSA) ಥ Remove the lower triple clamp. ( P. 13) ಥ Remove screw. Remove the steering stem. ಥ Clean the parts and check for damage. ಥ Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten screw. Specification Screw, bottom steering head ಥ M20x1,5 Install the lower triple clamp. ( 60Nm (44.26lbfft) Loctite® 243™ P. 14) 500104-10 Checking play of steering head bearing Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. ಥ Jack up the motorcycle. ( P. 8) 01/FORK, TRIPLE CLAMP 17 ಥ Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » 400189-10 ಥ If there is noticeable play present: (EXC-RSIXDAYS, XCR-WUSA) ಥ Adjust play of the steering head bearing. ( P. 17) (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Adjust play of the steering head bearing. ( P. 17) Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. » If click positions are noticeable: (EXC-RSIXDAYS, XCR-WUSA) ಥ Adjust play of the steering head bearing. ( P. 17) (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Adjust play of the steering head bearing. ( P. 17) ಥ ಥ Check the steering head bearing and replace if required. Remove the motorcycle from the work stand. ( P. 8) Adjusting play of steering head bearing (EXC-RSIXDAYS, XCR-WUSA) ಥ Jack up the motorcycle. ( P. 8) ಥ Loosen screw. Remove screw. ಥ Loosen and retighten screw. Specification Screw, top steering head M20x1,5 10Nm (7.38lbfft) ಥ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. ಥ Fully tighten screw. Specification 500103-11 Screw, top triple clamp ಥ 17Nm (12.54lbfft) Mount and tighten screw. Specification Screw, top steering stem ಥ M8 M8 17Nm (12.54lbfft) Loctite® 243™ Check play of steering head bearing. Adjusting play of steering head bearing (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) ಥ Jack up the motorcycle. ( ಥ Loosen screws and. ಥ Loosen and retighten screw. Specification P. 8) Screw, top steering head M20x1,5 10Nm (7.38lbfft) ಥ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. ಥ Fully tighten screw. Specification 100022-10 Screw, top triple clamp ಥ 20Nm (14.75lbfft) M8 20Nm (14.75lbfft) Tighten screw. Specification Screw, top steering stem ಥ M8 Check play of steering head bearing. 01/FORK, TRIPLE CLAMP Greasing the steering head bearing (EXC-RSIXDAYS, XCR-WUSA) Remove the lower triple clamp. ( P. 13) Install the lower triple clamp. ( P. 14) (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) Remove the lower triple clamp. ( P. 15) Install the lower triple clamp. ( P. 15) 18 03/FRAME 19 )5$0( Removing the engine sprocket cover ಥ Remove screw. ಥ Remove screw. Take off the engine sprocket cover. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the engine sprocket cover. Mount and tighten screw. Specification 500113-10 Installing the engine sprocket cover Remaining screws, chassis ಥ 25Nm (18.44lbfft) M6 10Nm (7.38lbfft) Mount and tighten screw. Specification Screw, clutch slave cylinder 500113-11 M8 04/SHOCK ABSORBER, SWINGARM 20 6+2&. $%625%(5 6:,1*$50 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 500129-10 Adjusting high-speed compression damping of the shock absorber Danger Danger of accidentsಗThe shock absorber is under high pressure. ಥ The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock absorber. Info The high-speed setting can be seen during the fast compression of the shock absorber. ಥ Turn the adjusting screw clockwise with a ring wrench until it stops. Info Do not loosen nut! ಥ Turn back counterclockwise the number of turns corresponding to the shock absorber type. Specification Compression damping, high-speed 400208-10 Comfort 2turns Standard 1.5turns Sport 1turn Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. Adjusting the low-speed compression damping of the shock absorber Danger Danger of accidentsಗThe shock absorber is under high pressure. ಥ The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock absorber. Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. ಥ Turn the adjusting screw clockwise with a screwdriver until it stops. Info Do not loosen nut! 400209-10 04/SHOCK ABSORBER, SWINGARM ಥ 21 Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Compression damping, low-speed Comfort 18clicks Standard 15clicks Sport 12clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. Adjusting rebound damping of the shock absorber Danger Danger of accidentsಗThe shock absorber is under high pressure. ಥ The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock absorber. ಥ Turn the adjusting screw clockwise until it stops. Info Do not loosen nut! ಥ Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Rebound damping Comfort 400210-10 24clicks Standard 22clicks Sport 20clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. Measuring rear wheel sag unloaded A 0 400220-10 ಥ Jack up the motorcycle. ( ಥ Measure the distance ಥ as vertical as possible ಥ between the rear axle and a fixed point, for example, a mark on the side cover. ಥ Make a note of the value as measurement . ಥ Remove the motorcycle from the work stand. ( P. 8) P. 8) 04/SHOCK ABSORBER, SWINGARM 22 Checking static sag of the shock absorber A 0 ಥ Measure distance ಥ Ask someone to help you by holding the motorcycle upright. ಥ Measure the distance between the rear axle and the fixed point again. ಥ Make a note of the value as measurement. of rear wheel unloaded. ( P. 21) Info The static sag is the difference between measurements ಥ and. Check the static sag. Static sag » 35mm (1.38in) If the static sag is less or more than the specified value: ಥ Adjust the spring preload of the shock absorber. B 0 400221-10 Checking the riding sag of the shock absorber A 0 ಥ Measure distance ಥ With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out. ಥ The other person now has to measure the distance between the rear axle and a fixed point. ಥ Make a note of the value as measurement. of rear wheel unloaded. ( P. 21) Info The riding sag is the difference between measurements ಥ Check the riding sag. Riding sag » C and. 105mm (4.13in) If the riding sag differs from the specified measurement: ಥ Adjust the riding sag. ( P. 23) 400222-10 Adjusting spring preload of the shock absorber Danger Danger of accidentsಗThe shock absorber is under high pressure. ಥ The shock absorber is filled with high density nitrogen. Follow the steps in the repair manual when working on the shock absorber. Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. ಥ Remove shock absorber. ( ಥ After removing the shock absorber, clean it thoroughly. P. 23) 04/SHOCK ABSORBER, SWINGARM 2 1 23 ಥ Loosen screw. ಥ Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) A ಥ Measure the overall spring length when not under tension. ಥ Tighten the spring by turning adjusting ring to measurement . Specification Spring preload Standard 9mm Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. ಥ Tighten screw. Specification Screw, shock absorber adjusting ring ಥ Installing shock absorber. ( M6 5Nm (3.69lbfft) P. 24) 400216-10 Adjusting riding sag ಥ Remove shock absorber. ( ಥ After removing the shock absorber, clean it thoroughly. ಥ Choose and fit a suitable spring. Specification P. 23) Spring rate Weight of rider: 65… 75kg (143.3… 165.34lb.) 69N/mm (394lb/in) Weight of rider: 75… 85kg (165.34… 187.39lb.) 72N/mm (411.13lb/in) Weight of rider: 85… 95kg (187.39… 209.44lb.) 76N/mm (433.97lb/in) Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. ಥ Installing shock absorber. ( ಥ Check the static sag of the shock absorber. ( P. 22) ಥ Check the riding sag of the shock absorber. ( P. 22) ಥ Adjust the rebound damping of the shock absorber. P. 24) Removing the shock absorber 500075-10 ಥ Jack up the motorcycle. ( ಥ Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. ಥ Remove screw, push splash protector to the side, and remove the shock absorber. P. 8) 04/SHOCK ABSORBER, SWINGARM 24 Installing shock absorber ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Push splash protector to the side and position the shock absorber. Mount and tighten screw. Specification Screw, top shock absorber ಥ 80Nm (59.01lbfft) Loctite® 243™ M12 80Nm (59.01lbfft) Loctite® 243™ Mount and tighten screw. Specification Screw, bottom shock absorber 500075-11 M12 Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be greased with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. ಥ Remove the motorcycle from the work stand. ( P. 8) 05/EXHAUST 25 (;+$867 Removing main silencer Warning Danger of burnsಗThe exhaust system gets very hot when the vehicle is driven. ಥ Allow the exhaust system to cool down. Do not touch hot components. ಥ Disconnect spring. ಥ Remove screws and take off main silencer. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the main silencer. Mount and tighten screws. Specification 400337-10 Fitting the main silencer Remaining screws, chassis ಥ Reconnect spring. ಥ Remove shock absorber. ( ಥ Remove the main silencer. ( M6 10Nm (7.38lbfft) 400337-11 Removing the manifold P. 23) P. 25) ಥ Remove screw. ಥ Remove the springs and take off the manifold. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the manifold and mount the springs. ಥ Mount and tighten screw. Specification 500076-10 Installing the manifold Remaining screws, chassis 500076-11 ಥ Fit the main silencer. ( ಥ Installing shock absorber. ( M8 P. 25) P. 24) 25Nm (18.44lbfft) 06/AIR FILTER 26 $,5 ),/7(5 Dismounting the air filter box lid ಥ Pull off the air filter box lid in area ಥ Insert the air filter box lid into the rear area to the side and remove to the front. 400338-10 Installing the air filter box lid and clip it into the front area. 400338-11 Removing the air filter Note Engine failureಗUnfiltered intake air has a negative effect on the service life of the engine. ಥ Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. ಥ Dismount the air filter box lid. ( ಥ Hang the air filter holder out to the bottom and swing it to the side. Remove the air filter with the air filter support. ಥ Remove the air filter from the air filter support. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the clean air filter onto the air filter support. ಥ Put in both parts together, position them and fix them with the air filter support. P. 26) 500107-10 Installing the air filter Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. ಥ 500107-10 Install the air filter box lid. ( P. 26) 06/AIR FILTER 27 Cleaning air filter Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. ಥ Remove the air filter. ( ಥ Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. P. 26) Cleaning substance for foam air filter ( P. 175) Info Only press the air filter to dry it, never wring it out. ಥ Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( P. 175) ಥ Clean the air filter box. ಥ Check carburetor connection boot for damage and tightness. ಥ Install the air filter. ( P. 26) Removing the carburetor connection boot ಥ Remove the air filter. ( ಥ Loosen the hose clip. Unhang the carburetor connection boot from the filter wall and remove it. P. 26) 500108-10 Installing the carburetor connection boot 500108-11 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the carburetor connection boot and hang it into the filter wall. Position the hose clip and tighten it. ಥ Install the air filter. ( P. 26) 07/FUEL TANK, SEAT, TRIM 28 )8(/ 7$1. 6($7 75,0 Opening filler cap ಥ Press release button, turn filler cap counterclockwise and lift it free. ಥ Replace the filler cap and turn clockwise until the release button locks in place. 400199-10 Closing filler cap Info Run the fuel tank breather hose without kinks. 400199-11 Removing the seat ಥ Remove screw. Lift up the seat at the rear, pull it back and then remove from above. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of the seat and simultaneously push it forwards. ಥ Make sure that the seat is correctly locked in. ಥ Mount and tighten the screw of the seat fixing. Specification 500080-10 Mounting the seat Remaining screws, chassis M6 10Nm (7.38lbfft) 500068-01 Dismounting the fuel tank Danger Fire hazardಗFuel can easily catch fire. ಥ Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. ಥ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel. 07/FUEL TANK, SEAT, TRIM 29 Warning Danger of poisoningಗFuel is poisonous and a health hazard. ಥ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. ಥ Remove the seat. ( ಥ Turn the handle of the fuel tap to the OFF position. (Figure500137-10 ಥ Pull off the fuel hose. P. 28) P. 30) Info Remaining fuel may run out of the fuel hose. ಥ Remove screws with collar sleeve. (Every EXC-R models) ಥ Hang the horn and horn bracket to one side. 500157-10 ಥ Remove screw with collar sleeve. ಥ Remove the tube from the fuel tank vent line. ಥ Pull both spoilers to the side of the radiator bracket and take the fuel tank away upwards. 500066-10 500067-10 Installing the fuel tank Danger Fire hazardಗFuel can easily catch fire. ಥ Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. ಥ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel. Warning Danger of poisoningಗFuel is poisonous and a health hazard. ಥ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. 07/FUEL TANK, SEAT, TRIM 30 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the fuel tank and fit the two spoilers to the side of the radiator fixing. ಥ Make sure that no cables or Bowden cables are trapped or damaged. ಥ Mount the fuel tank vent hose. ಥ Fit and tighten screw with collar sleeve. Specification 500067-01 Remaining screws, chassis M6 10Nm (7.38lbfft) (Every EXC-R models) ಥ Position horn with horn bracket. 500066-11 ಥ Fit and tighten screws with collar sleeve. Specification Remaining screws, chassis ಥ Connect fuel hose. ಥ Mount the seat. ( M6 10Nm (7.38lbfft) P. 28) 500157-11 Fuel tap The fuel tap is on the left of the fuel tank. With the tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF ಥNo fuel can flow from the tank to the carburetor. • Fuel supply open ON ಥFuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve. • Reserve fuel supply open RES ಥFuel can flow from the tank to the carburetor. The fuel tank empties completely. 500137-10 08/MASK, FENDER 31 0$6. )(1'(5 Dismounting the front fender ಥ Remove screws. Remove the front fender. ಥ Make sure that the distance bushings remain in place. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Make sure that the distance bushings are mounted in the fender. ಥ Position the front fender. Mount and tighten screws. Specification 500092-10 Installing the front fender Remaining screws, chassis M6 10Nm (7.38lbfft) Info Ensure that there is contact between the holding lugs and the start number plate or headlight mask. 500092-10 Removing headlight mask with headlight (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-WZA) ಥ Switch off all electrical equipment. ಥ Remove screw and take off clamp. ಥ Loosen the rubber band. Push up the headlight mask and swing it forwards. ಥ Pull out the electric plug connector and remove the headlight mask with the headlight. 500155-10 500156-10 Refitting the headlight mask with the headlight (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-WZA) 500156-11 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Connect the electric plug connector. 08/MASK, FENDER 32 ಥ Position the headlight mask and fix it with the rubber band. Info Take care with the contact of the holding lug at the fender. ಥ Position the brake line and cable harness. Put the clamp on, mount and tighten screw. ಥ Check the headlamp setting. 500155-11 Dismount the start number plate (XCR-WUSA) ಥ Remove screw and take off clamp. ಥ Remove screw with distance bushing. Remove the start number plate. 500101-10 Fitting the start number plate (XCR-WUSA) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the start number plate. Fit and tighten screw with distance bushing. Specification Remaining screws, chassis M6 10Nm (7.38lbfft) Info Take care with the contact of the holding lug at the fender. 500101-11 ಥ Position the brake line and cable harness. Put the clamp on, mount and tighten screw. 09/FRONT WHEEL 33 )5217 :+((/ Removing front wheel ಥ Jack up the motorcycle. ( ಥ Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. P. 8) Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. 500089-10 ಥ Remove screw. ಥ Loosen screw. ಥ Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. 500084-10 Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged. 500085-10 ಥ Remove distance bushing. 500086-10 Fitting front wheel Warning Danger of accidentsಗReduced braking due to oil or grease on the brake discs. ಥ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Clean and grease shaft seal rings and bearing surface ings. Long-life grease ( ಥ 500086-11 P. 175) Fit the distance bushings. of the distance bush- 09/FRONT WHEEL 34 ಥ Lift the front wheel into the fork, position it, and insert the wheel spindle. ಥ Mount and tighten screw. Specification Screw, front wheel spindle 500084-11 M24x1,5 40Nm (29.5lbfft) ಥ Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. ಥ Remove the motorcycle from the work stand. ( ಥ Pull the front wheel brake and push down hard on the fork several times to align the fork legs. ಥ Fully tighten screw. Specification Screw, fork stub P. 8) M8 15Nm (11.06lbfft) Checking brake discs ಥ Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement . Info A Wear reduces the thickness of the brake disc around the area used by the brake linings. Wear limit of brake discs 400257-10 » front 2.5mm (0.1in) Rear 3.5mm (0.14in) The brake disc thickness is less than the specified value. ಥ Replace the brake disc. Removing the front brake disc ಥ Remove front wheel. ( ಥ Remove screws. Take off the brake disc. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Clean the contact surface of the brake disc. ಥ Position the brake disc with the label facing outward. Mount and tighten screws. Specification P. 33) 500106-10 Installing the front brake disc Screw, front brake disc ಥ 500106-10 Fit front wheel. ( P. 33) M6 14Nm (10.33lbfft) 09/FRONT WHEEL 35 Tire condition checking Info Fit only tires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be fitted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces. ಥ Examine the tires for cuts, foreign bodies and other damage. ಥ Check the depth of the tread. » Info Note local national regulations concerning the minimum tread depth. Minimum tread depth: 싩2mm (싩0.08in) If the minimum tread depth is insufficient: ಥ Replace the tire(s). Checking tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. ಥ Remove dust cap. ಥ Check tire air pressure when tires are cold. Tire air pressure off road front 1bar (14.5psi) Rear 1bar (14.5psi) Road tire pressure (Every EXC-R models) 400241-01 » ಥ front 1.5bar (21.76psi) Rear 2bar (29.01psi) If the tire pressure does not meet specifications: ಥ Correct tire pressure. Mount dust cap. Checking spoke tension Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. ಥ To check spoke tension, tap each spoke with a screwdriver. Specification You should hear a high note. Spoke nipple, front wheel M4,5 5Nm (3.69lbfft) Spoke nipple, rear wheel M5 5Nm (3.69lbfft) Info 400228-01 If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions. 10/REAR WHEEL 36 5($5 :+((/ Removing rear wheel ಥ Jack up the motorcycle. ( ಥ Press the brake caliper by hand on to the brake disc in order to press back the brake piston. P. 8) Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. ಥ Remove nut. ಥ Remove chain adjuster. Withdraw the wheel spindle only enough to allow the rear wheel to be pushed forward. ಥ Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. ಥ Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the swing arm. Info Do not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged. 400258-10 ಥ Remove distance bushing. 400260-11 Fitting rear wheel Warning Danger of accidentsಗReduced braking due to oil or grease on the brake discs. ಥ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Clean and grease shaft seal rings and bearing surface ings. Long-life grease ( of the distance bush- P. 175) ಥ Fit the distance bushings. ಥ Lift the rear wheel into the swing arm, position it, and insert the wheel spindle. ಥ Put the chain on. 400260-10 400259-10 10/REAR WHEEL 37 ಥ Position the chain adjuster. Fit nut, but do not tighten it yet. ಥ Check the chain tension when fitting rear wheel. ( ಥ Make sure that the chain adjusters are fitted correctly on the adjusting screws. ಥ Tighten nut. Specification Nut, rear wheel spindle P. 37) M20x1,5 80Nm (59.01lbfft) Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°. ಥ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. ಥ Remove the motorcycle from the work stand. ( ಥ Remove the rear wheel. ( ಥ Remove screws. Take off the brake disc. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Clean the contact surface of the brake disc. ಥ Position the brake disc with the label facing outward. Mount and tighten screws. Specification P. 8) 400225-12 Removing the rear brake disc P. 36) 700075-10 Installing the rear brake disc Screw, rear brake disc ಥ Fit the rear wheel. ( M6 14Nm (10.33lbfft) P. 36) 700075-10 Checking the chain tension when fitting rear wheel Warning Danger of accidentsಗDanger caused by incorrect chain tension. ಥ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. 10/REAR WHEEL 38 ಥ Make sure that the chain adjusters are fitted correctly on the adjusting screws. ಥ Push the chain at the end of the chain sliding component upwards to measure chain tension . Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension 400213-10 » 8… 10mm (0.31… 0.39in) If the chain tension does not meet specifications: ಥ Adjust the chain tension when fitting rear wheel. ( P. 38) Adjusting chain tension - fitting rear wheel ಥ Loosen nuts. ಥ Adjust the chain tension by turning the adjusting screws left and right. Specification Chain tension 8… 10mm (0.31… 0.39in) Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. ಥ Tighten nuts. 400225-11 Checking the chain tension Warning Danger of accidentsಗDanger caused by incorrect chain tension. ಥ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. ಥ Jack up the motorcycle. ( ಥ Push the chain at the end of the chain sliding component upwards to measure the chain tension . P. 8) Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension » 400213-10 ಥ 8… 10mm (0.31… 0.39in) If the chain tension does not meet specifications: ಥ Adjusting chain tension - after checking. ( P. 39) Remove the motorcycle from the work stand. ( P. 8) 10/REAR WHEEL 39 Adjusting chain tension - after checking ಥ Loosen nut. ಥ Loosen nuts. ಥ Adjust the chain tension by turning the adjusting screws left and right. Specification Chain tension 8… 10mm (0.31… 0.39in) Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. ಥ Tighten nuts. ಥ Make sure that the chain adjusters are fitted correctly on the adjusting screws. ಥ Tighten nut. Specification Nut, rear wheel spindle M20x1,5 80Nm (59.01lbfft) Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°. 400225-13 Adjusting the chain tension Warning Danger of accidentsಗDanger caused by incorrect chain tension. ಥ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. ಥ Jack up the motorcycle. ( ಥ Push the chain at the end of the chain sliding component upwards to measure chain tension . P. 8) Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. 400213-10 10/REAR WHEEL 40 ಥ Loosen nut. ಥ Loosen nuts. ಥ Adjust the chain tension by turning the left and right adjusting screws. Specification Chain tension 8… 10mm (0.31… 0.39in) Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks. The rear wheel is then correctly aligned. ಥ Tighten nuts. ಥ Make sure that chain adjusters are fitted correctly on the adjusting screws. ಥ Tighten nut. Specification Nut, rear wheel spindle M20x1,5 80Nm (59.01lbfft) Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. Chain adjusters can be turned by 180°. 400225-10 ಥ Remove the motorcycle from the work stand. ( ಥ Remove screws and. Take off the chain guide. P. 8) Adjusting chain guide Conditions Number of teeth: 싨44teeth ಥ Insert nut in hole . Position the chain guide. ಥ Mount and tighten screws and. Specification Remaining screws, chassis M6 10Nm (7.38lbfft) Conditions Number of teeth: 싩45teeth ಥ Insert nut in hole. Position the chain guide. ಥ Mount and tighten screws and. Specification Remaining screws, chassis M6 10Nm (7.38lbfft) 400252-10 Checking the rear sprocket / engine sprocket for wear ಥ Check the rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: ಥ Replace rear sprocket / engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be replaced together. 400227-01 ಥ Check that the chain guide is firmly seated and not worn. 10/REAR WHEEL 41 Checking chain wear ಥ Jack up the motorcycle. ( ಥ Shift to neutral and pull the upper chain length with the specified tension . Specification P. 8) Chain tension A 0 ಥ 10… 15kg (22.05… 33.07lb.) Measure distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance at the longest chain section » 272mm (10.71in) If distance is greater than the specified measurement: ಥ Replace the chain. Info B 0 When you replace the chain, you should also replace the rear and engine sprockets. New chains wear out faster on old, worn sprockets. 1 2 3 16 17 18 ಥ Remove the motorcycle from the work stand. ( P. 8) 400226-10 Checking chain dirt ಥ Check the chain for coarse dirt accumulation. » If the chain is very dirty: ಥ Clean the chain. ( P. 41) Cleaning the chain Warning Danger of accidentsಗOil or grease on the tires reduces their grip. ಥ Remove oil and grease with a suitable cleaning material. Warning Danger of accidentsಗReduced braking due to oil or grease on the brake discs. ಥ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info The service life of the chain depends largely on its maintenance. ಥ Clean the chain regularly and then treat with chain spray. Chain cleaner ( P. 175) Offroad chain spray ( P. 175) 11/WIRING HARNESS, BATTERY 42 :,5,1* +$51(66 %$77(5< Removing a fuse ಥ Switch off all power-consuming components and switch off the engine. ಥ Dismount the air filter box lid. ( ಥ Remove the protection cover. P. 26) Info The fuse is located in the starter relay under the filter box cover. ಥ Remove the fuse. 400270-10 Replacing the fuse Warning Fire hazardಗThe electrical system can be overloaded by the use of incorrect fuses. ಥ Use only fuses with the prescribed amperage. Never by-pass or repair fuses. ಥ Check parts for damage and wear. Replace damaged or worn parts. Info A reserve fuse is located in the starter relay. Replace a burned-out fuse only by an equivalent fuse. ಥ Refit the fuse. Fuse(58011109110) Info 400273-10 If the new fuse burns out, contact an authorized KTM workshop. ಥ Replace the protection cover. ಥ Install the air filter box lid. ( P. 26) Removing the battery Warning Risk of injuryಗBattery acid and battery gases cause serious cauterization. ಥ Keep batteries out of the reach of children. ಥ Wear suitable protective clothing and goggles. ಥ Avoid contact with battery acid and battery gases. ಥ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. ಥ In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor. 500069-10 ಥ Switch off all power-consuming components and switch off the engine. ಥ Remove the seat. ( ಥ Disconnect the negative (minus) cable of the battery. ಥ Pull back the plus pole cover and disconnect the positive (plus) cable of the battery. ಥ Hang the rubber band out to the bottom. ಥ Lift the battery up. P. 28) 11/WIRING HARNESS, BATTERY 43 Installing the battery ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Place the battery in the battery holder. 4Ah battery(YTX5L-BS) ( P. 150) ಥ Reconnect the rubber band. ಥ Attach the plus cable and replace the plus pole cover. ಥ Attach the minus cable. ಥ Mount the seat. ( P. 28) 500069-11 Recharging the battery Warning Risk of injuryಗBattery acid and battery gases cause serious cauterization. ಥ Keep batteries out of the reach of children. ಥ Wear suitable protective clothing and goggles. ಥ Avoid contact with battery acid and battery gases. ಥ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. ಥ In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor. Warning Environmental hazardಗComponents and battery acid are a danger to the environment. ಥ Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced. If the battery is discharged from starting, it must be recharged immediately. If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed. The battery is maintenance-free, i.e., the acid level does not have to be checked. ಥ Switch off all power-consuming components and switch off the engine. ಥ Remove the seat. ( ಥ Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics. ಥ Connect the battery charger to the battery. Switch on the battery charger. P. 28) Battery charger(58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove the lid. Charge the battery according to the instructions on the battery casing. 400240-10 ಥ Switch off the charger after charging. Disconnect the battery. Specification The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use. 3months 11/WIRING HARNESS, BATTERY ಥ Mount the seat. ( 44 P. 28) 13/BRAKE SYSTEM 45 %5$.( 6<67(0 Checking the front brake linings ಥ Check the brake linings for minimum thickness . » Minimum thickness : 싩1mm (싩0.04in) If the minimum thickness is less than specified: ಥ Change the front brake linings. ಥ Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. 400235-10 Removing the front brake linings Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. 500089-11 ಥ Remove the locking split pins, withdraw the bolt, and take out the brake pads. ಥ Remove cable clip. Remove screws and take off brake caliper. ಥ Clean brake caliper and brake caliper support. Installing the front brake linings Warning Danger of accidentsಗReduced braking due to oil or grease on the brake discs. ಥ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidentsಗReduced braking due to use of non-approved brake linings. ಥ Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. ಥ Check the brake discs. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. Info The arrow on the leaf spring points in the rotation direction of the brake disc. 500091-10 ಥ Fit the brake linings, insert bolt, and mount locking split pins. ಥ Position brake caliper, mount and tighten screws. Specification Screw, front brake caliper 500089-12 M8 25Nm (18.44lbfft) Loctite® 243™ ಥ Fit cable clip . ಥ Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. 13/BRAKE SYSTEM 46 Changing the front brake linings Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info KTM recommends brake fluid DOT5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT4 and offers more protection under high load. Never user DOT5 brake fluid! This 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! ಥ Remove the front brake linings. ಥ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ಥ Remove screws. ಥ Remove cover with membrane. ಥ Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. ಥ Install the front brake linings. ( ಥ Add brake fluid to level . Specification Measurement of Brake fluid DOT 5.1 ( P. 45) 5mm (0.2in) P. 174) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 400230-10 Adjusting basic position of handbrake lever (Every XCR-W models) ಥ Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw. Info Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! 400196-12 ಥ Check the free play of the hand brake lever. ( P. 47) 13/BRAKE SYSTEM 47 Checking free play of hand brake lever Warning Danger of accidentsಗBrake system failure. ಥ If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications. (Every XCR-W models) ಥ Push the hand brake lever forwards and check free play. . Free play of hand brake lever » 싩3mm (싩0.12in) If the free travel does not meet specifications: ಥ adjust the basic position of handbrake lever. ( P. 46) 400196-11 (Every EXC-R models) ಥ Push the hand brake to the handlebar and check free play . Free play of hand brake lever » 싩3mm (싩0.12in) If the free travel does not meet specifications: ಥ Adjust the free travel of the handbrake lever. ( P. 47) 400196-13 Adjusting free travel of handbrake lever (Every EXC-R models) ಥ Adjust the free travel of the handbrake lever with the adjustment screw. Info Turn the adjustment screw clockwise to reduce free travel. The pressure point moves away from the handlebar. Turn the adjustment screw counterclockwise to increase free travel. The pressure point moves towards the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! 400196-12 ಥ Check the free play of the hand brake lever. ( ಥ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ಥ Check the brake fluid level in the viewer. » If the brake fluid is below theMIN mark: ಥ Add front brake fluid. P. 47) Checking the front brake fluid level 400231-10 13/BRAKE SYSTEM 48 Add front brake fluid Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info KTM recommends brake fluid DOT5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT4 and offers more protection under high load. Never user DOT5 brake fluid! This 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! ಥ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ಥ Remove screws. ಥ Remove cover with membrane. ಥ Add brake fluid to level . Specification Measurement of Brake fluid DOT 5.1 ( 5mm (0.2in) P. 174) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 400230-10 Changing the front brake fluid Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info KTM recommends brake fluid DOT5.1 fromMotorex®. This brake fluid has a higher wet boiling point than brake fluid DOT4 and offers more protection under high load. Never user DOT5 brake fluid! This 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! 13/BRAKE SYSTEM 49 ಥ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ಥ Remove screws. ಥ Remove cover with membrane. ಥ Extract the old brake fluid from the brake fluid reservoir with a syringe and add new brake fluid. Bleed syringe (50329050000) ( Brake fluid DOT 5.1 ( P. 177) P. 174) 400378-10 ಥ Pull off dust cap and connect a commercially available suction device (workshop equipment). ಥ Remove bleeder screw and suck out the old brake fluid. ಥ During suction, ensure that the brake fluid reservoir is always sufficiently filled with new brake fluid. ಥ Tighten the bleeder screw. Remove the suction device and attach the dust cap. ಥ Add brake fluid to level . Specification 700069-10 Measurement of Brake fluid DOT 5.1 ( 5mm (0.2in) P. 174) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the cover with the membrane. Mount and tighten the screws. ಥ Repeatedly activate the hand brake lever until a firm pressure point is reached. 400379-10 Info Clean up overflowed or spilt brake fluid immediately with water. Checking rear brake linings ಥ Check the brake linings for minimum thickness . » Minimum thickness : 싩1mm (싩0.04in) If the minimum thickness is less than specified: ಥ Change the rear brake linings. ಥ Press the brake caliper by hand on to the brake disc in order to press back the brake piston. 400238-10 Removing the rear brake linings Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. 400236-10 ಥ Remove locking split pins, withdraw bolt, and take out the brake pads. ಥ Clean the brake caliper and brake caliper support. 13/BRAKE SYSTEM 50 Installing the rear brake linings Warning Danger of accidentsಗReduced braking due to oil or grease on the brake discs. ಥ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidentsಗReduced braking due to use of non-approved brake linings. ಥ Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. ಥ Check the brake discs. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. Info The arrow on the leaf spring points in the rotation direction of the brake disc. 500122-10 ಥ Fit the brake linings, insert bolt, and mount locking split pins. Info Make sure that the decoupling plate is mounted on the piston side of the brake pad. ಥ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. 400237-10 Changing the rear brake linings Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info KTM recommends brake fluid DOT5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT4 and offers more protection under high load. Never user DOT5 brake fluid! This 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! 13/BRAKE SYSTEM 51 ಥ Remove the rear brake linings. ಥ Stand the vehicle upright. ಥ Remove screw cap with membrane and the O-ring. ಥ Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. ಥ Install the rear brake linings. ( ಥ Add brake fluid to level . Brake fluid DOT 5.1 ( 400233-10 P. 50) P. 174) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the screw cap with the membraneand the O-ring. Info Clean up overflowed or spilt brake fluid immediately with water. Checking free play of foot brake lever Warning Danger of accidentsಗBrake system failure. ಥ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications. ಥ Disconnect spring. ಥ Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play . Specification Free play at foot brake lever » ಥ 3… 5mm (0.12… 0.2in) If the free travel does not meet specifications: ಥ Adjust the basic position of the footbrake lever. ( P. 51) Reconnect spring. 500139-11 Adjusting basic position of footbrake lever Warning Danger of accidentsಗBrake system failure. ಥ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications. ಥ Disconnect spring. ಥ Loosen nut and with push rod, turn it back until you have maximum free play. ಥ To adjust the basic position of the footbrake lever individually, lossen nut and turn screw accordingly. Info The range of adjustment is limited. ಥ 500154-10 Turn push rod accordingly until you have free play . If necessary, adjust the basic position of the footbrake lever. Specification Free play at foot brake lever ಥ Hold screw and tighten nut. Specification Remaining nuts, chassis ಥ M8 30Nm (22.13lbfft) M6 15Nm (11.06lbfft) Hold push rod and tighten nut. Specification Remaining nuts, chassis ಥ 3… 5mm (0.12… 0.2in) Reconnect spring. 13/BRAKE SYSTEM 52 Checking rear brake fluid level ಥ Stand the vehicle upright. ಥ Check the brake fluid level in the viewer. » When in the viewer an air bubble is visible: ಥ Add rear brake fluid. 400234-10 Adding rear brake fluid Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info KTM recommends brake fluid DOT5.1 fromMotorex®. This brake fluid has a higher wet boiling point than brake fluid DOT4 and offers more protection under high load. Never user DOT5 brake fluid! This 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! ಥ Stand the vehicle upright. ಥ Remove screw cap with membrane and the O-ring. ಥ Add brake fluid to level . Brake fluid DOT 5.1 ( P. 174) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the screw cap with the membraneand the O-ring. Info 400233-10 Clean up overflowed or spilt brake fluid immediately with water. Changing the rear brake fluid Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info KTM recommends brake fluid DOT5.1 fromMotorex®. This brake fluid has a higher wet boiling point than brake fluid DOT4 and offers more protection under high load. Never user DOT5 brake fluid! This 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! 13/BRAKE SYSTEM 53 ಥ Stand the vehicle upright. ಥ Remove screw cap with membrane and the O-ring. ಥ Extract the old brake fluid from the brake fluid reservoir with a syringe and add new brake fluid. Bleed syringe (50329050000) ( Brake fluid DOT 5.1 ( P. 177) P. 174) 400380-10 ಥ Pull off dust cap and connect a commercially available suction device (workshop equipment). ಥ Remove bleeder screw and suck out the old brake fluid. Info During suction, ensure that the reservoir is always sufficiently filled with new brake fluid. ಥ Tighten the bleeder screw. Remove the suction device and attach the dust cap. ಥ Add brake fluid to level . 700068-10 Brake fluid DOT 5.1 ( ಥ P. 174) Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the screw cap with the membraneand the O-ring. ಥ Repeatedly activate the foot brake lever until a firm pressure point is reached. Info Clean up overflowed or spilt brake fluid immediately with water. 400381-10 14/LIGHT SYSTEM, INSTRUMENTS 54 /,*+7 6<67(0 ,167580(176 Adjusting speedometer functions Info In the condition at delivery, only the SPEED/H display mode and SPEED/ODO are active. Condition The motorcycle is standing. 400318-01 ಥ Press the button display. ಥ Press the button for 3 - 5 seconds. The Setup menu opens and the active functions are displayed. ಥ Switch to the function you require by briefly pressing the button . The selected function flashes. briefly and repeatedly until H appears at the bottom right of the Activating a function ಥ Press the button"+". The icon remains in the display and the display changes to the next function. Deactivating a function ಥ Press the button"ಣ". The icon disappears from the display and the display changes to the next function. ಥ Activate or deactivate all functions accordingly. ಥ Press the button for 3 - 5 seconds. The settings are saved and the Setup menu closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed. Setting kilometers or miles Info If you change the unit, the ODO value is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are deleted at the changeover. Condition The motorcycle is standing. ಥ Press the button display. ಥ Press the button for 3 - 5 seconds. The Setup menu opens and the active functions are displayed. ಥ Press the button briefly and repeatedly until H appears at the bottom right of the repeatedly until the Km/h / Mphdisplay flashes. Setting Km/h ಥ Press the button"+". 400329-01 Setting Mph ಥ Press the button"ಣ". ಥ Press the button for 3 - 5 seconds. The settings are saved and the Setup menu closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed. 14/LIGHT SYSTEM, INSTRUMENTS 55 Setting the clock Condition The motorcycle is standing. ಥ Press the button the display. ಥ Press the button for 3 - 5 seconds. The hour display flashes. briefly and repeatedly until CLK appears at the bottom right of ಥ Set the hour display with the button"+" and/or button"ಣ". ಥ Press the button briefly. The next segment of the display flashes and can be set. ಥ You can set the following segments in the same way as the hours by pressing the button"+" and the button"ಣ". 400330-01 Info The seconds can only be set to zero. ಥ Press the button for 3 - 5 seconds. The settings are saved and the Setup menu closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed. 30/ENGINE 56 (1*,1( Removing the engine ಥ Drain the coolant. ( ಥ Remove the carburetor. ( ಥ Remove the engine sprocket. ( ಥ Jack up the motorcycle. ( ಥ Disconnect the negative (minus) cable of the battery. ಥ Remove screws. Remove the foot brake cylinder and hang it on one side without tension. P. 133) P. 115) P. 131) P. 8) Info The brake line connection does not need to be disconnected. To not kink the brake line. Do not damage the bellows on the foot brake cylinder. 500116-10 ಥ Detach spring and take if off. ಥ Prop up the rear wheel. Remove screw. ಥ Remove nut. ಥ Remove the swingarm pivot. Remove the swingarm, shock absorber and rear wheel together. Info Having an assistant is helpful in this step. Ensure that the engine is adequately secured and will not fall over. 500117-10 ಥ Remove the main silencer. ( ಥ Remove screw. ಥ Remove springs ಥ Undo hose clamps . Take off the radiator hoses together. ಥ Undo hose clamps . Remove the radiator hoses together along with the thermostat. P. 25) and take off the manifold. 500076-13 500118-10 500119-10 ಥ Pull engine vent hose ಥ Pull off the spark plug connector. from the valve cover and engine case. 30/ENGINE 57 ಥ Remove the cable binder and disconnect all connectors of the engine wiring harness in area . ಥ Remove screws(1. Take off the slave cylinder of the clutch and hang it to one side. Info To not kink the clutch line. Do not activate the clutch lever if the slave cylinder of the clutch has been removed. 500120-10 ಥ Take out the clutch push rod. ಥ Slide back cover(2. Remove the nut from the electrical connection on the starter engine and take off the cable. ಥ Remove screws(3. Lift the engine out of the frame. Info Having an assistant is helpful in this step. Ensure that the engine is adequately secured and will not fall over. Protect the frame and attachments against damage. Installing the engine ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the engine in the frame. Mount screws but do not tighten them yet. Info Having an assistant is helpful in this step. Ensure that the engine is adequately secured and will not fall over. Protect the frame and attachments against damage. ಥ 500120-11 Position the electrical connection on the starter engine. Mount and tighten the nut. Slide on cover. Specification Remaining nuts, chassis M6 15Nm (11.06lbfft) ಥ Insert the clutch push rod with the small diameter facing the clutch side. ಥ Position the slave cylinder of the clutch. Mount and tighten screws. Specification Screw, clutch slave cylinder M6 10Nm (7.38lbfft) ಥ Attach all connectors of the engine wiring harness in area . ಥ Position the connectors, wiring harness and clutch line and fix them with cable binders. ಥ Attach the spark plug connector. ಥ Attach the engine vent hose on the valve cover and engine case. ಥ Attach the cooler hose with the thermostat. Position hose clamps and tighten. ಥ Attach the cooler hoses. Position hose clamps 500119-11 500118-11 and tighten. 30/ENGINE 58 ಥ Position the manifold and mount springs . ಥ Mount and tighten screw . Specification Remaining screws, chassis M8 25Nm (18.44lbfft) ಥ Fit the main silencer. ( ಥ Position the swingarm, shock absorber and rear wheel together. Insert the swingarm pivot. P. 25) 500076-14 Info Having an assistant is helpful in this step. Ensure that the engine is adequately secured and will not fall over. ಥ Mount nut and tighten. Specification Nut, swingarm pivot 500117-11 ಥ M16x1,5 100Nm (73.76lbfft) M10 60Nm (44.26lbfft) Fully tighten screws. Specification Engine carrying screw 500121-10 ಥ Position the shock absorber. Mount and tighten screw(1. Specification Screw, top shock absorber M12 80Nm (59.01lbfft) ಥ Reconnect spring(2. ಥ Position the foot brake cylinder. Mount and tighten screws(3. Specification Remaining screws, chassis M6 10Nm (7.38lbfft) 500116-11 ಥ Position the bellows on the foot brake cylinder. ಥ Connect the negative (minus) cable of the battery. ಥ Remove the motorcycle from the work stand. ( ಥ Install the engine sprocket. ( ಥ Install the carburetor. ( ಥ Refill the coolant. ( ಥ Make a short test ride. ಥ Check the engine for leakage. ಥ Check the engine oil level. ( ಥ Check the gear oil level. ( ಥ Check the cooling system for leakage. ಥ Check the coolant level. ( P. 131) P. 125) P. 133) P. 134) P. 138) P. 132) Loctite® 243™ P. 8) 30/DISASSEMBLING ENGINE 59 ',6$66(0%/,1* (1*,1( Preparations ಥ Thoroughly clean the outside of the engine and attach it to the universal mounting rack using the special tool. Engine holder (78029002000) ( P. 182) Universal mounting rack (56012001000) ( P. 178) ಥ Place a container suitable for draining oil beneath the engine. ಥ Remove engine oil plug screen. ಥ Completely drain the engine oil. ಥ Remove screws. Take off oil filter cover with the O-ring. ಥ Pull the oil filter insert out of the oil filter casing. 700020-01 Draining the engine oil 700021-10 Removing the oil filter 700022-10 Circlip pliers reverse (51012011000) ( 700023-10 Draining gear oil, cleaning gear oil screen ಥ 700025-10 Remove the gear oil drain plug. P. 177) 30/DISASSEMBLING ENGINE 60 ಥ Plug - remove the gear oil screen. ಥ Completely drain the gear oil. ಥ Remove screws and take off the starter engine. ಥ Remove screws. Take off the valve cover with the valve cover seal. ಥ Remove screw. Take off the shift lever. ಥ Remove the spark plug using the special tool. 700024-10 Removing the starter engine 200064-10 Removing the valve cover 700013-10 Removing the shift lever 700017-11 Removing the spark plug Spark plug wrench (75029172000) ( 700030-10 P. 181) 30/DISASSEMBLING ENGINE 61 Removing the generator cover ಥ Remove screws. Take off the generator cover. ಥ Remove centering pins. Take off generator cover seal and dispose of it. 700011-10 700010-10 Setting the engine to ignition top dead center ಥ Align camshaft marking ಥ Remove screw. ಥ Screw in special tool. with marking on the cylinder head. 200063-10 200061-10 Crankshaft locking bolt (113080802) ( 200062-10 P. 177) 30/DISASSEMBLING ENGINE 62 Removing the timing chain tensioner ಥ Remove screw. Take off seal ring. ಥ Pull out timing chain tensioner. Remove O-ring. ಥ Remove screw. Take off camshaft bracket. ಥ Pull the camshaft out of the bearing seats. Take the timing chain off of the camshaft gear. Remove the camshaft. ಥ Remove screw. ಥ Alternately loosen screws and remove them. ಥ Take off the cylinder head. ಥ Take off the dowels. Dispose of the cylinder head gasket. ಥ Slide the cylinder upward. 200074-10 Removing the camshaft 200076-10 200077-01 Removing the cylinder head 200082-10 Removing the piston Info Slide the cylinder up only as far as necessary to remove the piston pin. 200083-10 ಥ Remove piston pin retainer. ಥ Remove the piston pin. ಥ Take off the cylinder with the piston. ಥ Slide the piston up and out of the cylinder. Info If no further work is necessary on the cylinder and piston, the piston can remain in the cylinder. 30/DISASSEMBLING ENGINE 63 ಥ Remove dowels and cylinder base gasket. ಥ Remove nut with the spring washer. ಥ Attach special tool to the rotor. Apply counterpressure with the special tool and pull off the rotor by turning in the screw. 200090-11 Removing the rotor 200100-10 Extractor (58012009000) ( P. 178) 200101-10 Removing the balance weight ಥ Bend open lock washer. ಥ Undo nut and remove it. Remove the lock washer. Info Make sure that the crankshaft is blocked. ಥ Take off the balance weight. ಥ Remove screws. Remove timing chain guide rail toward the top. 700040-10 Removing the timing chain guide rail 700006-10 30/DISASSEMBLING ENGINE 64 Removing the timing chain tensioning rail ಥ Remove screw. Remove the timing chain guide railtoward the top. 700005-10 Removing the timing chain securing guide ಥ Remove screws. Remove the timing chain securing guide. ಥ Take off the timing chain. 700026-10 Removing the timing chain Info Mark the direction of travel. 200108-12 Removing the ignition pulse generator ಥ Remove screws. ಥ Pull the cable support sleeve out of the engine case. Take off the ignition pulse generator. ಥ Remove screws. ಥ Take off oil pump cover of the suction pump. 200107-12 Removing the suction pump 200128-10 30/DISASSEMBLING ENGINE ಥ Remove internal rotor with pin and external rotor. ಥ Remove O-ring . ಥ Remove screw. Take off the kickstarter. ಥ Remove screws. Take off the water pump cover. ಥ Take off the water pump cover seal and dispose of it. ಥ Remove crankshaft fixation element. ಥ Remove screws. Take off the clutch cover. ಥ Take out dowels. Take off clutch cover seal and dispose of it. 200129-10 Removing the kickstarter 200067-10 Removing the water pump cover 200071-10 Removing the clutch cover 700015-10 200073-12 65 30/DISASSEMBLING ENGINE 66 Removing the clutch discs ಥ Undo screws and remove them with the washers and springs. ಥ Take off the pressure cap. ಥ Take out clutch discs entirely. ಥ Block the outer clutch hub and primary gear using special tool. 200093-10 200094-11 Removing the primary gear nut Gear segment (80029004000) ( P. 183) Info LH thread ಥ Remove nut. ಥ Take off the pressure piece. ಥ Bend open the lock washer. ಥ Apply counterpressure against the inner clutch hub using the special tool. Loosen nut. 700041-10 Removing the outer clutch hub Clutch holder (51129003000) ( P. 178) ಥ Remove the nut with the lock washer. Dispose of the lock washer. ಥ Take off inner clutch hub and washer. 200095-10 Info The washer usually sticks to the inner clutch hub. ಥ 200096-10 Remove outer clutch hub. 30/DISASSEMBLING ENGINE Removing the balancer shaft ಥ Pull balancer shaft out of the bearing seats and remove it. ಥ Remove the screw with the washer. Take off torque limiter. ಥ Remove the lock ring. Take off the washer. Take off starter idler gear. ಥ Apply counterpressure to kickstarter spring. Remove screw. ಥ Remove spring hanger. Release tension on the kickstarter spring. ಥ Turn kickstarter shaft counterclockwise and pull it out. ಥ Remove the lock ring. Take off the washer. Take off kickstarter idler gear. 700029-10 Removing the torque limiter 200120-11 Removing the starter idler gear 200121-12 Removing the kickstarter shaft 200110-10 Removing the kickstarter idler gear 200120-12 67 30/DISASSEMBLING ENGINE 68 Removing the shift shaft ಥ Press sliding plate away from the shift drum locating. Remove shift shaft with the washer. 200109-10 Removing the shift drum locating ಥ Remove screw. ಥ Press locking lever away from shift drum locating and take off the shift drum locating. ಥ Release the locking lever. ಥ Undo screw and take off it together with locking lever, washer, sleeve and spring. ಥ Remove lock washers. ಥ Take off washers. ಥ Take off oil pump gears. ಥ Remove pins. 200122-10 Removing the locking lever 200123-10 removing the oil pump gears 200124-10 200127-10 30/DISASSEMBLING ENGINE 69 Removing the oil pumps ಥ Remove screws. ಥ Take off oil pump covers of the force pumps. ಥ Remove oil pump shaft of the gear oil force pump together with pin, internal rotor and external rotor . ಥ Remove internal rotor 200125-10 and external rotor of the engine oil force pump. 200126-10 Removing the primary gear with the free-wheel-gear ಥ Remove the primary gear and free-wheel-gear using the special tool. Extractor (78029033100) ( P. 183) Info The special tool must engage beneath the toothing for balancer shaft. 200135-10 Removing the left section of the engine case ಥ Take off needle bearing and collar of the outer clutch hub. ಥ Remove all engine case screws M6. ಥ Swing the left section of the engine case upward and remove the nut or screw of the engine holder. 200136-10 200137-10 30/DISASSEMBLING ENGINE ಥ 70 Mount special tool with suitable screws. Extractor (75029048000) ( P. 180) Info Use the bore labeled780. ಥ Pull off the engine case section. Info Do not warp the engine case section. 200138-10 ಥ Remove the special tool. ಥ Remove distance bushing. ಥ Take off the left section of the engine case. ಥ Remove shift rails together with top springs and lower springs. ಥ Swing shift forks to one side. 200139-10 Removing the shift rails 200141-10 Removing the shift roller Info Make sure not to misplace the shift drums. ಥ 200142-10 Remove shift roller. 30/DISASSEMBLING ENGINE 71 Removing the shift forks ಥ Take shift forks out of the shift grooves. Info Make sure not to misplace shift drums. 200144-10 Removing the transmission shaft ಥ Place the engine in an upright position. ಥ Remove lock ring. ಥ Pull both transmission shafts out of the bearing seats together. 200145-10 Info Make sure not to misplace the washers. 200146-10 Removing the crankshaft ಥ Attach the special tool to the crankshaft. Protection cover (75029090000) ( ಥ Mount special tool onto the engine case with suitable screws. Press-out device (78029049100) ( 200147-10 P. 181) P. 183) ಥ Press the crankshaft out of the bearing seat. ಥ Remove the crankshaft. ಥ Remove the special tools. ಥ Take off the right section of the engine case. 30/ENGINE - WORK ON INDIVIDUAL PARTS 72 (1*,1( :25. 21 ,1',9,'8$/ 3$576 Work on the right section of the engine case ಥ Remove the oil pressure regulator valve. ( ಥ Remove oil jet and. ಥ Remove the bearing retainer of crankshaft bearing, drive shaft bearing, countershaft bearing and shift drum bearing . ಥ Remove any sealing mass remnants and clean the engine case section thoroughly. ಥ Warm the engine case section in an oven. Specification P. 75) 150°C (302°F) ಥ Knock the engine case section against a level wooden plate. This will cause the bearings to drop out of the bearing seats. Info Any bearings that remain in the engine case section must be removed using a suitable tool. ಥ Press out the shaft seal ring of crankshaft from the inside to the outside. Info Do not press the shaft seal ring from the outside to the inside because there is a small collar on the inside. 200153-10 ಥ Remove the shaft seal ring of balancer shaft ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Treat the new shaft seal ring of the crankshaft and the seat of the shaft seal ring in the engine case section with activator. without damaging the engine case. Loctite®7471 Loctite®7649 ಥ Apply adhesive to the outside of the shaft seal ring. Loctite® 648™ ಥ Press the shaft seal ring of the crankshaft from the outside to the inside with the open side facing inward. Mounting sleeve (78029005000) ( P. 182) Info The shaft seal ring must be flush with the outside. ಥ Press in the shaft seal ring of the balancer shaft with the open side facing out. ಥ Warm the engine case section again. Specification 150°C (302°F) ಥ Slide the new bearing into the bearing seat of the hot engine case section and, if necessary, use a suitable press drift to push the bearing from the inside to the outside all the way or so it is flush. Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring, otherwise the bearings will be damaged when they are pressed in. ಥ After the engine case section has cooled, check that the bearings are firmly seated. Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine house when warm. In this case, the engine case must be renewed. ಥ Position all bearing retainers. Mount and tighten screws. Specification Locking screw for bearing M5 6Nm (4.43lbfft) Loctite® 243™ 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ Mount and tighten oil jet. Specification Oil jet, piston cooling ಥ 73 M5 2Nm (1.48lbfft) Loctite® 243™ M6x0,75 4Nm (2.95lbfft) Loctite® 243™ Mount and tighten oil jet. Specification Oil jet, conrod lubrication 400368-01 ಥ Blow though all oil holes with compressed air and check that they are clear. ಥ Install the oil pressure regulator valve. ( P. 75) Work on the left section of the engine case ಥ Remove all dowels. ಥ Remove oil jet. ಥ Remove the bearing retainer from crankshaft bearingand balancer shaft bearing. ಥ Remove the shaft seal ring of countershaft and shift shaft without damaging the engine case. Info Because of a small external collar, the shaft seal ring of crankshaft only be removed after the crankshaft bearing has been taken out. can ಥ Remove any sealing mass remnants and clean the engine case section thoroughly. ಥ Warm the engine case section in an oven. Specification 150°C (302°F) ಥ Knock the engine case section against a level wooden plate. This will cause the bearings to drop out of the bearing seats. Info Any bearings that remain in the engine case section must be removed using a suitable tool. 200152-10 ಥ Press out the shaft seal ring of crankshaft from the outside to the inside. Info Do not press the shaft seal ring from the inside to the outside because there is a small collar on the outside. ಥ Check parts for damage and wear. Replace damaged or worn parts. 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ 74 Treat the new shaft seal ring of the crankshaft and the seat of the shaft seal ring in the engine case section with activator. Loctite®7471 Loctite®7649 ಥ Apply adhesive to the outside of the shaft seal ring. Loctite® 648™ ಥ Press the shaft seal ring from the inside to the outside with the open side facing out. Info The shaft seal ring must be flush with the outside. ಥ Warm the engine case section again. Specification 150°C (302°F) ಥ Slide the new bearing into the bearing seat of the hot engine case section and, if necessary, use a suitable press drift to push the bearing in all the way or so it is flush. Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring, otherwise the bearings will be damaged when they are pressed in. ಥ After the engine case section has cooled, check that the bearings are firmly seated. Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine house when warm. In this case, the engine case must be renewed. ಥ Position all bearing retainers. Mount and tighten screws. Specification Locking screw for bearing M5 6Nm (4.43lbfft) Loctite® 243™ ಥ Press in the shaft seal ring of countershaft and shift shaft with the open side facing inward until it is flush. ಥ Mount and tighten oil jet. Specification Oil jet, piston cooling ಥ Mount the dowels. M5 2Nm (1.48lbfft) Loctite® 243™ 30/ENGINE - WORK ON INDIVIDUAL PARTS 75 400367-01 ಥ Blow though all oil holes with compressed air and check that they are clear. removing the oil pressure regulator valve ಥ Remove plug with sealing disc. ಥ Remove preload spring and ball. 200154-10 Checking the spring length of the oil pressure regulator valve ಥ Remove the oil pressure regulator valve. ( ಥ Measure the spring length of the oil pressure regulator valve. P. 75) Oil pressure regulator valve Minimum length of preload spring » ಥ 23.5mm (0.93in) If the measured value does not equal the specified value: ಥ Change the spring. Install the oil pressure regulator valve. ( P. 75) 200155-10 Installing the oil pressure regulator valve ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Insert ball and preload spring. ಥ Mount plug with sealing disc and tighten. Specification Oil pressure control valve plug 200154-11 M12x1,5 20Nm (14.75lbfft) 30/ENGINE - WORK ON INDIVIDUAL PARTS 76 Removing the crankshaft seal ring in the clutch cover ಥ Remove the crankshaft seal ring in clutch cover. 200194-10 Fitting the crankshaft seal ring into the clutch cover ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Press crankshaft seal ring into the clutch cover with the open side facing inwards until it is flush. ಥ Grease the sealing lip. ಥ Remove nut. ಥ Remove lock ring. Remove the drive wheel. ಥ Take off water pump wheel and the spacing washer. 200194-10 Removing the water pump 200195-10 Info If it is not possible to take off the water pump wheel, the water pump shaft can be pressed inward. ಥ Remove water pump shaft. ಥ Remove shaft seal ring. ಥ Remove shaft seal ring . 200196-10 200197-10 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ Press out bearing 77 of the water pump shaft using a suitable tool. Info Support the clutch cover as necessary when pressing it out. 200198-10 Installing the water pump ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Press in bearing of the water pump shaft using a suitable tool until it is flush. Info Support the clutch cover suitably when pressing it in. 200198-11 ಥ Press in shaft seal ring fully with the open side facing inwards. Info Spacers must face outwards. ಥ Press in shaft seal ring with the open side facing inwards until it is flush with spacer . ಥ Mount water pump shaft. 200197-11 Info Do not damage the shaft seal rings. ಥ Mount spacing washer and water pump wheel. ಥ Mount the drive wheel. Mount lock ring . ಥ Mount and tighten nut . Specification 200196-11 Nut, water-pump wheel 200195-11 M6 6Nm (4.43lbfft) Loctite® 648™ 30/ENGINE - WORK ON INDIVIDUAL PARTS 78 Checking the balancer shaft ಥ Check bearing surface of the balancer shaft for pitting corrosion. » If there is pitting corrosion: ಥ Change the balancer shaft. ಥ Check the remaining areas of the balancer shaft for damage and wear. » If there is damage or wear: ಥ Change the balancer shaft. 200205-10 Removing the timing chain sprocket ಥ Warm timing chain sprocket using a blow dryer. ಥ Pull off the timing chain sprocket. Info The timing chain sprocket usually becomes damaged when it is disassembled and needs to be replaced. 200156-10 Installing the timing chain sprocket Info Never place the crankshaft with a crankshaft journal in a vise to try to force on the timing chain sprocket. If you do so, the crank webs will be compacted, making the crankshaft unusable. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Heat up the new timing chain sprocket and immediately push it on to the crankshaft. Specification 150°C (302°F) 200157-10 Changing the conrod bearing ಥ Position special tool between the crank webs and place them on a press. Separator plate (78029009000) ( ಥ P. 183) Press the crank pin out of the upper crank web using special tool. Press drift (75029047000) ( P. 180) Info Hold the bottom crank web. 200208-10 ಥ Take off the connecting rod and bearing. ಥ Place connecting rod onto special tool without the bearing. Plate - Pressing device (78029008000) ( ಥ Press out the crank pin using the special tool. Press drift (75029047000) ( 200210-10 P. 180) P. 182) 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ 79 When the crank pin is pressed in, oil hole must be aligned with oil hole. Marking is opposite from oil hole and must be on the outside after mounting. Info If the oil holes are not correctly aligned, the conrod bearing will not be provided with oil. 200212-10 ಥ Place the crank web onto special tool. Plate - Pressing device (78029008000) ( P. 182) Info The special tool must be positioned with the flat surface facing downward. ಥ Press the new crank pin all the way in. ಥ Check the oil hole with compressed air to ensure it is clear. ಥ Mount bearing 200213-10 and connecting rod . Info Oil the bearing thoroughly. 200214-10 ಥ Position special tool and onto the press. Press drift (75029047000) ( P. 180) Plate - Pressing device (78029008000) ( P. 182) ಥ Fit the crank web with the connecting rod and bearing. Position the second crank web. ಥ Insert special tool. 200215-10 Plate - Pressing device (78029008000) ( P. 182) Info The flat surface of the special tool must face upward. 200216-10 ಥ Press the upper crank web all the way in. Info The press mandrel must be positioned above the crank pin. ಥ 200209-10 Take the crankshaft out of the special tool and check that the connecting rod can move freely. 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ Measure the external dimensions of the crankshaft - crank web. Crankshaft - external crank web dimension » ಥ 80 63¢0.05mm (2.48¢0.002in) If the specified value is not reached: ಥ Correct to the specified value. Check the crankshaft run-out on the bearing pin. ( P. 80) 200211-10 Checking the crankshaft run-out on the bearing pin ಥ Position the crankshaft on a roller block. ಥ Turn the crankshaft slowly. ಥ Check the crankshaft run-out on both bearing pins. Crankshaft - run-out on bearing pin » 싨0.16mm (싨0.01in) If the crankshaft run-out on the bearing pin is greater than the specified value: ಥ Align the crankshaft. 200207-10 Cylinder - Nikasil® coating Nikasil® is a surface protection layer for a coating procedure developed by the Mahle company. The name is derived from the two materials used in this procedure - a layer of nickel into which is embedded the particularly hard silicone carbide. The most important advantages of the Nikasil® coating are very good heat conductivity, resulting in much improved performance, low wear, and a lightweight cylinder. 200158-10 Checking/measuring the cylinder ಥ Check the cylinder bearing surface for damage. » If the cylinder bearing surface is damaged: ಥ Change the cylinder and piston. ಥ Measure the cylinder diameter at several places on the$ and% axes using a micrometer to check for oval wear. Specification Cylinder - bore diameter 400374-10 ಥ 200162-10 Size I 95… 95.012mm (3.74… 3.74in) Size II 95.013… 95.025mm (3.74… 3.74in) Cylinder size is marked on the side of the cylinder. 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ 81 Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041000) ( P. 179) Cylinder/cylinder head - sealing area distortion » 싨0.1mm (싨0.0039in) If the measured value does not equal the specified value: ಥ Change the cylinder. 400376-10 Checking/measuring the piston ಥ Check the piston bearing surface for damage. » If the piston bearing surface is damaged: ಥ Change the piston and, if necessary, the cylinder. ಥ Check that the piston rings can move easily in the piston ring grooves. » If the piston ring is stiff: ಥ Clean the piston ring groove. Tip Use an old piston ring to clean the piston ring groove. 200160-10 ಥ Check the piston rings for damage. » If the piston ring is damaged: ಥ Change the piston ring. Info Mount the piston ring with the marking facing upward. ಥ Check the piston pin for discoloration or signs of wear. » If the piston pin has strong discoloration/signs of wear: ಥ Change the piston pin. ಥ Insert the piston pin into the connecting rod and check the bearing for play. » If the piston pin bearing has too much play: ಥ Change the connecting rod and the piston pin. ಥ Measure the piston at the piston skirt, at right-angles to the piston pin. Specification Piston - diameter Size I 94.93… 94.96mm (3.74… 3.74in) Size II 94.95… 94.97mm (3.74… 3.74in) Info Piston size is marked on the piston head. 200161-10 Checking the piston ring end gap ಥ Remove the piston ring from the piston. ಥ Place the piston ring in the cylinder and align it with the piston. Specification Under the upper edge of the cylinder ಥ 10mm (0.39in) Measure the end gap with e feeler gauge . Specification Piston ring end gap 200163-10 ಥ Compression ring 싨1mm (싨0.04in) Oil scraper ring 싨1.2mm (싨0.05in) » If the end gap is more than the specified value: ಥ Check/measure the cylinder. ( P. 80) » If the cylinder wear is within the tolerance range: ಥ Change the piston ring. Mount the piston ring with the marking facing toward the piston head. 30/ENGINE - WORK ON INDIVIDUAL PARTS 82 Checking piston/cylinder mounting clearance ಥ Check/measure the cylinder. ( ಥ Check/measure the piston. ( ಥ The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston diameter. Specification P. 80) P. 81) Piston/cylinder - mounting clearance Size I 0.04… 0.082mm (0.0016… 0.0032in) Size II 0.043… 0.075mm (0.0017… 0.003in) Wear limit 싨0.12mm (싨0.0047in) Checking the oil pumps for wear Info The following figures show how to check the oil pumps for wear using the suction pump as an example, but the method applies to all pumps. ಥ Use feeler gauge to measure the play between the external rotor and the engine case. Oil pump Clearance between external rotor and engine housing » 싨0.2mm (싨0.01in) The measured value does not equal the specified value. ಥ Change the oil pump and, if necessary, the engine case. 200164-10 ಥ Use feeler gauge to measure the play between the external rotor and the internal rotor. Oil pump Clearance between external rotor and internal rotor » 싨0.2mm (싨0.01in) The measured value does not equal the specified value. ಥ Change the oil pump. 200165-10 Checking the lubrication system 1 30 0 4 0 8 0 3 0 3 60 0 8 0 1 0 3 0 0 40 3 1 0 5 0 9 0 2 0 0 1 3 0 7 0 30 0 6 200186-01 ಥ Renew the O-rings or seal ring with every oil change. ಥ Renew oil filter with every oil change. ಥ Renew the O-rings or shaft seal ring with every engine repair. ಥ Clean and check oil screens. Replace damaged or worn parts. ಥ Thoroughly clean the gear oil drain plug with magnet. ಥ Check oil pump cover and the engine case in the vicinity of the oil pumps for grooves. » If there are grooves: ಥ Change the oil pump cover and, if necessary, the engine case. ಥ Check the oil pumps for wear. ( ಥ Place oil pump shaft on a level surface and check for run-out. » If there is run-out: ಥ Change the oil pump shaft. ಥ Check oil pump gears for wear. » If the oil pump gear is worn: ಥ Change the oil pump gear. ಥ Check ball of the oil pressure regulator valve and its seat in the engine case for wear and scoring. » If there is wear or scoring: ಥ Change the ball and, if necessary, the engine case. P. 82) 30/ENGINE - WORK ON INDIVIDUAL PARTS 83 ಥ Check the spring length of the oil pressure regulator valve. ( ಥ Take lock ring off of the autodecompressor shaft and dispose of it. ಥ Pull autodecompression shaft out of the camshaft. ಥ Detach autodecompression spring and remove it. P. 75) Disassembling the autodecompressor 200166-10 200167-10 Info Autodecompression weight cannot be removed. 200168-10 Assembling the autodecompressor ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Insert the long prong of the autodecompression spring in the bore, push the autodecompression spring over bearing bolt and insert it into the autodecompression weight. ಥ Mount the autodecompression shaft in the camshaft. 200169-10 200167-11 30/ENGINE - WORK ON INDIVIDUAL PARTS 84 ಥ Mount a new lock ring. ಥ Check for correct functioning. » The autodecompression spring does not turn the autodecompression shaft fully back to the stop: ಥ Tighten the autodecompression spring or replace it. ಥ Check the camshaft for damage and wear. » If there is damage or wear: ಥ Change the camshaft. 200166-11 Checking the camshaft ಥ ಥ If the cam surface is damaged, check the oil supply to the camshaft and rocker arm. Measure the cams of the camshaft. Camshaft - cam height Intake 33… 33.2mm (1.3… 1.31in) Camshaft - cam height (Every 450 models) 200206-10 Exhaust 33.9… 34.1mm (1.33… 1.34in) Camshaft - cam height (Every 530 models) Exhaust » 34.2… 34.4mm (1.35… 1.35in) If the measured value does not equal the specified value: ಥ Change the camshaft. Checking the timing assembly 1 0 5 0 2 0 3 0 1 0 4 0 ಥ Clean all parts well. ಥ Check the timing chain wheel/timing chain sprocket for damage and wear. » If there is damage or wear: ಥ Change the timing chain wheel/timing chain sprocket. ಥ Check timing chain tensioning rail for damage and wear. » If there is damage or wear: ಥ Change the timing chain tensioning rail. ಥ Check timing chain guide rail for damage and wear. » If there is damage or wear: ಥ Change the timing chain guide rail. ಥ Check timing chain securing guide for damage and wear. » If there is damage or wear: ಥ Change the timing chain securing guide. ಥ Check timing chain for damage and wear. » If there is damage or wear: ಥ Change the timing chain. ಥ Check that the timing chain links move easily. Let the timing chain hang down freely. » If the chain links no longer straighten out: ಥ Change the timing chain. 200173-01 Preparing the timing chain tensioner for installation ಥ Fully compress the timing chain tensioner. Info This requires considerable force since the oil has to be pressed out. Without pressure, the timing chain tensioner expands fully. 200171-10 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ 85 Place 2 spacing washers or similar aids next to the piston of the timing chain tensioner. This should ensure that when pushed down, the piston does not fully withdraw. Specification Thickness of spacers 2… 2.5mm (0.08… 0.1in) 200172-10 ಥ Release the timing chain tensioner. The latching system locks and the piston stops moving. End position of piston after latching 3mm (0.12in) Info This position is necessary for installation. If the timing chain tensioner is now pressed in once more and then pulled out maximum halfway (preventing it to come out fully), the latching system locks and the timing chain tensioner can no longer be compacted - this function is necessary to ensure sufficient tension of the timing chain, even at low oil pressure. 200173-10 Removing the rocker arm ಥ Remove screws of the rocker arm shafts. Remove plugs. ಥ Screw a fitting screw into the rocker arm shafts. Pull out rocker arm shafts. ಥ Take off rocker arm. ಥ Take the shims out of the valve spring retainers and set them down according to their installation position. ಥ Pretension the valve springs using the special tool. 200203-10 200204-10 Removing the valves Valve spring mounter (59029019000) ( P. 178) Valve spring mounting device (78029060000) ( ಥ 200187-10 P. 183) Remove the valve keys and release the tension on the valve springs. 30/ENGINE - WORK ON INDIVIDUAL PARTS 86 ಥ Remove the spring retainer and spring. ಥ Pull the valve downward out of the valve guide, pry off the valve stem seal and remove the lower valve spring retainer. ಥ Mark the valve to indicate the installation position. 200188-10 Info Place the valve into a box according to the installation position and label the box. 200189-10 Replacing the camshaft bearing ಥ Clamp the cylinder head. Clamping plate (75029050000) ( ಥ P. 180) Remove the camshaft bearing using the special tool. Bearing puller (15112017000) ( P. 177) Push-out drift (75029051000) ( P. 180) 200202-10 ಥ Remove the small camshaft bearing using the special tool. Bearing puller (15112017000) ( P. 177) Insert for bearing puller (15112018100) ( P. 177) 200199-10 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Press the small camshaft bearing all the way in using special tool. Push-in drift (75029044020) ( P. 180) 200200-10 ಥ Press the large camshaft bearing all the way in using special tool. Push-in drift (75029044010) ( 200201-10 P. 179) 30/ENGINE - WORK ON INDIVIDUAL PARTS 87 Checking the valves Info The valve stem is chrome-hardened, and wear normally takes place in the valve guide. ಥ Check for valve retainer run-out. Valve Run-out on valve plate » 싨0.05mm (싨0.002in) If the measured value does not equal the specified value: ಥ Change the valve. 200193-10 ಥ Check sealing seat on the valve. Valve Sealing seat width, intake 1.5mm (0.06in) Valve 0 A Sealing seat width, exhaust » 2mm (0.08in) If the sealing area is not in the center of the valve seat or if it differs from the specified value: ಥ Machine the valve seat. 400373-10 Checking the valve springs ಥ Check the valve springs for breakage and wear (visual check). » If the valve spring is broken or worn: ಥ Change the valve spring. ಥ Measure the valve spring length. Valve spring Minimum length, intake (without bottom valve spring retainer) 46.5mm (1.83in) Valve spring Minimum length, exhaust (without bottom valve spring retainer) 200190-10 » 43mm (1.69in) If the measured value does not equal the specified value: ಥ Change the valve spring. Checking the lower valve spring retainer ಥ Check the lower valve spring retainer for breakage and wear (visual check). » If the lower valve spring retainer is broken or worn: ಥ Change the valve spring retainer. ಥ Measure the thickness of the lower valve spring retainers. Valve spring Bottom valve spring retainer » 500173-01 0.9… 1mm (0.04… 0.04in) If the measured value does not equal the specified value: ಥ Change the valve spring retainer. 30/ENGINE - WORK ON INDIVIDUAL PARTS 88 Checking the cylinder head ಥ Check the exhaust valve guides using special tool. Limit plug gauge (59029026006) ( » ಥ P. 179) If the special tool is easy to insert into the valve guide: ಥ Change the valve guide and valve. Check the intake valve guides using the special tool. Limit plug gauge (77029026000) ( » 200192-10 P. 181) If the special tool is easy to insert into the valve guide: ಥ Change the valve guide and valve. ಥ Check the sealing area of the spark plug thread and the valve seats for damage and tearing. » If there is wear or tearing: ಥ Change the cylinder head. ಥ Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041000) ( P. 179) Cylinder/cylinder head - sealing area distortion » 싨0.1mm (싨0.0039in) If the measured value does not equal the specified value: ಥ Change the cylinder head. 400375-10 ಥ Check sealing seat of the valves. Valve Sealing seat width, intake 1.5mm (0.06in) Valve 0 A Sealing seat width, exhaust » 400373-10 2mm (0.08in) If the measured value does not equal the specified value: ಥ Machine the valve seat. ಥ Blow though all oil holes with compressed air and check that they are clear. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount new valve stem seals. Position the lower valve spring retainers. ಥ Mark the valves according to their position in the engine. ಥ Mount the spring and spring retainer. ಥ Tension the valve springs with a special tool. Installing valves 200188-10 Valve spring mounter (59029019000) ( P. 178) Valve spring mounting device (78029060000) ( 200187-10 P. 183) 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ 89 Mount the valve keys. Info When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease. ಥ Place the shims in the valve spring retainers according to their position in the engine. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position rocker arm and slide in rocker arm shaft. 200191-10 Installing the rocker arm Info Ensure that the tapped hole of the rocker arm shaft is on the outside. Align bores of the rocker arm shafts with bores of the cylinder head. 200204-11 ಥ Mount and tighten screws of the rocker arm shafts. Specification Screw, rocker arm bearing ಥ M7x1 15Nm (11.06lbfft) M14x1,25 20Nm (14.75lbfft) Mount and tighten plugs . Specification Plug, rocker arm 200203-11 Checking the clutch ಥ Check pressure piece for damage and wear. » If there is damage or wear: ಥ Change the pressure piece. ಥ Check axial bearing for damage and wear. » If there is damage or wear: ಥ Change the axial bearing. ಥ Place push rod on a level surface and check for run-out. » If there is run-out: ಥ Change the push rod. ಥ Check the length of clutch springs. b0k bk b0k bk 4 0 9 0 b0l bl 5 0 b0m bm » 2 0 6 0 10 0 3 Clutch spring - length 70 0 8 43… 44.03mm (1.69… 1.73in) If the clutch spring length is less than the specified value: ಥ Change all clutch springs. ಥ Check the contact surface of pressure cap for damage and wear. » If there is damage or wear: ಥ Change the pressure cap. ಥ Check the contact surfaces of the clutch facing discs in outer clutch hub wear. Thrust surface, clutch facing discs in outer clutch hub 200176-01 » ಥ 싨0.5mm (싨0.02in) If the contact surface is very worn: ಥ Change the clutch facing discs and the outer clutch hub. Check needle bearing and collar for damage and wear. » If there is damage or wear: ಥ Change the needle bearing and collar. for 30/ENGINE - WORK ON INDIVIDUAL PARTS 90 ಥ Check intermediate discs for damage and wear. » If the intermediate discs are not level and have pittings: ಥ Change all intermediate discs. ಥ Check clutch facing discs(1 for discoloration and scoring. » If there is discoloration or scoring: ಥ Change all clutch facing discs. ಥ Check the thickness of clutch facing discs(1. Clutch facing disc - thickness » 2.6… 2.7mm (0.1… 0.11in) If the clutch facing disc does not meet specifications: ಥ Change all clutch facing discs. ಥ Check the pretension ring and support ring(2 for damage and wear. » If there is damage or wear: ಥ Change the pretension ring and support ring. ಥ Check inner clutch hub(3 for damage and wear. » If there is damage or wear: ಥ Change the inner clutch hub. ಥ Check shift forks at leaf Checking the shift mechanism for wear. Shift fork 7 0 Thickness at leaf 0 D C 0 E0 0 A » 1 0 5 0 4 0 6 0 3 0 5 0 B0 0 2 3 0 1 0 5 0 6 0 0 4 1 0 4 0 5 0 4.85… 4.95mm (0.19… 0.19in) If the measured value does not equal the specified value: ಥ Change the shift fork. ಥ Check shift grooves of the shift roller for wear. » If the shift groove is worn: ಥ Change the shift roller. ಥ Check the seat of the shift roller in the grooved ball bearing. » If the shift roller is not seated correctly: ಥ Change the shift roller and/or the grooved ball bearing. ಥ Check grooved ball bearing for smooth operation and wear. » If the grooved ball bearing does not move freely or is worn: ಥ Change the grooved ball bearing. ಥ Check shift drums for surface damage and cracks. » If the shift drum has surface damage and cracks: ಥ Change the shift drum. ಥ Check springs of the shift rails for damage and wear. » If the spring is broken or worn: ಥ Change the spring of the shift rail. ಥ Check the shift rails on a flat surface for run-out. » If there is run-out: ಥ Change the shift rail. ಥ Check shift rails for grooving, signs of corrosion and smooth operation in the shift fork. » The shift rail has grooving or signs of corrosion or is not smooth in operation in the shift fork: ಥ Change the shift rail. ಥ Check the sliding plate in the contact areas for wear. » If the sliding plate is worn: ಥ Change the sliding plate. ಥ Check return surface on the sliding plate for wear. » If deep notches are present: ಥ Change the sliding plate. ಥ Check guide pin for firm fitting and wear. » If the guide pin is loose and/or worn: ಥ Change the sliding plate. ಥ Preassemble the shift shaft. ( 200174-01 P. 91) 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ 91 Check clearance between sliding plate and shift quadrant. Shift shaft - play in sliding plate/shift quadrant A 0 » 0.4… 0.8mm (0.02… 0.03in) If the measured value does not equal the specified value: ಥ Change the sliding plate. 400372-01 Preassembling the shift shaft ಥ 5 0 Use vise protectors. 1 0 2 0 Fix the short end of the shift shaft in a vise. Specification ಥ 30 0 4 6 0 200175-01 Mount sliding plate with the guide pin facing down and attach the guide pin to the shift quadrant. ಥ Mount preload spring. ಥ Push on spring guide, push return spring over the spring guide with the offset end facing upwards and lift the offset end over abutment bolt. ಥ Mount stop disk . Dismantling the main shaft 8 0 0 7 5 0 3 60 0 b0k bl bk b0l 0 9 4 0 0 2 1 0 200177-01 ಥ Fix the main shaft in the vise with the geared end facing downwards. Specification Use vise protectors. ಥ Remove stop disk and fixed gear of the second gear. ಥ Remove the sixth-gear idler gear. ಥ Remove the divided needle bearing and stop disk. ಥ Remove lock ring . ಥ Remove the third/fourth-gear sliding gear . ಥ Remove lock ring . ಥ Remove stop disk ಥ Remove the divided needle bearing(2. and the fifth-gear idler gear(1. Assembling the main shaft Info Use new lock rings in every repair job. ಥ Oil all parts carefully before assembling. ಥ Check the transmission. ( P. 93) 30/ENGINE - WORK ON INDIVIDUAL PARTS 4 0 0 5 7 0 9 60 0 92 8 bk 0 b0k 2 0 0 10 3 b0l bl 200178-01 ಥ Fix the main shaft in the vise with the geared end facing downwards. Specification Use vise protectors. ಥ Mount the divided needle bearing, put on the fifth-gear idler gear with the shifting claws facing upwards. ಥ Mount stop disk and lock ring. ಥ Put on the third/fourth-gear sliding gear with the small gear wheel facing downwards and mount lock ring . ಥ Put on stop disk ಥ Put on the sixth-gear idler gear ಥ Put on the fixed gear(1 of the second-gear with the collar facing downwards and put on stop disk(2. ಥ Finally, check all gear wheels for smooth operation. and divided needle bearing . with the shifting claws facing downwards. Dismantling the countershaft 5 40 0 6 0 1 0 2 0 3 0 7 0 9 bk 0 b0k bbl 0lbm b0r b0m bbo 0o bbp 0p br 8 0 b0n bn b0s bs b0q bq 200179-01 ಥ Fix the countershaft in the vise with the geared end facing downwards. Specification Use vise protectors. ಥ Remove stop disk and the first-gear idler gear. ಥ Remove needle bearing and stop disk. ಥ Remove the fifth-gear sliding gear and lock ring . ಥ Remove stop disk ಥ Remove needle bearing ಥ Remove needle bearing(2 and stop disk(3. and the third-gear idler gear . and the fourth-gear idler gear(1. ಥ Remove lock ring(4 and the sixth-gear sliding gear(5. ಥ Remove stop disk(6 and lock ring(7. ಥ Remove the second-gear idler gear(8 and needle bearing(9. Assembling the countershaft Info Use new lock rings in every repair job. ಥ Oil all parts carefully before assembling. ಥ Check the transmission. ( P. 93) 30/ENGINE - WORK ON INDIVIDUAL PARTS b0o bbp 0pbo b0n bn b0s bs b0r br b0q bq b0k 0 bk 9 b0m bm 80 0 2 7 0 50 4 0 b0l bl 6 0 93 1 0 3 0 200180-01 ಥ Fix the countershaft in the vise with the geared end facing downwards. Specification Use vise protectors. ಥ Mount needle bearing and the second-gear idler gear on the countershaft with the protruding collar facing downwards. ಥ Fit lock ring and stop disk. ಥ Mount the sixth-gear sliding gear with the shift groove facing upwards. ಥ Mount lock ring ಥ Mount needle bearing ಥ Mount needle bearing(1 and third-gear idler gear(2 with the collar facing downwards. ಥ Mount stop disk(3 and lock ring(4. ಥ Mount the fifth-gear sliding gear(5 with the shift groove facing downwards and stop disk(6. ಥ Mount needle bearing(7, first-gear idler gear(8 with the groove facing downwards and stop disk(9. ಥ Finally, check all gear wheels for smooth operation. and stop disk . and fourth-gear idler gear with the collar facing upwards. Checking the transmission 40 0 1 6 0 40 0 1 5 0 2 6 0 5 0 70 0 6 67 0 40 0 1 41 0 00 5 70 0 6 60 0 7 40 0 1 67 0 6 0 3 5 0 40 0 1 500174-01 ಥ Check needle bearing for damage and wear. » If there is damage or wear: ಥ Change the needle bearing. ಥ Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: ಥ Change the main shaft and/or countershaft. ಥ Check the tooth profiles of main shaft and countershaft for damage and wear. » If there is damage or wear: ಥ Change the main shaft and/or countershaft. ಥ Check the pivot points of idler gears for damage and wear. » If there is damage or wear: ಥ Change the idler/fixed gear pair. ಥ Check the shift dogs of idler gears and fixed gears for damage and wear. » If there is damage or wear: ಥ Change the idler/fixed gear pair. 30/ENGINE - WORK ON INDIVIDUAL PARTS ಥ Check the tooth faces of idler gears and fixed gears for damage and wear. » If there is damage or wear: ಥ Change the idler/fixed gear pair. ಥ Check the tooth profiles of fixed gears for damage and wear. » If there is damage or wear: ಥ Change the idler/fixed gear pair. ಥ Check fixed gears for smooth operation in the profile of main shaft. » If the fixed gear does not move easily: ಥ Change the fixed gear or the main shaft. ಥ Check fixed gears for smooth operation in the profile of countershaft. » If the fixed gear does not move easily: ಥ Change the fixed gear or the countershaft. ಥ Check stop disks for damage and wear. » If there is damage or wear: ಥ Change the stop disk. ಥ Use new lock rings 94 in every repair job. Checking electric starter operation ಥ Check the toothing or seating of idler and the bearing bolt for wear. » The parts are worn: ಥ Change the idler with the bearing bolt. ಥ Check the toothing or seating of idler with the torque limiter and the bearing bolt for wear. » The parts are worn: ಥ Change the idler with the bearing bolt. ಥ Check the toothing and bearing of free-wheel gear for wear. » The parts are worn: ಥ Change the free-wheel gear and/or bearing. ಥ Check free-wheel when removed for wear and damage. » The free-wheel is damaged or worn: ಥ Change the free-wheel. ಥ Check the toothing of electric starter for wear. » The toothing is worn: ಥ Change the electric starter. ಥ Change the O-ring ಥ Press together spreader ring with suitable pliers and take it off. ಥ Take free-wheel out of the primary pinion. 5 0 6 0 2 0 1 0 3 0 4 0 of the electric starter. 200181-01 Removing the free-wheel 200183-10 200184-10 30/ENGINE - WORK ON INDIVIDUAL PARTS 95 Checking the free-wheel ಥ Place the free-wheel gear in primary pinion while rotating the primary pinion clockwise, but do not tilt it! ಥ Check the locking action of free-wheel gear. » The primary pinion cannot be rotated clockwise or does not block counterclockwise: ಥ Remove the free-wheel. ( P. 94) ಥ Turn the free-wheel 180°. ಥ Install the free-wheel. ( P. 95) 200182-10 Installing the free-wheel ಥ Clean the parts thoroughly and check for damage and wear. Replace damaged or worn parts. ಥ Oil all parts well. ಥ Slide free-wheel into the primary pinion. Info Note the direction of rotation. 200184-11 ಥ Mount spreader ring. ಥ Ensure that all protrusions of the spreader ring engage through slots wheel in groove of the primary pinion. 200183-11 200185-10 of the free- 30/ASSEMBLING ENGINE 96 $66(0%/,1* (1*,1( Installing the crankshaft ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Clamp the right section of the engine case into the engine work stand. ಥ Heat the inner ring of the crankshaft bearing. Specification 80°C (176°F) Info Do not damage the seal ring. 700014-01 ಥ Slide the crankshaft all the way into the bearing seat of the right section of the engine case. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide both transmission shafts into the bearing seats together. Installing the transmission shaft Info Make sure not to misplace the washers. 200146-10 ಥ Mount lock ring. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Oil all parts well. ಥ Shift fork has a smaller inner diameter. Mount it in the shift groove of the main shaft. ಥ Mount shift fork in the lower shift groove of the countershaft. ಥ Mount shift fork in the upper shift groove of the countershaft. ಥ Slide on shift drums. 200145-10 Installing the shift forks 200143-10 30/ASSEMBLING ENGINE 97 Installing the shift roller ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide shift roller into the bearing seat. ಥ Hang the shift forks into the shift roller. Info Make sure not to misplace the shift drums. 200142-11 Installing the shift rails ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Install shift rails together with upper springs and the lower springs. ಥ Check parts for damage and wear. Replace damaged or worn parts. 200141-10 Installing the left engine case ಥ Mount dowels on the left section of the engine case. ಥ Grease the sealing surfaces. Apply sealing compound to the left section of the engine case. Loctite®5910 Info To prevent sealing compound from entering into the oil drill holes, dowels must be mounted first. 200140-10 ಥ Mount the left section of the engine case. If necessary, knock it lightly with a rubber hammer. Info Do not tighten the engine case sections using the screws. ಥ Mount screws and tighten them when all screws have been mounted on the left section of the engine case. Specification Screw, engine housing 200137-11 ಥ 700003-01 10Nm (7.38lbfft) Mount screws and tighten all screws in a crisscross pattern. Specification Screw, engine housing ಥ M6x80 M6x65 Mount distance bushing with the O-ring. 10Nm (7.38lbfft) 30/ASSEMBLING ENGINE 98 ಥ Mount collar and needle bearing. 200136-12 Installing the primary gear with the free-wheel-gear ಥ Oil the free-wheel in the primary gear. ಥ Slide primary gear with the free-wheel onto free-wheel-gear and mount them both on crankshaft. Info The free-wheel-gear must rotate counterclockwise when it is mounted. 700004-01 Installing the oil pumps ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Oil the oil pump shaft, internal rotor and external rotor before fitting. Engine oil (SAE 10W/50) ( P. 174) ಥ Mount oil pump shaft. ಥ Mount pin of the engine oil force pump. Slide on the internal rotor with marking facing outward. Info The marking should be visible after installation. 200131-11 ಥ Mount external rotor with the marking facing inward. Info The marking should not be visible after installation. ಥ Mount oil pump shaft of the gear oil force pump with pin tor . ಥ Mount external rotor and internal ro- with the marking facing inward. Info The marking should not be visible after installation. 200126-11 ಥ Position oil pump cover . Mount and tighten screws(1. Specification Screw, oil pump cover 200125-11 M5 6Nm (4.43lbfft) Loctite® 222 30/ASSEMBLING ENGINE 99 Installing the oil pump gears ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Insert pins. ಥ Position oil pump gears. 200127-11 Info Ensure that the pins are seated correctly. ಥ Position washers. ಥ Mount shaft retainer. ಥ Crank the oil pump gears and check that they can be easily moved. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the locking lever with washer, sleeve and spring. ಥ Mount and tighten screw. Specification 200124-11 Installing the locking lever Screw, locking lever M5 6Nm (4.43lbfft) Loctite® 243™ 200123-11 Installing the shift drum locating ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Push locking lever away from the shift drum locatingand position shift drum locating. Info The flat surfaces of the shift drum locating are not symmetric. ಥ Release the locking lever. ಥ Mount and tighten screw. Specification 200122-11 Screw, shift drum locating M6 10Nm (7.38lbfft) Loctite® 243™ Installing the shift shaft 200109-11 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide shift shaft with the washer into the bearing seat. ಥ Push sliding plate away from the shift drum locating. Insert the shift shaft all the way. ಥ Let sliding plate engage in the shift drum locating. 30/ASSEMBLING ENGINE 100 Installing the kickstarter idler gear ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide on kickstarter idler gear with the collar facing the engine case. ಥ Slide on the washer. Mount the lock ring. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide the premounted kickstarter shaft into the bearing seat. 200120-12 Installing the kickstarter shaft Info The kickstarter ratchet wheel should not be in contact with stop plate. 200111-10 ಥ Turn kickstarter shaft clockwise all the way. ಥ Pretension kickstarter spring, and attach and position spring hanger. ಥ Mount and tighten screw . Specification Screw, kickstarter spring hanger M6 10Nm (7.38lbfft) 200110-11 Installing the starter idler gear ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide on the starter idler gear with the collar facing the engine case. ಥ Slide on the washer. Mount the lock ring. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide on torque limiter. Mount and tighten the screw with washer. Specification 200121-12 Installing the torque limiter Screw, torque governor 200120-11 M6 10Nm (7.38lbfft) Loctite® 243™ 30/ASSEMBLING ENGINE 101 Installing the balancer shaft ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide balancer shaft into the bearing seats. Align the marking on balance weight with the marking on primary pinion. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Slide the outer clutch hub onto the main shaft. Turn oil pump gear and kickstarter gear until the gearing of the outer clutch hub engages. ಥ Slide on washer and inner clutch hub. ಥ Position the new lock washer and mount nut. Fix the inner clutch hub using the special tool and tighten the nut. Specification 200134-11 Installing the outer clutch hub 200097-10 200096-12 Nut, inner clutch hub M18x1,5 Clutch holder (51129003000) ( 200095-01 80Nm (59.01lbfft) P. 178) ಥ Secure the nut with lock washer. ಥ Insert the pressure piece. ಥ Block the outer clutch hub and primary gear using special tool. Installing the primary gear nut Gear segment (80029004000) ( ಥ Mount and tighten the nut. Specification Nut, primary gear 200099-11 P. 183) M20LHx1,5 150Nm Loctite® 648™ (110.64lbfft) 30/ASSEMBLING ENGINE 102 Installing the clutch discs ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Oil the clutch facing discs well. Engine oil (SAE 10W/50) ( 400377-10 P. 174) ಥ Insert support ring into the outer clutch hub. ಥ Insert pretension ring with the open side facing outward. ಥ Place the machined clutch facing disc with the recess for the pretension ring into the outer clutch hub. ಥ Beginning with an intermediate disc, place all further clutch facing discs and intermediate discs alternately into the outer clutch hub. ಥ Fit the pressure cap. Mount screws with washers and springs. Tighten the screws diagonally. Specification Screw, clutch spring M6 10Nm (7.38lbfft) 200093-11 Installing the clutch cover ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount dowels. Fit the new clutch cover seal. ಥ Mount the clutch cover. 200073-11 Info Turn the water pump wheel lightly to engage the water pump drive. ಥ Mount screws and tighten them after all screws of the clutch cover have been mounted. Specification Screw, clutch cover M6x25 700015-11 ಥ 10Nm (7.38lbfft) Mount screws and tighten all screws in a crisscross pattern. Specification Screw, clutch cover M6x30 10Nm (7.38lbfft) Info Mount the left screw with the seal ring. ಥ Set the crankshaft to top dead center and block it using the special tool. Crankshaft locking bolt (113080802) ( P. 177) 30/ASSEMBLING ENGINE 103 Installing the water pump cover ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Fit the water pump cover seal. ಥ Install the water pump cover. Mount screw with the seal washer and tighten it after all screws of the water pump cover have been mounted. Specification Screw, water pump cover ಥ 200071-11 M6x25 Mount screws and tighten them after all screws of the water pump cover have been mounted. Specification Screw, water pump cover ಥ 10Nm (7.38lbfft) M6x25 10Nm (7.38lbfft) Mount screw and tighten all screws in a crisscross pattern. Specification Screw, water pump cover M6x55 10Nm (7.38lbfft) Installing the kickstarter ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the kickstarter. Mount and tighten screw. Specification Screw, kickstarter M8 25Nm (18.44lbfft) Loctite® 243™ 200067-10 Installing the suction pump ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Oil the internal rotor and external rotor before mounting. Engine oil (SAE 10W/50) ( P. 174) ಥ Insert O-ring. ಥ Position pin in oil pump shaft and slide on the internal rotor. Info Marking of the internal rotor faces outward. 200130-10 ಥ Mount the external rotor with the marking facing inward. Info The marking should not be visible after installation. 200129-11 ಥ Check that the pin of the suction pump is seated properly. ಥ Position oil pump cover . Mount and tighten screws . Specification Screw, oil pump cover 200128-11 M5 6Nm (4.43lbfft) Loctite® 222 30/ASSEMBLING ENGINE 104 Installing the ignition pulse generator ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the ignition pulse generator. Info Use the outermost pair of drill holes. ಥ Mount and tighten screws. Specification Screw, ignition pulse generator 200107-12 M5 6Nm (4.43lbfft) Loctite® 243™ ಥ Position the cable and insert the cable support sleeve into the engine case. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Thread the timing chain and place it over the timing chain sprocket. Installing the timing chain Info Note the running direction if installing a used timing chain. 200108-12 Installing the timing chain securing guide ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position ignition pulse generator cable in the timing chain securing guide. ಥ Mount cable support sleeve. ಥ Position the timing chain securing guide. Mount and tighten screws. Specification 200106-10 Screw, timing chain securing guide M6 10Nm (7.38lbfft) Loctite® 243™ 200105-12 Installing the timing chain tensioning rail ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Thread the timing chain tensioning rail from above. Mount and tighten screw. Specification Screw, timing chain tensioning rail 700005-10 M6 10Nm (7.38lbfft) Loctite® 243™ 30/ASSEMBLING ENGINE 105 Installing the timing chain guide rail ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Thread timing chain guide rail from above. Mount and tighten screws. Specification Screw, timing chain guide rail M6 10Nm (7.38lbfft) Loctite® 243™ 700006-11 Installing the balance weight ಥ Mount balance weight. Info The shape of the gearing prevents incorrect mounting of the balance weight. ಥ Mount and tighten the lock washer and nut. Tighten nut. Specification Balancer shaft nut 700007-11 M10x1 40Nm (29.5lbfft) ಥ Secure the nut with lock washer. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Ensure that the spring washer is seated properly. Mount the rotor. ಥ Mount and tighten the spring washer and nut. Tighten nut. Specification Installing the rotor Ignition rotor nut M12x1 60Nm (44.26lbfft) 200102-01 Installing the piston ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Shift the joint of the compression ring and oil scraper ring by 180°. ಥ Place the oiled piston on the cylinder. Tighten the piston rings using the special tool. Piston ring mounting tool (60029015000) ( P. 179) 200086-01 ಥ 200087-01 Using a plastic hammer, lightly hit the piston tension band from above until it is flush with the cylinder. 30/ASSEMBLING ENGINE 106 ಥ Carefully knock the piston into the cylinder using the hammer shaft. Info The piston tension band must press the piston rings together firmly and must be flush with the cylinder; the piston rings should not catch or else they will be damaged. 200088-01 ಥ Mount dowels and fit the cylinder base gasket. ಥ Ensure that piston marking faces the outfeed side. ಥ Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. 200090-10 200089-01 Info For clarity, the following steps are illustrated using a disassembled piston. 200091-10 ಥ 400366-10 Position the piston pin retainer. 30/ASSEMBLING ENGINE 107 ಥ Insert the special tool and firmly press it toward the piston. ಥ Turn the special tool counterclockwise, thereby pressing the piston pin retainer into the groove. Insert for piston pin retainer (77329030100) ( P. 181) 200084-10 ಥ Remove the cloth. Keep the timing chain tensioned. ಥ Push the cylinder down carefully and let the dowels engage. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount the dowels. Fit the new cylinder head gasket. ಥ Fit the cylinder head. ಥ Insert the washers of the cylinder-head bolts. ಥ Mount cylinder-head bolts and tighten all screws in a crisscross pattern. Specification 200092-01 Installing the cylinder head Screw, cylinder head M10x1,25 Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 10Nm (7.38lbfft) Step 2 30Nm (22.13lbfft) Step 3 50Nm (36.88lbfft) 200082-11 ಥ Engine oil (any) Mount and tighten screw. Specification Screw, cylinder head M6 10Nm (7.38lbfft) 30/ASSEMBLING ENGINE 108 Installing the camshaft ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Place the timing chain over the camshaft. Slide the camshaft into the bearing seats. The markings on camshaft and cylinder head must be aligned. Info Ensure that the crankshaft is located at top dead center. 200078-10 ಥ Position the camshaft support plate. Mount and tighten screw. Specification Screw, camshaft bearing support M6 10Nm (7.38lbfft) Loctite® 243™ 700016-11 Installing the timing chain tensioner ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ After it has been positioned in the installation location, insert timing chain tensioner with new O-ring. ಥ Mount plug with the new seal ring and tighten. Specification Plug, timing chain tensioner M24x1,5 25Nm (18.44lbfft) 200074-12 ಥ Remove screw and use the special tool to push the timing chain tensioner toward the timing chain. Release device for timing chain tensioner (77329051000) ( ಥ Mount and tighten screw. Specification Screw, unlocking of timing chain tensioner 200075-01 P. 182) M10x1 10Nm (7.38lbfft) 30/ASSEMBLING ENGINE 109 Checking the valve clearance ಥ Remove special tool. ಥ Crank the engine several times. ಥ Set the engine to ignition top dead center. ( ಥ On all valves, check valve clearance between the valve and rocker arm. Specification P. 61) 200062-11 Valve clearance Outfeed at: 20°C (68°F) 0.12… 0.17mm (0.0047… 0.01in) Infeed at: 20°C (68°F) 0.1… 0.15mm (0.0039… 0.01in) Feeler gauge (59029041000) ( » 700042-10 ಥ P. 179) If valve clearance does not meet specifications: ಥ Adjust the valve clearance. ( P. 109) Mount and tighten screw. Specification Plug, crankshaft location M8 10Nm (7.38lbfft) 200061-11 Adjusting the valve clearance ಥ Remove the timing chain tensioner. ( ಥ Remove the camshaft. ( P. 62) P. 62) ಥ Raise rocker arm on the outside. ಥ Remove shims and set them down according to the installation position. ಥ Correct the shims as indicated by the results of the valve clearance check. ಥ Insert fitting shims. ಥ Install the camshaft. ( ಥ Install the timing chain tensioner. ( ಥ Check the valve clearance. ( ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount centering pins. Fit generator cover seal. P. 108) P. 108) P. 109) 700043-10 Installing the generator cover 700010-11 30/ASSEMBLING ENGINE 110 ಥ Position the generator cover. Mount screws and tighten them after all screws of the generator cover have been mounted. Specification Screw generator cover ಥ M6x25 Mount screws and tighten all screws in a crisscross pattern. Specification Screw generator cover M6x40 700011-11 ಥ 10Nm (7.38lbfft) 10Nm (7.38lbfft) Mount and tighten screw. Specification Screw, generator cover (through-hole for chain shaft) M6x25 10Nm (7.38lbfft) Loctite® 222 Installing the shift lever ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the shift lever. Fit and tighten screw with collar sleeve. Specification Screw, shift lever M6 10Nm (7.38lbfft) Loctite® 243™ 700017-11 Installing the valve cover ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the valve cover seal. ಥ Fit the valve cover. Mount and tighten screws. Specification Screw, valve cover M6 10Nm (7.38lbfft) 700013-10 Installing the spark plug ಥ 700031-11 Fit and tighten the spark plug using a special tool. Specification Spark plug M12x1,25 Spark plug wrench (75029172000) ( P. 181) 15… 20Nm (11.06… 14.75lbfft) 30/ASSEMBLING ENGINE 111 Installing the starter motor ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Grease the O-ring. Mount the starter engine. Long-life grease ( ಥ P. 175) Mount and tighten screws. Specification Screw, starter motor M6 10Nm (7.38lbfft) 200064-10 Mounting oil filter ಥ Tilt the engine sideways and fill the oil filter housing to about 1/3 full with engine oil. ಥ Fill the oil filter with engine oil and place it in the oil filter container. ಥ Lubricate the o/ring of the oil filter cover. ಥ Refit the oil filter cover. ಥ Mount and tighten screws. Specification 700027-11 Screw, oil filter cover M5 6Nm (4.43lbfft) 700022-11 Filling up with engine oil ಥ Thoroughly clean the plug and gear oil screen. Check parts for damage and wear. Replace damaged or worn parts. ಥ Clean the sealing area on the engine. ಥ Refit the plug of engine oil screen with O-rings and tighten it. Specification Plug, engine oil screen M17x1,5 20Nm (14.75lbfft) 400364-10 ಥ Remove the screw cap on the generator cover and fill up with engine oil. Engine oil ಥ 700032-11 0.6l (0.63qt.) Mount and tighten screw cap. Engine oil (SAE 10W/50) ( P. 174) 30/ASSEMBLING ENGINE 112 Filling up with gear oil ಥ Thoroughly clean the plug, gear oil screen and gear oil drain plug. Check parts for damage and wear. Replace damaged or worn parts. ಥ Clean the sealing surfaces on the engine. ಥ Refit gear oil drain plug with seal ring and tighten it. Specification Gear oil drain plug with magnet ಥ 400365-10 M12x1,5 Refit plug of gear oil screen with O-rings and tighten it. Specification Plug, gear oil screen ಥ M16x1,5 0.9l (0.95qt.) Engine oil (SAE 10W/50) ( Mount and tighten screw cap. 700033-11 Removing the engine from the universal mounting rack ಥ Remove the screw/nut from the special tool. Engine holder (78029002000) ( ಥ 700020-01 20Nm (14.75lbfft) Remove the screw cap and fill up with gear oil. Gear oil ಥ 20Nm (14.75lbfft) P. 182) Remove the engine from the universal mounting rack. P. 174) 31/CARBURETOR 113 &$5%85(725 Choke (EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-W) The choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated. 500135-10 Possible states • Choke function activated ಥThe choke lever is pulled out to the stop. • Choke function deactivated ಥThe choke lever is pushed in to the stop. Choke (EXC-REU) The flasher switch is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated. 500136-10 Possible states • Choke function activated ಥThe choke lever is pulled to the stop. • Choke function deactivated ಥThe choke lever is pushed back to the stop. Checking the choke Bowden cable routing (EXC-REU) ಥ The choke Bowden cable must run behind the handlebar down to the frame. The choke Bowden cable runs to the carburetor behind the CDI controller directly on the left side of the frame. 700078-10 Checking the choke Bowden cable for play (EXC-REU) ಥ Move the handlebar to the straight-ahead position. ಥ Loosen screw but do not remove it. It must be possible to move the choke lever slightly. ಥ Move the choke lever back and forth slightly to ascertain the play in the choke Bowden cable. Choke Bowden cable play » 2… 3mm (0.08… 0.12in) If the choke Bowden cable play does not meet specifications: ಥ Adjust the choke Bowden cable play. ( P. 113) 700076-10 Adjusting the choke Bowden cable play (EXC-REU) ಥ Move the handlebar to the straight-ahead position. ಥ Check the choke Bowden cable routing. ( ಥ Push back bellows. ಥ Loosen screw but do not remove it. It must be possible to move the choke lever slightly. ಥ Turn nut in as far as possible. Turn adjusting screw until the choke lever exhibits the required choke Bowden cable play. Specification Choke Bowden cable play 700077-10 P. 113) 2… 3mm (0.08… 0.12in) ಥ Tighten nut. ಥ Tighten screw. The choke lever must remain in position when it is activated. 31/CARBURETOR 114 ಥ Push bellows on. ಥ The two gas Bowden cables must run parallel behind the handlebar down to the frame. They must be routed directly on the frame above the tank bearing to the carburetor. ಥ Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain the play in the gas Bowden cable. Checking gas Bowden cable route 500152-10 Checking play in the gas Bowden cable Play in gas Bowden cable » 3… 5mm (0.12… 0.2in) If the gas Bowden cable play does not meet specifications: ಥ Adjust the gas Bowden cable play. ( P. 114) Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. 400192-10 ಥ ಥ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. » If the idle speed changes: ಥ Adjust the gas Bowden cable play. ( P. 114) Adjusting the gas Bowden cable play ಥ Dismount the fuel tank. ( ಥ Check gas Bowden cable route. ( ಥ Move the handlebar to the straight-ahead position. P. 28) P. 114) ಥ Push back bellows. ಥ Loosen nut. Turn adjusting screw in as far as possible. ಥ Loosen nut. Turn adjusting screw so that there is play in the gas Bowden cable at the throttle grip. Specification Play in gas Bowden cable 500153-10 3… 5mm (0.12… 0.2in) ಥ Tighten nut. ಥ Press and hold the throttle grip in the closed setting. Turn adjusting screw out until there is no play in the Bowden cable . ಥ Tighten nut. ಥ Push bellows on. Check the throttle grip for smooth operation. ಥ Install the fuel tank. ( ಥ Check play in the gas Bowden cable. ( P. 29) P. 114) 31/CARBURETOR 115 Removing the carburetor ಥ Dismount the fuel tank. ( ಥ Remove the carburetor connection boot. ( ಥ Remove screw. Remove the carburetor cover. ಥ Push back bellows. ಥ Undo nuts, detach the Bowden cables and hang them to one side. ಥ Undo hose clip. ಥ Pull engine vent hose off of the carburetor. ಥ Unplug the connector of throttle valve sensorTPS . ಥ Unthread the carburetor vent hoses. Pull the carburetor out of the rubber sleeve and remove it. P. 28) P. 27) 500109-10 500110-10 (EXC-REU) ಥ Twist out the choke slide and hang it to one side together with the Bowden cable. 500111-10 Disassembling the carburetor ಥ Remove the carburetor. ( ಥ Remove screws and detach all vent hoses from the carburetor. ಥ Remove screws. Take off the throttle slide cover and seal. P. 115) 700034-10 700035-10 31/CARBURETOR 116 ಥ Remove screws with the spring and washer and slide stop. ಥ Pull the jet needle out of the throttle slide. ಥ Remove screw. ಥ Pull up throttle slide arm . Take throttle slide out of the carburetor along with throttle slide roller and the throttle slide plate. ಥ Remove screws . Take off the accelerator pump cover with the seal ring. ಥ Remove seal rings(1, spring(2 and membrane(3. ಥ Remove screws(4 and take off the float chamber body. ಥ Take leakage nozzle(5 out of the float chamber body. ಥ Remove fulcrum pin(6. Take off the float and float needle valve. ಥ Remove main jet(7. 700036-10 700037-10 700038-10 700039-10 700058-10 700044-10 31/CARBURETOR 117 ಥ Remove idling jet(8, cold start jet(9, needle jet(: and buffer plate)1. ಥ Screw in mixture control screw)2 to the stop, counting and noting down the number of rotations. ಥ Remove the mixture control screw with the spring, washer and O-ring. ಥ Screws)3 should not be removed. ಥ Remove screw)4. Pull the hose connector out of the carburetor. ಥ Remove screw)5. Take off throttle valve sensor)6. 700045-10 700046-10 700047-10 Info Only remove the throttle valve sensor if necessary. If screw)5 is loosened, the throttle valve sensor must be readjusted. (EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-W) ಥ Unscrew choke slide)7. 700048-10 ಥ Remove idle air jet)8. ಥ Clean all jets and other parts thoroughly and blow out with compressed air. Carburetor cleaner ( ಥ P. 175) Clean the carburetor housing and blow out all channels in the carburetor with compressed air. Carburetor cleaner ( P. 175) Info 700049-10 Do not use nitro thinner to clean the carburetor. 31/CARBURETOR 118 Checking the carburetor components 700073-01 ಥ Disassemble the carburetor. ( ಥ Check/adjust the accelerator pump. ( ಥ Check the choke slide. ( P. 119) ಥ Check the jet needle. ( P. 119) ಥ Check the throttle slide. ( ಥ Check the needle jet. ( ಥ Check the float needle valve. ( P. 120) ಥ Check/adjust the float level. ( P. 120) ಥ Check/adjust the throttle slide opening. ( ಥ Check throttle valve sensorTPS. ( ಥ Assemble the carburetor. ( P. 115) P. 118) P. 119) P. 120) P. 120) P. 121) P. 122) Checking/adjusting the accelerator pump ಥ Check the membrane for damage and brittleness. » If the membrane is damaged or brittle: ಥ Change the membrane. ಥ Check that the bores are clear. » If the bores are not clear: ಥ Clean the bores. Carburetor cleaner ( 700051-10 P. 175) 31/CARBURETOR 119 ಥ Check/adjust the throttle slide opening. ( P. 120) Info Adjusting the play of the accelerator pump changes the time at which injection starts and does not influence the injection rate or the intensity of the accelerator pump. ಥ Check piston rod overhang . Specification Piston rod overhang 700065-10 » 0.9… 1mm (0.04… 0.04in) If piston rod overhang does not equal the specified value: ಥ Correct the piston rod overhang by turning adjusting screw. ಥ Carburetor - adjust the idle speed. ( ಥ Check the choke slide for smooth operation. » If the choke slide cannot be moved easily or is soiled: ಥ Clean the choke slide and check the Bowden cable and lever if necessary. P. 126) Checking the choke slide Carburetor cleaner ( P. 175) ಥ The piston of the choke slide should not be damaged. » If the piston of the choke slide is damaged or worn: ಥ Change the choke slide. ಥ Check the rubber sleeve and lock. » If the rubber sleeve is damaged or brittle, or if the lock does not function: ಥ Change the choke slide. ಥ Check the jet needle for bending and wear of the coating. » If the jet needle is bent or the coating is damaged or worn: ಥ Change the jet needle. ಥ Check that the needle clip is tight. » If the needle clip is not tight: ಥ Change the needle clip or the jet needle. ಥ Check the throttle slide rollers for damage and wear. » If the throttle slide rollers do not turn easily, are worn or have flat area: ಥ Change the throttle slide. ಥ Except for throttle slide roller (removable), all rollers must rest flush against the throttle slide. » If the throttle slide rollers are loose: ಥ Change the throttle slide. ಥ Check the coating of the throttle slide and throttle slide plate for damage and wear. » If the coating is damaged or worn: ಥ Change the throttle slide. ಥ Check membrane of the throttle slide plate for damage, brittleness and tightness. » If the membrane is damaged or brittle: ಥ Change the membrane. ಥ Check that membrane is seated properly. » If the membrane is not seated properly: ಥ Position the membrane correctly. 700050-10 Checking the jet needle 700052-10 Checking the throttle slide 700055-10 700056-10 31/CARBURETOR 120 Checking the needle jet ಥ Use a new jet needle as a gauge. Apply a marking step at a distance of. Specification Distance on the jet needle above 3mm (0.12in) Info The marking should come off completely when cleaned away. 700053-10 ಥ Insert the marked jet needle into the needle jet being tested. Push the two pieces together carefully. ಥ Check the needle jet. » If marking on the jet needle is not visible on top edge of the needle jet: ಥ Change the needle jet. ಥ Check the float needle valve including the valve seat for deposits or wear. » If there are deposits or wear: ಥ Clean the valve seat. Clean or change the float needle valve. 700054-10 Checking the float needle valve Carburetor cleaner ( P. 175) ಥ Check the float needle valve for wear and the sealing areas of indentations. » If the sealing area is damaged or if there is wear: ಥ Change the float needle valve. ಥ Hold the carburetor at a slant, securing the pin against falling out of the float. ಥ Hold the carburetor at a slant so that the float lies against the float needle valve but does not press it together. » In this position, if the edge on the float is not parallel to the sealing area of the float chamber: ಥ Adjust the float level by bending float lever. 700057-10 Checking/adjusting the float level 700061-10 Checking/adjusting the throttle slide opening Info The basic setting of the throttle slide controls the time at which injection begins at the accelerator pump and the basic setting of the throttle valve sensor. ಥ Remove the carburetor. ( P. 115) 31/CARBURETOR 121 ಥ Check the throttle slide opening using a wire or a drill shank. Throttle slide opening » 1mm (0.04in) If the throttle slide opening does not equal the specified value: ಥ Adjust the throttle slide opening with adjusting screw. 700062-10 Checking throttle valve sensorTPS Info The value in the figure is an example only! ಥ Remove the carburetor. ( ಥ Check/adjust the throttle slide opening. ( P. 115) P. 120) Condition Component temperature: 20°C (68°F) ಥ Connect the positive wire of the multimeter to the blue (bu) cable and the ground wire to the black(bl) cable of the connector of throttle valve sensorTPS. Measure the total resistance Rtot of the throttle valve sensor. Specification Total resistance Rtot of the throttle valve sensor 4… 6k 700063-10 ಥ Connect the positive wire of the multimeter to the yellow (ye) cable and the ground wire to the black(bl) cable of the connector of throttle valve sensorTPS. ಥ Slowly open the throttle slide and measure the variable resistance Rvar of the throttle valve sensor. Variable resistance Rvar of the throttle valve sensor (throttle slide fully opened) » If the value does not increase smoothly: ಥ Change throttle valve sensorTPS. » If the value is outside of the specification: ಥ Adjust the position of throttle valve sensorTPS. ( 700064-10 ಥ 3… 4.5k Install the carburetor. ( P. 121) P. 125) Adjusting the position of throttle valve sensorTPS Info The value in the figure is an example. ಥ Remove the carburetor. ( ಥ Check/adjust the throttle slide opening. ( P. 115) P. 120) Conditions Component temperature: 20°C (68°F) ಥ Connect the positive wire of the multimeter to the blue (bu) cable and the ground wire to the black(bl) cable of the connector of throttle valve sensorTPS. Measure the total resistance Rtot of the throttle valve sensor. Specification Total resistance Rtot of the throttle valve sensor 700063-10 4… 6k 31/CARBURETOR 122 ಥ Multiply the total resistance Rtot of the throttle valve sensor by 0.17. This generates the variable resistanceRvar for the setting of the throttle valve sensor. ಥ Rtot x 0.17 = Rvar (tolerance¢0.05k˖) ಥ Connect the positive wire of the multimeter to the yellow (ye) cable and the ground wire to the black(bl) cable of the connector of throttle valve sensorTPS. ಥ Measure the variable resistance Rvar of the throttle valve sensor. 700064-10 Info The throttle slide must be in the neutral position. 700066-10 ಥ Loosen screw. Set throttle valve sensorTPS by turning it to the calculated value. ಥ Tighten screw. Specification Screw, throttle valve sensor ಥ M5 3.5Nm (2.58lbfft) Check the variable resistance Rvar of the throttle valve sensor again. » If the measured value is not equal to the calculated value: ಥ Repeat the adjustment procedure. ಥ Install the carburetor. ( ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Mount and tighten idle air jet. Specification P. 125) Assembling the carburetor Idle air jet M4,5x0,75 2Nm (1.48lbfft) Idle air jet(100) 700049-11 (EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-W) ಥ Mount and tighten choke slide. Specification Choke slide ಥ 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. 700048-11 ಥ Position the hose connection. Mount and tighten screw. Specification Screw, hose connection M4 2Nm (1.48lbfft) Loctite® 243™ Info The hose connection must be easy to turn when it is mounted. 700047-11 31/CARBURETOR 123 ಥ Screw in mixture control screw the stop. Specification together with the spring, washer and O-ring to Mixture control screw ಥ M6x0,5 1Nm (0.74lbfft) Unscrew mixture control screw again by the number of turns that was noted down earlier when it was disassembled or to the specified basic setting. Specification Idle mixture adjusting screw (XCR-WUSA) Open 700045-11 0.5turn Idle mixture adjusting screw (EXC-RSIXDAYS) Open 1turn Idle mixture adjusting screw (XCR-WZA, 530EXC-REU, 530EXC-RAUS/UK) Open 1.5turns Idle mixture adjusting screw (450EXC-REU, 450EXC-RAUS/UK, 450EXCRUSA) Open 1.75turns Idle mixture adjusting screw (530EXC-RUSA) Open 2turns Info The mixture control screw may be open by no more than 2 turns. If more than two turns are necessary (rich mixture), use a larger idling jet. ಥ Position buffer plate . Mount and tighten needle jet , cold start jet idling jet(1. Specification Needle jet M7x0,75 and 3.5Nm (2.58lbfft) Cold start jet M5x0,75 2Nm (1.48lbfft) Idling jet M6x0,75 2Nm (1.48lbfft) (EXC-REU, EXC-RAUS/UK) Cold start jet(65 (85)) (EXC-RSIXDAYS, EXC-RUSA, XCR-W) Cold start jet(85) (EXC-REU, EC-R AUS/UK, EXC-RSIXDAYS, XCR-W) Idling jet(40) (EXC-RUSA) Idling jet(48) ಥ Mount and tighten main jet(2. Specification Main jet M5x0,75 2Nm (1.48lbfft) (All EXC-Rmodels, XCR-WUSA) Main jet(180) (XCR-WZA) Main jet(185) 700044-11 ಥ Position the float and float needle valve, and mount fulcrum pin(3. ಥ Check/adjust the float level. ( ಥ Mount and tighten leakage nozzle(4. Specification Leakage nozzle Leakage nozzle(40) 700058-11 P. 120) M4x0,7 2Nm (1.48lbfft) 31/CARBURETOR 124 ಥ Position the float chamber and adjustment screw. ಥ Mount screws(5 but do not tighten them yet. ಥ Insert throttle slide(6 with throttle slide roller(7 and the throttle slide plate into throttle slide arm(8 and position them in the carburetor. ಥ Position the needle clip on the jet needle. Specification 700067-11 700037-11 Needle position (XCR-WUSA) 1st position from top Needle position (EXC-RSIXDAYS, 530EXC-RUSA) 3rd position from top Needle position (XCR-WZA, 450EXCREU, 450EXC-RAUS/UK, 450EXCRUSA) 4th position from top Needle position (530EXC-REU, 530EXC-RAUS/UK) 5th position from top (450XCR-W, 450EXC-RSIXDAYS) Jet needle(OBDTQ) (530XCR-W, 530EXC-RSIXDAYS) Jet needle(OBDTR) (450EXC-RUSA) Jet needle(OBDYU) (450EXC-REU, 450EXC-RAUS/UK) Jet needle(OBDYU (OBDTQ)) (530EXC-RUSA) Jet needle(OBDZT) (530EXC-REU, 530EXC-RAUS/UK) Jet needle(OBDZT (OBDTR)) ಥ Insert the jet needle. ಥ Mount and tighten screw(9 or slide stop(: with the spring and washer. Specification Needle screw/slide stop ಥ M8 3.5Nm (2.58lbfft) Mount and tighten screw)1. Specification Screw, throttle slide arm M4 2Nm (1.48lbfft) Loctite® 243™ 700036-11 ಥ Position the throttle slide cover with the seal. Mount and tighten screws)2. Specification Other screws, carburetor ಥ 700035-11 Check/adjust the throttle slide opening. ( M4 P. 120) 2Nm (1.48lbfft) 31/CARBURETOR 125 ಥ Check/adjust the accelerator pump. ( ಥ Position seal ring)3, membrane)4 and spring)5. P. 118) Info The label on the membrane must be visible when mounted. 700060-11 ಥ Position seal ring)6 in the accelerator pump cover with the rounded side facing outward. ಥ Position the accelerator pump cover. Mount and tighten screws)7. Specification 700059-11 Other screws, carburetor M4 2Nm (1.48lbfft) 700038-11 ಥ Position and mount the vent hoses. ಥ Position the hose holder. Mount the screws)8 and tighten all screws in a crisscross pattern. Specification Other screws, carburetor M4 2Nm (1.48lbfft) ಥ Adjust the position of throttle valve sensorTPS. ( ಥ Install the carburetor. ( ಥ Check parts for damage and wear. Replace damaged or worn parts. P. 121) P. 125) 700034-11 Installing the carburetor (EXC-REU) ಥ Mount and tighten the choke slide. Specification Choke slide ಥ M12 2.5Nm (1.84lbfft) Insert the carburetor into the rubber sleeve. Info 500111-11 Align nose on the carburetor with the notch in the rubber sleeve. The carburetor must be positioned vertically. ಥ Position the carburetor vent hoses. ಥ Attach the connector of throttle valve sensorTPS. 31/CARBURETOR 126 500110-11 ಥ Position hose clamp and tighten. ಥ Attach engine vent hose to the carburetor. ಥ Connect the Bowden cables. ಥ Check gas Bowden cable route. ( ಥ Move the handlebar to the straight-ahead position. P. 114) ಥ Turn adjusting screw in as far as possible. ಥ Turn adjusting screw so that there is play in the gas Bowden cable at the throttle grip. ಥ Tighten nut . ಥ Press and hold the throttle grip in the closed setting. Turn adjusting screw out until there is no play in the Bowden cable . ಥ Tighten nut . ಥ Position the carburetor cover. Mount and tighten screw . ಥ Push bellows(1 on. Check the throttle grip for smooth operation. ಥ Install the carburetor connection boot. ( ಥ Install the fuel tank. ( ಥ Check play in the gas Bowden cable. ( P. 27) P. 29) P. 114) (EXC-REU) ಥ Check the choke Bowden cable for play. ( P. 113) 500109-11 Carburetor - adjusting idle ಥ Screw in the idle adjusting screw until it stops and then to the prescribed basic setting. Specification Idle mixture adjusting screw (XCR-WUSA) Open 0.5turn Idle mixture adjusting screw (EXC-RSIXDAYS) Open 1turn Idle mixture adjusting screw (XCR-WZA, 530EXC-REU, 530EXC-RAUS/UK) 400341-10 Open 1.5turns Idle mixture adjusting screw (450EXC-REU, 450EXC-RAUS/UK, 450EXCRUSA) Open 1.75turns Idle mixture adjusting screw (530EXC-RUSA) Open 2turns Adjustment tool for mixture control screw (77329034000) ( ಥ P. 182) Run the engine until warm. Specification Warm-up time 싩5min Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. ಥ ಥ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Adjust the idle speed with the adjusting screw. Specification Choke function deactivated ಥThe choke lever is pushed in to the stop. ( P. 113) Choke function deactivated ಥThe choke lever is pushed back to the stop. ( P. 113) Idle speed ಥ 1550… 1650rpm Turn the idle adjusting screw slowly until the idle speed begins to fall. 31/CARBURETOR 127 ಥ Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls. ಥ Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extremely sporty rider will set the mixture about 1/4 of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle adjusting screw to the end without any change of engine speed, you have to fit a smaller idling jet. The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet. After changing the idling jet, start from the beginning with the adjusting steps. ಥ Adjust the idle speed with the adjusting screw. Specification Choke function deactivated ಥThe choke lever is pushed in to the stop. ( P. 113) Choke function deactivated ಥThe choke lever is pushed back to the stop. ( P. 113) Idle speed 1550… 1650rpm Info Following extreme air temperature or altitude changes, adjust the idle speed again. Emptying the carburetor float chamber Danger Fire hazardಗFuel can easily catch fire. ಥ Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. ಥ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel. Warning Danger of poisoningಗFuel is poisonous and a health hazard. ಥ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. Warning Environmental hazardಗImproper handling of fuel is a danger to the environment. ಥ Do not allow fuel to get into the ground water, the ground, or the sewage system. Info Carry out this work with a cold engine. ಥ Turn the handle of the fuel tap to the OFF position. (Figure500137-10 No more fuel flows from the tank to the carburetor. P. 30) 31/CARBURETOR 128 ಥ Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. 400341-11 ಥ Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber. ಥ Tighten screw. 32/CLUTCH 129 &/87&+ Checking fluid level of hydraulic clutch Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! ಥ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. ಥ Remove screws. ಥ Take off cover with membrane. ಥ Check the fluid level. Fluid level under top level of container. » If the level of the cooling liquid does not meet specifications: ಥ Correct the fluid level of the hydraulic clutch. Brake fluid DOT 5.1 ( 400339-10 4mm (0.16in) P. 174) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the cover with the membrane. Mount and tighten screws. Info Clean up overflowed or spilt fluid immediately with water. Changing fluid level of hydraulic clutch Warning Skin irritationsಗBrake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! 400339-10 ಥ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. ಥ Remove screws. ಥ Take off cover with membrane. 32/CLUTCH 130 ಥ Fill the bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) ( Brake fluid DOT 5.1 ( P. 177) P. 174) ಥ On the slave cylinder, remove the bleeder screw and fit the bleeding syringe. ಥ Inject the liquid into the system until it escapes from the bore hole ter cylinder without bubbles. ಥ To prevent overflow, drain fluid occasionally from the master cylinder reservoir. ಥ Remove the bleeding syringe. Mount and tighten screws bleeder screw. ಥ Correct the fluid level of the hydraulic clutch. Specification 500158-10 Fluid level under top level of container. 400340-10 4mm (0.16in) ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Position the cover with the membrane. Mount and tighten screws. Info Clean up overflowed or spilt fluid immediately with water. of the mas- 33/TRANSMISSION 131 75$160,66,21 Removing the engine sprocket ಥ Remove the engine sprocket cover. ( ಥ Press the rear brake and remove screw with spring washer. ಥ Pull the engine sprocket with the chain off of the countershaft. Remove the engine sprocket. ಥ Check parts for damage and wear. Replace damaged or worn parts. P. 19) 500115-10 Installing the engine sprocket Info The engine sprocket, rear sprocket and chain should always be replaced together. ಥ With the collar facing the engine, mount the engine sprocket in the chain and slide both onto the countershaft. ಥ Press the rear brake. Fit and tighten screw with spring washer. Specification 500115-10 Screw, engine sprocket M10 ಥ Check the chain tension. ( P. 38) ಥ Install the engine sprocket cover. ( 60Nm (44.26lbfft) P. 19) Loctite® 243™ 35/WATER PUMP, COOLING SYSTEM 132 :$7(5 3803 &22/,1* 6<67(0 Checking antifreeze and coolant level Warning Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure. ಥ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately. Warning Danger of poisoningಗCoolants are poisonous and a health hazard. ಥ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. ಥ Stand the motorcycle upright on a horizontal surface. ಥ Remove the radiator cap. ಥ Check antifreeze of coolant. -25… -45°C (-13… -49°F) » ಥ If the antifreeze of the cooling liquid does not meet specifications: ಥ Correct antifreeze of coolant. Check the coolant level in the radiator. Coolant level 400243-10 » above radiator fins. If the level of the cooling liquid does not meet specifications: ಥ Correct the coolant level. Alternative 1 Coolant ( P. 174) Alternative 2 Coolant (mixed ready to use) ( ಥ 10mm (0.39in) P. 174) Refit the radiator cap. Checking the coolant level Warning Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure. ಥ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately. Warning Danger of poisoningಗCoolants are poisonous and a health hazard. ಥ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. ಥ Stand the motorcycle upright on a horizontal surface. ಥ Remove the radiator cap. ಥ Check the coolant level in the radiator. Coolant level » 400243-10 above radiator fins. If the level of the cooling liquid does not meet specifications: ಥ Correct the coolant level. Alternative 1 Coolant ( P. 174) Alternative 2 Coolant (mixed ready to use) ( ಥ 10mm (0.39in) Refit the radiator cap. P. 174) 35/WATER PUMP, COOLING SYSTEM 133 Draining coolant Warning Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure. ಥ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately. Warning Danger of poisoningಗCoolants are poisonous and a health hazard. ಥ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. ಥ Stand the vehicle upright. ಥ Place a suitable container under the water pump cover. ಥ Remove screw. Remove the radiator cap. ಥ Completely drain the coolant. ಥ Fit screw with a new seal and tighten it. Specification Screw, water pump cover M6x25 10Nm (7.38lbfft) 400335-11 Refilling coolant Warning Danger of poisoningಗCoolants are poisonous and a health hazard. ಥ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. ಥ Make sure that the screw is tightened. ಥ Stand the vehicle upright. ಥ Pour coolant in up to measurement Specification above the radiator fins. 10mm (0.39in) Coolant 0.95l (1qt.) Coolant ( P. 174) Coolant (mixed ready to use) ( P. 174) 400244-10 ಥ Refit the radiator cap. ಥ Make a short test ride. ಥ Check the coolant level. ( P. 132) 38/LUBRICATION SYSTEM 134 /8%5,&$7,21 6<67(0 Oil cycle 400283-10 1 engine oil screen 2 Engine oil force pump 3 Oil pressure regulator valve 4 Oil filter insert 5 Oil jet, conrod lubrication 6 Oil jet, piston cooling 7 Timing chain tensioner 8 Lubrication, rocker arm shaft 9 Oil jet, rocker arm lubrication 10 Gear oil screen 11 Gear oil force pump 12 Oil channel, transmission lubrication 13 Lubrication, clutch push rod 14 Suction pump Checking engine oil level Info The engine oil level must be checked when the engine is cold. ಥ Stand the motorcycle upright on a horizontal surface. 38/LUBRICATION SYSTEM 135 Condition Engine is cold. ಥ Check the engine oil level. The engine oil must be between the halfway mark and the top of the oil level viewer. » If the engine oil level is below the specified level: ಥ Top up the engine oil. ( P. 137) 200119-10 Changing engine oil and oil filter, cleaning engine oil screen ಥ Drain the engine oil and clean the engine oil screen. ( ಥ Remove the oil filter. ( P. 135) ಥ Mount the oil filter. ( P. 136) ಥ Fill up with engine oil. ( P. 135) P. 136) Draining engine oil, cleaning engine oil screen Warning Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven. ಥ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Drain the engine oil only when the engine is warm. ಥ Stand the motorcycle on its side stand on a horizontal surface. ಥ Place a suitable container under the engine. ಥ Remove engine oil plug screen. ಥ Completely drain the engine oil. ಥ Thoroughly clean the plug and gear oil screen. ಥ Clean the sealing area on the engine. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Fit plug for the engine oil screen and tighten it. Specification 200112-10 Plug, engine oil screen M17x1,5 20Nm (14.75lbfft) Removing the oil filter Warning Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven. ಥ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. ಥ Place a suitable container under the engine. 38/LUBRICATION SYSTEM 136 ಥ Remove screws. Remove oil filter cover with O-ring. ಥ Pull the oil filter insert out of the oil filter casing. 200113-10 Circlip pliers reverse (51012011000) ಥ Completely drain the engine oil. ಥ Thoroughly clean parts and sealing area. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with engine oil. ಥ Fill the oil filter with engine oil and place it in the oil filter container. ಥ Lubricate the O/ring of the oil filter cover. ಥ Refit the oil filter cover. ಥ Mount and tighten screws. Specification 200114-10 Mounting oil filter 200114-11 Screw, oil filter cover ಥ M5 6Nm (4.43lbfft) Stand the motorcycle up. 200113-11 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. ಥ Remove the screw cap on the generator cover and fill up with engine oil. Engine oil ಥ 0.6l (0.63qt.) Engine oil (SAE 10W/50) ( P. 174) Mount and tighten screw cap. Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. ಥ 200115-10 When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. ಥ Start the engine and check that it is oil-tight. ಥ Check the engine oil level. ( P. 134) 38/LUBRICATION SYSTEM 137 Topping up engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. ಥ Remove the screw cap on the generator cover and fill up with engine oil. Engine oil (SAE 10W/50) ( ಥ P. 174) Mount and tighten screw cap. Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. ಥ 200115-10 When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. ಥ Start the engine and check that it is oil-tight. ಥ Check the engine oil level. ( P. 134) ಥ Check the engine oil level. ( P. 134) ಥ Remove the release screw of the chain adjuster. ಥ Mount and tighten special tool. Specification Checking the engine oil pressure 700074-10 ಥ Oil pressure adapter M10x1 Oil pressure adapter (77329006000) ( P. 181) 10Nm (7.38lbfft) Connect pressure testing tool without the T-plate to the special tool. Pressure testing tool (61029094000) ( P. 179) Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. ಥ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. ಥ Start the engine and let it warm up. ಥ Check the engine oil pressure. Engine oil pressure » ಥ Engine oil temperature: 80°C (176°F) Engine speed: 1600rpm 0.9bar (13.05psi) Engine oil temperature: 80°C (176°F) Engine speed: 6000rpm 2.5bar (36.26psi) If the specified value is not reached: ಥ Check the oil pumps for wear. Check that all oil holes are clear. Switch off the engine. Warning Danger of burnsಗSome vehicle components get very hot when the machine is driven. ಥ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. ಥ Detach the special tool. ಥ Mount and tighten the release screw of the chain adjuster. Specification Screw, unlocking of timing chain tensioner M10x1 10Nm (7.38lbfft) 38/LUBRICATION SYSTEM 138 Checking gear oil level Info The gear oil level must be checked when the engine is cold. ಥ Stand the motorcycle upright on a horizontal surface. Condition Engine is cold. ಥ Remove gear oil level check screw. Stand the vehicle upright. ಥ Check the gear oil level. A small amount of gear oil should flow out. » ಥ If no gear oil flows out: ಥ Top up with gear oil. ( P. 139) Mount and tighten the gear oil level check screw. Specification 200116-10 Screw, gear oil level check M6 10Nm (7.38lbfft) Changing gear oil, cleaning gear oil screen ಥ Drain the gear oil and clean the gear oil screen. ( ಥ Fill up with gear oil. ( P. 138) P. 139) Draining gear oil, cleaning gear oil screen Warning Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven. ಥ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Drain the gear oil only when the engine is warm. ಥ Stand the motorcycle on its side stand on a horizontal surface. ಥ Place a suitable container under the engine. ಥ Remove the gear oil drain plug. ಥ Remove the gear oil screen plug. ಥ Completely drain the gear oil. ಥ Thoroughly clean the gear oil drain plug with a magnet. ಥ Thoroughly clean the drain plug and gear oil screen with a magnet. ಥ Clean the sealing surface on the engine. ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Refit gear oil drain plug with seal ring and tighten it. Specification Gear oil drain plug with magnet ಥ 20Nm (14.75lbfft) Fit the plug for the gear oil screen and tighten it. Specification Plug, gear oil screen 500159-10 M12x1,5 M16x1,5 20Nm (14.75lbfft) 38/LUBRICATION SYSTEM 139 Filling up with gear oil Info Too little gear oil or poor-quality oil results in premature wear to the transmission. ಥ Remove the screw cap and fill up with gear oil. Gear oil ಥ 0.9l (0.95qt.) Engine oil (SAE 10W/50) ( P. 174) Mount and tighten screw cap. Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. ಥ 200118-10 When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. ಥ Start the engine and check that it is oil-tight. ಥ Check the gear oil level. ( P. 138) Topping up with gear oil Info Too little gear oil or poor-quality oil results in premature wear to the transmission. ಥ Remove gear oil level check screw. 200116-10 ಥ Remove screw cap. Stand the vehicle upright. ಥ Top up with gear oil until it flows out of the bore of the gear oil level screw. Engine oil (SAE 10W/50) ( ಥ P. 174) Mount and tighten the gear oil level check screw. Specification Screw, gear oil level check 200118-11 ಥ M6 10Nm (7.38lbfft) Mount and tighten screw cap. Danger Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death. ಥ ಥ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Start the engine and check that it is oil-tight. TROUBLESHOOTING 140 7528%/(6+227,1* Faults Possible cause Measure The engine cannot be cranked (electric starter). Operating error ಥ Perform the steps necessary to start the engine. Battery discharged ಥ Recharge the battery. ( ಥ Check the cause of discharging. ಥ Remove the fuse. ( P. 42) ಥ Replace the fuse. ( P. 42) ಥ Start the engine with the kickstarter. ಥ Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop. Operating error ಥ Perform the steps necessary to start the engine. Motorcycle was out of use for a long time and there is old fuel in the float chamber ಥ Empty the carburetor float chamber. ( P. 127) Fuel feed interrupted ಥ Check tank vent. ಥ Clean fuel tap. ಥ Clean carburetor. Engine flooded ಥ Clean and dry spark plug or replace if necessary. Spark plug oily or wet ಥ Clean and dry spark plug or replace if necessary. Electrode distance (plug gap) of spark plug too wide ಥ Adjust plug gap. Specification Spark plug electrode gap 0.8… 0.9mm (0.03… 0.04in) Fuse blown Low external temperature Engine turns but does not start. Spark plug connector or spark plug defective P. 43) Warning Risk of injuryಗThe ignition system is under high voltage. ಥ Do not touch parts of the ignition system. Have work on the ignition system carried out in an authorized KTM workshop. ಥ Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine. Specification You should see a strong spark on the spark plug. ಥ If there is no spark, change the spark plug. ಥ If there is still no spark, remove the spark plug cap from the ignition cable, hold it at the specified distance from the ground contact, and try to start the engine. Specification 5mm (0.2in) ಥ If you now have a spark, replace the spark plug connector. ಥ If there is no spark, have the ignition system checked. Short-circuit cable in cable harness frayed, short-circuit button or emergency OFF switch defective ಥ Check wiring harness. (visual check) ಥ Check electrical system. Socket connector of CDI control device, pulse generator or ignition coil oxidized. ಥ Clean socket connector and treat it with contact spray. TROUBLESHOOTING Faults 141 Possible cause Measure Engine turns but does not start. Water in carburetor or jets blocked ಥ Clean carburetor. Engine has no idle. Idling jet blocked ಥ Clean carburetor. Adjusting screws on carburetor distorted ಥ Have the carburetor adjusted. Spark plug defective ಥ Change spark plug. Ignition system defective ಥ Have ignition system checked. Carburetor running over because float needle dirty or worn. ಥ Have carburetor checked. Loose carburetor jets ಥ Have carburetor checked. Electronic ignition adjustment defective ಥ Have ignition system checked. Fuel feed interrupted ಥ Check tank vent. ಥ Clean fuel tap. ಥ Clean carburetor. Air filter very dirty ಥ Clean the air filter. ( Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer. ಥ Check exhaust system for damage. ಥ Change glass fiber yarn filling of main silencer. Valve clearance too little ಥ Have valve clearance adjusted. Engine does not speed up. Engine has too little power. Engine stalls or is popping into the carburetor. Engine overheats. P. 27) Electronic ignition adjustment defective ಥ Have ignition system checked. Lack of fuel ಥ Clean and check the fuel system and carburetor. Engine takes in bad air ಥ Check rubber sleeves and carburetor for tightness. Too little coolant in cooling system ಥ Check the cooling system for leakage. ಥ Check the coolant level. ( Too little air stream ಥ Switch off engine when standing. Radiator fins very dirty ಥ Clean radiator fins. Foam formation in cooling system ಥ Drain the coolant. ( P. 133) P. 133) P. 132) ಥ Refill the coolant. ( Bent radiator hose ಥ Replace the radiator hose. Thermostat defective ಥ Have thermostat removed and checked. Specification Opening temperature: 70°C (158°F) Defect in radiator fan system (EXC-RSIXDAYS, XCR-WZA) ಥ Have the radiator fan system checked. Engine vent hose bent ಥ Route the vent hose without bends or replace it if necessary. Engine oil level too high ಥ Check the engine oil level. ( Engine oil too thin (low viscosity) ಥ Change the engine oil and oil filter and clean the engine oil screen. ( P. 135) Battery discharged Battery is not charged by generator ಥ Check electrical system. Speedometer values deleted (time, stop watch, lap times) The battery in the speedometer ist empty. ಥ Change the battery in the speedometer. High oil consumption P. 134) TECHNICAL DATA - ENGINE 142 7(&+1,&$/ '$7$ (1*,1( Design 1-cyliner 4-stroke engine, water-cooled Displacement (Every 450 models) 449.3cm³ (27.42cuin) Displacement (Every 530 models) 510.4cm³ (31.15cuin) Stroke (Every 450 models) 63.4mm (2.5in) Stroke (Every 530 models) 72mm (2.83in) Bore 95mm (3.74in) Compression ratio 11,9:1 Idle speed 1550… 1650rpm Control 4 valves controlled via rocker arm, drive via tooth/wheel chain Valve diameter, intake 39.5mm (1.56in) Valve diameter, exhaust 31.7mm (1.25in) Valve clearance Outfeed at: 20°C (68°F) 0.12… 0.17mm (0.0047… 0.01in) Infeed at: 20°C (68°F) 0.1… 0.15mm (0.0039… 0.01in) Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing not a bearing bush - DLC-plated piston pins Pistons Forged light alloy Piston rings 1 compression ring, 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 rotor pumps (engine) / 1 rotor pump (transmission) Primary transmission 33:76 Clutch Multidisc clutch in oil bath / hydraulically activated Transmission ratio 1st gear 14:36 2nd gear 17:32 3rd gear 19:28 4th gear 22:26 5th gear 24:23 6th gear 26:21 Generator 12V, 150W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK LK AR 8A - 9 Spark plug electrode gap 0.8… 0.9mm (0.03… 0.04in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter / kickstarter Capacity- engine oil Engine oil 0.6l (0.63qt.) Engine oil (SAE 10W/50) ( P. 174) 0.9l (0.95qt.) Engine oil (SAE 10W/50) ( P. 174) Capacity - gear oil Gear oil TECHNICAL DATA - ENGINE 143 Capacity - coolant Coolant 0.95l (1qt.) Coolant ( P. 174) Coolant (mixed ready to use) ( P. 174) TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 7(&+1,&$/ '$7$ 72/(5$1&( :($5 /,0,76 2) (1*,1( Camshaft - cam height Intake 33… 33.2mm (1.3… 1.31in) Camshaft - cam height (Every 450 models) Exhaust 33.9… 34.1mm (1.33… 1.34in) Camshaft - cam height (Every 530 models) Exhaust 34.2… 34.4mm (1.35… 1.35in) Valve Sealing seat width, intake 1.5mm (0.06in) Sealing seat width, exhaust 2mm (0.08in) Run-out on valve plate 싨0.05mm (싨0.002in) Valve spring Minimum length, intake (without bottom valve spring retainer) 46.5mm (1.83in) Minimum length, exhaust (without bottom valve spring retainer) 43mm (1.69in) Bottom valve spring retainer 0.9… 1mm (0.04… 0.04in) Cylinder/cylinder head - sealing area distortion 싨0.1mm (싨0.0039in) Piston - diameter Size I 94.93… 94.96mm (3.74… 3.74in) Size II 94.95… 94.97mm (3.74… 3.74in) Cylinder - bore diameter Size I 95… 95.012mm (3.74… 3.74in) Size II 95.013… 95.025mm (3.74… 3.74in) Piston/cylinder - mounting clearance Size I 0.04… 0.082mm (0.0016… 0.0032in) Size II 0.043… 0.075mm (0.0017… 0.003in) Wear limit 싨0.12mm (싨0.0047in) Piston ring end gap Compression ring Oil scraper ring Conrod bearing - axial clearance 싨1mm (싨0.04in) 싨1.2mm (싨0.05in) 싨1.1mm (싨0.04in) Conrod bearing - radial clearance 싨0.05mm (싨0.002in) Crankshaft - run-out on bearing pin 싨0.16mm (싨0.01in) Crankshaft - external crank web dimension 63¢0.05mm (2.48¢0.002in) Clutch facing disc - thickness 2.6… 2.7mm (0.1… 0.11in) Clutch spring - length 43… 44.03mm (1.69… 1.73in) Thrust surface, clutch facing discs in outer clutch hub 싨0.5mm (싨0.02in) Oil pressure regulator valve Minimum length of preload spring 23.5mm (0.93in) Oil pump Clearance between external rotor and engine housing 싨0.2mm (싨0.01in) Clearance between external rotor and internal rotor 싨0.2mm (싨0.01in) Axial clearance 싨0.15mm (싨0.01in) Shift fork Thickness at leaf 4.85… 4.95mm (0.19… 0.19in) Shift shaft - play in sliding plate/shift quadrant 0.4… 0.8mm (0.02… 0.03in) Transmission shaft - run-out 싨0.06mm (싨0.0024in) 144 TECHNICAL DATA - ENGINE TIGHTENING TORQUES 145 7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6 Screw, cable holder in generator cover M4 4Nm (2.95lbfft) Loctite® 243™ Oil jet, rocker arm lubrication M5 2Nm (1.48lbfft) Loctite® 243™ Oil jet, piston cooling M5 2Nm (1.48lbfft) Loctite® 243™ Screw, locking lever M5 6Nm (4.43lbfft) Loctite® 243™ Screw, ignition pulse generator M5 6Nm (4.43lbfft) Loctite® 243™ Screw, clutch spring M6 10Nm (7.38lbfft) ಥ Locking screw for bearing M5 6Nm (4.43lbfft) Loctite® 243™ Screw, oil filter cover M5 6Nm (4.43lbfft) ಥ Screw, oil pump cover M5 6Nm (4.43lbfft) Loctite® 222 Oil jet, conrod lubrication M6x0,75 4Nm (2.95lbfft) Loctite® 243™ Nut, water-pump wheel M6 6Nm (4.43lbfft) Loctite® 648™ Screw, kickstarter stop M6 10Nm (7.38lbfft) Loctite® 243™ Screw, timing chain securing guide M6 10Nm (7.38lbfft) Loctite® 243™ Screw, exhaust flange M6 10Nm (7.38lbfft) ಥ Screw, torque governor M6 10Nm (7.38lbfft) Loctite® 243™ Screw, starter motor M6 10Nm (7.38lbfft) ಥ Screw, kickstarter spring hanger M6 10Nm (7.38lbfft) ಥ Screw, timing chain guide rail M6 10Nm (7.38lbfft) Loctite® 243™ Screw, generator cover (through-hole for chain shaft) M6x25 10Nm (7.38lbfft) Loctite® 222 Screw generator cover M6x25 10Nm (7.38lbfft) ಥ Screw generator cover M6x40 10Nm (7.38lbfft) ಥ Screw, gear oil level check M6 10Nm (7.38lbfft) ಥ Screw, clutch cover M6x25 10Nm (7.38lbfft) ಥ Screw, clutch cover M6x30 10Nm (7.38lbfft) ಥ Screw, clutch cover M6x55 10Nm (7.38lbfft) ಥ Screw, clutch slave cylinder M6 10Nm (7.38lbfft) ಥ Screw, engine housing M6x65 10Nm (7.38lbfft) ಥ Screw, engine housing M6x80 10Nm (7.38lbfft) ಥ Screw, camshaft bearing support M6 10Nm (7.38lbfft) Loctite® 243™ Screw, shift drum locating M6 10Nm (7.38lbfft) Loctite® 243™ Screw, shift lever M6 10Nm (7.38lbfft) Loctite® 243™ Screw, timing chain tensioning rail M6 10Nm (7.38lbfft) Loctite® 243™ Screw, stator bracket M6 10Nm (7.38lbfft) Loctite® 243™ Screw, valve cover M6 10Nm (7.38lbfft) ಥ Screw, water pump cover M6x25 10Nm (7.38lbfft) ಥ Screw, water pump cover M6x55 10Nm (7.38lbfft) ಥ Screw, idler M6 10Nm (7.38lbfft) Loctite® 243™ Screw, cylinder head M6 10Nm (7.38lbfft) ಥ Screw, rocker arm bearing M7x1 15Nm (11.06lbfft) ಥ Plug, oil channel M7 9Nm (6.64lbfft) Loctite® 243™ Screw, kickstarter M8 25Nm (18.44lbfft) Loctite® 243™ Plug, crankshaft location M8 10Nm (7.38lbfft) ಥ Balancer shaft nut M10x1 40Nm (29.5lbfft) ಥ Screw, unlocking of timing chain tensioner M10x1 10Nm (7.38lbfft) ಥ Screw, engine sprocket M10 60Nm (44.26lbfft) Loctite® 243™ Plug, oil channel M10 15Nm (11.06lbfft) Loctite® 243™ TECHNICAL DATA - ENGINE TIGHTENING TORQUES 146 Screw, cylinder head M10x1,25 Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 10Nm (7.38lbfft) Step 2 30Nm (22.13lbfft) Step 3 50Nm (36.88lbfft) Engine oil (any) Gear oil drain plug with magnet M12x1,5 20Nm (14.75lbfft) ಥ Ignition rotor nut M12x1 60Nm (44.26lbfft) ಥ Plug, SLS M12x1,5 20Nm (14.75lbfft) ಥ Oil pressure control valve plug M12x1,5 20Nm (14.75lbfft) ಥ Spark plug M12x1,25 15… 20Nm (11.06… 14.75lbfft) ಥ Plug, rocker arm M14x1,25 20Nm (14.75lbfft) ಥ Plug, gear oil screen M16x1,5 20Nm (14.75lbfft) ಥ Plug, engine oil screen M17x1,5 20Nm (14.75lbfft) ಥ Nut, inner clutch hub M18x1,5 80Nm (59.01lbfft) ಥ Nut, primary gear M20LHx1,5 150Nm (110.64lbfft) Loctite® 648™ Plug, timing chain tensioner M24x1,5 25Nm (18.44lbfft) ಥ TECHNICAL DATA - CARBURETOR 147 7(&+1,&$/ '$7$ &$5%85(725 450EXC-REU, 450EXC-RAUS/UK (3900I) Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900I Needle position 4th position from top Idle mixture adjusting screw Open Pump membrane stop 1.75turns 2.15mm (0.08in) Main jet 180 Jet needle OBDYU (OBDTQ) Idling jet 40 Main air jet 200 Idle air jet 100 Cold start jet 65 (85) Leakage nozzle 40 Throttle slide 15 Slide stop present 450EXC-RSIXDAYS, 450EXC-RUSA, 450XCR-W (3900L) Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900L Needle position (450XCR-WUSA) 1st position from top Needle position (450EXC-RSIXDAYS) 3rd position from top Needle position (450EXC-RUSA, 450XCR-WZA) 4th position from top Idle mixture adjusting screw (450XCR-WUSA) Open 0.5turn Idle mixture adjusting screw (450EXC-RSIXDAYS) Open 1turn Idle mixture adjusting screw (450XCR-WZA) Open 1.5turns Idle mixture adjusting screw (450EXC-RUSA) Open 1.75turns Pump membrane stop 2.15mm (0.08in) Main jet (450EXC-RSIXDAYS, 450EXC-RUSA, 450XCRWUSA) 180 Main jet (450XCR-WZA) 185 Jet needle (450XCR-W, 450EXC-RSIXDAYS) OBDTQ Jet needle (450EXC-RUSA) OBDYU Idling jet (450XCR-W, 450EXC-RSIXDAYS) 40 Idling jet (450EXC-RUSA) 48 Main air jet 200 Idle air jet 100 Cold start jet 85 Leakage nozzle 40 Throttle slide 15 TECHNICAL DATA - CARBURETOR 148 530EXC-REU, 530EXC-RAUS/UK (3900J) Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900J Needle position 5th position from top Idle mixture adjusting screw Open Pump membrane stop 1.5turns 2.15mm (0.08in) Main jet 180 Jet needle OBDZT (OBDTR) Idling jet 40 Main air jet 200 Idle air jet 100 Cold start jet 65 (85) Leakage nozzle 40 Throttle slide 15 Slide stop present 530EXC-RSIXDAYS, 530EXC-RUSA, 530XCR-W (3900M) Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900M Needle position (530XCR-WUSA) 1st position from top Needle position (530EXC-RSIXDAYS, 530EXC-RUSA) 3rd position from top Needle position (530XCR-WZA) 4th position from top Idle mixture adjusting screw (530XCR-WUSA) Open 0.5turn Idle mixture adjusting screw (530EXC-RSIXDAYS) Open 1turn Idle mixture adjusting screw (530XCR-WZA) Open 1.5turns Idle mixture adjusting screw (530EXC-RUSA) Open 2turns Pump membrane stop 2.15mm (0.08in) Main jet (530EXC-RSIXDAYS, 530EXC-RUSA, 530XCRWUSA) 180 Main jet (530XCR-WZA) 185 Jet needle (530XCR-W, 530EXC-RSIXDAYS) OBDTR Jet needle (530EXC-RUSA) OBDZT Idling jet (530XCR-W, 530EXC-RSIXDAYS) 40 Idling jet (530EXC-RUSA) 48 Main air jet 200 Idle air jet 100 Cold start jet 85 Leakage nozzle 40 Throttle slide 15 TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES 149 7(&+1,&$/ '$7$ &$5%85(725 7,*+7(1,1* 72548(6 Leakage nozzle M4x0,7 2Nm (1.48lbfft) ಥ Screw, throttle slide arm M4 2Nm (1.48lbfft) Loctite® 243™ Screw, hose connection M4 2Nm (1.48lbfft) Loctite® 243™ Other screws, carburetor M4 2Nm (1.48lbfft) ಥ Idle air jet M4,5x0,75 2Nm (1.48lbfft) ಥ Main jet M5x0,75 2Nm (1.48lbfft) ಥ Cold start jet M5x0,75 2Nm (1.48lbfft) ಥ Screw, throttle valve sensor M5 3.5Nm (2.58lbfft) ಥ Idling jet M6x0,75 2Nm (1.48lbfft) ಥ Needle jet M7x0,75 3.5Nm (2.58lbfft) ಥ Needle screw/slide stop M8 3.5Nm (2.58lbfft) ಥ Choke slide M12 2.5Nm (1.84lbfft) ಥ TECHNICAL DATA - CHASSIS 150 7(&+1,&$/ '$7$ &+$66,6 Frame Central tube frame made of chrome molybdenum steel tubing Fork WP 4860 MXMA PA Suspension travel front 300mm (11.81in) Rear 335mm (13.19in) Fork offset (EXC-RSIXDAYS, XCR-WUSA) Front marking 18mm (0.71in) Rear marking 20mm (0.79in) Fork offset (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA) 20mm (0.79in) Shock absorber WP PDS 5018 DCC Brake system Disc brakes, brake calipers on floating bearings Diameter of brake discs front 260mm (10.24in) Rear 220mm (8.66in) Wear limit of brake discs front 2.5mm (0.1in) Rear 3.5mm (0.14in) Tire air pressure off road front 1bar (14.5psi) Rear 1bar (14.5psi) Road tire pressure (Every EXC-R models) front 1.5bar (21.76psi) Rear 2bar (29.01psi) Rear wheel gearing (450EXC-REU, 450EXC-RAUS/UK, 450EXC-RUSA) 15:45 (14:52) Rear wheel gearing (450EXC-RSIXDAYS, XCR-WZA) 14:52 Rear wheel gearing (530EXC-RSIXDAYS, XCR-WUSA) 14:50 Rear wheel gearing (530EXC-REU, 530EXC-RAUS/UK) 15:45 (14:50) Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase 1475¢10mm (58.07¢0.39in) Seat height unloaded 925mm (36.42in) Ground clearance unloaded 380mm (14.96in) Weight without fuel (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS) 113.9kg (251.1lb.) Weight without fuel (XCR-WUSA) 112.2kg (247.36lb.) Weight without fuel (XCR-WZA) 113kg (249.12lb.) Weight without fuel (EXC-RUSA) 114.8kg (253.09lb.) Maximum permissible front axle load 145kg (319.67lb.) Maximum permissible rear axle load 190kg (418.87lb.) Maximum permissible overall weight 335kg (738.54lb.) 4Ah battery YTX5L-BS Battery voltage: 12V Nominal capacity: 4Ah maintenance-free TECHNICAL DATA - CHASSIS 151 Lighting equipment Headlight (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-WZA) BA20d 12V 35/35W Parking light (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, EXC-RUSA, XCR-WZA) W2,1x9,5d 12V 5W Indicator lights (Every EXC-R models) W2x4,6d 12V 1.2W Flasher light (EXC-REU, EXC-RAUS/UK) BA15s 12V 10W Flasher light (EXC-RUSA) BAU15s 12V 10W Brake / tail light (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, XCR-WZA) LED Brake / tail light (EXC-RUSA) BAY15d 12V 21/5W Licence plate lamp (EXC-REU, EXCRAUS/UK) W2,1x9,5d 12V 5W Validity Front tire Rear tire (Every EXC-R models) 90/90-2148M+SMTT Metzeler MCE6DAYSEXTREME 140/80-1870M+SMTT Metzeler MCE6DAYSEXTREME (Every XCR-W models) 80/100-2151MTT Bridgestone M59 110/100-1864MTT Bridgestone M402 Tires For further information, see: http://www.ktm.com Capacity - fuel Tank capacity (EXC-REU, EXC-RAUS/UK, EXC-RSIXDAYS, XCR-WZA) 9l (2.38USgal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 174) Tank capacity (EXC-RUSA, XCR-WUSA) 9.2l (2.43USgal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 174) TECHNICAL DATA - FORK 152 7(&+1,&$/ '$7$ )25. Fork part number (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCRW) 14.18.7D.06 Fork part number (EXC-RSIXDAYS) 14.18.7D.35 Fork WP 4860 MXMA PA Compression damping (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) Comfort 24clicks Standard 20clicks Sport 18clicks Compression damping (EXC-RSIXDAYS) Comfort 24clicks Standard 22clicks Sport 18clicks Rebound damping (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) Comfort 20clicks Standard 18clicks Sport 18clicks Rebound damping (EXC-RSIXDAYS) Comfort 20clicks Standard 20clicks Sport 18clicks Spring length with preload spacer(s) 510mm (20.08in) Spring rate (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) Weight of rider: 65… 75kg (143.3… 165.34lb.) 4.4N/mm (25.12lb/in) Weight of rider: 75… 85kg (165.34… 187.39lb.) 4.6N/mm (26.27lb/in) Weight of rider: 85… 95kg (187.39… 209.44lb.) 4.8N/mm (27.41lb/in) Spring rate (EXC-RSIXDAYS) Weight of rider: 65… 75kg (143.3… 165.34lb.) 4.6N/mm (26.27lb/in) Weight of rider: 75… 85kg (165.34… 187.39lb.) 4.8N/mm (27.41lb/in) Air chamber length +1.18 100+30 -20 mm (3.94-0.79 in) Spring preload - PreloadAdjuster (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) Comfort 2turns Standard 4turns Sport 7turns Spring preload - PreloadAdjuster (EXC-RSIXDAYS) Comfort 2turns Standard 2turns Sport 7turns Fork length Fork oil ( 940mm (37.01in) P. 174) SAE 5 TECHNICAL DATA - SHOCK ABSORBER 7(&+1,&$/ '$7$ 6+2&. $%625%(5 Shock absorber part number (EXC-REU, EXC-RAUS/UK, EXCRUSA, XCR-W) 12.18.7D.06 Shock absorber part number (EXC-RSIXDAYS) 12.18.7D.35 Shock absorber WP PDS 5018 DCC Compression damping, low-speed Comfort 18clicks Standard 15clicks Sport 12clicks Compression damping, high-speed Comfort 2turns Standard 1.5turns Sport 1turn Rebound damping Comfort 24clicks Standard 22clicks Sport 20clicks Spring preload Standard 9mm Spring rate Weight of rider: 65… 75kg (143.3… 165.34lb.) 69N/mm (394lb/in) Weight of rider: 75… 85kg (165.34… 187.39lb.) 72N/mm (411.13lb/in) Weight of rider: 85… 95kg (187.39… 209.44lb.) 76N/mm (433.97lb/in) Spring length 250mm (9.84in) Gas pressure 10bar (145.04psi) Static sag 35mm (1.38in) Riding sag 105mm (4.13in) Fitted length 411mm (16.18in) 153 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 154 7(&+1,&$/ '$7$ &+$66,6 7,*+7(1,1* 72548(6 Spoke nipple, front wheel M4,5 5Nm (3.69lbfft) ಥ Spoke nipple, rear wheel M5 5Nm (3.69lbfft) ಥ Remaining nuts, chassis M6 15Nm (11.06lbfft) ಥ Remaining screws, chassis M6 10Nm (7.38lbfft) ಥ Screw, rear brake disc M6 14Nm (10.33lbfft) ಥ Screw, front brake disc M6 14Nm (10.33lbfft) ಥ Screw, shock absorber adjusting ring M6 5Nm (3.69lbfft) ಥ Screw, ball joint of push rod on footbrake cylinder M6 10Nm (7.38lbfft) ಥ Nut, rear sprocket screw M8 35Nm (25.82lbfft) Loctite® 243™ Nut, rim lock M8 10Nm (7.38lbfft) ಥ Remaining nuts, chassis M8 30Nm (22.13lbfft) ಥ Remaining screws, chassis M8 25Nm (18.44lbfft) ಥ Screw, front brake caliper M8 25Nm (18.44lbfft) Loctite® 243™ Screw, top triple clamp (EXC-RSIXDAYS, XCR-WUSA) M8 17Nm (12.54lbfft) ಥ Screw, top triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCRWZA) M8 20Nm (14.75lbfft) ಥ Screw, bottom triple clamp (EXC-RSIXDAYS, XCR-WUSA) M8 12Nm (8.85lbfft) ಥ Screw, bottom triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCRWZA) M8 15Nm (11.06lbfft) ಥ Screw, fork stub M8 15Nm (11.06lbfft) ಥ Screw, top steering stem (EXC-RSIXDAYS, XCR-WUSA) M8 17Nm (12.54lbfft) Loctite® 243™ Screw, top steering stem (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCRWZA) M8 20Nm (14.75lbfft) ಥ Screw, handlebar clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W) M8 20Nm (14.75lbfft) ಥ Screw, handlebar clamp (EXC-RSIXDAYS) M8 16Nm (11.8lbfft) ಥ Screw, engine brace M8 33Nm (24.34lbfft) ಥ Screw, subframe M8 35Nm (25.82lbfft) Loctite® 243™ Screw, side stand fixing M8 40Nm (29.5lbfft) Loctite® 243™ Engine carrying screw M10 60Nm (44.26lbfft) ಥ Remaining nuts, chassis M10 50Nm (36.88lbfft) ಥ Remaining screws, chassis M10 45Nm (33.19lbfft) ಥ Screw, handlebar support M10 40Nm (29.5lbfft) Loctite® 243™ Nut, seat fixing M12x1 20Nm (14.75lbfft) ಥ Screw, top shock absorber M12 80Nm (59.01lbfft) Loctite® 243™ Screw, bottom shock absorber M12 80Nm (59.01lbfft) Loctite® 243™ Nut, swingarm pivot M16x1,5 100Nm (73.76lbfft) ಥ Screw-in nozzles, cooling system M20x1,5 12Nm (8.85lbfft) Loctite® 243™ Nut, rear wheel spindle M20x1,5 80Nm (59.01lbfft) ಥ Screw, top steering head M20x1,5 10Nm (7.38lbfft) ಥ Screw, bottom steering head (EXCRSIXDAYS, XCR-WUSA) M20x1,5 60Nm (44.26lbfft) Loctite® 243™ Screw, front wheel spindle M24x1,5 40Nm (29.5lbfft) ಥ CLEANING 155 &/($1,1* Cleaning motorcycle Note Material damageಗDamage and destruction of components by high-pressure cleaning equipment. ಥ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazardಗProblem materials cause environmental damage. ಥ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning. ಥ Before you clean the motocycle, seal the exhaust system to prevent penetration by water. ಥ First remove coarse dirt particles with a gentle water spray. ಥ Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush. Motorcycle cleaner ( P. 175) Info Use warm water containing normal motorcycle cleaner and a soft sponge. ಥ After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly. ಥ Empty the carburetor float chamber. ( P. 127) Warning Danger of accidentsಗReduced braking due to wet or dirty brakes. ಥ ಥ Clean or dry dirty or wet brakes by riding and braking gently. After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate. ಥ Push back the protection covers on the handlebar instruments to allow water to evaporate. ಥ After the motorcycle has cooled off, oil or grease all moving parts and bearings. ಥ Clean the chain. ( ಥ Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials. P. 41) Cleaning and polishing materials for metal, rubber and plastic ( ಥ Treat all painted parts with a mild paint polish. High-luster polish for paint ( ಥ P. 176) P. 176) To prevent electrical problems, treat electric contacts and switches with contact spray. Contact spray ( P. 176) (EXC-REU, EXC-RAUS/UK, EXC-RUSA) ಥ Lubricate the steering lock. Universal oil spray ( P. 175) STORAGE 156 6725$*( Storage Warning Danger of poisoningಗFuel is poisonous and a health hazard. ಥ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. Info If you want to garage the motorcycle for a longer period, take the following actions. Info Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. ಥ Clean the motorcycle. ( ಥ Change the engine oil and oil filter and clean the engine oil screen. ( ಥ Check the antifreeze and coolant level. ( ಥ Drain the fuel from the tank into a suitable container. ಥ Empty the carburetor float chamber. ( ಥ Checking the tire air pressure. ( ಥ Remove the battery. ( P. 42) ಥ Recharge the battery. ( Specification P. 43) P. 155) P. 135) P. 132) P. 127) P. 35) Storage temperature of battery without direct sunshine. 0… 35°C (32… 95°F) ಥ The storage place should be dry and not subject to large temperature differences. ಥ Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. Putting into operation after storage ಥ Install the battery. ( ಥ Fill up with fuel. ಥ Checks before putting into operation ಥ Take a short, careful test drive. P. 43) GREASING AND SERVICE TABLE 157 *5($6,1* $1' 6(59,&( 7$%/( Important maintenance work to be carried out by an authorized KTM workshop. Engine Change the engine oil and oil filter and clean the engine oil screen. ( Change the gear oil and clean the gear oil screen. ( P. 135) P. 138) S3N S15A • • • • Replace spark plug. Carburetor Attachments • Check and adjust valve clearance. • • Check engine mounting screws for tightness. • • Clean spark plug connectors and check for tightness. • • Check that the screws in the shift lever and the kickstarter are tight. • • Check carburetor connection boots for cracks and leakage. • Check vent hoses for damage and routing without sharp bends. • • Check idle. • • Check the cooling system for leakage. • • • • Check the antifreeze and coolant level. ( P. 132) Check the exhaust system for leakage and looseness. • Check Bowden cables for damage, smooth operation and routing without sharp bends. • • Check the fluid level of the hydraulic clutch. ( • • • • Clean the air filter. ( P. 129) P. 27) Check cables for damage and routing without sharp bends. Check that the electrical equipment is functioning properly. • • Check the headlamp setting. Brakes Check the front brake linings. • • Check the rear brake linings. • • Check the brake discs. • • Check the front brake fluid level. • • Check the rear brake fluid level. • • • • Check the free play of the hand brake lever. ( P. 47) • • Check the free play of the foot brake lever. ( P. 51) • • Check brake system function. • • Check screws and guide bolts of brake system for tightness. • • Check shock absorber and fork for leakage and functioning. • • Clean dust boots of fork legs. ( Bleed fork legs. ( P. 10) • P. 12) • Check swingarm bearing. Wheels • • Check brake lines for damage and leakage. Chassis • Check play of steering head bearing. • • Check all screws to see if they are tight. • • Check the spoke tension. • • Check rim run-out. • • • • • • Check the tire condition. ( P. 35) Checking the tire air pressure. ( Check the chain wear. ( P. 35) P. 41) Check the chain tension. ( Clean the chain. ( S30A P. 38) P. 41) • • • • • • Check wheel bearing for play. • • Clean and grease adjusting screws of chain adjuster. • • S3N: After 3 service hours S15A: Every 15 service hours / after every race S30A: Every 30 service hours GREASING AND SERVICE TABLE 158 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use S15A S30A Hobby use S45A S30A S60A J1A S90A Carry out a complete fork service. • Carry out a complete shock absorber service. Grease the steering head bearing. ( • P. 18) • Clean and adjust carburetor. • Treat electric contacts with contact spray. • Change hydraulic clutch fluid. ( P. 129) • Change the front brake fluid. ( P. 48) • Change the rear brake fluid. ( P. 52) • Clean spark arrestor. (EXC-RUSA, XCR-WUSA) Check wear of clutch discs. Check the clutch. ( • • P. 89) • • Check/measure the cylinder. ( P. 80) Change the piston. Check the camshaft. ( P. 84) Change the camshaft bearing. ( P. 86) • • • • • • • • • • • • • • • • • Check the radial clearance of the rocker arm rollers. • • Check the timing chain tensioner function. • • Check the balancer shaft. ( • • • • Check the lower valve spring retainer. ( Check the cylinder head. ( Check the valves. ( P. 87) P. 88) P. 87) Check the valve springs. ( P. 87) P. 78) Check the crankshaft run-out on the bearing pin. ( P. 80) Change conrod bearing. ( P. 78) • • Change the crankshaft main bearing. • • Check the transmission. ( J2A P. 93) Check the shift mechanism. ( P. 90) Check the spring length of the oil pressure regulator valve. ( P. 75) • • • • • • Change glass fiber yarn filling of main silencer. • • Replace foot brake cylinder seals. • • • • Check the carburetor components. ( P. 118) S15A: Every 15 service hours / after every race S30A: Every 30 service hours S45A: Every 45 service hours S60A: Every 60 service hours S90A: Every 90 service hours J1A: annually J2A: every 2 years Important checks and maintenance work to be carried out by the rider. NB1A Check the engine oil level. ( P. 134) • Check the front brake fluid level. • Check the rear brake fluid level. • Check the front brake linings. • Check the rear brake linings. • Check and adjust Bowden cables. • Bleed fork legs. ( • P. 12) GREASING AND SERVICE TABLE 159 NB1A Clean dust boots of fork legs. ( Clean the chain. ( P. 10) • P. 41) Check the chain tension. ( Check the chain wear. ( • P. 38) • P. 41) • Check the rear sprocket / engine sprocket for wear. ( Clean the air filter. ( P. 40) P. 27) Checking the tire air pressure. ( • • P. 35) • Check the tire condition. ( P. 35) • Check the coolant level. ( P. 132) • Empty the carburetor float chamber. ( P. 127) • Check that all operating elements for smooth operation. • Check braking. • Check all screws, nuts and hose clamps regularly for tightness. • NB1A: Depending on conditions of use according to requirements. br 4 2 wh bu re ye-re br 1 br br -bl 1 3 1 bt bu gn 1 9 ye C_ BC / 6 5 2 C_BF1/1 C _ BA1 / 1 2 1 ck C _ B G/ 3 C_BT/3 3 6 C_B K /4 4 3 2 1 C_BR/4 8 M 2 10 A 7 C_AF/4 4 3 bl cl G 1 C_AH2/2 2 wh br 2 4 3 1 2 3 ye cs C _ A K/ 2 C_AH/2 1 2 br bl pu 1 ye-re 1 C_CR1/1 6 4 re C_ A C/ 6 cq br 3 ye-re re C _ B S/ 2 dl 2 1 1 C_A T 1 / 2 2 C _A L 1 / 2 br bl 1 2 wh-gn wh br 2 U C _ B S/ 2 C _ B V/ 2 2.2 2.1 5 C_BG/3 3 2 bl C _ B V/ 2 C _B O / 2 1 br 2 ye-re br bl C_AK1/2 2 bs v 1 C _A L /2 2 C_BG1/3 pu ye-bl 1 1 wh bl ye ye -b l 2 C_AM/3 3 br br dk 1 wh-gn 2.1 6 11 10 12 13 14 bl 7 pu C_CX/2 C_CX1/2 bu 2 br bl C _ EI / 1 C_BA2/1 ye 5 C_A T /2 G 1 2 ye-bl C_EH/1 1 gr 4 C_ AR/ 3 3 ye-re 2 3 2 1 C_CW/2 C_AJ/3 C_CW1/2 ye ye-re or bu-wh 2 ye-bl bl C_BU/18 4 wh C_AJ1/3 C_CA/4 main harness 594.11.075.150 CDI harness 780.39.032.000 wh-gn ye-re br 1 re bm bk re-wh wh-re re-bl br cr gn bu br 2 wh br 1 4 br 3 2 wh pu bu wiring diagram ye-re gn br re bl C_AH1/2 C_CX2/2 C_DB/4 C_DA/4 bl bl bu 1 2 C_CW2/2 C_BP/4 1 br ct bo C_DG/4 C_CX3/2 C_CZ/3 C_CY/3 wh-re ye C_BF/1 bu-wh 3 pu re-bl ye C_CR/1 or gn ye-bl re-wh gr bl-wh co bn cm C_CW3/2 C_CX/2 C_CW/2 ye-re bl 160 WIRING DIAGRAM :,5,1* ',$*5$0 Wiring diagram (EXC-REU) C_BA/1 br C_CE/4 C_DI/2 cp cn bq bp 400308-10 WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Licence plate lamp 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Flasher switch 21 Flasher relay 22 Left front flasher 23 Left rear flasher 24 Right front flasher 25 Right rear flasher 26 Horn 27 Front brake light switch 28 Rear brake light switch 29 High beam indicator light 30 Flasher indicator light 31 Plug connector for radiator fan (optional) Cable colors bl black bl-wh black-white br brown br-bl brown-black bu blue bu-wh blue-white gn green gr gray or orange pu violet re red re-bl red-black re-wh red-white wh white wh-gn white-green wh-re white-red ye yellow ye-bl yellow-black ye-re yellow-red 161 cn 1 3 2 2 4 3 1 bl bl ye-re b r -b l br re bu wh br cp C _ BC / 6 C_ A C/ 6 9 3 6 4 5 1 2 C_BF1/1 C _BA1 /1 ye-re re y e- bl cq ye - b l bs G 6 C_ BG/ 3 C _BT/ 3 3 2 1 C_AH2/2 2 1 or pu bl C _ B V/ 2 C _ BO / 2 2 1 1 2 4 5 7 6 11 10 12 13 14 br C _ BK / 4 2 1 C_B R/ 4 4 3 2 1 C_AM/3 3 C_ A R/ 3 8 M C _ B S/ 2 dl 2 1 1 C _A L /2 2 C _A T /2 7 30 A 2 C_ A F /4 4 3 C_A T 1 / 2 2 1 C _A L 1 / 2 3 ye wh G 2 1 br ye-re ye wh cs C _ A K/ 2 C_AH/2 1 2 br bl pu 1 3 2 1 4 3 2 bl br br pu 1 2 br wh wh-gn 2 1 U C _ B V/ 2 C _ B S/ 2 2 .2 2 .1 5 C_BG/3 C_BA2/1 ye-bl C_BU/18 4 C_BG1/3 1 2 2 .1 C _EI/ 1 bl ye-bl C_EH/1 C_BA/1 ye-re or bm bk ye wh-gn co v pu bl ye wh-gn bu gn br wh 1 3 wh br C_CX/2 C_CX1/2 dk 1 2 2 1 4 3 br pu wh bu gn ye re br ye-re re-bl re-wh C_CR1/1 C_AJ1/3 C_CA/4 main harness 594.11.075.150 CDI harness 780.39.032.000 C_AJ/3 C_CW/2 3 2 1 C_CW1/2 bu br cr C_AK1/2 bl wh-re C_CR/1 C_BF/1 bu-wh ye-re br ye-re br bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl wiring diagram gn ye-re br re 1 bl 2 br 2 1 br ct bo C_AH1/2 C_CX2/2 br bl ye bu gr bl-wh cl bn bt C_CW2/2 C_BP/4 C_DB/4 C_DA/4 C_DG/4 C_CZ/3 C_CY/3 C_CX3/2 C_CX/2 C_CW/2 C_CW3/2 ye-re wh-re bl 162 WIRING DIAGRAM Wiring diagram (EXC-RAUS/UK) br C_CE/4 2 1 C_DI/2 cm ck bq bp 400334-10 WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Flasher switch 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Licence plate lamp 17 Electric starter button, emergency OFF switch 18 Flasher relay 19 Left front flasher 20 Left rear flasher 21 Right front flasher 22 Right rear flasher 23 Speedometer 24 Wheel speed sensor 25 Tripmaster switch (optional) 26 Horn 27 Front brake light switch 28 Rear brake light switch 29 High beam indicator light 30 Flasher indicator light 31 Plug connector for radiator fan (optional) Cable colors bl black bl-wh black-white br brown br-bl brown-black bu blue bu-wh blue-white gn green gr gray or orange pu violet re red re-bl red-black re-wh red-white wh white wh-gn white-green wh-re white-red ye yellow ye-bl yellow-black ye-re yellow-red 163 cn dm 4 2 br wh bu re ye-re 1 br br -bl bl bl cp bq cq br 2 3 2 1 C _B G/ 3 1 gn bs 6 4 3 C_ B R / 4 G 1 C_AH2/2 C _BK/4 2 2 1 cs C_BY/4 C _C V/ 4 8 3 9 4 M C_B K /4 2 1 C_BR/ 4 2 10 A 7 C_AF/4 4 3 wh br 2 4 3 1 dk 2 3 ye 1 ye-re 1 C_CR1/1 C _ BC/ 6 5 cr br C_B T /3 6 4 br C_ A C / 6 3 ye-re re C _ B S/ 2 2 1 dn C _ A K/ 2 C_AH/2 1 2 br bl pu br bl 1 2 2 2 1 1 wh gn- w h 3 br br pu 5 C_CW/2 3 2 3 1 2 1 C _ B V/ 2 C _B O / 2 1 1 C_A T 1 / 2 2 C _A L 1 / 2 C_BG1/3 2 1 C_A T /2 C _A L /2 2 G wh-gn co v ye C_ A R / 3 C_AM/3 1 ye-bl br 2 3 ye-re wh 2 ye pu bl 1 wh-gn ye-bl ye-re 3 C_BU/18 ye-bl ye re OFF ON C_BF/1 6 11 10 12 13 14 ye 7 bl 5 bl C_AJ1/3 main harness 594.11.075.244 CDI harness 780.39.032.000 C_CX/2 C_CX1/2 C_AJ/3 C_BG/3 C_CW1/2 bu 2 1 bl C_EI/1 br or C_EH/1 2.1 gr 4 re-wh bl br wh br 2 or br bl bm 4 wh-re re-bl 2 4 3 1 ye-re br wh br ye-re bk gn ye C_CR/1 ye-re gn bl br ct C_AK1/2 bu pu bu-wh 3 bu-wh C_DB/4 C_DA/4 black re bu wiring diagram re ye-re or re-bl 1 2 1 gn bu ye-re ye-bl 1 C_AH1/2 C_CX2/2 br re-wh dl bo C_CW2/2 C_BP/4 2 C_DG/4 C_CX3/2 C_CZ/3 C_CY/3 bl br cl bn bt C_CW3/2 C_CX/2 C_CW/2 pu gr bl-wh ye-bl C_BA/1 ye bu 164 WIRING DIAGRAM Wiring diagram (EXC-RUSA) C_CA/4 C_CE/4 U ck bp cm 400309-10 WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Emergency OFF switch 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Light switch 17 Flasher switch 18 Flasher relay 19 Left front flasher 20 Left rear flasher 21 Right front flasher 22 Right rear flasher 23 Speedometer 24 Wheel speed sensor 25 Tripmaster switch (optional) 26 Horn button 27 Horn 28 Ignition switch 29 Front brake light switch 30 Rear brake light switch 31 High beam indicator light 32 Flasher indicator light 33 Plug connector for radiator fan (optional) Cable colors bl black bl-wh black-white br brown br-bl brown-black bu blue bu-wh blue-white gn green gn-wh green-white gr gray or orange pu violet re red re-bl red-black re-wh red-white wh white wh-gn white-green wh-re white-red 165 WIRING DIAGRAM ye yellow ye-bl yellow-black ye-re yellow-red 166 WIRING DIAGRAM 167 cn 1 3 2 2 4 3 1 bl bl ye-re b r -b l br re bu wh br bt ye wh-gn C _ BC / 6 C_ A C/ 6 9 C_BF1/1 C _ BA1 / 1 ye-re ck ye- b l C _B O / 2 cp 2 1 6 C _B K / 4 4 3 2 1 C_BR /4 7 C_BU/18 bq t 5A cq C _ C V/ 2 C _B L /2 M co C _ B V/ 2 C _ B S/ 2 2 1 C_AM/3 C_ AR / 3 8 M 1 C_A T /2 C _A L /2 2 7 10 A 2 C_AF/4 4 3 C_A T 1 / 2 2 1 C _A L 1 / 2 3 ye wh G 2 1 br ye-re ye wh cm C_AH/2 C _ A K/ 2 1 2 1 4 3 2 br wh wh-gn 5 C_BG/3 re ye - bl 5 2 1 4 4 C_AJ/3 br 3 2 bk 3 2 1 br bl 6 11 10 12 13 14 1 bm C_CR1/1 br bl bl br ye-re br 3 6 4 5 1 2 2 .1 C _ EI / 1 C_EH/1 ye-bl bl C_BA/1 ye-re re-bl re-wh C_CA/4 main harness 594.11.075.000 CDI harness 780.39.032.000 ye wh-gn 1 2 1 2 bu gn br wh 3 gn br wiring diagram re wh bu gn ye re br bl ye-re wh-re br bl ye bu bs v C_AK1/2 C_BA2/1 bl C_BF/1 bu-wh bu br cl 2 1 4 3 1 br ye-bl ye-re br bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl gr bl-wh br bn bo C_AH1/2 C_DB/4 C_DA/4 C_BP/4 C_CZ/3 C_CY/3 C_DG/4 C_CX/2 C_CW/2 bl wh-re C_CR/1 168 WIRING DIAGRAM Wiring diagram (EXC-RSIXDAYS) C_CE/4 U C _ B S/ 2 bp 400307-10 WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Thermoswitch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Horn 21 Front brake light switch 22 Rear brake light switch 23 High beam indicator light 24 Radiator fan 25 Plug connector for flasher cable harness (optional) 26 Fuse, radiator fan Cable colors bl black bl-wh black-white br brown br-bl brown-black bu blue bu-wh blue-white gn green gr gray re red re-bl red-black re-wh red-white wh white wh-gn white-green wh-re white-red ye yellow ye-bl yellow-black ye-re yellow-red 169 WIRING DIAGRAM 170 Wiring diagram (XCR-WUSA) bo v bl bl re bu wh br bp bs bq br ye-re wh br wh bl gr bl-wh br 9 3 ye-bl bu-wh ye -bl wh bn bm ye ye-re wh-re 6 wirin g di ag ram m bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl bl bl bk ye bu br 8 M 4 ye-re br gn br re 10 A G ye-re 7 3 2 ye wh 1 br ye-re ye wh main harness 594.11.075.100 CDI harness 780.39.032.000 br wh-re re-bl re-wh wh br 5 bt U 400310-10 WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Light switch 14 Speedometer 15 Wheel speed sensor 16 Tripmaster switch (optional) 17 Plug connector for radiator fan (optional) 18 Plug connector, headlight (optional) 19 Plug connector, brake / tail light (optional) 21 Thermoswitch Cable colors bl black bl-wh black-white br brown bu blue bu-wh blue-white gn green gr gray re red re-bl red-black re-wh red-white wh white wh-re white-red ye yellow ye-bl yellow-black ye-re yellow-red 171 WIRING DIAGRAM 172 Wiring diagram (XCR-WZA) br bn bo v bl bl re bu wh br bs bt br ye-re wh br wh bl gr bl-wh br 9 3 ye-bl bu-wh ye -bl wh bq bm ye 6 wirin g di ag ram m bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl ye-re wh-re bl br bl br bl M br t cl ck bk ye bu cm bl br 5A ye-re br br bl 8 re M 4 gn 10 A G ye-re 7 3 2 ye wh 1 br ye-re ye wh main harness 594.11.075.100 CDI harness 780.39.032.000 br wh-re re-bl re-wh br wh 5 C _ B S/ 2 U bp 400311-10 WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Light switch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Radiator fan 21 Thermoswitch 22 Fuse, radiator fan Cable colors bl black bl-wh black-white br brown bu blue bu-wh blue-white gn green gr gray re red re-bl red-black re-wh red-white wh white wh-re white-red ye yellow ye-bl yellow-black ye-re yellow-red 173 SUBSTANCES 174 68%67$1&(6 Brake fluid DOT 5.1 according to ಥ DOT Specification ಥ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®BrakeFluidDOT5.1 Engine oil (SAE 10W/50) according to ಥ JASOT903MA ( ಥ SAE ( P. 184) P. 184) (SAE 10W/50) Specification ಥ Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex ಥ Motorex®CrossPower4T Coolant Specification ಥ Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. KTM recommends Motorex® products. Mixture ratio Antifreeze: -25… -45°C (-13… -49°F) 50% Anti-corrosion/antifreeze 50% distilled water Coolant (mixed ready to use) Antifreeze -40°C (-40°F) Supplier Motorex ಥ Motorex®AntiFreeze Super unleaded (ROZ 95 / RON 95 / PON 91) according to ಥ DINEN228 (ROZ 95 / RON 95 / PON 91) Fork oil (SAE 5) according to ಥ SAE (SAE 5) Specification ಥ Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®RacingForkOil AUXILIARY SUBSTANCES $8;,/,$5< 68%67$1&(6 Universal oil spray Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®Joker440Universal Long-life grease Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®LongTherm2000 Cleaning substance for foam air filter Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®TwinAirDirtBioRemover Oil for foam air filter Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®TwinAirLiquidPower Chain cleaner Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®ChainClean611 Offroad chain spray Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®ChainLube622 Carburetor cleaner Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®Carburetor Motorcycle cleaner Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®MotoClean900 175 AUXILIARY SUBSTANCES Cleaning and polishing materials for metal, rubber and plastic Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®Protect&Shine645 High-luster polish for paint Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®MotoPolish Contact spray Specification ಥ KTM recommends Motorex® products. Supplier Motorex ಥ Motorex®AccuContact 176 SPECIAL TOOLS 177 63(&,$/ 722/6 Crankshaft locking bolt ART. NO.: 113080802 400035-01 Bearing puller ART. NO.: 15112017000 400037-01 Insert for bearing puller ART. NO.: 15112018100 Feature 18… 23mm (0.71… 0.91in) 400038-01 Bleed syringe ART. NO.: 50329050000 400058-01 Circlip pliers reverse ART. NO.: 51012011000 400059-01 SPECIAL TOOLS 178 Clutch holder ART. NO.: 51129003000 400289-01 Work stand ART. NO.: 54829055000 500071-01 Universal mounting rack ART. NO.: 56012001000 400067-01 Extractor ART. NO.: 58012009000 400073-01 Valve spring mounter ART. NO.: 59029019000 400101-01 SPECIAL TOOLS 179 Limit plug gauge ART. NO.: 59029026006 400104-01 Feeler gauge ART. NO.: 59029041000 35 30 25 20 15 12 5 10 400110-01 Piston ring mounting tool ART. NO.: 60029015000 400123-01 Pressure testing tool ART. NO.: 61029094000 400149-01 Push-in drift ART. NO.: 75029044010 500163-01 SPECIAL TOOLS 180 Push-in drift ART. NO.: 75029044020 500162-01 Press drift ART. NO.: 75029047000 400185-01 Extractor ART. NO.: 75029048000 400162-01 Clamping plate ART. NO.: 75029050000 400163-01 Push-out drift ART. NO.: 75029051000 400164-01 SPECIAL TOOLS 181 Protection cover ART. NO.: 75029090000 400167-01 Spark plug wrench ART. NO.: 75029172000 400170-01 Limit plug gauge ART. NO.: 77029026000 400104-01 Oil pressure adapter ART. NO.: 77329006000 400176-01 Insert for piston pin retainer ART. NO.: 77329030100 400160-01 SPECIAL TOOLS 182 Adjustment tool for mixture control screw ART. NO.: 77329034000 400274-01 Release device for timing chain tensioner ART. NO.: 77329051000 400181-01 Engine holder ART. NO.: 78029002000 500161-01 Mounting sleeve ART. NO.: 78029005000 500167-01 Plate - Pressing device ART. NO.: 78029008000 500170-01 SPECIAL TOOLS 183 Separator plate ART. NO.: 78029009000 500169-01 Extractor ART. NO.: 78029033100 500166-01 Press-out device ART. NO.: 78029049100 500168-01 Valve spring mounting device ART. NO.: 78029060000 500165-01 Gear segment ART. NO.: 80029004000 500164-01 STANDARDS 184 67$1'$5'6 JASOT903MA Different technical development directions required a new specification for 4-stroke motorcycles ಥ the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements. SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality. INDEX 185 ,1'(; A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air filter box lid fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 B Battery fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Brake disc of front brake, mounting . . . . . . . . . . . . . . . . . . . . . . 34 of front brake, removing . . . . . . . . . . . . . . . . . . . . . . 34 of rear brake, mounting . . . . . . . . . . . . . . . . . . . . . . . 37 of rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . 37 Brake discs checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Brake fluid of front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . 48 of front brake, changing . . . . . . . . . . . . . . . . . . . . . . 48 of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . 52 of rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . 52 Brake fluid level of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 47 of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 52 Brake linings of front brake, changing . . . . . . . . . . . . . . . . . . . . . . 46 of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 45 of front brake, installing . . . . . . . . . . . . . . . . . . . . . . 45 of rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . 50 of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 49 of rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . 50 of rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . 49 Bremsbeläge of front brake, removing . . . . . . . . . . . . . . . . . . . . . . 45 C Carburetor adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 emptying the float chamber . . . . . . . . . . . . . . . . . . . 127 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Carburetor - Work on individual parts checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 checking the choke slide . . . . . . . . . . . . . . . . . . . . . 119 checking the float needle valve . . . . . . . . . . . . . . . . . 120 checking the jet needle . . . . . . . . . . . . . . . . . . . . . . 119 checking the needle jet . . . . . . . . . . . . . . . . . . . . . . 120 checking/adjusting the accelerator pump . . . . . . . . . . 118 checking/adjusting the float level . . . . . . . . . . . . . . . 120 Carburetor components checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Carburetor connection boot installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Chain cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Chain guide adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Chain tension adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Chain wear checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Choke Bowden cable play adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Choke Bowden cable routing checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Clutch changing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . 129 Compression damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compression damping, high-speed of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 20 Compression damping, low-speed of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 20 Coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Coolant level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . . . . 80 Cylinder head checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 D Dust boots cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E Engine installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Engine - Work on individual parts assembling the autodecompressor . . . . . . . . . . . . . . . . 83 assembling the countershaft . . . . . . . . . . . . . . . . . . . 92 assembling the main shaft . . . . . . . . . . . . . . . . . . . . . 91 changing the conrod bearing . . . . . . . . . . . . . . . . . . . 78 checking electric starter operation . . . . . . . . . . . . . . . 94 checking piston/cylinder mounting clearance . . . . . . . . 82 checking the balancer shaft . . . . . . . . . . . . . . . . . . . . 78 checking the camshaft . . . . . . . . . . . . . . . . . . . . . . . 84 checking the clutch . . . . . . . . . . . . . . . . . . . . . . . . . 89 checking the crankshaft run-out on the bearing pin . . . . 80 checking the free-wheel . . . . . . . . . . . . . . . . . . . . . . . 95 checking the lower valve spring retainer . . . . . . . . . . . . 87 INDEX checking the lubrication system . . . . . . . . . . . . . . . . . 82 checking the oil pumps for wear . . . . . . . . . . . . . . . . . 82 checking the piston ring end gap . . . . . . . . . . . . . . . . 81 checking the shift mechanism . . . . . . . . . . . . . . . . . . 90 checking the spring length of the oil pressure regulator valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 checking the timing assembly . . . . . . . . . . . . . . . . . . 84 checking the transmission . . . . . . . . . . . . . . . . . . . . . 93 checking the valve springs . . . . . . . . . . . . . . . . . . . . . 87 checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . . 87 checking/measuring the cylinder . . . . . . . . . . . . . . . . . 80 checking/measuring the piston . . . . . . . . . . . . . . . . . . 81 Cylinder - Nikasil® coating . . . . . . . . . . . . . . . . . . . . . 80 disassembling the autodecompressor . . . . . . . . . . . . . . 83 dismantling the countershaft . . . . . . . . . . . . . . . . . . . 92 dismantling the main shaft . . . . . . . . . . . . . . . . . . . . 91 fitting the crankshaft seal ring into the clutch cover . . . . 76 installing the free-wheel . . . . . . . . . . . . . . . . . . . . . . 95 installing the oil pressure regulator valve . . . . . . . . . . . 75 installing the rocker arm . . . . . . . . . . . . . . . . . . . . . . 89 installing the timing chain sprocket . . . . . . . . . . . . . . . 78 installing the water pump . . . . . . . . . . . . . . . . . . . . . 77 installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 left engine case section . . . . . . . . . . . . . . . . . . . . . . . 73 preassembling the shift shaft . . . . . . . . . . . . . . . . . . . 91 preparing the timing chain tensioner for installation . . . 84 removing the crankshaft seal ring in the clutch cover . . . 76 removing the free-wheel . . . . . . . . . . . . . . . . . . . . . . 94 removing the oil pressure regulator valve . . . . . . . . . . . 75 removing the rocker arm . . . . . . . . . . . . . . . . . . . . . . 85 removing the timing chain sprocket . . . . . . . . . . . . . . . 78 removing the valves . . . . . . . . . . . . . . . . . . . . . . . . . 85 removing the water pump . . . . . . . . . . . . . . . . . . . . . 76 replacing the camshaft bearing . . . . . . . . . . . . . . . . . . 86 right engine case section . . . . . . . . . . . . . . . . . . . . . . 72 Engine assembly adjusting the valve clearance . . . . . . . . . . . . . . . . . . 109 checking the valve clearance . . . . . . . . . . . . . . . . . . 109 cleaning the gear oil screen . . . . . . . . . . . . . . . . . . . . 59 Filling up with engine oil . . . . . . . . . . . . . . . . . . . . . 111 Filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . 112 installing the balance weight . . . . . . . . . . . . . . . . . . 105 installing the balancer shaft . . . . . . . . . . . . . . . . . . . 101 installing the camshaft . . . . . . . . . . . . . . . . . . . . . . 108 installing the clutch cover . . . . . . . . . . . . . . . . . . . . 102 installing the clutch discs . . . . . . . . . . . . . . . . . . . . 102 installing the crankshaft . . . . . . . . . . . . . . . . . . . . . . 96 installing the cylinder head . . . . . . . . . . . . . . . . . . . 107 installing the generator cover . . . . . . . . . . . . . . . . . . 109 installing the ignition pulse generator . . . . . . . . . . . . 104 installing the kickstarter . . . . . . . . . . . . . . . . . . . . . 103 installing the kickstarter idler gear . . . . . . . . . . . . . . 100 installing the kickstarter shaft . . . . . . . . . . . . . . . . . 100 installing the left engine case . . . . . . . . . . . . . . . . . . . 97 installing the locking lever . . . . . . . . . . . . . . . . . . . . . 99 Installing the oil pump gears . . . . . . . . . . . . . . . . . . . 99 installing the oil pumps . . . . . . . . . . . . . . . . . . . . . . . 98 installing the outer clutch hub . . . . . . . . . . . . . . . . . 101 installing the piston . . . . . . . . . . . . . . . . . . . . . . . . 105 installing the primary gear nut . . . . . . . . . . . . . . . . . 101 installing the primary gear with the free-wheel-gear . . . . 98 186 installing the rotor . . . . . . . . . . . . . . . . . . . . . . . . . 105 installing the shift drum locating . . . . . . . . . . . . . . . . 99 installing the shift forks . . . . . . . . . . . . . . . . . . . . . . . 96 installing the shift lever . . . . . . . . . . . . . . . . . . . . . . 110 installing the shift rails . . . . . . . . . . . . . . . . . . . . . . . 97 installing the shift roller . . . . . . . . . . . . . . . . . . . . . . 97 installing the shift shaft . . . . . . . . . . . . . . . . . . . . . . . 99 installing the spark plug . . . . . . . . . . . . . . . . . . . . . 110 installing the starter idler gear . . . . . . . . . . . . . . . . . 100 Installing the starter motor . . . . . . . . . . . . . . . . . . . . 111 installing the suction pump . . . . . . . . . . . . . . . . . . . 103 installing the timing chain . . . . . . . . . . . . . . . . . . . . 104 installing the timing chain guide rail . . . . . . . . . . . . . 105 installing the timing chain securing guide . . . . . . . . . 104 installing the timing chain tensioning rail . . . . . . . . . . 104 installing the timing chain tensioner . . . . . . . . . . . . . 108 installing the transmission shaft . . . . . . . . . . . . . . . . . 96 installing the valve cover . . . . . . . . . . . . . . . . . . . . . 110 installing the water pump cover . . . . . . . . . . . . . . . . 103 mounting oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 111 removing the engine from the universal mounting rack . 112 Engine disassembly Draining the engine oil . . . . . . . . . . . . . . . . . . . . . . . 59 draining the gear oil . . . . . . . . . . . . . . . . . . . . . . . . . 59 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 removing the balance weight . . . . . . . . . . . . . . . . . . . 63 removing the balancer shaft . . . . . . . . . . . . . . . . . . . . 67 removing the camshaft . . . . . . . . . . . . . . . . . . . . . . . 62 removing the clutch cover . . . . . . . . . . . . . . . . . . . . . 65 removing the clutch discs . . . . . . . . . . . . . . . . . . . . . 66 removing the crankshaft . . . . . . . . . . . . . . . . . . . . . . 71 removing the cylinder head . . . . . . . . . . . . . . . . . . . . 62 removing the generator cover . . . . . . . . . . . . . . . . . . . 61 removing the ignition pulse generator . . . . . . . . . . . . . 64 removing the kickstarter . . . . . . . . . . . . . . . . . . . . . . 65 removing the kickstarter idler gear . . . . . . . . . . . . . . . 67 removing the left section of the engine case . . . . . . . . . 69 removing the locking lever . . . . . . . . . . . . . . . . . . . . . 68 Removing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . 59 removing the oil pump gears . . . . . . . . . . . . . . . . . 68-69 Removing the oil pump gears . . . . . . . . . . . . . . . . . 68-69 removing the outer clutch hub . . . . . . . . . . . . . . . . . . 66 removing the piston . . . . . . . . . . . . . . . . . . . . . . . . . 62 removing the primary gear nut . . . . . . . . . . . . . . . . . . 66 removing the primary gear with the free-wheel-gear . . . . 69 removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . . . 63 removing the shift drum locating . . . . . . . . . . . . . . . . . 68 removing the shift forks . . . . . . . . . . . . . . . . . . . . . . . 71 removing the shift lever . . . . . . . . . . . . . . . . . . . . . . . 60 removing the shift rails . . . . . . . . . . . . . . . . . . . . . . . 70 removing the shift roller . . . . . . . . . . . . . . . . . . . . . . . 70 removing the shift shaft . . . . . . . . . . . . . . . . . . . . . . . 68 removing the spark plug . . . . . . . . . . . . . . . . . . . . . . 60 Removing the starter engine . . . . . . . . . . . . . . . . . . . . 60 removing the starter idler gear . . . . . . . . . . . . . . . . . . 67 removing the suction pump . . . . . . . . . . . . . . . . . . . . 64 removing the timing chain . . . . . . . . . . . . . . . . . . . . . 64 removing the timing chain guide rail . . . . . . . . . . . . . . 63 removing the timing chain securing guide . . . . . . . . . . 64 removing the timing chain tensioner . . . . . . . . . . . . . . 62 removing the timing chain tensioning rail . . . . . . . . . . . 64 INDEX removing the torque limiter . . . . . . . . . . . . . . . . . . . . 67 removing the transmission shaft . . . . . . . . . . . . . . . . . 71 removing the valve cover . . . . . . . . . . . . . . . . . . . . . . 60 removing the water pump cover . . . . . . . . . . . . . . . . . 65 setting the engine to ignition top dead center . . . . . . . . 61 Engine oil changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Engine oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Engine oil pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 engine oil screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Engine oil screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Engine sprocket installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Engine sprocket cover installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F Filler cap closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Foot brake pedal adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 51 checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fork legs bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fork offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fork protector fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Front wheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fuel tank installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuse fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 G Gas Bowden cable route checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 187 gear oil changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Gear oil draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 gear oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 gear oil screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Gear oil screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 GREASING AND SERVICE TABLE . . . . . . . . . . . . . . . . . 157-159 H Hand brake lever adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 46 adjusting free travel . . . . . . . . . . . . . . . . . . . . . . . . . 47 checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 47 L Lower triple clamp fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13, 15 M Main silencer fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Manifold installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Motorcycle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 O Oil cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Oil filter changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Oil pressure regulator valve checking the spring length . . . . . . . . . . . . . . . . . . . . . 75 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 P Play in choke Bowden cable checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Play in gas Bowden cable adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Putting into operation after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 R Rear sprocket / engine sprocket checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Rear wheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Rebound damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INDEX of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 21 Riding sag adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 S Seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Shock absorber checking riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . 22 checking static sag . . . . . . . . . . . . . . . . . . . . . . . . . . 22 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Speedometer adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Setting kilometers or miles . . . . . . . . . . . . . . . . . . . . . 54 Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Spoke tension checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Spring preload fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 22 Start number plate fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Steering head bearing greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Steering head bearing play adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 T Technical data Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147-148 Carburetor tightening torques . . . . . . . . . . . . . . . . . . 149 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150-151 chassis tightening torques . . . . . . . . . . . . . . . . . . . . 154 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142-143 Engine - tolerance, wear limits . . . . . . . . . . . . . . . . . 144 Engine tightening torques . . . . . . . . . . . . . . . . . 145-146 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Throttle slide opening checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 120 Throttle valve sensorTPS adjusting the position . . . . . . . . . . . . . . . . . . . . . . . 121 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Tire air pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 140-141 W Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 160-173 188 *3206054en* 3206054en 08.10.2007 Photo Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com
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